Rear Differential Disassembly And Reassembly (KX Models 4WD)
Rear Differential Disassembly and Reassembly (KX Models 4WD)
View
1. Rear Differential Exploded View (Dual Pump System)
Exploded View
Disassembly
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Oil Filler Plug And Drain Plug (Dual Pump System)
1. Remove the drain plug (A) and the oil filler plug (B) with sealing washers (C).
2. Rear Differential Companion Flange (Dual Pump System)
1. Pry up the stake on the locknut (A) from the groove of the clutch guide, making sure the tab completely clears the groove to prevent damaging the clutch guide.
2. Install the companion flange holder (A) and holder handle (B) on the companion flange.
3. Loosen the locknut (A) counterclockwise so its tab (B) comes out from the groove (C) in the clutch guide.
4. Tighten the locknut (A) until its tab (B) aligns with the groove (C).
5. Clean any dirt from inside the groove in the clutch guide, then loosen the locknut.
6. Remove the locknut (A), the spring washer (B), the back-up ring (C), the O-ring (D), and the companion flange (E).
3. Torque Control Differential Case
1. Remove the eight mounting bolts (A) in a crisscross pattern in several steps.
2. Remove the torque control differential (TCD) case (B) and the 6 x 10 mm dowel pins (C).
4. Rear Differential Clutch Assembly
1. Remove the 30 mm shim (A) and the differential clutch assembly (B).
2. Remove the six steel balls (A), the base cam (B).
NOTE: Do not lose the steel balls.
3. Remove the thrust needle bearings (C), and the pressure plate (D).
4. Remove the oil pump driveshaft (A).
5. Oil Pump Body Assembly
1. Remove the three mounting bolts (A) and the oil pump body assembly (B).
2. Remove the oil pump pin (C), the 8 x 10 mm dowel pins (D), the magnet (E), and the fluid strainer (F).
Reassembly
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Oil Pump Body Assembly
1. Apply Dual Pump Fluid II to the rubber pinion of the fluid strainer (A), then install the fluid strainer.
2. Install the magnet (B), the 8 x 10 mm dowel pins (C), and the oil pump pin (D) in the differential carrier assembly.
3. Align the grooves (A) of the rear oil pump with the oil pump pins (B), then install the oil pump body assembly (C) on the differential carrier assembly.
4. Tighten the oil pump body assembly with the three mounting bolts (A).
5. Install the oil pump driveshaft (B) by aligning the projection (C) of the oil pump driveshaft with the groove of the front oil pump in the oil pump body assembly.
6. Install the thrust needle bearing (D).
2. Rear Differential Clutch Assembly
1. Install the six steel balls (A), the base cam (B), the thrust needle bearing (C), and the pressure plate (D) on the differential clutch assembly (E).
NOTE: Align the tabs (F) of the pressure plate with the grooves (G) of the differential clutch assembly.
2. Make a mark (A) on the outside of the differential clutch assembly (B) that corresponds to the position of the tab (C) of the pressure plate (D) as shown.
3. Make a mark (E) on the outside of the oil pump body assembly (F) that corresponds to the position of the groove (G) in the oil pump driveshaft (H) as shown.
4. Support the pressure plate and the differential clutch assembly by hand so that they do not misalign. With the marks aligned, install the differential clutch assembly to the oil pump body assembly.
5. Install the 30 mm shim (I).
6. Make sure that the differential clutch assembly and the pressure plate are correctly installed.
7. If the differential clutch assembly can be pushed down as in the figure, proceed to next procedure. If not, return to step 1.
NOTE: If incorrectly installed, the differential clutch assembly may be damaged when excessive force is applied.
3. Torque Control Differential Case
1. Remove the dirt and oil from the sealing surfaces.
2. Apply liquid gasket (P/N 08718-0004 or 08718-0009) evenly to the sealing surface.
3. Install the component within 5 minutes of applying the liquid gasket. Make sure you seal the entire circumference of the bolt holes to prevent fluid leakage.
NOTE:
* If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
* Allow it to cure at least 30 minutes after assembly before filling the differential with the recommended fluid.
4. Install the 6 x 10 mm dowel pins (A) and the torque control differential (TCD) case (B).
NOTE: Be careful not to damage the lip of the oil seal (C) when installing the torque control differential (TCD) case on the differential carrier case. If the oil seal is damaged, replace it.
5. Torque the eight mounting bolts in a crisscross pattern in several steps.
4. Rear Differential Companion Flange (Dual Pump System)
1. Install the companion flange (A) to the shaft of the clutch guide.
2. Apply Dual Pump Fluid II to a new O-ring (B).
3. Install the O-ring, a new back-up ring (C), the spring washer (D), and a new locknut (E).
4. Install the companion flange holder (A) and holder handle (B) on the companion flange.
5. Tighten the locknut to the specified torque.
6. Stake the locknut tab (A) into the groove in the clutch guide.
5. Oil Filler Plug And Drain Plug (Dual Pump System)
1. Install the drain plug (A) and the oil filler plug (B) with new sealing washers (C).