Center Differential

DISASSEMBLY
1. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE





a) Using a feeler gauge, measure the high speed output gear thrust clearance.
Standard clearance: 0.10-0.25 mm (0.0039-0.0098 inch)
Maximum clearance: 0.25 mm (0.0098 inch)





b) Using a dial indicator, measure the high speed output gear radial clearance.
Standard clearance: 0.035-0.091 mm (0.00138-0.00358 inch)
Maximum clearance: 0.091 mm (0.00358 inch)





2. REMOVE FRONT DRIVE GEAR PIECE
a) Using a snap ring expander, remove the snap ring.
b) Using SST and a press, remove the front drive gear piece
SST 09950-00020, 09950-60010 (09951-00320)

NOTICE: Be careful not to drop the center differential assembly.





3. REMOVE FRONT TAPER ROLLER BEARING
Using SST and a press, remove the front taper roller bearing.
SST 09950-00020

NOTICE: Set the claw of SST to the bearing inner race securely.





4. REMOVE HIGH SPEED OUTPUT GEAR
5. REMOVE 2 NEEDLE ROLLER BEARINGS





6. REMOVE HIGH AND LOW CLUTCH SLEEVE





7. REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB
a) Using SST, remove the high speed output gear bushing and clutch hub.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00320)
b) Using a magnetic finger, remove the straight pin from the differential front case.





8. REMOVE REAR TAPER ROLLER BEARING
Using SST and a press, remove the rear taper roller bearing.
SST 09950-00020, 09950-60010 (09951-00320)

NOTICE: Set the claw of SST to the bearing inner race securely.





9. REMOVE DIFFERENTIAL REAR CASE
Remove the 12 bolts and differential rear case.





10. REMOVE THRUST WASHER AND REAR SIDE GEAR
11. REMOVE PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS





a) Remove the straight pin from the pinion shaft.





b) Remove the pinion shaft, 2 pinion gears and thrust washers.





c) Remove the front side gear and thrust washer.





12. REMOVE LOW GEAR
Using a plastic hammer, tap and remove the low gear.

NOTICE: Be careful not to damage the low gear.

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.





1. INSTALL LOW GEAR
a) Clean the contact surface of the differential case.
b) Heat the low gear in boiling water.
c) Carefully remove the low gear from the water.
d) After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.





2. INSTALL THRUST WASHER AND FRONT SIDE GEAR
3. INSTALL PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS





a) Install the pinion shaft, 2 pinion gears and thrust washers to the differential front case.








b) Using a dial indicator, measure the front case backlash.

HINT: Push the pinion shaft.

Minimum backlash: 0.05 mm (0.0020 inch)

If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer.
c) In the same way, measure the rear case backlash.
4. INSTALL STRAIGHT PIN TO PINION SHAFT
5. INSTALL REAR SIDE GEAR AND THRUST WASHER





6. INSTALL DIFFERENTIAL REAR CASE
a) Install the differential rear case and 12 set bolts.
Torque: 88 Nm (900 kg-cm, 65 ft. lbs.)
b) Turn the pinion gear.
c) Loosen the 12 rear case set bolts.
d) Torque the 12 rear case set bolts.
Torque: 98 Nm (1,000 kg-cm, 72 ft. lbs.)





7. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing.
SST 09316-12010





8. INSTALL CLUTCH HUB
Using SST and a press, install the clutch hub.
SST 09316-12010, 09316-60011 (09316-00011)
9. INSTALL HIGH SPEED OUTPUT GEAR BUSHING





a) Apply MP grease to the straight pin.
b) Install the straight pin, as shown.





c) Using SST and a press, install the high speed output gear bushing.
SST 09316-12010, 09316-60011 (09316-00011)

NOTICE: Before pressing on the differential front case, align the groove on the bushing with the pin on the shaft.





10. INSTALL HIGH AND LOW CLUTCH SLEEVE

HINT: Make sure to install the high and low clutch sleeve in the correct direction.

11. INSTALL NEEDLE ROLLER BEARING AND HIGH SPEED OUTPUT GEAR
a) Apply gear oil to the needle roller bearing.
b) Install the needle roller bearing and high speed output gear.





12. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing.
SST 09316-12010, 09316-60011 (09316-00011)





13. INSTALL FRONT DRIVE GEAR PIECE
Using SST and a press, install the front drive gear piece.
SST 09316-12010, 09316-60011 (09316-00011)








14. INSTALL SNAP RING
a) Select a snap ring that will allow the minimum axial play.
b) Using a snap ring expander, install a new snap ring.
15. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE