Get MANUAL TRANSAXLE (C50, C250) -> Differential Case Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MX–38

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

DIFFERENTIAL CASE

MX00J–03

COMPONENTS

z Outer Race and SideBearing

Pinion Thrust Washer

z Oil Seal

Ring Gear

Pinion Gear

Pinion Shaft

Shim

77 (790, 57)

x 8

z Side Bearing and OuterRace

Side Gear

Side Gear Thrust Washer

Shim

Differential Case

Straight Pin

Speed Sensor Drive Gear

z Oil Seal

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

Z17126

AVENSIS/CORONA SUP (RM781E)

MX–39

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

MX00K–03

DISASSEMBLY

1.

REMOVE RING GEAR

(a) Place matchmarks on the ring gear and case.

(b) Remove the 8 bolts.

Matchmarks

(c) Using a copper hammer, tap on the ring gear to remove

it from the case.

D00855

2.

Speed Sensor Drive Gear Side:

REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

(a) Using SST, remove the side bearing.

SST 09950–00020, 09950–00030, 09950–60010

(09951–00360)

SST

HINT:

Set the claw of SST to the bearing inner race at the position

where the speed sensor drive gear is indented.

(b) Remove the speed sensor drive gear.

Z16131

Q07848

Q00807

3.

Ring Gear Side:

SST

REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

Using SST, remove the side bearing.

SST 09950–00020, 09950–00030, 09950–60010

(09951–00360)

HINT:

Set the claw of SST to the bearing inner race at the position

where the differential case is indented.

4.

INSPECT SIDE GEAR BACKLASH

Using a dial indicator, measure the backlash of one side gear

while holding one pinion toward the case.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

If the backlash is not within the specification, install the correct

thrust washer to the side gears.

5.

DISASSEMBLE DIFFERENTIAL CASE

(a) Using a pin punch and hammer, drive out the straight pin.

(b) Remove the pinion shaft from the case.

(c) Remove the 2 pinions and side gears with the 4 thrust

washers from each gear.

AVENSIS/CORONA SUP (RM781E)

MX–40

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

6.

Transmission Case Side:

IF NECESSARY, REPLACE OIL SEAL AND SIDE

BEARING OUTER RACE

SST

(a) Using a screwdriver and hammer, drive out the oil seal.

(b) Using SST, pull out the outer race and shim.

SST 09612–65014

(c) Place the shim into the case.

N00098

(d) Using SST and a hammer, drive in a new outer race.

SST 09950–60020 (09951–00710), 09950–70010

(09951–07150)

SST

Q08120

(e) Using SST and a hammer, drive in a new oil seal.

SST 09350–32014 (09351–32111, 09351–32130)

Drive in depth: 9.9 ± 0.3 mm (0.390 ± 0.012 in.)

9.9 ± 0.3 mm

SST

(f)

Coat the lip of the oil seal with MP grease.

Q08121

7.

Transaxle Case Side:

IF NECESSARY, REPLACE OIL SEAL AND SIDE

BEARING OUTER RACE

(a) Using a screwdriver and hammer, drive out the oil seal.

(b) Using SST, pull out the outer race and shim.

SST 09612–65014

SST

(c) Place the shim into the case.

N00100

(d) Using SST and a hammer, drive in a new outer race.

SST 09950–60020 (09951–00680), 09950–70010

(09951–07150)

SST

Z16127

AVENSIS/CORONA SUP (RM781E)

MX–41

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

(e) Using SST and a hammer, drive in a new oil seal.

SST 09350–32014 (09351–32130, 09351–32150)

Drive in depth: 1.9 ± 0.3 mm (0.075 ± 0.012 in.)

1.9 ± 0.3 mm

(f)

Coat the lip of the oil seal with MP grease.

SST

Z02714

AVENSIS/CORONA SUP (RM781E)

MX–42

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

MX00L–03

REASSEMBLY

1.

ASSEMBLE DIFFERENTIAL CASE

(a) Install the correct thrust washers and side gears. Refer to

the table below, select thrust washers which will allow that

the backlash is within the specification.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

Thickness mm (in.)

0.95(0.0374)

Thickness mm (in.)

1.10(0.0433)

N00102

1.00(0.0394)

1.15(0.0453)

1.05(0.0413)

1.20(0.0472)

(b) Install the thrust washers and side gears in the differential

case.

(c) Install the pinion shaft.

(d) Using a dial indicator, check the side gear backlash. Mea-

sure the side gear backlash while holding one pinion gear

toward the case.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

If the backlash is not within the specification, install a thrust

washer of different thickness.

(e) Using a pin punch and hammer, drive in the straight pin

through the case and hole in the pinion shaft.

Q00807

Z00728

Q00808

(f)

2.

Stake the differential case.

Ring Gear Side:

INSTALL SIDE BEARING

Using SST and a press, install a new side bearing.

SST 09550–10013 (09252–10010, 09556–10011)

SST

3.

Speed Sensor Drive Side:

INSTALL SIDE BEARING

(a) Install the speed sensor drive gear.

Case Side

AVENSIS/CORONA SUP (RM781E)

MX–43

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

(b) Using SST and a press, install a new side bearing.

SST 09550–10013 (09556–10011), 09950–60010

(09951–00460), 09950–70010 (09951–07150)

SST

4.

INSTALL RING GEAR ON DIFFERENTIAL CASE

(a) Clean the contact surface of the differential case.

(b) Heat the ring gear in boiling water.

(c) Carefully take the ring gear out of the water.

(d) After the moisture on the ring gear has completely evapo-

rated, quickly install the ring gear to the differential case.

HINT:

SST

Z00729

Align the matchmarks on the differential case and contact the

ring gear.

(e) Temporarily install the 8 set bolts.

NOTICE:

The ring gear set bolts should not be tightened until the

ring gear has cooled sufficiently.

(f)

After the ring gear has cooled sufficiently, torque the ring

gear set bolts uniformly at a time.

Case

Side

Torque: 77 N·m (790 kgf·cm, 57 ft·lbf)

Q08183

5.

INSPECT DIFFERENTIAL SIDE BEARING PRELOAD

(a) Install the differential case assembly to the transaxle

case.

(b) Install the transmission case.

(c) Install and torque the case bolts.

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

CM0061

AVENSIS/CORONA SUP (RM781E)

MX–44

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

(d) Using SST and a torque wrench, measure the preload.

SST 09564–32011

Preload (at starting):

New bearing

0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)

Reused bearing

SST

0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)

If the preload is not within the specification, remove the trans-

mission case side outer race of the side bearing with SST.

(See page MX–39)

MT0092

Select another shim.

HINT:

The preload will change by about 0.3 – 0.4 N·m (3 – 4 kgf·cm,

2.6 – 3.5 in.·lbf) with each 0.05 mm change in shim thickness.

Mark

A

Thickness mm (in.)

2.10(0.0827)

2.15(0.0846)

2.20(0.0866)

2.25(0.0886)

2.30(0.0906)

2.35(0.0925)

2.40(0.0945)

2.45(0.0965)

2.50(0.0984)

2.55(0.1004)

Mark

L

Thickness mm (in.)

2.60(0.1024)

2.65(0.1043)

2.70(0.1063)

2.75(0.1083)

2.80 (0.1102)

2.85 (0.1122)

2.90 (0.1142)

2.95 (0.1161)

3.00 (0.1181)

–

B

M

N

C

D

P

E

Q

R

F

G

H

S

T

J

U

K

–

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (C50, C250) -> Differential Case for Your Toyota Avensis 4 Door First Generation (1997-2003)

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