DIFFERENTIAL CASE REASSEMBLY

PROCEDURE

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

   
   

   1. 

      Coat the rotating surface of the front differential side gear with gear oil.

   2. Install the 2 front differential side gears and 2 front differential side gear thrust washers to the front differential case.

2. INSTALL FRONT DIFFERENTIAL PINION

   
   

   1. 

      Coat the rotating surface of the front differential pinion with gear oil.

   2. Install the 2 front differential pinion thrust washers and 2 front differential pinions from the differential case.

      Tech Tips

      Install the 2 front differential pinions with the front differential washers while turning the front differential pinion.

   3. 

      Install the No. 1 front differential pinion shaft into the differential case.

   4. 

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

   5. 

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

3. INSTALL FRONT DIFFERENTIAL RING GEAR

   
   
   1. 

      *1	90 to 100°C

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

   2. Heat the front differential ring gear to 90 to 110°C (194 to 230°F) in boiling water.

   3. 

      Text in Illustration

      *1

      Matchmark

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

   4. Install the 16 bolts.

      Torque:

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

4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

   
   

   1. 

      Using SST and a press, press in a new front tapered roller bearing.

      SST

      09309-14010

5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

   
   

   1. 

      Using SST and a press, press in a new rear tapered roller bearing.

      SST

      09554-22010