Now we're ready to re-assemble the trans. First up the diff installing as per the E250 Manual, you need to install the differential & output shaft & measure the side bearing preload, & the output shaft preload. You will need to assemble the transmission without the FIPG and test the torque that it takes to start turning the diff, then the output shaft. Mine were close enough to being in spec to not worry about changing the shims. The shim for the differential side bearing is hard to change as you need to use the bearing puller to press out the bearing halve on the oil baffle/oil seal side.
Next up remove the case halve & remove the output shaft. Install the input & output shaft together as they won't go in separately. In goes the reverse idler gear & rocker arm, the three selector shafts & selectors.
Case halve goes on with the FIPG gasket. You need to either use the genuine Toyota Red FIPG which is about $40 for the tube or a FIPG that is suitable for use with gear oil. The standard off the shelf stuff, even the high temp red/copper will eventually fail as it's not suitable for use with gear oil. It needs to be specifically for differentials or manual gearboxes. I used the toyota red FIPG.
AWD Transfer Box
Now there's the problem of installing the bolt studs. The genuine bolt studs are M12x1.25 68mm long. Unfortunately they were not available here in AUS, so I've ended up getting 1m of high tensile threaded rod and making my own studs. The problem is that they were not zinc plated, so would rust & be pretty hard to get off next time so I got some "cold galv" & painted them. I'll also paint them after installing just to make sure it's not going to rust. Left is the original stud in the E250F Trans, Right are the new high tensile threaded rod studs. I cut them with a hacksaw - which took a very long time - as I didn't want heat de-grading the tensile strength of the stud using a friction saw. This may not be necessary but thought I'd take the precaution.
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Next is sliding the transfer case into place & doing up the bolts
Posted by ST: 27th May 2013
Additional Pics Differentials;
Left E250 (Rav), right E53 (Camry)
E53 Dissasembled;
E53 inside gearbox;
The rest of the images are on the previous post "Dissasembling the E250F & E53 Transaxles #2"
Updated by ST: 19th Sept 2016
Posted by ST: 27th May 2013
Additional Pics Differentials;
Left E250 (Rav), right E53 (Camry)
E53 Dissasembled;
E53 inside gearbox;
The rest of the images are on the previous post "Dissasembling the E250F & E53 Transaxles #2"
Updated by ST: 19th Sept 2016
Hey, are you still working on this? That is a very respectable project!
ReplyDeleteWould you happen to have any pictures of the E53 differential?
I'm pretty much finished the project with only a few things to tinker with.
DeleteThe E53 and E250 differential are identical from the outside which is why I was able to swap the crown gear off the E53 onto the E150 front/centre differential. Internally the E53 has only one set of spider gears where the E150 has 2 sets making it a centre and front diff in one unit which is pretty cool. I'll add some more pics shortly to this page.
Alright cool! I was somewhat curious as to make my own Camry AWD, But seeing as the diff is so much different, I might just have to settle with putting a Quaife LSD into it. Still need to confirm if it'll fit my gearbox though, prior to ordering it.
DeleteActually scratch that, I suppose that's still possible to do, However I'd have to ditch the idea of getting a bolt-in LSD for the front wheels.
DeleteI would like to know if you used the same shafts from the RAV4 into the Camry Transaxle?
ReplyDeleteNo, I used the Rav4 CV Shafts as they suit the AWD transfer case, you wouldn't be able to use the camry CV's unless you modified them somewhat. Rav CV's should be more than strong enough for NA 3VZ.
DeleteAwesome project. Doesn't changing the front diff ratio from 4.9 to 3.6 affect your rear diff ratio?
ReplyDeleteHi Garry,
DeleteThe front and centre diff are within the same housing. The Ring gear drives into the centre diff, then the drive is split between the front & rear diff, so changing the ring gear ratio just changes the final drive ratio. The transfer case is just a "Right angle drive" that transfers one side of the centre diff to the rear. So changing the transfer case or rear diff ratio will change the front/rear ratio's.
In your experience with both transaxles, the E250F and the S53. I am incline to believe that a Cusco LSD FWD Transaxle from the S53 will work on the RAV4 E250 Transaxle. What do you think?
ReplyDeleteDo you still have the 4.9 final drive crown and pinion?
ReplyDelete