ASSEMBLY OF DIFFERENTIAL CASE 1. ASSEMBLE DIFFERENTIAL CASE (a) Install the proper thrust washers to the side gears. (b) Assemble the side gear, pinion gear, pinion shaft and pinion thrust washer into the differential case. HINT: Align the hole of the pinion shaft and case. (c) Measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05 — 0.20 mm (0.0020 — 0.0079 in.) If the backlash is not within specification, install a thrust washer of different thickness. (d) Using the table below, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides. Thrust washer thickness mm (in.) 1.58 — 1.62 (0.062 — 0.064) 1.68 — 1.72 (0.066 — 0.068) 1.78 — 1.82 (0.070 — 0.072) (e) Using a hammer and punch, install the straight pin through the case and hole of the pinion shaft.