Differential Case

DISASSEMBLY
1. REMOVE DIFFERENTIAL RING GEAR





a. Place the matchmarks on the ring gear and the differential case.





b. Remove the 16 bolts.





c. Using a plastic hammer, tap on the ring gear to remove it from the case.
2. REMOVE FRONT DIFFERENTIAL





a. Remove the differential LH case from the differential case assembly.





b. Remove the front differential case from the differential LH case.





c. Remove the front differential side gear, front differential side gear thrust washer, conical washer and center differential side gear thrust washer No. 2 from the differential LH case.





d. Using a snap ring expander, remove the snap ring from the front differential case.





e. Remove the spacer from the front differential case.





f. Remove the 3 pinion shafts from the front differential case.





g. Remove the 4 front differential pinions, 4 front differential pinion thrust washers, front differential pinion shaft holder, front differential side gear and front differential side gear thrust washer from the front differential case.





3. REMOVE LH BEARING
Using SST, remove the tapered roller bearing.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00060)
4. REMOVE CENTER DIFFERENTIAL





a. Using snap ring expander, remove the snap ring.
b. Slide down the spacer to remove the 4 center differential pinion shafts.





c. Remove the 4 center differential pinion shafts, 4 center differential pinions, 4 center differential pinion thrust washers, center differential pinion shaft holder, center differential side gear, conical washer and center differential side gear thrust washer No. 1 from the differential RH case.
d. Remove the spacer.





5. REMOVE RH BEARING
Using SST and a press, remove the tapered roller bearing.
SST 09950-00020, 09950-60010 (09951-00600)





6. REMOVE TRANSAXLE HOUSING SIDE BEARING OUTER RACE
Using SST, remove the outer race.
SST 09308-00010





7. REMOVE TRANSAXLE HOUSING OIL SEAL
Using SST, remove the oil seal from the transaxle housing.
SST 09649-17010, 09950-70010 (09951-07100)





8. REMOVE TRANSAXLE CASE SIDE BEARING OUTER RACE
Using SST remove the outer race.
SST 09300-00010





9. REMOVE TRANSAXLE CASE OIL SEAL
Using SST, remove the oil seal from the transaxle case.
SST 09649-17010, (09950-70010 (09951-07100)

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with ATF before reassembly.





1. INSTALL TRANSAXLE HOUSING SIDE BEARING OUTER RACE
Using SST and a hammer, install the bearing outer race.
SST 09350-32014 (09351-32111), 09950-70010 (09951-07150)





2. INSTALL TRANSAXLE CASE SIDE BEARING OUTER RACE
a. Install the plate washer to the transaxle case.

HINT: First select and install a plate washer of less thickness than before.

b. Using SST and a hammer, install the bearing outer race.
SST 09223-15020, 09950-70010 (09951-07100)
3. INSTALL FRONT DIFFERENTIAL CASE





a. Coat the front differential side gear thrust washer, front differential side gear, front differential pinion shaft holder, 4 front differential pinion thrust washers, the 4 front differential pinions with ATF, install them to the front differential case.





b. Install the 3 pinion shafts to the front differential case.





c. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.002 - 0.008 inch)

NOTICE: Do not mount the surface of front differential case which contacts with bushing in a vise.

If the backlash is not within the specified value, refer to the table and select a thrust washer which will ensure that the backlash is within the specified value.





Thrust washer thickness: mm (inch)





d. Engage the front differential side gear to the above mentioned front differential case.
e. Install the differential case LH to the front differential case and measure its center.
f. After that, remove the differential case LH.





g. Using a straight edge and feeler gauge, measure the clearance between the front differential case and the front differential side gear.
t = Thrust washer thickness
L =Clearance
t = L 0.16 - 0.27 mm (0.0063 - 0.0106 inch)

HINT: Refer to the table and select a thrust washer which will ensure that the clearance is within the specification.





Thrust washer thickness: mm (inch)

If the clearance is not within the specified value, parts may have been assembled incorrectly, so check and reassemble it.





h. Install the spacer to the front differential case.





i. Using a snap ring expander, install the snap ring, as shown.

HINT: Before installing the shaft snap ring, wrap vinyl tape around the case to avoid damaging the case.

4. INSTALL DIFFERENTIAL RH CASE





a. Install the spacer to the differential RH case.
b. Slide down the spacer to install the 4 center differential pinion shafts.





c. Install the center differential side gear thrust washer No. 1, conical washer, center differential side gear, center differential pinion shaft holder, 4 center differential pinions, 4 center differential pinion thrust washers and 4 center differential pinion shafts to the differential RH case.

HINT: Ensure that the conical washers is installed correctly.

5. CHECK CENTER DIFFERENTIAL PINION GEAR BACKLASH OF DIFFERENTIAL RH CASE SIDE





a. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specified value, refer to the table and select a thrust washer which satisfied the specified value.





