Toyota Yaris: Differential Case / Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR (w/o LSD)

(a) Coat the front differential side gear, front No. 1 differential side gear thrust washer and conical spring with gear oil.

*1	Front Differential Side Gear
*2	Conical Spring
*3	Front No. 1 Differential Side Gear Thrust Washer
	Gear Oil

(b) Install the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs to the front No. 1 differential case sub-assembly. NOTICE: Do not drop the front differential side gear, front No. 1 differential side gear thrust washer and conical spring. Make sure that the conical spring is installed in the correct orientation.

*1 Front Differential Side Gear *2 Conical Spring *3 Front No. 1 Differential Side Gear Thrust Washer

(c) Set SST as shown in the illustration and tighten it.

SST: 09528-52010

09528-05010

09953-05010

NOTICE:

Do not overtighten SST, as doing so will damage the front differential side gear, conical spring, front No. 1 differential side gear thrust washer and front No. 1 differential case sub-assembly.

(d) Coat the front differential pinion and front differential pinion thrust washer with gear oil.

Gear Oil

(e) Using SST as shown in the illustration, rotate the front differential side gear and install the 2 front differential pinions and 2 front differential pinion thrust washers. SST: 09528-52010 09528-05030 CAUTION: Be careful not to catch your fingers between the front differential pinion and front No. 1 differential case sub-assembly. NOTICE: Do not drop the front differential pinion and front differential pinion thrust washer.

*a Turn

2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH (w/o LSD)

Click here

3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT (w/o LSD)

(a) Coat a front No. 1 differential pinion shaft with gear oil.

Gear Oil

(b) Install the front No. 1 differential pinion shaft to the front No. 1 differential case sub-assembly so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front No. 1 differential case sub-assembly.

4. INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY (w/o LSD)

Click here

5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (w/o LSD)

(a) Using a 5 mm pin punch and hammer, install the front differential pinion shaft straight pin to the front No. 1 differential case sub-assembly.

(b) Using a chisel and hammer, stake the front No. 1 differential case sub-assembly.

6. INSTALL FRONT DIFFERENTIAL RING GEAR

(a) Using a heater, heat the front differential ring gear to 90 to 100°C (194 to 212°F).

CAUTION:

Use thick gloves to protect your hands as the front differential ring gear is hot.

(b) Clean the contact surface of the front No. 1 differential case sub-assembly and front differential ring gear.

(c) While aligning the matchmarks, quickly install the front differential ring gear to the front No. 1 differential case sub-assembly with the 16 bolts. Torque: 106 N·m {1081 kgf·cm, 78 ft·lbf}

*a Matchmark