Get MANUAL TRANSAXLE (S54, S55) -> Differential Case Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MX–35

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

DIFFERENTIAL CASE

MX03H–04

COMPONENTS

Shim

z Outer Race and Side Bearing

Pinion Thrust Washer

Ring Gear

Pinion Gear

Pinion Shaft

83 (850, 61)

x 8

z

Side Bearing and Outer Race

Shim

Side Gear

Side Gear Thrust Washer

Differential Case

Straight Pin

Speed Sensor Drive Gear

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

Z19302

AVENSIS/CORONA SUP (RM781E)

MX–36

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

MX03I–04

DISASSEMBLY

SST

1.

Speed Sensor Drive Gear Side:

REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

(a) Using SST, remove the bearing from the drive gear side

of the case.

SST 09950–00020, 09950–00030

(b) Remove the speed sensor drive gear.

Q08148

2.

REMOVE RING GEAR

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

(b) Remove the 8 bolts.

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

it from the case.

3.

Ring Gear Side:

REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

Using SST, remove the bearing from the ring gear side of the

case.

SST 09950–00020, 09950–00030

SST

Q04969

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.

AT2799

AVENSIS/CORONA SUP (RM781E)

MX–37

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

6.

Transmission Case Side:

IF NECESSARY, REPLACE DIFFERENTIAL SIDE

BEARING RETAINER OIL SEAL

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

retainer.

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

(09951–07150)

SST

Q08145

SM0286

SM0155

Z00442

MT0634

(b) Using SST and a hammer, drive in a new oil seal until its

surface is flush with the case surface.

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

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

SST

7.

Transaxle Case Side:

IF NECESSARY, REPLACE SIDE OIL SEAL

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

(b) Using SST and a hammer, drive in a new oil seal until its

surface is flush with the case surface.

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

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

SST

8.

Transmission Case Side:

IF NECESSARY, REPLACE SIDE BEARING OUTER

RACE

(a) Using a brass bar and hammer, drive out the bearing out-

er race.

(b) Install the bearing retainer without an O–ring.

(c) Install and torque the 6 bolts.

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

(d) Place the thinnest shim into the case.

(e) Using SST and a press, install a new bearing outer race.

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

(09951–07150)

SST

(f)

Remove the 6 bolts.

(g) Remove the bearing retainer and shim.

AVENSIS/CORONA SUP (RM781E)

MX–38

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

9.

Transaxle Case Side:

IF NECESSARY, REPLACE SIDE BEARING OUTER

RACE

(a) Using a brass bar and hammer, drive out the bearing out-

er race and shim.

(b) Place the shim into the case.

SST

(c) Using SST and a press, install a new bearing outer race.

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

(09951–07150)

Q08184

AVENSIS/CORONA SUP (RM781E)

MX–39

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

MX03J–04

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. 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.)

0.95(0.0374)

Thickness mm (in.)

1.10(0.0433)

1.00(0.0394)

1.15(0.0453)

1.05(0.0413)

1.20(0.0472)

Install the thrust washers and side gears in the differential

case.

(b) Install the pinion shaft.

(c) Inspect the side gear backlash.

Using a dial indicator, measure 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.

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

through the case and hole in the pinion shaft.

(e) Stake the differential case.

AT2981

2.

INSTALL RING GEAR ON DIFFERENTIAL CASE

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

threads of the ring gear and differential case.

(b) Heat the ring gear in boiling water.

(c) Carefully remove the ring gear from the water.

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

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

HINT:

Align the matchmark on the differential case with the one on the

ring gear.

(e) Temporarily install the 8 bolts.

NOTICE:

The ring gear set bolts should not be torqued until the ring

gear has cooled sufficiently.

(f)

After the ring gear has cooled sufficiently, torque the ring

gear set bolts.

Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)

Q08147

AVENSIS/CORONA SUP (RM781E)

MX–40

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

3.

INSTALL SIDE BEARING TO DIFFERENTIAL CASE

(a) Using SST and a press, install a new side bearing to the

transmission case side.

SST 09316–60011 (09316–00011), 09350–32014

(09351–32120)

SST

SM0287

(b) Install the speed sensor drive gear to the transaxle case

side.

Case Side

Q08649

(c) Using SST and a press, install a new side bearing to the

transaxle case side.

SST 09316–60011 (09316–00011), 09350–32014

(09351–32120)

SST

NOTICE:

Install the black cage bearing on the speed sensor drive

gear side.

4.

ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-

LOAD

SM0289

(a) Install the differential 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)

(d) Install the shim into the transmission case.

(e) Install the bearing retainer without an O–ring.

(f)

Install and torque the 6 bolts.

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–41

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

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

SST 09564–32011

Preload (at starting):

1.0–1.6 N·m (10–16 kgf·cm, 8.7–13.9 in.·lbf)

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

mission case side bearing retainer. Select another shim.

HINT:

SST

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

2.6–3.5 in.·lbf) corresponding to a change of 0.05 mm in shim

thickness.

Z00620

Mark

1

Thickness mm (in.)

1.90(0.0748)

1.95(0.0768)

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)

Mark

11

Thickness mm (in.)

2.40(0.0945)

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

12

13

14

15

16

17

18

19

–

3

4

5

6

7

8

9

10

(h) Remove the 6 bolts.

(i)

(j)

Remove the bearing retainer and shim.

Remove the 17 bolts.

(k) Remove the transmission case.

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (S54, S55) -> Differential Case for Your Toyota Avensis 4 Door First Generation (1997-2003)

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