DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR (w/ Pre-torque Mechanism)


    1. A01VKF9E01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Front Conical Spring Washer
      *3 Front No. 1 Differential Side Gear Thrust Washer
      A01VL3H Gear Oil

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

    2. A01VIX3E02
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Front Conical Spring Washer
      *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 front conical spring washers to the front differential case.

      Note


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

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

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

      A01VGWYE02
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09953-05010, 09528-05020 )

      Note

      Do not overtighten SST as doing so will damage the front differential side gears, front conical spring washers, 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. A01VHZG

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

      Text in Illustration
      A01VL3H Gear oil
    5. A01VKWKE01
      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.

      SST
      09528-52010   ( 09528-05040 )

      CAUTION:

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

      Note

      Do not drop the front differential pinion or front No. 1 differential pinion thrust washer.

  2. INSTALL FRONT DIFFERENTIAL SIDE GEAR (w/o Pre-torque Mechanism)


    1. Coat the contact surfaces of the front differential side gears with manual transaxle oil.

    2. Install the 2 front No. 1 differential side gear thrust washers to the 2 front differential side gears.

    3. A01VLWM

      Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential pinion thrust washers to the front differential case.

      Tech Tips

      While rotating the front differential side gears, install the 2 front differential pinions and 2 front differential pinion thrust washers.

  3. INSPECT FRONT DIFFERENTIAL PINION BACKLASH (w/ Pre-torque Mechanism)

    Click here

  4. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01VHFF

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

      Text in Illustration
      A01VL3H Gear oil

    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.

  5. INSPECT FRONT DIFFERENTIAL CASE (w/ Pre-torque Mechanism)

    Click here

  6. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH (w/o Pre-torque Mechanism)

    Click here

  7. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01VGAI

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

    2. A01VJYI

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