DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL CASE


    1. A0137DZ

      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 (0.0020 to 0.0079 in.)
      Thickness mm (in.) Thickness mm (in.)
      0.50 (0.0197) 0.75 (0.0295)
      0.55 (0.0217) 0.80 (0.0315)
      0.60 (0.0236) 0.85 (0.0335)
      0.65 (0.0256) 0.90 (0.0354)
      0.70 (0.0276) 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 (0.0020 to 0.0079 in.)

      If the backlash is not within the specification, 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 chisel and hammer, caulk the pin holes around the circumference of the front differential case.

  2. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A0136X7E05

      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. A0136YQE04

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

      Torque:
      124 N*m  { 1,260 kgf*cm, 91 ft.*lbf }

  3. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A0138KSE01

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

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

  4. INSTALL FR0NT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0137TZE01

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

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