Differential Assembly

Disassembly





1. Using special tool, remove R bearing (1).
Special tool
(A): 09913-61510
(B): 09925-88210

NOTE: Change removed bearing to new one.

2. Take out speedometer drive gear.
3. Remove L bearing by using puller while supporting its center shaft as described above.
4. Support differential case (1) with soft jawed vise and remove final gear bolts then take out final gear (2).





5. Using special tool and hammer, drive out differential side pinion shaft pin and then disassemble component parts.
Special tool (C): 09922-85811 (4.5 mm)

Reassembly
Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that all parts are clean.
1. Assemble differential gear and measure thrust play of differential gear as follows.
Special tool
(A): 09900-20606
(B): 09900-20701
Differential gear thrust play: 0.05 - 0.33 mm (0.002 - 0.013 inch)

Left side





^ Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top surface of gear (2).
^ Using 2 screwdrivers (1), move gear up and down and read movement of dial gauge pointer.

Right side





^ Using similar procedure to the above, set dial gauge tip to gear (1) shoulder.
^ Move gear up and down by hand and read dial gauge.

2. If thrust play is out of specification, select suitable thrust washer from among the following available size, install it and check again that specified gear play is obtained.
Available thrust washer thickness 0.90, 0.95, 1.00, 1.05, 1.10, 1.15 and 1.20 mm (0.035, 0.037, 0.039, 0.041, 0.043, 0.045, and 0.047 inch)
3. Drive in spring pin from right side till it is flush with differential case (2) surface.





4. Press-fit L bearing (1) by using special tool and copper hammer.
Special tool (A): 09951-76010
5. Install speedometer drive gear.





6. Press-fit R bearing (1) by using special tools and copper hammer.
Special tool
(A): 09924-74510
(B): 09951-16060
(C): 09913-85230





7. Hold differential assembly with soft jawed vise (3), install final gear (2) and bevel gear and then tighten them with 10 bolts (1) to specified torque.

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

"A": Thread lock cement (BOND 1303B) 99000-32030
Tightening torque
Final gear bolt (a): 90 Nm (9.0 kgf-m, 65.0 ft. lbs.)
8. Install differential assembly into right case.





9. Measure clearance "a" (between differential side face and side bearing outer race (2)) and "b" (bearing retainer (1)).





10. Select the shim.
Available shim thickness 0.30, 0.60, 0.63, 0.66, 0.69, 0.72, 0.75, 0.78, 0.81, 0.84, and 0.87 mm (0.011, 0.023, 0.024, 0.025, 0.027, 0.028, 0.029, 0.030, 0.031, 0.033 and 0.034 inch)





11. Insert speedometer driven gear case assembly applied with oil to its O-ring and gear, then tighten it with bolt.

CAUTION:
^ While inserting case assembly into transmission, turn final gear by hand slightly so that gear can mesh easily.
^ Never push or hit slit portion of case when inserting it. Such attempt may cause case to break.

Tightening torque
Speedometer driven gear mounting bolt (a): 5.5 Nm (0.55 kgf-m, 4.0 ft. lbs.)