DIFFERENTIAL CASE REASSEMBLY

PROCEDURE

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

   1. 

      *1	Front Differential Side Gear
      *2	Conical Spring
      *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 conical spring with gear oil.

   2. 

      *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 assembly with ring gear.

      Note:

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

      • Make sure that the conical spring is installed with the correct orientation.

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

      

      *a

      Turn

      *b

      Hold

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      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 assembly with ring gear.

      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 assembly with ring gear.

      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 the front No. 1 differential pinion shaft with gear oil.

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

4. INSPECT FRONT DIFFERENTIAL CASE ASSEMBLY WITH RING GEAR

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5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

   1. 

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

   2. 

      Using a chisel and hammer, stake the front differential case assembly with ring gear.