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A/T Differential

A/T Differential

A/T Differential Component Location Index 4WD:




A/T Differential Component Location Index 2WD:





Backlash Inspection

NOTE: The illustration shows the 4WD transmission; the 2WD transmission is similar.

1. Install the drive shaft and intermediate shaft into the differential assembly.
2. Secure the driveshaft (A) in a bench vise (B) with soft jaws (C). To prevent damage to the driveshaft, always use soft jaws or equivalent material between the driveshaft and the vise.





3. Place the intermediate shaft (D) on a V-block (E), then fix the intermediate shaft using a grip (F) or equivalent.
4. Measure the backlash of the final driven gear (G) with a dial indicator (H).

Standard: 1.1 - 1.6 mm (0.04 - 0.06 in.)

5. If the backlash is out of standard, replace the differential carrier; 4WD, 2WD.

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 a 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 transmission; the 2WD transmission is similar.

1. 4WD: Remove the final driven gear and transfer drive gear.
2WD: 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 40 x 50 mm attachment 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 and transfer drive gear on the differential carrier in the direction shown.
3. Tighten the bolts to the specified torque in a crisscross pattern in two or more steps.

Differential Carrier and Final Driven Gear Replacement

2WD
1. Remove the final driven gear (A) from the differential carrier (B).

NOTE: The final driven gear bolts have left-hand threads.





2. Install the final driven gear on the differential carrier in the direction shown.
3. Tighten the bolts to the specified torque in a crisscross pattern in two or more steps.

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 transmission; the 2WD transmission 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 oil seal driver and attachment.





4. Install the new oil seal (A) in the torque converter housing with the oil seal driver and attachment.





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 transmission; the 2WD transmission 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 more than 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. Install the bearing outer race securely in the torque converter housing with the driver and 78 x 90 mm attachment.





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).

NOTE: Install the 76.2 mm thrust washer with the "41382RKY" mark facing downward.





6. With the driver and 72 x 75 mm attachment, install the bearing outer race 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 transmission; the 2WD transmission 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 more than 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.

NOTE: Install the 76.2 mm thrust washer with the "41382RKY" mark facing downward.

4. With the driver and 72 x 75 mm attachment, install the bearing outer race 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).





6. Install the three dowel pins (C) and a new gasket (D) on the torque converter housing.
7. Align the spring pin (E) of the control shaft (F) with the transmission housing groove (G) by turning the control shaft. Do not squeeze the end of the control shaft tips together when turning the shaft.
8. Place the transmission housing (H) on the torque converter housing.
9. Install the transmission housing mounting bolts (20 bolts) along with the transmission hanger (I) and harness clamp brackets (J). Tighten the mounting bolts to 44 N-m (4.5 kgf-m, 33 lbf-ft) in two or more steps in a crisscross pattern.
10. Rotate the differential assembly in both directions to seat the bearings.
11. Measure the starting torque of the differential assembly with the preload inspection tool, a torque wrench (A), and a socket (B). Measure the starting torque at normal room temperature in both directions.





12. 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 N-m (3 - 4 kgf-cm, 2.7 - 3.5 lbf-in.).

THRUST SHIM, 76 mm (Part 1):




THRUST SHIM, 76 mm (Part 2):




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