DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL DIFFERENTIAL SIDE GEAR


    1. A002A47C01
      *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. A01GEFW

      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. A01GEG1

      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. A01GERK

      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. B003Z32N02

      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 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   ( 09951-00890 )
      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. A0027HGN02

      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 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   ( 09951-00890 )
      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. A002747

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

    3. B003ZUEN01

      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. B003ZATN01

      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
      0.8 to 1.4 N*m (9 to 14 kgf*cm, 8 to 12 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. A002BZM

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

    7. A002747

      Remove the differential case from the transaxle case 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 front differential case.

    3. A002822C03
      *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. A01GEKQ

      Install and tighten the 12 bolts.

      Torque:
      120 N*m  { 1223 kgf*cm, 88 ft.*lbf }

      Note

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

  9. INSTALL FRONT DRIVE SHAFT OIL SEAL LH


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

    2. B00403BN02

      Using SST and a hammer, install the front drive shaft oil seal LH 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 LH is installed in the correct direction.

  10. INSTALL FRONT DRIVE SHAFT OIL SEAL RH


    1. Inside:


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

      2. A00296SN01

        Using SST and a hammer, install the front drive shaft oil seal RH to the differential case.

        SST
        09950-60010   ( 09951-00410 )
        09950-70010   ( 09951-07200 )
        Standard Depth
        21.5 to 22.5 mm (0.846 to 0.886 in.)

    2. Outside:


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

      2. A002782N03

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

        SST
        09649-17010
        09950-70010   ( 09951-07200 )
        Standard Depth
        5.5 to 6.5 mm (0.217 to 0.256 in.)

        Note

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