Assembly

DIFFERENTIAL ASSEMBLY

Assembly






1.Apply thread locking sealant into the threaded holes of the drive gear and install the new drive gear bolts.
- Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to "Recommended Chemical Products and Sealants" Recommended Chemical Products and Sealants.

CAUTION:
Clean degrees drive gear back and threaded holes sufficiently.
2.Install the drive gear to differential case assembly.

CAUTION:
Align the matching marks of differential case assembly and drive gear
3.Tighten the drive gear 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 at the specified angle.





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





4.Press side bearing inner races to the differential case with the drift (A) and the base (B).






CAUTION:
Never reuse side bearing inner races.
5.Install housing spacer.





6.Install the differential case assembly with the side bearing outer races into the gear carrier.

CAUTION:
- Never reuse side bearing outer race when replacing side bearing inner race (replace as a set).
- Apply differential gear oil to the side bearings.





7.Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier.





8.Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque.

CAUTION:
Align matching marks on bearing cap with that on gear carrier.





9.Install side oil seal (left side) until it becomes flush with the gear carrier with the drift (A and B).






CAUTION:
- Never reuse side 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.
10.Check and adjust drive gear runout, tooth contact, backlash, and total preload torque. Refer to "Adjustment" Adjustment.
Recheck above items. Readjust the above description, if necessary.





11.Apply sealant to match surface of carrier cover.
- Use Genuine Silicone RTV or equivalent. Refer to "Recommended Chemical Products and Sealants" Recommended Chemical Products and Sealants.

CAUTION:
Remove any old sealant adhering to the mating surfaces.
Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
12.Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque.
13.Install side shaft. Refer to "Assembly" Assembly.
14.Install bushing with drift (commercial service tool).