Differential Case

DISASSEMBLY





1. 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.





2. Vehicle speed sensor drive gear side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE
a. Using SST, remove the side bearing.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)

HINT: Set the claw of SST to the bearing inner race at the position where the vehicle speed sensor drive gear is indented.

b. Remove the vehicle speed sensor drive gear.





3. Ring gear side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE
Using SST, remove the side bearing.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)

HINT: Set the claw of SST to the bearing inner race at the position where the differential case is indented.





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 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.
6. Transmission case side: IF NECESSARY, REPLACE OIL SEAL AND SIDE BEARING OUTER RACE
a. Using a screwdriver and hammer, drive out the oil seal.





b. Using SST, pull out the outer race and shim.
SST 09612-65014
c. Place the shim into the case.





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





e. Using SST and a hammer, drive in 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 MP grease.
7. Transaxle case side: IF NECESSARY, REPLACE OIL SEAL AND SIDE BEARING OUTER RACE
a. Using a screwdriver and hammer, drive out the oil seal.





b. Using SST, pull out the outer race and shim.
SST 09612-65014
c. Place the shim into the case.





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





e. Using SST and a hammer, drive in 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 to the side gears. Select thrust washers which will allow that the backlash is within the specification.
b. Install the side gears with washers, pinion gears and thrust washers 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, drive in the straight pin through the case and hole in the pinion shaft.
f. Stake the differential case.





2. Ring gear side: INSTALL SIDE BEARING
Using SST and a press, install a new side bearing.
SST 09550-10013 (09556-10011), 09950-70010 (09951-07100)
3. Vehicle speed sensor drive gear side: INSTALL SIDE BEARING





a. Install the vehicle speed sensor drive gear.





b. Using SST and a press, install a new side bearing.
SST 09550-10013 (09556-10011), 09950-60010 (09951-00460), 09950-70010 (09951-07150)





4. 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. Temporarily install the 8 set bolts.

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

f. After the ring gear has cooled sufficiently, torque the ring gear set bolts uniformly and a little at a time.
Torque: 77 Nm (785 kgf-cm, 57 ft. lbs.)
5. 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 about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.6 - 3.5 inch lbs.) with each 0.05 mm change in shim thickness.