DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. A01VKF9E01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 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 conical spring washer with gear oil.

    2. A01VIX3E02
      Text in Illustration
      *1 Front Differential Side Gear
      *2 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 conical spring washers to the front differential case assembly with ring gear.

      Note


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

      • Make sure that the 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, conical spring washers, front No. 1 differential side gear thrust washers and front differential case assembly with ring gear.

      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 assembly with ring gear.

      Note

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

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  3. 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 assembly with ring gear so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case assembly with ring gear.

  4. INSPECT FRONT DIFFERENTIAL CASE

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  5. 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 assembly with ring gear.

    2. A01VJYI

      Using a chisel and a hammer, stake the front differential case assembly with ring gear.