DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. A01RAE8C05
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      B007WXX ATF WS

      Coat the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs with ATF.

    2. A01RAA9C01
      *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.

      Note


      • Do not drop the front differential side gears, front No. 1 differential side gear thrust washers or conical springs.

      • Make sure that the conical springs are installed with the correct orientation.

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

      A01R91ZC01
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )

      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.

      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. A01RA8EC01
      B007WXX ATF WS

      Coat the 2 front differential pinions and 2 front differential pinion thrust washers with ATF.

    5. A01R9D0C01
      *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 to the front differential case.

      SST
      09528-52010   ( 09528-05030 )

      CAUTION:

      Be careful not to pinch your fingers between the front differential pinion and front differential case.

      Note

      Do not drop the front differential pinions or front differential pinion thrust washers.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01R9XDC01
      B007WXX ATF WS

      Coat the front No. 1 differential pinion shaft with ATF.

    2. 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.

  4. INSPECT FRONT DIFFERENTIAL CASE

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  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01REU5

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

    2. A01REFP

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

  6. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A01R96G

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

      Note

      Do not heat the front differential ring gear to more than 110°C (230°F).

    2. A01R91WC01
      *a Matchmark

      Clean the contact surface of the front differential case.

    3. Align the matchmarks, and install the front differential ring gear to the front differential case quickly.

    4. A01RBLI

      Install the 12 bolts.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }

      Note


      • Tighten the bolts after the front differential ring gear has cooled down sufficiently.

      • Tighten the bolts evenly in a diagonal pattern using several steps.

  7. INSTALL FRONT DRIVE SHAFT OIL SEAL RH (INNER)


    1. Coat the lip of a new front drive shaft oil seal RH (inner) with MP grease.

    2. A01REI3C01
      *a Depth

      Using SST and a hammer, install the front drive shaft oil seal RH (inner) to the front differential case.

      SST
      09950-60010   ( 09951-00410 )
      09950-70010   ( 09951-07200 )
      Standard Depth
      21.5 to 22.5 mm (0.846 to 0.886 in.)

      Note

      Do not damage the front drive shaft oil seal RH (inner) lip.