Differential Assembly (With A540H Transaxle)

COMPONENTS

DISASSEMBLY OF DIFFERENTIAL ASSEMBLY




1. REMOVE RIGHT SIDE BEARING OUTER RACE




2. CHECK DIFFERENTIAL END PLAY
Using a dial indicator, measure the differential end play.

End play: 0.18 - 0.82 mm (0.0071 - 0.0323 in.)




3. REMOVE RING GEAR MOUNTING CASE SLEEVE




4. REMOVE OIL SEAL RINGS
Remove four oil seal rings from the ring gear mounting right case.




5. REMOVE SPEEDOMETER DRIVE GEAR
Using snap ring pliers, remove the snap ring and the speedometer drive gear.




6. REMOVE RING GEAR MOUNTING LEFT CASE
a. Place matchmarks on the ring gear mounting left case and right case.
b. Remove the twelve bolts and left case.

7. REMOVE RING GEAR




a. Place matchmarks on the ring gear and left case.




b. Place the left case on SST.
SST 09350-32014 (09351-32090)
c. Using a plastic hammer, remove the ring gear from the left case.

8. REMOVE FRONT DIFFERENTIAL CASE




a. Remove the No.2 thrust washer.




b. Remove the front differential case from the ring gear mounting right case.




9. REMOVE FRONT DIFFERENTIAL LEFT CASE
a. Using a torx wrench, remove the sixteen screws from the left case.
b. Separate the left case and right case.

CAUTION: Do not scratch the contact surface of the needle bearing.




10. REMOVE DIFFERENTIAL PINIONS AND SIDE GEARS
Remove the two differential side gears, two side thrust washers, differential spider, four differential pinions and four pinion washers from the front differential cases.




11. REMOVE NO.1 THRUST WASHER




12. CHECK OPERATION OF CLUTCH PISTONS
a. Plug one hole of the right case with your hand.
b. Apply compressed air into the other hole and confirm that the pistons move.

13. REMOVE HYDRAULIC MULTIPLATE CLUTCH DISCS AND PLATES




a. Using a screwdriver, remove the snap ring.




b. Remove the flange, eleven discs and eleven plates.



c. Place SST, and compress the return spring.
SST 09350-32014 (09351-32070)

d. Using snap ring pliers, remove the snap ring.




e. Apply compressed air to the right case hole to remove the No.1 piston.
f. Remove the O-ring from the No.1 piston.




g. Using a small screwdriver, remove the reaction sleeve and No.2 piston.
h. Remove the three O-rings from the reaction sleeve and No.2 piston.

REPLACEMENT OF RING GEAR MOUNTING CASE BEARINGS




1. REMOVE RING GEAR MOUNTING LEFT CASE BEARING
Using SST, remove the bearing.
SST 09950-00020, 09950-00030




2. INSTALL RING GEAR MOUNTING LEFT CASE BEARING
Using a press and SST, press in the bearing.
SST 09316-20011, 09350-32014 (09351-32090)

3. REMOVE RING GEAR MOUNTING RIGHT CASE BEARING




a. Using a chisel and hammer, cut out the bearing cage.

CAUTION: Do not damage the right case.




b. Using a press and SST, press out the bearing inner race.
SST 09350-32014 (09351-32090), 09950-00020




4. INSTALL RING GEAR MOUNTING RIGHT CASE BEARING
Using a press and SST, press in the new bearing.
SST 09316-60010 (09316-00010), 09502-12010

5. REMOVE RING GEAR MOUNTING LEFT CASE BEARING OUTER RACE FROM LH BEARING RETAINER




a. Using a hammer and screwdriver, remove the oil seal.
b. Remove the oil baffle from the LH bearing retainer




c. Using a hammer and brass bar, drive out the outer race and adjusting shim from LH bearing retainer.

6. INSTALL ADJUSTING SHIM AND BEARING OUTER RACE TO LH BEARING RETAINER




a. Place the adjusting shim into the LH bearing retainer.

NOTE: Use either the shim which was removed or one 2.40 mm (0.0945 in.).




b. Using SST, press the outer race into the LH retainer.
SST 09316-20011, 09350-32014 (09351-32150)

NOTE: Install the oil baffle and oil seal after adjusting the differential side bearing preload.


INSPECTION OF HYDRAULIC MULTIPLATE CLUTCH




INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of discs, plates and flange are worn or burnt. If necessary, replace them.

NOTE:
- If the lining of the disc is exfoliated or discolored, or even a part of the printed number is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least fifteen minutes.


ASSEMBLY OF DIFFERENTIAL ASSEMBLY
1. INSTALL PISTONS AND SLEEVE




a. Coat the four O-rings with ATF.
b. Install the four O-rings to the reaction sleeve and pistons.




c. Install the No.1 (A), No.2 (B) pistons and reaction sleeve (C) to the ring gear mounting right case.




