Differential: Service and Repair
NOTE: For removal and installation procedures refer to "Manual Transmission/Transaxle, Service and Repair."DIFFERENTIAL CASE DISASSEMBLY
1. Remove side bearing from differential case.
Using Special Service Tool (SST) 09950 - 00020, 09950 - 00030, 09950 - 60010 (09951 -00360) or equivalent, remove the bearings from both sides of the case.
b. Remove the speedometer drive gear from the RH side.
2. Remove ring gear.
a. Place match marks on the ring gear and case.
b. Remove the 6 bolts.
Using a plastic hammer, tap on the ring gear to remove it from the case.
3. Inspect side gear backlash.
Using a dial indicator, measure the backlash of oil side gear while holding one pinion toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install the correct thrust washer to the side gears.
4. Disassemble differential case.
Using a pin punch and hammer, drive out the pinion shaft straight pin.
b. Remove the pinion shaft from the case.
c. Remove the 2 pinion gears and side gears with the 4 thrust washers from each gear.
5. If necessary, replace oil seal and side bearing outer race from transmission case side.
a. Using a screwdriver and hammer, drive out the oil seal.
b. Using Special Service Tool (SST) 09612 - 65014 or equivalent, pull out the outer race and plate washer.
c. Place the plate washer into the case.
d. Using SST 09950 - 60020 (09951 - 00710) 09950 -70010 (09951 - 07150), and a hammer, drive in a new outer race.
e. Using SST 09350 - 32014 (09351 - 32111, 09351 - 32130) and a hammer, drive in a new oil seal.
e. Drive in depth: 2.4 +/- 0.3 mm (0.094 +/- 0.012 in.)
f. Coat the lip of the oil seal with MP grease.
6. If necessary, replace oil seal and side bearing outer race from transaxle case side.
a. Using a screwdriver and hammer, drive out the oil seal.
b. Using SST 09612 - 65014, pull out the outer race and plate washer.
c. Place the plate washer into the case.
d. Using SST 09950 - 60020 (09951 - 00680), 09950-70010 (09951 -07150) and a hammer, drive in a new outer race.
e. Using SST 09350 - 32014 (09351 - 32130, 09351 - 32150) and a hammer, drive in a new oil seal.
Drive in depth: 1.9 +/- 0.3 mm (0.075 +/- 0.012 in.)
f. Coat the lip of the oil seal with MP grease.
DIFFERENTIAL CASE ASSEMBLY
1. Assemble differential case.
a. Install the correct thrust washers and side gears.
Select thrust washers which will ensure that the backlash is within the specification. Try to select washers of the same size for both sides.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
b. Install the thrust washers and side gears in the differential case.
c. Install the pinion shaft.
d. Using a dial indicator, check the side gear backlash.
e. Measure the side gear backlash while holding a pinion gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install a thrust washer of different thickness.
Using a pin punch and hammer, drive in the straight pin through the case and hole in the pinion shaft.
f. Stake the differential case.
2. Install ring gear on differential case.
a. Clean the contact surface of the differential case.
b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
NOTE: Align the matchmarks on the differential case and contact the ring gear.
e. Install the 6 set bolts. Tighten each set bolt uniform! a little at a time in succession. Torque the bolts.
Torque: 124 Nm (1.260 kgf/cm, 91 ft.lbs.)
3. Install side bearing.
a. Install the speedometer drive gear to the RH side.
b. Using SST 09350 - 32014 (09351 - 32090, 09351 - 32120) and a press, install new side bearings to the both sides of the case.
4. Inspect differential side bearing preload.
a. Install the differential case assembly to the transaxle case.
b. Install the transmission case.
c. Install and torque the case bolts.
Torque: 29 Nm (300 kgf/cm, 22 ft.lbs.)
d. Using SST 09564 - 32011 and a torque wrench, measure the preload.
Preload (at starting):
- New bearing 0.8 - 1.6 Nm (8 - 16 kgf/cm, 6.9 - 13.9 in.lbs.)
- Reused bearing 0.5 - 1.0 Nm (5 - 10 kgf/cm, 4.3 - 8.7 in.lbs.)
If the preload is not within the specification, remove the transmission case side outer race of the side bearing with SST.
Select another shim.
NOTE: The preload will change by about 0.3 - 0.4 Nm (3 - 4 kgf/cm, 2.6 - 3.5 in.lbs.) with each 0.05 mm chance in shim thickness.