Overhaul (Differential)
A/T DifferentialA/T Differential 4WD Model:
A/T Differential 2WD Model:
Backlash Inspection
NOTE: The illustration shows 4WD model; 2WD model is similar.
1. Install the driveshaft and intermediate shaft on the differential, then place the axles on V-blocks.
2. Check the backlash of the pinion gears (A) with a dial indicator (B).
Standard: 0.05 - 0.15 mm (0.002 - 0.006 inch)
3. If the backlash is out of standard, replace the differential carrier.
Carrier Bearing Replacement
Special Tools Required
^ Attachment, 40 x 50 mm 07LAD-PW50601
NOTE:
^ The bearing and bearing outer race should be replaced as a set.
^ Inspect and adjust the carrier bearing preload whenever bearing is replaced.
^ Check the bearing for wear and rough rotation. If the bearing is OK, removal is not necessary.
^ The illustration shows 4WD model; 2WD model is similar.
1. Remove the carrier bearing (A) with a commercially available puller (B), bearing separator (C), and stepper adapter (D).
2. Install the new bearings with the special tool and a press. Press the bearing on securely so there is no clearance between the bearing and the differential carrier.
Differential Carrier, Final Driven Gear, and Transfer Drive Gear Replacement
4WD Model
1. Remove the final driven gear (A) and transfer drive gear (B) from the differential carrier (C).
NOTE: The final driven gear bolts have left-hand threads.
2. Install the final driven gear with the chamfered side on the inner bore facing the differential carrier.
3. Tighten the bolts to the specified torque in a crisscross pattern.
Differential Carrier, Final Driven Gear Replacement
2WD Model
1. Remove the final driven gear (A) from the differential carrier (B).
NOTE: Differential carrier bolts have left-hand threads.
2. Install the final driven gear in the direction shown on the differential carrier.
3. Tighten the bolts to the specified torque in a crisscross pattern.
Oil Seal Replacement
Special Tools Required
^ Driver 07749-0010000
^ Oil seal driver attachment 07947-SD90101
^ Oil seal driver attachment 07JAD-PH80101
NOTE: The illustration shows 4WD model; 2WD model is similar.
1. Remove the oil seal from the transmission housing.
2. Remove the oil seal from the torque converter housing.
3. Install the new oil seal (A) in the transmission housing with the special tools.
4. Install the new oil seal (A) in the torque converter housing with the special tools.
Carrier Bearing Outer Race Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 78 x 90 mm 07GAD-SD40101
^ Attachment, 72 x 75 mm 07746-0010600
NOTE:
^ The bearing and bearing outer race should be replaced as a set.
^ Replace the bearing with a new one whenever the outer race is replaced.
^ Do not use the thrust shim on the torque converter housing.
^ Adjust bearing preload after replacing the bearing and outer race.
^ Coat all parts with ATF during installation.
^ The illustration shows 4WD model; 2WD model is similar.
1. Remove the bearing outer race (A), 76.2 mm thrust washer (B), and 76 mm thrust shim (C) from the transmission housing (D) by heating the housing to about 212°F (100°C) with heat gun (E). Do not heat the housing in excess of 212°F (100°C).
NOTE: Let the transmission housing cool to room temperature before installing the bearing outer race.
2. Remove the bearing outer race (A) and 80 mm thrust washer (B) from the torque converter housing (C).
3. Install the 80 mm thrust washer and the new bearing outer race in the torque converter housing.
4. Drive the bearing outer race securely in the housing with the special tools.
5. Install the 76 mm thrust shim (A) 76.2 mm thrust washer (B), and the new bearing outer race (C) in the transmission housing (D).
6. With the special tools, drive the bearing outer race in securely so there is no clearance between the outer race, thrust washer, shim, and-housing.
Carrier Bearing Preload Inspection
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 72 x 75 mm 07746-0010600 Preload inspection tool 07HAJ-PK40201
NOTE: If the transmission housing, torque converter housing, differential carrier, carrier bearing and outer race, or thrust shim were replaced, the bearing preload must be adjusted. Coat all parts with ATF during installation. Do not use the thrust shim in the torque converter housing. The illustration shows 4WD model; 2WD model is similar.
1. Remove the bearing outer race (A), 76.2 mm thrust washer (B), and 76 mm thrust shim (C) from the transmission housing (D) by heating the housing to about 212°F (100°C) with heat gun (E). Do not heat the housing in excess of 212°F (100°C).
NOTE: Let the transmission housing cool to room temperature before adjusting the bearing preload.
2. Install the 76 mm thrust shim (A) in the transmission housing (B). If you replace the 76 mm thrust shim with a new one, use the same thickness shim as the old one.
3. Install the 76.2 mm thrust washer (C) and the bearing outer race (D) in the transmission housing.
4. With the special tools, drive the bearing outer race in securely so there is no clearance between the outer race, thrust washer, shim, and housing.
5. Install the differential assembly (A) in the torque converter housing (B), and install the gasket (C) and dowel pins (D) on the housing.
6. Install the transmission housing (E) with the transmission hanger (F) and harness clamp brackets (G), then tighten the bolts.
7. Rotate the differential assembly in both directions to seat the bearings. rings.
8. Measure the starting torque of the differential assembly with the special tool, a torque wrench (A), and a socket (B). Measure the starting torque at normal room temperature in both directions.
9. If the measurement is out of standard, remove the thrust shim and select the thrust shim from table. Install the new thrust shim and recheck. To increase the starting torque, increase the thickness of the thrust shim. To decrease the starting torque, decrease the thickness of the shim. Changing the thickness of shim by 0.05 mm will increase or decrease starting torque about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.7 - 3.5 inch lbs.)
