Service

DIFFERENTIAL CASE

1. Using a suitable torque wrench, measure total bearing preload.
2. Measure side gear backlash while retaining one pinion against case. Backlash should be .002-.0079 inch.

Fig. 12 Exploded view of differential assembly. 1986-88 Corolla w/A131 automatic transaxle & 1987-88 Tercel sedan:

3. Remove six LH bearing retainer attaching bolts, then the retainer, Fig. 12.
4. Remove RH side bearing cap, then the differential case, outer race and adjusting shim.
5. Using a suitable torque wrench, measure drive pinion preload. Drive pinion preload should be 4.3-6.9 inch lbs. Total preload determined in step 1, minus drive pinion preload should be 1.2-1.9 inch lbs. If result is not as specified, a faulty side bearing is indicated.
6. Remove side bearing from differential case using tool No. 09502-10012. Remove speedometer drive gear. Install new bearings using tool No. 09350-32013 and a suitable press.
7. If necessary to replace ring gear, proceed as follows:
a. Loosen staked portion of lock plate.
b. Remove 8 attaching bolts, then the locking plates from case.
c. Tap ring gear from case, using a suitable mallet.
d. Clean contact surface of differential case.
e. Place ring gear in a suitable oil bath, then heat to approximately 212 degrees F.
f. Clean contact surface of ring gear, using a suitable solvent, then install into differential case.
g. Install new locking plates, then insert attaching bolts.
h. Alternately torque attaching bolts to 71 ft. lbs.
i. Stake locking plates using a hammer and suitable drift. Stake one claw flush with flat surface of nut. Stake only half of claw contacting protruding part of nut.
8. Measure backlash of one side gear while holding one pinion and other side gear toward case. If backlash is not as previously specified, install a suitable thrust washer onto side gears.
9. Drive pinion shaft lock pin from side which ring gear was installed.
10. Remove pinion shaft from case, then the two pinions, two side gears and four thrust washers for each gear.
11. Install removed thrust washers, side gears and pinion gears into differential case, then the pinion shaft.

Fig. 9 Thrust washer thickness chart. Exc. MR2, Pickup, 4Runner & 1984-86 Tercel & 1987-88 Tercel wagon:

12. Measure side gear backlash with one pinion gear held against case. Backlash should be .0020-.0079 inch. If backlash is not as specified, select a suitable thrust washer from chart, Fig. 9, that will bring backlash within specifications.
13. Drive lock pin through case and hole in pinion shaft using a hammer and differential case.

DRIVE PINION SHAFT

Removal

1. Measure drive pinion preload using a suitable torque wrench. On a new bearing, preload should be 8.7-13.9 inch lbs. On a used bearing, preload should be 4.3-6.9 inch lbs.
2. Remove drive pinion cap, then loosen staked part of nut using suitable tool and remove counter driven gear.
3. Remove drive pinion retaining nut, using tool No.09350-32013.
4. Remove drive gear and bearing using tool No. 09350-32013.
5. Remove outer race from case using tool No. 09350-32013.
6. Remove oil slinger, spacer and governor body drive gear.
7. Remove snap ring, then slide a suitable brass drift into case hole and drive out drive pinion.
8. If necessary, remove governor drive gear using a press and split plate.
9. Remove the bearing cage from drive pinion, then the O-ring from bearing cage.

Installation

1. Replace counter driven gear bearing using split plate tool No. 09950-00020.
2. Drive in new bearing using tool Nos. 09350-32013 and 09351-32090.
3. Remove drive pinion shaft bearing and outer race using a suitable press and split plate tool No. 09950-00020.
4. Install new bearing using tool No. 09950-32013.
5. Remove outer race from bearing cage using tool No. 09350-21013, then install new outer race into bearing cage using tool Nos. 09350-21013 and 09351-32111.
6. Remove oil seals from cage, then press in new oil seal with lip facing downward using tool No. 09350-32013. Ensure oil seal is pressed in to a depth of .143 inch.
7. Face lip of second oil seal upward, then press inward using tool No. 09350-32013, until end of seal is flush with surface of cage. Apply a suitable lubricant to lip of seal.