DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. A0053J4E01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Center Differential Side Gear Conical Spring Washer
      *3 Front No. 1 Differential Side Gear Thrust Washer
      A0054DN Gear Oil

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

    2. A0058EEE06
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Center Differential Side Gear 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 center differential side gear 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 center differential side gear conical spring washer.

      • Make sure that the center differential side gear conical spring washer is installed in the correct direction.

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

      SST
      09528-52010   ( 09953-05010, 09528-05010 )
      A00564GE05
      Text in Illustration
      *a Turn *b Hold

      Note

      Do not overtighten SST, as doing so will damage the front differential side gear, center differential side gear conical spring washer, front No.1 differential side gear thrust washer 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. A005682

      Coat the front differential pinion with gear oil.

      Text in Illustration
      A0054DN Gear Oil
    5. A00564C

      Coat the front differential pinion thrust washer with gear oil.

      Text in Illustration
      A0054DN Gear Oil
    6. A00563ZE06

      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   ( 09528-05030 )

      CAUTION:

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

      Note

      Do not drop the front differential pinions and front No. 1 differential pinion thrust washers.

    7. Remove SST from the front differential case.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

    Click here

  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A0057XV

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

      Text in Illustration
      A0054DN 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.

  4. INSPECT FRONT DIFFERENTIAL CASE

    Click here

  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A0055KX

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

      Note

      Align the holes in the front differential case and front No. 1 differential pinion shaft and install the front differential pinion shaft straight pin.

    2. A0059AF

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

  6. INSTALL FRONT DIFFERENTIAL RING GEAR


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

    2. Using a heater, heat the front differential ring gear to 90 to 100°C (194 to 212°F).

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

    4. A005307

      Install the 12 bolts.

      Torque:
      106 N*m  { 1081 kgf*cm, 78 ft.*lbf }

      Note

      Tighten the bolts in diametrically opposite pairs.