Overhaul (Differential)
A/T DifferentialA/T Differential Component Location Index 2003-2005 Model:
Component Location Index
Backlash Inspection
1. Install both axles into the differential, and place the axles on V-blocks (A).
2. Measure the backlash of the pinion gears (B) with a dial indicator (C).
Standard: 0.05 - 0.15 mm (0.002 - 0.006 inch)
3. If the backlash is out of standard, replace the differential carrier.
Differential Carrier, Final Driven Gear Replacement
NOTE: Inspect and adjust the carrier bearing preload whenever the differential carrier is replaced.
1. Remove the final driven gear (A) from the differential carrier (B). The final driven gear bolts have left-hand threads.
2003-2005 Model:
2. Install the final driven gear on the differential carrier in the direction shown. Tighten the bolts to 101 Nm (10.3 kgf-m, 74.5 ft. lbs.) in a crisscross pattern in two or more steps.
Carrier Bearing Replacement
Special Tools Required
Attachment, 45 x 55 mm 07MAD-PR90100
NOTE:
^ The bearing and outer race should be replaced as a set.
^ Inspect and adjust the bearing preload whenever bearing is replaced.
^ Check the bearing for wear and rough rotation. If the bearing is OK, removal is not necessary.
1. Remove the carrier bearing (A) with a commercially available bearing puller (B), bearing separator (C), and stepper adapter (D).
2. Install the carrier bearing with the special tool using the small end and a press until it bottoms. Press the bearing on securely so there is no clearance between the bearing and the differential carrier.
Oil Seal Replacement
Special Tools Required
^ Driver 07749-0010000
^ Seal driver attachment 07GAD-PG40101 or 07GAD-PG40100
^ Oil seal driver attachment 07JAD-PH80101
1. Remove the oil seal from the transmission housing.
2. Remove the oil seal from the torque converter housing.
3. Install the new oil seal (A) in the transmission housing with the special tools.
4. Install the oil seal (A) in the torque converter housing with the special tools.
Carrier Bearing Outer Race Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 78 x 80 mm 07NAD-PX40100
^ Attachment, 78 x 90 mm 07GAD-SD40101 (2006-2007 models)
NOTE:
^ The bearing and bearing outer race should be replaced as a set.
^ Replace the bearing with a new one whenever the outer race is replaced.
^ Do not use shim(s) on the torque converter housing side.
^ Adjust bearing preload after replacing the bearing and outer race.
^ Coat all parts with ATF during installation.
1. Remove the bearing outer race (A), thrust washer (B), and thrust shim (C) from the transmission housing (D) by heating the housing to about 212°F (100°C) with a heat gun (E). Do not heat the housing to more than 212°F (100°C).
NOTE: Let the transmission housing cool to room temperature before installing the bearing outer race.
2. Remove the bearing outer race (A) and thrust washer (B) from the torque converter housing (C).
3. Install the thrust washer and the new bearing outer race in the torque converter housing.
4. Drive the bearing outer race into the housing with the special tools.
5. Install the thrust shim (A), thrust washer (B), and the new bearing outer race (C) in the transmission housing (D).
6. Drive the bearing outer race into the housing with the special tools so there is no clearance between the outer race, thrust washer, shim and housing.
Carrier Bearing Preload Inspection
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 78 x 80 mm 07NAD-PX40100
^ Preload inspection tool 07HAJ-PK40201
2003-2005 Models
NOTE: If the transmission housing, torque converter housing, differential carrier, tapered roller bearing, outer race, or thrust shim were replaced, the bearing preload must be adjusted.
1. Remove the bearing outer race (A), thrust washer (B), and thrust shim (C) from the transmission housing (D) by heating the housing to about 212°F (100°C) with a heat gun (E). Do not heat the housing to more than of 212°F (100°C).
NOTE: Let the transmission housing cool to room temperature before adjusting the bearing preload.
2. Replace the tapered roller bearing when the outer race is to be replaced.
3. Do not use a shim on the torque converter housing side.
4. Install the 81 mm thrust shim (A), thrust washer (B), and bearing outer race (C) in the transmission housing (D). If you replace the 81 mm thrust shim with a new one, use the same thickness shim as the old one.
5. Drive in the outer race with the special tools.
6. Check that there is no clearance between the thrust washer, outer race, shim, and transmission housing.
7. Install the differential assembly (A) in the torque converter housing (B), and install the gasket (C) and dowel pins (D) on the housing.
8. Align the spring pin on the selector control shaft (E) with the transmission housing groove.
9. Install the transmission housing (F), transmission hangers (G), and harness clamp bracket (H) then tighten the bolts.
10. Rotate the differential assembly in both directions to seat the bearing.
11. Measure the starting torque of the differential assembly with the special tool, a torque wrench (A) and socket (B) at normal room temperature in both directions.
THRUST SHIM, 81 mm:
12. If the measurement is out of standard, remove the thrust shim and select the thrust shim from table. Install the now thrust shim and recheck. To increase the starting torque, increase the thickness of the thrust shim. To decrease the starting torque, decrease the thickness of the shim. Changing the shim to the next size will increase or decrease starting torque about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 3 - 3 inch lbs.).
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 78 x 90 mm 07GAD-SD40101
^ Preload inspection tool 070AJ-0020101
2006-2007 Models
NOTE: If the transmission housing, torque converter housing, differential carrier, tapered roller bearing, outer race, or thrust shim were replaced, the bearing preload must be adjusted.
1. Remove the bearing outer race (A), thrust washer (B), and thrust shim (C) from the transmission housing (D) by heating the housing to about 212°F (100°C) with a heat gun (E). Do not heat the housing to more than of 212°F (100°C).
NOTE: Let the transmission housing cool to room temperature before adjusting the bearing preload.
2. Replace the tapered roller bearing when the outer race is to be replaced.
3. Do not use a shim on the torque converter housing side.
4. Install the 85 mm thrust shim (A), thrust washer (B), and bearing outer race (C) in the transmission housing (D). If you replace the 85 mm thrust shim with a new one, use the same thickness shim as the old one.
5. Drive in the outer race with the special tools.
6. Check that there is no clearance between the thrust washer, outer race, shim, and transmission housing.
7. Install the differential assembly (A) in the torque converter housing (B), and install the gasket (C) and dowel pins (D) on the housing.
8. Align the spring pin on the selector control shaft (E) with the transmission housing groove.
9. Install the transmission housing (F), transmission hangers (G), and harness clamp bracket (H) then tighten the bolts.
10. Rotate the differential assembly in both directions to seat the bearing.
11. Measure the starting torque of the differential assembly with the special tool, a torque wrench (A) and socket (B) at normal room temperature in both directions.
12. If the measurement is out of standard, remove the thrust shim and select the thrust shim from table. Install the new thrust shim and recheck. To increase the starting torque, increase the thickness of the thrust shim. To decrease the starting torque, decrease the thickness of the thrust shim. Changing the shim to the next size will increase or decrease starting torque about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2 - 3 inch lbs.).