Differential Case: Reassembly

1. After applying ATF to the 2 front differential side gears, 2 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers, install them to the front differential case.

HINT:

When installing them, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes are aligned with the holes in the differential case.

Fig 1: Identifying Front Differential Side Gear

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1. Install the front No. 1 differential pinion shaft aligning the lock pin holes in the pinion shaft and front differential case.
   Fig 2: Installing Front No. 1 Differential Pinion Shaft

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1. Using a pin punch and a hammer, install the pinion shaft straight pin.
   Fig 3: Installing Front Differential Pinion Shaft Straight Pin

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2. Using a chisel and a hammer, stake the pinion shaft straight pin.
   Fig 4: Staking Pinion Shaft Straight Pin

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1. Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
2. Clean the contact surface of the front differential case.
   Fig 5: Heating Front Differential Ring Gear

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3. Align the matchmarks, and install the front differential ring gear case quickly.
   NOTE: Do not install the bolts while the ring gear is hot.
   Fig 6: Identifying Matchmarks On Front Differential Ring Gear Case

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4. Install 4 new ring gear lock plates with the 8 bolts.

   Torque: 88 N*m (898 kgf*cm, 65 ft.*lbf) 

   Fig 7: Identifying Ring Gear Lock Plates With Bolts

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5. Using SST, stake the ring gear lock plate.

   SST 09930-00010 

   Fig 8: Staking Ring Gear Lock Plate

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1. Using SST and a press, install the front differential case rear tapered roller bearing inner race to the differential case.

   SST 09726-40010, 09950-60020 (09951-00790) 

   Fig 9: Installing Front Differential Case Rear Tapered Roller Bearing

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2. Using SST and a press, install the shim and bearing outer race to the transaxle case.

   SST 09950-60020 (09951 -00720), 09950-60010 (09951-00650), 09950-70010 (09951-07100,09951-07200) 

Fig 10: Installing Shim And Transaxle Case

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