Differential Case

DISASSEMBLY
1. REMOVE RING GEAR





a. Place the matchmarks on the ring gear and differential case.





b. Remove the 12 bolts.





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





2. REMOVE TAPERED ROLLER BEARING
Using Special Service Tool (SST) and a press, remove the tapered roller bearing FR and RR.
SST 09950-00020, 09950-00030, 09950-60011 (09951-00480, 09951-00500)
3. DISASSEMBLY DIFFERENTIAL CASE





a. Using a pin punch and 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 SST, remove outer race and adjust shim.
SST 09308-00010





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 SIDE BEARING OUTER RACE OF TRANSAXLE CASE
Using SST, remove the outer race and shim.
SST 09308-00010





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

REASSEMBLY





1. INSTALL BEARING OUTER RACE OF TRANSAXLE HOUSING
a. Using Special Service Tool (SST), a press and a hammer, press in a new bearing outer race into the transaxle housing.
SST 09950-60020 (09951-00890), 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 (09951-00890), 09950-70010 (09951-07150)

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

3. ASSEMBLY DIFFERENTIAL CASE





a. Coat the thrust washers, the side gears, pinion gears and pinion thrust washers with Automatic Transmission Fluid (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 specification, 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 specification. Try to select washers of the same size for both side.





Thrust washer thicknesses

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





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





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





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





b. Using SST and a press, install the tapered roller bearing RH 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 the transaxle housing.
d. Install the transaxle housing and 16 bolts to the transaxle case.

HINT: Although the bolt A is a non-reusable seal bolt, in the case, clean the bolts and tighten them as well as the bolts B and C.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
Bolt length:
Bolt A: 50.0 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 snug the bearing down.
SST 09564-32011
f. Using SST and a torque meter, measure the preload of the side bearing.
SST 09564-32011
Preload (at starting):
New bearing: 0.8 - 1.3 Nm (8 - 13 kgf-cm, 6.9 - 11.3 inch lbs.)
Used bearing: 0.4 - 0.6 Nm (4 - 6 kgf-cm, 3.5 - 5.2 inch lbs.)
If the preload is not within specification, remove the differential from the transaxle case. Re-select the transaxle case side adjusting shim according to the table.





Adjusting shim thickness





g. Using a plastic a hammer, remove the 17 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 10 minutes.
c. Carefully remove the ring gear from the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





e. Install the 12 bolts.
Torque: 96.5 Nm (985 kgf-cm, 71 ft. lbs.)





9. INSTALL TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, driven in a new oil seal.
SST 09608-10010, 09950-70010, (09951-07150)
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.