Installation of Differential

INSTALLATION OF DIFFERENTIAL



1. PLACE OUTER RACE AND SELECTED ADJUSTING ONTO RH SIDE BEARING




2. PLACE DIFFERENTIAL CASE INTO CASE
Be sure to install the adjusting shim into place.

3. INSTALL LH BEARING RETAINER



a. Install a new O-ring.
b. Position the retainer by tapping it while holding the differential case center with the retainer.
c. Clean the threads of the bolts and case with white gasoline.




d. Coat the threads of the bolts with sealer.
Sealer: Part No.08833 - 00070, THREE BOND 1324 or equivalent
e. Temporarily tighten the bolts evenly and gradually while turning the ring gear.




4. INSTALL RH SIDE BEARING CAP
Tighten the bolts evenly and gradually while turning the ring gear.

Torque: 730 kg.cm (53 ft.lb, 72 N.m)




5. TIGHTEN LH BEARING RETAINER

Torque: 195 kg.cm (14 ft.lb, 19 N.m)




6. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload of the drive pinion shaft.
Total preload (at starting):
Add drive pinion preload
New bearing: 2.9 - 4.0 kg.cm (2.5 - 3.5 in.-lb, 0.3 - 0.4 N.m)
Reused bearing: 1.5 - 2.0 kg.cm (1.3 - 1.7 in.lb, 0.1 - 0.2 N.m)

If the preload is not within specification, disassemble and readjust.




7. STAKE COUNTER DRIVEN GEAR NUT
8. INSTALL DRIVE PINION CAP




9. INSTALL CARRIER COVER
a. Clean the threads of the bolts and case with white gasoline.
b. Coat the threads of the bolts with sealer.
Sealer: Part No.08833 - 00070, THREE BOND 1324 or equivalent

c. Install the carrier cover over the gasket.

Torque: 250 kg.cm (18 ft.lb, 25 N.m)

POST ASSEMBLY
1. INSTALL MANUAL SHAFT AND LEVER
2. INSTALL PARKING LOCK PAWL
3. INSTALL PARKING LOCK ROD AND BRACKET




4. INSTALL NEW OVERDRIVE CLUTCH APPLY GASKET AND NEW OVERDRIVE BRAKE GASKET
Coat the new gaskets with petroleum jelly, and install onto the case.

5. INSTALL OVERDRIVE UNIT



a. Install the intermediate shaft into the overdrive case.




b. Place the overdrive unit over a new gasket. Be sure to install the intermediate shaft into the case.

NOTE: Do not damage the bushing and oil seal ring.

c. Turn the counter driven gear with a screw drive install the overdrive unit. Tighten the bolts.

Torque: 250 kg.cm (18 ft.lb, 25 N.m)

6. INSTALL VALVE BODY
7. INSTALL SPEED SENSOR OR GOVERNOR BODY
8. INSTALL OIL PAN
9. INSTALL SPEEDOMETER DRIVEN GEAR
10. INSTALL NEUTRAL START SWITCH