Differential Case

DISASSEMBLY
1. REMOVE DIFFERENTIAL RING GEAR





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





b. Using a screwdriver and hammer, unstake the lock plate.
c. Remove the 4 lock plate and 8 bolts.





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





2. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
Using SST remove the rear tapered roller bearing.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00440)





3. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
Using SST remove the front tapered roller bearing.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00440)
4. REMOVE FRONT DIFFERENTIAL CASE





a. Using a pin punch and hammer, drive out the straight pin.





b. Remove the pinion shaft, 2 pinions, 2 pinion thrust washers, 2 side gears and 2 side gear thrust washers from the front differential case.





5. REMOVE OIL SEAL NO. 1
Using SST, remove the oil seal.
SST 09308-00010





6. REMOVE TRANSAXLE HOUSING OIL SEAL
Using SST, remove the oil seal.
SST 09308-00010
7. REMOVE FRONT AND REAR BEARING RACE





a. Using a brass bar and hammer, remove the rear bearing race and plate washer.





b. Using a brass bar and hammer, remove the front bearing race.

REASSEMBLY
1. INSTALL FRONT AND REAR BEARING RACE





a. Using SST and a press, press in the front bearing race.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
b. Install the plate washer to the transaxle case.





c. Using SST and a press, press in the rear bearing race.
SST 09950-60020 (09951-00720), 09950-70010 (09951-07150)
2. ASSEMBLE FRONT DEFERENTIAL CASE





a. Coat the front differential side gear thrust washer and front differential pinion thrust washer with ATF.
b. Install the 2 side gears, 2 pinions and 4 thrust washers to the differential case.





c. Install the pinion shaft No. 1 so that the hole for a straight pin will be aligned with the hole in the differential case.





d. Using a dial indicator, measure the backlash of side gear while holding the pinion toward the case.
Standard backlash: 0.05 - 0.20 mm (0.002 - 0.008 inch)

NOTICE: Do not mount the surface of front differential case which contacts with bushing in a vise.

If the backlash is not within the specified value, refer to the table and select a thrust washer which will ensure that the backlash is within the specified value.





Thrust washer thickness: mm (inch)





e. Using a pin punch and hammer, install the straight pin.





f. Using SST and a press, press in the front tapered roller bearing.
SST 09350-32014 (09351-32090, 09351-32120)





g. Using SST and a press, press in the rear tapered roller bearing.
SST 09350-32014 (09351-32150)
3. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and the ring gear.





b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.





d. Align the matchmarks on the differential case and ring gear and install the ring gear quickly.





e. Install the 4 new lock plates and 8 bolts.
Torque: 96 Nm (980 kgf-cm, 71 ft. lbs.)

NOTICE:
- Tighten the bolts evenly in diagonal sequence over several times.
- Tighten the bolt after the ring gear is cooled down.

f. Using a screwdriver and hammer, stake the lock plate.
4. CHECK PRELOAD OF DIFFERENTIAL CASE





a. Install the differential assembly to the transaxle case.
b. Install the transaxle housing to the transaxle case.





c. Install the 16 bolts.
Torque:
Bolt A: 29 Nm (300 kgf-cm, 22 ft. lbs.)
Bolt B: 29 Nm (300 kgf-cm, 22 ft. lbs.)
Bolt C: 22 Nm (224 kgf-cm, 16 ft. lbs.)
Bolt length:
Bolt A: 42 mm (1.654 inch)
Bolt B: 50 mm (1.969 inch)
Bolt C: 50 mm (1.969 inch)





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





e. Using SST and torque wrench, measure the differential preload.
SST 09564-32011
Preload (at starting)
New bearing: 1.0 - 1.6 Nm (10.0 - 16.3 kgf-cm, 8.7 - 14.2 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5.1 - 8.2 kgf-cm, 4.4 - 7.1 inch lbs.)

HINT: If the preload is not within the specified value, refer to the table and select a thrust washer which preload is within the specified value.





Plate washer thickness: mm (inch)





f. Remove the 16 bolts and transaxle housing.





g. Remove the differential from the transaxle case.





5. INSTALL TRANSAXLE HOUSING OIL SEAL
a. Using SST and a hammer, drive in a new oil seal.
SST 09350-32014 (09351-32150), 09950-70010 (09951-07150)
Oil seal drive in depth: 0 ± 0.5 mm (0 ± 0.0197 inch)
b. Coat the lip of oil seal with MP grease.





6. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL NO. 1
a. Using SST and a hammer, drive in a new oil seal.
SST 09350-32014 (09351-32150), 09950-70010 (09951-07150)
Oil seal drive in depth: 2.7 ± 0.5 mm (0.1063 ± 0.0197 inch)
b. Coat the lip of oil seal with MP grease.