Disassembly and Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

Apply gear oil to sliding area of differential case, each gear, and thrust washer.
Install side gear thrust washers and side gears into differential case.
While rotating pinion mate thrust washers and pinion mate gears, aligning them diagonally, install them into differential case.

Fig 1: Locating Side Gear Thrust Washers
Insert pinion mate shaft into differential case.
CAUTION: Be sure not to damage pinion mate thrust washers.

Fig 2: Inserting Pinion Shaft Into Differential Case
Measure end play of side gears following the procedure below. Then select side gear thrust washer.
1. Put differential case vertically so that its side gear to be measured faces upward.
2. Place the preload adapter and a dial indicator onto side gears.
  
  Fig 3: Measuring End Play Of Side Gears
3. Move side gears up and down to measure the clearance and select thrust washer so that it satisfies the standard value. Refer to "DIFFERENTIAL SIDE GEAR THRUST WASHER ".
  Allowable Clearance between side gear and differential case with thrust washer
  
  : Refer to "DIFFERENTIAL SIDE GEAR THRUST WASHER ".
  
  Fig 4: Checking Clearance Between Side Gear And Differential Case
  CAUTION:
  - There should be no resistance and gears should rotate freely.
  - Place differential case upside down. Measure the end play for opposite side-gears likewise securely.
  - Only one thrust washer can be selected.
Install retaining pin into pinion mate shaft using a pin punch.
CAUTION: Never reuse retaining pin.

Fig 5: Installing Retaining Pin Into Pinion Mate Shaft
Press in differential side bearing (transaxle case side) to differential case using the drifts.
CAUTION: Replace differential side bearing and differential side bearing outer race as a set.

Fig 6: Pressing In Differential Side Bearing
Align and install speedometer drive gear onto differential case.

Fig 7: Aligning Speedometer Drive Gear Onto Differential Case
Press in differential side bearing (clutch housing side) to differential case using the drifts.
1. Drift [SST: ST30720000 (J-25405)]
2. Drift [SST: KV38102510 ( - )]
CAUTION:
- Never reuse differential side bearing and differential side bearing outer race.
- Replace differential side bearing and differential side bearing outer race as a set.
  
  Fig 8: Identifying Differential Side Bearing (Clutch Housing Side)
Install final gear into differential case and tighten final gear mounting bolts to the specified torque. Refer to "FINAL DRIVE COMPONENTS ".

Fig 9: Locating Differential Case Bolts