Assembly

1. Install bevel gear and bevel pinion together. with washers, and insert pinion shaft (1).

NOTE: Face the chamfered side of washer toward gear.








2. Measure backlash between bevel gear and pinion. If it is not within 0.13 - 0.18 mm (0.0051 - 0.0071 inch), install a suitable washer to adjust it.
ST1 498247001 Magnet Base, or equivalent
ST2 498247100 Dial Gauge, or equivalent

NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.





3. Align pinion shaft and differential case at their holes, and drive straight pin (5) into holes from the hypoid driven gear side, using ST.
ST 899904100 Remover, or equivalent

NOTE: Lock straight pin after installing.





4. Install roller bearing (40 x 80 x 19.75) to differential case.
ST1 499277100 Bush 1-2 Installer, or equivalent
ST2 398497701 Adapter, or equivalent

NOTE: Be careful because roller bearing outer races are used as a set.





5. Install hypoid driven gear (4) to differential case (10) using twelve bolts (3). Tightening torque: 62 +/-5 Nm (45.6 +/-3.6 ft. lbs.).








6. Position drive axle shaft in differential case and hold it with outer snap ring (28). Using a thickness gauge, measure clearance between the shaft and case is within 0 - 0.2 mm (0 - 0.008 inch). If it is not within 0 - 0.2 mm (0 - 0.008 inch), replace snap ring with a suitable one.