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Home >> Toyota >> 2004 >> Matrix 4WD L4-1.8L (1ZZ-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Service and Repair >> Part 2

Part 2

OVERHAUL





51. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
a. Remove the 10 bolts from the differential carrier.
b. Using a brass bar and a hammer, remove the side bearing retainer from the differential carrier.

NOTICE: Place the brass bar on the rib of differential side bearing retainer.

52. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY
53. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG
a. Using a screwdriver, remove the breather plug from the side bearing retainer.

HINT: Tape the screwdriver tip before use.

54. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
55. REMOVE DIFFERENTIAL DRIVE PINION
56. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
57. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER





58. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, remove the bearing from the drive pinion.
SST 09950-00020

HINT: If the drive pinion and ring gear are damaged, replace them as a set.

b. Remove the plate washer.





59. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the outer race from the differential carrier.
SST 09612-65014 (09612-01020, 09612-01050)





60. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the outer race from the differential carrier.





61. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, remove the outer race RH.
SST 09950-60010 (09951-00580), 09950-70010 (09951-07100)





62. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, remove the outer race LH.
SST 09950-60010 (09951-00580), 09950-70010 (09951-07100), 09223-15020
63. REMOVE REAR DIFFERENTIAL PINION SHAFT PIN
a. Remove the 2 straight pins from the rear differential carrier and the side bearing.





64. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the case bearing (RH) from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011), 09950-60010 (09951-00270, 09951-00370, 09952-06010)





65. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the case bearing (LH) from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00270, 09951-00370, 09952-06010)





66. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Remove the 10 ring gear set bolts.
c. Using a plastic hammer, tap the ring gear to separate it from the differential case.





67. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY
a. Using a pin punch and a hammer, remove the straight pin.
b. Remove the pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and 2 side gear thrust washers.
68. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check the differential pinion and side gear for wear.
69. INSPECT REAR DIFFERENTIAL CASE SUB-ASSY
a. Check the differential case for a crack or a damage.
70. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
a. Install the 2 proper thrust washer on the 2 side gears.

NOTICE:
^ When installing a thrust washer, side gear, pinion check for dust or chip.
^ When replacing a side gear and a pinion, replace both of them together.
^ Apply hypoid gear oil to the sliding part and rotating part.

b. Install the 2 side gears, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft in the differential case.

HINT: Align the holes of the differential case and pinion shaft.





c. Measure the side gear backlash with holding 1 pinion gear toward the differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.

HINT: Refer to the table and select 2 thrust washers, which ensures that the backlash is within the specification.





Side gear thrust washer





d. Using a pin punch and a hammer, install the straight pin through the differential case and hole of the pinion shaft.
e. Using a chisel and a hammer, stake the outside of the differential case pin hole.
71. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.





b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





e. Align the matchmarks on the ring gear and differential case.
f. Temporarily install 10 new bolts.
g. After the ring gear cools down enough, torque the 10 bolts uniformly at a time.
Torque: 78 Nm (795 kgf-cm, 58 ft. lbs.)





72. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the rear differential case bearing RH (inner race) into the differential case.
SST 09223-46011





73. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the rear differential case bearing LH (inner race) into the differential case.
SST 09223-46011

NOTICE: Use the removed rear differential drive pinion washer when installation.

74. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN
a. Using a plastic hammer, install 2 rear differential pinion shaft pins to the rear differential carrier and the side bearing.





75. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Front side: Using SST, bolt, nut and a washer, install the FR outer race to the differential carrier.
SST 09950-60010 (09951-00490, 09951-00540, 09951-00620), 09950-60020 (09951-00680)
76. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Rear side: Using SST, bolt, nut and a washer, install the RR outer race to the differential carrier.
SST 09950-60010 (09951-00540, 09951-00620), 09950-60020 (09951-00680)





77. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the removed plate washer on the drive pinion.
b. Using SST and a press, install the rear bearing onto the drive pinion.
SST 09316-60011 (09316-00071)





78. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the rear differential side gear shaft washer and rear differential case bearing RH (outer race) into the rear differential carrier.
SST 09950-60010 (09951-00580, 09952-06010), 09950-60020 (09951-00680), 09950-70010 (09951-07100)

NOTICE:
^ Use the removed rear differential side gear shaft washer when installation.
^ When replacing the bearing, replace the outer race and the inner race together.

HINT: Install the oil seal after adjusting the gear control pattern.





79. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the rear differential side gear shaft washer and rear differential case bearing LH (outer race) into the differential side bearing retainer.
SST 09950-60010 (09951-00580, 09952-06010), 09950-60020 (09951-00680), 09950-70010 (09951-07100)

NOTICE:
^ Use the removed rear differential side gear shaft washer when installation.
^ When replacing the bearing, replace the outer race and the inner race together.

HINT: Install the oil seal after adjusting the gear contact pattern.

80. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion and front bearing.
b. Coat the threads of the nut with MP grease.





c. Using SST, adjust the drive pinion preload by tightening nut.
SST 09564-16020
Torque: 223 Nm (2,270 kgf-cm, 164 ft. lbs.) or less

NOTICE: Tighten the rear drive pinion nut gradually. Never tighten excessively.

