Differential

DIFFERENTIAL

Pre-Inspection
Backlash Of Side Gear And Pinion Gear



1. Before disassembly, measure backlash of side gears and pinion gears. If not within specification, replace differential assembly.

Backlash:
Standard: 0.001 - 0.004 inch (0.025 - 0.1 mm)
Maximum: 0.020 inch (0.5 mm)


Disassembly





NOTICE: Do not remove side bearings unless necessary.

1. Remove two side gears and two thrust washers.

NOTICE:
a) Use protective plates in vise to prevent damage to differential.
b) Insert punch into spring pin hole from ring gear side.





2. Place gear case on a vise and knock pin out with suitable pin punch and hammer. Then remove two thrust washers, two pinion gears and pinion shaft.
3. Remove side bearing inner race (side opposite ring gear) from gear case with SST (OK130 171 013) or equivalent.





4. Remove speedometer drive gear.





5. Remove side bearing (ring gear side) from gear case with SST (OK670 990 AAO) or equivalent.


Re-Assembly



1. Set speedometer drive gear onto ring gear and case assembly.

NOTICE: Do not reuse side bearings if they were removed.

2. Press side bearing (side opposite ring gear) into ring gear and case assembly with SST (OK990 175 AAI) or equivalent.





3. Press on other side bearing (ring gear side) in same manner.
4. Install pinion gears and thrust washers into case.





5. Install pinion shaft.





6. Install spring pin, and stake hole to prevent spring pin from coming out of gear case.
7. Install thrust washers and side gears into gear case at same time, then rotate them around pinion gears and align them with driveshaft holes.





NOTICE: Be certain that both side gears are centered in their respective driveshaft holes. If not, remove both side gears and re-install them.

8. Measure backlash of side gears and pinion gears as follows:
a. Install left and right driveshafts in differential assembly.
b. Support driveshafts on V-blocks.
c. Measure backlash of both pinion gears.

Backlash:
Standard: 0.001 - 0.004 inch (0.025 - 0.1 mm)
Maximum: 0.020 inch (0.5 mm)





9. 1 backlash is not within specification, replace differential assembly.

Differential Bearing (Side Bearing) Preload

NOTICE: The next eighteen steps measure differential side bearing preload and select proper adjustment shim(s).





1. Remove side bearing outer race and adjustment shims from transaxle case.
2. Set transaxle case on a stand and install SST (OK1 30 191 A07/K94A-4200-T).





3. Tighten SST (OK130 191 A06/K94A-4200-T) to specified torque.

Tightening torque: 27 - 38 ft. lbs. (36 - 51 Nm, 3.7 - 5.3 kg.m)

4. Set differential assembly into converter housing.

NOTICE: Eliminate gap (arrow) by turning either A or B of selector. Do not overtighten.





5. Install side bearing outer race removed from transaxle case into SST (OK201 175 A01 / K94A-4200-T). Set SST and outer race onto differential assembly.





6. Set SST (OK1 30 175 A02/K94A-4200-T) on converter housing in positions shown.
7. To seat bearing, turn SST (OK201 175 AOI / K94A-4200-T) to increase clearance indicated by arrow with SST (OK130 175 A03/K94A-4200-T) until it no longer turns.





8. Turn selector in opposite direction until gap is reduced.
9. Insert SST through transaxle case and attach it to pinion shaft.
10. Install torque meter.

NOTICE: Read preload when differential is rotating.

11. Adjust clearance between A and B to obtain specified preload reading.

Preload: 4.3 inch lbs. (0.5 Nm, 0.05 kg)





12. Measure clearance between A and B.





13. Add 0.0118 inch (0.3 mm) to measured clearance and select shim(s) closest in value to measurement.

NOTICE:
a) Measure clearance around entire circumference and select shims based on Maximum clearance.
b) The Maximum allowable number of shims is 3.

14. Remove transaxle case and SST (K94A-4200-T).





15. Install required shim(s) and tap bearing race into transaxle case.
16. Install transaxle case.

Tightening torque: 28 - 38 ft. lbs. (38 - 51 Nm, 3.8 - 5.1 kg.m)





17. Using SST (OK1 30 191 A05/K94A-4200-T) and a torque meter, verify that preload is within specification. If not within specification, return to Step 1.

Preload: 27.6 - 33.6 inch lbs. (3.0 - 3.9 Nm, 30 - 40 kg.cm)

18. Remove transaxle case.