DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. A004PVUE01
      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
      A004NPW Gear Oil

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

    2. A004SYLE03
      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 No. 1 differential case sub-assembly.

      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 )
      A004PX7E03
      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 No. 1 differential case sub-assembly.

      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. A004P6E

      Apply gear oil to the front differential pinion thrust washer.

      Text in Illustration
      A004NPW Gear Oil
    5. A004OB1

      Apply gear oil to the front differential pinion.

      Text in Illustration
      A004NPW Gear Oil
    6. A004RHBE01
      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   ( 09528-05030 )

      CAUTION:

      Be careful not to catch your fingers between the front differential pinion and front No. 1 differential case sub-assembly.

      Note

      Do not drop the front differential pinion and front differential pinion thrust washer.

  2. INSPECT FRONT DIFFERENTIAL PINIONBACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINIONSHAFT


    1. A004T9W

      Apply gear oil to the front No. 1 differential pinion shaft.

      Text in Illustration
      A004NPW Gear Oil

    2. Install the front No. 1 differential pinion shaft to the front No. 1 differential case sub-assembly so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front No. 1 differential case sub-assembly.

  4. INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

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  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A004NZE

      Using a 5 mm pin punch and hammer, tap in the front differential pinion shaft straight pin to the front No. 1 differential case sub-assembly.

    2. A004QZZ

      Using a chisel and hammer, stake the front No. 1 differential case sub-assembly.

  6. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. Clean the contact surfaces of the front No. 1 differential case sub-assembly 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. A004TVOE01
      Text in Illustration
      *a Matchmark

      While aligning the matchmarks, quickly install the front differential ring gear to the front No. 1 differential case sub-assembly with the 16 bolts.

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

  7. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A004ROZE01

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

      SST
      09523-36010
      09950-60010   ( 09951-00460, 09951-00560, 09952-06010 )
      09950-70010   ( 09951-07150 )

      Note

      Be sure to install the front differential case front taperd roller bearing so that there is no clearance between the bearing inner race and front No. 1 differential case sub-assembly.

  8. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A004N48E01

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

      SST
      09554-22010

      Note

      Be sure to install the front differential case rear taperd roller bearing so that there is no clearance between the bearing inner race and front No. 1 differential case sub-assembly.