Toyota Celica 1986-1993 Repair Guide

Differential Carrier Overhaul

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DISASSEMBLY



  1. On the conventional carrier, remove the side gear shafts by first removing the 2 shaft snaprings. On the limited slip carrier, use a slap hammer to remove the side gear shafts.
  2.  
  3. Remove the side gear shaft oil seals with SST 09308-00010.
  4.  
  5. Remove the companion flange, loosening the staked nut with a chisel and holding and removing the flange with SST's 09330-00021 and 09557-22022, respectively.
  6.  
  7. Remove the front oil seal and oil slinger, using SST 09308-10010.
  8.  
  9. Remove the front bearing and the bearing spacer with SST 09556-22010.
  10.  
  11. Place matchmarks on the bearing cap and differential carrier and remove the caps.
  12.  
  13. Using SST 09504-22011, remove the 2 side bearing preload adjusting plates.
  14.  


WARNING
Measure the adjusting plate washer and note the thickness.

  1. Remove the differential case and bearing outer race from the carrier, tagging the bearing outer races for reassembly.
  2.  
  3. Remove the drive pinion from the differential carrier.
  4.  
  5. Remove the drive pinion bearing and the plate washer, using SST 09950-00020 and a press.
  6.  


WARNING
If the pinion or the ring gear are damaged, replace them as a set.

  1. Remove the front and rear bearing outer races, using a brass bar.
  2.  
  3. Place matchmarks on the ring gear and the differential case, unstake the lock plates and remove the bolts and the ring gear.
  4.  
  5. Remove the side bearings, using SST 09950-20017.
  6.  
  7. On the conventional carrier, disassemble the differential case, removing the pinion shaft, gears and washers.
  8.  

REASSEMBLY



  1. On the conventional carrier, install the thrust washers to the side gears and the gears with the pinion shaft to the carrier.
  2.  
  3. Check the side gear backlash while holding 1 pinion gear toward the case. The backlash should be 0.002-0.079 in. (0.05-0.02mm). If not within specifications, install different washers.
  4.  


WARNING
Use washers of the same thickness on both the right and left sides.

  1. Drive in the straight pin and stake the case.
  2.  
  3. On both type units, install the ring gear on the differential case by heating the gear (no more than 230°F (110°C), installing and then allowing to cool before coating the set bolts and evenly torquing to 71 ft. lbs. (97 Nm.).
  4.  
  5. Stake the lock plates.
  6.  


WARNING
Stake 1 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.

  1. Install the side bearings into the case with SST 09710-22020.
  2.  
  3. With no play in the bearings, check the ring gear runout, which should be no more than 0.0028 in. (0.07mm).
  4.  
  5. Install the front and rear bearing outer races, using SST's and a press.
  6.  
  7. Install with a press the plate washer and the rear bearing to the drive pinion with the chamfered end of the plate washer facing the pinion gear.
  8.  
  9. Temporarily adjust the drive pinion preload by tightening the companion flange nut.
  10.  


WARNING
Assemble the spacer, oil slinger and the oil seal after adjusting the gear contact pattern.

  1. Using a torque wrench, measure the preload. At starting, with a new bearing, it should be 8.7-13.9 inch lbs. With a used bearing it should be 4.3-6.9 inch lbs.
  2.  
  3. Install the case into the carrier.
  4.  
  5. Adjust the ring gear backlash:
    1. Install only the plate washer on the ring gear backside, insuring that the ring gear has backlash.
    2.  
    3. Snug down the washer and the bearing by tapping on the ring gear with a plastic hammer.
    4.  
    5. Using a dial indicator measure the backlash, which should be 0.0051 in. (0.13mm).
    6.  
    7. Select a ring gear teeth side washer with a thickness which eliminates any clearance between the outer race and the case.
    8.  
    9. Remove the plate washer and the differential case.
    10.  
    11. Install the plate washer into the ring gear back side.
    12.  
    13. Place the other plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier.
    14.  
    15. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear.
    16.  
    17. Using a dial indicator measure the ring gear backlash, which should be 0.0051-0.0071 in. (0.13-0.18mm).
    18.  
    19. If not within specifications, adjust by either increasing or decreasing the number of washers on both sides by an equal amount. There should be no clearance between the plate washer and the case. Insure that there is ring gear backlash.
    20.  

