Differential Case Reassembly

Coat the rotating surface of the front differential side gear with gear oil.

Install the 2 front 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 side gear thrust washers to the front differential case.

HINT:

Install the 2 front differential pinions with the front differential washers while turning the front differential pinion.

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

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 pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.

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

Hold 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 backlash is out of specification, select another front differential side gear thrust washer and adjust backlash.

Thrust Washer:

Part No.	Thickness: mm (in.)	Mark
41361-28230	1.00 (0.0394)	1
41361-28240	1.10 (0.0433)	2
41361-28250	1.20 (0.0472)	3
41361-28260	1.30 (0.0512)	4

Clean the surface that contacts the differential case.

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

After moisture on the ring gear has completely evaporated, align the matchmarks and quickly install the front differential ring gear to the front differential case with the 16 bolts.

Torque:

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

Install the speedometer drive gear to the front differential case.