Center Differential: Reassembly

HINT:

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

1. INSTALL LOW GEAR 
   1. Clean the contact surface of the differential case.
   2. Heat the low gear in boiling water.
   Fig 1: Heating Low Gear In Boiling Water
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   3. Carefully remove the low gear from the water.
   4. 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 
   Fig 2: Installing Thrust Washer & Front Side Gear

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3. INSTALL PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS 
   1. Install the pinion shaft, 2 pinion gears and thrust washers to the differential front case.
      Fig 3: Installing Pinion Shaft, Pinion Gears & Thrust Washers To Differential Front Case

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   2. Using a dial indicator, measure the front case backlash.
      Fig 4: Measuring Front Case Backlash

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      HINT:

      Push the pinion shaft.

      1. Maximum backlash: 0.05 mm (0.0020 in.) 

      If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer.

      Fig 5: Thrust Washer Thickness Specification Table

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   3. 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 
   1. Install the differential rear case and 12 set bolts.
      1. Torque: 88 N.m (900 kgf.cm, 65 ft.lbf) 
   2. Turn the pinion gear.
   3. Loosen the 12 rear case set bolts.
   4. Torque the 12 rear case set bolts.
      1. Torque: 98 N.m (1,000 kgf.cm, 72 ft.lbf) 
   Fig 6: Installing Differential Rear Case & Bolts

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7. INSTALL REAR TAPER ROLLER BEARING 

   Using SST and a press, install the rear taper roller bearing.

   1. SST 09316-12010
   Fig 7: Installing Rear Taper Roller Bearing Using SST & Press

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8. INSTALL CLUTCH HUB 

   Using SST and a press, install the clutch hub.

   1. SST 09316-12010, 09316-60011 (09316-00011)
   Fig 8: Installing Clutch Hub Using SST & Press

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9. INSTALL HIGH SPEED OUTPUT GEAR BUSHING 
   1. Apply MP grease to the straight pin.
   2. Install the straight pin, as shown in Fig 9 .
      Fig 9: Installing Straight Pin

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   3. Using SST and a press, install the high speed output gear bushing.
      1. SST 09316-12010, 09316-60011 (09316-00011)
      NOTE: Before pressing on the differential front case, align the groove on the bushing with the pin on the shaft.