Get MANUAL TRANSAXLE (E351) -> Differential Case Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MX–38

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

DIFFERENTIAL CASE

MX060–04

COMPONENTS

Pinion Thrust Washer

z Oil Seal

Pinion Gear

Straight Pin

Pinion Shaft

Side Gear

Side Gear Thrust

Washer

z Tapered Roller Bearing

and Outer Race

x16

106(1,080, 78)

Oil Baffle

Diferential

Case

Speed Sensor

Drive Gear

Ring Gear

z Tapered Roller Bearing and Outer Race

Shim

z Oil Seal

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

D10266

AVENSIS/CORONA SUP (RM781E)

MX–39

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

MX09A–03

DISASSEMBLY

1.

Speed sensor drive gear side:

SST

REMOVE TAPERED ROLLER BEARING FROM DIF-

FERENTIAL CASE

(a) Using SST, remove the tapered roller bearing.

SST 09950–00020, 09950–00030, 09950–40011

(09957–04010), 09950–60010 (09951–00530)

HINT:

Set the claw of SST to the bearing inner race securely.

(b) Remove the speed sensor drive gear.

SST

D08953

2.

REMOVE RING GEAR

x16

Matchmarks

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

(b) Remove the 16 bolts.

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

it from the differential case.

D08954

3.

Ring gear side:

REMOVE TAPERED ROLLER BEARING FROM DIF-

FERENTIAL CASE

Using SST, remove the tapered roller bearing.

SST 09950–00020, 09950–00030, 09950–40011

(09957–04010), 09950–60010 (09951–00450)

HINT:

SST

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

where the differential case is indented.

SST

Q04969

4.

INSPECT SIDE GEAR BACKLASH

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

while holding one pinion toward the differential 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.

Q00807

AVENSIS/CORONA SUP (RM781E)

MX–40

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

5.

DISASSEMBLE DIFFERENTIAL CASE

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

(b) Remove the pinion shaft from the differential case.

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

washers from each gear.

6.

Transmission Case Side:

IF NECESSARY, REPLACE OIL SEAL AND TAPERED

ROLLER BEARING OUTER RACE

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

(b) Using a brass bar and hammer, drive out the tapered roll-

er bearing outer race lightly and evenly.

(c) Remove the shim.

(d) Install the shim.

HINT:

D09378

D09379

D08955

D08956

First select and install a shim of lesser thickness than before.

(e) Using SST and a press, install a new tapered roller bear-

ing outer race.

SST 09316–60011 (09316–00011, 09316–00041)

NOTICE:

SST

When replacing the tapered roller bearing outer race, re-

place the tapered roller bearing along with it.

(f)

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

SST 09316–60010 (09316–00011, 09316–00031)

Drive in depth: 3.5 ± 0.5 mm (0.138 ± 0.020 in.)

SST

(g) Coat the lip of oil seal with MP grease.

3.5 ± 0.5 mm

7.

Transaxle Case Side:

IF NECESSARY, REPLACE OIL SEAL AND TAPERED

ROLLER BEARING OUTER RACE

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

from the transaxle case.

(b) Using SST, remove the tapered roller bearing outer race.

SST 09316–60011 (09316–00011, 09316–00021)

(c) Remove the oil baffle.

SST

AVENSIS/CORONA SUP (RM781E)

MX–41

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

(d) Install the oil baffle.

HINT:

Install the oil baffle projection into the case side cutout.

(e) Using SST and a press, install a new tapered roller bear-

ing outer race.

SST 09950–60020 (09951–00890), 09950–70010

(09951–00150)

SST

D08957

(f)

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

SST 09316–60011 (09316–00011, 09316–00041)

Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)

(g) Coat the oil seal lip with MP grease.

SST

D08958

AVENSIS/CORONA SUP (RM781E)

MX–42

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

MX09B–03

REASSEMBLY

HINT:

Coat all of the sliding and rotating surfaces with gear oil before

reassembly.

1.

ASSEMBLE DIFFERENTIAL CASE

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

Refer to the table below, select thrust washers which will

ensure that the backlash is within the specification. Try to

select washers of the same size for both sides.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

Thickness mm (in.)

1.00(0.0394)

Thickness mm (in.)

1.20(0.0472)

D06021

1.10(0.0433)

1.30(0.0512)

(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.

Measure the side gear backlash while holding one pinion

toward the differential 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 differential case and hole in the pinion shaft.

Q00807

(f)

Using a chisel and hammer, caulk the pin holes around

the circumference of the differential case.

AVENSIS/CORONA SUP (RM781E)

MX–43

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

2.

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:

Case Side

Align the matchmarks on the differential case and contact the

ring gear.

D08961

(e) Temporarily install the 16 set bolts.

CAUTION:

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.

Torque: 106 N·m (1,080 kgf·cm, 78 ft·lbf)

3.

Ring gear side:

INSTALL TAPERED ROLLER BEARING

Using SST and a press, install a new tapered roller bearing.

SST 09316–60011 (09316–00011)

NOTICE:

SST

When replacing the tapered roller bearing outer race, re-

place the tapered roller bearing along with it.

HINT:

Set SST to the bearing inner race securely.

D08959

D08960

D08962

4.

Speed sensor drive gear side:

INSTALL TAPERED ROLLER BEARING

(a) Place the speed sensor drive gear in position to stop it

turning, and install the speed sensor drive gear.

NOTICE:

Be sure to install the speed sensor drive gear in the correct

direction, as shown in the illustration.

Case Side

(b) Using SST, a steel plate and press, install a new tapered

roller bearing.

SST 09316–20011, 09316–60011 (09316–00011)

NOTICE:

When replacing the tapered roller bearing outer race, re-

place the tapered roller bearing along with it.

HINT:

SST

Set SST to the bearing inner race securely.

AVENSIS/CORONA SUP (RM781E)

MX–44

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

5.

INSPECT DIFFERENTIAL TAPERED ROLLER BEAR-

ING PRELOAD

NOTICE:

Perform this only when replacing the tapered roller bearing

and outer race of the differential case.

(a) Install the differential case assembly to the transaxle

case.

(b) Install the transmission case to the transaxle case with

the 17 bolts.

CM0061

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

(c) Using SST and a torque wrench, turn the differential case

assembly right and left 2 or 3 times to allow the bearings

to settle.

SST 09564–32011

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

SST 09564–32011

SST

Preload (at starting):

New bearing

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

Reused bearing

D09380

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 tapered roller bearing with

SST (See page MX–39). Select an appropriate shim.

Mark

Thickness mm (in.)

2.00(0.0787)

2.05(0.0807)

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)

Mark

9

Thickness mm (in.)

2.45(0.0965)

2.50(0.0984)

2.55(0.1004)

2.60(0.1024)

2.65(0.1043)

2.70(0.1063)

2.75(0.1083)

2.80 (0.1102)

2.85 (0.1122)

0

1

2

3

4

5

6

7

8

A

B

C

D

E

F

G

H

(e) Remove the 17 bolts and transmission case.

(f) Remove the differential case assembly.

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (E351) -> Differential Case for Your Toyota Avensis 4 Door First Generation (1997-2003)

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