Assembly

DIFFERENTIAL ASSEMBLY


AWD : Assembly

1. Install circular clip to side gear.

CAUTION:
Never damage side gear.





2. 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.
3. Install side gears and thrust washers into differential case.






CAUTION:
Make sure that the circular clip is installed to side gears.
4. 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.





5. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
6. 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.

Standard
Side gear back clearance : Refer to DLN-207, "Differential Side Gear Clearance". Differential Side Gear Clearance


CAUTION:
To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.





c. If the back clearance is outside the specification, use a thicker/thinner side gear thrust washer to adjust.

When the back clearance is large: Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.


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





7. Drive a lock pin into pinion mate shaft, using a punch.
Make sure lock pin is flush with differential case.

CAUTION:
Never reuse lock pin.





8. Align the matching mark of differential case with the mark of drive gear, then place drive gear.
9. Apply thread locking sealant into the thread hole of drive gear.





- Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.

CAUTION:
Clean and degrease drive gear back and threaded holes sufficiently.





10. Install drive gear on the mounting bolts.

CAUTION:
- Tighten bolts in a crisscross fashion.
- After tightening the bolts to the specified torque, tighten the bolts additionally by turning the bolts 31 to 36 degrees.





11. Press side bearing inner races to differential case, using the drift
(A) [SST: KV38100300 (J-25523)] and the base (B) [SST:
ST33061000 (J-8107-2)].

CAUTION:
Never reuse side bearing inner race.





12. Install differential case assembly with side bearing outer races into gear carrier.
13. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers. Refer to Adjustment.





14. Insert selected left and right side bearing adjusting washers in place between side bearings and gear carrier. Refer to Adjustment.
15. Align matching marks on bearing cap with that on gear carrier.





16. Install bearing caps and tighten bearing cap mounting bolts.
17. Using the drift (A) [SST: KV38100200 (J-26233)], drive side oil seals until it becomes flush with the case end.






CAUTION:
- Never reuse oil seal.
- When installing, never incline oil seal.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
18. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to Adjustment.
Recheck above items. Readjust the above description, if necessary.





19. Apply sealant (A) to mating surface of rear cover.
- Use Genuine Silicone RTV or equivalent. Refer to Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
20. Install rear cover on gear carrier and tighten mounting bolts.





21. Install side flange with the following procedure.
a. Attach the protector [SST: KV38107900 (J-39352)] to side oil seal.
b. After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the protector.
c. Put a suitable drift on the center of side flange, then drive it until sound changes.

NOTE:
When installation is completed, driving sound of the side flange turns into a sound that seems to affect the whole final drive.





d. Confirm that the dimension of the side flange installation measurement (A) in the figure comes into the following.

Standard
A : 326 - 328 mm (12.83 - 12.91 in)