Assembly of Differential

HINT: Coat all of the sliding and rotating surface with ATF before assembly.




1. ASSEMBLE DIFFERENTIAL CASE
a. Install the thrust washer to the side gear.




b. Install the side gears with thrust washers, pinion gears and pinion thrust washers into the differential case.




c. Install the pinion shaft so as to align the lock pin holes on the pinion shaft and differential case.




2. CHECK SIDE GEAR BACKLASH
a. 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 out of specification, install the correct thrust washer to the side gear.

Thrust Washer Thicknesses:

b. Referring to the table below, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size of both sides.

If the backlash is not within specification, install a thrust washer of a different thickness.




3. INSTALL LOCK PIN
a. Using a hammer and punch, drive the lock pin through the case and hole in the pinion shaft.




b. Stake the differential case.




4. INSTALL SIDE BEARINGS TO DIFFERENTIAL CASE
a. Using SST and press, press the side bearing into the differential case.
SST 09710-30030 (09710-03160)




b. Install the speedometer drive gear to the differential case.




c. Using SST and press, press the side bearing into the differential case.
SST 09350-32014 (09351-32090, 09351-32120)




5. INSTALL RING GEAR TO DIFFERENTIAL
a. Clean the contact surface of the differential case.
b. Heat the ring gear to about 212 °F (100 °C) in an oil bath.

NOTE: Do not heat the ring gear above 230 °F (110 °C).

c. Clean the contact surface of the ring gear with cleaning solvent.




d. Quickly install the ring gear on the differential case.
e. Install new locking plates and set bolts.

HINT: Tighten the set bolts uniformly and a little at a time. Torque the bolts.

Torque: 985 kg-cm (71 ft-lb, 97 N-m)




f. Using a hammer and drift punch, stake the locking plates.

HINT: Stake one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the' nut, stake only the half on the tightened side.




6. ADJUST SIDE BEARING PRELOAD
a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transmission case.




b. Install the differential to the transaxle case.




c. Install the transmission case to the transaxle case.
d. Install and torque the seventeen bolts.

Torque: 300 kg-cm (22 ft-lb, 29 N-m)




e. Using SST, rotate the differential in both directions to snug the bearing down.
SST 09564-32011
f. Using SST and a torque meter, measure the preload of the side bearing.
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 bearing retainer from the case. Re-select the transmission case side adjusting 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.




7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM




8. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with plastic hammer.




9. REMOVE DIFFERENTIAL ASSEMBLY FROM TRANSAXLE CASE