DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. A01GCN0C01
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      A01GAQ1 Gear Oil

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

    2. A01GC86C01
      *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.

      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      A01GB13C01
      *a Turn *b Hold

      Note

      Do not overtighten SST, as doing so will damage the front differential side gear, conical spring, 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. A01GCJ3C01
      A01GAQ1 Gear Oil

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

    5. A01GBKIC01
      *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 PINION BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01GD8VC01
      A01GAQ1 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. A01GAX8

      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. A01GCPH

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

  6. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. Clean the contact surface 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. A01GC23C01
      *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. A01GCIVN01

      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
      09316-20011

      Note

      Be sure to install the front differential case front tapered 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. A01GAB1N01

      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

      Note

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

  9. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL


    1. Coat the lip of a new front differential case oil seal with MP grease.

    2. A01GC0HC01
      *a 21.5 to 22.5 mm (0.847 to 0.885 in.)

      Using SST and a hammer, tap in a new front differential case oil seal to the front differential case.

      SST
      09950-60010   ( 09951-00410 )
      09950-70010   ( 09951-07200 )
      Standard depth
      21.5 to 22.5 mm (0.847 to 0.885 in.)

      Note

      Do not damage the front differential case oil seal lip.