DIFFERENTIAL CASE REASSEMBLY

INSTALL DIFFERENTIAL SIDE GEAR
1. Coat the 2 front 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.
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.

INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

Hold the differential case in a vise between aluminum plates.

Note

Do not overtighten the vise.
Place a dial indicator on the tip of the side gear tooth at a right angle.

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

Standard backlash
0.05 to 0.2 mm (0.00197 to 0.00787 in.)

Thrust Washer Thickness
Thickness [mm (in.)]
1.00 (0.0394)
1.10 (0.0433)
1.20 (0.0472)
1.30 (0.0512)

If the backlash is greater than the standard range, select another side gear thrust washer.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a 5 mm pin punch and hammer, install the front differential pinion shaft straight pin.
  
  Note
  
  Align the holes, and install the front differential pinion shaft straight pin.
2. Using a chisel and hammer, stake the differential case.
  
  Note
  
  Stake the differential case after adjusting the backlash.
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 front 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. 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 bearing and transaxle case sub-assembly.
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 front differential case.
  
  SST
  
  09523-36010
  
  09950-60010 ( 09951-00540 )
  
  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.
  
  SST
  
  09950-60020 ( 09951-00790 )
  
  09950-70010 ( 09951-07150 )
  
  Note
  
  Ensure that there is no clearance between the bearing and transaxle housing.

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

Remove packing material from the contact surfaces between the transaxle housing and case.
Install the differential assembly to the transaxle case sub-assembly.
Install the transaxle housing to the transaxle case sub-assembly with the 20 bolts.

Torque:

Bolt A

23 N*m { 231 kgf*cm, 17 ft.*lbf }

except Bolt A

31 N*m { 312 kgf*cm, 22 ft.*lbf }

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
0.89 to 1.31 Nm (9.08 to 13.35 kgfcm, 7.88 to 11.59 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)

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

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 ring gear to more than 110°C (230°F).
2. Clean the contact surface of the front differential case.
3. Align the matchmarks, set the front differential ring gear to the front differential case.
  
  Text in Illustration
  
  *a Matchmark
4. Install the 12 bolts.
  
  Torque:
  
  120 N*m { 1224 kgf*cm, 88 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.
INSTALL TRANSAXLE CASE OIL SEAL
1. Coat the lip of a new transaxle case oil seal with a small amount of MP grease.
2. Using SST and a hammer, tap in the transaxle case oil seal.
  
  SST
  
  09316-10010
  
  09950-70010 ( 09951-07100 )
  
  Oil seal tap 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.
INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. Coat the lip of a new front transaxle case oil seal with a small amount of MP grease.
2. Using SST and a hammer, tap in the front transaxle case oil seal.
  
  SST
  
  09308-14010
  
  Oil seal tap 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.