DIFFERENTIAL CASE REASSEMBLY

INSTALL DIFFERENTIAL SIDE GEAR
1. 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.
INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
1. Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.

INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

Hold the differential case in a vise between aluminum plates.

Note

Do not overtighten the vise.
Place a dial indicator on the tip of the differential side gear tooth at a right angle.

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

Standard backlash
0.05 to 0.2 mm (0.00197 to 0.00787 in.)

Thrust Washer Thickness
Thickness
1.00 mm (0.0394 in.)
1.10 mm (0.0433 in.)
1.20 mm (0.0472 in.)
1.30 mm (0.0512 in.)

If the backlash is greater than the standard range, select another No. 1 front differential side gear thrust washer.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a 5 mm pin punch and hammer, install the front differential pinion shaft straight pin.
  
  Note
  
  Align the holes, and install the front differential pinion shaft straight pin.
2. Using a chisel and hammer, stake the differential case.
  
  Note
  
  Stake the differential case after adjusting the backlash.
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install a new front differential case rear 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 front differential case rear tapered roller bearing cage when installing front differential case rear tapered roller bearing.
  
  Ensure that there is no clearance between the front differential case rear tapered roller bearing and differential case.
2. Using SST and a hammer, install a new front differential case rear tapered roller bearing outer race to the transaxle case.
  
  SST
  
  09950-60020 ( 09951-00810 )
  
  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.
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install a new front differential case front tapered roller bearing to the differential case.
  
  SST
  
  09523-36010
  
  09950-60010 ( 09951-00540 )
  
  09950-70010 ( 09951-07100 )
  Note
  
  Do not damage the front differential case front tapered roller bearing cage when installing front differential case front tapered roller bearing.
  Note
  
  Ensure that there is no clearance between the front differential case front tapered roller bearing and differential case.
2. Install the shim to the transaxle housing.
3. Using SST and a hammer, install a new front differential case front tapered roller bearing outer race to the transaxle housing.
  
  SST
  
  09950-60020 ( 09951-00790 )
  
  09950-70010 ( 09951-07150 )
  
  Note
  
  Ensure that there is no clearance between the front differential case front tapered roller bearing outer race, shim and transaxle housing.

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

Install the differential assembly to the transaxle case.
Clean the contact surfaces of the transaxle case and transaxle housing.
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 { 234 kgf*cm, 17 ft.*lbf }
Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearings.

SST

09564-33010

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

SST: 09564-33010

Turning Torque
0.7 to 2.3 Nm (7 to 23 kgfcm, 6 to 20 in.*lbf)

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)

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

INSTALL FRONT DIFFERENTIAL RING GEAR
1. 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. Text in Illustration
  
  *1 Matchmark
  
  Align the matchmarks, and install the front differential ring gear to differential case quickly.
  
  Note
  
  Do not install the bolts while the front differential ring gear is hot.
4. Install the 12 bolts.
  
  Torque:
  
  120 N*m { 1223 kgf*cm, 88 ft.*lbf }
  
  Note
  
  Tighten the bolts incrementally in diagonal order.
INSTALL TRANSAXLE CASE OIL SEAL
1. Coat the lip of a new transaxle case oil seal with MP grease.
2. Using SST and a hammer, install the transaxle case oil seal to transaxle case.
  
  SST
  
  09316-10010
  
  09950-70010 ( 09951-07100 )
  
  Standard Depth
  
  -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. 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 to transaxle housing.
  
  SST
  
  09308-14010
  
  Standard Depth
  
  -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)