RING GEAR AND DIFFERENTIAL ASSEMBLY

id051700664100


Structural view

bcw6ja00000032

1
Differential gear case
2
Thrust washer (selection)
3
Side gear
4
Thrust washer
5
Pinion gear
6
Pinion shaft
7
Roll pin
8
Ring gear
9
10 Bolts (M11 x 1.0 bolt, length approx. 24 mm {0.94 in})
10
Tapered roller bearing (converter housing side)
(inner diameter approx. 40 mm {1.6 in})
11
Tapered roller bearing (transaxle case side)
(inner diameter approx. 40 mm {1.6 in})


Assembly Procedure

1.  Assemble the thrust washers to the side gears.

azzjjw00001535
azzjjw00001536

2.  Assemble the side gears which have the thrust washers assembled to them.

bcw6ja00000153
bcw6ja00000277

3.  Assemble the thrust washers to the pinion gears.

azzjjw00001539
azzjjw00001540

4.  Assemble the pinion gears which have the thrust washers assembled to them using the following procedure:

(1)  Assemble the pinion gears which have the thrust washers assembled to them.
bcw6ja00000152
bcw6ja00000278
(2)  Rotate the pinion gears so that the pinion shaft holes of the differential gear case and the pinion gears are aligned as shown in the figure.
Note
•  If the pinion shaft holes of the differential gear case and the pinion gears are not aligned, remove the pinion gears, change the engagement with the side gears, and reassemble.
bcw6ja00000246

5.  Assemble the pinion shaft.

Caution
•  Assemble the pinion shaft so that the roll pin holes of the differential gear case and the pinion shaft are aligned.
bcw6ja00000150
bcw6ja00000247

6.  Assemble a new roll pin to the position shown in the figure using a pin punch.

Note
•  Use a pin punch with an end outer diameter of 5 mm {0.2 in} or more and less than 8 mm {0.3 in}.
bcw6ja00000034
bcw6ja00000035
A  :--1—0 mm {-0.03—0.00 in}

7.  Assemble the ring gear using the following procedure:

bcw6ja00000248

1
Ring gear
2
10 Bolts (M11 x 1.0 bolt, length approx. 24 mm {0.94 in})

(1)  Assemble the ring gear.
Note
•  Assemble the ring gear so that the differential holes and ring gear holes shown in the figure are aligned.
bcw6ja00000212
bcw6ja00000213
(2)  Assemble and temporarily tighten the bolts to the positions shown in the figure.
Note
•  Bolt size: M11 x 1.0 bolt, length approx. 24 mm {0.94 in}
bcw6ja00000214
(3)  Secure the ring gear and differential in a vise.
Caution
•  Insert a protective plate between the vise and the part so as not to damage the part.
azzjjw00001004
A  :Vise
(4)  Tighten the bolt shown in the figure.
Note
•  Change the vise securing position of the ring gear and differential and tighten all of the bolts shown in the figure.
bcw6ja00000249
Tightening torque
91—98 N·m {9.3—9.9 kgf·m, 68—72 ft·lbf}
(5)  Remove the ring gear and differential from the vise.
azzjjw00001006
A  :Vise

8.  Assemble the tapered roller bearing (converter housing side) using the following procedure:

Note
•  Tapered roller bearing size: Inner diameter approx. 40 mm {1.6 in}
(1)  Apply ATF (ATF FZ) to the engagement area of the tapered roller bearing and differential.
(2)  Using the SST and press, assemble the tapered roller bearing.
bcw6ja00000036
bcw6ja00001050
A  :Press

9.  Assemble the tapered roller bearing (transaxle case side) using the following procedure:

Note
•  Tapered roller bearing size: Inner diameter approx. 40 mm {1.6 in}
(1)  Apply ATF (ATF FZ) to the engagement area of the tapered roller bearing and differential.
(2)  Using the SST and press, assemble the tapered roller bearing.
bcw6ja00000038
bcw6ja00001147
A  :Press

10.  Perform the differential backlash measurement/adjustment. (See DIFFERENTIAL BACKLASH MEASUREMENT/ADJUSTMENT.)