Differential Case

DIFFERENTIAL CASE

COMPONENTS:

DISASSEMBLY

1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Put matchmarks on the front differential ring gear and differential case.

(b) Remove the 12 bolts.

2. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case front tapered roller bearing from the differential case.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00480)

(b) Using SST, remove the front differential case front tapered roller bearing outer race and shim from the transaxle housing.
SST 09308-00010

3. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered roller bearing from the differential case.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00480)

(b) Using SST, remove the front differential case rear tapered roller bearing outer race from the transaxle case.
SST 09308-00010

4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
(a) Using a pin punch (3 mm) and hammer, remove the straight pin.

NOTICE: Before removing the straight pin, unstake it with a pin punch.

5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT
(a) Remove the front No. 1 differential pinion shaft from the differential case.

6. REMOVE DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears, and 2 side gear thrust washers from the differential case.

7. REMOVE FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, remove the front transaxle case oil seal from the transaxle housing.
SST 09950-60010 (09951-00540), 09950-70010 (09951-07200)

8. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, remove the transaxle case oil seal from transaxle case.
SST 09950-60010 (09951-00650), 09950-70010 (09951-07100)

INSPECTION

1. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
(a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

(b) Place a dial indicator on the tip of the side gear tooth at a right angle.
(c) Hold the pinion gear in the differential case and measure the backlash of the side gear.
Standard backlash: 0 to 0.15 mm (0 to 0.0059 in.)

Thrust washer thickness:

If the backlash is greater than the standard range, select another side gear thrust washer.

REASSEMBLY

1. INSTALL DIFFERENTIAL SIDE GEAR
(a) Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.

2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
(a) Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.

3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
(a) Using a pin punch (3 mm) and hammer, install the pinion shaft straight pin.

NOTICE: Align the holes, and install the pinion shaft straight pin.

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

NOTICE: Stake the differential case after adjusting the backlash.

5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case rear tapered roller bearing to the differential case.
SST 09710-04081, 09950-60010 (09951-00480), 09950-70010 (09951-07100)

NOTICE: Do not damage the bearing cage during bearing inner race installation.

(b) Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle case.
SST 09950-70010 (09951-07150), 09950-60020 (09951-00790)

NOTICE: Ensure that there is no clearance between the bearing and transaxle case.

6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case front tapered roller bearing to the differential case.
SST 09710-04081, 09950-60010 (09951-00480), 09950-70010 (09951-07100)

NOTICE: Do not damage the bearing cage during bearing inner race installation.

(b) Install the shim to the transaxle housing.

(c) Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing.

NOTICE: Ensure that there is no clearance between the bearing and transaxle housing.

7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install the differential assembly to the transaxle case.
(b) Clean the contact surfaces of the transaxle case and transaxle housing.

(c) Install the transaxle housing to the transaxle case with the 20 bolts.
Torque: Bolt A 31 N*m (316 kgf*cm, 23 ft.*lbf)
Bolt B 23 N*m (234 kgf*cm, 17 ft.*lbf)

(d) Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing.
SST 09564-33010
(e) Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 rpm.
SST 09564-33010
Turning torque: 1.05 to 1.93 N*m (10.70 to 19.67 kgf*cm, 9.29 to 17.08 in.*lbf)

If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

Shim thickness: mm (in.):

(f) Remove the 20 bolts and the transaxle housing from the transaxle case.

(g) Remove the differential assembly from the transaxle case.

8. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).

NOTICE: Do not heat the ring gear to more than 110°C (230.0° F).

(b) Clean the contact surface of the front differential case.

(c) Align the matchmarks, and install the front differential ring gear case quickly.

NOTICE: Do not install the bolts while the ring gear is hot.

(d) Tighten the 12 bolts.
Torque: 120 N*m (1,223 kgf*cm, 88 ft.*lbf)

NOTICE: Tighten the bolts a little at a time in diagonal order.

9. INSTALL TRANSAXLE CASE OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.

(b) Using SST and a hammer, install the oil seal.
SST 09316-10010, 09950-70010 (09951-07100)
Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

10. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.

(b) Using SST and a hammer, install the oil seal.
SST 09308-14010
Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)