DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL CASE

    A0137DZ

    1. Install the appropriate thrust washers and side gears.

      Refer to the table below and select thrust washers that bring the backlash to within the specifications. Select washers of the same size for both sides.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)
      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)
    2. A013678

      Install the thrust washers and the side gears into the differential case.

    3. A0136LS

      Install the pinion shaft.

    4. A0136I3

      Using a dial indicator, check the side gear backlash.

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

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      If the backlash is not within the specifications, install a thrust washer of a different thickness.

    5. A0136M4

      Using a pin punch and a hammer, install the pinion shaft slotted spring pin through the front differential case and the hole in the pinion shaft.

    6. A0138RT

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

  2. INSTALL FRONT DIFFERENTIAL RING GEAR

    A0137C3

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

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

    3. A0136YQE06
      Text in Illustration
      *a Matchmark

      Aligning the matchmarks, quickly install the front differential ring gear onto the front differential case with the 6 bolts.

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

  3. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    A0138KSE01

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

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

  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    A0137TZE01

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

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