DIFFERENTIAL CASE > REASSEMBLY

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1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

  1. Coat the contact surfaces of the front differential side gears with gear oil.

  1. Install the 2 front No. 1 differential side gear thrust washers onto the 2 front differential side gears.



    C193765

  1. Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential pinion thrust washers onto the front differential case.

    HINT:
    While rotating the front differential side gears, install the 2 front differential pinions and 2 front differential pinion thrust washers.



2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

  1. Coat the front No. 1 differential pinion shaft with MP grease.



    C193760

  1. Install the front No. 1 differential pinion shaft onto 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.



3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH


    C193757

  1. Install the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

    Standard backlash:
    0.05 to 0.20 mm (0.00197 to 0.00787 in.)

    If the backlash is out of specification, replace the side gear thrust washers.

    Thrust Washer Thickness:
    Parts No.
    		Mark
    		Thickness
    mm (in.)
    41361-22140
    		14
    		0.95 (0.0374)
    41361-22020
    		02
    		1.00 (0.0394)
    41361-22150
    		15
    		1.05 (0.0413)
    41361-22030
    		03
    		1.10 (0.0433)
    41361-22160
    		16
    		1.15 (0.0453)
    41361-22040
    		04
    		1.20 (0.0472)
    41361-22170
    		17
    		1.25 (0.0492)
    41361-22120
    		12
    		1.30 (0.0512)
    41361-22180
    		18
    		1.35 (0.0531)
    41361-22130
    		13
    		1.40 (0.0551)

    HINT:
    1. Measure the thickness with a micrometer to select a proper thrust washer because the thrust washers do not have any distinguishing marks.
    2. Select washers of the same thickness for both the right and left sides.



4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    C193766

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



    C193767

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



5. INSTALL FRONT DIFFERENTIAL RING GEAR


    C166738E02

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

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

  1. After moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.



    C193755E02

  1. Align the matchmarks on the front differential ring gear with that on the front differential case, and quickly install it.
    Text in Illustration 
    *1
    		Matchmark

  1. Install the 8 bolts.

    Torque:
    88 N*m{ 901 kgf*cm , 65 ft.*lbf }