Toyota Yaris: Differential Case / Inspection

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Drivetrain / Ea67f (manual Transmission / Transaxle) / Differential Case / Inspection

INSPECTION

PROCEDURE

1. INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Using SST, rotate the front differential side gear as shown in the illustration.

SST: 09528-52010

09528-05030

Standard:

The front differential side gear does not lock when rotated in either direction.

  • If the front differential side gear locks, perform all remaining inspection procedures.
  • Replace any parts that do not meet the specifications.
  • If the front differential side gear locks after performing the inspection procedures, replace the front No. 1 differential case sub-assembly.

2. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

(a) Secure the front differential case assembly with ring gear in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(b) Using SST and a dial indicator, measure the front differential side gear thrust amount.

SST: 09528-52010

09528-05030

Front Differential Side Gear Thrust Amount:

0.08 mm (0.00315 in.) or less

HINT:

  • Measure the front differential side gear thrust amount while slowly rotating the front differential side gear.
  • Make sure to measure the front differential side gear thrust amount for both of the 2 front differential side gears.

If the result is not as specified, replace the 2 front differential side gears, 2 front differential pinions and 2 conical springs.

*a

Front Differential Side Gear Thrust Amount

3. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

(a) Set SST as shown in the illustration and tighten it.

*a

Turn

*b

Hold

SST: 09528-52010

09528-05010

09953-05010

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.

*1

Front No. 1 Differential Pinion Shaft

(c) Using a dial indicator, measure the front differential pinion backlash.

Standard Backlash:

0.15 mm (0.00591 in.) or less

If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select a front No. 1 differential side gear thrust washer which will ensure that the backlash is within the specification.

Front No. 1 Differential Side Gear Thrust Washer Thickness:

Specified Condition

1.25 mm (0.0492 in.)

1.30 mm (0.0512 in.)

1.35 mm (0.0531 in.)

1.40 mm (0.0551 in.)

1.45 mm (0.0571 in.)

1.50 mm (0.0591 in.)

1.55 mm (0.0610 in.)

1.60 mm (0.0630 in.)

1.65 mm (0.0650 in.)

1.70 mm (0.0669 in.)

1.75 mm (0.0689 in.)

1.80 mm (0.0709 in.)

1.85 mm (0.0728 in.)

1.90 mm (0.0748 in.)

1.95 mm (0.0768 in.)

HINT:

Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

4. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER

(a) Using a micrometer, measure the thickness of the front differential pinion thrust washer.

Minimum Thickness:

0.54 mm (0.0213 in.)

If the thickness is less than the minimum, replace the front differential pinion thrust washer.

5. INSPECT FRONT NO. 1 DIFFERENTIAL PINION SHAFT

(a) Using a micrometer, measure the outer diameter of the front No. 1 differential pinion shaft.

Minimum Outer Diameter:

20.499 mm (0.807 in.)

If the outer diameter is less than the minimum, replace the front No. 1 differential pinion shaft.

*a

Outer Diameter

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