Center Differential

CENTER DIFFERENTIAL

Components:

DISASSEMBLY





1. CHECK HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE
a. Using a feeler gauge, measure the high speed output gear thrust clearance.
Standard clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 inch)
Maximum clearance: 0.25 mm (0.0098 inch)
If the clearance is greater than the maximum, replace the high speed output gear, needle roller bearing, high speed output gear bush low gear, clutch hub or front differential case.





b. Using a dial indicator, measure the high speed output gear radial clearance.
Standard clearance: 0.035 to 0.091 mm (0.00138 to 0.00358 inch)
Maximum clearance: 0.091 mm (0.00358 inch)
If the clearance is greater than the maximum, replace the high speed output gear, needle roller bearing, high speed output gear bush low gear, clutch hub or front differential case.





2. REMOVE FRONT DRIVE GEAR PIECE
a. Using a snap ring expander, remove the snap ring.
b. Using SST and a press, remove the front drive gear piece.
SST 09950-00020, 09950-60010 (09951-00320)

NOTICE: Be careful not to drop the center differential assembly.





3. REMOVE FRONT TAPER ROLLER BEARING
a. Using SST and a press, press out the taper roller bearing.
SST 09950-00020

NOTICE: Set the claw of SST to the bearing inner race securely.





4. REMOVE HIGH SPEED OUTPUT GEAR
5. REMOVE NEEDLE ROLLER BEARING





6. REMOVE HIGH AND LOW CLUTCH SLEEVE





7. REMOVE HIGH SPEED OUTPUT GEAR BUSH AND CLUTCH HUB
a. Using SST, remove the high speed output gear bush and clutch hub.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00320)
b. Using a magnetic finger, remove the straight pin from the front differential case.





8. REMOVE REAR TAPER ROLLER BEARING
a. Using SST and a press, press out the taper roller bearing.
SST 09950-00020, 09950-60010 (09951-00320)

NOTICE: Set the claw of SST to the bearing inner race securely.





9. REMOVE REAR DIFFERENTIAL CASE
a. Remove the 12 bolts and differential case.





10. REMOVE THRUST WASHER AND REAR SIDE GEAR





11. REMOVE PINION SHAFT, PINION GEAR AND THRUST WASHER
a. Remove the straight pin from the pinion shaft.





b. Remove the pinion shaft, 2 pinion gears and 2 thrust washers.





c. Remove the front side gear and thrust washer.





12. REMOVE LOW GEAR
a. Using a plastic-faced hammer, tap out the low gear.

NOTICE: Be careful not to damage the low gear.

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly





1. INSTALL LOW GEAR
a. Clean the contact surface of the differential case.
b. Heat the low gear in boiling water.
c. Carefully remove the low gear from the water.
d. After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.





2. INSTALL PINION SHAFT, PINION GEAR AND THRUST WASHER
a. Install the front side gear and thrust washer.





b. Install the pinion shaft, 2 pinion gears and thrust washers to the front differential case.





c. Using a dial indicator, measure the front case backlash.

HINT: Push the pinion shaft.

Maximum backlash: 0.05 mm (0.0020 inch)
If the backlash is greater than the maximum, replace the thrust washer with one of the correct size and reinstall the thrust washer.

Standard Snap Ring Thickness:

d. Use the procedures described for the front case backlash to measure the rear case backlash.





e. Install the straight pin to the pinion shaft.





3. INSTALL THRUST WASHER AND REAR SIDE GEAR





4. INSTALL REAR DIFFERENTIAL CASE
a. Install the differential case with the 12 set bolts.
Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.)
b. Turn the pinion gear.
c. Loosen the 12 case set bolts.
d. Torque the 12 case set bolts.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)





5. INSTALL REAR TAPER ROLLER BEARING
a. Using SST and a press, press in the taper roller bearing.
SST 09316-12010





6. INSTALL CLUTCH HUB
a. Using SST and a press, press in the clutch hub.
SST 09316-12010, 09316-60011 (09316-00011)





7. INSTALL HIGH SPEED OUTPUT GEAR BUSH
a. Apply MP grease to the straight pin.
b. Install the straight pin, as shown in the illustration.





c. Using SST and a press, press in the high speed output gear bushing.
SST 09316-12010, 09316-60011 (09316-00011)

NOTICE: Before pressing on the front differential case, align the groove on the bushing with the pin on the shaft.





8. INSTALL HIGH AND LOW CLUTCH SLEEVE

HINT: Make sure to install the high and low clutch sleeve in the correct direction.

9. INSTALL NEEDLE ROLLER BEARING AND HIGH SPEED OUTPUT GEAR
a. Apply gear oil to the needle roller bearing.
b. Install the needle roller bearing and high speed output gear.





10. INSTALL FRONT TAPER ROLLER BEARING
a. Using SST and a press, press in the taper roller bearing.
SST 09316-12010, 09316-60011 (09316-00011)





11. INSTALL FRONT DRIVE GEAR PIECE
a. Using SST and a press, press in the drive gear piece.
SST 09316-12010, 09316-60011 (09316-00011)





12. INSTALL SNAP RING
a. Select a snap ring that will allow the minimum axial play

Standard Snap Ring Thickness:

b. Using a snap ring expander, install a new snap ring.
13. CHECK HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE