Refit

Differential Assembly

Service repair No - 41.20.13

Refit

1. Clean differential components.
2. Lubricate components with gearbox oil.





3. Position differential in soft jawed vice and fit front bearing using tool LRT-41-008.





4. Invert differential in soft jawed vice, and fit low range gear with dog teeth facing uppermost.
5. Fit high/low hub ensuring that machined groove on hub teeth faces towards low range gear.
6. Fit high/low selector sleeve ensuring that alignment marks on hub and sleeve are together.
7. Fit bush to high range gear ensuring collar is uppermost.
8. Fit high range gear and bush onto shaft.





9. Fit new rear bearing using tool LRT-41-008.





10. Using tool LRT-41-007, fit new bearing retaining nut and tighten to 72 Nm (53 lbf.ft). Do not stake nut at this stage.





11. Using feeler gauges, determine clearance between low range gear and high/low hub:
^ Clearance =0.05 to 0.15 mm (0.002 to 0.006 in).
12. If clearance is not as specified, fit a new low range gear and high/low hub and re-check.





13. Using feeler gauges, determine clearance between high range gear and high/low hub:
^ Clearance =0.05 to 0.15 mm (0.002 to 0.006 in).
14. If clearance is not as specified, fit new high range gear and high/low hub and re-check.
15. Using a suitable drift, stake collar of nut into differential shaft recess.





16. Using LRT-51 -009, fit new rear bearing track into main casing.
17. Using a straight edge and feeler gauges, check that bearing track is recessed 1 mm (0.04 in) below outer face of main casing.
18. Apply sealant. Part No. STC 3254 to rear output shaft housing face.
19. Position housing to main casing.
20. Apply Loctite 290 to bolt threads fit housing to main case bolts and tighten by diagonal selection to 45 Nm (33 lbf.ft).
21. 03 MY only: Fit high/low selector fork and spring to high/low selector shaft, fit retaining clips.

CAUTION: Ensure ends of spring are fully seated in recess in clips.

22. Position high/low selector shaft and fork to differential ensuring that fingers of selector fork are located in selector sleeve.
23. Position differential assembly into main casing ensuring that splines of rear output shaft are engaged in differential.
24. Position new differential front bearing track ensuring that track is seated squarely.





25. Position tool LRT-41-014/3 onto main casing.
26. Screw tool LRT-41-014/4 into tapped hole in main casing and attach suitable DTI to pillar.
27. Position stylus of gauge to setting block LRT-41-014/3 and zero gauge.





28. Position stylus onto front bearing outer track and record reading.
29. Taking care not to disturb bearing, position stylus on opposite side of bearing track and record reading.
30. Obtain average of the 2 readings and record figure.





31. Position depth block tool LRT-41 -014/2 and cross bar tool LRT-41-014/1 to front output housing.
32. Position DTI to tool LRT-41-014/1 crossbar and zero DTI on depth block.
33. Position DTI to cross bar and record reading obtained.
34. Using the formula: 3.05 mm (0.120 in) + B - A = D
where:
B= Height difference recorded between depth block and cross bar.
A= Average of readings to differential front bearing outer track.
D= Thickness of shim required to give differential bearing pre-load of 0.05 mm (0.002 in).
35. From the resultant figure obtained, select appropriate thickness shim from the range available.
36. Shims are available from 2.00 to 3.25 mm (0.08 to 0.13 in) thickness, rising in increments of 0.05 mm (0.002 in).





37. Heat the front output housing to 100 degree C (210 degree F) and fit new output shaft bearing using tool LRT-41-011.
38. Allow housing to air cool.
39. Fit new bearing retaining circlip ensuring that circlip is fully seated.





40. Using tool LRT-41-012, fit new output shaft oil seal. Check that oil seal is just contacting circlip.





41. Position selected shim in front output housing and using tool LRT-54-003, fit new differential front bearing track.





42. Fit bearing spacer to output shaft with chamfer on spacer towards threaded end.
43. If fitted: Fit dog clutch with flange on clutch facing towards splined end.
44. Using a copper mallet, drive output shaft into bearing.

NOTE: Carry out the following operations for transfer boxes fitted with differential lock.

45. Compress differential lock selector spring and fit selector fork.
46. Position selector fork to groove in dog clutch.
47. Fit selector shaft and locate in housing recess, rotate shaft until the two flats for retaining clips are at right angles to the cover plate mating face.
48. Compress selector spring and fit retaining clips at each end of spring.

CAUTION: Ensure ends of spring are fully seated in recess of clips.

49. Fit detent ball and spring.
50. Apply Loctite 290 to threads of detent plug.
51. Fit and tighten detent plug, then loosen 2 complete turns.
52. Fit new 'O' ring to differential lock selector housing.
53. Fit selector housing, ensure selector finger is located in shaft recess.
54. Apply Loctite 290 to threads of bolts, and tighten selector housing bolts to 25 Nm (18 lbf.ft).





55. Clean threads of differential lock warning lamp switch(es).
56. Up to 03 MY: Fit nut to switch head with counterbore positioned towards switch head.
The nut acts as a spacer to ensure that switch setting is correct. Always ensure that nut is fully tightened to switch head (no gap).
57. Apply Hylomar PL 32 sealant to threads of differential warning lamp switch(es).
58. Up to 03 MY: Position switch into front output housing until nut bottoms out on housing; tighten nut to 11 Nm (8 lbf.ft)
59. 03 MY onwards: Fit new sealing washers to switches, fit switches in front output housing and tighten to 25 Nm (18 lbf.ft).

NOTE: Carry out the following operations for all transfer boxes.

60. Apply sealant, Part No. STC 3254 to front output shaft housing.
61. Position housing ensuring that output shaft and dog clutch splines - if fitted are correctly engaged.
62. Clean output housing bolt threads.
63. Apply Loctite 290 to threads of bolts.
64. Fit output shaft housing bolts and tighten in a diagonal sequence to 45 Nm (33 lbf.ft).
65. Fit output flange, new felt washer, steel washer and new retaining nut.





66. Using tool LRT-51-003 to restrain flange, tighten output flange nut to 162 Nm (119 lbf.ft).
67. If fitted - Operate differential lock selector lever and check that detent ball can be felt to positively engage/disengage with grooves in shaft. Screw plug in or out until setting is correct.
68. Fit high/low selector shaft detent ball and spring.
69. Apply Loctite 290 sealant to threads of high/low selector shaft detent plug.
70. Fit and tighten plug, then loosen 2 complete turns.
71. Operate high/low selector lever and check that detent ball can be felt to positively engage/disengage with grooves in shaft. Screw plug in or out until setting is correct.
72. Fit intermediate gear cluster.