DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. B003YWLN05

      Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the front 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 (inner race) cage when installing the front differential case rear tapered roller bearing (inner race).

      • Ensure that there is no clearance between the front differential case rear tapered roller bearing (inner race) and front differential case.

    2. B00403UN04

      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.

  2. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. B003Z9SN02

      Using SST and a press, install a new front differential case front tapered roller bearing (inner race) to the front 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 (inner race) cage when installing the front differential case front tapered roller bearing (inner race).

      • Ensure that there is no clearance between the front differential case front tapered roller bearing (inner race) and front differential case.

    2. B003ZNQN04

      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.

  3. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. B00408FC02
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      B003ZIE ATF

      Coat the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs with ATF.

    2. B003YWVC01
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer

      Install the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs to the front differential case.

      Note


      • Do not drop the front differential side gear, front No. 1 differential side gear thrust washer or conical spring.

      • Make sure that the conical spring is installed with the correct orientation.

    3. Install SST as shown in the illustration and tighten it.

      B003YX8C01
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )

      Note

      Do not overtighten SST as doing so will damage the front differential side gears, conical springs, front No. 1 differential side gear thrust washers and front differential case.

      Tech Tips


      • Tighten SST to create the necessary clearance to install the front differential pinions.

      • When installing the front differential pinions, do not overtighten SST, as it is necessary to rotate the front differential side gears.

    4. B003YYUC02
      B003ZIE ATF

      Coat the 2 front differential pinions and 2 front differential pinion thrust washers with ATF.

    5. B003ZNBC01
      *a Turn

      Using SST as shown in the illustration, rotate the front differential side gear and install the 2 front differential pinions and 2 front differential pinion thrust washers.

      SST
      09528-52010   ( 09528-05030 )

      CAUTION:

      Be careful not to catch your fingers between the front differential pinion and front differential case.

      Note

      Do not drop the front differential pinion or front differential pinion thrust washer.

  4. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

    Click here

  5. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. B003ZKUC01
      B003ZIE ATF

      Coat the front No. 1 differential pinion shaft with ATF.

    2. Install the front No. 1 differential pinion shaft to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.

  6. INSPECT FRONT DIFFERENTIAL CASE

    Click here

  7. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. B003ZQV

      Using a 5 mm pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.

    2. B003ZUB

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

  8. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

    Tech Tips


    • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.

    • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

      Serial Number Factory
      3########## for TMMWV Made
      ##A######## for AISIN AW Made

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

    2. B003Z2J

      Install the front 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 front 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 differential side bearings 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.)
      for TMMWV Made:
      No. Thickness No. Thickness
      90564-A0260 2.000 (0.0787) 90564-A0278 2.450 (0.0965)
      90564-A0261 2.025 (0.0797) 90564-A0279 2.475 (0.0974)
      90564-A0262 2.050 (0.0807) 90564-A0280 2.500 (0.0984)
      90564-A0263 2.075 (0.0817) 90564-A0281 2.525 (0.0994)
      90564-A0264 2.100 (0.0827) 90564-A0282 2.550 (0.100)
      90564-A0265 2.125 (0.0837) 90564-A0283 2.575 (0.101)
      90564-A0266 2.150 (0.0846) 90564-A0284 2.600 (0.102)
      90564-A0267 2.175 (0.0856) 90564-A0285 2.625 (0.103)
      90564-A0268 2.200 (0.0866) 90564-A0286 2.650 (0.104)
      90564-A0269 2.225 (0.0876) 90564-A0287 2.675 (0.105)
      90564-A0270 2.250 (0.0886) 90564-A0288 2.700 (0.106)
      90564-A0271 2.275 (0.0896) 90564-A0289 2.725 (0.107)
      90564-A0272 2.300 (0.0906) 90564-A0290 2.750 (0.108)
      90564-A0273 2.325 (0.0915) 90564-A0291 2.775 (0.109)
      90564-A0274 2.350 (0.0925) 90564-A0292 2.800 (0.110)
      90564-A0275 2.375 (0.0935) 90564-A0293 2.825 (0.111)
      90564-A0276 2.400 (0.0945) 90564-A0294 2.850 (0.112)
      90564-A0277 2.425 (0.0955) 90564-A0295 2.875 (0.113)
      for AISIN AW Made:
      No. Thickness No. Thickness
      90564-69001 2.000 (0.0787) 90564-69021 2.450 (0.0965)
      90564-69002 2.025 (0.0797) 90564-69022 2.475 (0.0974)
      90564-69003 2.050 (0.0807) 90564-69023 2.500 (0.0984)
      90564-69004 2.075 (0.0817) 90564-69024 2.525 (0.0994)
      90564-69005 2.100 (0.0827) 90564-69025 2.550 (0.100)
      90564-69006 2.125 (0.0837) 90564-69026 2.575 (0.101)
      90564-69007 2.150 (0.0846) 90564-69027 2.600 (0.102)
      90564-69008 2.175 (0.0856) 90564-69028 2.625 (0.103)
      90564-69009 2.200 (0.0866) 90564-69029 2.650 (0.104)
      90564-69010 2.225 (0.0876) 90564-69030 2.675 (0.105)
      90564-69011 2.250 (0.0886) 90564-69031 2.700 (0.106)
      90564-69012 2.275 (0.0896) 90564-69032 2.725 (0.107)
      90564-69013 2.300 (0.0906) 90564-69033 2.750 (0.108)
      90564-69014 2.325 (0.0915) 90564-69034 2.775 (0.109)
      90564-69015 2.350 (0.0925) 90564-69035 2.800 (0.110)
      90564-69016 2.375 (0.0935) 90564-69036 2.825 (0.111)
      90564-69017 2.400 (0.0945) 90564-69037 2.850 (0.112)
      90564-69020 2.425 (0.0955) 90564-69038 2.875 (0.113)
    6. B004061

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

    7. B003Z2J

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

  9. 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. B003ZNWC02
      *a Matchmark

      Clean the contact surface of the front differential case.

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

    4. B00400R

      Install 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.

  10. INSTALL FRONT DRIVE SHAFT OIL SEAL LH


    1. B003Z9RN01

      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.

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

      Note


      • Make sure that the front drive shaft oil seal LH is installed in the correct direction.

      • Do not damage the lip of the front drive shaft oil seal LH.

  11. INSTALL FRONT DRIVE SHAFT OIL SEAL RH


    1. B003ZG1N01

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

    2. Using SST and a hammer, install the front drive shaft oil seal RH.

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

      Note


      • Make sure that the front drive shaft oil seal RH is installed in the correct direction.

      • Do not damage the lip of the front drive shaft oil seal RH.