FRONT DIFFERENTIAL ASSEMBLY

Assembly Procedure

1. Apply ATF to each part immediately before assembly.

2. Set the sun gear onto the gear case.

3. Install the bearing using the SST.

4. Install the thrust washer to the gear case.

5. Install the side gear.

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

7. Install the pinion carrier.

8. Install the pinion shafts.

Caution

• Assemble the roll pin so that the roll pin opening is perpendicular to the pinion shaft.

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

10. Install the side gear and thrust washer.

11. Install the differential cover.

Tightening torque

7.9-10.7 N·m {80-110 kgf·cm, 70-95 in·lbf}

12. Measure the backlash of the side gear as follows:

(1) Install the left and right drive shafts in the differential.

(2) Support the drive shaft on V-blocks.

(3) Measure the backlash of both side gears.

• If the backlash is not within the specification, adjust the thrust washer.

Backlash

Standard: 0.025-0.10 mm {0.0010-0.0039 in}

Maximum: 0.10 mm {0.0039 in}

13. Select the thrust washer so that the backlash is as specified.

Thickness of thrust washer

14. Install the SST to locate gear case and sun gear.

15. Install the sun gear using the press.

16. Install the ring gear.

Tightening torque

152-176.5 N·m {15.5-17.9 kgf·m, 112-130 ft·lbf}