DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01CDB9E01

      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 cage when installing the front differential case rear tapered roller bearing.

      • Ensure that there is no clearance between the front differential case rear tapered roller bearing and front differential case.

    2. A01CE4RE01

      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. A01CEG6E07

      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 cage when installing the front differential case front tapered roller bearing.

      • Ensure that there is no clearance between the front differential case front tapered roller bearing and front differential case.

    2. Install the shim to the transaxle housing.

    3. A01CF1ME01

      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. A01CGFUE01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      A01CFEA ATF WS

      Coat the front differential side gear, front No. 1 differential side gear thrust washer and conical spring with ATF WS.

    2. A01CC0AE01
      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.

      A01CC9GE01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09953-05010, 09528-05010 )

      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. A01CG6P

      Coat the front differential pinion and front differential pinion thrust washer with ATF WS.

      Text in Illustration
      A01CFEA ATF WS
    5. A01CDX1E01
      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.

      A01CEUKE01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09953-05010, 09528-05010 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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

      Note

      Do not overtighten the vise.

    3. A01CBYEE01
      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 (0.00591in.) or less

      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 a front No. 1 differential side gear thrust washer 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 (0.0670)
      41361-33070 1.75 (0.0689)
      41361-33080 1.80 (0.0709)
      41361-33090 1.85 (0.0728)
      41361-33100 1.90 (0.0748)

      Tech Tips

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

  5. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01CBUH

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

      Text in Illustration
      A01CFEA ATF WS

    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. A01CEG4E01

      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.

  7. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01CEAQ

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

    2. A01CDUF

      Using a chisel and 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.

    2. A01CAVE

      Install the differential case to the transaxle case.

    3. A01CBCUE01

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

      Torque:
      Bolt (A)
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    4. A01CE3BE01

      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 differential side bearing while rotating SST at 10 rpm.

      SST
      09564-33010
      Turning Torque
      0.8 to 1.4 N*m (8 to 14 kgf*cm, 7 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
      Part No.

      Thickness

      (mm (in.))
      90564-79054 2.000 (0.0787)
      90564-79055 2.025 (0.0797)
      90564-79056 2.050 (0.0807)
      90564-79057 2.075 (0.0817)
      90564-79058 2.100 (0.0827)
      90564-79059 2.125 (0.0837)
      90564-79060 2.150 (0.0846)
      90564-79061 2.175 (0.0856)
      90564-79062 2.200 (0.0866)
      90564-79063 2.225 (0.0876)
      90564-79064 2.250 (0.0886)
      90564-79065 2.275 (0.0896)
      90564-79066 2.300 (0.0906)
      90564-79067 2.325 (0.0915)
      90564-79068 2.350 (0.0925)
      90564-79069 2.375 (0.0935)
      90564-79070 2.400 (0.0945)
      90564-79071 2.425 (0.0955)
      90564-79072 2.450 (0.0965)
      90564-79073 2.475 (0.0974)
      90564-79074 2.500 (0.0984)
      90564-79075 2.525 (0.0994)
      90564-79076 2.550 (0.100)
      90564-79077 2.575 (0.101)
      90564-79078 2.600 (0.102)
      90564-79079 2.625 (0.103)
      90564-79080 2.650 (0.104)
      90564-79081 2.675 (0.105)
      90564-71082 2.700 (0.106)
      90564-71083 2.725 (0.107)
      90564-71084 2.750 (0.108)
      90564-71085 2.775 (0.109)
      90564-71086 2.800 (0.110)
      90564-71087 2.825 (0.111)
      90564-71088 2.850 (0.112)
      90564-71089 2.875 (0.113)
    6. A01CBCUE04

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

    7. A01CAVE

      Remove the differential case from the transaxle case.

  9. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A01CFDW

      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. Clean the contact surface of the front differential case.

    3. A01CEA0E03
      Text in Illustration
      *a Matchmark

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

    4. A01CGB4

      Install the 12 bolts.

      Torque:
      120 N*m  { 1223 kgf*cm, 88 ft.*lbf }

      Note


      • Install 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. A01CD06E01

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

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

      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. A01CCNSE01

      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.

      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.