Automatic Transaxle (Service Information): Diagnosis Scion xD I

ON-VEHICLE INSPECTION

1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY Apply the parking brake and turn the ignition switch ON. Depress the brake pedal and check that the engine starts when the shift lever is set in the N or P positions, but does not start in the other positions. Check that the back-up light illuminates and the reverse warning buzzer sounds when the shift lever is set in the R position, but does not function in the other positions. If a malfunction failure is found, check the park/neutral position switch for continuity.

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1. REMOVE ENGINE UNDER COVER LH
2. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY Remove the nut and disconnect the transmission control cable assembly from the control shaft lever. Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.
3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY Disconnect the connector from the park/neutral position switch assembly. Remove the nut, washer and control shaft lever. Pry out the lock plate and remove the manual valve shaft nut. Remove the 2 bolts and pull out the park/neutral position switch assembly.

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1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Shift Lever Position Specified Condition 4 (B) - 5 (L) P or N Below 1 ohms Except P and N 10 kohms or higher 2 (RB) - 6 (PL) P Below 1 ohms Except P 10 kohms or higher 1 (RL) - 2 (RB) R Below 1 ohms Except R 10 kohms or higher 2 (RB) - 9 (NL) N Below 1 ohms Except N 10 kohms or higher 2 (RB) - 7 (DL) D or 3 Below 1 ohms Except D and 3 10 kohms or higher 2 (RB) - 3 (2L) 2 Below 1 ohms Except 2 10 kohms or higher 2 (RB) - 8 (LL) L Below 1 ohms Except L 10 kohms or higher If the resistance is not as specified, replace the park/neutral position switch assembly.

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1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY Install the park/neutral position switch assembly onto the manual valve lever shaft. Provisionally install the 2 bolts. Replace the lock plate with a new one and tighten the manual valve shaft nut. Torque: 6.9 N*m ( 70 kgf*cm, 61 ft.*lbf) Provisionally install the control shaft lever. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove the control shaft lever. Align the groove with the neutral basic line. Hold the switch in this position and tighten the 2 bolts. Torque: 5.4 N*m ( 55 kgf*cm, 48 ft.*lbf) Using a screwdriver, stake the nut with the lock plate. Install the control shaft lever with the nut and washer. Torque: 13 N*m ( 129 kgf*cm, 9 in.*lbf) Connect the connector to the park/neutral position switch assembly.
2. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY Install the transmission control cable assembly onto the control shaft lever with the nut. Torque: 12 N*m ( 122 kgf*cm, 9 in.*lbf) Fix the transmission control cable assembly onto the control cable bracket with a new clip. NOTE: Make sure that the marking on the cable is aligned with the slit in the transmission control cable bracket before installing the cable.
3. INSPECT SHIFT LEVER POSITION . See step 1
4. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY . See step 1
5. INSTALL ENGINE UNDER COVER LH Torque: 5.0 N*m ( 51 kgf*cm, 44 ft.*lbf)

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1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID . See step 2
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY . See step 3
4. REMOVE VALVE BODY OIL STRAINER ASSEMBLY . See step 4
5. REMOVE TRANSMISSION VALVE BODY ASSEMBLY . See step 5
6. REMOVE TRANSMISSION WIRE Remove the bolt and the transmission wire from the transaxle case. Remove the O-ring from the transmission wire.

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1. INSPECT TRANSMISSION WIRE Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1 (THO) - 6 (E2) Always 79 ohms to 156 kohms 1 (THO) - Body ground Always 10 kohms or higher 6 (E2) - Body ground Always 10 kohms or higher HINT: If the resistance is out of the specified range with the ATF temperature shown in the table below, the driveability of the vehicle may decrease. ATF Temperature Specified Condition 10°C (50°F) 5 to 8 kohms 25°C (77°F) 2.5 to 4.5 kohms 110°C (230°F) 0.22 to 0.28 kohms If the resistance is not as specified, replace the transmission wire.

