Differential Reassembly

Differential Reassembly

Differential:

Special Tools Required
^ Holder handle 07JAB-001020A
^ Companion flange holder 07RAB-TB4010B

1. Apply Dual Pump Fluid to the rubber of the ATF strainer (A), then install the ATF strainer, the magnet (B), the oil pump pin (C), and the collar (D) in the differential carrier assembly.





2. Align the tabs (A) of the collar (B) with the oil pump pin (C). Align the grooves (D) of the rear oil pump with the oil pump pin and collar tabs, then install the oil pump body assembly (E) on the differential carrier assembly.





3. Tighten the oil pump body assembly mounting bolts.
4. Install the oil pump driveshaft (A) by aligning the projection (B) of the oil pump driveshaft with the groove of the front oil pump in the oil pump body assembly.





5. Install the thrust needle bearing (C).
6. If necessary, reassemble the differential clutch, and note these items:
^ Install, one metal clutch plate (A) and one fiber clutch disc (B) in the clutch guide (C), then install the clutch hub with snap ring (D) into the clutch guide.
^ Make sure the splines of the clutch hub and fiber clutch disc line up below the snap ring (E),
^ Install the remaining metal clutch plates and fiber clutch discs alternately until you have installed a total of eleven plates and ten discs, then install the pressure plate (F).
^ Make sure the differential clutch is assembled correctly. The pressure plate should be flush with the top of the clutch guide.





7. Install the differential clutch assembly (A) by aligning the tabs of the pressure plate (B) with the grooves of the oil pump driveshaft (C). Be careful not to let the pressure plate fall out of the clutch guide during assembly.





8. Remove the dirt and oil from the sealing surfaces. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent fluid leakage.

NOTE:
^ Do not install the components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.
^ Allow it to cure at least 30 minutes after assembly before filling the differential with the recommended fluid.





9. Install the 30 mm shim (A), the 6 x 1.0 mm dowel pins (B), and the torque control differential case (C). Torque the eight mounting bolts in a crisscross pattern in several steps.





10. Install the companion flange (A), a new O-ring (B), back-up ring (C), disc spring washer (D), and a new locknut (E).

NOTE: Apply the recommended fluid to the O-ring.





11. Install the special tools (A) to the companion flange, then tighten the new locknut to the specified torque.





12. Stake the locknut tab (A) into the groove in the clutch guide.





13. Install the drain plug (A) and the oil filler plug (B) with new washers (C).