Differential Assembly: Reassembly

On transaxle case cover side of transaxle case, using appropriate driver and a hammer, tap in NEW oil seal to a depth of .083-.106" (2.10-2.70 mm). Coat oil seal lip with grease. If tapered roller bearing was replaced, install NEW selected shim into transaxle case. If tapered roller bearing was not replaced, install original shim into transaxle case. Using appropriate adapter and a hammer, install tapered roller bearing outer race into transaxle case.
On differential assembly side of transaxle case, install plate washer into transaxle case. Using appropriate adapter and a hammer, install tapered roller bearing outer race. Using appropriate driver and a hammer, tap in oil seal to a depth of .062-.087" (1.60-2.20 mm). Coat oil seal lip with grease.
If backlash was incorrect during disassembly inspection, select NEW side gear thrust washers to correct backlash. Side gear thrust washers are available in thicknesses from .059" (1.50 mm) to .069" (1.75 mm), in .002" (.05 mm) increments.
Install thrust washers of equal thickness to side gears. Install side gears with thrust washers, pinion thrust washers and pinions gears into differential case. Install pinion shaft. Recheck side gear backlash while holding one pinion gear toward case. Backlash should be .002-.008" (.05-.20 mm). Correct as needed. Using a pin punch and a hammer, tap in pinion shaft straight pin through differential case and hole in pinion shaft. Using a chisel and a hammer, stake pin holes around circumference of differential case.
On ring gear side, using appropriate adapter and a press, install tapered roller bearing. On vehicle speed sensor drive gear side, place drive gear in position to stop turning, and install drive gear. Ensure drive gear is installed in correct direction. Using appropriate adapter and a press, install tapered roller bearing. Clean contact surface of differential case. Heat ring gear to 212°F (100°C) in boiling water. Remove ring gear from water. After moisture on ring gear has completely evaporated, install ring gear onto differential case.
Align match marks on ring gear and differential case. Temporarily install 6 set bolts. Once ring gear has cooled sufficiently, tighten bolts to specification. See TORQUE SPECIFICATIONS .

Fig 1: Exploded View Of Differential Assembly

Fig 2: Measuring Side Gear Backlash