Differential Case Reassembly

After applying ATF to the 2 front differential side gears, 2 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers, install them to the front differential case.

HINT:

When installing them, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes are aligned with the holes in the differential case.

Install the front No. 1 differential pinion shaft so as to align the lock pin holes in the pinion shaft and front differential case.

Measure the differential side gear backlash while holding 1 pinion gear toward the case.

Standard backlash:

0.05 to 0.20 mm (0.00196 to 0.00787 in.)

Referring to the table below, select thrust washers which will ensure that the backlash is within the specified range for both sides.

Thrust Washer Thickness:

Thickness mm (in.)	Thickness (mm (in.))
0.95 (0.0374)	1.10 (0.0433)
1.00 (0.0394)	1.15 (0.0453)
1.05 (0.0413)	1.20 (0.0472)

Using a pin punch and a hammer, install the pinion shaft straight pin.

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

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

Clean the contact surface of the front differential case.

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

NOTICE:

Do not install the bolts while the ring gear is hot.

Install 4 new ring gear lock plates with the 8 bolts.

Torque:

88 N*m{898 kgf*cm, 65 ft.*lbf}

Using SST, stake the ring gear lock plate.

SST

09930-00010

Using SST and a press, install the front differential case rear tapered roller bearing inner race to the differential case.

SST

09726-40010
09950-60020(09951-00790)

Using SST and a press, install the shim and bearing outer race to the transaxle case.

SST

09950-60020(09951-00720)
09950-60010(09951-00650)
09950-70010(09951-07100,09951-07200)

Using SST and a press, install the front differential case front tapered roller bearing inner race to the differential case.

SST

09950-60010(09951-00460)
09950-70010(09951-07100)

Using SST and a press, install the front differential case front tapered roller bearing to the transaxle housing.

SST

09950-70010(09951-07150)
09950-60020(09951-00680)