DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL DIFFERENTIAL SIDE GEAR

    A01IU2FE01

    1. Coat the 2 differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.

  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

    A01IQFO

    1. Coat the front No. 1 differential pinion shaft with ATF and install it to the differential case.

  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

    A01IU5FE01

    1. Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator at a right angle to one of the side gear teeth.

    3. Hold the pinion gear in the differential case and measure the backlash of the side gear.

      Standard backlash
      0 to 0.15 mm (0 to 0.00591 in.)

      If the backlash is not within the specified range, replace both side gear thrust washers with side gear thrust washers of a different thickness.

      Thrust Washer Thickness
      Thickness Thickness
      1.50 mm (0.0591 in.) 1.75 mm (0.0689 in.)
      1.55 mm (0.0610 in.) 1.80 mm (0.0709 in.)
      1.60 mm (0.0630 in.) 1.85 mm (0.0728 in.)
      1.65 mm (0.0650 in.) 1.90 mm (0.0748 in.)
      1.70 mm (0.0669 in.) -

  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

    A01ISWT

    1. Using a 3 mm pin punch and hammer, install the pinion shaft straight pin.

      Note

      Align the holes in the differential case and differential pinion shaft and install the pinion shaft straight pin.

    2. A01ITM8

      Using a chisel and hammer, stake the differential case.

      Note

      Stake the differential case after inspecting the backlash.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01ITENE01

      Using SST and a press, install a new front differential case rear tapered roller bearing to the differential case.

      SST
      09710-30012   ( 09710-04081 )
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )

      Note

      Do not damage the bearing cage during bearing inner race installation.

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    A01ISS7E02

    1. Using SST and a press, install a new front differential case front tapered roller bearing to the differential case.

      SST
      09710-30012   ( 09710-04081 )
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )

      Note

      Do not damage the bearing cage during bearing inner race installation.

  7. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A01IRF7E10

      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 ring gear to more than 110°C (230°F).

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

    3. A01IRGME05
      Text in Illustration
      *1 Matchmark

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

      Note

      Do not install the bolts while the ring gear is hot.

    4. A01IRO8

      Install and tighten the 12 bolts.

      Torque:
      120 N*m  { 1223 kgf*cm, 88 ft.*lbf }

      Note

      Tighten the bolts in diametrically opposite pairs.