1

Front Differential Bearing Spacer

2

Front Drive Pinion Gear Shaft Thrust Bearing Assembly (LHS)

3

Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly

4

Front Drive Pinion Gear Shaft Thrust Bearing Assembly - Selective (RHS)

5

Front Differential Carrier Assembly (FWD)

6

Torque Damper Housing Outer Seal

1

Front Differential Drive Pinion Gear Roller Bearing Assembly

Tip
After placing the bearing cup on the gear, place DT-47800-2 which is part of DT-47800 kit , onto the bearing cup.

Special Tools

For equivalent regional tools, refer to Special Tools .

2

Front Differential Drive Pinion Gear Bearing Cup

Tip
After placing the bearing cup on the gear, place DT-47800-2 which is part of DT-47800 kit , onto the bearing cup.

Special Tool

DT-47800 Thrust Washer Selection Gauge Kit

For equivalent regional tools, refer to Special Tools .

3

Torque Damper and Differential (w/Fluid Pump) Housing Assembly

Tip

Special Tools

For equivalent regional tools, refer to Special Tools .

1

Spacer Bolts M8 x 127 mm (Qty: 8)

Caution: Refer to Fastener Caution in the Preface section.

Procedure

1. Install the remaining spacers evenly at every other bolt hole.
2. Remove the DT-47800-10 thrust washer selection bolts, spacer and shims , guide pins and install spacer bolts in all bolt holes at spacer locations.
3. Tighten the bolts in sequence shown.

Tighten
30 N·m (22 lb ft)

Special Tools

For equivalent regional tools, refer to Special Tools .

2

Front Differential Carrier Assembly

Caution: If the bearings are not properly seated into the bearing cups, the washer selection will be inaccurate and the bearing pre-load will be set too low. Low bearing pre-load will cause premature failure of the front differential drive pinion gear.

Tip
DT-47793 rotating tool can be used to rotate the differential from the case side.

Special Tools

DT-47793 Differential Rotating Tool

For equivalent regional tools, refer to Special Tools .

1

Front Differential Bearing Washer

Procedure

1. Place DT-47800-7 in the gap in DT-47800-2 which are both part of DT-47800 kit , to determine the proper thrust washer. Choose the correct thrust washer. Refer to Taper Bearing Preload Selective Specifications .
2. Continue trying different sizes of DT-47800-7 which is part of DT-47800 kit , until the gauge will no longer fit into the gap. The correct thrust washer size is equal to the largest blade gauge that fits into the gap.
3. Match the size of the correct DT-47800-7 blade which is part of DT-47800 kit , to the colour code in the thrust washer specification chart. The washer colour coding is on the outside diameter of the washer.
4. The gap in DT-47800-2 which is part of DT-47800 kit , may not be even. Hold the top of the gauge and rotate the bottom of the gauge to even out the gap. Take two gap measurements 180 degrees apart. Average the two measurements and select the thrust washer that is closest to the average.
5. The washer colour coding is on the outside diameter of the washer.

Special Tools

DT-47800 Thrust Washer Selective Gauge Kit

For equivalent regional tools, refer to Special Tools .

2

Front Differential Drive Pinion Gear Bearing Thrust Washer

Procedure

1. Place DT-47800-7 in the gap in DT-47800-1 which are both part of DT-47800 kit , to determine the proper thrust washer. Choose the correct thrust washer. Refer to Taper Bearing Preload Selective Specifications .
2. Continue trying different sizes of DT-47800-7 which is part of DT-47800 kit , until the gauge will no longer fit into the gap. The correct thrust washer size is equal to the largest blade gauge that fits into the gap.
3. Match the size of the correct DT-47800-7 blade which is part of DT-47800 kit , to the colour code in the thrust washer specification chart. The washer colour coding is on the outside diameter of the washer.
4. The gap in DT-47800-1 which is part of DT-47800 kit , may not be even. Hold the top of the gauge and rotate the bottom of the gauge to even out the gap. Take two gap measurements 180 degrees apart. Average the two measurements and select the thrust washer that is closest to the average.
5. The washer colour coding is on the outside diameter of the washer.

Special Tools

DT-47800 Thrust Washer Selection Gauge Kit

For equivalent regional tools, refer to Special Tools .

3

Torque Damper and Differential (w/Fluid Pump) Housing Assembly

Procedure

1. Remove the DT-47800-3 which is part of DT-47800 kit , bolts and spacers.
2. Remove the torque damper housing.
3. Remove the DT-47800-1 and DT-47800-2 which are both part of DT-47800 kit .
4. Remove the torque damper housing seal.
5. Remove the pinion gear and differential bearing cups.
6. Install the bearing cups and thrust washers into the torque damper housing according to the replacement procedures. Refer to Front Differential Drive Pinion Gear Bearing Cup Removal - Torque Damper Side and Front Differential Drive Pinion Gear Roller Bearing and Lubricant Dam Replacement .

Tip
DT-47800-1 and DT-47800-2 which are both part of DT-47800 kit , may stick in the torque damper housing. Be careful not to drop the gauges.

Special Tool

DT-47800 Thrust Washer Selection Gauge Kit

For equivalent regional tools, refer to Special Tools .