Differential Assembly
DIFFERENTIAL ASSEMBLYComponents
Differential Case Disassembly
1. REMOVE SIDE BEARING
Using Special Service Tool (SST), remove the two side bearings.
SST 09550-20017
2. REMOVE RING GEAR
a. Place the matchmarks on both the differential case and ring gear.
b. Remove the sixteen bolts.
c. Using a plastic hammer, tap out the ring gear.
3. DISASSEMBLY OF DIFFERENTIAL CASE
a. Place the matchmarks on the differential right and left case.
b. Using a torx wrench, remove the sixteen torx screws.
c. Using a plastic hammer, tap out the differential left case.
d. Remove the speedometer drive gear from the differential right case.
e. Remove the two differential side gears, two side thrust washers, differential spider, four differential pinions and four pinion washers from the differential left case.
4. DISASSEMBLY LH BEARING RETAINER
a. Using a hammer and screwdriver, remove the oil seal.
b. Remove the oil baffle from the LH bearing retainer.
c. Using a hammer and brass bar, drive out the outer race and adjusting shim from LH bearing retainer.
5. REMOVE RH OIL SEAL FROM RH RETAINER
Using a hammer and screwdriver, drive out the oil seal.
Differential Case Assembly
1. INSTALL RH OIL SEAL TO RH RETAINER
a. Using Special Service Tool (SST), drive in a new oil seal until its surface is flush with the surface of RH retainer.
SST 09316-60010 (09316-00010)
b. Coat the oil seal lip with Multipurpose (MP) grease.
2. INSTALL ADJUSTING SHIM AND BEARING OUTER RACE TO LH BEARING RETAINER
a. Place the adjusting shim into the LH bearing retainer.
HINT: Use either the shim which was removed or one 2.40 mm (0.0945 inch).
b. Using SST, press the outer race into the LH retainer.
SST 09316-20011, 09350-32014 (09351-32150)
HINT: Install the oil baffle and oil seal after adjusting the differential side bearing preload.
3. ASSEMBLE DIFFERENTIAL CASE
HINT: Coat all of the sliding and rotating surface with ATF before assembly.
a. Install the thrust washer to the side gear.
b. Install the four pinions and thrust washers to the spider.
c. Install the side gear and spider with four pinions to the Awl, differential left case.
d. Using a dial indicator, measure the backlash of one pinion gear while holding the side gear.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
e. Install the side gear and spider with four pinions to the right side of the differential case. And check the pinion gear backlash.
f. Referring to the table below, select the side gear thrust washer which will ensure that the backlash is within specification. Try to select a washer of the same size.
g. Install the speedometer drive gear.
h. Align the matchmarks on the differential cases.
i. Using a plastic hammer, carefully tap the differential right case.
j. Using a torx wrench, install and torque the sixteen torx screws.
Torque: 63 Nm (640 kgf-cm, 46 ft. lbs.)
4. INSTALL RING GEAR
a. Clean the contact surface of the differential case.
b. Heat the ring gear to about 100°C (212°F) in an oil bath.
NOTICE: Do not heat the ring gear above 110°C (230°F).
c. Clean the contact surface of the ring gear with cleaning solvent.
d. Quickly install the ring gear on the differential case.
Install the sixteen bolts.
HINT: Align the matchmarks on the differential left case and contact the ring gear.
e. Tighten the set bolts uniformly and a little at a time.
Torque the bolts.
Torque: 124 Nm (1,260 kgf-cm, 91 ft. lbs.)
5. INSTALL SIDE BEARINGS
a. Using SST and a press, install the RH side bearing to the differential case.
SST 09361-20011
b. Using SST and a press, install the LH side bearing.
SST 09316-60010 (09316-00010)
COMPONENT PARTS INSTALLATION
Disassembly, inspection and assembly of each component group have been indicated above. Before assembly, make sure, again, that all component groups are assembled correctly.
If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
Recommended ATF: DEXRON II
GENERAL INSTALLATION NOTES:
a. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
b. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least fifteen minutes.
c. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
d. Use petroleum jelly to keep small parts in their places.
e. Do not use adhesive cements on gaskets and similar parts.
f. When assembling the transaxle, be sure to use new gaskets and O-rings.
g. Dry all parts with compressed air-never use shop rags.
h. Be sure to install the thrust bearings and races in the correct direction and position.
Differential And Drive Pinion Installation
1. INSTALL DRIVE PINION INTO TRANSAXLE CASE
a. Place the bearing cage onto the drive pinion shaft.
NOTICE: Be careful not to damage the oil seals with the pinion shaft.
b. Using a hammer and brass bar, slightly tap the bearing cage into the transaxle case until the snap ring groove in the bore can be seen.
c. Using Special Service Tool (SST), install snap ring into the bore.
