Differential: Service and Repair
NOTE: For removal and installation procedures refer to "Automatic Transmission/Transaxle, Service and Repair." Service and RepairDIFFERENTIAL DISASSEMBLY
1. Remove ring gear.
a. Place the matchmarks on the ring gear and differential case.
b. Loosen the staked part of the locking plate.
c. Remove the 8 bolts and 4 locking plates.
d. Using a plastic hammer, tap on the ring gear to remove it from the case.
2. Remove side bearings from differential case.
a. Setting Special Service Tool (SST) 09502 - 10012 or equivalent, to the cut-out portion on the speedometer drive gear, remove the bearing from the differential case.
b. Remove the speedometer drive gear.
c. Setting SST 09502 - 10012 to the cut-out portion on the differential case, remove the bearing.
3. Disassemble differential case.
a. Drive out the pinion shaft lock pin from the ring gear side.
b. Remove the pinion shaft from the case.
c. Remove the 2 pinions, 2 side gears and 4 thrust washers.
4. Remove oil seal of transaxle housing.
Using a screwdriver, remove the oil seal.
5. Remove side bearing outer race of transaxle housing.
Using SST 09350 - 32014 (09351 - 32090) and a hammer, drive out the outer race and shim.
6. Remove oil seal of transaxle case.
Using a screwdriver, remove the oil seal.
7. Remove side bearing outer race of transaxle case.
Using SST 09350 - 32014 (09351 - 32130, 09351 - 32150) and a hammer, drive out the outer race and adjusting shim.
DIFFERENTIAL ASSEMBLY
1. Install side bearing outer race of transaxle housing.
a. Place the shim onto the transaxle housing.
b. Using SST 09350 - 32014 (09351 - 32111, 09351 - 32130) and press, press a new outer race into the transaxle housing.
2. Install side bearing outer race of transaxle case.
Place the adjusting shim onto the transaxle case.
Using SST 09350 - 32014 (09351 - 32111, 09351 - 32130) and press, press a new outer race into the transaxle case.
3. Assemble differential case.
a. Install the thrust washers to the side gears.
b. Install the side gears with thrust washers, pinion gears and pinion thrust washers into the differential case.
c. Install the pinion shaft so as to align the lock pin holes on the pinion shaft and differential case.
4. Check side gear backlash.
a. 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 out of specification, install the correct thrust washer to the side gear.
b. 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 thicknesses mm (in.)
0.95 (0.0374), 1.00 (0.0394), 1.10 (0.0433), 1.15 (0.0453), 1.05 (0.0413), 1.20 (0.0472)
If the backlash is not within specification, install a thrust washer of a different thickness.
5. Install lock pin.
a. Using a hammer and punch, drive the lock pin through the case and hole in the pinion shaft.
b. Stake the differential case.
6. Install side bearings to differential case.
a. Using SST 09710 - 30030 (09710 - 03160) and press, press the side bearing into the differential case.
b. Install the speedometer drive gear to the differential case.
c. Using SST 09350 - 32014 (09351 - 32090, 09351 - 32120) and press, press the side bearing into the differential case.
7. Adjust side bearing preload.
a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case.
b. Install the differential to the transaxle case.
c. Install the transaxle housing to the transaxle case.
d. Install and tighten the bolts.
Torque: 29 N.m (300 kgf-cm, 22 ft.lbf)
e. Using SST 09563 - 32011, rotate the differential in both directions to snug the bearing down.
f. Using SST 09564 - 32011 and a torque meter, measure the preload of the side bearing.
Preload (at starting):
- New bearing 0.8 - 1.4 N.m (8 - 14 kgf-cm, 6.9 - 12.2 in.lbf)
- Used bearing 0.4 - 0.7 N.m (4 - 7 kgf-cm. 3.5 - 6.1 in.lbf)
If the preload is not within specification, remove the differential from the transaxle case. Re-select the transaxle case side adjusting shim.
Adjusting shim thickness: mm (in.)
2.00 (0.0787), 2.05 (0.0807), 2.10 (0.0827), 2.15 (0.0846), 2.20 (0.0866), 2.25 (0.0886), 2.30 (0.0906), 2.35 (0.0925), 2.40 (0.0945), 2.45 (0.0965), 2.50 (0.0984), 2.55 (0.1004), 2.60 (0.1024), 2.65 (0.1043), 2.70 (0.1063), 2.75 (0.1083), 2.80 (0.1102), 2.85 (0.1122), 2.90 (0.1142)
HINT: The preload will change about 0.3 - 0.4 N.m (3 - 4 kgf-cm, 2.6 - 2.9 in..lbf) with a change in shim thickness of 0.05 mm.
g. Remove the bolts and transaxle housing.
h. Remove the differential from the transaxle case.
8. Install ring gear to differential.
a. Clean the contact surface of the differential case.
b. Heat the ring gear in boiling water for about 10 minutes.
c. Carefully remove the ring gear from the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
e. Install new locking plates and set bolts uniformly a little at a time.
When the ring gear has cooled sufficiently, tighten the bolts.
Torque: 97 N.m (985 kgf-cm, 71 ft.lbf)
f. Using a hammer and drift punch, stake the locking plates.
HINT: Stake one claw 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.
9. Install oil seal of transaxle case.
a. Using SST 09350-32014 (09351-32111, 09351-32130) and a hammer, drive in a new oil seal.
b. Coat the lip of the oil seal with MP grease.
10. Install oil seal of transaxle housing.
a. Using SST 09350-32014 (09351-32130, 09351-32150) and a hammer, drive in a new oil seal.
b. Coat the lip of oil seal with MP grease.