DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL CASE


    1. A0137DZE01

      Install the front differential side gear thrust washers to the front differential side gears.

    2. A013678E01

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

    3. A0136LSE01

      Install the front differential pinion shaft to the front differential case.

    4. A0136I3E01

      Using a dial indicator, measure the front differential side gear backlash.

      Tech Tips

      Measure the front differential side gear backlash while holding one pinion gear toward the front differential case.

    5. If the backlash is not as specified, replace the front differential side gear thrust washers with washers of a different thickness. Use the table below to select a front differential side gear thrust washer which will ensure that the backlash is within the specification.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)
      Front Differential Side Gear Thrust Washer Thickness
      Part No.

      Thickness

      mm (in.)
      41361-70010 0.50 (0.0197)
      41361-70020 0.55 (0.0217)
      41361-70030 0.60 (0.0236)
      41361-70040 0.65 (0.0256)
      41361-70050 0.70 (0.0276)
      41361-70060 0.75 (0.0295)
      41361-70070 0.80 (0.0315)
      41361-70080 0.85 (0.0335)
      41361-70090 0.90 (0.0354)
      41361-70100 0.95 (0.0374)
    6. A0136M4E01

      Using a pin punch 3 mm and a hammer, tap in the front differential pinion shaft straight pin through the front differential case and the hole in the front differential pinion shaft.

    7. A0138RTE01

      Using a hammer and a chisel, stake the pin holes around the circumference of the front differential case.

  2. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. Clean the contact surfaces of the front differential case and the front differential ring gear.

    2. A0137C3

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

    3. A0136YQE06
      Text in Illustration
      *a Matchmark

      After the moisture on the front differential ring gear has completely evaporated, quickly align the matchmarks on the front differential ring gear and the front differential case and install the front differential ring gear to the front differential case.

    4. Install the 6 bolts.

      Torque:
      124 N*m  { 1260 kgf*cm, 91 ft.*lbf }

  3. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A0138KSE02

      Using SST and a press, install the front differential case rear tapered roller bearing to the front differential case.

      SST
      09350-32014   ( 09351-32120, 09351-32140 )

  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0137TZE01

      Using SST and a press, install the front differential case front tapered roller bearing to the front differential case.

      SST
      09350-32014   ( 09351-32120, 09351-32140 )