Reassembly

U151E AUTOMATIC TRANSAXLE: DIFFERENTIAL CASE: REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

(a) Apply ATF to the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers and install them to the differential case.





2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION SHAFT

(a) Coat the No. 1 front differential pinion shaft with ATF, and install it to the differential case.





3. INSPECT BACKLASH Differential Case

4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

(a) Using a pin punch and a hammer, install the pinion shaft straight pin.





(b) Using a chisel and a hammer, stake the differential case.





NOTICE:
Stake the differential case after adjusting the backlash.

5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, install the front differential case front tapered roller bearing to the differential case.





SST : 09316-12010

SST : 09550-60010

09951-00490

SST : 09950-70010

09951-07100

NOTICE:
Do not damage the bearing cage when installing the bearing inner race.

(b) Using SST and a hammer, install the front differential case tapered roller bearing front outer race to the transaxle housing.





SST : 09550-60010

09951-00490

SST : 09950-60020

09951-00910

6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST and a press, install the front differential case front tapered roller bearing to the differential case.





SST : 09316-12010

SST : 09550-60010

09951-00490

SST : 09950-70010

09951-07100

09951-07150

NOTICE:
Do not damage the bearing cage when installing the bearing inner race.

(b) Using SST and a hammer, install the front differential case tapered roller bearing rear outer race to the transaxle housing.





SST : 09950-70010

09951-07100

09951-07150

SST : 09950-60020

09951-00890

NOTICE:
No clearance is allowed between the bearing and transaxle housing.

7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Install the differential assembly to the transaxle case.





(b) Clean the mating surfaces of the transaxle case and transaxle housing.





(c) Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.

Bolt A - Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

Bolt B - Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)

Bolt C - Torque : 29 Nm (295 kgf-cm, 21 ft-lbf)

Bolt D - Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

HINT
Apply adhesive or equivalent to bolts A and D.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Bolt length:

Bolt A, B
50 mm (1.969 in.)

Bolt C
42 mm (1.654 in.)

Bolt D
72 mm (2.835 in.)

NOTICE:
Apply adhesive to the bolts and tighten them within 10 minutes of application.

HINT
Bolt A is a non-reusable bolt. However, bolt A can be used after cleaning it.

(d) Using SST, turn the differential assembly to the right and left 2 or 3 times to settle the bearing.





SST : 09564-32011

(e) Using SST and a torque wrench, measure the turning torque of the differential.

SST : 09564-32011

Turning torque at 60 rpm:

New bearing
0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to 6.1 in.*lbf)

Used bearing
0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf)

HINT
If the turning torque is not as specified, refer to the table below to select a thrust washer so that the specified value is achieved.





(f) Remove the 16 bolts and the transaxle housing.





(g) Remove the differential assembly.





8. INSTALL FRONT DIFFERENTIAL RING GEAR

(a) Using ATF and heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).





NOTICE:
Do not heat the ring gear to more than 110°C (230.0°F).

(b) Clean the contact surface of the front differential case.

(c) Align the matchmarks, and install the front differential ring gear case quickly.





NOTICE:
Do not install the bolts while the ring gear is hot.

(d) Tighten the 14 bolts.





Torque : 95 Nm (970 kgf-cm, 70 ft-lbf)

NOTICE:
Tighten the bolts a little at a time in a diagonal pattern.

9. INSTALL TRANSAXLE HOUSING OIL SEAL

(a) Using SST and a hammer, install a new oil seal.





SST : 09316-60011

09316-00011

(b) Coat the lip of oil seal with a little MP grease.

Oil seal installation depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

10. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL

(a) Using SST and a hammer, install a new oil seal.





SST : 09223-15020

SST : 09950-70010

09951-07150

(b) Coat the lip of the oil seal with a little MP grease.

Oil seal installation depth:

-0.5 to 0.2 mm (-0.020 to 0.008 in.)