Differential Case Disassembly

REMOVE OR DISCONNECT

The removal and installation steps should be used only when service to the differential is required.

1. Park/Neutral Position (PNP) switch.
2. Vehicle Speed Sensor (VSS).
3. Governor body.
4. Oil pan.
5. Valve body.
6. Transaxle rear cover with 11 bolts and tap with a plastic hammer to remove it.
7. Intermediate shaft.
8. Parking lock pawl bracket and rod.
9. Parking lock pawl.
10. Manual valve lever and shaft.
11. Governor pressure adapter.
12. Carrier cover.

DISASSEMBLE

- Tools Required:
- J 8001 Dial Indicator Set
- J 22888-D Right Differential Side Bearing Puller
- J 35378 Bearing Puller Pilot
- J 35409 Differential Side Bearing Installer
- J 25025-1 Dial Indicator Mounting Post





1. Measure total preload. Using a toque wrench, measure the total preload.





2. Measure backlash of side gear using J 8001 dial indicator and J 25025-1 dial indicator mounting post.
3. Left bearing retainer with 6 bolts.
4. Tap the retainer with a plastic hammer to remove it.
5. O-ring from the retainer.
6. Right side bearing cap.
7. Differential case, outer race, and adjusting shim.





8. Measure drive pinion preload. Using a torque wrench, measure the drive pinion preload.





9. Side bearing from differential case using a J 22888-D right differential side bearing puller and a J 35378 bearing puller pilot.





- Install bearing using a J 35409 dial indicator mounting post.
10. Align the marks on the ring gear and differential case.
A. Remove the 8 bolts and locking plates. Tap on the ring gear to remove it from the case.
B. Install new set bolts with plates loosely.
C. Tighten the set bolts uniformly, and a little at a time.

Tighten
- Set bolts to 97 N.m (71 lb. ft.).
- Using a hammer and drift punch, stake the locking plates.

Important
- Stake one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake only the half on the tightening side.

11. Measure the backlash of one side gear while holding one pinion and the other side gear toward the case.





- If the backlash is out of specification, install the correct thrust washer to the side gears.





12. Drive out the pinion shaft lock pin from the side on which the ring gear is installed. remove the pinion shaft from the case and the two pinions and two side gears with the four thrust washers from each gear.

ASSEMBLE

1. Thrust washers.





2. Thrust washers, side gears, and pinion gears in the differential case.





3. Pinion shaft.
4. Check the side gear backlash. Measure the side gear backlash while holding one pinion gear toward the case.
- Standard backlash 0.05 to 0.20 mm (0.0020 to 0.0079-inch).





5. Referring to the table, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size on both sides.
- If the backlash in not within specification, install a new thrust washer.
- Install pinions and shaft.





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