Assembly of Differential Case

1. ASSEMBLE DIFFERENTIAL CASE
a. Install the correct thrust washers and side gears. Referring to the table, select thrust washers which will ensure that the backlash is within specification.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)

b. Install the thrust washers and side gears in the differential case.
c. Install the pinion shaft.




d. Using a dial indicator, 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.
e. Using a pin punch and hammer, drive in the straight pin through the case and hole in the pinion shaft.
f. Stake the differential case.




2. RING GEAR SIDE: INSTALL SIDE BEARING
Using SST and a press, install the side bearing.
SST 09550-10012(09252-10010, 09556-10010)




3. VEHICLE SPEED SENSOR DRIVE GEAR SIDE: INSTALL SIDE BEARING
a. Install the vehicle speed sensor drive gear.




b. Using SST and a press, install the side bearing.
SST 09550-10012 (09252-10010, 09556-10010, 09560-10010)




4. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surface of the differential case.
b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

HINT : Align the matchmarks on the differential case and contact the ring gear.




e. Temporary install the 4 lock plates and 8 bolts.

NOTE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.

f. After the ring gear has cooled sufficiently, torque the ring gear set bolts.

Torque: 97 N-m (985 kgf-cm, 71 ft-lbf)

g. Using a hammer and drift punch, stake the locking plate.

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 tightening side.




5. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
a. Install the differential case assembly 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 a torque wrench, 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 with SST.
Select another shim.

HINT : The preload will change by about 0.3 - 0.4 N-m (3 - 4 kgf-cm, 2.6 - 3.5 in.-lbf) with each 0.05 mm change in shim thickness.