DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

    A0056JV

    1. Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF WS and install them to the differential case.

  2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION SHAFT

    A0056Y6

    1. Coat the front differential pinion shaft with ATF WS and install it to the differential case.

  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH

    Click here

  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

    A005542

    1. Using a pin punch and hammer, tap in the pinion shaft straight pin.

    2. A0057PD

      Using a chisel and hammer, stake the differential case.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A0057H4E08

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

      SST
      09608-06041
    2. A0054YHE09

      Using SST and a hammer, tap the selected shim and a new front differential case rear tapered roller bearing rear outer race into the transaxle case.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0055NVE07

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

      SST
      09608-06041
    2. A00554ZE07

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

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00340 )

  7. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A00595K

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

    2. Clean the contact surface of the front differential case.

    3. A0057NRE12
      Text in Illustration
      *1 Matchmark

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

    4. A0052ZI

      Install the 10 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  8. INSPECT TAPERED ROLLER BEARING PRELOAD

    A0058LK

    1. Install the differential assembly to the transaxle case.

    2. Install the transaxle housing to the transaxle case.

    3. A00583DE02

      Install the 18 bolts.

      Torque:
      for bolt A
      22 N*m  { 225 kgf*cm, 16 ft.*lbf }
      for bolt B and C
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
      for bolt D
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
      for bolt E
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt F
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      for bolt A, B, E and F
      50 mm (1.97 in.)
      for bolt C and D
      42 mm (1.66 in.)
    4. A0057IGE07

      Using SST and a torque wrench, turn SST at 60 rpm and measure the preload of the differential.

      SST
      09564-32011
      Standard turning torque at 60 rpm
      for new bearing
      0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to 6.1in.*lbf)
      for used bearing
      0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1in.*lbf)

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

      Adjusting Shim Thickness
      Mark Thickness
      0 1.90 mm (0.074 in.)
      1 1.95 mm (0.077 in.)
      2 2.00 mm (0.079 in.)
      3 2.05 mm (0.081 in.)
      4 2.10 mm (0.083 in.)
      5 2.15 mm (0.085 in.)
      6 2.20 mm (0.087 in.)
      7 2.25 mm (0.089 in.)
      8 2.30 mm (0.091 in.)
      9 2.35 mm (0.093 in.)
      A 2.40 mm (0.094 in.)
      B 2.45 mm (0.096 in.)
      C 2.50 mm (0.098 in.)
      D 2.55 mm (0.100 in.)
      E 2.60 mm (0.102 in.)
      F 2.65 mm (0.104 in.)
      G 2.70 mm (0.106 in.)
      H 2.75 mm (0.108 in.)
      J 2.80 mm (0.110 in.)
    5. A00574N

      Remove the 18 bolts.

    6. Using a plastic-faced hammer, remove the transaxle housing.

    7. A0058LK

      Remove the differential.

  9. INSTALL TRANSAXLE HOUSING OIL SEAL

    A0055D9E01

    1. Using SST and a hammer, tap in a new oil seal.

      SST
      09316-60011   ( 09316-00011 )
      Standard depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Do not damage the oil seal lip.

    2. Coat the lip of the oil seal with a small amount of MP grease.

  10. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL

    A005835E01

    1. Using SST and a hammer, tap in a new oil seal.

      SST
      09649-17010
      09950-70010   ( 09951-07150 )
      Standard depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Do not damage the oil seal lip.

    2. Coat the lip of the oil seal with a small amount of MP grease.