Differential Case

DISASSEMBLY
1. REMOVE RING GEAR

a. Place matchmarks on the ring gear and differential case.
b. Remove the 8 bolts.
c. Using a copper hammer, tap out the ring gear.
2. Vehicle Speed Sensor Drive Gear Side: REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE

a. Using SST, remove the tapered roller bearing.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00350)

HINT: Set the claw of SST to the bearing inner race securely.

b. Remove the vehicle speed sensor drive gear.

3. Ring Gear Side: REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE
Using SST, remove the tapered roller bearing.
SST 09950-40011, 09950-0010 (09951-00350)

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

4. Only w/o LSD: INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the differential 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 a hammer, tap out the straight pin.
b. Remove the pinion shaft from the differential case.
c. Remove the 2 pinions and side gears with the 4 thrust washers from each gear.

REPLACEMENT
1. Transmission Case Side: REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE

a. Using SST, remove the tapered roller bearing outer race and shim.
SST 09612-65014

b. Using SST and a hammer, tap out the oil seal.
SST 09226-10010

c. Using SST and a hammer, tap in a new oil seal.
SST 09220-10010
Depth: 9.9 ± 0.3 mm (0.390 ± 0.012 inch)
d. Coat the lip of the oil seal with MP grease.
e. Place the shim into the differential case.

HINT: In case that the tapered roller bearing is new, install the shim by selecting among the thin ones. In case that the tapered roller bearing is a used one, its better to install the shim which has the same thickness before disassembling.

f. Using SST and a press, press in a new tapered roller bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)

NOTICE: When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it.

2. Transaxle Case Side: REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE

a. Using a screwdriver and a hammer, tap out the oil seal.

b. Using SST, remove the tapered roller bearing outer race and spacer.
SST 09612-65014
c. Place the spacer into the differential case.

d. Using SST and a press, press in a new tapered roller bearing outer race.
SST 09950-60020 (09951-00680), 09950-70010 (09951-7150)

NOTICE: When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it.

e. Using SST and a hammer, tap in a new oil seal.
SST 09710-28021 (09710-08041)
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 above, 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 toward the differential 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 a hammer, tap in the straight pin through the differential case and hole in the pinion shaft.
f. Using a chisel and a hammer, caulk the pin holes around the circumference of the differential case.

2. Ring Gear Side: INSTALL TAPERED ROLLER BEARING
Using SST and a press, press in a new tapered roller bearing.
SST 09350-32014 (09351-32120, 09351-32140)

NOTICE: When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it.

HINT: Set SST to the bearing inner race securely.
3. Vehicle Speed Sensor Drive Gear Side: INSTALL TAPERED ROLLER BEARING

a. Place the vehicle speed sensor drive gear in position to stop turning, and install the vehicle speed sensor drive gear.

NOTICE: Be sure to install the vehicle speed sensor drive gear in the correct direction, as shown in the illustration.

b. Using SST and a press, press in a new side bearing.
SST 09316-60011 (09316-00011), 09350-32014 (09351-32120)

NOTICE: When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it.

HINT: Set SST to the bearing inner race securely.

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.

CAUTION: 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 at a time.

Torque

5. INSPECT DIFFERENTIAL TAPERED ROLLER BEARING PRELOAD (IN CASE THAT w/o LSD)

NOTICE:
^ Perform this only when replacing the tapered roller bearing and outer race of the differential case.
^ The thickness of the shim installed on the transmission should be selected from the thin ones.

a. Install the differential case assembly to the transaxle case.

NOTICE: Place it gently to protect the diff side bearing from being damaged.

b. Install the transmission case to the transaxle case with the 16 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)

c. Using SST and a torque wrench, turn the differential case assembly right and left 2 or 3 times to allow the bearings to settle.
SST 09564-32011
d. Using SST and a torque wrench, measure the preload.
SST 09564-32011

Preload (at starting)

If the preload is not within the specification and when there is a clearance, remove the transmission case side outer race of the tapered roller bearing with SST, and select the thick shim. Then, exchange the shim and measure the preload again.

HINT: The preload will change by about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.6 - 3.5 inch lbs.) corresponding to a change of 0.05 mm (0.0020 inch) in shim thickness.

6. INSPECT DIFFERENTIAL TAPERED ROLLER BEARING PRELOAD (IN CASE THAT w/ LSD)

NOTICE:
^ Perform this only when replacing the tapered roller bearing and outer race of the differential case.
^ The thickness of the shim installed on the transmission should be selected from the thin ones.

a. Assemble the differential case assembly and output shaft assembly on the transaxle case, then on top of that, assemble the transmission case with the 16 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
b. Install the snap ring in the outer groove of the output shaft center bearing.

c. Using a socket wrench (27 mm) and a torque wrench, turn the output shaft right and left 2 or 3 times to allow the bearings to settle.
d. Using a socket wrench (27 mm) and a torque wrench, measure the preload.

HINT: The preload will change by about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.6 - 3.5 inch lbs.) corresponding to a change of 0.05 mm (0.0020 inch) in shim thickness.