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Home >> Toyota >> 1996 >> Tercel Sedan 2-Door L4-1497cc 1.5L DOHC (5E-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Disassembly and Assembly >> With 3 Speed A/T >> Differential Assembly

Differential Assembly

DIFFERENTIAL ASSEMBLY





Components

Differential Case Disassembly
1. REMOVE RING GEAR





a. Loosen the staked part of the lock plate.
b. Remove the 8 bolts and locking plates.





c. Using a copper hammer, tap on the ring gear to remove it from the case.





2. REMOVE SIDE BEARINGS
Fasten SST under the bearing above the cut- outs on the speedometer drive gear. Remove the bearing from the case.
SST 09502-10012





3. CHECK SIDE GEAR BACKLASH
Using a dial gauge, measure the backlash of each side gear while holding one pinion toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)

4. DISASSEMBLE DIFFERENTIAL CASE





a. Drive out the pinion shaft lock pin from the side on which the ring gear is installed.





b. Remove the pinion shaft from the case.
c. Remove the 2 pinions and 2 side gears with the 4 thrust washers.





5. REMOVE LH OIL SEAL FROM LH SIDE BEARING RETAINER
Using a hammer and screwdriver, remove the oil seal.





6. REMOVE BEARING OUTER RACE FROM LH SIDE BEARING RETAINER
Using SST, press out the outer race and shim.
SST 09350-32014 (09351-32090)





7. REMOVE RH OIL SEAL
Using a hammer and screwdriver, remove the oil seal.

Differential Case Assembly
1. INSTALL RH OIL SEAL





a. Using SST, drive in a new oil seal until its surface is flush with the surface of the case.
SST 09350-32014 (09351-32130, 09351-32150)
b. Coat the oil seal lip with MP grease.

2. INSTALL BEARING OUTER RACE TO LH SIDE BEARING RETAINER
a. Place the shim onto the retainer.

HINT: Use either the shim which was removed or one 2.10 mm (0.0827 inch) thick.





b. Using SST, press a new outer race into the retainer. SST 09350-32014 (09351 -32111)

3. INSTALL LH OIL SEAL





a. Using SST, drive in a new oil seal. SST 09350-32014 (09351-32130, 09351-32150)

Oil seal drive in depth: 0 mm (0 inch)

b. Coat the oil seal lip with MP grease.

4. ASSEMBLE DIFFERENTIAL CASE





a. Install the removed thrust washers to the side gears.





b. Install the side gears with thrust washers, pinion thrust washers and pinion gears.





c. Install the pinion shaft.





d. Check the side gear backlash.
Measure the side gear backlash while holding one pinion gear toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)

Refering to the table below, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides.





If the backlash is not within specification, install a thrust washer of a different thickness.





e. Using a hammer and punch, drive the lock pin through the case and hole in the pinion shaft.
f. Stake the differential case.

5. INSTALL SIDE BEARINGS





a. Install the speedometer drive gear onto the differential case.





b. Using SST and a press, press each side bearing onto the differential case.
SST 09350-32014 (09351 -32090, 09351 -32180)

6. INSTALL RING GEAR
a. Clean the contact surface of the differential case.





b. Heat the ring gear to about 100°C (212°F) in an oil bath.

NOTICE: Do not heat the ring gear above 110°C (230°F).

c. Clean the contact surface of the ring gear with cleaning solvent.





d. Quickly install the ring gear on the differential case.
e. Install new locking plates and set bolts. Tighten the set bolts uniformly and little at a time. Torque the bolts.

Torque:
A131L: 97 Nm (985 kg-cm, 71 ft. lbs.)
A132L: 124 Nm (1,260 kg-cm, 91 ft. lbs.)





f. Using hammer and drift punch, stake the locking plates.

HINT: Stake one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake only the half on the tightening side.

Drive Pinion Disassembly





1. REMOVE GOVERNOR DRIVE GEAR
Using a shop press, press out the governor drive gear.





2. REMOVE BEARING CAGE FROM DRIVE PINION





3. REMOVE DRIVE PINION SHAFT BEARING
Using SST, press out the bearing.
SST 09950-00020





4. REMOVE OIL SEALS FROM CAGE
Using SST press out the 2 oil seals together.
SST 09350-32014 (09351-32090)





5. REMOVE SHAFT BEARING OUTER RACE FROM CASE
Using a hammer and brass bar, drive out the outer race from the cage.





6. REMOVE COUNTER DRIVEN GEAR BEARING
Using SST, press out the bearing.
SST 09950-00020

Drive Pinion Assembly





1. INSTALL COUNTER DRIVEN GEAR BEARING
Using SST, press in a new bearing.
SST 09350-32014 (09351-32090)





2. INSTALL OIL SEALS TO CAGE
a. Using SST, press in a new oil seal with the lip facing downward.
SST 09350-32014 (09351-32090)

Oil seal press in depth (from flat end):
A131L: 8.0 mm (0.315 inch)
A132L: 9.5 mm (0.374 inch)





b. Measure the oil seal press in depth.

Oil seal press in depth: 4 mm (0.16 inch)





c. With the oil seal lip facing upward, use SST to press in a new oil seal until its end is flush with the surface of the cage.
SST 09350-32014 (09351-32090)
d. Coat the oil seal lip with MP grease.





3. INSTALL SHAFT BEARING OUTER RACE TO CAGE
Using SST, press a new outer race into the cage.
SST 09350-32014 (09351-32111, 09351-32130)





4. INSTALL DRIVE PINION SHAFT BEARING
Using SST, press in a new bearing.





5. PLACE BEARING CAGE ONTO DRIVE PINION SHAFT
Be careful not to damage the oil seal with the splines.





6. INSTALL GOVERNOR DRIVE GEAR


Differential Side Bearing Preload Adjustment





1. PLACE OUTER RACE AND ADJUSTING SHIM ONTO RH SIDE BEARING
Use the adjusting shim which was removed or one of 2.40 mm (0.0945 inch) thickness.

2. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE
Be sure to install the adjusting shim.

3. INSTALL LH BEARING RETAINER
a. Do not install the 0-ring yet.
b. Do not coat the bolt threads with sealant yet.





c. Temporarily tighten the 6 bolts (A131L) or 5 bolts (A132L) evenly and gradually while turning the ring gear.





4. INSTALL RH SIDE BEARING CAP
Tighten the bolts evenly and gradually while turning the ring gear.

Torque 49 Nm (500 kg-cm, 36 ft. lbs.)





5. TIGHTEN LH BEARING RETAINER

Torque: 19 Nm (195 kg-cm, 14 ft. lbs.)





6. ADJUST SIDE BEARING PRELOAD
Using SST and a torque meter, measure the preload of the ring gear.
SST 09564-32011

Preload (at starting):
New bearing 1.0 - 1.6 Nm (10 - 16 kg-cm, 8.7 - 13.9 inch lbs.)
Reused bearing 0.5 - 0.8 Nm (5 - 8 kg-cm, 4.3 - 6.9 inch lbs.)





If the preload is not within specification, remove the differential case assembly. Reselect the RH adjusting shim.





HINT: The preload will change about 0.3 - 0.4 Nm (3 - 4 kg-cm, 2.6 - 3.5 inch lbs.) with a change in shim thickness of 0.05 mm (0.0020 inch).





7. REMOVE DIFFERENTIAL CASE AND COMPONENT PARTS
If the preload is adjusted within specification, remove the bearing retainer, differential case, RH side bearing and shim. Be careful not to lose the adjusting shim.
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