Reassembly

C59 MANUAL TRANSMISSION / TRANSAXLE: DIFFERENTIAL CASE: REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

(a) Coat the sliding and rotating surfaces of the front differential side gears with gear oil.





(b) Install the 2 front No. 1 differential side gear thrust washers onto the 2 front differential side gears.

(c) Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential pinion thrust washers onto the front differential case.

HINT
While rotating the front differential side gears, install the 2 front differential pinions and 2 front differential pinion thrust washers.

2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

(a) Coat the front No. 1 differential pinion shaft with MP grease.





(b) Install the front No. 1 differential pinion shaft onto the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.

3. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH

(a) Install the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.





Standard backlash:

0.05 to 0.20 mm (0.00197 to 0.00787 in.)

(b) If the backlash is out of specification, replace the side gear thrust washers.

Thrust Washer Thickness:





HINT
* Measure the thickness with a micrometer to select a proper thrust washer because the thrust washers do not have any distinguishing marks.
* Select washers of the same thickness for both the right and left sides.
4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

(a) Using a pin punch (dia3 mm) and a hammer, install the front differential pinion shaft straight pin onto the front differential case.





(b) Using a chisel and a hammer, stake the front differential case hole.





5. INSTALL FRONT DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the front differential case and ring gear.





(b) Using a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).

(c) After moisture on the ring gear has completely evaporated, align the matchmarks and quickly install the front differential ring gear onto the front differential case.





(d) Install the 8 bolts.

Torque : 77 Nm (790 kgf-cm, 57 ft-lbf)

6. INSTALL SPEEDOMETER DRIVE GEAR

(a) Install the speedometer drive gear onto the front differential case.