Rear Differential Disassembly And Reassembly (KA, KC Models AWD)

Rear Differential Disassembly and Reassembly (KA, KC Models AWD)





View

1. Rear Differential Exploded View (Real Time AWD System)

Exploded View





Disassembly

1. Rear Differential Harness Bracket





1. Remove the harness clip (A) and the harness bracket (B).

2. Rear Differential Motor Connector





1. Disconnect the connector (A).

3. Rear Differential Motor Assembly





1. Remove the rear differential pump motor (A) and the O-ring (B).

4. Rear Differential Sensor Cover





1. Remove the rear differential sensor cover (A).

5. Rear Differential Fluid Temperature Sensor Connector





1. Disconnect the connector (A).

6. Rear Differential Fluid Temperature Sensor





1. Remove the rear differential fluid temperature sensor (A) and the O-ring (B).

7. Rear Differential Fluid Pressure Sensor Connector





1. Disconnect the connector (A).

8. Rear Differential Fluid Pressure Sensor





1. Remove the rear differential fluid pressure sensor (A) and the O-ring (B).

9. Rear Differential Solenoid Valve Connector





1. Disconnect the connector (A).





2. Remove the rear differential solenoid valve connector (A).

10. Oil Filler Plug And Drain Plug





1. Remove the drain plug (A) and the oil filler plug (B) with sealing washers (C).

11. Rear Differential Subharness





1. Disconnect the ground terminal (A).

2. Remove the rear differential subharness (B).

12. Rear Differential Companion Flange (Real Time AWD System)





1. Pry up the stake on the locknut (A) from the groove of the clutch guide, making sure the tab completely clears the groove to prevent damaging the clutch guide.





2. Install the companion flange holder (A) and holder handle (B) on the companion flange.





3. Loosen the locknut (A) counterclockwise so its tab (B) comes out from the groove (C) in the clutch guide.





4. Tighten the locknut (A) until its tab (B) aligns with the groove (C).

5. Clean any dirt from inside the groove in the clutch guide, then loosen the locknut.





6. Remove the locknut (A), the spring washer (B), the back-up ring (C), the O-ring (D), and the companion flange (E).

13. Oil Pump Cover





1. Remove the oil pump cover (A) and oil pump cover seal (B).

2. Remove the inner rotor (C) and the outer rotor (D).

3. Remove the fluid strainer (E) and the dowel pins (F).

14. Oil Pump Case





1. Remove the oil pump case (A).

2. Remove the dowel pins (B).

15. Rear Differential Clutch Assembly





1. Remove the baffle cover (A).

2. Remove the differential clutch assembly (B).

16. Oil Pump Body Assembly





1. Remove the 32.3 mm shim (A).

2. Remove the 94.6 mm shim (B).





3. Remove the oil pump body assembly (A).

4. Remove the dowel pins (B) and the O-ring (C).

17. Rear Differential Solenoid Valve





1. Remove the rear differential solenoid valve (A), the O-ring (B), and the square washer (C) from the oil pump body assembly (D).

Reassembly

1. Rear Differential Solenoid Valve





1. Apply Dual Pump Fluid II to a new O-ring (A).

2. Install the rear differential solenoid valve (B) with the O-ring, and the square washer (C).

2. Oil Pump Body Assembly





1. Apply Dual Pump Fluid II to a new O-ring (A).

2. Install the dowel pins (B) with the O-ring.

3. Install the oil pump body assembly (C).





4. Install the 32.3 mm shim (A).

5. Install the 94.6 mm shim (B).

3. Rear Differential Clutch Assembly





1. Install the differential clutch assembly (A).

2. Install the baffle cover (B).

4. Oil Pump Case





1. Remove the dirt and oil from the sealing surfaces.

2. Apply liquid gasket (P/N 08718-0004 or 08718-0009) evenly to the sealing surface.

3. Install the component within 5 minutes of applying the liquid gasket. Make sure you seal the entire circumference of the bolt holes to prevent fluid leakage.

NOTE:
* If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
* Allow it to cure at least 30 minutes after assembly before filling the differential with the recommended fluid.





4. Install the dowel pins (A).

5. Install the oil pump case (B).

6. Torque the eight mounting bolts in a crisscross pattern in several steps.

5. Oil Pump Cover





1. Install the fluid strainer (A) and the dowel pins (B).

2. Install the inner rotor (C) and the outer rotor (D) with the "" marks (E) facing the oil pump case side.

3. Install the oil pump cover (F) with a new oil pump cover seal (G).

4. Torque the six mounting bolts in a crisscross pattern in several steps.

6. Rear Differential Companion Flange (Real Time AWD System)





1. Install the companion flange (A) to the shaft of the clutch guide.

2. Apply Dual Pump Fluid II to a new O-ring (B).

3. Install the O-ring, a new back-up ring (C), the spring washer (D), and a new locknut (E).





4. Install the companion flange holder (A) and holder handle (B) on the companion flange.

5. Tighten the locknut to the specified torque.












6. Stake the locknut tab (A) into the groove in the clutch guide.

7. Rear Differential Subharness





1. Install the rear differential subharness (A).

2. Connect the ground terminal (B).

8. Oil Filler Plug And Drain Plug





1. Install the drain plug (A) and the oil filler plug (B) with new sealing washers (C).

9. Rear Differential Solenoid Valve Connector





1. Install the rear differential solenoid valve connector (A).





2. Connect the connector (A).

10. Rear Differential Fluid Pressure Sensor





1. Install the rear differential fluid pressure sensor (A) with a new O-ring (B).

11. Rear Differential Fluid Pressure Sensor Connector





1. Connect the connector (A).

12. Rear Differential Fluid Temperature Sensor





1. Apply Dual Pump Fluid II to a new O-ring (A).

2. Install the rear differential fluid temperature sensor (B) with the O-ring.

13. Rear Differential Fluid Temperature Sensor Connector





1. Connect the connector (A).

14. Rear Differential Sensor Cover





1. Install the rear differential sensor cover (A).

2. Connect the breather hoses (B) to the clamps (C).

15. Rear Differential Motor Assembly





1. Install the rear differential pump motor (A) with a new O-ring (B).

16. Rear Differential Motor Connector





1. Connect the connector (A).

17. Rear Differential Harness Bracket





1. Install the harness bracket (A) and the harness clip (B).