Differential: Service and Repair

COMPONENTS

DISASSEMBLY OF DIFFERENTIAL
1. REMOVE RING GEAR




a. Place the matchmarks on the ring gear and differential case.




b. Loosen the staked part of the locking plate.




c. Remove the eight bolts and four locking plates.




d. Using a plastic hammer, tap on the ring gear to remove it from the case.

2. REMOVE SIDE BEARINGS FROM DIFFERENTIAL CASE




a. Setting SST to the cut-out portion on the speedometer drive gear, remove the bearing from the differential case.

SST 09502 - 10012

b. Remove the speedometer drive gear.




c. Setting SST to the cut-out portion on the differential case, remove the bearing.

SST 09502 - 10012

3. DISASSEMBLY DIFFERENTIAL CASE




a. Drive out the pinion shaft lock pin from the ring gear side.




b. Remove the pinion shaft from the case.




c. Remove the two pinions, two side gears and four thrust washers.




4. REMOVE OIL SEAL OF TRANSAXLE HOUSING
Using a screwdriver, remove the oil seal.




5. REMOVE SIDE BEARING OUTER RACE OF TRANSAXLE HOUSING
Using SST and a hammer, drive out the outer race and shim.

SST 09350 - 32014 (09351 - 32090)




6. REMOVE OIL SEAL OF TRANSAXLE CASE
Using a screwdriver, remove the oil seal.




7. REMOVE SIDE BEARING OUTER RACE OF TRANSAXLE CASE
Using SST and a hammer, drive out the outer race and adjusting shim.

SST 09350 - 32014 (09351 - 32130, 09351 - 32150)

ASSEMBLY OF DIFFERENTIAL




1. INSTALL SIDE BEARING OUTER RACE OF TRANSAXLE HOUSING
a. Place the shim onto the transaxle housing.
b. Using SST and press, press a new outer race into the transaxle housing.

SST 09350 - 32014 (09351 - 32111, 09351 - 32130)




2. INSTALL SIDE BEARING OUTER RACE OF TRANSAXLE CASE
a. Place the adjusting shim onto the transaxle case.
b. Using SST and press, press a new outer race into the transaxle case.

SST 09350 - 32014 (09351 - 32111, 09351 - 32130)

3. ASSEMBLY DIFFERENTIAL CASE




a. Install the thrust washers to the side gears.




b. Install the side gears with thrust washers, pinion gears pinion thrust washers into the differential case.




c. Install the pinion shaft so as to align the lock pin holes on the pinion shaft and differential case.




4. CHECK SIDE GEAR BACKLASH
a. Measure the side gear backlash while holding one pinion gear toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)

If the backlash is out of specification, install the correct thrust washer to the side gear.




b. Referring to the table, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size of both sides.

If the backlash is not within specification, install a thrust washer of a different thickness.

5. INSTALL LOCK PIN




a. Using a hammer and punch, drive the lock pin through the case and hole in the pinion shaft.




b. Stake the differential case.

6. INSTALL SIDE BEARINGS TO DIFFERENTIAL CASE




a. Using SST and press, press the side bearing into the differential case.

SST 09710 - 30030 (09710 - 03160)




b. Install the speedometer drive gear to the differential case.




c. Using SST and press, press the side bearing into the differential case.

SST 09350 - 32014 (09351 - 32090, 09351 - 32120)

7. ADJUST SIDE BEARING PRELOAD




a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transmission case.




b. Install the differential to the transaxle case.




c. Install the transaxle housing to the transaxle case.
d. Install and tighten the bolts.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)

HINT: Each bolt length (mm) is indicated in the illustration.

e. Using SST, rotate the differential in both directions to snug the bearing down.

SST 09563 - 32011




f. Using SST and a torque meter, measure the preload of the side bearing.

SST 09564 - 32011

Preload (at starting):
New bearing 0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in.lbf)
Used bearing 0.4 - 0.7 N.m (4 - 7 kgf.cm, 3.5 - 6.1 in.lbf)




If the preload is not within specification, remove the differential from the transaxle case. Re-select the transaxle case side adjusting shim.

HINT: The preload will change about 0.3 - 0.4 N.m (3 - 4 kgf.cm, 2.6 - 2.9 in.lbf) with each shim thickness.




g. Remove the bolts and transaxle housing.




h. Remove the differential from the transaxle case.

8. INSTALL RING GEAR TO DIFFERENTIAL




a. Clean the contact surface of the differential case.
b. Heat the ring gear in boiling water.
c. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.




d. Install new locking bolts uniformly and a little at a time. Torque the bolts.

Torque: 97 N.m (985 kgf.cm, 71 ft.lbf)




e. Using a hammer and drift punch, stake the locking plates.

HINT: Stake one claw with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake only the half on the tightened side.




9. INSTALL OIL SEAL OF TRANSAXLE CASE
a. Using SST and a hammer, drive in a new oil seal.

SST 09350 - 32014 (09351 - 32111, 09351 - 32130)

b. Coat the lip of the oil seal with MP grease.




10. INSTALL OIL SEAL OF TRANSAXLE HOUSING
a. Using SST and a hammer, drive in a new oil seal.

SST 09350 - 32014 (09351 - 32130, 09351 - 32150)

b. Coat the lip of oil seal with MP grease.