Differential Assembly

DISASSEMBLY
Follow disassembly steps outlined in illustration.

NOTE: Disassembly service points as follows:





A. Bearing removal. (3)
1. Using the special tool, remove the bearing.





B. Lock pin removal. (5)
1. Using a pin punch, drive out the lock pin.

NOTE: The lock pin may be removed with a light punch.

ASSEMBLY
Assembly in reverse order as Disassembly.

NOTE: Assembly service points as follows:

A. Spacer / side gear washer / pinion / pinion shaft installation. (6, 7, 8, 9 & 10)





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 at the same time into position 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 (.00098-.00591 inch)
5. If the backlash is out of specification, select the appropriate spacer and disassemble and reassemble the gears as necessary.

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





B. Lock pin installation. (5)
1. Align the lock pin hole in pinion shaft with that in the case and install the lock pin.

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





C. Bearing installation. (3)





D. Bolts installation. (1)
1. Apply ATF to the differential drive gear bolts, install and tighten with specified torque in the order shown in the figure.
Differential drive gear bolt: 135 Nm (98 ft. lbs.)