Differential Case

DISASSEMBLY





1. Vehicle Speed Sensor Drive Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE
a. Using SST, remove the bearing from the drive gear side of the case.
SST 09950-00020, 09950-00030
b. Remove the vehicle speed sensor drive gear.
2. REMOVE RING GEAR
a. Place matchmarks on the ring gear and case.
b. Remove the 8 bolts.
c. Using a copper hammer, tap on the ring gear to remove it from the case.





3. Ring Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE
Using SST, remove the bearing from the ring gear side of the case.
SST 09950-00020, 09950-00030





4. 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.
5. DISASSEMBLE DIFFERENTIAL CASE
a. Using a pin punch and hammer, drive out the straight pin.
b. Remove the pinion shaft from the case.
c. Remove the 2 pinions and side gears with the 4 thrust washers from each gear.
6. Transaxle Case Side: IF NECESSARY, REPLACE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL





a. Using SST and a hammer, drive out the oil seal from the retainer.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)





b. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface.
SST 09350-32014 (09351-32130, 09351-32150)
c. Coat the lip of the oil seal with MP grease.





7. Transmission Case Side: IF NECESSARY, REPLACE SIDE OIL SEAL
a. Using a screwdriver and hammer, drive out the oil seal.
b. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface.
SST 09350-32014 (09351-32130, 09351-32150)
c. Coat the lip of the oil seal with MP grease.
8. Transaxle Case Side: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE





a. Using a brass bar and hammer, drive out the bearing outer race.
b. Install the bearing retainer without an O-ring.
c. Install and torque the 6 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





d. Place the thinnest shim into the case.
e. Using SST and a press, install a new bearing outer race.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
f. Remove the 6 bolts.
g. Remove the bearing retainer and shim.





9. Transaxle Case Side: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE
a. Using a brass bar and hammer, drive out the bearing outer race and shim.
b. Place the shim into the case.
c. Using SST and a press, install a new bearing outer race.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)

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





c. Inspect the side gear backlash.
Using a dial indicator, 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.
d. Using a pin punch and hammer, drive in the straight pin through the case and hole in the pinion shaft.
e. Stake the differential case.





2. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surface of the differential case and the threads of the ring gear and differential case.
b. Heat the ring gear in boiling water.
c. Carefully take the ring gear out of the water.
d. After 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 the ring gear.

e. Temporarily install the 8 bolts.

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

f. After the ring gear has cooled sufficiently, torque the ring gear set bolts.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)
3. INSTALL SIDE BEARING TO DIFFERENTIAL CASE





a. Using SST and a press, install a new side bearing to the transmission case side.
SST 09316-60011 (09316-00011), 09350-32014 (09351-32120)





b. Install the vehicle speed sensor drive gear to the transaxle case side.





c. Using SST and a press, install a new side bearing to the transaxle case side.
SST 09316-60011 (09316-00011), 09350-32014 (09351-32120)

NOTICE: Install the black cage bearing on the vehicle speed sensor drive gear side.

4. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD
a. Install the differential 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. Install the shim into the transmission case.
e. Install the bearing retainer without an O-ring.
f. Install and torque the 6 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





g. Using SST and a torque wrench, measure the preload.
SST 09564-32011
Preload (at starting): 0.8 - 1.6 Nm (8 - 16 kgf-cm, 6.9 - 13.9 inch lbs.)
If the preload is not within the specification, remove the transmission case side bearing retainer. Select another shim.





HINT: The preload will change about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.6 - 3.5 inch lbs.) with each 0.05 mm (0.0019 inch) change in shim thickness.

h. Remove the 6 bolts.
i. Remove the bearing retainer and shim.
j. Remove the 17 bolts.
k. Remove the transmission case.