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 of the fluid strainer (A) and the collar (B), then install the fluid strainer, the magnet (C), the oil pump pin (D), and the collar in the rear differential carrier assembly.






2. Align the tabs (A) of the collar (B) with the oil pump pin (C). Align the grooves (D) of the rear oil pump with the oil pump pin and the collar tabs, then install the oil pump body assembly (E) on the rear differential carrier assembly.






3. Tighten the oil pump body assembly bolts (A).





4. 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. Then install the thrust needle bearing (D).

5. If necessary, reassemble the differential clutch, and note these items:

- Install one of clutch disc B and one of clutch disc A in the clutch guide (C) as shown, then install the clutch hub (D) with the set ring (E) into the clutch guide.
- Make sure the splines of the clutch hub and clutch disc B line up below the set ring.
- Install remaining clutch disc B and clutch disc A alternately until you have installed a total of ten clutch disc B and ten clutch disc A, then install the clutch plate (F) and the pressure plate (G).
- Make sure the differential clutch is assembled correctly. The pressure plate should be flush with the top of the clutch guide.





6. Install the differential clutch assembly (A) by aligning the tabs of the pressure plate (B) with the grooves of the oil pump driveshaft (C). Be careful not to let the pressure plate fall out of the clutch guide during assembly.






7. 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.





8. Install the 30 mm shim (A), the dowel pins (B), and the torque control differential (TCD) case (C). Torque the eight mounting bolts in a crisscross pattern in several steps.






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

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






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










11. Stake the locknut tab (A) into the groove in the clutch guide.






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