HINT: Using a torque wrench with a fulcrum length of 500 mm (19.685 inch)





d. Using SST and a torque wrench, measure the preload.
SST 09556-16011





Preload (at starting)

81. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
a. Install the differential case with 10 bolts to the differential carrier.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)





82. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Using SST and a dial indicator, measure the ring gear backlash during holding the drive pinion.
SST 09556-16011, 09564-32011
Backlash: 0.10 - 0.15 mm (0.0039 - 0.059 inch)
If the value is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by equal amount.

HINT:
^ When the backlash is smaller than specified value, select the thick washer in the RH side and thin washer in the LH side.
^ When the backlash is larger than the specified value, select the thin washer in the RH side and thick washer in the LH side.








Washer thickness





83. MEASURE TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload.
SST 09556-16011
Total preload (at starting): Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)

HINT: Turn the drive pinion counterclockwise and clockwise several times. If the preload non-standard again select proper washer (RH side).

NOTICE: When changing the rear differential side gear shaft washer, adjust the ring gear backlash first, then adjust the total preload.

84. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Remove the 10 bolts and the differential side bearing retainer.
b. Remove the differential case from the differential carrier.
c. Coat 3 or 4 teeth at 4 different positions on the ring gear with red lead primer.
d. Install the differential case to the differential carrier.
e. Install the differential side bearing retainer and the 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
f. Turn the differential drive pinion several times.
g. Remove the 10 bolts and the differential side bearing retainer.





h. Inspect the tooth pattern.





i. If the tooth contact is not good, perform the following procedures.
1) In the case of face contact or frank contact, select the rear differential side gear shaft washer with the same thickness increased and decreased in the right and left, or vice versa, and install the rear differential case bearing outer race.

NOTICE: When changing the thickness of the rear differential side gear shaft washer, adjust the ring gear backlash and total preload before adjusting the tooth contact of the ring gear and that of the drive pinion.

2) In the case of heel contact or toe contact, select the rear differential drive pinion washer again, and install the rear drive pinion tapered roller bearing RR.

NOTICE: When changing the thickness of the rear differential side gear shaft washer, adjust the drive pinion preload, ring gear backlash and total preload before adjusting the tooth contact of the ring gear and that of the drive pinion.





Washer thickness

85. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY
a. Remove the 10 bolts and the side bearing retainer.
b. Remove the drive pinion.
86. REMOVE DIFFERENTIAL DRIVE PINION
87. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new rear differential drive pinion bearing spacer to the differential drive pinion.
88. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Install the rear differential drive pinion oil slinger to the differential drive pinion.

NOTICE: Face the smaller inside diameter to the front.

89. INSTALL DIFFERENTIAL DRIVE PINION





90. INSTALL REAR DRIVE PINION NUT
a. Coat the threads of a new nut with hypoid gear oil.
b. Using SST, adjust the drive pinion preload by tightening nut.
SST 09564-16020
Torque: 223 Nm (2,270 kgf-cm, 164 ft. lbs.) or less

HINT: Using a torque wrench with a fulcrum length of 500 mm (19.685 inch).





91. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Using SST and a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
SST 09556-16011





Preload (at starting)

If the preload is less than the specification, retighten the nut 5° to 10° each at a time with SST, and adjust so that the starting torque meets the specified value.
If the preload is less than the specification, retighten the nut 13 Nm (130 kgf-cm, 9 ft. lbs.) of torque at a time until reaching the specified value.
Torque: 223 Nm (2,270 kgf-cm, 164 ft. lbs.) or less
Even if the tightening torque of the rear drive pinion nut exceeds 245 Nm (2,500 kgf-cm, 181 ft. lbs.), if the preload is less than the specification, loosen the rear drive pinion nut once and check if the screw top of the rear drive pinion nut and that of the differential drive pinion is crushed.
If the screw top is not crushed, replace the rear differential drive pinion spacer, apply hypoid gear oil API GL-5 to the screw, and repeat the procedure.
92. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
93. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
a. Install the differential side bearing retainer and the 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
94. INSPECT DIFFERENTIAL RING GEAR BACKLASH
SST 09556-16011, 09560-32011





95. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload.
SST 09556-16011
Total preload (at starting): Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)

HINT: Turn the drive pinion counterclockwise and clockwise several times. If the preload non-standard again select proper washer (RH side).

NOTICE: When changing the rear differential side gear shaft washer, adjust the ring gear backlash first, then adjust the total preload.

96. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
a. Install the rear differential breather plug oil deflector with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)





97. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
a. Remove the 10 bolts and the side bearing retainer.
b. Install the 2 bolts and oil deflector to the side bearing retainer.
c. Install the breather plug to the side bearing retainer.
d. Using a scraper and a wire brush, clean the seal packing attached to the rear differential carrier and the differential side bearing retainer.

NOTICE: Do not damage the installation surface.

e. Clean contacting surfaces of any residual FIPG material by using gasoline or alcohol.
f. Apply FIPG to the side bearing retainer.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

HINT:
^ FIPG should be applied 2 to 3 mm in diameter with no break.
^ Allow on overlap of 10 mm (0.37 inch) or more between the start and end of FIPG application.
^ Install the carrier cover within 3 minutes after applying FIPG.
^ Begin the application in the range of "A".
^ Do not add oil or drive the vehicle immediately after installing the cover, and leave it as it is for an hour or more. Also, for 12 hours or more, avoid rapid acceleration/deceleration.

g. Install the side bearing retainer with the 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
98. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG
a. Install the rear differential carrier cover breather plug.





99. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload.
SST 09550-16011
Total preload (at starting): Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)

HINT: Turn the drive pinion counterclockwise and clockwise several times.

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