DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. B000L30E03
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      B000K70 ATF

      Coat the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs with ATF.

    2. B000IDZE01
      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.

      Note


      • Do not drop the front differential side gears, front No. 1 differential side gear thrust washers or conical springs.

      • Make sure that the conical springs are installed with the correct orientation.

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

      B000IOHE01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )

      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.

      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. B000IT2

      Coat the 2 front differential pinions and 2 front differential pinion thrust washers with ATF.

      Text in Illustration
      B000K70 ATF
    5. B000KNZE01
      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 to the front differential case.

      SST
      09528-52010   ( 09528-05030 )

      CAUTION:

      Be careful not to pinch your fingers between the front differential pinion and front differential case.

      Note

      Do not drop the front differential pinions or front differential pinion thrust washers.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH


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

      B000JD2E01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Secure the front differential case with front differential ring gear in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. B000JX0E01
      Text in Illustration
      *1 Front No. 1 Differential Pinion Shaft

      Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.

    4. Using a dial indicator, measure the front differential pinion backlash.

      Standard Backlash
      0.20 mm (0.00787 in.) or less

      If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select front No. 1 differential side gear thrust washers which will ensure that the backlash is within the specification.

      Tech Tips

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

      Front No. 1 Differential Side Gear Thrust Washer Thickness:
      Part No. Thickness (mm (in.))
      41361-73050 0.90 (0.0354)
      41361-73010 1.00 (0.0394)
      41361-73020 1.10 (0.0433)
      41361-73030 1.20 (0.0472)

  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. B000MOQ

      Coat the front No. 1 differential pinion shaft with ATF.

      Text in Illustration
      B000K70 ATF

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

  4. INSPECT FRONT DIFFERENTIAL CASE


    1. B000KCJE01

      Using SST, rotate the front differential side gear as shown in the illustration.

      SST
      09528-52010   ( 09528-05030 )
      Standard
      The front differential side gear does not lock when rotated in either direction.

      • If the front differential side gear locks, perform all of the following inspections.

      • If the front differential side gear still locks after replacing the malfunctioning parts, replace the front differential case.

      • Replace any parts that do not meet the specifications.

  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. B000IUG

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

    2. B000IJ3

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

  6. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. B000MS5

      Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).

      Note

      Do not heat the front differential ring gear to more than 110°C (230°F).

    2. Clean the contact surface of the front differential case.

    3. B000JBFE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks, and install the front differential ring gear to the front differential case quickly.

    4. B000NHX

      Install the 12 bolts.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }

      Note


      • Tighten the bolts after the front differential ring gear has cooled down sufficiently.

      • Tighten the bolts evenly in a diagonal pattern using several steps.