DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL DIFFERENTIAL SIDE GEAR


    1. B003ZXOC01
      *1 Front Differential Pinion
      *2 Front Differential Pinion Thrust Washer
      *3 Differential Side Gear
      *4 Front No. 1 Differential Side Gear Thrust Washer

      Coat the 2 differential side gears, 2 front No. 1 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. A01GF1F

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

  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

    Click here

  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01GEK8

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

      Note

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

    2. A01GEOE

      Using a chisel and a hammer, stake the differential case.

      Note

      Stake the differential case after adjusting the backlash.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. B003YWLN07

      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 the 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. B00403UN03

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

      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 sub-assembly.

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. B003Z9SN01

      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 the front differential case front tapered roller bearing.

      • 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. B003ZNQN03

      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.

  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case sub-assembly.

    2. B003Z2J

      Install the differential case to the transaxle case sub-assembly.

    3. B00407AN05

      Install the transaxle housing to the transaxle case sub-assembly with the 20 bolts.

      Torque:
      Bolt (A)
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
    4. B003Z44N16

      Using SST, turn the differential case 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 counter driven gear while rotating SST at 10 rpm.

      SST
      09564-33010
      Turning Torque
      1.5 to 1.7 N*m (16 to 17 kgf*cm, 14 to 15 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)
    6. B004061

      Remove the 20 bolts and transaxle housing from the transaxle case sub-assembly.

    7. B003Z2J

      Remove the differential case from the transaxle case sub-assembly.

  8. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. B003ZAY

      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. B003YY1C10
      *a Matchmark

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

      Note

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

    4. B00400R

      Install and tighten the 12 bolts.

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

      Note


      • Tighten the bolts after the front differential ring gear has cooled down sufficiently.

      • Tighten the bolts evenly in a diagonal pattern using several steps.

  9. INSTALL FRONT DRIVE SHAFT OIL SEAL RH


    1. Coat the lip of a new front drive shaft oil seal RH with MP grease.

    2. B00403BN02

      Using SST and a hammer, install the front drive shaft oil seal RH to the transaxle case sub-assembly.

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

      Note

      Check that the front drive shaft oil seal RH is installed in the correct direction.

  10. INSTALL FRONT DRIVE SHAFT OIL SEAL LH


    1. B003ZMVN01

      Coat the lip of a new front drive shaft oil seal LH with MP grease.

    2. Using SST and a hammer, install the front drive shaft oil seal LH to the transaxle housing.

      SST
      09308-14010
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Check that the front drive shaft oil seal LH is installed in the correct direction.