Toyota Corolla Cross: Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY	-		-	-
2	STUD BOLT	-		-	-
3	REAR DIFFERENTIAL DRAIN PLUG	41110D		-	-
4	REAR DIFFERENTIAL FILLER PLUG	41110H		-	-
5	REAR DIFFERENTIAL CARRIER COVER PLUG	41108A		-	-
6	REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG	41108C		-	-
7	INSPECT RUNOUT OF TRANSMISSION COUPLING ASSEMBLY	-		-	-
8	TRANSMISSION COUPLING ASSEMBLY	41330D		-	-
9	TRANSMISSION COUPLING CONICAL SPRING WASHER	41330E	-	-	-
10	TRANSMISSION COUPLING SHIM	41330J	-	-	-
11	INSPECT DIFFERENTIAL RING GEAR BACKLASH	-		-	-
12	INSPECT DIFFERENTIAL DRIVE PINION PRELOAD	-		-	-
13	INSPECT TOTAL PRELOAD	-		-	-
14	REAR DRIVE SHAFT OIL SEAL RH	42330G		-	-
15	REAR DRIVE SHAFT OIL SEAL LH	42340D		-	-
16	DIAPHRAGM OIL SEAL	41410D		-	-
17	REAR DRIVE PINION NUT	41204B		-	-
18	REAR DRIVE PINION FRONT BEARING (INNER RACE)	41201B		-	-

Procedure		Part Name Code
19	DIFFERENTIAL SIDE BEARING RETAINER	-		-	-
20	REAR DIFFERENTIAL CASE SUB-ASSEMBLY	41301	-	-	-
21	DIFFERENTIAL DRIVE PINION	-	-	-	-
22	REAR DIFFERENTIAL DRIVE PINION BEARING SPACER	41231	-	-	-
23	REAR DRIVE PINION REAR BEARING (INNER RACE)	41201A		-	-
24	REAR DRIVE PINION FRONT BEARING (OUTER RACE)	41201B		-	-
25	REAR DRIVE PINION REAR BEARING (OUTER RACE)	41201A		-	-
26	REAR DIFFERENTIAL CASE BEARING RH (OUTER RACE)	41301A		-	-
27	REAR DIFFERENTIAL CASE BEARING LH (OUTER RACE)	41301A		-	-
28	REAR DIFFERENTIAL CASE BEARING RH (INNER RACE)	41301A		-	-
29	REAR DIFFERENTIAL CASE BEARING LH (INNER RACE)	41301A		-	-
30	DIFFERENTIAL RING GEAR	-		-	-
31	REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR	41183		-	-
32	STRAIGHT PIN	-	-	-	-
33	INSPECT DIFFERENTIAL SIDE GEAR BACKLASH	-		-	-

CAUTION / NOTICE / HINT

NOTICE:

Before installation of each part, thoroughly clean and dry it. Then apply gear oil to it. Do not use alkaline chemicals to clean aluminum parts, rubber parts or ring gear set bolts. Also, do not use non-residue solvent or other cleaning oils to clean O-rings, oil seals or rubber parts.

PROCEDURE

1. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY

(1) Secure the rear differential carrier assembly to the overhaul attachment.

2. REMOVE STUD BOLT

(1) Using 2 nuts, remove the 4 stud bolts from the transmission coupling assembly.

3. REMOVE REAR DIFFERENTIAL DRAIN PLUG

(1) Using a 10 mm socket hexagon wrench, remove the rear differential drain plug and gasket.

4. REMOVE REAR DIFFERENTIAL FILLER PLUG

(1) Using a 10 mm socket hexagon wrench, remove the rear differential filler plug and gasket.

5. REMOVE REAR DIFFERENTIAL CARRIER COVER PLUG

(1) Using an 8 mm socket hexagon wrench, remove the rear differential carrier cover plug.

6. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG

(1) Using a chisel and hammer, slightly pry out the rear differential carrier cover breather plug.

(2) Using a screwdriver, lightly pry up and remove the rear differential carrier cover breather plug.

7. INSPECT RUNOUT OF TRANSMISSION COUPLING ASSEMBLY

(1) Attach a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the transmission coupling assembly.

