Reassembly

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL LOW GEAR

(a) Clean the contact surface of the differential case. (b) Heat the low gear in boiling water. (c) Carefully remove the low gear from the water.

(d) After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.

2. INSTALL THRUST WASHER AND FRONT SIDE GEAR

3. INSTALL PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS

(a) Install the pinion shaft, 2 pinion gears and thrust washers to the differential front case.

(b) Using a dial indicator, measure the front case backlash.

HINT: Push the pinion shaft.

Maximum backlash: 0.05 mm (0.0020 in.)

If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer.

(c) In the same way, measure the rear case backlash.

4. INSTALL STRAIGHT PIN TO PINION SHAFT

5. INSTALL REAR SIDE GEAR AND THRUST WASHER

6. INSTALL DIFFERENTIAL REAR CASE

(a) Install the differential rear case and 12 set bolts.

Torque: 88 N·m

(b) Turn the pinion gear. (c) Loosen the 12 rear case set bolts.

(d) Torque the 12 rear case set bolts.

Torque: 98 N·m

7. INSTALL REAR TAPER ROLLER BEARING

Using SST and a press, install the rear taper roller bearing.

SST 09316-12010

8. INSTALL CLUTCH HUB

Using SST and a press, install the clutch hub.

SST 09316-12010, 09316-60011 (09316-00011)

9. INSTALL HIGH SPEED OUTPUT GEAR BUSHING

(a) Apply MP grease to the straight pin.

(b) Install the straight pin, as shown.

(c) Using SST and a press, install the high speed output gear bushing.

SST 09316-12010, 09316-60011 (09316-00011)

NOTICE: Before pressing on the differential front case, align the groove on the bushing with the pin on the shaft.

10. INSTALL HIGH AND LOW CLUTCH SLEEVE

HINT: Make sure to install the high and low clutch sleeve in the correct direction.

11. INSTALL NEEDLE ROLLER BEARING AND HIGH SPEED OUTPUT GEAR

(a) Apply gear oil to the needle roller bearing.

(b) Install the needle roller bearing and high speed output gear.

12. INSTALL FRONT TAPER ROLLER BEARING

Using SST and a press, install the front taper roller bearing.

SST 09316-12010, 09316-60011 (09316-00011)

13. INSTALL FRONT DRIVE GEAR PIECE

Using SST and a press, install the front drive gear piece.

SST 09316-12010, 09316-60011 (09316-00011)

14. INSTALL SNAP RING

(a) Select a snap ring that will allow the minimum axial play.

(b) Using a snap ring expander, install a new snap ring.

15. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE ( TR-28 )