Differential Case

DISASSEMBLY





1. REMOVE RING GEAR
a. Place the matchmarks on the ring gear and differential case.





b. Remove the 1 bolts.





c. Using a plastic hammer, tap on the ring gear to remove it from the case.





2. REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing FR speedometer drive gear and RR.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00480, 09951-00500)
3. DISASSEMBLY DIFFERENTIAL CASE





a. Using a pin punch and a hammer, drive out the pin from the ring gear side.





b. Remove the differential pinion shaft from the case.





c. Remove the 2 differential pinions, 2 differential side gears, 2 differential pinion thrust washers and 2 differential side gear thrust washers.





4. REMOVE SIDE BEARING OUTER RACE OF TRANSAXLE HOUSING
Using a brass bar and a hammer, drive out the outer race and adjust the shim.





5. REMOVE OIL SEAL OF TRANSAXLE HOUSING
Using SST and a hammer, drive out the oil seal.
SST 09649-17010, 09950-70010 (09951-07100)





6. REMOVE OIL SEAL OF TRANSAXLE CASE
Using SST, remove the oil seal.
SST 09308-00010





7. REMOVE SIDE BEARING OUTER RACE OF TRANSAXLE CASE
Using a brass bar and a hammer, drive out the outer race and shim.

REASSEMBLY





1. INSTALL BEARING OUTER RACE OF TRANSAXLE HOUSING
Using SST, a press and a hammer, press in a new bearing outer race into the transaxle housing.
SST 09950-60020 (09951-00750), 09950-70010 (09951-07150)

NOTICE: Press-fit the bearing outer race until it contacts the transaxle housing.





2. INSTALL SIDE BEARING OUTER RACE TRANSAXLE CASE
a. Install the shim to the transaxle case.

HINT: First install a shim of the same thickness as before.

b. Using SST, a press and a hammer, press in a new outer race into the transaxle case.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07150)

NOTICE: Press-fit the shim until it contacts the transaxle case.

3. ASSEMBLY DIFFERENTIAL CASE





a. Coat the thrust washers, side gears, pinion gears and pinion thrust washers with ATF.
b. Install the 2 differential side gear thrust washers to the 2 differential side gears.





c. Install the 2 side gears with the 2 thrust washers, 2 pinion gears 2 pinion thrust washers into the differential case.





d. 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 1 pinion gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is out of specified range, install the correct thrust washer to the side gear.
b. Referring to the table, select thrust washers which will ensure that the backlash is within specified range. Select, washers of the same size for both sides.





Thrust washer thickness: mm (in.)

If the backlash is not within the specified range, install a thrust washer of a different thickness.
5. INSTALL PIN





a. Using a hammer and a punch, drive the pin through the case and a hole in the pinion shaft.





b. Using a hammer and a chisel, stake the differential case.
6. INSTALL TAPERED ROLLER BEARING TO DIFFERENTIAL CASE





a. Using SST and a press, install the tapered roller bearing RR into the differential case.
SST 09316-20011 09649-17010





b. Using SST and a press, install the speedometer drive gear and tapered roller bearing FR into the differential case.
SST 09649-17010
7. ADJUST SIDE BEARING PRELOAD
a. Remove any FIPG 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. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transaxle case and transaxle housing.
d. Install the transaxle housing and 1 bolts to the transaxle case.

HINT: Although bolt A is a non-reusable seal bolt, in this case, clean the bolts and tighten them as well as bolts B and C.

Torque:
Bolt A: 22 Nm (224 kgf-cm, 16 ft. lbs.)
Bolt B and C: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
Bolt length:
Bolt A: 60.0 mm (1.969 inch)
Bolt B: 50.0 mm (1.969 inch)
Bolt C: 42.0 mm (1.654 inch)





e. Using SST, rotate the differential in both directions to make the bearing fit.
SST 09564-32011
f. Using SST and a torque meter, measure the preload of the side bearing.
SST 09564-32011
Preload (at starting):
Now bearing: 0.20 - 0.69 Nm (2 - 7 kgf-cm, 1.8 - 6.1 inch lbs.)
Used bearing: 0.10 - 0.35 Nm (1 - 4 kgf-cm, 0.9 - 3.1 inch lbs.)
If the preload is not within the specified range, remove the differential from the transaxle case. Re-select the transaxle case side adjusting shim according to the following table.





Adjusting shim thickness: mm (in.)





g. Remove the 1 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 water and boil for 15 minutes.
c. Carefully take the ring gear out from the water.
d. Immediately after the moisture on the ring gear has completely evaporated, install the ring gear to the differential case.





e. Install the 1 bolts.
Torque: 95.1 Nm (970 kgf-cm, 70 ft. lbs.)





9. INSTALL TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, drive in a new oil seal.
SST 09649-17010
b. Coat the lip of the oil seal with MP grease.





10. INSTALL TRANSAXLE HOUSING OIL SEAL
a. Using SST and a hammer, drive in a new oil seal.
SST 09608-10010, 09950-70010 (09951-07150)
b. Coat the lip of oil seal with MP grease.