DIFFERENTIAL CASE REASSEMBLY

INSTALL DIFFERENTIAL SIDE GEAR
1. Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 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 at a right angle to one of the side gear teeth.

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.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch (3 mm) and hammer, install the pinion shaft straight pin.
  
  Note
  
  Align the holes, and install the 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 differential case.
  
  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.
  
  SST
  
  09950-60020 ( 09951-00890 )
  
  09950-70010 ( 09951-07150 )
  
  Note
  
  Ensure that there is no clearance between the bearing and transaxle case.
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.
  
  SST
  
  09316-12010
  
  09649-17010
  
  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
  
  09950-60010 ( 09951-00910 )
  
  09950-70010 ( 09951-07150 )
  
  Note
  
  Ensure that there is no clearance between the bearing and transaxle housing.

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

Install the differential assembly to the transaxle case.
Clean the contact surfaces of the transaxle case and transaxle housing.
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 { 234 kgf*cm, 17 ft.*lbf }
Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing.

SST

09564-33010

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 Nm (11 to 19 kgfcm, 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)

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

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. Text in Illustration
  
  *1 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. Install and tighten the 12 bolts.
  
  Torque:
  
  120 N*m { 1223 kgf*cm, 88 ft.*lbf }
  
  Note
  
  Tighten the bolts a little at a time in a diagonal sequence.
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 oil seal.
  
  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.
INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. Inside:
  1. Coat the lip of a new front transaxle case oil seal with MP grease.
  2. Using SST and a hammer, tap in the front transaxle case oil seal.
    
    SST
    
    09950-60010 ( 09951-00410 )
    
    09950-70010 ( 09951-07200 )
    
    Oil seal driven in depth
    
    21.5 to 22.5 mm (0.846 to 0.886 in.)
2. Outside:
  1. Coat the lip of a new front transaxle case oil seal with MP grease.
  2. Using SST and a hammer, tap in the front transaxle case oil seal.
    
    SST
    
    09649-17010
    
    09950-70010 ( 09951-07200 )
    
    Oil seal driven in depth
    
    5.5 to 6.5 mm (0.217 to 0.256 in.)
    
    Note
    
    Check that the oil seal is installed in the correct direction.