Assembly

ASSEMBLY





1. Install side gear and thrust washers in differential case.
2. Install pinion mate gears and thrust washers in differential case while rotating them.
- Apply ATF to any parts





3. Measure clearance between side gear and differential case & viscous coupling with washers using the following procedure:

Differential case side
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflection.

Clearance between side gear and differential case with washers:
0.1 - 0.2 mm (0.004 - 0.008 in)

c. If not within specification adjust clearance by changing thickness of side gear thrust washer.

Side gear thrust washers for differential case side:
Refer to SDS.

Viscous coupling side





a. Place side gear and thrust washer on pinion mate gears installed on differential case.
b. Measure dimension X.
- Measure dimension X in at least two places.





c. Measure dimension Y.
- Measure dimension Y in at least two places.

Clearance between side gear and viscous coupling
= X + Y - 2A: 0.1 - 0.2 mm (0.004 - 0.008 in)
A: Height of gauge

d. If not within specification, adjust clearance by changing thickness of side gear thrust washer.

Side gear thrust washers for viscous coupling side:
Refer to SDS.





4. Install retaining pin.
- Make sure that retaining pin is flush with case.





5. Install side gear (viscous coupling side) on differential case and then install viscous coupling.





6. Instal speedometer drive gear on differential case.
- Align the projection of speedometer drive gear with the groove of differential case.





7. Install final gear and tighten fixing bolts in numerical order.





8. Press on differential side bearings.