Toyota Celica 1986-1993 Repair Guide

Differential

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REMOVAL & INSTALLATION



In order to remove the differential assembly, it is necessary to remove the transaxle from the vehicle and partially disassemble it. For this procedure see Transaxle Disassembly and Reassembly.

OVERHAUL



S53 and C52 Transaxles
DIFFERENTIAL PARTS REPLACEMENT
  1. Remove the side bearing from the differential case, being careful not to damage the speedometer drive gear.
  2.  
  3. Remove the speedometer drive gear.
  4.  
  5. Replace the ring gear by unstaking the lock plate and removing the bolts. Tap off the ring gear with a copper hammer.
  6.  
  7. After parts have been thoroughly cleaned, install the ring gear by heating the gear to no more than 230°F in an oil bath, then install with the gear hot. Torque the bolts evenly to 71 ft. lbs. (97 Nm).
  8.  
  9. Stake the locking plates, staking one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake only the half on the tightening side.
  10.  
  11. Check the side gear backlash.
  12.  
  13. Measure the backlash of one side gear while holding one pinion toward the case. It should be 0.0020-0.0079 inch (0.05-0.20mm). If not within specifications, install a different thrust washer to the side gears.
  14.  

DIFFERENTIAL CASE DISASSEMBLY
  1. Drive out the pinion shaft lock pin from the side on which the ring gear is installed.
  2.  
  3. Remove the pinion shaft from the case.
  4.  
  5. Remove the two pinions, side gears and four thrust washers.
  6.  

DIFFERENTIAL CASE REASSEMBLY
  1. Install the removed thrust washers to the side gears.
  2.  
  3. Install the side gears with the thrust washers, pinion thrust washers and pinion gears.
  4.  
  5. Install the pinion shaft.
  6.  
  7. Measure the backlash of one side gear while holding one pinion toward the case. It should be 0.0020-0.0079 inch (0.05-0.20mm). If not within specifications, install a different thrust washer to the side gears, trying to make sure they are the same thickness on each side.
  8.  
  9. Install the lock pin, then stake the differential case.
  10.  



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Fig. Fig. 1 Unstaking ring gear lock plateS53 and C52 transaxles



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Fig. Fig. 2 Installing ring gear lock plates and set boltsS53 and C52 transaxles



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Fig. Fig. 3 Checking side gear backlashS53 and C52 transaxles

E50F2 and E150F Transaxles
DISASSEMBLY OF DIFFERENTIAL CASE
  1. Remove the differential left case bolts.
  2.  



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Fig. Fig. 4 Differential case componentsE50F2 transaxle



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Fig. Fig. 5 Differential case componentsE150F transaxle



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Fig. Fig. 6 Aligning matchmarks on left case and intermediate caseE50F2 transaxle

  1. Remove the left case upward.
  2.  



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Fig. Fig. 7 Making sure the conical spring washer is installed correctlyE50F2 transaxle



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Fig. Fig. 8 Aligning matchmarks on right case and intermediate caseE50F2 transaxle

  1. Place matchmarks on the differential case and the ring gear.
  2.  
  3. Tap off the ring gear with a plastic hammer.
  4.  
  5. Remove the No. 2 differential side gear thrust washer and conical spring washer.
  6.  
  7. Remove the differential No. 2 case assembly.
  8.  
  9. Disassemble the differential No. 2 case:
    1. Remove the front differential side gear together with the thrust washer.
    2.  
    3. Remove the front differential side gear thrust washer from the side gear.
    4.  
    5. Remove the snapring.
    6.  
    7. Push out the 3 straight pins, then remove the 2 front differential pinion shafts and No. 2 front differential pinion shaft.
    8.  
    9. Remove the pinion shaft holder, differential side gear, thrust washer, spider, pinions and washers from the case.
    10.  

  10.  
  11. Remove the intermediate case. Disassemble the right case, removing the spider, pinions, thrust washers, side gear subassembly, conical spring washer and No. 2 side gear thrust washer.
  12.  
  13. Remove the speedometer drive gear. Remove the side bearing.
  14.  
  15. Replace the transaxle case side oil seal and race, if necessary:
    1. Remove the oil seal.
    2.  
    3. Remove the oil baffle.
    4.  
    5. Remove the race evenly and lightly with a brass bar, then remove the shim.
    6.  
    7. Install the shim, but first use one of a lesser thickness than before.
    8.  
    9. Install the race with a press.
    10.  
    11. Install the oil baffle.
    12.  
    13. Install a new seal and coat the lip with grease.
    14.  

  16.  

REASSEMBLY OF DIFFERENTIAL CASE

WARNING
Coat all of the sliding and rotating surfaces with gear oil before assembly.

