Differential Case

Differential Case:

DISASSEMBLY
1. REMOVE DIFFERENTIAL RING GEAR





a. Place the matchmarks on the ring gear and differential case.





b. Unstake the lock plates.
c. Remove the 8 bolts and 4 lock plates.





d. Using a plastic hammer, tap on the ring gear to remove it from the case.





2. REMOVE TAPERED ROLLER BEARING AND SPEEDOMETER DRIVE GEAR OF TRANSAXLE HOUSING SIDE
Using SST, remove the tapered roller bearing and speedometer drive gear of transaxle housing side.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061), 09950-60010 (09951-00330)





3. REMOVE TAPERED ROLLER BEARING OF TRANSAXLE CASE SIDE
Using SST, remove the tapered roller bearing of transaxle case side.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061), 09950-60010 (09951-00330)
4. DISASSEMBLE DIFFERENTIAL CASE





a. Using a pin punch and hammer, drive out the pin from the ring gear side.





b. Remove the differential pinion shaft from the case.





c. Remove the 2 differential pinion gears, 2 differential side gears, 2 differential pinion thrust washers and 2 differential side gear thrust washers.





5. REMOVE OIL SEAL OF TRANSAXLE HOUSING
Using SST and a hammer, remove the oil seal.
SST 09950-60010 (09951-00520), 09950-70010 (09951-07200)





6. REMOVE SIDE BEARING OUTER RACE OF TRANSAXLE HOUSING
Using a screwdriver and hammer, remove the bearing outer race.





7. REMOVE OIL SEAL OF TRANSAXLE CASE
Using SST and a hammer, remove the oil seal.
SST 09238-47012





8. REMOVE SIDE BEARING OUTER RACE OF TRANSAXLE CASE
Using SST, remove the bearing outer race and shim.
SST 09612-55010

REASSEMBLY





1. INSTALL SIDE BEARING OUTER RACE OF TRANSAXLE HOUSING
Using SST and a hammer, install a new bearing outer race into the transaxle housing.
SST 09515-35010





2. INSTALL SIDE BEARING OUTER RACE OF TRANSAXLE CASE
a. Install the shim to the transaxle case.

HINT: First install a shim of the same thickness as before.

b. Using SST and a hammer, install the bearing outer race into the transaxle case.
SST 09608-32010, 09950-70010 (09951-07200)
3. ASSEMBLY DIFFERENTIAL CASE





a. Coat the thrust washers, side gears, pinion gears and pinion thrust washers with ATF.
b. Install the 2 differential side gear thrust washers to 2 differential side gears.





c. Install the 2 side gears with 2 thrust washers, 2 pinion gears and 2 pinion thrust washers into the differential case.
d. Coat the pinion shaft with ATF.





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





4. CHECK SIDE GEAR BACKLASH
a. Measure the side gear backlash while holding 1 pinion gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is out of specification, install the correct thrust washer to the side gear.
b. Referring to the table below, select thrust washers which will ensure that the backlash is within the specification.
Try to select washers of the same size for both sides.





Thrust washer thickness: mm (inch)

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





a. Using a hammer and punch, drive in the pin through the case and hole in the pinion shaft.





b. Using a hammer and chisel, stake the differential case.





6. INSTALL TAPERED ROLLER BEARING OF TRANSAXLE CASE SIDE
Using SST and a press, install the tapered roller bearing into the differential case.
SST 09316-20011, 09950-60010 (09951-00470)





7. INSTALL TAPERED ROLLER BEARING OF TRANSAXLE HOUSING SIDE
Using SST and a press, install the tapered roller bearing into the differential case.
SST 09608-06041
8. ADJUST PRELOAD OF DIFFERENTIAL GEAR
a. Remove any FIPG material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case.
b. Install the differential to the transaxle case.





c. Install the transaxle housing and 14 bolts of the transaxle temporarily.
d. Tighten 7 or 8 bolts out of 14 bolts of the transaxle housing completely.
Torque:
Bolt A: 29 Nm (300 kgf-cm, 21 ft. lbs.)
Bolt B: 22 Nm (220 kgf-cm, 16 ft. lbs.)





e. Using a SST, turn the differential gear assembly right and left 2 or 3 times to allow the bearing settle.
SST 09564-32011





f. Using SST and small torque wrench, measure the preload of the differential gear.
SST 09564-32011
Preload:
New bearing: 0.78 - 1.37 Nm (8.0 - 14.0 kgf-cm, 6.9 - 12.2 inch lbs.)
Used bearing: 0.39 - 0.69 Nm (4.0 - 7.0 kgf-cm, 3.5 - 6.1 inch lbs.)
If the preload is not within the specification, remove the differential from the transaxle case. Re-select the transaxle case side adjusting shim according to the following table.





Adjusting shim thickness: mm (inch)





g. Using a plastic hammer, remove the 14 bolts and transaxle housing.
h. Remove the differential gear from the transaxle case.
9. INSTALL RING GEAR TO DIFFERENTIAL





a. Clean the contact surface of the differential case.
b. Heat the ring gear in water and boil for 10 minutes.
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.





e. Install the 4 lock plates and 8 bolts.
Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.)





10. INSTALL TRANSAXLE HOUSING OIL SEAL
Using SST and a hammer, drive in a new oil seal.
SST 09710-30050, 09950-70010 (09951-07200)
Oil seal in depth:
U340E: 2 ± 0.5 mm (0.079 ± 0.020 inch)
U341E: 0 ± 0.5 mm (0 ± 0.020 inch)





11. INSTALL TRANSAXLE CASE OIL SEAL
Using SST and a hammer, drive in a new oil seal.
SST 09350-32014 (09351-32150), 09950-70010 (09951-07150)
Oil seal in depth:
U340E: 5.9 ± 0.5 mm (0.232 ± 0.020 inch)
U341E: 2.7 ± 0.5 mm (0.106 ± 0.020 inch)