Front Differential Assembly

Front Differential Assembly
REMOVAL
Remove the transmission assembly from the vehicle.
Extract the torque converter clutch assembly. Remove the input shaft.





Lift-up lever behind the transmission harness connector and disconnect it from stay.
Disconnect inhibitor switch from stay.
Remove the oil charge pipe.
Remove the oil cooler inlet and outlet pipes.
Separation of converter case and transmission case.
Remove the seal pipe.
Remove the differential side retainer with ST.

Note: Hold the differential case assembly by hand to avoid damaging retainer mounting hole of the converter case.

ST 32005023 WRENCH ASSY
Remove the differential assembly without damaging installation part of retainer.





INSTALLATION
Install the differential assembly to the case, paying special attention not to damage the inside of the case (particularly, the differential side retainer contact surface).





(A) Differential assembly
Install the O-rings from left and right side retainer.
Using ST, install the side retainers.
ST 32005023 WRENCH ASSY
Adjust the front differential backlash.
Install the lock plate.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)





(A) Lock plate
Install the new seal pipe to the converter case.





(A) Seal pipe
Install the converter case to transmission case.
Insert inhibitor switch and transmission connector into stay.





(A) Transmission harness
(B) Inhibitor switch harness
Install oil cooler pipes.
Install the oil charge pipe with O-ring
Insert the input shaft while turning lightly by hand and verify the protrusion amount.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)





Install the torque converter clutch assembly.
Install the transmission assembly to the vehicle.

DISASSEMBLY
DIFFERENTIAL CASE ASSEMBLY
Using a press and ST, remove the taper roller bearing.
ST 32005088 REMOVER





Secure the case in a vise and remove the hypoid driven gear tightening bolts, then separate the hypoid driven gear, case (RH) and case (LH).





(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
Pull out the straight pin and shaft, and remove the differential bevel gear, washer, and differential bevel pinion.





(A) Differential case (RH)

SIDE RETAINER

Note: After adjusting the drive pinion backlash and tooth contact, remove and install the oil seal and O-rings

Remove O-rings





Remove oil seal.





Take out either split pin, remove claw.
ST 32005071 PULLER ASSY





(A) Claw
(B) Split pin
(C) Pin
Securely attach two claws to outer race, set ST to side retainer.
ST 32005071 PULLER ASSY





(A) Shaft
(B) Claw
Return removed claw to the original position, and install pin and split pin.
Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race.
ST 32005071 PULLER ASSY

Note: Replace bearing inner and outer races as a single unit.





(A) Shaft
(B) Side retainer

INSPECTION
^ Check each component for harmful cuts, damage and other faults.
^ Measure the backlash and adjust to within specifications.

ADJUSTMENT
Using ST, screw in the retainer until light contact is felt.

Note: Screw in the RH side slightly deeper than the LH side.

ST 32005023 WRENCH ASSY





Remove the oil pump housing.
Thoroughly remove the liquid gasket from the case mating surface beforehand.

Install the oil pump housing assembly to the converter case, and secure evenly by tightening four bolts.

Note: Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.

Tightening torque: 41 Nm (4.2 kgf-m, 30.4 ft. lbs.)





Rotate the drive pinion several times with ST1 and ST2.
ST1 32005120 HOLDER
ST2 32005154 WRENCH





Tighten the LH retainer until contact is felt while rotating the shaft. Then loosen the RH retainer. Keep tightening the LH retainer and loosening the RH retainer until the pinion shaft can no longer be turned. This is the zero state.





(A) Retainer
After the zero state is established, back off the LH retainer 3 notches and secure it with the lock plate. Then back off the RH retainer and retighten until it stops. Rotate drive pinion a few times. Tighten the RH retainer 1-3/4 notches further. This sets the preload. Finally, secure the retainer with its lock plate.





(A) Lock plate

Note: Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 inch).





Turn the drive pinion several rotations with ST1 and check to see if the backlash is within the standard value with ST2, ST3, ST4 and ST5.

ST1 32005154 WRENCH
ST2 32005094 MAGNET BASE
ST3 32005095 DIAL GAUGE
ST4 32005153 ADAPTER
ST5 32005096 PLATE
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)





Adjust the tooth contact between front differential and drive shaft.