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1. INSTALL TRANSMISSION WIRE Coat a new O-ring with Toyota Genuine ATF WS or equivalent and install it onto the transmission wire. Pass the transmission wire through the transaxle. Install the transmission wire with the bolt. Torque: 5.4 N*m ( 55 kgf*cm, 48 ft.*lbf)
2. INSTALL TRANSMISSION VALVE BODY ASSEMBLY . See step 1
3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY . See step 2
4. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY . See step 3
5. ADD AUTOMATIC TRANSAXLE FLUID
6. INSPECT AUTOMATIC TRANSAXLE FLUID LEVEL . See step 1
7. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK
8. INSTALL ENGINE UNDER COVER LH Torque: 5.0 N*m ( 51 kgf*cm, 44 ft.*lbf)

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1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID . See step 2
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY Remove the 19 bolts and remove the automatic transaxle oil pan sub-assembly and oil pan gasket. NOTE: Some fluid will remain in the oil pan. Remove all the oil pan bolts, and carefully remove the oil pan sub-assembly. Remove the 2 oil cleaner magnets from the automatic transaxle oil pan sub-assembly. TEXT IN ILLUSTRATION *1 Oil Cleaner Magnet Examine the particles in the pan. Collect any steel chips using the removed magnets. Carefully inspect the foreign matter and particles in the pan and on the magnets to guess at the type of wear which might be found in the transaxle. Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bearing wear
4. REMOVE VALVE BODY OIL STRAINER ASSEMBLY Remove the 3 bolts and remove the valve body oil strainer assembly. NOTE: Perform the operation carefully as some fluid will come out from the oil strainer. Remove the oil strainer gasket from the valve body oil strainer assembly. TEXT IN ILLUSTRATION *1 Oil Strainer Gasket
5. REMOVE TRANSMISSION VALVE BODY ASSEMBLY Remove the bolt and lock plate and separate the ATF temperature sensor. Disconnect the 5 shift solenoid valve connectors. Remove the 2 bolts and remove the manual detent spring cover and manual detent spring. TEXT IN ILLUSTRATION *1 Manual Detent Spring *2 Manual Detent Spring Cover Remove the 13 bolts and remove the transmission valve body assembly. NOTE: Do not drop the check ball body, check ball body spring or accumulator piston. Remove the check ball body and check ball body spring. TEXT IN ILLUSTRATION *1 Check Ball Body *2 Check Ball Body Spring Remove the transaxle case 2nd brake gasket and transaxle case gasket.

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1. REMOVE SHIFT SOLENOID VALVE S1 Remove the bolt and pull out the shift solenoid valve S1.
2. REMOVE SHIFT SOLENOID VALVE S2 Remove the bolt and pull out the shift solenoid valve S2.
3. REMOVE SHIFT SOLENOID VALVE SLU Remove the bolt and solenoid lock plate. TEXT IN ILLUSTRATION *1 Solenoid Lock Plate Pull out the shift solenoid valve SLU.
4. REMOVE NO. 3 SOLENOID LOCK PLATE Remove the 2 bolts and No. 3 solenoid lock plate from the valve body. TEXT IN ILLUSTRATION *1 No. 1 Solenoid Lock Plate *2 No. 3 Solenoid Lock Plate *3 Shift Solenoid Valve ST *4 Shift Solenoid Valve SLT Pull out the shift solenoid valve ST from the valve body. Remove the No. 1 solenoid lock plate from the shift solenoid valve SLT. Pull out the shift solenoid valve SLT from the valve body.
5. REMOVE MANUAL VALVE Remove the manual valve from the valve body.

