Differential, Disassembling and Assembling Overview
Differential, Disassembling and Assembling
Special Tools And Equipment
- VW295 Needle Bearing Drift
- VW401 Thrust Plate
- VW402 Thrust Plate
- VW407 Punch
- VW408A Punch
- VW447H Thrust Pad
- VW4471 Thrust Pad
- VW472/1 Pressure Piece
- VW511 Thrust Pad
- 30-11 Thrust Pad
- 30-205 Thrust Pad
- 40-21 Sleeve
- 40-105 Thrust Piece
- 3138 Drift
- 3144 Press Support
- 3296 Tube
- Sealant AMV 188 001 02
- Kukko 20/10 Two-arm Puller Or Kukko 44/2 Puller
- Kukko 204/2 Two-arm Puller
Notes:
- Replace both tapered roller bearings together.
- Adjustments are required when replacing components marked with (1).
1. Transmission - Housing (1)
2. Shim S2
- Note thickness
3. Right Tapered Roller Bearing Outer Race (1)
- Left and right tapered roller bearings are identical (not for transmission without polygon bearing), Application and ID
- Driving out for transmission with polygon bearing, Fig. 1 Remove Right Bearing Outer Race W/Polygon Bearing
- Driving out for transmission without polygon bearing, Fig. 2 Remove Right Bearing Outer Race W/O Polygon Bearing
- Driving in for transmission with polygon bearing, Fig. 3 Install Right Bearing Outer Race In Transmission Housing
- Driving in for transmission without polygon bearing using VW295 needle bearing drift and 30-205 thrust pad
4. Right Tapered Roller Bearing Inner Race (1)
- Left and right tapered roller bearings are identical (not for transmission without polygon bearing).
- Pull off using 3296 tube, Fig. 4 Pulling Off Right Tapered Roller Bearing Inner Race
- Pressing on for transmission with polygon bearing, Fig. 5 Pressing on Right Tapered Roller Bearing Inner Race
- Pressing on for transmission without polygon bearing using 40-21 sleeve
5. Ring Gear (1)
- Is matched to pinion shaft (gear set)
- Allocate according to transmission code letters using parts supplier.
- Remove from transmission housing using drift, Fig. 10 Driving Out Ring Gear From Housing
- Installing on differential housing, Fig. 11 Installing Ring Gear
6. Differential Housing (1)
- Allocate according to transmission code letters using parts supplier.
7. Bolt
- Always replace
- Tighten to 60 Nm (44 ft. lbs.) and then tighten another 45°
- Lightly tighten bolts then tighten diagonally to correct torque
8. Left Tapered Roller Bearing Inner Race (1)
- Left and right tapered roller bearings are identical (not for transmission without polygon bearing).
- Pulling off, Fig. 6 Pulling Off Left Tapered Roller Bearing Inner Race
- Driving in for transmission with polygon bearing, Fig. 7 Installing Left Tapered Roller Bearing Inner Race
- Pressing on for transmission without polygon bearing using 40-21 sleeve
9. Drive Gear For Vehicle Speed Sensor (VSS)
- Removing and installing, Refer to Manual Transmission/Transaxle, Sensors and Switches - M/T, Service and Repair.
- Carefully install onto differential without canting. Do not use force: the drive gear can break easily.
10. Left Tapered Roller Bearing Outer Race (1)
- Left and right tapered roller bearings are identical (not for transmission without polygon bearing).
- Driving out, Fig. 8 Driving Out Left Bearing Outer Race From Cover
- Driving in for transmission with polygon bearing, Fig. 9 Driving In Left Bearing Outer Race Into Cover
- Driving in for transmission without polygon bearing using VW295 needle bearing drift and 51 1205 thrust pad
11. Adjustment - Shim S1
- Note thickness
12. Final Drive Cover (1)
- Coat sealing surfaces with a thin layer of sealant AMV 188 00102.
13. Large Differential Bevel Gear
- Installing, Fig. 12 Installing Differential Bevel Gears
14. Differential Bevel Gear Shaft
- Drive out using drift after removing roll pin
15. Roll Pin
- For securing differential bevel gear shaft
- Version with annular groove: Removing and installing Fig. 13 Removing and Installing Roll Pin
- Version without annular groove: drive out using drift
16. Small Differential Bevel Gear
- Installing, Fig. 12 Installing Differential Bevel Gears
17. Thrust Washer Assembly
- Lubricate with transmission fluid before installing