(2) Using SST, rotate the transmission coupling assembly forward and in reverse and measure the vertical runout.

SST: 09564-32011

Maximum vertical runout:

0.06 mm (0.00236 in.)

HINT:

If the measurement is more than the maximum, replace the transmission coupling assembly.

(3) Set the dial indicator at a right angle to the transmission coupling assembly in the position shown in the illustration.

(4) Using SST, rotate the transmission coupling assembly forward and in reverse and measure the lateral runout.

SST: 09564-32011

Maximum lateral runout:

0.07 mm (0.00276 in.)

HINT:

If the measurement is more than the maximum, replace the transmission coupling assembly.

8. REMOVE TRANSMISSION COUPLING ASSEMBLY

(1) Remove the 4 bolts.

(2) Using a brass bar and hammer, lightly tap the transmission coupling assembly to remove it from the rear differential carrier assembly.

NOTICE:

• Put the brass bar against the rib of the transmission coupling assembly.
• When removing the transmission coupling assembly, be careful not to scratch the installation surface.

HINT:

To prevent the transmission coupling assembly from falling, leave 2 of the bolts screwed in by 5 or 6 threads.

(1) Using a snap ring expander, remove the snap ring.

(2) Remove the 4WD linear solenoid from the yoke.

(3) Remove the O-ring from the 4WD linear solenoid.

(4) Using a 5 mm socket hexagon wrench, remove the 2 bolts and the yoke from the rear differential carrier assembly.

9. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER

10. REMOVE TRANSMISSION COUPLING SHIM

11. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(1) Insert a dial indicator into the rear differential side gear shaft oil seal hole, and place it perpendicular to the edge of a ring gear tooth.

(2) Using SST, secure the differential drive pinion.

SST: 09556-52010

(3) Using SST, check the backlash while rotating the rear differential case sub-assembly forward and in reverse.

SST: 09564-32011

Standard backlash:

0.088 to 0.208 mm (0.00347 to 0.00818 in.)

NOTICE:

Measure the ring gear at 3 or more locations.

12. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(1) Using SST and a torque wrench, measure the preload (starting torque) of the backlash between the differential drive pinion and differential ring gear.

SST: 09556-52010

Standard preload (at starting):

0.77 to 1.26 N*m (8 to 12 kgf*cm, 7 to 11 in.*lbf)

13. INSPECT TOTAL PRELOAD

(1) Using SST and a torque wrench, measure the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

SST: 09556-52010

Standard preload (at starting):

Total preload = drive pinion preload + 0.58 to 1.01 N*m (6 to 10 kgf*cm, 6 to 8 in.*lbf)

NOTICE:

Measure the preload after rotating the case bearing several times in the forward and reverse directions to make sure the bearing is operating correctly.

14. REMOVE REAR DRIVE SHAFT OIL SEAL RH

(1) Using SST, remove the rear drive shaft oil seal RH from the rear differential carrier assembly.

SST: 09308-00010

15. REMOVE REAR DRIVE SHAFT OIL SEAL LH

(a) Perform the same procedure as for the RH side.

16. REMOVE DIAPHRAGM OIL SEAL

(1) Using SST, remove the diaphragm oil seal from the rear differential carrier assembly.

SST: 09308-10010

17. REMOVE REAR DRIVE PINION NUT

(1) Using SST and a hammer, loosen the staked part of the rear drive pinion nut.

SST: 09930-00010

NOTICE:

• Use SST with the tapered surface facing the shaft side.
• Do not grind the end of SST with a grinder or other tool.
• Completely loosen the staked part of the rear drive pinion nut.
• Do not damage the threads of the differential drive pinion.

(2) Using SST, secure the differential drive pinion and remove the rear drive pinion nut from the differential drive pinion.

SST: 09556-52010

SST: 09564-16020

18. REMOVE REAR DRIVE PINION FRONT BEARING (INNER RACE)

(1) Using SST, remove the rear drive pinion front tapered roller bearing (inner race) from the rear differential carrier assembly.

SST: 09556-30010

19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

(1) Remove the 8 bolts.

(2) Using a brass bar and hammer, lightly tap the differential side bearing retainer and remove it.

