Rear Differential Reassembly

Rear Differential Reassembly

Exploded View





Special Tools Required

- Holder Handle 07JAB-001020A
- Companion Flange Holder 07RAB-TB4010B

1. Apply Dual Pump Fluid II to the rubber pinion of the fluid strainer (A), then install the fluid strainer, the magnet (B), the dowel pins (C), and the oil pump pin (D) in the differential carrier assembly.






2. 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.






3. Tighten the oil pump body assembly with the three mounting bolts (A), then 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.





4. Install the thrust needle bearing (D).

5. Install the six steel balls (A), the base cam (B), the thrust needle bearing (C), and the pressure plate (D) on the clutch assembly (E).

NOTE: Align the tabs (F) of the pressure plate with the grooves (G) of the clutch assembly.






6. Make a mark (A) on the outside of the clutch assembly (B) that corresponds to the position of the tab (C) of the pressure plate (D) as shown. Make a mark (E) on the outside of the oil pump assembly (F) that corresponds to the position of the groove (G) in the oil pump driveshaft (H) as shown.





7. Support the pressure plate and clutch assembly by hand so that they do not misalign. With the marks aligned, install the clutch assembly to the oil pump assembly. Install the 30 mm shim (I).

8. Make sure that the clutch assembly and pressure plate are correctly installed. If the clutch assembly can be pushed down as in the figure, proceed to step 9 Rear Differential Reassembly. If not, return to step 5 Rear Differential Reassembly.

NOTE: If incorrectly installed, the clutch assembly may be damaged when excessive force is applied.






9. Remove the dirt or oil from the sealing surfaces. Apply liquid gasket (P/N 08717-0004, 08718-0001,08718-0003, or 08718-0009) evenly to the sealing surface. Install the component with in 5 minutes of applying the liquid gasket. Make sure you seal the entire circumference of the bolt holes to prevent fluid leakage.

NOTE:

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- 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.





10. Install the dowel pins (A) and the torque control differential (TCD) case (B). Torque the eight mounting bolts in a crisscross pattern in several steps.






11. Install the companion flange (A), a new O-ring (B), the back-up ring (C), the disc spring washer (D), and a new locknut (E).

NOTE: Apply Dual Pump Fluid II to the O-ring.






12. Install the companion flange holder (A) and the holder handle (B) to the companion flange, then tighten the locknut to the specified torque.










13. Stake the locknut shoulder (A) into the groove in the clutch guide.






14. Install the drain plug (A) and the filler plug (B) with new sealing washers (C).





15. Install the rear differential Rear Differential Installation.