DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL DIFFERENTIAL SIDE GEAR


    1. A01G752

      Coat the 2 differential side gears, 2 No. 1 front 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. A01G9Q0

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

  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01G75Y

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator at a right angle to one of the side gear teeth.

    3. Hold the pinion gear in the differential case and measure the backlash of the side gear.

      Standard backlash
      0.05 to 0.15 mm (0.00197 to 0.00591 in.)
      No. 1 Front Differential Side Gear Thrust Washer Thickness
      Thickness Thickness
      1.50 mm (0.0591 in.) 1.75 mm (0.0689 in.)
      1.55 mm (0.0610 in.) 1.80 mm (0.0709 in.)
      1.60 mm (0.0630 in.) 1.85 mm (0.0728 in.)
      1.65 mm (0.0650 in.) 1.90 mm (0.0748 in.)
      1.70 mm (0.0669 in.) -

      If the backlash is not within the standard range, select another No. 1 front differential side gear thrust washer.

  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01G454

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

      Note

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

    2. A01G6VU

      Using a chisel and hammer, stake the differential case.

      Note

      Stake the differential case after adjusting the backlash.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01G7DAE01

      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 bearing cage during bearing inner race installation.

    2. A01G98ZE01

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

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07150 )

      Note

      Ensure that there is no clearance between the bearing and transaxle case.

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01G73BE01

      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 bearing cage during bearing inner race installation.

    2. Install the shim to the transaxle housing.

    3. A01G809E01

      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 bearing and transaxle housing.

  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A01G72E

      Install the front differential case to the transaxle case.

    2. Clean the contact surfaces of the transaxle case and transaxle housing.

    3. A01G8VNE01

      Install the transaxle housing to the transaxle case with the 20 bolts.

      Torque:
      Bolt A
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      Bolt B
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    4. A01G81QE01

      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 bearing while rotating SST at 10 rpm.

      SST
      09564-33010
      Turning torque
      1.1 to 1.9 N*m (11 to 19 kgf*cm, 10 to 17 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. A01G8VNE04

      Remove the 20 bolts and transaxle housing from the transaxle case.

    7. A01G72E

      Remove the front differential case from the transaxle case.

  8. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A01G5VD

      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 ring gear to more than 110°C (230°F).

    2. Clean the contact surface of the differential case.

    3. A01G54EE08
      Text in Illustration
      *a Matchmark

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

      Note

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

    4. A01G6JX

      Install and tighten the 12 bolts.

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

      Note

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

  9. INSTALL TRANSAXLE CASE OIL SEAL


    1. Coat the lip of a new transaxle case oil seal with MP grease.

    2. A01G6Q4E01

      Using SST and a hammer, install the transaxle case oil seal to the transaxle case.

      SST
      09316-10010
      09950-70010   ( 09951-07100 )
      Oil seal driven in depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Check that the transaxle case oil seal is installed in the correct direction.

  10. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A01G5CPE01

      Coat the lip of a new front transaxle case oil seal with MP grease.

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

      SST
      09308-14010
      Oil seal driven in depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Check that the front transaxle case oil seal is installed in the correct direction.