DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSPECT FRONT DIFFERENTIAL SIDE GEAR


    1. A0053J4E01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *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 conical spring with gear oil.

    2. A0055CSE03
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *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 springs 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 or conical spring.

      • Make sure that the conical spring is installed with the correct orientation.

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

      SST
      09528-52010   ( 09528-05020, 09953-05010 )
      A00579WE06
      Text in Illustration
      *a Turn *b Hold

      Note

      Do not overtighten SST as doing so will damage the front differential side gears, conical springs, 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. A005842

      Coat the front differential pinion thrust washer with gear oil.

      Text in Illustration
      A0054DN Gear Oil
    5. A0057EX

      Coat the front differential pinion with gear oil.

      Text in Illustration
      A0054DN Gear Oil
    6. A0054I7E05
      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 and front differential pinion thrust washer.

    7. Remove SST from the front differential case assembly with ring gear.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A0057SB

      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 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 ASSEMBLY WITH RING GEAR

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  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A005329

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

    2. A0056DE

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