Differential Assembly: Reassembly

Install side gears and thrust washers in differential case. Install pinion gears and thrust washers in case by rotating gears. Apply ATF to all components. Using a dial indicator and Adapter (KV38105710) on RE4F03B or Adapter (KV38107700) on RE4F03W, measure clearance on differential case side, between side gear thrust washer and differential case. Move side gear up and down to measure deflection. Always measure deflection on both side gears. See Fig 2 .

Specified clearance is .004-.008" (.10-.20 mm). If clearance is not as specified, adjust clearance by changing thickness of side gear thrust washers. Washers are available in increments of .002" (.05 mm). See DIFFERENTIAL SIDE GEAR THRUST WASHER SPECIFICATIONS (RE4F03B) or DIFFERENTIAL SIDE GEAR THRUST WASHER SPECIFICATIONS (RE4F03W) table.

DIFFERENTIAL SIDE GEAR THRUST WASHER SPECIFICATIONS (RE4F03B)

DIFFERENTIAL SIDE GEAR THRUST WASHER SPECIFICATIONS (RE4F03W)

Part No.

In. (mm)

38424-D2111 ⁽¹⁾

.0295-.0315 (.750-.800)

38424-D2112 ⁽¹⁾

.0315-.0335 (.800-.850)

38424-D2113 ⁽¹⁾

.0335-.0354 (.850-.900)

38424-D2114 ⁽¹⁾

.0354-.0374 (.900-.950)

38424-D2115 ⁽¹⁾

.0374-.0394 (.950-1.000)

38424-D2116

.0394-.0413 (1.000-1.050)

38424-D2117

.0413-.0433 (1.050-1.100)

38424-D2118

.0433-.0453 (1.100-1.150)

38424-D2119

.0453-.0472 (1.150-1.200)

38424-D2120

.0472-.0492 (1.200-1.250)

38424-D2121

.0492-.0512 (1.250-1.300)

38424-D2122

.0512-.0531 (1.300-1.350)

⁽¹⁾	Part numbers used on differential case side. (All shims may be used on vicious coupling side).

Place side gear and thrust washer on pinion gears installed on viscous coupling side of differential. Using a height gauge, measure dimension "X" of differential case and dimension "Y" of viscous coupling in at least 2 places. See Fig 3 .
Clearance between side gear and viscous coupling is determined by using the following equation: X + Y - 2A = CLEARANCE (Dimension A = height of gauge spacer). Specified clearance is .004-.008" (.10-.20 mm). If clearance is not as specified, adjust clearance by changing thickness of side gear thrust washers. Washers are available in increments of .002" (.05 mm). See DIFFERENTIAL SIDE GEAR THRUST WASHER SPECIFICATIONS (RE4F03W) table.
Install retaining pin. Ensure retaining pin is flush with case. Install side gear (viscous coupling side), on differential case, then install viscous coupling. Install speedometer drive gear in differential case. Align projections of speedometer drive gear with groove in differential case. See Fig 4 .
Press differential side bearings on differential case. Install ring gear and tighten bolts in numerical order. See Fig 5 . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Fig 1: Exploded View Of Torque Converter Housing & Differential Components