Differential Overhaul
BACKLASH INSPECTION1. Place the differential assembly on V-blocks and install both axles.
2. Check backlash of both pinion gears,
Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 inch)
3. If the backlash is not within the standard, replace the differential carrier.
BEARING REPLACEMENT
NOTE: Check the bearings for wear and rough rotation. If the bearings are OK, removal is not necessary.
1. Remove the ball bearings using a bearing puller.
2. Install the new ball bearings using the special tool with a press as shown.
DIFFERENTIAL CARRIER REPLACEMENT
1. Remove the final driven gear from the differential carrier.
NOTE: The final driven gear bolts have left-hand threads.
2. Pry the snap ring off differential carrier, then remove the speedometer drive gear and 5 x 10 mm roller.
3. Install the 5 x 10 mm roller in the differential carrier.
4. Install the speedometer drive gear with its chamfered side facing the carrier. Align the cutout on the bore of the speedometer drive gear with the 5 x 10 mm roller.
5. Align the hooked end of the snap ring with the pinion shaft as shown, then install the snap ring in the differential carrier groove.
6. Install the final driven gear, then tighten the bolts to the specified torque.
TORQUE: 103 Nm (10.5 kgf.m, 76 ft. lbs.)
NOTE: The final driven gear bolts have left-hand threads.
7. Install the ball bearings.
OIL SEAL REMOVAL
1. Remove the differential assembly.
2. Remove the oil seal from the transmission housing.
3. Remove the oil seal from the torque converter housing.
OIL SEAL INSTALLATION/SIDE CLEARANCE
1. Install a 2.50 mm (0.098 inch) thrust shim in the transmission housing.
NOTE: Do not install the oil seal yet.
2. Install the differential assembly into the torque converter housing using the special tool as shown.
3. Assemble the transmission. Install the transmission housing and tighten the bolts.
4. Tap on the transmission housing side of the differential assembly with the special tool to seat the differential assembly in the torque converter housing.
5. Measure the clearance between the thrust shim and outer race of the ball bearing in the transmission housing.
6. If out of limits, select a new thrust shim from the following table:
NOTE: If the thrust shim-to-ball bearing outer race clearance measured in step 5 is within the standard, it is not necessary to perform steps 7 and 8.
7. Remove the transmission housing.
8. Replace the 2.50 mm (0.098 inch) thrust shim with the one of the correct thickness selected in step 6.
9. Install the transmission housing.
10. Install the oil seal flush with the transmission housing using the special tools as shown.
11. Install the oil seal flush with the torque converter housing using the special tools as shown.