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1. INSPECT SHIFT SOLENOID VALVE S1 Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *a Component without harness connected (Shift Solenoid Valve S1) Standard Resistance Tester Connection Condition Specified Condition Solenoid Connector - Solenoid Body 15 to 25°C (59 to 77°F) 11 to 15 ohms If the value is not as specified, replace the shift solenoid valve. Connect a positive (+) battery lead to the terminal of the solenoid connector, and a negative (-) battery lead to the solenoid body, and check the operation of the valve. NOTE: When using battery voltage during this inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. OK The solenoid makes an operating sound. If the operation cannot be done as specified, replace the shift solenoid valve.
2. INSPECT SHIFT SOLENOID VALVE S2 HINT: For inspection procedure, refer to shift solenoid valve S1 above.
3. INSPECT SHIFT SOLENOID VALVE ST HINT: For inspection procedure, refer to shift solenoid valve S1 above.
4. INSPECT SHIFT SOLENOID VALVE SLT Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *a Component without harness connected (Shift Solenoid Valve SLT) Standard Resistance Tester Connection Condition Specified Condition 1 - 2 20°C (68°F) 5.0 to 5.6 ohms If the value is not as specified, replace the shift solenoid valve. Connect a positive (+) battery lead with a 21 W bulb to terminal 2 and a negative (-) battery lead to terminal 1 of the solenoid valve connector, and check the operation of the valve. NOTE: When using battery voltage during this inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. OK The solenoid makes an operating sound. If the operation cannot be done as specified, replace the shift solenoid valve.
5. INSPECT SHIFT SOLENOID VALVE SLU HINT: For inspection procedure, refer to shift solenoid valve SLT above.

1. INSPECT SHIFT LEVER POSITION When shifting the lever from P to the R position with the ignition switch ON and the brake pedal depressed, make sure that the shift lever moves smoothly and correctly into position. Start the engine and make sure that the vehicle moves forward when shifting the lever from N to the D position and moves rearward when shifting the lever to the R position. If the operation cannot be performed as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition.
2. INSPECT SHIFT LOCK SYSTEM Check the shift lock operation. Move the shift lever to P. Turn the ignition switch OFF. Check that the shift lever cannot be moved to any position other than P. Turn the ignition switch ON, depress the brake pedal and check that the shift lever can be moved to other positions. Check the shift lock release button operation. When operating the shift lever with the shift lock release button pressed, check that the lever can be moved to any position. If the operation cannot be performed as specified, check the shift lever assembly. Check the key interlock operation. Turn the ignition switch ON. Depress the brake pedal and move the shift lever to any position other than P. Check that the ignition switch cannot be turned OFF. Move the shift lever to P, turn the ignition switch off and check that the key can be removed. If the results are not as specified, inspect the shift lock control unit.

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1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY Remove the shift lever knob sub-assembly from the shift lever.
2. REMOVE UPPER CONSOLE PANEL . Refer to «REMOVAL - Step 2»(ref-388756-S29932361262011031100000)
3. REMOVE REAR CONSOLE BOX COVER . Refer to «REMOVAL - Step 3»(ref-388756-S29932361262011031100000)
4. REMOVE CONSOLE BOX CARPET . Refer to «REMOVAL - Step 4»(ref-388756-S29932361262011031100000)
5. REMOVE REAR CONSOLE BOX SUB-ASSEMBLY . Refer to «REMOVAL - Step 5»(ref-388756-S29932361262011031100000)
6. REMOVE FRONT CONSOLE BOX . Refer to «REMOVAL - Step 28»(ref-388757-S39306545862011031100000)
7. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY Disconnect the transmission control cable assembly from the transmission floor shift assembly. Turn the nut and separate the transmission control cable assembly from the shift lever retainer.
8. REMOVE FLOOR SHIFT ASSEMBLY Separate the shift lock control computer connector and indicator light wire sub-assembly connector. Separate the 2 wire harness clamps from the transmission floor shift assembly. Remove the 4 bolts and remove the transmission floor shift assembly.

