Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSTOYOTA2003PRIUSREPAIR AND DIAGNOSISTRANSMISSIONTRANSMISSION CONTROL SYSTEMSTRANSMISSION CONTROL SYSTEM TRANSAXLE CONTROL SYSTEMDIFFERENTIAL CASEREASSEMBLY

2003 Toyota Prius

Differential Case: Reassembly

2003 Toyota PriusSECTION Reassembly

ASSEMBLE DIFFERENTIAL CASE

Coat the 2 side gear thrust washers and 2 pinion thrust washers with ATF.
Install the 2 side gears, 2 pinions and 4 thrust washers to the case.

Fig 1: Assembling Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the side gear backlash.

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

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.)

Fig 2: Measuring Side Gear Backlash Using Dial Indicator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Using a pin punch and a hammer, install the straight pin.
Stake the differential case.

Fig 3: Installing Straight Pin Using Pin Punch & Hammer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 2 TAPERED ROLLER BEARINGS
CAUTION:
1. A: The one which has bigger rollers
  (The number of rollers is 22.)
2. B: The one which has smaller rollers
  (The number of rollers is 24.)
  
  Fig 4: Identifying Tapered Roller Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press in the tapered roller bearing RH. (Bearing B)
  SST 09710-22021 (09710-01031), 09950-70010 (09951-07100)
  
  Fig 5: Pressing Tapered Roller Bearing RH Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the tapered roller bearing LH. (Bearing A)
  SST 09710-22021 (09710-01031), 09950-70010 (09951-07100)
  
  Fig 6: Pressing Tapered Roller Bearing LH Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.