Differential Case Reassembly

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

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

Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential pinion thrust washers to 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.

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

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.

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.)

Standard Thrust Washer Thickness:

Mark	Specified Condition
1	1.00 mm (0.0394 in.)
2	1.10 mm (0.0433 in.)
3	1.20 mm (0.0472 in.)
4	1.30 mm (0.0511 in.)

HINT:

Select washers of the same thickness for both the right and left sides.

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

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

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

Heat the front differential ring gear to 90 to 110°C (194 to 230°F) in boiling water.

After the moisture on the ring gear has completely evaporated, quickly align the matchmarks on the ring gear and the differential case and install the ring gear to the differential case.

Install the 12 bolts.

Torque:

106 N*m{1081 kgf*cm, 78 ft.*lbf}