RING GEAR AND DIFFERENTIAL ASSEMBLY [FW6A-EL/FW6AX-EL]

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Structural View

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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
12 bolts (M13×1.0 bolt, length to approx. 26.2 mm {1.03 in})
10
Taper roller bearing (converter housing side)
(inner diameter approx. 45 mm {1.8 in})
11
Taper roller bearing (transaxle case side)
(inner diameter approx. 45 mm {1.8 in})


Assembly Procedure

1.  Assemble the thrust washers to the side gears.

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

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3.  Assemble the thrust washers to the pinion gears.

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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.
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(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 side gears combination, and reassemble.
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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.
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6.  Assemble a new roll pin to the position shown in the figure using a pin punch.

Caution
•  Assemble so that the end gap of the roll pin is positioned in the direction shown in the figure.
Note
•  Use a pin punch with an end outer diameter of 5 mm {0.197 in} or more, and within 8 mm {0.314 in}.
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A  :–0.5—0.5 mm {–0.01—0.01 in}

7.  Assemble the ring gear using the following procedure:

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1
Ring gear
2
12 bolts (M13×1.0 bolt, length to approx. 26.2 mm {1.03 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.
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(2)  Assemble and temporarily tighten the bolts to the positions shown in the figure.
Note
•  Bolt size: M13×1.0 bolt, length to approx. 26.2 mm {1.03 in}
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(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.
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A  :Vise
(4)  Tighten the bolts 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.
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Tightening torque
152—176 N·m {16—17 kgf·m, 113—129 ft·lbf}
(5)  Remove the ring gear and differential from the vise.
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A  :Vise

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

Note
•  Taper roller bearing size: Inner diameter approx. 45 mm {1.8 in} (2WD)
•  Taper roller bearing size: Inner diameter approx. 55 mm {2.2 in} (4WD)
(1)  Apply ATF (ATF FZ) to the engagement area of the taper roller bearing and differential.
(2)  Using the SST and press, assemble the taper roller bearing.
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A  :Press

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

Note
•  Taper roller bearing size: Inner diameter approx. 45 mm {1.8 in}
(1)  Apply ATF (ATF FZ) to the engagement area of the taper roller bearing and differential.
(2)  Using the SST and press, assemble the taper roller bearing.
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A  :Press

10.  Perform the differential backlash measurement/adjustment. (See DIFFERENTIAL BACKLASH MEASUREMENT/ADJUSTMENT [FW6A-EL/FW6AX-EL].)