SST 09350-32014 (09351-32050)
2. PLACE SENSOR ROTOR ONTO DRIVE PINION SHAFT
3. PLACE OIL SLINGER AND NEW SPACER
HINT: Install the spacer with the small end downward.
4. INSTALL OUTER RACE TO TRANSAXLE CASE
Using SST, press in the outer race.
SST 09350-32014 (09351-32100, 09351-32140)
5. INSTALL COUNTER DRIVE GEAR
a. Place SST into the transaxle hole to hold the drive pinion shaft.
SST 09350-32014 (09351-32130, 09351-32150)
b. Using SST, press in the counter driven gear until slightly thickness between the counter driven gear bearing and outer race.
SST 09350-32014 (09351 -32140)
6. INSTALL NEW LOCK NUT AND ADJUST DRIVE PINION PRELOAD
a. Install the new lock nut.
b. Using SST to hold the gear, tighten the nut.
Torque: 206 Nm (2,100 kgf-cm, 152 ft. lbs.)
SST 09330-00021, 09350-32014 (09351-32032)
c. Turn the gear counterclockwise and clockwise several times.
d. Using a torque meter, measure the preload of the drive pinion.
Drive pinion preload (at starting):
New bearing: 1.0 - 1.6 Nm (10 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
- If the preload is greater than specified, replace the bearing spacer.
- If the preload is less then specified, retighten the nut 13 Nm (130 kgf-cm, 9 ft. lbs.) at a time until the specified preload is reached.
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
Maximum torque: 353 Nm (3,600 kgf-cm, 260 ft. lbs.)
e. If the preload is adjusted within specification, make a note of it.
f. Stake the lock nut.
7. INSTALL APPLY GASKET
8. PLACE OUTER RACE AND SHIM ONTO RH SIDE BEARING
9. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE
Be sure to install the shim and outer race into place.
10. INSTALL CARRIER COVER
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the carrier cover and transaxle case.
b. Apply seal packing to the carrier cover, as shown.
Seal packing: Part No. 08826 - 00090, THREE BOND 1281 or equivalent
HINT: Install the carrier cover within ten minutes after applying seal packing.
c. Install and torque the eleven bolts.
Torque: 39 Nm (400 kgf.cm, 29 ft. lbs.)
HINT: Each bolt length (mm, inch) is indicated in the illustration.
11. ADJUST SIDE BEARING PRELOAD
a. Remove any packing material on the contacting surfaces of the LH bearing retainer and transaxle case.
HINT: Do not apply seal packing yet.
b. Install the LH bearing retainer and torque the six bolts.
Torque: 19 Nm (195 kgf.cm, 14 ft. lbs.)
c. Snap down the bearings by turning the differential case several times.
d. Using a torque meter, measure the differential total preload.
Total preload (at starting): (Add drive pinion preload)
New bearing: 0.2 - 0.4 Nm (2.5 - 5.1 kgf.cm, 2.2 - 3.6 inch lbs.)
Reused bearing: 0.1 - 0.2 Nm (1.3 - 2.0 kgf.cm, 1.1 - 1.7 inch lbs.)
If the preload is not within specification, replace the adjusting shim in the LH bearing retainer with another thickness one.
12. INSTALL LH BEARING RETAINER
a. Remove the six bolts and LH bearing retainer.
b. Remove any packing material on the contacting surfaces of the LH bearing retainer, transaxle case and carrier cover.
c. Apply the seal packing to the transaxle case and carrier cover, as shown.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent
HINT: Install the LH bearing retainer with ten minutes after applying seal packing.
d. Install the LH bearing retainer.
e. Coat the threads of bolts with sealer.
Sealer: Part No. 08833-00070, THREE BOND 1324 or equivalent
f. Tighten the bolts.
Torque: 19 Nm (195 kgf -cm, 14 ft. lbs.)
g. Snap down the bearings.
h. Recheck the differential total preload.
13. INSTALL NEW OIL SEAL
a. Place the oil baffle onto the LH bearing retainer.
b. Using SST, driven in a new oil seal unit its end is flush with surface of the LH bearing retainer.
SST 09223 -15010
14. INSTALL RH RETAINER
a. Remove any packing material on the contacting surfaces of RH retainer and transaxle case.
b. Apply the seal packing to the RH retainer, as shown.
Seal packing: Part No. 08826 - 00090, THREE BOND 1281 or equivalent
HINT: Install the RH retainer within ten minutes after applying seal packing.
c. Coat the threads of bolts with sealer.
Sealer: Part No. 08833 - 00070, THREE BOND 1324 or equivalent
d. Tighten the bolts.
Torque: 19 Nm (195 kgf -cm, 14 ft. lbs.)
15. INSTALL DRIVE PINION CAP
a. Install a new O-ring to the cap.
b. Install the drive pinion cap to the transaxle case.