Differential: Service and Repair
DISASSEMBLY OF DIFFERENTIAL CASE
1. REMOVE RING GEAR
a. Place the matchmarks on the ring gear and the case.
b. Using a hammer and chisel, unstake the lock plate.
c. Remove the eight bolts.
d. Using a copper hammer, tap on the ring gear to remove it from the case.
2. REMOVE SIDE BEARING FROM DIFFERENTIAL CASE
a. Using SST, remove the bearings from both sides of the case.
SST 09502-10012
b. Remove the speedometer drive gear from the RH side.
3. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash does not meet specification, install the correct thrust washer to the side gears.
4. DISASSEMBLE DIFFERENTIAL CASE
a. Using a pin punch and hammer, drive Out the straight pin.
b. Remove the pinion shaft from the case.
c. Remove the two pinions and two side gears with the four thrust washers from each gear.
5. IF NECESSARY, REPLACE LH SIDE OIL SEAL
a. Using SST and a press, remove the oil seal from the retainer.
SST 09608-20012 (09608-03020, 09608-03060)
b. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface.
SST 09350-32014 (09351-32130, 09351-32150)
c. Coat the lip of the oil seal with MP grease.
6. (Transaxle Case Side)
IF NECESSARY, REPLACE OIL SEAL
a. Using a screwdriver and hammer, drive out the oil seal with a screwdriver.
b. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface.
SST 09350-32014 (09351-32130, 09351-32150)
c. Coat the lip of oil seal with MP grease.
7. (Transmission Case Side)
IF NECESSARY, REPLACE OUTER RACE OF SIDE BEARING
a. Using a brass bar and hammer, drive Out the outer race.
b. Install the bearing retainer without an O-ring.
c. Install and torque the retainer bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N.m)
d. Place the thinnest shim into the case.
e. Using SST and a press, install a new outer race.
SST 09608-20012 (09608-03020, 09608-03060)
8. (Transaxle Case Side)
IF NECESSARY, REPLACE OUTER RACE OF SIDE BEARING
a. Using a brass bar and hammer, drive out the outer race.
b. Place the shim into the case.
c. Using SST and a press, install a new outer race.
SST 09608-20012 (09608-03020, 09608-03060)
ASSEMBLY OF DIFFERENTIAL CASE
1. ASSEMBLE DIFFERENTIAL CASE
a. Install the correct thrust washers and side gears.
Thrust Washer Thicknesses:
Referring to the image, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Install the thrust washers and side gears in the differential case.
b. Install the pinion shaft.
c. Inspect the side gear backlash.
Measure the side gear backlash while holding one pinion gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within specification, install a thrust washer of different thickness.
d. Using a pin punch and hammer, drive in the straight pin through the case and hole in the pinion shaft
e. Stake the differential case.
2. INSTALL SIDE BEARINGS
a. Install the speedometer drive gear to the RH side.
b. Using SST and a press, install the side bearings to the both sides of the case.
SST 09316-60010 (09316-00010) 09350-32014 (09351-32120)
NOTE: Install the black cage bearing on the speedometer drive gear side.
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surface of the differential case.
b. Heat the ring gear to about 100 °C (212 °F) in an oil bath.
NOTE: Do not heat the ring gear above 110 °C (230 °F)
c. Clean the contact surface of the ring gear with cleaning solvent.
d. Then quickly install the ring gear on the differential case.
e. Align the matchmarks on the ring gear and differential case.
f. Install the six set bolts. Tighten the set bolts uniformly and a little at a time in succession. Torque the bolts.
Torque: 985 kg-cm (71 ft-lb, 97 N.m)
g. Using a hammer and drift punch, stake the lock plates
HINT: Stake one claw flush with the flat surface of the bolt. For the claw contacting the protruding portion of the bolt, stake only the half on the tightened side.
4. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
a. Install the differential to the transaxle case.
b. Install the transmission case.
c. Install and torque the case bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)
d. Using SST and torque meter, measure the preload.
SST 09564-32011
Preload (at starting): 8 - 16 kg-cm (6.9 - 13.9 in.-lb, 0.8 - 1.6 N.m)
If the preload is not within specification, remove the transmission case side outer race of the side bearing with SST.
Select another shim.
HINT: The preload will change about 3 - 4 kg-cm (2.6 3.5 in.-lb, 0.3 - 0.4 N.m) with each shim thickness.