  1. Check and adjust center differential side gear backlash, first the differential side gear subassembly:
    1. Install the No. 2 side gear thrust washer.
    2.  
    3. Add a 0.039 inch (1mm) thrust washer for checking backlash.
    4.  
    5. Install the subassembly, side gear and spider to the differential left case.
    6.  
    7. Measure the backlash of one pinion gear while holding the differential side gear subassembly toward the case. It should be 0.0020-0.0079 inch (0.05-0.20mm). Push the pinion gear of the right side of the case.
    8.  
    9. Select the thrust washer that will ensure that the backlash is within specification.
    10.  
    11. Remove the differential right case.
    12.  

  2.  
  3. Adjust the No. 2 differential case:
    1. Install the No. 2 side gear thrust washer.
    2.  
    3. Add a 0.039 inch (1mm) thrust washer for checking backlash.
    4.  
    5. Install the intermediate case to the differential left case, aligning the matchmarks. Install the spider, pinions and washers to the intermediate case.
    6.  
    7. Measure the backlash of one pinion gear while holding the No. 2 differential case. It should be 0.0020-0.0079 inch (0.05-0.20mm). Push the pinion gear of the differential intermediate case.
    8.  
    9. Select the thrust washer that will ensure that the backlash is within specification.
    10.  
    11. Remove the differential left case.
    12.  

  4.  
  5. Assemble the differential right case. Install the No. 2 side gear thrust washer previously selected, conical spring washer and side gear subassembly to the right case.
  6.  


WARNING
Make sure the conical spring washer is not installed backwards.

  1. Install the spider, pinions and washers to the differential case.
  2.  
  3. Install the speedometer driven gear.
  4.  
  5. Align the matchmarks on the cases and torque the screws to 46 ft. lbs. (63 Nm).
  6.  
  7. Check and adjust front side gear backlash (differential No. 2 case):
    1. Install the front side gear thrust washer, side gear, pinion shaft holder, pinions and washers.
    2.  
    3. Fit No. 2 case pin hole and pinion shaft pin hole, install the No. 2 pinion shaft and 2 pinion shafts to the No. 2 case.
    4.  
    5. Install the 3 straight pins.
    6.  
    7. Measure the backlash of one pinion gear while holding the front differential side gear toward the case. It should be 0.0020-0.0079 inch (0.05-0.20mm). Do NOT mount in a vice the surface of No. 2 differential case, which contacts with bushing.
    8.  
    9. Select the thrust washer that will ensure that the backlash is within specification.
    10.  

  8.  
  9. Install the snapring.
  10.  
  11. Check and adjust front differential side gear thrust clearance (differential left case):
    1. Install the No. 2 side gear thrust washer.
    2.  
    3. Add a 0.039 inch (1mm) thrust washer for checking thrust clearance. Assemble the case, engaging the front differential side gear and pinion gear of the No. 2 case.
    4.  
    5. Measure the thrust clearance of front differential side gear while holding the No. 2 case on the left side. It should be 0.006-0.008 inch (0.14-0.21mm).
    6.  
    7. Remove the differential left case.
    8.  

  12.  
  13. Assemble the differential left case:
    1. Install the No. 2 side gear thrust washer previously selected and conical spring washer to the left case. Make sure the conical spring washer is not installed backwards.
    2.  
    3. Install the front differential side gear thrust washer and side gear to the left case. Engage the front differential side gear and pinion gear of No. 2 case.
    4.  
    5. Turning the differential No. 2 case, check that it turns smoothly.
    6.  
    7. Install the intermediate case to the differential left case, aligning the matchmarks on the differential left case and connect the intermediate case.
    8.  

  14.  
  15. Install the ring gear by heating the gear to no more than 230°F in an oil bath, then install with the matchmarks. Torque the bolts evenly to 91 ft. lbs. (124 Nm).
  16.  
  17. Install the side bearings. Press the bearing on the ring gear side first.
  18.  
  19. Adjust the output shaft assembly preload.
  20.  
  21. Install the differential case assembly to the transaxle case.
  22.  
  23. Install the output shaft assembly.
  24.  
  25. Install the transmission case and torque the bolts to 22 ft. lbs. (29 Nm).
  26.  
  27. Drive in the output shaft outer race and install the shim.
  28.  
  29. Install the rear bearing retainer and torque the screws to 31 ft. lbs. (42 Nm).
  30.  
  31. Adjust the differential case preload.
    1. Install the new locknut to the output shaft.
    2.  
    3. Turn the output shaft back and forth to settle the bearings.
    4.  
    5. Measure the preload. With a new bearing, it should be 1.6-3.2 inch lbs. With a used bearing, it should be 1.0-2.0 inch lbs.
    6.  
    7. If the preload is not within specifications, select different thrust washers.
    8.  

  32.  
  33. Remove the bearing retainer and the shim.
  34.  
  35. Remove the transaxle case, the output shaft assembly and the differential case assembly, completing the adjustments.
  36.  

 
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