DIFFERENTIAL CASE REASSEMBLY

PROCEDURE

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

    1. C288461C01

      *1

      Front Differential Side Gear

      *2

      conical spring

      *3

      Front No. 1 Differential Side Gear Thrust Washer
      V100135

      Gear Oil

      Coat the front differential side gear, front No. 1 differential side gear thrust washer and conical spring with gear oil.

    2. C287713C01

      *1

      Front Differential Side Gear

      *2

      conical spring

      *3

      Front No. 1 Differential Side Gear Thrust Washer

      Install the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs to the front No. 1 differential case sub-assembly.

      Note:

      • Do not drop the front differential side gear, front No. 1 differential side gear thrust washer and conical spring.

      • Make sure that the conical spring is installed in the correct orientation.

    3. Set SST as shown in the illustration and tighten it.

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      09528-05010

      09953-05010

      C290677C01

      *a

      Turn

      *b

      Hold
      Note:

      Do not overtighten SST, as doing so will damage the front differential side gear, conical spring, front No. 1 differential side gear thrust washer and front No. 1 differential case sub-assembly.

      Tip:

      • Tighten SST to create the necessary clearance to install the front differential pinions.

      • When installing the front differential pinions, do not overtighten SST, as it is necessary to rotate the front differential side gears.

    4. C301356C01
      V100135

      Gear Oil

      Coat the front differential pinion and front differential pinion thrust washer with gear oil.

    5. C287718C01

      *a

      Turn

      Using SST as shown in the illustration, rotate the front differential side gear and install the 2 front differential pinions and 2 front differential pinion thrust washers.

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      09528-05030

      CAUTION:

      Be careful not to catch your fingers between the front differential pinion and front No. 1 differential case sub-assembly.

      Note:

      Do not drop the front differential pinion and front differential pinion thrust washer.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

    1. C287719C01
      V100135

      Gear Oil

      Coat a front No. 1 differential pinion shaft with gear oil.

    2. Install the front No. 1 differential pinion shaft to the front No. 1 differential case sub-assembly so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front No. 1 differential case sub-assembly.

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

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  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

    1. C287720

      Using a 5 mm pin punch and hammer, install the front differential pinion shaft straight pin to the front No. 1 differential case sub-assembly.

    2. C287721

      Using a chisel and hammer, stake the front No. 1 differential case sub-assembly.

  6. INSTALL FRONT DIFFERENTIAL RING GEAR

    1. Clean the contact surface of the front No. 1 differential case sub-assembly and front differential ring gear.

    2. Using a heater, heat the front differential ring gear to 90 to 100°C (194 to 212°F).

    3. C299266C01

      *a

      Matchmark

      While aligning the matchmarks, quickly install the front differential ring gear to the front No. 1 differential case sub-assembly with the 16 bolts.

      106 N*m

      1081 kgf*cm

      78 ft.*lbf

  7. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    1. C287723N01

      Using SST and a press, install a new front differential case front tapered roller bearing to the front No. 1 differential case sub-assembly.

      09523-36010

      09950-60010

      09951-00460

      09951-00560

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      09950-70010

      09951-07150

      Note:

      Be sure to install the front differential case front tapered roller bearing so that there is no clearance between the bearing inner race and front No. 1 differential case sub-assembly.

  8. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    1. C287724N01

      Using SST and a press, install a new front differential case rear tapered roller bearing to the front No. 1 differential case sub-assembly.

      09554-22010

      Note:

      Be sure to install the front differential case rear tapered roller bearing so that there is no clearance between the bearing inner race and front No. 1 differential case sub-assembly.