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1. REMOVE UPPER POSITION INDICATOR HOUSING Disengage the 4 claws using a screwdriver and remove the upper position indicator housing from the shift lock control unit assembly.
2. REMOVE NO. 2 CONTROL POSITION INDICATOR PLATE Disengage the claw using a screwdriver and remove the No. 2 control position indicator plate from the upper position indicator housing.
3. REMOVE SHIFT LOCK RELEASE BUTTON COVER Remove the shift lock release button cover from the upper position indicator housing.
4. REMOVE POSITION INDICATOR SLIDE COVER Remove the position indicator slide cover from the shift lock control unit assembly.
5. REMOVE NO. 2 POSITION INDICATOR SLIDE COVER Remove the No. 2 position indicator slide cover from the position indicator slide cover.
6. REMOVE SHIFT LOCK RELEASE BUTTON Remove the shift lock release button and shift lock release spring from the shift lock control unit assembly.
7. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY Remove the indicator light wire sub-assembly from the shift lock control unit assembly.

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1. INSPECT SHIFT LOCK CONTROL ECU SUB-ASSEMBLY Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition 12 (KLS+) - 8 (E) Ignition switch on (ACC) and shift lever P Below 1 V Ignition switch on (ACC) and shift lever except P 7.5 to 11 V Ignition switch on (ACC) and shift lever except P (after approximately 1 second) 6 to 9 V 6 (ACC) - 8 (E) Ignition switch on (IG) 11 to 14 V Ignition switch on (ACC) 11 to 14 V Ignition switch off Below 1 V 7 (STP) - 8 (E) Depress brake pedal 11 to 14 V Release brake pedal Below 1 V 1 (IG) - 8 (E) Ignition switch on (IG) 11 to 14 V Ignition switch off Below 1 V Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 8 (E) - Body ground Always Below 1 ohms If the result is not as specified, replace the shift lock control unit assembly.

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1. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY Install the indicator light wire sub-assembly into the shift lock control unit assembly. NOTE: Fit the indicator light wire sub-assembly into the shift lock control unit, as shown in the illustration.
2. INSTALL SHIFT LOCK RELEASE BUTTON Install the shift lock release button and shift lock release spring into the shift lock control unit assembly.
3. INSTALL NO. 2 POSITION INDICATOR SLIDE COVER Install the No. 2 position indicator slide cover onto the position indicator slide cover.
4. INSTALL POSITION INDICATOR SLIDE COVER Install the position indicator slide cover onto the shift lock control unit assembly. NOTE: Install the slide cover onto the shift lock control unit with the arrow mark directed forward.
5. INSTALL SHIFT LOCK RELEASE BUTTON COVER Install the shift lock release button cover onto the upper position indicator housing.
6. INSTALL NO. 2 CONTROL POSITION INDICATOR PLATE Engage the claw, and install the No. 2 control position indicator plate onto the upper position indicator housing.
7. INSTALL UPPER POSITION INDICATOR HOUSING Engage the 4 claws, and install the upper position indicator housing onto the shift lock control unit assembly. NOTE: Securely engage the 4 claws.

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1. INSTALL FLOOR SHIFT ASSEMBLY Provisionally install the shift lever with the 4 bolts. NOTE: Do not jam the wiring of the indicator light or shift lock. Tighten the 4 bolts in order, from A to D. Torque: 12 N*m ( 122 kgf*cm, 9 in.*lbf) Install the shift lock control computer connector and indicator light connector.
2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Turn the nut on the control cable and push in the lock. Install the control cable onto the shift lever retainer. WARNING: Install the cable with the projection of the cable outer facing upward. After installing, check that the lock of the cable outer is protruding beyond portion A-A, as shown in the illustration. Connect the control cable to the shift lever. NOTE: Connect the control cable so that the adjusting mechanism lock of the control cable is installed on the left side of the vehicle.
3. INSPECT SHIFT LEVER POSITION . See step 1
4. ADJUST SHIFT LEVER POSITION Shift the shift lever to the N position. Slide the adjuster case cover in the direction shown in the illustration and pull out the lock piece. Gently pull the cable rod toward the rear of the vehicle by hand to pull the cable taut. Press the lock piece into the adjuster case and lock it. Slide the cover in the direction shown in the illustration. NOTE: Slide the cover past the protrusion on the lock piece. Inspect the operation after the adjustment.
5. INSTALL FRONT CONSOLE BOX . Refer to «INSTALLATION - Step 16»(ref-388757-S06079887162011031100000)
6. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-388756-S01871674392011031100000)
7. INSTALL CONSOLE BOX CARPET . Refer to «INSTALLATION - Step 2»(ref-388756-S01871674392011031100000)
8. INSTALL REAR CONSOLE BOX COVER . Refer to «INSTALLATION - Step 3»(ref-388756-S01871674392011031100000)
9. INSTALL UPPER CONSOLE PANEL . Refer to «INSTALLATION - Step 4»(ref-388756-S01871674392011031100000)
10. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY Install the shift lever knob sub-assembly onto the shift lever.

