Differential Case Assembly

Install the bevel gear and bevel pinion together with washers, and insert the pinion shaft.
NOTE: Face the chamfered side of washer toward gear.

Fig 1: Installing Bevel Gear And Bevel Pinion
Measure the backlash between the bevel gear and pinion. If backlash is not within specified value, install a suitable washer to adjust. < Ref. to ADJUSTMENT , Front Differential Assembly. >
NOTE: Be sure the pinion gear teeth contacts adjacent gear teeth during measurement.

ST1 498247001 MAGNET BASE

ST2 498247100 DIAL GAUGE

Standard backlash

0.13 - 0.18 mm (0.0051 - 0.0071 in)

Fig 2: Measuring Backlash Between Differential Bevel Gear And Pinion
Align the pinion shaft and differential case with each hole, and drive the straight pin into the holes from the hypoid driven gear using the ST.
NOTE: Lock the straight pin after installing.

ST 899904100 REMOVER

Fig 3: Identifying Pinion Shaft, Differential Case And Straight Pin
Install the roller bearing to differential case.
NOTE:
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
- Be careful because the roller bearing outer races are used as a set.
ST1 499277100 BUSHING 1-2 INSTALLER

ST2 398497701 ADAPTER

Fig 4: Installing Roller Bearing Using Bushing 1-2 Installer ST1 499277100
Install the hypoid driven gear to the differential case using twelve bolts.
Tightening torque:

T: 62 N.m (6.3 kgf-m, 45.6 ft-lb)

Fig 5: Identifying Hypoid Driven Gear And Differential Case