Differential Assembly Installation

INSTALLATION

NOTE: If the differential case is replaced, the 26 mm shim must be adjusted. If the differential case was not replaced, go to step 4.

1. Install the differential assembly.





2. Measure the clearance between the differential case and the torque converter housing.





3. Select the 26 mm shim from the following table.





4. Install the two dowel pins on the differential assembly.





5. Attach the differential assembly to the engine, then tighten the four mounting bolts to the specified torque.
6. Install the 26 mm shim, then tighten the mounting bolts to the specified torque.





7. Install the right engine mount.





8. Install the right engine mount bracket, then right and left engine mount bracket nuts.
9. Remove the chain hoist.





10. Install the engine stop mount bracket bolts.





11. Apply Super High Temp Urea Grease (P/N 08798 - 9002) to the splines of the extension shaft, then install the new set ring.





12. Install the extension shaft using the special tool as shown.

NOTE: Push the extension shaft in the secondary driven gear shaft until the extension shaft stops.





13. Fill the secondary gear with Super High Temp Urea Grease (P/N 08798 - 9002), then install the 36 mm sealing bolt.

NOTE:
- Shift the transmission into the EN position to lock the secondary gear.
- Apply liquid gasket (P/N 08718 - 0001) to the 36 mm sealing bolt threads.





14. Install the right exhaust manifold cover, then install the breather tube to the clamp.





15. Install the power steering pump, then adjust the belt tension of pump belt.





16. Install the air cleaner housing assembly.





17. Install the Vehicle Speed Sensor (VSS)/power steering speed sensor, then connect the VSS connector.





18. Remove the steering gearbox mounting bolts, then install the lower plate and the steering gearbox mounting bolts.
19. Install the driveshafts and the intermediate shaft.

CAUTION: While installing the driveshaft and the intermediate shaft in the differential, be sure not to allow dust and other foreign particles to enter into the differential.

20. Install the damper fork, then install the right and left ball joints to the each lower arm with the castle nuts and new cotter pins.





21. Install the splash shield.
22. Refill the differential with the recommended oil.