Reassembly

U151F AUTOMATIC TRANSAXLE: DIFFERENTIAL CASE: REASSEMBLY

REASSEMBLY

1. INSTALL NO. 2 DIFFERENTIAL CASE SUB-ASSEMBLY





(a) Coat the front No. 1 differential side gear thrust washer, front differential planetary ring gear, front No. 2 differential pinion, front No. 2 differential pinion thrust washer, front differential pinion shaft holder, front differential pinion shaft, and 2 differential pinion shafts with ATF, and install them to the No. 2 differential case.





(b) Using a pin punch and a hammer, install the 3 straight pins.





(c) Using a snap ring expander, install the pinion shaft spacer snap ring.
2. INSPECT FRONT DIFFERENTIAL Differential Case
3. INSTALL CENTER DIFFERENTIAL PLANETARY GEAR ASSEMBLY





(a) Install the center differential side gear, conical spring washer, and No. 2 center differential side gear thrust washer RH from the differential case RH.
HINT: Ensure that the conical washers are installed correctly.





(b) Hold the differential case RH in a vice. Install the center differential pinion and pinion thrust washer to the differential spider and install them to the differential case RH.
NOTICE:
When holding the differential case RH in a vise, be sure to place aluminum plates between them and use a minimum force.





(c) Pressing and holding the differential spider toward the differential case RH, measure the pinion's backlash with a dial indicator as illustrated.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.










(d) Temporarily install the No. 2 differential side gear thrust washer LH, center differential side gear conical spring washer, and No. 2 differential case to the differential case LH.
HINT: Ensure that the conical washers are installed correctly.





(e) Install the differential intermediate case to the differential case and secure the assembled parts with the 4 bolts.





(f) Remove the differential spider, 5 center differential pinions, and 5 center differential pinion thrust washers from the differential case RH. Put them in the differential intermediate case and secure the case.





(g) Pressing and holding the differential spider toward the differential intermediate case, measure the pinion's backlash with a dial indicator.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.










(h) Remove the 4 bolts and disconnect the differential case LH from the differential intermediate case.





(i) Remove the No. 2 differential case from the differential case LH.





(j) Install the selected No. 2 differential side gear thrust washer LH and center differential planetary gear to the differential case LH.





(k) Install the No. 2 differential case to the differential case LH again.





(l) Install the adjusted differential case RH to the intermediate case and tighten the 15 bolts using a "TORX" socket wrench (T50).
Torque: 63 Nm (642 kgf-cm, 46ft-lbf)
NOTICE:
Align the matchmarks.

4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING





(a) Using SST and a press, install the front differential case tapered roller bearing FR to the differential case.
SST: 09950-70010
09951-07100
SST: 09649-17010
NOTICE:
Do not damage the bearing cage while installing the bearing inner race.





(b) Using SST, install the outer race of the tapered roller bearing FR.
SST: 09527-17011
SST: 09950-60020
09951-01030
- Clearance is not allowed between the plate washer and transaxle housing.
- When replacing the bearing, be sure to replace both outer and inner races.
- When replacing the bearing, be sure to replace both left and right bearings as a set.

5. INSTALL FRONT DIFFERENTIAL SIDE GEAR





(a) Using SST and a press, install the front differential case tapered roller bearing RR to the differential case.
SST: 09316-20011
SST: 09214-76011
NOTICE:
Do not damage the bearing cage while installing the bearing inner race.

(b) Install the front differential case shim RR to the transaxle case.
If the bearing is new, select a front differential case shim RR of proper thickness starting from the thinner ones. If the bearing is reused, select a front differential case shim RR starting from the same thickness as the one installed before disassembly.





(c) Using SST, install the outer race of the front differential case tapered roller bearing RR.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07100
NOTICE:
Clearance is not allowed between the differential case shim and transaxle case.

6. ADJUST TAPERED ROLLER BEARING PRELOAD Differential Case
7. INSTALL FRONT DIFFERENTIAL RING GEAR





(a) Using ATF and heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).
NOTICE:
Do not heat the ring gear to more than 110°C (230.0°F).

(b) Clean the contact surface of the front differential case.





(c) Align the matchmarks and install the front differential ring gear case quickly.
- Do not install the bolts while the ring gear is hot.
- Check the number and position of the gear teeth.





(d) Temporarily install the 8 bolts as shown in the illustration.





(e) Remove the 4 bolts shown in the illustration.
(f) Temporarily install the remaining 8 set bolts.
(g) Fully tighten the set bolts.
Torque: 95 Nm (970 kgf-cm, 70ft-lbf)
NOTICE:
Tighten the bolts a little at a time in a diagonal pattern.

8. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL





(a) Using SST and a hammer, install a new oil seal.
SST: 09223-15020
SST: 09950-70010
09951-07100
Standard installation depth:
5.5 to 0.2 mm (-0.020 to 0.008 in.)
(b) Coat the lip of oil seal with a little MP grease.
9. INSTALL TRANSAXLE HOUSING OIL SEAL





(a) Wrap vinyl tape around SST at the place 6.0 mm (0.236 in.) above the bottom end until the thickness of the wrapped tape is approximately 5.0 mm (0.197 in.).
SST: 09950-60020
09951-00730
NOTICE:
Remove foreign matter such as grease on the SST before winding the tape.

(b) Coat the lip of oil seal with a little MP grease.





(c) Using SST, install a new oil seal.
SST: 09950-60020
09951-00730
SST: 09950-70010
09951-07150
Standard installation depth:
5.5 to 6.5 mm (0.217 to 0.256 in.)
NOTICE:
Stop pressing when the wrapped vinyl tape contacts the transaxle housing.