Assembly

DIFFERENTIAL ASSEMBLY

Assembly






1.Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.





2.Install side gears and thrust washers into differential case.
3.Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.





4.Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5.Measure side gear end play. If necessary, select the appropriate side gear thrust washers.





a.Place differential case straight up so that side gear to be measured comes upward.





b.Using feeler gauge, measure the clearance between side gear back and differential case at 3 different points, while rotating side gear. Average the 3 readings, and then measure the clearance of the other side as well.
Side gear back clear: Refer to Differential Side Gear Clearance

CAUTION:
To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.
- If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. For selecting thrust washer, refer to the latest parts information.







CAUTION:
Select a side gear thrust washer for right and left individually.





6.Drive a lock pin into pinion mate shaft, using a punch.

CAUTION:
Never reuse lock pin.





7.Apply thread locking sealant into the thread hole of drive gear.
Use Genuine High Strength Thread Locking Sealant or equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Clean and degrees drive gear back and threaded holes sufficiently.
8.Install the drive gear to differential case.

CAUTION:
Align the matching mark of differential case and drive gear.





9.Tighten the mounting bolts with the following procedure.

CAUTION:
Apply anti-corrosion oil to the thread and seat of mounting bolts.
a.Tighten the bolts in a crisscross fashion to the specified torque.







b.Tighten the bolts additionally to the specified angle.
Drive gear mounting : 31 to 36 degree bolts tightening angle

CAUTION:
Check the tightening angle using the angle wrench [SST: KV-10112100 (BT-8653-A)]. Never make judgment by visual inspection.





10.Press side bearing inner races to differential case, using the drift (A) and the adaptor (B).






CAUTION:
Never reuse side bearing inner race.





11.Set the drifts (A) and base tube (B) to the right and left side bearing adjusting washers individually. Compress differential case assembly and side bearing to install gear carrier assembly to differential case assembly.






CAUTION:
- The drift shall be placed on the center of the adjusting washers.
- The pressure shall be as low as possible to install differential assembly into gear carrier assembly. The maximum pressure shall be 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
- If the adjusting washers are installed by tapping, the gear carrier may be damaged. Avoid tapping.
12.Install dummy cover set [SST: KV-381091S0 (-)], check and adjust drive gear runout, tooth contact, backlash, and total preload torque. Adjustment.
13.Remove dummy cover set.





14.Apply liquid gasket (A) to mating surface of rear cover.
Use Genuine Silicone RTV or equivalent. Recommended Chemical Products And Sealants.

CAUTION:
- Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering to the mounting surfaces.
- The width of sealant bead is approximately 3 mm (0.12
in). Apply sealant evenly.





15.Set the drift (A) and base tube (B) to the right and left side bearing adjusting washers individually. Compress differential case assembly and side bearing to install rear cover.






CAUTION:
- The drift shall be placed on the center of the adjusting washers.
- The pressure shall be as low as possible to install the rear cover. The maximum pressure shall be 10 kN (1 ton, 1.0
Imp ton).
- If rear cover is forced in by tapping, rear cover may be damaged by adjusting washers. Avoid tapping.
16.Tighten rear cover mounting bolts to the specified torque.





17.Using the drift (A) [SST: KV-40104710 (-)], drive side oil seals until it becomes flush with the carrier end.

CAUTION:
- Never reuse oil seals.
- When installing, do not incline oil seals.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
18.Check total preload torque. Adjustment.