Assembly

DIFFERENTIAL ASSEMBLY

2WD : Assembly

1.Install circular clip to side gear.

CAUTION:
Never damage side gear.





2.Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.





3.Install side gears and thrust washers into differential case.

CAUTION:
Make sure that the circular clip is installed to side gears.
4.Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.





5.Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
6.Measure side gear end play. If necessary, select the appropriate side gear thrust washers.





a.Place differential case straight up so that side gear to be measured comes upward.





b.Using feeler gauge, measure the clearance between side gear back and differential case at 3 different points, while rotating side gear. Average the 3 readings, and then measure the clearance of the other side as well.

Side gear back clearance: Refer to "Differential Side Gear Clearance" Differential Side Gear Clearance.

CAUTION:
To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.
c.If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. For selecting thrust washer, refer to the latest parts information.





CAUTION:
Select a side gear thrust washer for right and left individually.





7.Drive a lock pin into pinion mate shaft, using a punch.
Make sure lock pin is flush with differential case.

CAUTION:
Never reuse lock pin.





8.Apply thread locking sealant into the thread hole of drive gear.
Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to "Recommended Chemical Products and Sealants" Recommended Chemical Products and Sealants.

CAUTION:
Clean and degrease drive gear back and threaded holes sufficiently.
9.Install the drive gear to differential case.

CAUTION:
Align the matching marks of differential case and drive gear.





10.Tighten the mounting bolts with the following procedure.

CAUTION:
Apply anti-corrosion oil to the thread and seat of mounting bolts.
a.Tighten the bolts in a crisscross fashion to the specified torque.





b.Tighten the bolts additionally to the specified angle.





CAUTION:
Check the tightening angle using the angle wrench [SST: KV10112100 (BT-8653-A)]. Never make judgment by visual inspection.





11.Press side bearing inner races to differential case, using the drift (A) and the base (B).






CAUTION:
Never reuse side bearing inner race.





12.Set bearing outer races to differential case assembly, and install it with removed side bearing adjusting washer or same thickness washer into gear carrier.

CAUTION:
- Apply differential gear oil to the side bearings.
- Install side bearing and side bearing adjusting washer in correct location. (drive gear tooth side or drive gear back side)
13.Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers. Refer to "2WD : Adjustment" Adjustment.





14.Align matching marks on bearing cap with that on gear carrier.
15.Install bearing caps and tighten bearing cap mounting bolts.





16.Using the drift [SST: KV38100200 (J-26233)], drive side oil seals until it becomes flush with the case end.

CAUTION:
- Never reuse oil seal.
- When installing, never incline oil seal.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
17.Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to DLN178, "2WD : Adjustment".
Recheck above items. Readjust the above description, if necessary.





18.Apply sealant to mating surface of rear cover.
-Use Genuine Silicone RTV or equivalent. Refer to "Recommended Chemical Products and Sealants" Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
19.Install rear cover on gear carrier and tighten mounting bolts.





20.Install side flange with the following procedure.
a.Attach the protector [SST: KV38107900 (J-39352)] to side oil seal.
b.After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the protector.
c.Put a suitable drift on the center of side flange, then drive it until sound changes.
NOTE:
When installation is completed, driving sound of the side flange turns into a sound that seems to affect the whole final drive.





d.Confirm that the dimension of the side flange (1) installation measurement (A) in the figure comes into the following.