DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL DIFFERENTIAL SIDE GEAR


    1. A019OXT

      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.

  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A019ML8

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

  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A019LIE

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator on the tip of the side gear tooth at a right angle.

    3. 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
      Part No. Thickness [mm (in.)] Mark
      41361-73010 1.00 (0.0394) -
      41361-73020 1.10 (0.0433) -
      41361-73030 1.20 (0.0472) -
      41361-73040 1.30 (0.0512) -

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

  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A019M6U

      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. A019NAT

      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. A019NO6E01

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

      SST
      09710-30012   ( 09710-04081 )
      09950-60010   ( 09951-00480 )
      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. A019NUAE01

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

      SST
      09950-60020   ( 09951-00810 )
      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.

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A019LS3E01

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

      SST
      09523-36010
      09950-60010   ( 09951-00540 )
      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. A019LVCE01

      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) 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. A019KI0

      Install the differential case to the transaxle case.

    3. A019MYJE01

      Install the transaxle housing to the transaxle case 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, 23 ft.*lbf }
    4. A019JY0E01

      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
      1.3 to 1.7 N*m (13 to 17 kgf*cm, 12 to 15 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.)] Mark
      90564-69001 2.000 (0.0787) -
      90564-69002 2.025 (0.0797) -
      90564-69003 2.050 (0.0807) -
      90564-69004 2.075 (0.0817) -
      90564-69005 2.100 (0.0827) -
      90564-69006 2.125 (0.0837) -
      90564-69007 2.150 (0.0846) -
      90564-69008 2.175 (0.0856) -
      90564-69009 2.200 (0.0866) -
      90564-69010 2.225 (0.0876) -
      90564-69011 2.250 (0.0886) -
      90564-69012 2.275 (0.0896) -
      90564-69013 2.300 (0.0906) -
      90564-69014 2.325 (0.0915) -
      90564-69015 2.350 (0.0925) -
      90564-69016 2.375 (0.0935) -
      90564-69017 2.400 (0.0945) -
      90564-69020 2.425 (0.0955) -
      90564-69021 2.450 (0.0965) -
      90564-69022 2.475 (0.0974) -
      90564-69023 2.500 (0.0984) -
      90564-69024 2.525 (0.0994) -
      90564-69025 2.550 (0.100) -
      90564-69026 2.575 (0.101) -
      90564-69027 2.600 (0.102) -
      90564-69028 2.625 (0.103) -
      90564-69029 2.650 (0.104) -
      90564-69030 2.675 (0.105) -
      90564-69031 2.700 (0.106) -
      90564-69032 2.725 (0.107) -
      90564-69033 2.750 (0.108) -
      90564-69034 2.775 (0.109) -
      90564-69035 2.800 (0.110) -
      90564-69036 2.825 (0.111) -
      90564-69037 2.850 (0.112) -
      90564-69038 2.875 (0.113) -
    5. A019MYJ

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

    6. A019KI0

      Remove the differential case from the transaxle case.

  8. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A019PERE13

      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. A019LG5E06
      Text in Illustration
      *a Matchmark

      Align the matchmarks and set the front differential ring gear to the differential case.

    4. A019KQI

      Install the 12 bolts.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 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.

  9. INSTALL TRANSAXLE CASE OIL SEAL


    1. A019JNTE01

      Coat the lip of a new transaxle case oil seal with a small amount of 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.

  10. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A019LMXE01

      Coat the lip of a new front transaxle case oil seal with a small amount of 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.