DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01G5N2E02

      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. A01G98ZE03

      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. A01G92HE02

      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. 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   ( 09951-00790 )
      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. A01G9JAE05
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      A01G8AH ATF

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

    2. A01G4H3E01
      Text in Illustration
      *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.

      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 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. A01G597

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

      Text in Illustration
      A01G8AH ATF
    5. A01G7M5E01
      Text in Illustration
      *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


    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
      0.20 mm (0.00787 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.)]
      41361-73050 0.90 (0.0354)
      41361-73010 1.00 (0.0394)
      41361-73020 1.10 (0.0433)
      41361-73030 1.20 (0.0472)

  5. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01G76V

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

      Text in Illustration
      A01G8AH 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


    1. A01G8NPE03

      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.

  7. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01G4NK

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

    2. A01G5OF

      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. A01G6NC

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

    3. A01G5TFE01

      Install the transaxle housing to the transaxle case sub-assembly with the 20 bolts.

      Torque:
      Bolt (A)
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      23 N*m  { 234 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.

    5. Using SST and a torque wrench, measure the turning torque of the differential side bearings while rotating SST at 10 rpm.

      Turning Torque
      1.3 to 1.7 N*m (13 to 17 kgf*cm, 11 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
      Part No.

      Thickness

      (mm (in.))
      90564-69001 2.000 (0.0787)
      90564-69002 2.025 (0.0797)
      90564-69003 2.050 (0.0807)
      90564-69004 2.075 (0.0817)
      90564-69005 2.100 (0.0827)
      90564-69006 2.125 (0.0837)
      90564-69007 2.150 (0.0846)
      90564-69008 2.175 (0.0856)
      90564-69009 2.200 (0.0866)
      90564-69010 2.225 (0.0876)
      90564-69011 2.250 (0.0886)
      90564-69012 2.275 (0.0896)
      90564-69013 2.300 (0.0906)
      90564-69014 2.325 (0.0915)
      90564-69015 2.350 (0.0925)
      90564-69016 2.375 (0.0935)
      90564-69017 2.400 (0.0945)
      90564-69020 2.425 (0.0955)
      90564-69021 2.450 (0.0965)
      90564-69022 2.475 (0.0974)
      90564-69023 2.500 (0.0984)
      90564-69024 2.525 (0.0994)
      90564-69025 2.550 (0.100)
      90564-69026 2.575 (0.101)
      90564-69027 2.600 (0.102)
      90564-69028 2.625 (0.103)
      90564-69029 2.650 (0.104)
      90564-69030 2.675 (0.105)
      90564-69031 2.700 (0.106)
      90564-69032 2.725 (0.107)
      90564-69033 2.750 (0.108)
      90564-69034 2.775 (0.109)
      90564-69035 2.800 (0.110)
      90564-69036 2.825 (0.111)
      90564-69037 2.850 (0.112)
      90564-69038 2.875 (0.113)
    6. A01G5AX

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

    7. A01G6NC

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

  9. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. 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. A01G5VD

      Clean the contact surface of the front differential case.

    3. A01G54EE11
      Text in Illustration
      *a Matchmark

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

    4. A01G6JX

      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 TRANSAXLE CASE OIL SEAL


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

    2. A01G73ME02

      Using SST and a hammer, install the transaxle case oil seal 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 transaxle case oil seal is installed in the correct direction.

  11. INSTALL FRONT TRANSAXLE CASE OIL SEAL


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

    2. A01G4K4E02

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

      SST
      09308-14010
      Standard 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.