DIFFERENTIAL CASE REASSEMBLY

PROCEDURE

  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. C200235

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

      Tip:

      While rotating the 2 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. C200236

      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

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  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

    1. C200237

      Using a 5 mm pin punch and hammer, tap in the front differential pinion shaft straight pin to the front differential case.

    2. C200238

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

  5. INSTALL FRONT DIFFERENTIAL RING GEAR

    1. Clean the contact surfaces of the front differential case and front differential ring gear.

    2. Heat the front differential ring gear to 90 to 110°C (194 to 230°F) in boiling water.

    3. C199116C02

      *a

      Matchmark

      After the moisture on the front differential ring gear has completely evaporated, quickly align the matchmarks on the front differential ring gear and the differential case and install the front differential ring gear to the front differential case.

    4. Install the 12 bolts.

      106 N*m

      1081 kgf*cm

      78 ft.*lbf