Differential Assembly (A-541E) Disassembly & Reassembly: Reassembly

Match side gears and pinion gears with corresponding thrust washers. Install gears in differential case. Install pinion shaft. Check pinion gear backlash.
If backlash is not within specification, replace side gear thrust washers with matched set. Washers are available in 3 thicknesses: .063" (1.60 mm), .067" (1.70 mm) and .071" (1.80 mm). Recheck backlash after washers have been replaced.
Drive in pinion shaft roll pin. Ensure ring gear mounting surface is clean and free of burrs or scratches. Heat ring gear in oil bath to 212°F (100°C). DO NOT exceed temperature. Install ring gear, aligning reference marks made during disassembly. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install speedometer drive gear. Press side bearing onto differential case. Lubricate all moving parts with ATF.

Fig 1: Measuring Differential Pinion Bearing Backlash (A-541E)

Fig 2: Exploded View Of Differential Assembly (A-541E)