Differential Overhaul

PRESET TORQUE

On-Vehicle Inspection
1. Lift up right rear wheel, and place the safety stand.
2. Block the other three wheels.





3. Measure preset torque clockwise using a torque wrench as shown.

Standard: 59 - 137 Nm (6 - 14 kg/m; 43 - 101 ft. lbs.)
Service Limit: 29 Nm (3 kg/m; 22 ft. lbs.)

4. If preset torque is less than the service limit, replace the clutch discs with new ones. Adjust the thrust shim whenever the clutch discs are replaced.

Assembly:





1. Place one special tool in a vise. Place the left side of the differential assembly on the special tool, then preset the differential with 3-5 rotations, both clockwise and counterclockwise.





2. Measure preset torque clockwise using a torque wrench as shown.

Standard: 59 - 137 Nm (6 - 14 kg/m; 43 - 101 ft. lbs.)
Service Limit: 29 Nm (3 kg/m; 22 ft. lbs.)

3. If preset torque is less than the service limit, replace the clutch discs with new ones. Adjust the thrust shim whenever the clutch discs are replaced.

BEARING
Replacement

NOTE:
- The bearing and outer race should be replaced as a set.
- Inspect and adjust the bearing preload whenever the bearing is replaced.





1. Remove the tapered roller bearings using the bearing pullers.





2. Install the tapered roller bearings using a special tool and a press as shown. Press the tapered roller bearings squarely until they bottom against the case.

DIFFERENTIAL
Disassembly





1. Hold the differential in a bench vise using a special tool, then remove the differential housing mounting bolts in a crisscross pattern in several steps.





2. Remove the differential housing, then install the special tools on the stop plate.





3. Compress the spring plate.
4. Remove the stop clip.





5. Remove the special tools, and then remove the stop plate, spring plate, and 60 mm washer.





6. Remove the 112 mm thrust shim, clutch discs, clutch plates, and 102 mm washer.





7. Remove the carrier assembly, central gear, clutch plate, and clutch disc.





8. Screw two 8 x 1.0 mm bolts into the threaded holes in the differential housing cover to push it away from the final driven gear. Turn each bolt two turns at a time to prevent cocking the differential housing cover excessively.

CLUTCH DISC, CLUTCH PLATE
Replacement

NOTE: The clutch discs and clutch plates should be replaced as a set.

1. Remove the clutch discs and clutch plates.
2. Soak the clutch discs for five minutes in transmission oil.








3. Install the clutch discs, clutch plates, and a standard shim.

NOTE: Position the 112 mm thrust shim with the thickness size mark facing away from the clutch discs.

4. Install the differential housing. Tighten the bolts evenly in several steps, then torque them in a crisscross pattern.

Torque: 39 Nm (4.0 kg/m; 29 ft. lbs.)

5. Make sure the preset torque is within the standard.
6. If preset torque is beyond the standard, replace the 112 mm thrust shim as necessary.

DIFFERENTIAL
Reassembly





1. Install the clutch disc, clutch plate, central gear, and carrier assembly. Lubricate the clutch disc surface with transmission fluid.





2. Install the final driven gear. Align the mark on the differential housing cover with the mark on the final driven gear.




3. Install the 102 mm washer, clutch discs, clutch plates, and 112 mm thrust shim. Lubricate the clutch discs with transmission fluid. Position the 112 mm thrust shim with the thickness size mark facing away from the clutch discs.





4. Install the 60 mm washer, spring plate, and stop plate.





5. Install the special tools on the stop plate.





6. Compress the spring plate, then install the stop clip.





7. Install the differential housing. Align the fingers of the clutch plates and clutch discs.





8. Make sure the differential housing touches the final driven gear.





9. Hold the differential in a bench vise using a special tool, then install the differential housing mounting bolts. Tighten the bolts in a crisscross pattern in several steps.

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.

BEARING OUTER RACE
Replacement (Torque Converter Housing Side)

NOTE:
- The outer race and bearing should be replaced as a set.
- Inspect and adjust the bearing preload whenever the bearing is replaced.





1. Remove the bearing outer race, 90 mm washer, and oil guide ring using the special tools.





2. Install the oil guide ring and 90 mm washer, then drive the outer race into the torque converter housing using the special tools.

BEARING PRELOAD
Adjustment

NOTE: If any of the items listed below are replaced, the bearing preload must be adjusted.
- TRANSMISSION HOUSING
- TORQUE CONVERTER HOUSING
- DIFFERENTIAL
- TAPERED ROLLER BEARING and OUTER RACE
- 75 mm THRUST SHIM
- 90 mm WASHER
- OIL GUIDE RING





1. Remove the bearing outer race and 75 mm thrust shim from the transmission housing by prying up on the bearing outer race or by heating the housing to about 212°F (100°C).

CAUTION: Do not reuse the thrust shim if the outer race was pried out.

NOTE:
- If the outer race was removed by heating the case, let the transmission cool to room temperature before adjusting the bearing preload.
- Do not heat the transmission housing in excess of 212°F (100°C).
- Replace the bearing with a new one whenever the outer race is replaced.
- Repeat on the torque converter side.








2. Install the standard shim and bearing outer race into the transmission housing using the special tools as shown. Install the bearing outer race squarely.

Check that there is no clearance between the bearing outer race, shim, and transmission housing.

3. Lubricate the tapered roller bearing with transmission fluid, then install the differential.
4. Install the transmission housing. Do not install the mainshaft, countershaft, reverse idle gear shaft, and secondary shaft.

Torque: 54 Nm (5.5 kg/m; 40 ft. lbs.)

5. Rotate the differential assembly in both directions to seat the bearings.





6. Measure the starting torque of the differential assembly with a special tool and a torque wrench. Measure the bearing preload at normal room temperature in both directions.

Standard: 3.3 - 4.5 Nm (33 - 45 kg/cm; 29 - 39 inch lbs.)

7. If the bearing preload is not within the standard, select the shim that will give you the correct preload, and recheck.
Changing one of the shims to the next size will increase or decrease preload about 0.3 - 0.4 Nm (3 - 4 kg/cm; 2.60 - 3.47 inch lbs.)

OIL SEAL
Installation





1. Install the oil seal into the transmission housing using the special tools.





2. Install the oil seal into the torque converter housing using the special tools.