DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. B001O9XE03
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      B001O8N ATF

      Coat the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs with ATF.

    2. B001OO7E04
      Text in Illustration
      *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 differential case.

      Note


      • Do not drop the front differential side gears, front No. 1 differential side gear thrust washers or conical springs.

      • Make sure that the conical springs are installed with the correct orientation.

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

      B001OANE05
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )

      Note

      Do not overtighten SST, as doing so will damage the front differential side gears, conical springs, front No. 1 differential side gear thrust washers and front differential case.

      Tech Tips


      • 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. B001O9E

      Coat the 2 front differential pinions and 2 front differential pinion thrust washers with ATF.

      Text in Illustration
      B001O8N ATF
    5. B001O90E01
      Text in Illustration
      *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 to the front differential case.

      SST
      09528-52010   ( 09528-05030 )

      CAUTION:

      Be careful not to pinch your fingers between the front differential pinion and front differential case.

      Note

      Do not drop the front differential pinions or front differential pinion thrust washers.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. B001NYH

      Coat the front No. 1 differential pinion shaft with ATF.

      Text in Illustration
      B001O8N ATF

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

  4. INSPECT FRONT DIFFERENTIAL CASE

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  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. B001OR4

      Using a 5 mm pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.

    2. B001OB7

      Using a chisel and a hammer, stake the front differential case.

  6. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. B001NXI

      Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).

      Note

      Do not heat the front differential ring gear to more than 110°C (230°F).

    2. Clean the contact surface of the front differential case.

    3. B001NMIE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks, and install the front differential ring gear to the front differential case quickly.

    4. B001ODX

      Install the 12 bolts.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }

      Note


      • Tighten the bolts after the front differential ring gear has cooled down sufficiently.

      • Tighten the bolts evenly in a diagonal pattern using several steps.