Thrust washer thickness: mm (inch)





b. Slide up the spacer to the install the snap ring.
c. Using a snap ring expander, install the snap ring as shown.
6. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR THRUST CLEARANCE (FRONT DIFFERENTIAL LH CASE SIDE)





a. Temporarily install the front differential case assembly' front differential side gear, front differential side gear thrust washer, (temporarily install) a 1.0 mm (0.039 inch) thick center differential side gear thrust washer No. 2 and center differential side gear thrust washer No. 2 to the differential RH case.

HINT:
- Engage the front differential side gear and pinion gear of the differential RH case.
- The temporarily installed a 1.0 mm (0.039 inch) thick center differential side gear thrust washer No. 2 is used for reference when checking backlash.





b. Clean the contact surface of the center differential side gear thrust washer No. 2 and differential LH case.
c. Apply plastigage on the center differential side gear thrust washer No. 2, as shown.

HINT: Apply the plastigage on the center differential side gear thrust washer No. 2 in the 4 positions directly above the pinion shafts in the differential RH case's position.





d. Install the differential LH case downward.

HINT: Align the matchmarks on the differential RH case and contact the differential LH case.





e. Temporarily install the differential RH case and service 4 bolts to the differential LH case.
Parts No:
Service bolt: 90105-08100
Torque: 33 Nm (337 kgf-cm, 24 ft. lbs.)
f. Remove the 4 bolts and differential LH case upward.





g. Measure the plastigage at widest point.
Standard clearance: 0.16 - 0.25 mm (0.006 - 0.010 inch)
Refer to the table, select the thrust washer No. 2 which will ensure that the backlash is within the specification. Try to select a washer of the same size.





Thrust washer thickness: mm (inch)

h. Remove the differential LH case, center differential side gear thrust washer No. 2 and (temporarily install) a 1.0 mm (0.039 inch) thick center differential side gear thrust washer No. 2.





i. Install the conical washer and center differential side gear thrust washer No. 2 (previously selected) from differential case.

HINT: Be careful not to mistake the direction of the conical washer.





j. Install the differential LH case downward.

HINT: Align the matchmarks on the differential RH case and contact the differential LH case.





k. Temporarily install the differential RH case and 4 service bolts to the differential LH case.
Parts No:
Service bolt: 90105-03100
Torque: 33 Nm (337 kgf-cm, 24 ft. lbs.)
7. CHECK PRELOAD OF DIFFERENTIAL CASE





a. Using SST and a press, install the side bearing RR and FR to the differential case.
SST 09214-76011, 09252-10010, 09316-20011, 09649-17010





b. Install the differential to the T/F case.





c. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transaxle case and the transaxle housing.
d. Install the transaxle housing and 16 bolts to the transaxle case.

HINT: Although the bolt A is a non-reusable seal bolt, in the case, clean the bolts and tighten them as well as the bolts B and C.

Torque:
Bolt A: 22 Nm (226 kgf-cm, 16 ft. lbs.)
Bolt B and C: 29 Nm (300 kgf-cm, 22 ft. lbs.)
Bolt length:
Bolt A: 50.0 mm (1.969 inch)
Bolt B: 50.0 mm (1.969 inch)
Bolt C: 42.0 mm (1.654 inch)





e. Temporarily install the intermediate shaft.
f. Turn the intermediate shaft right and left 2 or 3 times to allow the bearing settle.
g. Remove the intermediate shaft.





h. Using SST and torque wrench, measure the turning torque of the differential.
SST 09560-32011
Turning torque at 60 rpm:
New bearing: 0.20 - 0.69 Nm (2 - 7 kgf-cm, 1.8 - 6.1 inch lbs.)
Used bearing: 0.10 - 0.35 Nm (1 - 4 kgf-cm, 0.9 - 3.1 inch lbs.)

HINT: If the preload is not within the specified value, refer to the table and select a thrust washer which preload is within the specified value.





Plate washer thickness: mm (inch)





i. Remove the 16 bolts and the transaxle housing.





j. Remove the differential from the transaxle case.
8. INSTALL RING GEAR ON DIFFERENTIAL CASE





a. Clean the contact surfaces of the differential case and the ring gear.
b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.





d. Install the ring gear to the differential.





e. Temporarily install the 8 bolts.





f. Remove the 4 service bolts.
g. Temporarily install the 8 bolts.
h. Tighten the 16 bolts.
Torque: 95 Nm (970 kgf-cm, 70 ft. lbs.)





9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
a. Using SST, install the new oil seal.
SST 09600-10010, 09950-70010 (09951-07150)
b. Coat a lip of oil seal with petroleum jelly.
10. INSTALL TRANSAXLE HOUSING OIL SEAL





a. Wind a vinyl tape around SST at the place 6.0 mm (0.236 inch) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 inch).
SST 09950-60010 (09951-00730)

NOTICE: Clean SST to remove deposited oil, before winding a vinyl tape.

b. Coat the lip of oil seal with petroleum jelly.





c. Using SST, install the new oil seal.
SST 09950-60020 (09951-00730), 09950-70010 (09951-07150)
Oil seal depth: 5.5 - 6.5 mm (0.217 - 0.256 inch)

NOTICE: When the wound vinyl tape contacts the transaxle housing stop press-fitting.