Service
Fig. 7 Exploded view of drive pinion assembly. Exc. MR2, Pickup, 4Runner, Tercel & 1986-88 Corolla w/A131 automatic transaxle:
Differential Side Bearings & Ring Gear
1. Using SST 09502-10012 or equivalent and a suitable wrench, remove side bearings from both sides of differential unit, Fig. 7.
2. Using a suitable tool, remove speedometer drive gear.
3. Using SST 09350-32010 or equivalent and a suitable press, install side bearings onto differential unit.
Ring Gear
1. Using suitable drift and hammer, loosen staked part of ring gear bolt lock plate.
2. Using a piece of chalk, place alignment marks on ring gear and differential unit.
3. Remove ring gear bolts and locking plates.
4. Using a suitable hammer, tap ring gear from differential unit.
5. Clean differential and ring gear mating surfaces with a suitable solvent.
6. Heat ring gear with hot oil to approximately 212°F. Do not heat ring gear above 230°F, as damage to ring gear may result.
7. Install ring gear onto differential unit.
8. Align marks placed previously on differential unit and ring gear.
9. Install ring gear locking plates, then finger tighten ring gear bolts.
10. Tighten ring gear bolts alternately and evenly a little at a time.
11. Torque ring gear bolts to 71 ft. lbs.
Fig. 8 Staking ring gear bolt locking plate. Exc. MR2, Pickup, 4Runner, Tercel & 1986-88 Corolla w/A131 automatic transaxle:
12. Using a drift and hammer, stake ring gear bolt locking plates. Stake one tang of locking plate with flat surface of ring gear bolt, Fig. 8. For the tang contacting the protruding portion of the ring gear bolt, stake only that half on the tightening side indicated by arrow, Fig. 8.
13. Install dial indicator onto differential unit and measure side gear backlash while holding one pinion toward transaxle case.
14. Backlash reading should be .0020-.0079 inch.
Fig. 9 Thrust washer thickness chart. Exc. MR2, Pickup, 4Runner & 1984-86 Tercel & 1987-88 Tercel wagon:
15. If correct backlash reading cannot be obtained, install a thrust washer of correct thickness. Thrust washers are available in different thicknesses as shown in Fig. 9.
16. To install thrust washer(s), proceed as follows:
a. Using a drift and hammer, drive out pinion shaft lock pin from differential unit.
b. Remove pinion shaft from differential unit.
c. Remove pinions, side gears and the four thrust washers from each gear.
d. Install correct size thrust washer(s), side gears and pinion shaft.
e. Using a dial indicator, check side gear backlash. Measure side gear backlash while holding one pinion gear toward transaxle case.
f. Backlash reading should be .0020-.0079 inch.
g. Using a drift and hammer, install pinion lock pin.
Drive Pinion Shaft
1. Using a suitable torque wrench, measure drive pinion preload.
2. Drive pinion preload for new bearing should be 8.7-13.9 inch lbs. Drive pinion preload for used bearing should be 4.3-6.9 inch lbs.
3. Remove transmission case cap bolts, then the case cap.
4. Using a suitable chisel and hammer, carefully loosen staked portion of nut.
5. Install holder tool SST 09350-32010 onto counter driven gear and loosen gear nut.
6. Using a suitable puller, remove counter driven gear and bearing from transaxle case.
7. Using a suitable puller, remove bearing outer race from transaxle case.
8. Remove oil slinger, spacer and rotor sensor from transaxle case.
9. Using snap ring pliers, remove drive pinion snap ring.
10. Insert a suitable brass drift into transaxle case and tap drive pinion from case.
11. Remove bearing cage from bearing bore.
12. Remove bearing cage from drive pinion and O-ring from bearing cage.
13. Install differential unit into transaxle case.
14. Using SST 09564-32010 or equivalent and a torque wrench, measure ring gear preload. Ring gear preload for new bearing should be 8.7-13.9 inch lbs. Ring gear preload for used bearing should be 4.3-6.9 inch lbs.
15. If correct ring gear preload cannot be obtained, install a correct size adjusting shim onto differential. Ring gear preload will change approximately 2.6-3.5 inch lbs. with each shim thickness.
16. If correct ring gear preload is obtained, remove differential assembly with right hand side bearing and shim from transaxle case.
17. Install O-ring onto bearing cage.
18. Install bearing cage onto pinion shaft.
19. Install drive pinion into transaxle case. Using a suitable drift and hammer, tap bearing cage until bearing cage surface passes through bore groove.
20. Install snap ring onto drive pinion.
21. Install rotor sensor with magnet facing outward.
22. Install oil slinger with oil slinger lip facing outward.
23. Using SST 09350-32010 or equivalent and a hammer, drive bearing outer race into transaxle case.
24. Install a new spacer with small end facing transaxle case onto drive pinion.
25. Install counter driven gear onto drive pinion shaft as follows:
a. Place a suitable bar at drive pinion side and position other end of bar into a soft jawed vise.
b. Using a suitable drift and a hammer, drive counter driven gear in until gear nut can be installed onto drive pinion shaft threads.
26. Adjust drive pinion preload as follows:
a. Coat counter driven gear nut threads with a suitable grease.
b. Install holder tool SST 09350-32010 or equivalent onto counter driven gear.
c. Torque nut to 127 ft. lbs.
d. Turn gear counterclockwise and clockwise several times.
e. Using a torque wrench, measure drive pinion preload. Preload for new bearing should be 8.7-13.9 inch lbs. Preload for used bearing should be 4.3-6.9 inch lbs.
f. If drive pinion preload exceeds limit specified, replace bearing spacer.
g. If drive pinion preload is less than limit specified, retorque nut in 9 ft. lb. increments until specified drive pinion preload is obtained. If specified torque is exceeded while retightening counter driven gear nut, replace bearing spacer and repeat steps 26a through 26g.