Differential: Service and Repair
1. REMOVE SIDE BEARING
Using SST, remove the two side bearings.
SST 09950-20017
2. REMOVE RING GEAR
a. Place the matchmarks on both the differential case and ring gear.
b. Remove the sixteen bolts.
c. Using a plastic hammer, tap out the ring gear.
3. DISASSEMBLE OF DIFFERENTIAL CASE
a. Place the matchmarks on the differential right and left case.
b. Using a torx wrench, remove the sixteen torx screws.
Torx wrench T50 09042-00040
c. Using a plastic hammer, tap out the differential left case.
d. Remove the speedometer drive gear from the differential right case.
e. Remove the two differential side gears, two side thrust washers, differential spider, four differential pinions and four pinion washers from the differential left case.
4. (Transmission Case Side)
IF NECESSARY, REPLACE OIL SEAL AND TAPER ROLLER BEARING OUTER RACE
a. Using screwdriver, remove the oil seal.
b. Remove the transmission oil baffle.
c. Using a brass bar and hammer, drive out the bearing outer race lightly and evenly.
d. Remove the shim.
e. Install the shim.
NOTE: First select and install a shim of lesser thickness than before.
f. Using SST and a press, install the taper roller bearing outer race.
SST 09316-60010 (09316-00010, 09316-00040)
g. Install the transmission oil baffle.
NOTE: Install the transmission oil baffle projection into the case side cutout.
h. Using SST and a hammer, drive in a new oil seal.
SST 09223-15010
i. Coat the lip of oil seal with MP grease.
5. (Transaxle Case Side)
IF NECESSARY, REPLACE OIL SEAL AND TAPER ROLLER BEARING OUTER RACE
a. Remove the four bolts and three nuts.
b. Using a plastic hammer, tap the stud bolt and remove the transaxle case cover.
c. Using a screwdriver and hammer, drive out the oil seal.
d. Using SST, brass bar and hammer, remove the taper roller bearing outer race.
SST 09612-65014 (09612-01020)
e. Using SST and a hammer, install the taper roller bearing.
SST 09316-60010 (09316-00010, 09316-00040)
f. Using SST and a hammer, drive in a new oil seal.
SST 09316-60010 (09316-00010)
g. Coat the lip of oil seal with MP grease.
h. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transaxle case or case cover.
i. Apply seal packing to the transaxle case cover as shown in the figure.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent
NOTE: Install the transaxle case cover as soon as the seal packing is applied.
j. Apply liquid sealant to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
k. Install and torque the four bolts and three nuts.
Torque: 550 kg-cm (40 ft-lb, 54 N-m)
6. ASSEMBLE OF DIFFERENTIAL CASE
NOTE: Coat all of the sliding and rotating surface with gear oil before assembly.
a. Install the thrust washer to the side gear.
b. Install the four pinions and thrust washers to the spider.
c. Install the side gear and spider with four pinions to the differential left case.
d. Using a dial indicator, measure the backlash of one pinion gear while holding the No.2 differential case.
Standard backlash: 0.05-0.20 mm (0.0020 - 0.0079 in.)
NOTE: Push the pinion gear of the left side of the differential case.
e. Install the side gear and spider with four pinions to the right side of the differential case.
And check the side gear backlash.
f. Referring to the table below, select the thrust washer which will ensure that the backlash is within specification. Try to select a washer of the same size.
g. Install the speedometer driven gear.
h. Align the matchmarks on the differential cases.
i. Using plastic hammer, carefully tap the differential case.
j. Using a torx wrench, install and torque the sixteen torx screws.
Torx wrench T50 09042-00040
Torque: 640 kg-cm (46 ft-lb, 63 N-m)
7. INSTALL RING GEAR
a. Clean the contact surface of the differential case.
b. 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)
c. Clean the contact surface of the ring gear with cleaning solvent.
d. Quickly install the ring gear on the differential case. Install the sixteen bolts.
NOTE: Align the matchmarks on the differential left case and contact the ring gear.
e. Tighten the set bolts uniformly and a little at a time. Torque the bolts.
Torque: 1,260 kg-cm (91 ft-lb, 124 N-m)
8. INSTALL SIDE BEARING
Using SST and a press, install the side bearings onto the differential case.
SST 09316-60010 (09316-00010)
NOTE: Press the bearing on the ring gear side first.
9. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
10. INSTALL DIFFERENTIAL CASE ASSEMBLY
Install the differential case assembly to the transaxle case.
11. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case, install the input shaft assembly.
12. INSTALL TRANSMISSION CASE
a. Install the transmission case.
NOTE: If necessary, tap on the case with a plastic hammer.
b. Install and torque the seventeen bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N-m)
13. INSTALL OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE
14. INSTALL SHIM
NOTE: Install the previously selected shim.
15. INSTALL REAR BEARING RETAINER
Using a torx wrench, install and torque the seven torx screws.
Torx wrench T45 09042-00050
Torque: 430 kg-cm (31 ft-lb, 42 N-m)
16. ADJUST DIFFERENTIAL CASE PRELOAD
a. Install the new lock nut to the output shaft.
b. Turn the output shaft right and left two or three times to allow the bearings to settle.
c. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing
Add output shaft preload
1.9 - 3.7 kg-cm (1.6 - 3.2 in-lb, 0.2 - 0.4 N-m)
Reused bearing
Add output shaft preload
1.2 - 2.3 kg-cm (1.0 - 2.0 in-lb, 0.1 - 0.2 N-m)
If the preload is not within specification, select the thrust washers.
NOTE: The total preload will change about 1 - 2 kg-cm (0.9 - 1.7 in.-lb, 0.1 - 0.2 N-m) with each shim thickness.
17. REMOVE REAR BEARING RETAINER
Using torx wrench, remove the seven torx screws and rear bearing retainer.
Torx wrench T45 09042-00050
18. REMOVE SHIM
19. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with a plastic hammer.
20. REMOVE OUTPUT SHAFT ASSEMBLY
21. REMOVE DIFFERENTIAL CASE ASSEMBLY