DIFFERENTIAL CASE REASSEMBLY

PROCEDURE

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

   1. 

      *1	Front Differential Side Gear
      *2	Center Differential Side Gear Conical Spring Washer
      *3	Front No. 1 Differential Side Gear Thrust Washer
      	Gear Oil

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

   2. 

      *1	Front Differential Side Gear
      *2	Center Differential Side Gear Conical Spring Washer
      *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 center differential side gear conical spring washers to the front differential case.

      Note:

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

      • Make sure that the center differential side gear conical spring washer is installed in the correct direction.

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

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      *a

      Turn

      *b

      Hold

      Note:

      Do not overtighten SST, as doing so will damage the front differential side gear, center differential side gear conical spring washer, front No.1 differential side gear thrust washer and front differential case sub-assembly.

      Tip:

      • 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. 

      Gear Oil

      Coat the front differential pinion and front differential pinion thrust washer with gear oil.

   5. 

      *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.

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      CAUTION:

      Be careful not to catch your fingers between the front differential pinion and front differential case sub-assembly.

      Note:

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

2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   1. 

      Gear Oil

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

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

4. INSPECT FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

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5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

   1. 

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

   2. 

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

6. INSTALL FRONT DIFFERENTIAL RING GEAR

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

   2. Using a heater, heat the front differential ring gear to 90 to 100°C (194 to 212°F).

   3. 

      *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 front differential case sub-assembly and install the front differential ring gear to the front differential case sub-assembly.

   4. Install the 12 bolts.

      106 N*m

      1081 kgf*cm

      78 ft.*lbf