DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. Coat the contact surfaces of the front differential side gears with gear oil.

    2. Install the 2 front No. 1 differential side gear thrust washers onto the 2 front differential side gears.

    3. A0116YY

      Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential pinion thrust washers onto the front differential case.

      Tech Tips

      While rotating the front differential side gears, install the 2 front differential pinions and 2 front differential pinion thrust washers.

  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. Coat the front No. 1 differential pinion shaft with MP grease.

    2. A011AWSE01

      Install the front No. 1 differential pinion shaft onto 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.

  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A0119P4

      Install the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      If the backlash is out of specification, replace the side gear thrust washers.

      Thrust Washer Thickness
      Parts No. Mark

      Thickness

      mm (in.)
      41361-22140 14 0.95 (0.0374)
      41361-22020 02 1.00 (0.0394)
      41361-22150 15 1.05 (0.0413)
      41361-22030 03 1.10 (0.0433)
      41361-22160 16 1.15 (0.0453)
      41361-22040 04 1.20 (0.0472)
      41361-22170 17 1.25 (0.0492)
      41361-22120 12 1.30 (0.0512)
      41361-22180 18 1.35 (0.0531)
      41361-22130 13 1.40 (0.0551)

      Tech Tips


      • Measure the thickness with a micrometer to select a proper thrust washer because the thrust washers do not have any distinguishing marks.

      • Select washers of the same thickness for both the right and left sides.

  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A011B4I

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

    2. A011BKO

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