Differential: Service and Repair
COMPONENTS
REMOVAL OF DIFFERENTIAL
1. REMOVE SPEEDOMETER DRIVEN GEAR
2. REMOVE SPEED SENSOR AND SENSOR ROTOR
3. REMOVE OIL PUMP
SST 09350-32013 (09351-32061)
4. REMOVE TRANSAXLE HOUSING
5. REMOVE DIFFERENTIAL
REPLACEMENT OF DIFFERENTIAL
1. REPLACE SIDE BEARING FROM DIFFERENTIAL CASE
a. Setting SST to the cut-out portion on the speedometer drive gear, remove the bearings from both sides of the case.
SST 09502-10012
b. Using SST and a press, press the side bearings onto the differential case.
SST 09350-32013 (09351-32090, 09351-32120)
2. REPLACE RING GEAR
a. Loosen the staked part of the lock plate.
b. Remove the eight bolts and locking plates.
c. Using a copper hammer, tap on the ring gear to remove it from the case.
d. Clean the contact surface of the differential case.
e. Heat the ring gear to about 100°C (212°F) in an oil bath.
CAUTION: Do not heat the ring gear above 110°C (230°F).
f. Clean the contact surface of the ring gear with cleaning solvent.
g. Quickly install the ring gear on the differential case.
h. Install new locking plates and set bolts.
Tighten the set bolts uniformly and a little at a time. Torque the bolts.
Torque: 985 kg.cm. (71 ft.lb., 97 N.m)
i. Using a hammer and drift punch, stake the locking plates.
NOTE: Stake one claw flush with the flat surface of the nut For the claw contacting the protruding portion of the nut, stake only the half on the tightened side.
REPLACEMENT OF OIL SEAL AND OUTER RACE
1. REPLACE LH OIL SEAL
a. Remove the oil seal.
b. Using SST, drive in a new oil seal.
SST 09350-32013 (09351-32130, 09351-32150)
c. Coat the lip of the oil seal with MP grease.
2. REPLACE LH SIDE BEARING OUTER RACE
a. Remove the oil seal.
b. Using SST, drive out the outer race and shim.
SST 09350-32013 (09351-32130, 09351-32150)
c. Place the shim onto the transaxle case.
d. Using SST, drive in a new outer race into the transaxle case.
SST 09350-32013 (09351-32111, 09351-32130)
e. Install a new oil seal.
f. Coat the lip of the oil seal with MP grease.
3. REPLACE RH OIL SEAL
a. Remove the oil seal.
b. Using SST, drive in a new oil seal.
SST 09350-32013 (09351-32130, 09351-32150)
c. Coat the lip of the oil seal with MP grease.
4. REPLACE RH SIDE BEARING OUTER RACE
a. Remove the oil seal.
b. Using SST, drive out the outer race and shim.
SST 09350-32013 (09351-32090)
c. Place the shim onto the transaxle case.
d. Using SST, press a new outer race into the transaxle case.
SST 09350-32013 (09351-32111, 09351-32130)
e. Install a new oil seal.
f. Coat the lip of the oil seal with MP grease.
ADJUSTMENT OF DIFFERENTIAL CASE
1. CHECK SIDE GEAR BACKLASH
Measure the backlash of the side gear while holding one pinion toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is Out of specification, install the correct thrust washer to the side gears.
2. DISASSEMBLE DIFFERENTIAL CASE
a. Drive out the pinion shaft lock pin from the side on which the ring gear is installed.
b. Remove the pinion shaft from the case.
c. Remove the two pinions, two side gears and four thrust washers.
3. ASSEMBLE DIFFERENTIAL CASE
a. Install the removed thrust washers to the side gears.
b. Install the side gears with pinion thrust washers and pinion gears in the differential case.
c. Install the pinion shaft.
d. Check the side gear backlash.
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.)
e. Refering to the table below, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size of both sides.
f. If the backlash is not within specification, install a thrust washer of a different thickness.
g. Install the lock pin.
1. Using a hammer and a punch, drive the lock pin through the case and hole in the pinion shaft.
2. Stake the differential case.
ADJUSTMENT OF DIFFERENTIAL SIDE BEARING PRELOAD
1. REMOVE RING GEAR FROM DIFFERENTIAL
2. REPLACE LH ADJUSTING SHIM
a. Remove the LH oil seal.
b. Using SST, drive out the outer race and shim.
SST 09350-32013 (09351-32130, 09351-32150)
c. Place 2.40 mm (0.0945 in.) shim onto the transaxle case.
d. Using SST, press the outer race into the transaxle case.
SST 09350-32013 (09351-32111, 09351-32130)
3. INSTALL DIFFERENTIAL CASE
a. Install the differential case to the transaxle case.
b. Install the transaxle housing and tighten the bolts.
Torque: 300 kg.cm. (22 ft.lb., 29 N.m)
NOTE: Each bolt length (mm) is indicated in the figure.
4. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a. Rotate the differential in both directions to snug the bearing down.
b. Using SST and a torque meter, measure the preload of the side bearing.
SST 09564-32011
Preload (at starting):
New bearing 8 - 14 kg.cm. (6.9 - 12.2 in.lb, 0.8 - 1.4 N.m)
Reused bearing 4 - 7 kg.cm. (3.5 - 6.1 in.lb, 0.4 - 0.7 N.m)
If the preload is not within specification, remove the differential from the transaxle case.
Re-select LH adjusting shim.
NOTE: The preload will change about 3 - 4 kg.cm. (2.6 - 3.5 in.lb, 0.3 - 0.4 N.m) with each shim thickness.
5. REMOVE DIFFERENTIAL
a. Remove the transaxle housing.
b. Remove the differential from the transaxle case.
6. INSTALL RING GEAR TO DIFFERENTIAL CASE
INSTALLATION OF DIFFERENTIAL
1. INSTALL DIFFERENTIAL
2. INSTALL TRANSAXLE HOUSING
a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transmission case.
b. Apply seal packing to the transaxle housing as shown.
Seal packing: Part No.08833-00090, THREE BOND 1131, LOCTITE 518 or equivalent
c. Install and tighten the eighteen bolts.
Torque: 300 kg.cm. (22 ft.lb., 29 N.m)
NOTE: Each bolt length (mm) is indicated in the figure.
3. INSTALL OIL PUMP
4. INSTALL SENSOR ROTOR AND SPEED SENSOR
5. INSTALL SPEEDOMETER DRIVEN GEAR