DIFFERENTIAL CASE DISASSEMBLY


  1. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01G9BJE01

      Using SST, remove the front transaxle case oil seal from the transaxle housing.

      SST
      09308-00010

  2. REMOVE TRANSAXLE CASE OIL SEAL


    1. A01G8WKE01

      Using SST, remove the transaxle case oil seal from the transaxle case.

      SST
      09308-00010

  3. INSPECT FRONT DIFFERENTIAL CASE


    1. A01G8NPE01

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

      SST
      09528-52010   ( 09528-05030 )
      Standard
      The front differential side gear does not lock when rotated in either direction.

      • If the front differential side gear locks, perform all inspections.

      • If the front differential side gear still locks even after replacing the malfunctioning parts, replace the front differential case.

      • Replace any parts that do not meet the specifications.

  4. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT


    1. A01G908E01
      Text in Illustration
      *a Front Differential Side Gear Thrust Amount

      Using SST and a dial indicator, measure the front differential side gear thrust amount.

      SST
      09528-52010   ( 09528-05030 )
      Front Differential Side Gear Thrust Amount
      0.08 mm (0.00315 in.) or less

      Tech Tips


      • Measure the front differential side gear thrust amount while slowly rotating the front differential side gear.

      • Make sure to measure the front differential side gear thrust amount for both of the front differential side gears.

      If the result is not as specified, replace the 2 front differential side gears, 2 front differential pinions and 2 conical springs.

  5. REMOVE FRONT DIFFERENTIAL RING GEAR


    1. A01G5YUE03
      Text in Illustration
      *a Matchmark

      Put matchmarks on the front differential ring gear and front differential case.

    2. A01G6JX

      Remove the 12 bolts from the front differential ring gear.

    3. A01G7DG

      Using a plastic hammer, tap on the front differential ring gear to remove it from the front differential case.

  6. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. Secure the front differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01G879

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

  7. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01G8YM

      Remove the front No. 1 differential pinion shaft from the front differential case.

  8. INSPECT FRONT DIFFERENTIAL PINION BACKLASH


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

      A01G4G3E01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Secure the front differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. A01G6WSE01
      Text in Illustration
      *1 Front No. 1 Differential Pinion Shaft

      Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.

    4. Using a dial indicator, measure the front differential pinion backlash.

      Standard Backlash
      0.15 mm (0.00591 in.) or less

      Tech Tips

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

      If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select front No. 1 differential side gear thrust washers which will ensure that the backlash is within the specification.

      Front No. 1 Differential Side Gear Thrust Washer Thickness:
      Part No. Thickness (mm (in.))
      41361-33020 1.50 (0.0591)
      41361-33030 1.55 (0.0610)
      41361-33040 1.60 (0.0630)
      41361-33050 1.65 (0.0650)
      41361-33060 1.70 (0.0669)
      41361-33070 1.75 (0.0689)
      41361-33080 1.80 (0.0709)
      41361-33090 1.85 (0.0728)
      41361-33100 1.90 (0.0748)

  9. REMOVE FRONT DIFFERENTIAL SIDE GEAR


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

      A01G7FYE01
      Text in Illustration
      *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 until there is clearance between the front differential pinions and front differential side gears.

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

    2. A01G9GDE01
      Text in Illustration
      *a Turn

      Install SST as shown in the illustration, rotate the front differential side gear, and then remove the 2 front differential pinions and 2 front differential pinion thrust washers from the front differential case.

      SST
      09528-52010   ( 09528-05030 )

      Note

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

    3. A01G4H3E01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer

      Remove SST from the front differential case, and then remove the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs from the front differential case.

      Note

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

  10. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01G60QE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the front differential case front tapered roller bearing (inner race) from the front differential case.

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00480 )
      09950-40011   ( 09957-04010 )
    2. A01G49OE02

      Using SST, remove the front differential case front tapered roller bearing (outer race) and shim from the transaxle housing.

      SST
      09308-00010

  11. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01G71ME02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00480 )
      09950-40011   ( 09957-04010 )
    2. A01G8RUE01

      Using SST, remove the front differential case rear tapered roller bearing (outer race) from the transaxle case.

      SST
      09308-00010