Assembly

SPACER/SIDE GEAR WASHER/PINION/PINION SHAFT INSTALLATION

1. Fit the spacer to the back face of the side gear, then install the gear into the differential case.

2. Fit washer to back of pinion and rotate two pinions simultaneously to mesh with the side gear.




3. Insert the pinion shaft.




4. Measure the backlash between the side gear and pinion.

Standard value: 0.025-0.150 mm (0.00098-0.00591 in.)

5. If the backlash is out of specification, select the appropriate spacer. Then disassemble and reassemble the gears to install the new spacer.

NOTE: Adjust so that the backlash in both side gears equals.




LOCK PIN INSTALLATION

Align the lock pin hole in pinion shaft with that in the case and install the lock pin.

Caution:

1. Do not reuse lock pins
2. Make the lock pin lower than the surface of the differential case flange.
3. Press-fitting load is over 5,000 Nm (1,100 lbs.)




TAPER ROLLER BEARING INSTALLATION

Use the special tool to press-fit the bearings into both sides of the differential case.




BEARING INSTALLATION




BOLTS INSTALLATION

Apply ATF to the differential drive gear bolts, install and tighten to the specified torque in the order shown in the figure.

Differential drive gear bolt: 135 Nm (98 ft.lbs.)