NOTE: Refer to the Exploded View as needed during the following procedure.
1.
Oil Filler Plug and Drain Plug - Remove
1.
Remove the drain plug (A) with the sealing washer (B).
2.
Remove the oil filler plug (C) with the sealing washer (D).
2.
Companion Flange - Remove
1.
Pry up the stake on the locknut (A) from the groove of the differential clutch assembly, making sure the tab completely clears the groove to prevent damaging the differential clutch assembly.
2.
Install the companion flange holder and the holder handle on the companion flange.
3.
Loosen the locknut (A) counterclockwise so its tab (B) comes out from the groove (C) in the differential clutch assembly.
4.
Tighten the locknut (A) until its tab (B) aligns with the groove (C).
5.
Clean any dirt from inside the groove in the differential clutch assembly, then loosen the locknut.
6.
Remove the locknut (A), the spring washer (B), the backup ring (C), the O-ring (D), and the companion flange (E).
3.
Torque Control Differential Case - Remove
1.
Remove the eight mounting bolts (A) in a crisscross pattern in several steps.
2.
Remove the torque control differential (TCD) case (B) and the 6 x 10 mm dowel pins (C).
4.
Differential Clutch Assembly - Remove
1.
Remove the 30 mm shim (A).
2.
Remove the differential clutch assembly (B).
3.
Remove the six steel balls (A) and the base cam (B).
4.
Remove the thrust needle bearings (C) and the pressure plate (D).
5.
Remove the oil pump driveshaft (A).
5.
Oil Pump Body Assembly - Remove
1.
Remove the three mounting bolts (A) and the oil pump body assembly (B).
2.
Remove the oil pump pin (C), the 8 x 10 mm dowel pins (D), the magnet (E), and the fluid strainer (F).
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 lbf·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.
