Differential Case
DIFFERENTIAL CASECOMPONENTS:
COMPONENTS:
DISASSEMBLY
1. 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 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00390)
b) Using SST, remove the front differential case front tapered roller bearing outer race from the transaxle housing.
SST 09387-00041 (09387-02010, 09387-02020)
2. 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 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00430)
b) Using SST, remove the outer race and shim.
SST 09612-65014 (09612-01010)
3. REMOVE SPEEDOMETER DRIVE GEAR
a) Remove the speedometer drive gear from the differential case.
4. REMOVE FRONT DIFFERENTIAL RING GEAR
a) Place matchmarks on the front differential ring gear and differential case.
b) Using SST and a hammer, unstake the lock plate.
SST 09930-00010
c) Remove the 8 bolts and lock plate.
d) Using a plastic-faced hammer, tap out the front differential ring gear from the differential case.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a) Using a pin punch and hammer, unstake the differential case.
b) Using a pin punch and hammer, tap out the straight pin.
6. REMOVE FRONT DIFFERENTIAL NO. 1 PINION SHAFT
a) Remove the pinion shaft from the front differential case.
7. REMOVE FRONT DIFFERENTIAL SIDE GEAR
a) Remove the 2 pinions, 2 thrust washers, 2 side gears and 2 thrust washers from the front differential case.
8. REMOVE DIFFERENTIAL DRIVE PINION PLUG
a) Using a brass bar and plastic-faced hammer, tap out the differential drive pinion plug.
9. REMOVE COUNTER DRIVEN GEAR
a) Using SST and a press, press out the counter driven gear from the differential drive pinion.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07150)
REASSEMBLY
1. INSTALL COUNTER DRIVEN GEAR
a) Using SST and a press, press in the counter driven gear to the differential drive pinion.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07150)
NOTICE: When replacing the counter driven gear, replace the counter drive gear in the transaxle case, too.
HINT: The differential drive pinion should be pressed in until it comes in contact with the counter driven gear.
2. INSTALL DIFFERENTIAL DRIVE PINION PLUG
a) Using SST and a plastic-faced hammer, tap in a new differential drive pinion plug to the differential drive pinion.
SST 09221-25026 (09221-00071)
Standard clearance A: 2.5 to 2.6 mm (0.0984 to 0.1023 inch)
3. INSTALL FRONT DIFFERENTIAL SIDE GEAR
a) After applying ATF to the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers, install them to the front differential case.
HINT: At the time of installation, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes will be aligned with the holes in the differential case.
4. INSTALL FRONT DIFFERENTIAL NO. 1 PINION SHAFT
a) Install the pinion shaft to align the lock pin holes on the pinion shaft and differential case.
5. INSPECT BACKLASH
a) Measure the side gear backlash while holding 1 pinion gear toward the case.
Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not within the specification, install the correct thrust washer to the side gear.
b) Referring to the table, select thrust washers which will ensure that the backlash is within the specification for both sides.
Standard thrust washer thickness
Standard thrust washer thickness:
If the backlash is not within the specification, install a thrust washer of a different thickness.
6. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a) Using a pin punch and hammer, tap in the pinion shaft straight pin.
b) Using a chisel and hammer, stake the differential case.
7. 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).
b) Clean the contact surface of the front differential case.
c) Install the 4 lock plates and 8 bolts.
Torque: 88.2 Nm (899 kgf-cm, 65 ft. lbs.)
d) Stake the ring gear lock plate.
8. INSTALL SPEEDOMETER DRIVE GEAR
a) Install the speedometer drive gear to the differential case.
9. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a) Using SST and a press, press in the front differential case front tapered roller bearing to the differential case.
SST 09316-60011 (09316-00011)
b) Using SST and a press, press in the front differential case front tapered roller bearing to the transaxle housing.
SST 09950-60020 (09951-00750), 09950-70010 (09951-07150)
10. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a) Using SST and a press, press in the front differential case rear tapered roller bearing to the differential case.
SST 09726-40010, 09950-60020 (09951-00790)
b) Using SST and a press, press in the shim and front differential case rear tapered roller bearing outer race to the transaxle case.
SST 09950-60010 (09951-00650, 09950-60020 (09951-00720), 09950-70010 (09951-07100, 09951-07200)
11. ADJUST TAPERED ROLLER BEARING PRELOAD
a) Coat the front differential case and bearing with ATF, and install them to the transaxle case.
b) Install the 14 bolts and transaxle housing.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.) for bolt A
22.1 Nm (225 kgf-cm, 16 ft. lbs.) for bolt B
c) Using SST and a small torque wrench, measure the preload of the differential gear.
SST 09564-32011
New bearing preload: 0.98 to 1.57 N/m (10.0 to 16.0 kgf-cm, 8.7 to 13.9 inch lbs.)
Used bearing preload: 0.49 to 0.78 N/m (5.0 to 8.0 kgf-cm, 4.3 to 6.9 inch lbs.)
If the preload is not within the specification, remove the differential from the transaxle case. Reselect the transaxle case side adjusting shim according to the table.
Standard adjusting shim thickness
Standard adjusting shim thickness:
Standard adjusting shim thickness:
