Disassembly of Differential Case

1. 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 transaxle case side.




2. REMOVE RING GEAR
a. Place the matchmarks on the ring gear and the case.
b. Remove the six bolts.




c. Using a copper hammer, tap on the ring gear to remove it from the case.




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. DISASSEMBLY DIFFERENTIAL CASE
a. Using a pin punch and hammer, drive out the pinion shaft lock 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. (Transmission Case Side) IF NECESSARY, REPLACE OIL SEAL
a. Using a screwdriver and hammer, drive Out the oil seal with a screwdriver.




b. Using SST, pull out the outer race and shim.
SST 09612-65014
c. Place the shim into the case.




d. Using SST and a hammer, drive in a new outer race.
SST 09608-20012 (09608-03020, 09608-03090)




e. Using SST and a hammer, drive in a new oil seal.
SST 09350-32014 (09351-32111, 09351-32130)

Drive in depth: 2.1 - 2.7 mm (0.083 - 0.106 in.)

f. 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.




b. Using SST, pull Out the outer race and shim.
SST 09612-65014
c. Place the shim into the case.




d. Using SST and a hammer, drive in a new outer race.
SST 09608-20012 (09608-03020, 09608-03060)




e. Using SST and a hammer, drive in a new oil seal.
SST 09350-32014 (09351-32130, 09351-32150)

Drive in depth: 1.6 - 2.2 mm (0.063 - 0.087 in.)

f. Coat the lip if the oil seal with MP grease.