Front Differential

OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR [41221 / 98-12]





a. Place the match-marks on the ring gear and differential case.





b. Remove the 10 bolts.





c. Using a plastic hammer, tap on the ring gear to remove it from the case.
2. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING [41311E / 98-14]





a. Using SST, remove the front differential case front tapered roller bearing from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00340)





b. Using SST, remove the front differential case front tapered roller bearing outer race and differential case washer.
SST 09387-00040 (09387-01030, 09387-01040, 09387-02010, 09387-02020)
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING [41311F / 8-14]





a. Using SST, remove the front differential case rear tapered roller bearing from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00340)





b. Using SST, remove the front differential case rear tapered roller bearing rear outer race and differential case washer.
SST 09387-00040 (09387-01030, 09387-01040, 09387-02010, 09387-02020)
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN [41342A / 98-14]





a. Using a punch and a hammer, loosen the staked part of the differential case.





b. Using a pin punch (5mm), drive out the p0in from the ring gear side.





5. REMOVE FRONT DIFFERENTIAL PINION SHAFT NO.1 [41342F / 98-12]
a. Remove the front differential pinion shaft No. 1 from the differential case.





6. REMOVE FRONT DIFFERENTIAL SIDE GEAR [41331F / 98-12]
a. Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears and 2 side gear thrust washers from the differential case.





7. REMOVE DIFFERENTIAL SIDE BEARING TRANSFER OIL SEAL [41141H / 98-12]
a. Place the transaxle case in vise.
b. Using SST, remove the oil seal.
SST 09308-00010





8. REMOVE TRANSAXLE HOUSING OIL SEAL [35111D / 98-12]
a. Place the transaxle housing in vise.
b. Using SST, remove the oil seal.
SST 09308-00010





9. INSTALL FRONT DIFFERENTIAL SIDE GEAR [41331F / 98-12]
a. Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.





10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1 [41342F / 98-12]
a. Coat the front differential pinion shaft No. 1 with ATF and install it to the differential case.





11. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Using a dial indicator, inspect the backlash of the side gear.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)





Thrust washer thickness

12. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN [41342A / 98-12]





a. Using a pin punch and hammer, install the pinion shaft straight pin.





b. Using a chisel and hammer, stake the differential case.
13. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING [41311F / 98-12]





a. Using SST and a press, install the front differential case tapered roller bearing rear inner race to the differential case.
SST 09608-06041





b. Using SST and a hammer, install the case washer and front differential case tapered roller bearing rear outer race to the transaxle case.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
14. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING [41311E / 98-12]





a. Using SST and a press, install the front differential case tapered roller bearing front inner race to the differential case.
SST 09608-06041





b. Using SST and a hammer, install the front differential case tapered roller bearing front outer race to the transaxle housing.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07100), 09950-60010 (09951-00340)
15. INSTALL FRONT DIFFERENTIAL RING GEAR [41221 / 98-12]





a. Using ATF and hear, hear the front differential ring gear to 90 - 110°C (194.0 - 230.0°F).
b. Clean the contact surface of the front differential case.





c. Set the match-marks, install the front differential ring gear case quickly.





d. Tighten the 10 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
16. INSPECT TAPERED ROLLER BEARING PRELOAD





a. Install the differential assy to the transaxle case. (b) Install the transaxle housing to the transaxle case.








c. Install the 16 bolts.
Torque:
Bolt A, B: 29.4 Nm (300 kgf-cm, 21.7 ft. lbs.)
Bolt C: 22.1 Nm (225 kgf-cm, 16.3 ft. lbs.)





d. Using SST, turn the differential assy.
SST 09564-32011





e. Using SST and torque wrench, measure the preload of the differential assy.
SST 09564-32011
Preload
New bearing: 0.20 - 0.69 Nm (2.0 - 7.0 kgf-cm, 1.8 - 6.1 inch lbs.)
Used bearing: 0.10 - 0.35 Nm (1.0 - 3.6 kgf-cm, 0.9 - 3.1 inch lbs.)





Adjusting shim thickness: mm (in.)





f. Remove the 16 bolts.
g. Using a practice hammer, remove the transaxle housing.





h. Remove the differential assy.





17. INSTALL TRANSAXLE HOUSING OIL SEAL [35111D / 98-12]
a. Using SST, drive into a new oil seal.
SST 09350-32014 (09351-32150), 09950-70010 (09951-07150)
b. Coat the rip of oil seal with a little MP grease.





18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL [41141H / 98-12]
a. Using SST, drive into a new oil seal.
SST 09350-32014 (09351-32150), 09950-70010 (09951-07150)
b. Coat the rip of the oil seal with a little MP grease.