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 to the 2 front differential side gears.

    3. A01IO4K

      Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential pinion thrust washers to 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. A01IS33

      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.

  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01IRGS

      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 not as specified, replace the side gear thrust washers with washers of a different thickness. Use the table below to select a side gear thrust washer which will ensure that the backlash is within the specification.

      Thrust Washer Thickness
      Part No. Mark Specified Condition
      41361-22140 14 0.95 mm (0.0374 in.)
      41361-22020 02 1.00 mm (0.0394 in.)
      41361-22150 15 1.05 mm (0.0413 in.)
      41361-22030 03 1.10 mm (0.0433 in.)
      41361-22160 16 1.15 mm (0.0452 in.)
      41361-22040 04 1.20 mm (0.0472 in.)

      Tech Tips

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

  4. 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.

    2. A01IQRN

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