Front Differential

DISASSEMBLY AND REASSEMBLY

SERVICE POINTS OF DISASSEMBLY




3. REMOVAL OF BALL BEARING
Using the special tool, remove the ball bearing.

CAUTION: Do not reuse the bearing if it has been removed from differential case.




4. REMOVAL OF LOCK PIN
Drive out the lock pin from hole A using a punch.

SERVICE POINTS OF REASSEMBLY




9. INSTALLATION OF SPACER / 8. SIDE GEAR / 7. WASHER / 6. PINION / 5. PINION SHAFT
1. Fit a spacer on to the back of the side gear and then install the gear in the differential case.

CAUTION: When a new side gear is used, use a spacer of intermediate thickness [0.93 - 1.00 mm (.0366 - .0394 in.)]




2. Place a washer at the back of each of the two pinions and insert the two pinions at the same time, meshing them with the side gear and rotating them.
3. Insert the pinion shaft.




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

Standard value: 0.025 - 0.150 mm (.0001 - .0060 in.)

5. If the backlash is out of specification, disassemble and reassemble the gears with a new spacer.

CAUTION: Adjust to provide the same backlash for both side gears.




4. INSTALLATION OF LOCK PIN
Align the lock pin hole in the pinion shaft with that in the case and press the lock pin into position.

CAUTION:
1. Do not reuse the lock pin.
2. Make sure that the lock pin head is lower than the differential case flange surface.




3. INSTALLATION OF BALL BEARINGS
Install the ball bearings in both sides of the differential case.




1. INSTALLATION OF BOLTS
Apply adhesive to the entire thread section of the bolts and quickly tighten bolts to specification in the order shown.
Specified adhesive: 3M Stud Locking Part No.4170 or equivalent

CAUTION: If the bolts are to be reused, completely remove old adhesive from the threads.