Reassembly (from 07/2011)

C50 MANUAL TRANSMISSION / TRANSAXLE: DIFFERENTIAL CASE (for Hatchback): REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR





(a) Coat the sliding and rotating surfaces of the front differential side gear with gear oil.

(b) Install the 2 front No. 1 differential side gear thrust washers onto the 2 front differential side gears.

(c) Install the 2 front differential side gears, 2 front differential pinions and 2 front differential pinion thrust washers onto the front differential case.

HINT
Revolving the front differential side gear, install the 2 front differential pinions and 2 front differential pinion thrust washers.

2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT





(a) Coat the front No. 1 differential pinion shaft with MP grease.

(b) Install the front No. 1 differential pinion shaft onto the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.

3. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH





(a) Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Standard backlash:

0.05 to 0.20 mm (0.00197 to 0.00787 in.)

If the backlash is outside the specifications, replace the front No. 1 differential side gear thrust washer.

Thrust Washer Thickness:





HINT
* Because the front No. 1 differential side gear thrust washer does not have any marks for distinction, measure the thickness with a micrometer to select a proper front No. 1 differential side gear thrust washer.
* Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left.

4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN





(a) Using a pin punch (dia3 mm) and a hammer, install the front differential pinion shaft straight pin onto the front differential case.

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





5. INSTALL FRONT DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the front differential case and front differential ring gear.

(b) Using a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).





Text in Illustration





(c) After the moisture on the front differential ring gear has completely evaporated, quickly install the front differential ring gear onto the differential case.

(d) Aligning the 2 matchmarks, quickly install the front differential ring gear onto the front differential case.





Text in Illustration





(e) Install the 8 bolts.

Torque : 77 Nm (789 kgf-cm, 57 ft-lbf)

6. INSTALL SPEEDOMETER DRIVE GEAR





(a) Install the speedometer drive gear onto the front differential case.