DIFFERENTIAL CASE REASSEMBLY

  1. INSTALL DIFFERENTIAL SIDE GEAR

    1. 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.

      A011V1E

  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

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

      A011TKQ

  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

    1. Hold the differential case in a vise between aluminum plates.

      A011U4O

      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.)
      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 side gear thrust washer.

  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

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

      A011V5H

      Note

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

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

      A011QN0

      Note

      Stake the differential case after adjusting the backlash.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    1. Using SST and a press, install a new front differential case rear tapered roller bearing to the differential case.

      A011UZVE01
      SST
      09726-36010
      09950-70010   ( 09951-07100 )

      Note

      Do not damage the bearing cage during bearing inner race installation.

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

      A011RBSE01
      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. Using SST and a press, install a new front differential case front tapered roller bearing to the differential case.

      A011SQIE01
      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. Using SST and a hammer, install a new front differential case front tapered roller bearing outer race to the transaxle housing.

      A011TGXE01
      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. Install the differential assembly to the transaxle case.

      A011R5J

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

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

      A011TPIE02
      Torque:
      Bolt A
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt B
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

    4. Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearings.

      A011SOBE01
      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. Remove the 20 bolts and transaxle housing from the transaxle case.

      A011TPIE04

    7. Remove the differential assembly from the transaxle case.

      A011R5J

  8. 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).

      A011UE0

      Note

      Do not heat the ring gear to more than 110°C (230°F).

    2. Clean the contact surface of the front differential case.

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

      A011RBNE08
      Text in Illustration
      *a Matchmark

      Note

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

    4. Install and tighten the 12 bolts.

      A011RXQ
      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 TRANSAXLE CASE OIL SEAL

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

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

      A011S06E01
      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 oil seal is installed in the correct direction.

  10. INSTALL FRONT TRANSAXLE CASE OIL SEAL

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

      A011T2OE01

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

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

      Note

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