Disassembly and Reassembly

Disassembly

Special Tools Required
^ Holder handle 07JAB-001020A
^ Companion flange holder 07RAB-TB4010B





1. Carefully clamp the rear differential in a vise.





2. Pry out the output shafts (A) with the pry bars (B).





3. Remove the output shafts.





4. Remove the 10 mounting bolts in a crisscross pattern in several steps, then remove the differential case assembly.





5. Make a mark on the bearing cap, adjust screw, and differential carrier case.





6. Remove the lock plates and bearing caps.





7. Remove the adjustment screws (A), bearing outer races (B), and Torsen LSD assembly (C).





8. Install the special tools on the companion flange, then remove the locknut (A) and pinion washer (B).





9. Remove the companion flange using a commercially available bearing puller as shown.





10. Remove the drive pinion (A) and pinion spacer (B) by tapping on the drive pinion with a plastic hammer.





11. Remove the bearing outer race (A), tapered roller bearing (B), thrust washer (C), and oil seal (D) from the differential carrier housing.





12. Remove the bearing outer race from the differential carrier housing.





13. Remove the tapered roller bearing (A) and thrust washer (B) from the drive pinion (C) using a commercially available bearing separator and a press as shown.





14. Remove the tapered roller bearings from the Torsen LSD assembly using a commercially available bearing puller as shown.





15. Remove the ten mounting bolts in a crisscross pattern in several steps, then remove the ring gear.





16. Remove the breather plate (A), filler plug (B), drain plug (C), and sealing washers.





17. Remove the oil seals.

Reassembly

Special Tools Required
^ Attachment, 40 x 50 mm I.D. 07LAD-PW50601
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300
^ Attachment, 45 x 55 mm I.D. 07MAD-PR90100
^ Driver 07749-0010000
^ Attachment, 78 x 80 mm 07NAD-PX40100
^ Flange holder 07RAB-TB4010B
^ Holder handle 07JAB-001020A
^ Universal holder 07725-0030000
^ Oil seal driver 07JAD-PL90100





1. Apply Honda lock 1 (P/N 08713-0001) to the surface of the ring gear and 10 mounting bolts.





2. Install the ring gear, then tighten the 10 mounting bolts in a crisscross pattern in several steps.





3. Install the tapered roller bearing using the special tools and a press as shown.





4. Install the standard thrust washer 3.47 mm (0.1366 inch) (A) onto the drive pinion (B). Then install the tapered roller bearing (C) using the old pinion spacer (D) and special tools as shown.














5. Install the bearing outer races (A) into the differential carrier housing using the special tools as shown.





6. Apply lubricant to the tapered roller bearing, then install the drive pinion and pinion spacer into the differential carrier housing.





7. Apply lubricant to the tapered roller bearing, then install the tapered roller bearing and thrust washer (A) using the special tools while holding the drive pinion (B).





8. Install the oil seal using the companion flange and special tool as shown.





9. Apply molybdenum grease to the surface end of the companion flange, then install the companion flange, drive pinion washer, and locknut.





10. Install the special tool to the companion flange, then tighten the locknut to 20 Nm (2.0 kgf-m, 14 ft. lbs.).





11. Rotate the drive pinion several times to assure proper tapered roller bearing contact. Measure the drive pinion turning torque.





12. Tighten the locknut to 127 Nm (13.0 kgf-m, 94 ft. lbs.), then remove the special tool.





13. Rotate the drive pinion several times to assure proper tapered roller bearing contact. Measure the drive pinion turning torque.
^ If the drive pinion turning torque exceeds the standard, replace the distance piece.
^ If the drive pinion turning torque less than the standard, adjust by tightening the locknut a little at a time, but keep the torque within 127 - 284 Nm (13.0 - 29.0 kgf-m, 94 - 210 ft. lbs.). If this is not possible, replace the pinion spacer.
Turning Torque: 0.88 - 1.37 Nm (9.0 - 14.0 kgf-cm, 7.8 - 12.1 inch lbs.) +Tp (from step 11)
Tp: Actual measurement of drive pinion turning torque





14. Install the Torsen LSD assembly (A), bearing outer races (B), adjustment screws (C) onto the differential carrier housing.

NOTE:
^ Reinstall the adjustment screws in their original position on the differential carrier housing.
^ Align the threads of the adjustment screws and differential carrier housing.





15. Install the bearing caps (A) while aligning both the marks (B) on the threads of the adjustment screws and bearing caps, then install the mounting bolts finger-tight.








16. Measure the backlash of the ring gear.
^ Set the dial gauge tip at a right angle to the ring gear teeth.
^ Measure four points on the ring gear 90° apart.
^ Backlash will be within the standard if at one point the ring gear backlash is within the standard, minimum measurement of 0.05 mm or above and the difference between the maximum and minimum measurements do not exceed 0.07 mm.
^ Both adjustment screws must be adjusted.
Backlash:
Standard: 0.09 - 0.11 mm (0.0035 - 0.0043 inch)
Minimum: 0.05 mm (0.0020 inch)
Difference range: 0.07 mm (0.0028 inch)





17. Tighten the bearing cap mounting bolts.
18. Thoroughly clean the ring gear and drive pinion teeth, and paint the ring gear teeth with Prussian Blue lightly and evenly.





19. Rotate the pinion three full turns in the forward and reverse directions to produce a contact pattern on the ring gear. During this operation resistance should be applied to the ring gear.

















20. Check the tooth contact, and adjust it if needed.
^ Toe Contact: Use a thinner thrust washer to move the drive pinion away from the ring gear.
^ Heel Contact: Use a thicker thrust washer to move the drive pinion toward from the ring gear.
^ Flank Contact: To move the ring gear away from the drive pinion, tighten the adjustment screw on the drive pinion side and loosen the adjustment screw on the ring gear side. Recheck backlash after adjusting the adjustment screws. If out of specification, adjust as described under Toe Contact.
^ Face Contact: To move the ring gear toward the drive pinion, tighten the adjustment screw on the ring gear side and loosen the adjustment screw on the drive pinion side. Recheck backlash after adjusting the adjustment screws. If out of specification, adjust as described under Heel Contact.





Thrust Washer





21. Rotate the Torsen LSD assembly several times to assure proper tapered roller bearing contact. Measure the Torsen LSD assembly preload using the push/pull gauge.
^ If the Torsen LSD assembly preload exceeds the standard, adjust by loosening the adjustment screws a notch at a time.
^ If the Torsen LSD assembly preload is less than the standard, adjust by tightening the adjustment screws a notch at a time.





22. Install the lock plates (A).





23. Install the oil seal using the special tools as shown.





24. Install the breather plate (A), filler plug (B), drain plug (C), and sealing washers.





25. Remove the dirty oil from the differential case sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface.
Be sure to seal the entire circumference of the bolt holes to prevent oil leakage.

NOTE:
^ If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings.
^ Allow it to cure at least 20 minutes after assembly before filling the differential with oil.





26. Install the differential case assembly.





27. Tighten the 10 mounting bolts in a crisscross pattern in several steps.
24 Nm (2.4 kgf-m, 17 ft. lbs.)





28. Install the clips (A) on the output shafts, then install the output shafts (B).