(Differential)

A/T Differential

A/T Differential:

Backlash Inspection

NOTE: The illustration shows the 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 final driven gear.

Standard: 0.05-0.15 mm (0.002-0.006 in.)

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 the 4WD model; 2WD model is similar.

1. 4WD model: Remove the final driven gear and transfer drive gear.
2WD model: Remove the final driven gear.
2. Remove the carrier bearing (A) with a commercially available puller B, bearing separator (C), and stepper adapter (D).

3. 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
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 and Final Driven Gear Replacement

2WD
1. Remove the final driven gear from the differential carrier, and replace the differential carrier or final driven gear.
2. Install the final driven gear (A) in the direction shown on the differential carrier (B).

NOTE: Differential carrier bolts have left-hand threads.

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 the 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 the 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 the 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 and transmission housing.
-1 Install the differential assembly (A) in the toque converter housing (B), and install the three dowel pins (C) and a new gasket (D) on the torque converter housing.
-2 Place the transmission housing (E) on the torque converter housing.
-3 Install the transmission housing mounting bolts (20 bolts) along with the transmission hanger (F) and harness clamp brackets (G).
-4 Tighten the 20 bolts to 44 Nm (4.5 kgf-m, 33 lbf-ft) in two or more steps in a crisscross pattern.

6. Rotate the differential assembly in both directions to seat the bearings.
7. 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.

8. 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 lbf-in.).

Inspection
1. Set the dial indicator (A) on the companion flange (B).

2. Measure the transfer gear backlash.

Standard: 0.06-0.16 mm (0.02-0.06 in.)

3. Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

4. Rotate the companion flange several times to seat the tapered roller bearings.
5. Measure the starting torque at the companion flange (C) with a torque wrench (D) and a socket (E).

Standard: 2.75-4.22 Nm (28.1-43.1 kgf-cm, 24.4-37.4 lbf-in.)

6. Remove the transfer assembly from the vise.
7. Remove the transfer holder (A) from the transfer housing (B), then remove the O-ring (C) from the transfer holder.

8. Apply Prussian Blue to both side of the transfer drive gear teeth lightly and evenly.
9. Install the transfer holder, and tighten the bolts. Do not install the O-ring on the transfer holder.
10. Rotate the companion flange in both directions until the transfer gears rotate one full turn in both directions.
11. Remove the transfer holder, and check the transfer drive gear tooth contact pattern. The pattern should be centered on the gear teeth as shown.

12. If the measurements are out of standard or the tooth contact pattern are incorrect, disassemble the transfer assembly and repair.