Toyota Corolla 2004 Repair Manual - DIFFERENTIAL CASE ASSY

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OVERHAUL

–MANUAL TRANSMISSION/TRANSAXLE DIFFERENTIAL CASE ASSY (C59)

4107L–01

1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR

(a) Remove the speedometer drive (MTM) gear from the front

differential case.

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Matchmarks

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2. REMOVE FRONT DIFFERENTIAL RING GEAR

(a) Place matchmarks on the front differential ring gear and

front differential case.

(b) Remove the 8 bolts. Using a hammer, remove the front

differential ring gear.

3. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH

(a) Fixing the front differential pinion from the front differential

case side. Using a dial indicator, measure the backlash of
the front differential side gear.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

If the backlash is not within the specification, install the connect
side gear thrust washers.

2004 COROLLA (RM1037U)

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–MANUAL TRANSMISSION/TRANSAXLE DIFFERENTIAL CASE ASSY (C59)

4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN

(a) Using a chisel and a hammer, loosen the staked part of

the front differential case.

(b) Using a pin punch (φ 3 mm) and a hammer, remove the

front differential pinion shaft straight pin from the front dif­ferential case.

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5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1

(a) Remove the front differential pinion shaft No.1 from the

front differential case.

6. REMOVE FRONT DIFFERENTIAL SIDE GEAR

(a) Remove the 2 front differential pinions, 2 front differential

pinion thrust washers, 2 front differential side gear thrust
washers and 2 front differential side gears from the front
differential case.

HINT:
Turning the front differential pinion, remove the 2 pinions and
side gear.

2004 COROLLA (RM1037U)

7. INSPECT FRONT DIFFERENTIAL PINION THRUST
WASHER

(a) Using a micrometer, measure the thickness of the front

differential pinion thrust washer.

Minimum thickness: 0.92 mm (0.0362 in.)

If the clearance is below the minimum, replace the front differ­ential pinion thrust washer.

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