DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSPECT FRONT DIFFERENTIAL SIDE GEAR


    1. A002NFWE01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      A002OPC Gear Oil

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

    2. A002ORPE02
      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 )
      A002PWPE05
      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. A002NUB

      Coat the front differential pinion thrust washer with gear oil.

      Text in Illustration
      A002OPC Gear Oil
    5. A002N4E

      Coat the front differential pinion with gear oil.

      Text in Illustration
      A002OPC Gear Oil
    6. A002OLYE04
      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. A002LU4

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

      Text in Illustration
      A002OPC 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. A002M9Q

      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. A002M0M

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