Rear Differential Side Case Replacement
Rear Differential Side Case Replacement
1. Remove the rear differential Rear Differential Removal.
2. Remove the rear differential front mounting brackets (A) from the rear differential (B).
3. Remove the rear differential fluid temperature sensor cover (A), the rear differential fluid temperature sensor (B), and the O-ring (C).
4. Remove rear differential harness bracket D.
5. Remove the rear differential left side case (A) or the rear differential right side case (D), and the 10 x 12 mm dowel pins (E) from the rear differential center case (F).
6. Remove rear differential harness bracket B and rear differential harness bracket C.
7. Replace the rear differential left side case or the rear differential right side case.
8. Remove the ring gear (A), the needle bearing (B), and the 60.2 mm shim (C) from the rear differential side case (D).
9. Measure the distance (1) between the end of the rear differential side case (A) and the 60.2 mm shim contact area (B) of the planetary gear with a straight edge (C) and a depth gauge (D).
Measure at three locations, and average the reading.
NOTE:
- Carry out the measurement at normal room temperature.
- Clean the parts thoroughly before measure.
10. Measure the distance (2) between the end of the rear differential center case (A) and the ring gear contact area (B) of the taper roller bearing with a straight edge (C) and a depth gauge (D).
Measure at three locations, and average the reading.
NOTE:
- Carry out the measurement at normal room temperature.
- Clean the parts thoroughly before measure.
11. Measure the distance (3) between the needle bearing (A) and the taper roller bearing contact area (B) of ring gear with a depth gauge (C).
Measure at three locations, and average the reading.
NOTE:
- Carry out the measurement at normal room temperature.
- Clean the parts thoroughly before measure.
Shim Selection Formula
12. Select the proper 60.2 mm shim from the table. Follow the example below, and use the measurements you made in step 9 to 11.
Select the 1.60 mm shim from the table.
60.2 mm shim
13. Place one strip of plastigage (A) on the 60.2 mm shim contact area (B) of planetary gear. Install the 60.2 mm shim (C), the needle bearing (D), and the ring gear (E).
Measure at three locations as shown.
NOTE:
- Carry out the measurement at normal room temperature.
- Clean the parts thoroughly before measure.
14. Install the 10 x 12 mm dowel pins (A), the rear differential right side case (B) or the rear differential left side case (C), and the mounting bolts (D) onto the rear differential center case (E).
15. Tighten the mounting bolts in a crisscross pattern in several steps, then tighten the bolts to the specified torque.
16. Remove the rear differential left side case (A) or the rear differential right side case (B), and the 10 x 12 mm dowel pins (C) from the rear differential center case (D).
17. Remove the ring gear (A), the needle bearing (B), and the 60.2 mm shim (C) from the rear differential side case (D).
18. Measure the widest part of the plastigage.
Measure at three locations, and average the reading.
- If the clearance exceeds the standard, go to step 8.
- If the clearance is within the standard, go to step 19.
19. Install the 60.2 mm shim (A), the needle bearing (B), and the ring gear (C) onto the rear differential side case (D).
20. Remove the dirt and oil from the sealing surfaces. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009) to the sealing surface. Make sure you seal up to the inside edge of the bolt holes to prevent oil leakage.
NOTE:
- You must assemble the housings within 5 minutes after applying the liquid gasket. If you applied liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If not, the sealing surface must be cleaned, and the liquid gasket reapplied.
- Allow the liquid gasket to cure at least 30 minutes after assembly before filling the differential with fluid.
Left side case/Right side case
21. Install the 10 x 12 mm dowel pins (A), the rear differential right side case (D) or the rear differential left side case (E), and the mounting bolts (F) onto the rear differential center case (G).
22. Install rear differential harness bracket B and rear differential harness bracket C.
23. Tighten the mounting bolts in a crisscross pattern in several steps, then tighten the bolts to the specified torque.
24. Install rear differential harness bracket D.
25. Install the rear differential fluid temperature sensor (A) with a new O-ring (B), and install the rear differential fluid temperature sensor cover (C).
26. Temporarily install the rear differential front mounting brackets (A) with new bolts (B) on the rear differential (C).
27. Install the rear differential Rear Differential Installation.
28. Do the SH-AWD differential clutch torque memorization SH-AWD Differential Clutch Torque Memorization.