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1. REMOVE UPPER CONSOLE PANEL . Refer to «REMOVAL - Step 2»(ref-388756-S29932361262011031100000)
2. REMOVE REAR CONSOLE BOX COVER . Refer to «REMOVAL - Step 3»(ref-388756-S29932361262011031100000)
3. REMOVE CONSOLE BOX CARPET . Refer to «REMOVAL - Step 4»(ref-388756-S29932361262011031100000)
4. REMOVE REAR CONSOLE BOX SUB-ASSEMBLY . Refer to «REMOVAL - Step 28»(ref-388757-S39306545862011031100000)
5. REMOVE FRONT CONSOLE BOX . Refer to «REMOVAL - Step 28»(ref-388757-S39306545862011031100000)
6. REMOVE BATTERY . Refer to «REMOVAL - Step 2»(ref-388728-S39495453982011031100000)
7. REMOVE BATTERY TRAY
8. REMOVE AIR CLEANER ASSEMBLY . Refer to «REMOVAL - Step 19»(ref-388728-S39495453982011031100000)
9. REMOVE AIR CLEANER BRACKET . Refer to «REMOVAL - Step 20»(ref-388728-S39495453982011031100000)
10. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to «REMOVAL - Step 54»(ref-388728-S39495453982011031100000)
11. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR Remove the 2 bolts and the nut and remove the front No. 1 floor heat insulator.
12. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY Disconnect the transmission control cable assembly from the transmission floor shift assembly. Turn the nut and separate the transmission control cable assembly from the shift lever retainer. Disconnect the transmission control cable assembly from the transmission control cable support. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever. Remove the clip and separate the transmission control cable assembly from the control cable bracket. Remove the 3 nuts and remove the transmission control cable assembly.

INSPECTION

1. INSPECT OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length 17.88 mm (0.7039 in.)

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1. INSTALL REAR TRANSAXLE COVER NEEDLE ROLLER BEARING Coat a new needle roller bearing with Toyota Genuine ATF WS or equivalent. Using SST and a press, install the needle roller bearing into the rear transaxle cover. SST: 09950-60010 09951-00190 09952-06010 SST: 09950-70010 09951-07100 Standard clearance 25.1 mm (0.988 in.)
2. INSTALL CLUTCH DRUM OIL SEAL RING Compress the oil seal ring from both sides to reduce dimension A. Dimension A 5.0 mm (0.197 in.) Coat 3 oil seal rings with Toyota Genuine ATF WS or equivalent and install it to the rear transaxle cover.
3. INSTALL 2ND COAST AND OVERDRIVE O-RING Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the 2nd coast and overdrive brake piston. NOTE: Do not damage the O-rings.
4. INSTALL 2ND COAST AND OVERDRIVE BRAKE PISTON Coat the piston with Toyota Genuine ATF WS or equivalent and install it to the transaxle rear cover. NOTE: Do not damage the O-rings.
5. INSTALL OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY Using SST and a press, install the overdrive brake return spring and snap ring to the transaxle rear cover. SST: 09387-00070 NOTE: Stop pressing the press when the spring sheet is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from deforming. Do not expand the snap ring excessively.
6. INSTALL REAR TRANSAXLE COVER PLUG Coat 4 new O-rings with Toyota Genuine ATF WS or equivalent, and install them to the 4 rear transaxle cover plugs. Install the 4 rear transaxle cover plugs to the rear transaxle cover. Torque: 7.4 N*m ( 76 kgf*cm, 66 ft.*lbf) NOTE: Do not damage the O-rings.

