Reassembly

U241E AUTOMATIC TRANSAXLE: DIFFERENTIAL CASE: REASSEMBLY

REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

(a) Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF, and install them into the differential case.
2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION SHAFT

(a) Coat the front differential pinion shaft with ATF, and install it into the differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH

(a) Using a dial indicator, measure the backlash of the side gear.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0070 in.)
Standard thrust washer thickness:

4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

(a) Using a pin punch and hammer, tap in the pinion shaft straight pin.

(b) Using a chisel and hammer, stake the differential case.
5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST and a press, press in the front differential case tapered roller bearing rear inner race to the differential case.
SST: 09608-06041

(b) Using SST and a hammer, tap in the case washer and front differential case tapered roller bearing rear outer race to the transaxle case.
SST: 09950-60020
09951-00710
SST: 09950-70010
09951-07100
6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, press the front differential case tapered roller bearing front inner race into the differential case.
SST: 09608-06041

(b) Using SST and a hammer, tap the front differential case tapered roller bearing front outer race into the transaxle housing.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07100
SST: 09950-60010
09951-00340
7. INSTALL FRONT DIFFERENTIAL RING GEAR

(a) Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
(b) Clean the contact surface of the front differential case.

(d) Tighten the 10 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
8. INSPECT TAPERED ROLLER BEARING PRELOAD

(a) Install the differential assembly into the transaxle case.
(b) Install the transaxle housing into the transaxle case.

(c) Install the 18 bolts.
Torque: 22 Nm (220 kgf-cm, 16 ft-lbf)
Torque: 29 Nm (300 kgf-cm, 21 ft-lbf)
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
Each bolt length is indicated below.:

(d) Using SST, turn the differential.
SST: 09564-32011

(e) Using SST and torque wrench, measure the preload of the differential.
SST: 09564-32011
Standard turning torque at 60 rpm - Torque: 0.20 to 0.69 Nm (2.0 to 7.0 kgf-cm, 1.8 to 6.1 in-lbf)
Standard turning torque at 60 rpm - Torque: 0.10 to 0.35 Nm (1.0 to 3.6 kgf-cm, 0.9 to 3.1 in-lbf)
Standard adjusting shim thickness:

(f) Remove the 18 bolts.
(g) Using a plastic-faced hammer, remove the transaxle housing.

(h) Remove the differential.

9. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Coat the lip of a new oil seal with a small amount of MP grease.
(b) Using SST and a hammer, tap in the oil seal.
SST: 09350-32014
09351-32150
SST: 09950-70010
09951-07150

10. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
(a) Coat the lip of a new oil seal with a small amount of MP grease.
(b) Using SST and a hammer, tap in the oil seal.
SST: 09350-32014
09351-32150
SST: 09950-70010
09951-07150