2001 Toyota PriusFACTORY OEM SERVICE PROCEDURE

Differential Case: Reassembly

  1. ASSEMBLE DIFFERENTIAL CASE 
    1. Coat the 2 side gear thrust washers and 2 pinion thrust washers with ATF.
    2. Install the 2 side gears, 2 pinions and 4 thrust washers to the case.
      Fig 1: Installing Side Gears, Pinions And Thrust Washers To Differentials Case
      G03452901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the side gear backlash.

      Measure the side gear backlash while pushing one pinion gear toward the case.

      Fig 2: Measuring Side Gear Backlash
      G03452902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.) 

      Referring to the table below, select thrust washers which backlash is surely within the specified range. Select washers of the same size for both sides. 

      Thrust washer thickness 

      THRUST WASHER THICKNESS SPECIFICATIONS

      Thickness Thickness
      0.95 mm (0.0374 in.) 1.10 mm (0.0433 in.)
      1.00 mm (0.0394 in.) 1.15 mm (0.0453 in.)
      1.05 mm (0.0414 in.) 1.20 mm (0.0472 in.)

      If the backlash is not within the specified range, install a thrust washer of a different thickness.

      Fig 3: Installing Straight Pin
      G03452903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a pin punch and a hammer, install the straight pin.
    5. Stake the differential case.
  2. INSTALL 2 TAPERED ROLLER BEARINGS 
    CAUTION: A: The one which has bigger rollers (The number of rollers is 22.)
    B: The one which has smaller rollers (The number of rollers is 24.)
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