Differential Case

DIFFERENTIAL CASE 4WD:

DISASSEMBLY
1. REMOVE NO. 2 DIFFERENTIAL CASE
a. Remove the 16 bolts.
b. Remove the NO. 2 differential case upward.
2. REMOVE DIFFERENTIAL RING GEAR





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





b. Using a plastic hammer, tap out the ring gear.
3. REMOVE NO. 2 DIFFERENTIAL SIDE GEAR THRUST WASHER AND CONICAL SPRING WASHER
4. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY
5. DISASSEMBLE FRONT DIFFERENTIAL CASE
a. Remove the front differential side gear together with the thrust washer from the front differential case.
b. Remove the front differential side gear thrust washer from the side gear.





c. Using a snap ring expander, remove the snap ring and spacer.

HINT: Before removing the shaft snap ring, wrap vinyl tape around the case to prevent from damage.





d. Remove the parts from the front differential case.
1. Remove the 2 front differential pinion shafts.
2. Remove the No. 2 front differential pinion shaft.
3. Remove the front differential pinion shaft holder.
4. Remove the 4 differential pinions.
5. Remove the 4 differential pinion thrust washers.
6. Remove the front differential side gear.
7. Remove the front differential side gear thrust washer.
6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
a. Using a snap ring expander, remove the snap ring.
b. Remove the spacer and vehicle speed sensor drive gear.





7. DISASSEMBLE NO. 1 DIFFERENTIAL CASE
Remove the parts from the No. 1 differential case.
1. Remove the 4 differential pinion shafts.
2. Remove the pinion shaft holder.
3. Remove the 4 differential pinions.
4. Remove the 4 differential pinion thrust washers.
5. Remove the differential side gear subassembly.
6. Remove the conical spring washer.
7. Remove the No. 2 differential side gear thrust washer.





8. NO. 2 Differential Case Side: REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00520)





9. No. 1 Differential Case Side: REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00450)

INSPECTION





1. MEASURE NO. 1 AND NO. 2 DIFFERENTIAL CASES
Using a cylinder gauge, measure the inner diameter of the NO. 1 and NO. 2 differential cases bushing.
Standard diameter:
A: 104.000 - 104.035 mm (4.0945 - 4.0959 inch)
B: 97.000 - 97.035 mm (3.8189 - 3.8203 inch)
Maximum diameter:
A: 104.060 mm (4.0969 inch)
B: 97.060 mm (3.8213 inch)





2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of the front differential case.
Standard diameter:
A: 103.929 - 103.964 mm (4.0917 - 4.0931 inch)
B: 96.929 - 96.964 mm (3.8161 - 3.8175 inch)
Minimum diameter:
A: 103.850 mm (4.0887 inch)
B: 96.850 mm (3.8130 inch)





3. MEASURE CONICAL SPRING WASHER
Using calipers, measure the height of the conical spring washer.
Standard height:
NO. 2 differential case side 2.60 - 2.80 mm (0.102 - 0.110 inch)
NO. 1 differential case side 1.55 - 1.75 mm (0.061 - 0.069 inch)
Minimum height:
NO. 2 differential case side 2.50 mm (0.098 inch)
NO. 1 differential case side 1.60 mm (0.063 inch)

REPLACEMENT
1. Transmission Case Side: REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE
a. Using a screwdriver and a hammer, remove the oil seal.





b. Using a brass bar and hammer, drive out the tapered roller bearing outer race lightly and evenly.
c. Remove the shim.
d. Install the shim.

HINT: First select and install a shim of lesser thickness than before.





e. Using SST and a press, install a new tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00041)

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





f. Using SST and a hammer, drive in a new oil seal.
SST 09316-60010 (09316-00011, 09316-00031)
Drive in depth: 0 ± 0.5 mm (0 ± 0.020 inch)
g. Coat the lip of oil seal with MP grease.
2. Transaxle Case Side: REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE
a. Using a screwdriver and hammer, drive out the oil seal from the transaxle case.





b. Using SST, remove the tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
c. Remove the oil baffle.
d. Install the oil baffle.

HINT: Install the oil baffle projection into the case side cutout.





e. Using SST and a press, install the tapered roller bearing outer race. SST 09316-60011 (09316-00011,09316-00041)





f. Using SST and a hammer, drive in a new oil seal.
SST 09316-60011 (09316-00011, 09316-00041)
Drive in depth: 6.9 ± 0.5 mm (0.272 ± 0.020 inch)
g. Coat the oil seal lip with MP grease.

REASSEMBLY

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





1. NO. 1 Differential Case Side: INSTALL TAPERED ROLLER BEARING
Using SST, install a new tapered roller bearing.
SST 09316-20011





2. NO. 2 Differential Case Side: INSTALL TAPERED ROLLER BEARING
Using SST, install a new tapered roller bearing.
SST 09316-20011
3. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR BACKLASH (DIFFERENTIAL SIDE GEAR SUB ASSEMBLY SIDE)





a. Install the parts to the No. 1 differential case.
1. Install the No. 2 differential side gear thrust washer.
2. Install the temporarily install a 1.0 mm (0.039 inch) thick thrust washer.
3. Install the differential side gear subassembly.
4. Install the pinion shaft holder.
5. Install the 4 differential pinions.
6. Install the 4 differential pinion thrust washers.
7. Install the 4 differential pinion shafts.





b. Using a dial indicator, measure the backlash of one pinion gear while holding the differential side gear sub assembly toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)

HINT: Push the pinion gear of the right side of the differential case.

