DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. B00408MN01

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

      SST
      09726-36010
      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   ( 09951-00890 )
      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 sub-assembly.

  2. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. B003YYDN03

      Using SST and a press, install a new front differential case front 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 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   ( 09951-00890 )
      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.

  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. B003Z9PC02
      *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.

      B003ZHWC01
      *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. B00409LC01
      *a Turn

      Using SST as shown in the illustration, rotate the front differential side gear to 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. A002971

      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. A0029NK

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

    2. A0029GL

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

  8. 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.

  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. B003ZD8C01
      *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. A002B9U

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

    2. B003ZUFN02

      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 front drive shaft oil seal LH lip.

  11. INSTALL FRONT DRIVE SHAFT OIL SEAL RH


    1. for Inside:


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

      2. B00405EN02

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

        Note

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

    2. for Outside:


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

      2. B00402BE03

        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


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

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