DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL DIFFERENTIAL SIDE GEAR


    1. A019OR2

      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.

  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A019KPD

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

  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A019MIK

      Hold the differential case in a vise between aluminum plates.

      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. A019M2U

      Using a 3mm pin punch and hammer, install the front differential pinion shaft straight pin to the differential case.

      Note

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

    2. A019LGR

      Using a chisel and hammer, stake the differential case.

      Note

      Stake the differential case after adjusting the backlash.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A019KYJE01

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

    2. A019MWME01

      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 front differential case rear tapered roller bearing outer race and transaxle case.

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A019LBNE01

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

    2. Install the shim to the transaxle housing.

    3. A019PG4E01

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

      SST
      09950-60020   ( 09951-00910 )
      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.

  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case.

    2. A019OAS

      Install the differential assembly to the transaxle case.

    3. A019NO4E02

      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 }
    4. A019JY0E01

      Using SST, turn the differential assembly 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 bearings 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: 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. A019NO4E01

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

    7. A019OAS

      Remove the differential assembly from the transaxle case.

  8. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A019PER

      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 differential case.

    3. A019NOKE01
      Text in Illustration
      *1 Matchmark

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

      Note

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

    4. A019KQI

      Install 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.

  9. INSTALL TRANSAXLE CASE OIL SEAL


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

    2. A019MPOE01

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

      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.

  10. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A019LHGE01

      Inside:


      1. 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 to the differential case.

        SST
        09950-60010   ( 09951-00410 )
        09950-70010   ( 09951-07200 )
        Standard Depth
        21.5 to 22.5 mm (0.846 to 0.886 in.)
    2. A019LLPE01

      Outside:


      1. 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 to the transaxle housing.

        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 front transaxle case oil seal is installed in the correct direction.