4. Differential Replacement

Differential Replacement

^ Tools Required
- J 22888-20A Differential Side Bearing Puller
- J 35378 Differential Side Bearing Puller Pilot
- J 35409 Differential Side Bearing Installer
- J 35405 Differential Preload Wrench
- J 8001 Dial Indicator

Removal Procedure





1. Remove the differential from the transaxle. Refer to Transaxle Disassemble.
2. Remove the side bearings using a J 22888-20A and a J 35378. Place the legs of the puller into the cutouts on the speedometer driver gear.
3. Remove the following components:
^ Eight ring gear bolts
^ The locking plates
4. Remove the ring gear using a copper or a brass hammer.
5. Discard the bolts and the locking plates.





6. Remove the pinion shaft lock pin.

Important:
Remove the peened over cast flashing prior to lock pin removal.

7. Remove the pinion shaft from the case.
8. Remove the following components:
^ Two pinion gears
^ Two thrust washers
9. Remove the following components:
^ Two side gears
^ Two thrust washers
10. Inspect the following parts for chips or excessive wear:
^ The side bearings
^ The ring gear
^ The pinion shaft
^ The pinion gears
^ The thrust washers
11. Replace all faulty components.

Installation Procedure





1. Notice:
Refer to Fastener Notice in Service Precautions.

Install the ring gear bolts.
Tighten the ring gear bolts uniformly and incrementally to 77 Nm (57 ft. lbs.).
2. Install the side bearings using a J 35409 and a press.





3. Install the following components:
^ Two pinion gears
^ Two thrust washers
4. Install the following components:
^ Two side gears
^ Two thrust washers





5. Install the pinion shaft.





6. Measure the pinion gear backlash with a J 8001. Measure one side of the gear while holding one pinion toward the case. If the backlash is not 0.05-0.20 mm (0.0020-0.0079 inch), install different thrust washers. Refer to Transaxle Specifications (Selective Snap Ring Table) Transaxle Specifications (5th Gear Selective Snp Rng Tbl) Transaxle Specifications (Thrust Washer Thickness) Transaxle Specifications (Selective Bearing Shim Table).
7. Select washers of the same size for both sides of the gear.





8. Install the pinion shaft lock pin.





9. After you obtain the correct backlash, stake the differential case.
10. Install the differential into the transaxle.
11. Pre-assemble the transaxle to measure bearing preload.





12. Measure the side bearing preload with the thinnest shim in the transaxle case, using a J 35405 and a torque wrench. Verify that one of the following conditions is true:
^ New bearing preload is 0.8 - 1.6 Nm (6.9 - 13.9 ft. lbs.)
^ Reused bearing preload is 0.5 - 1.0 Nm (4.3 - 8.7 ft. lbs.)
13. If the appropriate condition is true, then you are finished with the installation procedure. If the appropriate condition is not true, then continue with the remainder of the procedure.
14. Remove the outer race (transaxle case side) of the side bearing. Refer to Transaxle Disassemble.
15. Select an adjusting shim. Refer to Transaxle Specifications (Selective Snap Ring Table) Transaxle Specifications (5th Gear Selective Snp Rng Tbl) Transaxle Specifications (Thrust Washer Thickness) Transaxle Specifications (Selective Bearing Shim Table). The preload will change 0.3 - 0.4 Nm (2.6 - 3.5 ft. lbs.) with each shim thickness.