DIFFERENTIAL CASE REASSEMBLY

CAUTION / NOTICE / HINT

Note:

When replacing any tapered roller bearing, replace both the tapered roller bearing and tapered roller bearing outer race with new ones.

PROCEDURE

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

    1. Coat the 2 front differential side gears, 2 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers with gear oil.

    2. G021409

      Install the 2 front differential side gear thrust washers to the 2 front differential side gears.

    3. C303546

      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.

    4. G021411

      Coat the front differential pinion shaft with gear oil and install it to the front differential case.

    5. Inspect the front differential side gear backlash.

      Click here

    6. G021414

      Using a 3 mm pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.

    7. G021556

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

  2. INSTALL FRONT DIFFERENTIAL RING GEAR

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

    2. C166738

      Using a heater, heat the front differential ring gear to between 90 and 110°C (194 and 230°F).

    3. G021558C03

      *a

      Matchmark
      V100136

      Upper

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

    4. Install the 6 bolts.

      123.6 N*m

      1260 kgf*cm

      91 ft.*lbf

  3. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    1. G021559N01

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

      09350-32014

      09351-32120

      09351-32140

      Note:

      • Be sure to install the front differential case rear tapered roller bearing so that there is no clearance between the front differential case rear tapered roller bearing and front differential case.

      • Do not damage or deform the cage of the front differential case rear tapered roller bearing.

  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    1. F100233N01

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

      09350-32014

      09351-32120

      09351-32140

      Note:

      • Be sure to install the front differential case front tapered roller bearing so that there is no clearance between the front differential case front tapered roller bearing and front differential case.

      • Do not damage or deform the cage of the front differential case front tapered roller bearing.