  6.  
  7. Adjust the side bearing preload:
    1. Remove the ring gear teeth side plate washer and measure the thickness.
    2.  
    3. Install a new plate washer of 0.0024-0.0035 in. (0.06-0.09mm) thicker than the removed washer, one that can be pressed in 2 / 3 of the way by finger.
    4.  
    5. Using a hammer and SST 09504-22011, tap in the side washer.
    6.  
    7. Install the side bearing caps, aligning the matchmarks, and torque to 58 ft. lbs. (78 Nm).
    8.  
    9. Recheck the ring gear backlash, which should be 0.0051-0.0071 in. (0.13-0.18mm).
    10.  
    11. If not within specifications, adjust by either increasing or decreasing the washers on both sides by an equal amount.
    12.  

  8.  


WARNING
The backlash will change about 0.0008 in. (0.02mm) with 0.0012 in. (0.03mm) alteration of the side washer.

  1. Measure the total preload, using a torque wrench. At starting, the preload should be 2.6-4.3 inch lbs. (0.3-0.5 Nm).
  2.  
  3. Inspect the tooth contact between the ring gear and the drive pinion.
  4.  
  5. Remove the companion flange and the front bearing.
  6.  
  7. Install a new bearing spacer, front bearing and the oil slinger.
  8.  
  9. Install a new oil seal to a depth of 0.079 in. (2.0mm), using SST 09554-22010. Apply multi-purpose grease to the oil seal lip.
  10.  
  11. Install the companion flange:
    1. Install the plate washer.
    2.  
    3. Coat the threads of a new nut with gear oil.
    4.  
    5. Using the SST to hold the flange, tighten the nut to 80 ft. lbs. (108 Nm).
    6.  

  12.  
  13. Using a torque wrench measure the drive pinion bearing preload of the backlash between the drive pinion and the ring gear:
    1. At starting, with a new bearing, it should be 8.7-13.9 inch lbs. With a used bearing it should be 4.3-6.9 inch lbs.
    2.  
    3. If the preload is greater than specification, replace the bearing spacer.
    4.  
    5. If the preload is less than specification, retighten the nut 9 ft. lbs. (13 Nm) at a time until the specified preload is reached.
    6.  

  14.  


WARNING
If the maximum torque of 174 ft. lbs. (235 Nm) is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload.

  1. Recheck the total preload.
  2.  
  3. Check the ring gear backlash, using a dial indicator. It should be 0.0051-0.0071 in. (0.13-0.18mm). If not within specifications, adjust the side bearing preload.
  4.  
  5. Inspect the tooth contact between the ring gear and the drive pinion.
  6.  
  7. Check the companion flange runout. The maximum radial and lateral runout is 0.0039 in. (0.10mm).
  8.  
  9. Stake the drive pinion nut.
  10.  
  11. Install new side gear shaft oil seals until they are flush with the carrier end surface. Coat the oil seal lips with multi-purpose grease.
  12.  
  13. On the conventional unit, install the side gear shafts, then the 2 snaprings. On the limited slip unit, drive the axles in, making sure the snaprings are engaged.
  14.  



Click image to see an enlarged view

Fig. Fig. 1 Differential carrier components4wd Celica



Click image to see an enlarged view

Fig. Fig. 2 Driving in straight pin through case and hole in pinion shaft4wd Celica

  1. Install the carrier cover. Apply seal packing to the carrier and allow 3 minutes to dry. Tighten the bolts to 34 ft. lbs. (47 Nm).
  2.  

 
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