Final Drive: Assembly

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.
3. Move side gears up and down to measure the clearance and select thrust washer so that it satisfies the standard value.
  
  Fig 3: Measuring End Play Of Side Gears
  
  Allowable Clearance between side gear and differential case with thrust washer: Refer to "DIFFERENTIAL SIDE GEAR CLEARANCE ".
  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.
    
    Fig 4: Checking Clearance Between Side Gear And Differential Case
Install retaining pin into pinion mate shaft using a pin punch.
CAUTION: Do not reuse retaining pin.

Fig 5: Identifying Lock Pin On Pinion Shaft
Press in differential side bearing (transaxle case side) to differential case using the drifts.

Fig 6: Pressing Differential Side Bearing To Differential Case
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 ( - )]
  
  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.

Fig 9: Tightening Differential Case Bolts