DIFFERENTIAL CASE REASSEMBLY

PROCEDURE

1. INSPECT FRONT DIFFERENTIAL SIDE GEAR

   1. 

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

      Table 1. Text in Illustration

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

   2. 

      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.

      Table 2. Text in Illustration

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

      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.

      09528-52010

      09528-05020

      09953-05010

      

      Table 3. Text in Illustration

      *a

      Turn

      *b

      Hold

      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. 

      Coat the front differential pinion thrust washer with gear oil.

      Table 4. Text in Illustration

      Gear Oil

   5. 

      Coat the front differential pinion with gear oil.

      Table 5. Text in Illustration

      Gear Oil

   6. 

      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.

      09528-52010

      09528-05040

      Table 6. Text in Illustration

      *a

      Turn

      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 and front differential pinion thrust washer.

   7. Remove SST from the front differential case assembly with ring gear.

2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   1. 

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

      Table 7. Text in Illustration

      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 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.