Rear Differential Disassembly and Reassembly (4WD): Reassembly
NOTE: Refer to the Exploded View as needed during the following procedure.
- 1. Oil Pump Body Assembly - Install
1. Apply DPSF II to the rubber pinion of the fluid strainer (A), then install the fluid strainer
2. Install the magnet (B), the 8 x 10 mm dowel pins (C), and the oil pump pin (D) in the differential carrier assembly.
3. Align the grooves (A) of the rear oil pump with the oil pump pin (B), then install the oil pump body assembly (C) on the differential carrier assembly. 4. Tighten the oil pump body assembly with the three mounting bolts (A) 5. Install the oil pump driveshaft (B) by aligning the projection (C) of the oil pump driveshaft with the groove of the front oil pump in the oil pump body assembly
6. Install the thrust needle bearing (D).
- 2. Differential Clutch Assembly - Install
1. Install the six steel balls (A), the base cam (B), the thrust needle bearing (C), and the pressure plate (D) on the differential clutch assembly (E).
NOTE: Align the tabs (F) of the pressure plate with the grooves (G) of the differential clutch assembly.
2. Make a mark (A) on the outside of the differential clutch assembly (B) that corresponds to the position of the tab (C) of the pressure plate (D) as shown 3. Make a mark (E) on the outside of the oil pump body assembly (F) that corresponds to the position of the groove (G) in the oil pump driveshaft (H) as shown
4. Support the pressure plate and the differential clutch assembly by hand so that they do not misalign. With the marks aligned, install the differential clutch assembly to the oil pump body assembly
5. Install the 30 mm shim (I).
6. Make sure that the differential clutch assembly and the pressure plate are correctly installed 7. If the differential clutch assembly can be pushed down as in the figure, proceed to next procedure. If not, return to step 1.NOTE: If incorrectly installed, the differential clutch assembly may be damaged when excessive force is applied.
- 3. Torque Control Differential Case - Install
1. Clean any dirt and oil from the sealing surface of the torque control differential (TCD) case and the differential carrier assembly
2. Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) evenly to the sealing surface
3. Install the component within 4 minutes of applying the liquid gasket. Make sure you seal the entire circumference of the bolt holes to prevent fluid leakage.
NOTE:
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
- Allow it to cure at least 30 minutes after assembly before filling the differential with the recommended fluid.
4. Install the 6 x 10 mm dowel pins (A) and the torque control differential (TCD) case (B).NOTE: Be careful not to damage the lip of the oil seal (C) when installing the torque control differential (TCD) case on the differential carrier case. If the oil seal is damaged, replace it 5. Torque the eight mounting bolts in a crisscross pattern in several steps.
- 4. Companion Flange - Install
1. Install the companion flange (A) to the shaft of the differential clutch assembly
2. Apply DPSF II to a new O-ring (B)
3. Install the O-ring, a new back-up ring (C), the spring washer (D), and a new locknut (E).
NOTE: Be sure to install the spring washer in the direction shown.
4. Install the companion flange holder and holder handle on the companion flange 5. Tighten the locknut to the specified torque.
Specified Torque: 147 N.m (15.0 kgf.m, 108 lb.ft) 6. Stake the locknut tab (A) into the groove in the differential clutch assembly. - 5. Oil Filler Plug and Drain Plug - Install
1. Install the drain plug (A) with a new sealing washer (B)
2. Install the oil filler plug (C) with a new sealing washer (D) finger-tight.