If the backlash is out of the specification, refer to the table and select a thrust washer, which will ensure that the backlash is within the specification.

Thrust Washer Thickness [mm (inch)]:

Thrust washer thickness mm (inch)

c. Disassemble the NO. 1 differential case.





4. ASSEMBLE NO. 1 DIFFERENTIAL CASE
Install the parts to the No. 1 differential case.
1. Install the No. 2 side gear thrust washer (previously selected).
2. Install the conical spring washer.
3. Install the differential side gear subassembly.
4. Install the pinion shaft holder.
5. Install the 4 differential pinions.
6. Install the 4 differential pinion thrust washers.
7. Install the 4 differential pinion shafts.

HINT: Ensure that the conical spring washer is installed correctly.





5. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR
a. Install the vehicle speed sensor drive gear and spacer.
b. Using a snap ring expander, install the snap ring.
6. CHECK AND ADJUST FRONT SIDE GEAR BACKLASH (FRONT DIFFERENTIAL CASE SIDE)





a. Install the parts to the front differential case.
1. Install the front differential side gear thrust washer.
2. Install the front differential side gear.
3. Install the front differential pinion shaft holder.
4. Install the 4 differential pinions.
5. Install the 4 differential pinion thrust washers.
6. Install the No. 2 front differential pinion shaft.
7. Install the 2 front differential pinion shafts.





b. 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)

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

If the backlash is out of the specification, refer to the table and select a thrust washer, which will ensure that the backlash is within the specification.

Thrust Washer Thickness [mm (inch)]:

Thrust washer thickness: mm (inch)

7. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR THRUST CLEARANCE (NO. 2 DIFFERENTIAL CASE SIDE)





a. Engage the side gear to the above mentioned front differential case.
b. Install the differential case LH to the front differential case and measure its center.
c. After that, remove the differential case LH.





d. Using a straight edge and feeler gauge, measure the clearance between the front differential case and the 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)]:

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.





8. INSTALL SNAP RING
a. Install the spacer.
b. Using a snap ring expander, install the shaft snap ring, as shown.

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

9. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR THRUST CLEARANCE (FRONT DIFFERENTIAL CASE SIDE)





a. Install the parts to the No. 2 differential case.
1. Install the front differential case assembly.
2. Install the front differential side gear.
3. Install the front differential side gear thrust washer.
4. Install the temporarily install a 1.0 mm (0.039 inch) thick NO. 2 differential side gear thrust washer.
5. Install the NO. 2 differential side gear thrust washer.

HINT:
^ Engage the front differential side gear and pinion gear of the NO. 1 differential case.
^ The temporarily installed a 1.0 mm (0.039 inch) thick NO. 2 side gear thrust washer is used for reference when checking backlash.





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

HINT: Apply the plastigage on the NO. 2 side gear thrust washer in the 4 positions directly above the pinion shafts in the NO. 1 differential case's position.

d. Install the ring gear.
1. Clean the contact surface of the differential left case.





2. Heat the ring gear to about 100°C (212°F) in boiling water.
3. Carefully take the ring gear out of the water.
4. Clean the contact surface of the ring gear with cleaning solvent.





5. Quickly install the ring gear on the differential case.

HINT: Align the matchmarks on the NO. 2 differential case and connect the ring gear.





e. Install the NO. 2 differential case downward.

HINT: Align the matchmarks on the NO. 1 differential case and contact the NO. 2 differential case.

f. Temporarily install the 4 service bolts.
Parts No: Service bolt: 90105-08055
Torque: 33 Nm (337 kgf-cm, 24 ft. lbs.)
g. Remove the 4 service bolts and NO. 2 differential case upward.





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

Thrust Washer Thickness [mm (inch)]:

Thrust washer thickness: mm (inch)

i. Remove the NO. 2 differential case, NO. 2 side gear thrust washer and (temporarily install) a 1.0 mm (0.039 inch) thick NO. 2 side gear thrust washer.
10. ASSEMBLE NO. 2 DIFFERENTIAL CASE





a. Install the NO. 2 side gear thrust washer (previously selected) and conical spring washer to the front differential case.

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





b. Install the NO. 2 differential case to the NO. 1 differential case.

HINT: Align the matchmarks on the NO. 2 differential case and connect the NO. 1 differential case.

c. Temporarily install the 4 service bolts.
Parts No: Service bolt: 90105-08055
Torque: 33 Nm (337 kgf-cm, 24 ft. lbs.)
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD
a. Install the differential case assembly to the transaxle case.
b. Install the transmission case.

HINT: If necessary, tap on the transmission case with a plastic hammer.





c. Install and torque the 17 bolts.
Torque:
29 Nm (300 kgf-cm, 21 ft. lbs.) for transaxle case side
30 Nm (306 kgf-cm, 22 ft. lbs.) for transmission case side





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





g. Using SST and torque wrench, measure the differential preload.
SST 09560-32011
Preload (at starting)
New bearing: 0.8 - 1.6 Nm (8.0 - 16.3 kgf-cm, 7.1 - 14.2 inch lbs.)
Reused bearing: 0.5 - 1.0 Nm (5.1 - 10.2 kgf-cm, 4.4 - 8.6 inch lbs.)
If the preload is not within the specification, select an appropriate adjusting shim.

HINT: The total preload will change about 5.1 N (0.5 kgf, 1.1 lbs) for every 0.05 mm change in adjusting shim thickness.

Thrust Washer Thickness [mm (inch)]:

Thrust washer thickness: mm (inch)

h. Remove the 17 bolts, tap the transmission case with a plastic hammer and remove it.
i. Remove the differential case assembly.