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1. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST, remove the front differential case front tapered roller bearing from the differential case. SST: 09950-40011 09951-04010 09952-04010 09953-04030 09954-04010 09955-04061 09957-04010 09958-04011 SST: 09950-60010 09951-00390 Using SST, remove the front differential case RH tapered roller bearing outer race from the transaxle housing. SST: 09387-00041 09387-02020 09387-02010
2. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST, remove the front differential case tapered roller bearing from the differential case. SST: 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04061 09957-04010 09958-04011 SST: 09950-60010 09951-00430 Using SST, remove the front differential case tapered roller bearing outer race from the transaxle case. SST: 09612-65014 09612-01010
3. REMOVE FRONT DIFFERENTIAL RING GEAR Place matchmarks on the front differential ring gear and differential case. Using SST and a hammer, release the lock plate. SST: 09930-00010 Remove the 8 bolts and the lock plate. Using a plastic hammer, remove the front differential ring gear from the differential case.
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using a punch and a hammer, release the differential case. Using a pin punch and a hammer, remove the straight pin.
5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT Remove the front No. 1 differential pinion shaft from the front differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR Remove the 2 front differential pinions, 2 front differential side gear thrust washers, 2 front differential side gears and 2 front differential side gear thrust washers from the front differential case.

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1. INSTALL FRONT DIFFERENTIAL SIDE GEAR After applying Toyota Genuine ATF WS or equivalent to the 2 front differential side gears, 2 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers, install them to the front differential case. HINT: When installing them, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes are aligned with the holes in the differential case.
2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT Install the No. 1 pinion shaft so as to align the lock pin holes in the pinion shaft and differential case.
3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Measure the differential side gear backlash while holding 1 pinion gear toward the case. Standard backlash 0.05 to 0.20 mm (0.0020 to 0.0079 in.) If the backlash is outside the specifications, install the correct thrust washer to the side gear. Referring to the table below, select thrust washers which will ensure that the backlash is within the specifications for both sides. Thrust washer thickness Thickness mm (in.) Thickness mm (in.) 0.95 (0.0374) 1.10 (0.0433) 1.00 (0.0394) 1.15 (0.0453) 1.05 (0.0413) 1.20 (0.0472) If the backlash is not within the specifications, install a thrust washer of a different thickness.
4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using a pin punch and a hammer, install the pinion shaft straight pin. Using a chisel and a hammer, stake the differential case.
5. INSTALL FRONT DIFFERENTIAL RING GEAR Using Toyota Genuine ATF WS or equivalent and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F). Clean the contact surface of the front differential case. Install 4 new ring gear lock plates with the 8 bolts. Torque: 88 N*m ( 898 kgf*cm, 65 in.*lbf) Using SST, stake the ring gear lock plate. SST: 09930-00010
6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST and a press, install the front differential case LH tapered roller bearing inner race to the differential case. SST: 09726-40010 SST: 09950-60020 09951-00790 Using SST and a press, install the shim and bearing outer race to the transaxle case. SST: 09950-60020 09951-00720 SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07100 09951-07200
7. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST and a press, install the bearing inner race to the differential case. SST: 09950-60010 09951-00460 SST: 09950-70010 09951-07100 Using SST and a press, install the tapered roller bearing to the transaxle housing. SST: 09950-70010 09951-07150 SST: 09950-60020 09951-00680