Differential

DIFFERENTIAL

Tools Required
KM-709 Bearing Puller Adapter
KM-695 Bearing Installer
KM-J 28544 Adapter
KM-674 Oil Seal Installer
KM-210-A Bearing Puller

Disassembly Procedure

Notice: Install the bearing puller to the cut out portion of the differential case.





1. Using a bearing puller, remove the outer bearing.





2. Using a suitable bearing puller, remove the inner bearing.

WARNING: USE CAUTION WHEN REMOVING THE SPEEDOMETER DRIVE GEAR OR PERSONAL INJURY MAY RESULT.





3. Remove the speedometer drive gear.





4. Index mark the differential ring gear and the differential case using a scribe.





5. Tap down the tabs of the differential ring gear bolt lock plate.





6. Remove and discard the differential ring gear bolts and lock plates.





7. Using a plastic hammer, tap the on the ring gear to remove.





8. Remove and discard the oil seal from the transaxle case side.





9. Remove and discard the oil seal from the transaxle housing side.

Notice: If equipped, remove preload shim.





10. Using bearing puller KM-210-A and bearing puller adapter KM-709, remove the bearing cup from the transaxle case side.





11. Using bearing puller KM-210-A and bearing puller adapter KM-709, remove the bearing cup from the transaxle housing side.

Assembly Procedure
1. Clean the components using a clean, high-quality parts cleaning solvent and use compressed air to dry all parts. Inspect all parts for damage or wear.





2. Using bearing installer KM-695, install the bearing cup into the transaxle housing.

Notice: If equipped, install preload shim.





3. Using bearing installer KM-695, install the bearing cup into the transaxle case.

Caution: Do not heat the differential ring gear above 110°C (255°F).





4. Using a oil bath or an oven, heat the differential ring gear to 90 - 100°C (219 - 237°F).

Notice: Clean the oil from the contact surface of the differential ring gear. Tighten the bolts evenly and gradually.





5. Install the differential ring gear on the differential case. Install new differential ring gear bolts and lock plates.
Tighten
Tighten ring gear bolts to 90 - 103 Nm (66 - 76 ft. lbs.).





6. Bend the differential ring gear bolt lock plate tabs in the locked position.

WARNING: USE CAUTION WHEN INSTALLING THE SPEEDOMETER DRIVE GEAR OR PERSONAL INJURY MAY RESULT.





7. Install the speedometer drive gear.





8. Using a press, press the outer bearing onto the differential case.





9. Using a press, press the inner bearing onto the differential case.





10. Install the differential assembly in the transaxle case.

Notice: Tighten the bolts evenly and gradually.





11. Apply sealer to the transaxle case and install the transaxle housing.
Tighten
Tighten the bolts to 23 - 35 Nm (17 - 26 ft. lbs.).











12. Using adapter KM-J-28644, measure the starting preload.
- Rotate the differential in both directions to seat the bearing.
- If the preload is not within specifications, remove the differential assembly. Remove the outer bearing race and select the correct adjusting shim. If the preload is below specifications, install a thicker shim. If the preload is above specifications, install a thinner shim.
- Install selected shim, reinstall differential assembly and recheck preload.

Notice: The distance from the outer edge of the seal to the transaxle housing should be 0.500 mm (0.019 inch). Apply Transjel Assembly Lubricant J-36850 to the oil seal lip.





13. Using oil seal installer KM-674, install a new oil seal into the transaxle housing.

Notice: Install the oil seal until the seal touches the transaxle case. Apply Transjel Assembly Lubricant J-36850 to the oil seal lip.





14. Using oil seal installer KM-674, install a new oil seal into the transaxle case.