Differential Assembly

DIFFERENTIAL ASSEMBLY
Servicing procedure for differential assembly is similar to that for manual transmission.

Disassembly





1. Remove diff. side bearing (L). Use special tool and puller for its removal.
Special Tool
(A): 09925-88210





2. Remove final gear.
Hold diff. case with soft jawed vise and remove 8 bolts then take out final gear.
3. Remove diff. side bearing (R). Drive it out by using special tool, bearing puller and press.
Special Tool
(B): 09913-80112
4. Remove speedometer drive gear.





5. Remove side pinion shaft pin. Use special tool and hammer for its removal.
Special Tool
(C): 09922-85811
6. Remove side pinion shaft, differential pinions with each washer, differential gears with each washer.

Adjustment and Reassembly
Prepare replacing parts as required and proceed to reassembly.
Make sure that all parts are clean.
1. Install differential gears.
Measure and adjust thrust play and then assemble them with suitable thrust washers.
2. Drive in side pinion shaft pin from right side till it is flush with diff. case surface.





3. Install diff. side bearing (L). Face its seal side inward (diff. case side. and press-fit by using the same special tool with right hand bearing in step 5).
4. Install speedometer drive gear.
5. Install diff. side bearing (R). Face its seal side inward and press fit it by using special tool with copper hammer. While press-fitting, support diff. assembly as illustrated so that left hand bearing is floating.
Special Tool
(A): 09951-76010
(B): 09951-16060





6. Hold differential assembly with soft jawed vise, install final gear and then tighten it with 8 bolts to specified torque.

NOTE: Place offset side of final gear flange toward differential case.

CAUTION: Use of any other bolts than specified ones is prohibited.

Tightening Torque
(a): 85 Nm (8.5 kg-m, 61.5 ft. lbs.)

Shim Adjustment For Differential Side Bearing





Before installing differential assembly to transmission case, select a differential side bearing shim as follows.





1. With gasket removed, measure dimension "a" of transmission case housing (from mating surface to bearing bore bottom) by using straightedge and vernier caliper.
The dimension "a" can be obtained by subtracting straightedge width "d" from measured value.
Dimension "a" = measured value - straightedge width "e"





2. In the same manner as the above 1), measure dimension "b" of transmission case (from mating surface to bearing bore bottom).
Dimension "b" = measured value - straightedge width "e"





3. Place differential assembly on surface plate and measure dimension "c" (bearing-to-bearing).
Dimension "c" = measured value - straightedge width "d"
4. Obtain case-to-bearing clearance "d" in following calculation.
"d" = ("a" + "b" + 0.4 - ("c" + 0.2)
0.4 mm (0.016 inch): Gasket thickness
0.2 mm (0.008 inch): Intended to absorb the measurement error
5. Select a shim from among available sizes and install it between transmission case and side bearing.

CAUTION: Installing of over sized shim beyond specification may cause tight rotation and consequential bearing damage.