Differential Case

DIFFERENTIAL CASE (2WD)





Components

Disassembly

NOTICE: When working with FIPG material, you must observe the following items.
- Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a non-residue solvent.
- Apply FIPG in an approx. 1 mm (0.04 inch) wide bead along the sealing surface.
- Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.





1. REMOVE TAPERED ROLLER BEARING
Using SST, remove the left and right bearings.
SST 09950-40010
2. REMOVE RING GEAR
a. Place matchmarks on both the differential case and ring gear.
b. Remove the 16 bolts.
c. Using a plastic hammer, tap the ring gear and remove it.
3. DISASSEMBLE DIFFERENTIAL CASE





a. Place matchmarks on the differential right and left cases.
b. Using a torx wrench J50), remove the 16 torx screws.
c. Using a plastic hammer, tap the differential left case.
d. Remove the vehicle speed sensor drive gear from the differential right case.





e. Remove the 2 differential side gears, side gear thrust washers, 4 differential pinions and pinion thrust washers from the differential left case.
4. TRANSMISSION CASE SIDE:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE
a. Using a screwdriver, remove the oil seal.
b. Remove the oil baffle.





c. Using a brass bar and hammer, drive out the bearing outer race lightly and evenly.
d. Remove the shim.
e. Install the shim.

HINT: First select and install a shim of lesser thickness than before.





f. Using SST and a press, install a new tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00041)





g. Install the oil baffle.

HINT: Install the oil baffle projection into the case side cutout.





h. Using SST and a hammer, drive in a new oil seal.
SST 09223-15020, 09950-70010 (09951-07150)
i. Coat the lip of oil seal with MP grease.
5. TRANSAXLE CASE SIDE:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE
a. Remove the 4 bolts and 3 nuts.





b. Using a plastic hammer, tap the stud bolt and remove the transaxle case cover.
c. Using a screwdriver and hammer, drive out the oil seal from the transaxle case cover.





d. Using SST, a brass bar and hammer, remove the tapered roller bearing outer race.
SST 09612-65014





e. Using SST and a press, install a new tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00041)





f. Using SST and a hammer, drive in a new oil seal.
SST 09316-60011(09316-00011)
g. Coat the oil seal lip with MP grease.





h. Apply FIPG to the transaxle case cover, as shown.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

i. Apply sealant to the bolt threads. Aft

Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

j. Install the stud bolt and cover to the transaxle case.
k. Install and torque the 4 bolts and 3 nuts.

Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

Reassembly

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. ASSEMBLE DIFFERENTIAL CASE





a. Install the thrust washer to the side gear.
b. Install the 4 pinions and thrust washers to the spider.
c. Install the side gear and spider with the 4 pinions to the differential left case.
d. Using a dial indicator, measure the backlash of the pinion gear while holding the differential left case.

Standard backlash: 0.05-0.20 mm (0.0020-0.0079 inch)

HINT: Push the pinion gear and spider with the 4 pinions to the differential left case.








e. Install the side gear and spider with the 4 pinions to the right side of the differential case. Check the side gear backlash.





f. Refer to the table, select the thrust washer which will ensure that the backlash is within the specification. Try to select a washer of the same size.





g. Install the vehicle speed sensor drive gear.





h. Align the matchmarks on the differential cases.
i. Using a plastic hammer, carefully tap the differential case to install it.
j. Using a torx wrench (T50), install and torque the 16 torx screws.

Torque: 63 Nm (640 kgf-cm, 46 ft. lbs.)

2. INSTALL RING GEAR
a. Clean the contact surface of the differential case and the threads of the ring gear and differential case.
b. Heat the ring gear to about 100°C (212°F) in boiling water.
c. Carefully take the ring gear out of the water.
d. Clean the contact surface of the ring gear with cleaning solvent.
e. Quickly install the ring gear on the differential case.

HINT: Align the matchmarks on the differential left case and contact the ring gear.





f. Temporarily install the 16 bolts.

NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.

g. After the ring gear has cooled sufficiently, torque the ring gear set bolts.

Torque: 124 Nm (1,260 kgf-cm, 91 ft. lbs.)





3. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto the differential case.
SST 09316-20011, 09316-60011 (09316-00011)

HINT: Press the bearing on the ring side first.

4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO TRANSAXLE CASE
6. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assembly.
7. INSTALL TRANSMISSION CASE
a. Install the transmission case.

HINT: If necessary, tap on the case with a plastic hammer.

b. Install and torque the 17 bolts.

Torque: 29 Nm (300 kgf-cm 22 ft. lbs.)

8. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
9. INSTALL SHIM

HINT: Install the previously selected shim.

10. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.

Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)

11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD
a. Install a new lock nut to the output shaft.





b. Turn the output shaft right and left 2 or 3 times to allow the bearings to settle.





c. Using a torque wrench, measure the preload.

Preload (at starting):
New bearing (Output shaft preload plus) 0.2 - 0.3 Nm (1.8 - 3.5 kgf-cm, 1.6 - 3.0 inch lbs.)
Reused bearing (Output shaft preload plus) 0.1 - 0.2 Nm (1.1 - 2.2 kgf-cm, 1.0 - 1.9 inch lbs.)

If the preload is not within the specification, select an appropriate adjusting shim.





HINT: The total preload will change by about 0.1 - 0.2 Nm (1 - 2 kgf-cm, 0.9 - 1.7 inch lbs.) with each 0.05 mm change in adjusting shim thickness.

12. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear bearing retainer.
13. REMOVE SHIM
14. REMOVE TRANSMISSION CASE
a. Remove the 17 bolts.
b. Using a plastic hammer, tap the transmission case.
15. REMOVE OUTPUT SHAFT ASSEMBLY
16. REMOVE DIFFERENTIAL CASE ASSEMBLY