Differential Case

DIFFERENTIAL CASE

COMPONENTS:

REMOVAL
1. REMOVE DIFFERENTIAL GEAR ASSEMBLY

DISASSEMBLY

1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Put matchmarks on the front differential ring gear and differential case.

(b) Remove the 10 bolts.

2. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case front tapered roller bearing from the differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00480)

(b) Using SST, remove the front differential case front tapered roller bearing outer race.
SST 09308-00010

3. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered roller bearing from the differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09955-04061, 09957-04010, 0995804011), 09950-50013 (09951-05010, 0995205010, 09953-05020, 09954-05021, 0995505010), 09950-60010 (09951-00480), 09950-70010 (09951-07100)

(b) Using SST, remove the front differential case rear tapered roller bearing outer race.
SST 09308-00010

4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
(a) Using a pin punch and hammer, remove the straight pin.

NOTICE: Before removing the straight pin, unstake it with a pin punch.

5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT
(a) Remove the front No. 1 differential pinion shaft from the differential case.

6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears and 2 side gear thrust washers from the differential case.

7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, remove the oil seal.
SST 09950-70010 (09951-07200), 09950-60010 (09951-00630)

8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
(a) Using SST and a hammer, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010

INSPECTION

1. INSPECT BACKLASH
(a) Using a dial indicator, inspect the backlash of the side gear.

Thrust washer thickness:

REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.

2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
(a) Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.

3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
(a) Using a pin punch and hammer, install the pinion shaft straight pin.

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

NOTICE: Stake it after adjusting the backlash.

4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case front tapered roller bearing to the differential case.
SST 09550-60010 (09951-00480), 09950-70010 (09951-07100), 09710-04081

NOTICE: Do not damage the bearing cage during installation of the bearing inner race.

(b) Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing.
SST 09950-60020 (09951-00750), 09950-70010 (09951-07200)

5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case rear tapered roller bearing to the differential case.
SST 09710-04081, 09550-60010 (09951-00480), 09950-70010 (09951-07100)

NOTICE: Do not damage the bearing cage during installation of the bearing inner race.

(b) Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle housing.
SST 09550-60010 (09951-00790), 09950-70010 (09951-00710)

NOTICE: Clearance is not allowed between the bearing and transaxle housing.

6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install the differential assembly to the transaxle case.

(b) Clean the matching surfaces of the transaxle case and transaxle housing.
(c) Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.
Torque:
Bolt A 22 Nm (225 kgf-cm, 16 ft. lbs.)
Bolt B, C 29 Nm (299 kgf-cm, 22 ft. lbs.)
Bolt length:
Bolt A: 50 mm (1.969 inch)
Bolt B: 50 mm (1.969 inch)
Bolt C: 42 mm (1.654 inch)

(d) Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing.
SST 09564-32011
(e) Using SST and a torque wrench, measure the turning torque of the differential.
SST 09564-32011
Turning torque at 60 rpm:
New bearing: 0.20 to 0.69 Nm (2.0 to 7.0 kgf-cm, 1.8 to 6.1 inch lbs.)
Used bearing: 0.10 to 0.35 Nm (1.0 to 3.6 kgf-cm, 0.9 to 3.1 inch lbs.)

HINT: If the turning torque is not within the specified range, refer to the table below to select a thrust washer so that the turning torque is within the specified range.

Flange thickness: mm (inch):

(f) Remove the 16 bolts and the transaxle housing.

(g) Remove the differential assembly.

7. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).

NOTICE: Do not overheat the ring gear over 110°C (230.0°F).

(b) Clean the contact surface of the front differential case.

(c) Align the matchmarks, and install the front differential ring gear case quickly.

NOTICE: Do not install the bolts while the ring gear is hot.

(d) Tighten the 10 bolts.
Torque: 95 Nm (970 kgf-cm, 70 ft. lbs.)

NOTICE: Tighten the bolts a little at a time in diagonal order.

8. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09608-32010, 09950-70010 (09951-07150)
(b) Coat the lip of the oil seal with a small amount of MP grease.
Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 inch)

9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09726-36010, 09950-70010 (09951-07150)
(b) Coat the lip of the oil seal with a small amount of MP grease.
Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 inch)

INSTALLATION
1. INSTALL DIFFERENTIAL GEAR ASSEMBLY