NOTICE:

• Put the brass bar against the rib of the differential side bearing retainer.
• When removing the differential side bearing retainer, be careful not to scratch the installation surface.

HINT:

Prevent the differential side bearing retainer from falling by screwing in 2 bolts by 5 or 6 threads.

20. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

21. REMOVE DIFFERENTIAL DRIVE PINION

22. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

23. REMOVE REAR DRIVE PINION REAR BEARING (INNER RACE)

(1) Using SST and a press, remove the rear drive pinion rear tapered roller bearing (inner race) from the differential drive pinion.

SST: 09950-00020

NOTICE:

If the rear differential driver pinion or differential ring gear is damaged, replace them both.

(2) Remove the rear differential drive pinion washer.

24. REMOVE REAR DRIVE PINION FRONT BEARING (OUTER RACE)

(1) Attach the claws of SST to the rear drive pinion front tapered roller bearing (outer race) from the notches in the differential carrier sub-assembly.

SST: 09612-65014

09612-01020

09612-01050

(2) Using SST, remove the rear drive pinion front tapered roller bearing (outer race) from the rear differential carrier assembly.

SST: 09612-65014

09612-01020

09612-01050

25. REMOVE REAR DRIVE PINION REAR BEARING (OUTER RACE)

(1) Using a brass bar and hammer, uniformly lightly tap the rear drive pinion rear tapered roller bearing (outer race) and remove it.

NOTICE:

Put the brass bar into one of the notches.

26. REMOVE REAR DIFFERENTIAL CASE BEARING RH (OUTER RACE)

(1) Using SST and a press, remove the rear differential case bearing RH (outer race) and rear differential side gear shaft washer from the rear differential carrier assembly.

SST: 09950-60011

09951-00510

SST: 09950-70010

09951-07100

27. REMOVE REAR DIFFERENTIAL CASE BEARING LH (OUTER RACE)

(1) Using SST and a press, remove the rear differential case bearing LH (outer race) and rear differential side gear shaft washer from the differential side bearing retainer.

SST: 09649-17010

SST: 09950-60011

09951-00460

SST: 09950-70010

09951-07100

28. REMOVE REAR DIFFERENTIAL CASE BEARING RH (INNER RACE)

(1) Using SST, remove the rear differential case bearing RH (inner race) from the rear differential case sub-assembly.

SST: 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST: 09950-60011

09951-00320

NOTICE:

Before using SST center bolt (09953-04020), apply oil to its threads and tip.

HINT:

• If the race remains on the rear differential case sub-assembly, repeat the step above to remove the rear differential case bearing RH (inner race).
• If the rear differential case bearing RH (inner race) is deformed, replace it with a new one.

29. REMOVE REAR DIFFERENTIAL CASE BEARING LH (INNER RACE)

(1) Using SST, remove the rear differential case bearing LH (inner race) from the rear differential case sub-assembly.

SST: 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04071

09957-04010

09958-04011

SST: 09950-60011

09951-00320

NOTICE:

Before using SST center bolt (09953-04020), apply oil to its threads and tip.

HINT:

• If the race remains on the rear differential case sub-assembly, repeat the step above to remove the rear differential case bearing LH (inner race).
• If the rear differential case bearing LH (inner race) is deformed, replace it with a new one.

30. REMOVE DIFFERENTIAL RING GEAR

(1) Mount the rear differential case sub-assembly in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(2) Put matchmarks on the rear differential case sub-assembly and differential ring gear.

(3) Remove the 10 rear differential case bolts.

(4) Using a plastic-faced hammer, lightly tap the periphery of the differential ring gear to remove it from the rear differential case sub-assembly.

HINT:

Place a cloth on the teeth side of the ring gear to prevent damage.

31. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(1) Using a 5 mm socket hexagon wrench, remove the 2 bolts and rear differential breather plug oil deflector.

32. REMOVE STRAIGHT PIN

33. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

(1) Mount the rear differential case sub-assembly in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(2) Using a dial indicator, measure the differential side gear backlash.

Standard backlash:

0.05 to 0.20 mm (0.00197 to 0.00787 in.)

(3) If the backlash is not as specified, replace the rear differential case sub-assembly.

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