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. Check 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, press in 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 drift punch and hammer, 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. MEASURE 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 - 18 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.