20. Front Differential Carrier Assembly Assemble

Front Differential Carrier Assembly Assemble

Special Tools

J 35405 Differential Preload Wrench




1. Install the front differential side gear.

Note: When installing them, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes are aligned with the holes in the differential case.

2. After applying ATF WS to the front differential side gears, front differential side gear thrust washers, front differential pinions, and front differential pinion thrust washers, install them to the front differential case.




3. Install the front differential pinion shaft so as to align the lock pin holes in the pinion shaft and front differential case.




4. Inspect the differential side gear backlash.
5. Measure the differential side gear backlash while holding one pinion gear toward the case.

Standard backlash - 0.05-0.20 mm (0.0019-0.0078 in)

6. If the backlash is not within the specified range, install the correct thrust washer to the side gear.
7. Select thrust washers which will ensure that the backlash is within the specified range for both sides. Refer to Transmission General Specifications (Transmission General Specifications) for the differential side gear thrust washer chart.
If the backlash is not within the specified range, install a thrust washer of a different thickness.




8. Using a pin punch and a hammer, install the pinion shaft pin.




9. Using a chisel and a hammer, stake the differential case.




10. Install the front differential ring gear.
11. Using ATF WS and a heater, heat the front differential ring gear to 90-110°C (194-230°F).
12. Clean the contact surface of the front differential case.





Caution: Refer to Fastener Caution (Fastener Caution) Fastener Caution.

13. Install the new ring gear lock plates with the bolts and tighten to 88 Nm (65 lb ft).




14. Using a punch (1) and hammer, stake the ring gear lock plate.




15. Using a press (1), install the front differential case rear bearing inner race to the differential case.




16. Using a press (2), install the shim and bearing outer race to the transaxle case.




17. Using a press, install the front differential case front bearing inner race to the differential case.




18. Using a press (1), install the front differential case front bearing to the transaxle housing.
19. Check each bearing position and installation direction.
20. Inspect the differential case tapered roller bearing preload.
21. Coat the front differential case and bearing with ATF WS and install them to the transaxle case.




22. Install the transaxle housing with the bolts (1-2).

* Tighten bolts (1) to 29 Nm (21 lb ft).
* Tighten bolts (2) to 22 Nm (16 lb ft).




23. Using J 35405 (1) and a small torque wrench, measure the preload of the differential gear. Refer to Transmission General Specifications (Transmission General Specifications) Transmission General Specifications for Preload.
24. If the preload is not within the specification, remove the differential from the transaxle case.
25. Select a new transaxle case side adjusting shim in accordance with the specification. Refer to Transmission General Specifications (Transmission General Specifications) Transmission General Specifications for adjusting shim thickness.