Assemble

DIFFERENTIAL CASE ASSEMBLY





1. Assemble differential case.
a. Install the correct thrust washers and side gears.
- Refer to the table, select thrust washers which will ensure that the backlash is within the specification.





Standard backlash: 0.05-0.20 mm (0.0020-0.0079 inch).
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 inch) .
If the backlash is not within the 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 a new 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 a new side bearing.
SST 09950-10012 (09556-10010), 09950-60010 (09951-00460), 09950-70010 (09951-07150)





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 8 set bolts.

NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently. After the ring gear has cooled sufficiently, torque the ring gear set bolts uniformly and a little at a time.
Torque: 77 N.m (57 ft. lbs.).





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 (22 ft. lbs.).





d. Using SST and a torque wrench, measure the preload.
SST 09564-32011





- Preload (at starting):
New bearing: 0.8-1.6 N.m (6.9-13.9 inch lbs.).
Reused bearing: 0.5-1.0 N.m (4.3-8.7 inch lbs.).
If the preload is not within the 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 (2.6-3.5 inch lbs.) with each 0.05 mm change in shim thickness.