Assembly of Differential Case

Thrust Washer Thickness:

1. ASSEMBLE DIFFERENTIAL CASE
a. Install the correct thrust washers and side gears. Referring to the images, 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.
Using a dial indicator, 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 the lock pin through the case and hole in the pinion shaft.




e. Stake the differential case.




2. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surfaces of the differential case and the threads of the ring gear and differential case.
b. Heat the ring gear in boiling water.
c. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.




d. Align the matchmarks on the ring gear and differential case.
e. Install the six set bolts. Tighten the set bolts uniformly and a little at a time in succession. Torque the bolts.

Torque: 124 N.m (1,260 kgf.cm, 91 ft.lbf)




3. INSTALL SIDE BEARINGS
a. Install the speedometer driven gear to the RH side.
b. Using SST and a press, press the side bearings to the both sides of the case.
SST 09350-32014 (09351-32090, 09351-32120)




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: 29 N.m (300 kgf.cm, 22 ft.lbf)







d. Using SST and torque meter, measure the preload.
SST 09564-32011
Preload (at starting):

New bearing: 0.8 - 1.6 N.m (8 - 16 kgf.cm, 6.9 - 13.9 in.lbf)
Reused bearing: 0.5 - 1.0 N.m (5 - 10 kgf.cm, 4.3 - 8.7 in.lbf)

If the preload is not within specification, remove the transmission case side outer race of the side bearing wit SST.
(See steps 6-(b) to (d).

HINT: The preload will change about 0.3 - 0.4 N.m (3 - 4 kgf.cm, 2.6 3.5 in.lbf) with each shim thickness.