#
DIFFERENTIAL DISASSEMBLY/ASSEMBLY

D6E051727100A01

## Differential Disassembly

1. Perform the preinspeciton before disassembly. (See Differential Preinspection.)

2. Disassemble in the order indicated in the table.

1 | Side gear
2 | Thrust washer
3 | Roll pin (See Roll pin disassembly note.)
4 | Pinion shaft
5 | Pinion gear
6 | Thrust washer
7 | Bearings (See Bearings disassembly note.)
8 | Ring gear
9 | Gear case
10 | Bolt

### Roll pin disassembly note

1. Place the gear case in a vise.

2. Insert a 2.0 mm {0.07 in} punch into the roll pin hole from the ring gear side, and remove the roll pin.

### Bearings disassembly note

1. Remove the bearing (speedometer drive gear side) from the gear case using the SSTs.

2. Remove the bearing (ring gear side) from the gear case using the SST.

## Differential Assembly

1. Assemble in the reverse order of disassembly.

1 | Bolt
2 | Gear case
3 | Ring gear
4 | Sensor rotor
5 | Bearings
6 | Thrust washer
7 | Pinion gear
8 | Pinion shaft
9 | Roll pin
10 | Thrust washer
11 | Side gear

### Assembly Procedure

1. Install the ring gear to the gear case.

2. Tighten the bolts evenly and gradually in the order shown. (bolt fixed type)

Tightening torque

  152-176.4 N·m
  {15.5-17.9 kgf·m, 112-130 ft·lbf}

  Note

  • If the gear case has been newly replaced perform Step (3).

3. Install the sensor rotor to the gear case using the SST and suitable plate.

4. Install a new bearing.

  (1) Press the new bearing (sensor rotor side) onto the gear case using the SST.
  (2) Press on the other new bearing (ring gear side) in the same manner.

5. Apply ATF to the thrust washers and pinion shaft.

6. Install the pinion gear and thrust washers into the gear case.

7. Install the pinion shaft.

8. Install the roll pin, and crimp it to prevent it from coming out of the gear case.

9. Apply ATF to the thrust washers.

10. Install the thrust washers and side gears into the gear case, then turn the side gears and align them with the drive shaft holes.

11. Measure the backlash of the side gears as follows:

  (1) Install the left and right drive shafts in the differential.
  (2) Support the drive shafts on V-blocks.
  (3) Measure the backlash of both side gears.
Differential backlash

  Standard: 0.05-0.15 mm {0.002-0.005 in}
  Maximum: 0.5 mm {0.020 in}

  • If not as specified, replace the differential.