Differential Case

DIFFERENTIAL CASE





COMPONENTS


DISASSEMBLY





1. REMOVE SIDE BEARING FROM DIFFERENTIAL CASE
a. Using Special Service Tool (SST), remove the bearings from both sides of the case.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)
b. Remove the speedometer drive gear from the RH side.





2. REMOVE RING GEAR
a. Place matchmarks on the ring gear and case.
b. Remove the 6 bolts.
c. Using a plastic hammer, remove the ring gear from the case.





3. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the case.

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

If the backlash is not within the specification, install the correct thrust washer to the side gears.





4. DISASSEMBLE DIFFERENTIAL CASE
a. Using a pin punch and hammer, remove the pinion shaft straight pin.
b. Remove the pinion shaft from the case.
c. Remove the 2 pinion gears and side gears with the 4 thrust washers from each gear.
5. Transmission Case Side: IF NECESSARY, REPLACE OIL SEAL AND SIDE BEARING OUTER RACE
a. Using a screwdriver and hammer, remove the oil seal.





b. Using SST, remove the outer race and plate washer.
SST 09612-65014
c. Place the plate washer into the case.





d. Using SST and a hammer, install a new outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)





e. Using SST and a hammer, install a new oil seal.
SST 09350-32014 (09351-32111, 09351-32130)

Drive in depth: 2.4 ± 0.3 mm (0.094 ± 0.012 inch)

f. Coat the lip of the oil seal with Multipurpose (MP) grease.
6. Transaxle e Case Side: IF NECESSARY, REPLACE OIL SEAL AND SIDE BEARING OUTER RACE
a. Using a screwdriver and hammer, remove the oil seal.





b. Using SST, remove the outer race and plate washer.
SST 09612-65014
c. Place the plate washer into the case.





d. Using SST and a hammer, install a new outer race.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)





e. Using SST and a hammer, install a new oil seal.
SST 09350-32014 (09351-32130, 09351-32150)

Drive in depth: 1.9 ± 0.3 mm (0.075 ± 0.012 inch)

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


REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE





a. Install the correct thrust washers and side gears.





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

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

b. Install the thrust washers and side gears in the differential case.
c. Install the pinion shaft.





d. Using a dial indicator, check the side gear backlash.
Measure the side gear backlash while holding one pinion gear toward the case.

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

If the backlash is not within the specification, install a thrust washer of different thickness.
e. Using a pin punch and hammer, install the straight pin through the case and hole in the pinion shaft.
f. Stake the differential case.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surface of the differential case.
b. Heat the ring gear in boiling water.
c. Carefully take the ring gear out of the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





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

e. Install the 6 set bolts. Tighten each set bolt uniformly, at a time in succession. Torque the bolts.

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





3. INSTALL SIDE BEARING
a. Install the speedometer drive gear to the RH side.
b. Using Special Service Tool (SST) and a press, install new side bearings to the both sides of the case.
SST 09350-32014 (09351-32090, 09351-32120)
4. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD





a. Install the differential case assembly to the transaxle case.
b. Install the transmission case.
c. Install and torque the case bolts.

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





d. Using SST and a torque wrench, measure the preload.
SST 09564-32011

Preload (at starting):
New bearing 0.8 - 1.6 Nm (8 - 16 kgf-cm, 6.9 - 13.9 inch lbs.)
Reused bearing 0.5 - 1.0 Nm (5 - 10 kgf-cm, 4.3 - 8.7 inch lbs.)

If the preload is not within the specification, remove the transmission case side outer race of the side bearing with SST. Select another shim.





HINT: The preload will change by approximately 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.6 - 3.5 inch lbs.) corresponding to a change of 0.05 mm in shim thickness.