DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. A012I6HC01
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      A012M0O Gear Oil

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

    2. A012GZZC01
      *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 No. 1 differential case sub-assembly.

      Note


      • Do not drop the front differential side gear, front No. 1 differential side gear thrust washer and conical spring.

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

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

      A012HPGC01
      *a Turn *b Hold
      SST
      09528-52010   ( 09953-05010, 09528-05010 )

      Note

      Do not overtighten SST, as doing so will damage the front differential side gear, conical spring, front 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. A012MALC01
      A012M0O Gear Oil

      Coat the front differential pinion and front differential pinion thrust washer with gear oil.

    5. A012LAYC01
      *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 No. 1 differential pinion thrust washer.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A012G27C01
      A012M0O Gear Oil

      Coat a front No. 1 differential pinion shaft with 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. A012III

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

    2. A012LZS

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

  6. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A012J19C01
      *a 90 to 100°C (194 to 212°F)

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

    2. Clean the contact surface of the front No. 1 differential case sub-assembly.

    3. A012M6RC01
      *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. A012KMPN01

      Using SST and a press, install a new front differential case front tapered roller bearing to the front No. 1 differential case sub-assembly.

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

  8. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A012KHKN01

      Using SST and a press, install a new front differential case rear tapered roller bearing to the front No. 1 differential case sub-assembly.

      SST
      09554-22010