DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL DIFFERENTIAL SIDE GEAR


    1. A01HO2T

      Coat the 2 differential side gears, 2 No. 1 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers with ATF and install them to the differential case.

  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01HMEL

      Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.

  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01HMTH

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator at a right angle to one of the side gear teeth.

    3. Hold the pinion gear in the differential case and measure the backlash of the side gear.

      Standard backlash
      0.05 to 0.15 mm (0.00197 to 0.00591 in.)
      Thrust Washer Thickness
      Thickness Thickness
      1.50 mm (0.0591 in.) 1.75 mm (0.0689 in.)
      1.55 mm (0.0610 in.) 1.80 mm (0.0709 in.)
      1.60 mm (0.0630 in.) 1.85 mm (0.0728 in.)
      1.65 mm (0.0650 in.) 1.90 mm (0.0748 in.)
      1.70 mm (0.0669 in.) -

      If the backlash is not within the standard range, select another side gear thrust washer.

  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01HODN

      Using a pin punch (3 mm) and hammer, install the front differential pinion shaft straight pin.

      Note

      Align the holes, and install the front differential pinion shaft straight pin.

    2. A01HNXL

      Using a chisel and hammer, stake the differential case.

      Note

      Stake the differential case after adjusting the backlash.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01HQLHE01

      Using SST and a press, install a new front differential case rear tapered roller bearing to the differential case.

      SST
      09726-36010
      09950-70010   ( 09951-07100 )

      Note

      Do not damage the bearing cage during front differential case rear tapered roller bearing installation.

    2. A01HNIJE01

      Using SST and a hammer, install a new front differential case rear tapered roller bearing outer race to the transaxle case.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07150 )

      Note

      Ensure that there is no clearance between the front differential case rear tapered roller bearing outer race and transaxle case.

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01HQOVE01

      Using SST and a press, install a new front differential case front tapered roller bearing to the differential case.

      SST
      09710-30012   ( 09710-04081 )
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )

      Note

      Do not damage the bearing cage during front differential case front tapered roller bearing installation.

    2. Install the shim to the transaxle housing.

    3. A01HP9UE01

      Using SST and a hammer, install a new front differential case front tapered roller bearing outer race to the transaxle housing.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07150 )

      Note

      Ensure that there is no clearance between the front differential case front tapered roller bearing outer race and transaxle housing.

  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A01HPRJ

      Install the differential assembly to the transaxle case.

    2. Clean the contact surfaces of the transaxle case and transaxle housing.

    3. A01HOQME02

      Install the transaxle housing to the transaxle case with the 20 bolts.

      Torque:
      Bolt (A)
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    4. A01HPAQE01

      Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearings.

      SST
      09564-33010

    5. Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 rpm.

      SST
      09564-33010
      Turning Torque
      for TMH made
      0.8 to 1.4 N*m (8 to 14 kgf*cm, 7 to 12 in.*lbf)
      for TMMWV made
      1.1 to 1.9 N*m (11 to 19 kgf*cm, 10 to 17 in.*lbf)

      Tech Tips

      Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

      Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

      Serial Number Factory
      2########## for TMH made
      3########## for TMMWV made

      If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

      Shim Thickness: mm (in.)
      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.225 (0.0876) 2.450 (0.0965) 2.675 (0.105)
      2.025 (0.0797) 2.250 (0.0886) 2.475 (0.0974) 2.700 (0.106)
      2.050 (0.0807) 2.275 (0.0896) 2.500 (0.0984) 2.725 (0.107)
      2.075 (0.0817) 2.300 (0.0906) 2.525 (0.0994) 2.750 (0.108)
      2.100 (0.0827) 2.325 (0.0915) 2.550 (0.100) 2.775 (0.109)
      2.125 (0.0837) 2.350 (0.0925) 2.575 (0.101) 2.800 (0.110)
      2.150 (0.0846) 2.375 (0.0935) 2.600 (0.102) 2.825 (0.111)
      2.175 (0.0856) 2.400 (0.0945) 2.625 (0.103) 2.850 (0.112)
      2.200 (0.0866) 2.425 (0.0955) 2.650 (0.104) 2.875 (0.113)
    6. A01HOQME04

      Remove the 20 bolts and transaxle housing from the transaxle case.

    7. A01HPRJ

      Remove the differential assembly from the transaxle case.

  8. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A01HPYW

      Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).

      Note

      Do not heat the front differential ring gear to more than 110°C (230°F).

    2. Clean the contact surface of the differential case.

    3. A01HNG4E08
      Text in Illustration
      *a Matchmark

      Align the matchmarks, and install the front differential ring gear quickly.

      Note

      Do not install the bolts while the front differential ring gear is hot.

    4. A01HPX3

      Install and tighten the 12 bolts.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }

      Note

      Tighten the bolts a little at a time in a diagonal sequence.

  9. INSTALL TRANSAXLE CASE OIL SEAL


    1. Coat the lip of a new transaxle case oil seal with MP grease.

    2. A01HQZBE01

      Using SST and a hammer, install the transaxle case oil seal.

      SST
      09316-10010
      09950-70010   ( 09951-07100 )
      Oil Seal Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Check that the transaxle case oil seal is installed in the correct direction.

  10. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A01HP4IE01

      Coat the lip of a new front transaxle case oil seal with MP grease.

    2. Using SST and a hammer, install the front transaxle case oil seal.

      SST
      09308-14010
      Oil Seal Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Check that the front transaxle case oil seal is installed in the correct direction.