DIFFERENTIAL CASE REASSEMBLY


  1. INSPECT FRONT DIFFERENTIAL SIDE GEAR


    1. A01IRLME01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      A01ISM9 Gear Oil

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

    2. A01INI6E01
      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 assembly with ring gear.

      Note


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

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

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

      SST
      09528-52010   ( 09528-05020, 09953-05010 )
      A01IR6HE01
      Text in Illustration
      *a Turn *b Hold

      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 assembly with ring gear.

      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. A01IUMB

      Coat the front differential pinion thrust washer with gear oil.

      Text in Illustration
      A01ISM9 Gear Oil
    5. A01IOY4

      Coat the front differential pinion with gear oil.

      Text in Illustration
      A01ISM9 Gear Oil
    6. A01IOR3E01
      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.

      SST
      09528-52010   ( 09528-05040 )

      CAUTION:

      Be careful not to catch your fingers between the front differential pinion and front differential case assembly with ring gear.

      Note

      Do not drop the front differential pinion and front differential pinion thrust washer.

    7. Remove SST from the front differential case assembly with ring gear.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH


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

      SST
      09528-52010   ( 09528-05020, 09953-05010 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      A01IT56E01
      Text in Illustration
      *a Turn *b Hold

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

      Note

      Do not overtighten the vise.

    3. A01IP0FE01
      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 a front No. 1 differential side gear thrust washer which will ensure that the backlash is within the specification.

      Front No. 1 Differential Side Gear Thrust Washer Thickness
      Mark Specified Condition
      19 0.90 mm (0.0354 in.)
      14 0.95 mm (0.0374 in.)
      02 1.00 mm (0.0394 in.)
      15 1.05 mm (0.0413 in.)
      03 1.10 mm (0.0433 in.)
      16 1.15 mm (0.0453 in.)
      04 1.20 mm (0.0472 in.)

      Tech Tips

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

  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01IPXU

      Coat the front No. 1 differential pinion shaft with gear oil.

      Text in Illustration
      A01ISM9 Gear Oil

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

  4. INSPECT FRONT DIFFERENTIAL CASE ASSEMBLY WITH RING GEAR


    1. A01IROAE01

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

      SST
      09528-52010   ( 09528-05040 )
      Standard
      The front differential side gear does not lock when rotated in either direction.

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

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

  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01IPQH

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

    2. A01IQRN

      Using a chisel and hammer, stake the front differential case assembly with ring gear.