Differential Case

DIFFERENTIAL CASE

COMPONENTS:

DISASSEMBLY





1. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case front tapered roller bearing from the differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00390)





(b) Using SST, remove the front differential case RH tapered roller bearing outer race from the transaxle housing.
SST 09387-00041 (09387-02020, 09387-02010)





2. REMOVE SPEEDOMETER DRIVE GEAR
(a) Remove the speedometer drive gear from the differential case.





3. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case tapered roller bearing from the differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00430)





(b) Using SST, remove the front differential case tapered roller bearing outer race from the transaxle case.
SST 09612-65014 (09612-01010)





4. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place matchmarks on the front differential ring gear and differential case.





(b) Using SST and a hammer, release the lock plate.
SST 09930-00010





(c) Remove the 8 bolts and the lock plate.





(d) Using a plastic hammer, remove the front differential ring gear from the differential case.





5. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
(a) Using a punch and a hammer, release the differential case.





(b) Using a pin punch and a hammer, remove the straight pin.





6. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT
(a) Remove the pinion shaft from the front differential case.





7. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 pinions, 2 thrust washers, 2 side gears and 2 thrust washers No. 1 from the front differential case.

REASSEMBLY





1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) After applying ATF to the 2 front differential side gears, 2 side gear thrust washers No. 1, 2 front differential pinions and 2 pinion thrust washers, install them onto the front differential case.

HINT: When installing them, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes are aligned with the holes in the differential case.





2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
(a) Install the pinion shaft so as to align the lock pin holes in the pinion shaft and differential case.





3. INSPECT BACKLASH
(a) Measure the side gear backlash while holding 1 pinion gear toward the case.
Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is outside the specifications, 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 the specifications for both sides.

Thrust washer thickness:

If the backlash is not within the specifications, install a thrust washer of a different thickness.





4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
(a) Using a pin punch and a hammer, install the pinion shaft straight pin.





(b) Using a chisel and a hammer, stake the differential case.





5. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
(b) Clean the contact surface of the front differential case.





(c) Install 4 new ring gear lock plates with the 8 bolts.
Torque: 88 N*m (900 kgf*cm, 65 ft.*lbf)





(d) Using SST, stake the ring gear lock plate.
SST 09930-00010





6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case LH tapered roller bearing inner race onto the differential case.
SST 09726-40010, 09950-60020 (09951-00790)





(b) Using SST and a press, install the shim and bearing outer race onto the transaxle case.
SST 09950-60020 (09951-00720), 09950-60010 (09951-00650), 09950-70010 (09951- 07100, 09951-07200)





7. INSTALL SPEEDOMETER DRIVE GEAR
(a) Install the speedometer drive gear onto the differential case.





8. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, install the bearing inner race onto the differential case.
SST 09950-60010 (09951-00460), 09950-70010 (09951-07100)





(b) Using SST and a press, install the tapered roller bearing onto the transaxle housing.
SST 09950-70010 (09951-07150), 09950-60020 (09951-00680)