Rear Differential Reassembly
Rear Differential Reassembly
Exploded View
Special Tools Required
- Holder Handle 07JAB-001020A
- Companion Flange Holder 07RAB-TB4010B
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Apply Dual Pump Fluid II to the rubber pinion of the fluid strainer (A), then install the fluid strainer, the magnet (B), the 8 x 10 mm dowel pins (C), and the oil pump pin (D) in the differential carrier assembly.
2. Align the grooves (A) of the rear oil pump with the oil pump pins (B), then install the oil pump body assembly (C) on the differential carrier assembly.
3. Tighten the oil pump body assembly with the three mounting bolts (A), and then install the oil pump driveshaft (B) by aligning the projection (C) of the oil pump driveshaft with the groove of the front oil pump in the oil pump body assembly.
4. Install the thrust needle bearing (D).
5. Install the six steel balls (A), the base cam (B), the thrust needle bearing (C), and the pressure plate (D) on the differential clutch assembly (E).
NOTE: Align the tabs (F) of the pressure plate with the grooves (G) of the differential clutch assembly.
6. Make a mark (A) on the outside of the differential clutch assembly (B) that corresponds to the position of the tab (C) of the pressure plate (D) as shown. Make a mark (E) on the outside of the oil pump body assembly (F) that corresponds to the position of the groove (G) in the oil pump driveshaft (H) as shown.
7. Support the pressure plate and the differential clutch assembly by hand so that they do not misalign. With the marks aligned, install the differential clutch assembly to the oil pump body assembly. Install the 30 mm shim (I).
8. Make sure that the differential clutch assembly and the pressure plate are correctly installed. If the differential clutch assembly can be pushed down as in the figure, go to step 9. If not, return to step 5.
NOTE: If incorrectly installed, the differential clutch assembly may be damaged when excessive force is applied.
9. Remove the dirt and oil from the sealing surfaces. Apply liquid gasket (P/N 08717-0004, 08718-0001,08718-0003, 08718-0004, or 08718-0009) evenly to the sealing surface. Install the component within 5 minutes of applying the liquid gasket. Make sure you seal the entire circumference of the bolt holes to prevent fluid leakage.
NOTE:
- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
- Allow it to cure at least 30 minutes after assembly before filling the differential with the recommended fluid.
10. Install the 6 x 10 mm dowel pins (A) and the torque control differential (TCD) case (B). Torque the eight mounting bolts in a crisscross pattern in several steps.
NOTE: Be careful not to damage the lip of the oil seal (C) when installing the the torque control differential (TCD) case on the differential carrier case. If the oil seal is damaged, replace it.
11. Install the companion flange (A) to the shaft of the clutch guide.
NOTE: Check if the reference mark (B) exists on the companion flange and the shaft of clutch guide; install the companion flange to the shaft of the clutch guide by aligning the reference mark.
12. Install a new O-ring (C), a new back-up ring (D), the spring washer (E), and a new locknut (F).
NOTE: Apply Dual Pump Fluid II to the O-ring.
13. Install the companion flange holder (A) and the holder handle (B) to the companion flange, then tighten the locknut to the specified torque.
14. Stake the locknut tab (A) into the groove in the clutch guide.
15. Install the drain plug (A) and the oil filler plug (B) with new sealing washers (C).
16. Reinstall rear differential mounting brackets A and B, and the rear differential mounting stiffener Service and Repair.