Assembly

1. Assemble differential case as follows:
a. Install side gears and thrust washers into the differential. Position oil groove side of thrust washer toward side gear.
b. Assemble differential pinions, then insert pinion shaft with straight pin holes aligned.
c. Before installing straight pin, differential side gear backlash must be adjusted.

Fig. 3 Differential Side Gear Backlash Measurement:

Fig. 20 Side Gear Thrust Washer Identification. Cressida & Supra w/Independent Rear Suspension:

2. Adjust differential side gear backlash as follows:
a. Place dial gauge spindle against fixed pinion, measure backlash by moving side gear, Fig. 3. Backlash should be .0020-.0079 in. (.05-.20mm).
b. If backlash is incorrect, install thrust washers of the proper thickness to obtain correct backlash, Fig. 20.
3. Drive straight pin through case and pinion shaft hole, then stake straight pin and differential case.
4. Press differential side bearings onto case, using tool No. 09726-12021.
5. Install ring gear on differential case as follows:
a. Heat ring gear to approximately 212°F (100°C) in oil bath, then quickly install ring gear on differential case. When heating ring gear, do not exceed temperatures of more than 230°F (110°C).
b. Align differential case and ring gear marks, then install ring gear lock plates and attaching bolts. Torque bolts to 67-75 ft. lbs.
c. Lock bolt by prying up lock plate.
d. Install bearing races on case bearings and mount case assembly in carrier.

Fig. 22 Ring Gear Runout Measurement:

e. Install suitable shims to eliminate side clearance, then measure ring gear runout, Fig. 22. Maximum runout is 0.0028 inch.
f. Remove differential assembly from carrier.
6. Install spacer washer and press rear bearing onto pinion, then mount pinion assembly in carrier.

Fig. 5 Companion Flange Replacement:

7. Install front bearing and companion flange, then press companion flange onto pinion shaft with SST 09557-22022 or equivalent, Fig. 5. Bearing spacer, oil slinger and seal are installed after assembly adjustments have been performed.

Fig. 6 Preload (rotating Torque) Measurement:

8. Install washer and nut, hold companion flange and tighten nut to obtain specified pinion preload. To prevent bearing damage, tighten nut in small increments, checking preload with torque wrench after each adjustment, Fig. 6.
9. Install outer races over differential case bearings, mount differential assembly in carrier and adjust backlash and preload as follows:

Fig. 23 Ring Gear Backlash Adjustment. Cressida w/Independent Rear Suspension:

Fig. 24 Ring Gear Backlash Measurement. Cressida w/Independent Rear Suspension:

Fig. 25 Side Bearing Washer Identification. Cressida & Supra:

a. Install side bearing washer removed during disassembly on the back side of ring gear, Fig. 23.
b. Seat washer by tapping ring gear with mallet, then measure ring and pinion backlash, Fig. 24.
c. If backlash is not 0.0039 inch, replace side bearing washer on back side of ring gear with one that will provide proper backlash, Fig. 25. Backlash changes approximately 0.0008 inch for each 0.0012 inch change in washer thickness.
d. Select a side bearing spacer washer for ring gear face side that completely eliminates clearance between bearing race and carrier.
e. Remove differential assembly and selected washers.

Fig. 27 Differential & Side Bearing Washer Installation:

f. Mount washer for bearing behind ring gear in carrier, hold washer selected for gear face side on bearing race and reinstall differential assembly, Fig. 27.
g. Seat washers and differential assembly by tapping ring gear with mallet, then measure ring and pinion backlash.
h. Adjust backlash to 0.0051-0.0071 inch by altering thicknesses of washers on both sides of ring gear by equal amounts, ensuring that there is no clearance between washers and carrier. Backlash changes approximately 0.0008 inch for each 0.0012 alteration in washer thickness. If backlash is excessive, increase thickness of washer on rear side of gear and decrease washer on face side by an equal amount. If clearance is insufficient, decrease thickness of washer on rear side of gear and increase thickness of washer on face side by an equal amount.
i. Remove and measure washer from face side of ring gear.
j. Set bearing preload by selecting a washer, Fig. 25, 0.0024-0.0035 inch thicker than the washer removed.
k. Install selected washer, tapping washer into place with mallet, then recheck backlash.
l. If backlash is not within specifications, repeat step ``h.''

Fig. 6 Preload (rotating Torque) Measurement:

m. Measure total assembly preload with torque wrench, Fig. 6.
n. If torque is not greater than pinion preload by 3.5-5.2 inch lbs. on Cressida and Supra, or 2.7-4.3 inch lbs. on Celica, recheck differential installation.
10. Coat several ring gear teeth at 3 evenly spaced locations with lead marking compound.

Fig. 9 Ring Gear & Pinion Tooth Contact Inspection:

11. Hold companion flange to place drag on assembly, rotate ring gear in both directions and inspect gear tooth contact, Fig. 9.
12. Remove differential and pinion assemblies from carrier.

Fig. 28 Pinion Washer Identification. Cressida w/Independent Rear Suspension:

13. If gear tooth contact is incorrect, replace washer between rear bearing and pinion with one that will provide proper contact, Fig. 28. If pinion depth adjustment is necessary, repeat steps 6-13 until correct tooth contact is obtained.
14. Install selected washer and press front bearing onto pinion, then mount pinion assembly in carrier.
15. Install new bearing spacer, front bearing and oil slinger onto pinion shaft.

Fig. 11 Pinion Seal Installation:

16. Install pinion seal to a depth of 0.059 inch on Cressida and Supra, or 0.079 inch on Celica, using a suitable driver, Fig. 11.

Fig. 5 Companion Flange Replacement:

Fig. 6 Preload (rotating Torque) Measurement:

17. Install companion flange and press into place using SST 09557-22022 or equivalent, Fig. 5.
18. Install washer and pinion nut, hold companion flange and torque nut to 80 ft. lbs., then measure pinion preload, Fig. 6.
19. If preload is greater than specified, replace bearing spacer and repeat steps 15-18. If preload is less than specified, continue tightening nut in 9 ft. lbs. increments until specified preload is obtained. If maximum torque of 174 ft. lbs. is exceeded when tightening nut, replace bearing spacer and repeat procedure. Do not loosen nut to reduce torque or preload.

Fig. 29 Companion Flange Runout Measurement:

20. Ensure companion flange runout is less than 0.004 inch, Fig. 29, then stake shoulder of pinion nut.
21. Install and adjust differential assembly as outlined in step 9.
22. Install side gear shaft seals, then the side gear shafts, tapping shafts in until bottomed. On Cressida, install new snap rings on side gear shafts prior to installation.
23. On Celica and Supra, install side gear shaft snap rings.

Fig. 30 Side Gear Shaft Runout Measurement:

24. Check runout of side gear shafts, Fig. 30, and replace shaft if runout exceeds 0.0079 inch.
25. Install carrier cover using a new gasket.