2. INSTALL PISTON RETURN SPRING
a. Place the spring on the piston.
b. Place SST on the spring retainer, and compress the spring with a press.
SST 09350-32014 (09351-32070)
c. Using snap ring pliers, install the snap ring.

3. INSTALL PLATE, DISCS AND FLANGE



a. Install the plate and discs.

Install in order: P = Plate D = Disc
P-D-P-D-P-D-P-D-P-D-P-D-P-D-P-D-P-D-P-D-P-D

NOTE: Before assembling new discs, soak them in ATF for at least fifteen minutes.




b. Install the flange with the flat end facing downward.




c. Using a screwdriver, install the snap ring.




4. CHECK OPERATION OF CLUTCH PISTONS
a. Plug one hole with your hand.
b. Apply compressed air into the other hole and make sure that the pistons move.




5. INSTALL NO.1 THRUST WASHER

6. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH

(Front Differential Left Case)




a. Install the following parts:
- Side gear thrust washer
- Side gear
- Four differential pinion gears
- Four pinion gear thrust washers
- Differential spider




b. Using a dial indicator, measure the backlash of one pinion gear while holding the side gear toward the case.

Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)

If not within specification select the side gear thrust washer.

CAUTION: Do not tighten the vise too tight.

c. Remove four pinion gears, four thrust washers and spider.

(Front Differential Right Case)




a. Install the following parts:
- Side gear thrust washer
- Side gear
- Four differential pinion gears
- Four pinion gear thrust washers
- Differential spider




b. Using a dial indicator, measure the backlash of one pinion gear while holding the side gear toward the case.

Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)




Referring to the table above, select the side gear thrust washer which will ensure that the backlash is within specification. Try to select a washer of the same size.

7. INSTALL FRONT DIFFERENTIAL LEFT CASE




a. Install the left case to the right case.

NOTE: Align the matchmarks on the left case and right case.




b. Using a torx wrench, torque the sixteen torx screws.

Torque: 340 kg.cm. (25 ft.lb., 33 N.m)

CAUTION: Do not scratch the contact surface of the needle bearing.

8. INSTALL FRONT DIFFERENTIAL CASE




a. Install the front differential case to the ring gear mounting right case.

NOTE: Align the flukes of the discs in the hydraulic multiplate clutch.




b. Install the No.2 thrust washer.

9. INSTALL RING GEAR




a. Clean the contact surface of the ring gear mounting left case.
b. Heat the ring gear to about 212°F (100°C) in an oil bath.

CAUTION: Do not heat the ring gear above 230°F (110°C).

c. Clean the contact surface of the ring gear with cleaning solvent.




d. Quickly install the ring gear on the ring gear mounting left case.

NOTE: Align the matchmarks on the ring gear mounting left case and the ring gear.




e. Install the ring gear and ring gear mounting left case on the ring gear mounting right case. Install the twelve bolts.

NOTE: Align the matchmarks on the ring gear mounting left case and contact the right case.

f. Tighten the set bolts uniformly and a little at a time. Torque the bolts.

Torque: 1,260 kg.cm. (91 ft.lb. 124 N.m)




10. CHECK OPERATION OF FRONT DIFFERENTIAL
Check that the front differential turns smoothly.




11. INSTALL SPEEDOMETER DRIVE GEAR
a. Place the speedometer drive gear on the ring gear mounting case.
b. Install the snap ring.




12. INSTALL OIL SEAL RINGS
Install the four oil seal rings to the ring gear mounting right case.




13. INSTALL RING GEAR MOUNTING CASE SLEEVE




14. INSTALL RIGHT SIDE BEARING OUTER RACE

DISASSEMBLY OF DRIVE PINION




1. REMOVE DRIVE PINION SHAFT BEARING
Using SST and a press, remove the bearing.
SST 09950-00020




2. REMOVE PINION SHAFT BEARING OUTER RACE FROM CAGE
Using SST, remove the outer race.
SST 09612-65014




3. REMOVE COUNTER DRIVEN GEAR BEARING
Using SST and a press, remove the bearing.
SST 09950-00020

ASSEMBLY OF DRIVE PINION SHAFT COMPONENTS




1. INSTALL COUNTER DRIVEN GEAR BEARING
Using SST, press in a new bearing.
SST 09350-32014 (09351-32090)




2. INSTALL SHAFT BEARING OUTER RACE TO CAGE
Using SST, press the outer race into the cage.
SST 09350-32014 (09351-32111)




3. INSTALL DRIVE PINION SHAFT BEARING Using SST, press in the bearing.
SST 09350-32014 (09351-32100)