Differential Reassembly
Differential ReassemblySpecial Tools Required
^ Oil seal driver 07JAD-PL90100
^ Holder handle 07JAB-001020A
^ Attachment, 40 x 50 mm I.D. 07LAD-PW50601
^ Attachment, 45 x 55 mm I.D. 07MAD-PR90100
^ Attachment, 78 x 80 mm 07NAD-PX40100
^ Companion flange holder 07RAB-TB4010B
^ Universal holder 07725-0030000
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300
^ Driver 07749-0010000
1. Apply Hondalock 1 (P/N 08713-0001) to the surface of the ring gear and ten mounting bolts.
2. Install the ring gear, then tighten the ten mounting bolts in a crisscross pattern in several steps.
3. Install the tapered roller bearing using the 40 x 50 mm I.D. attachment (A) and a press as shown.
4. Install the standard thrust washer 3.47 mm (0.1366 in.) (A) onto the drive pinion gear (B). Then install the tapered roller bearing (C) using the old pinion spacer (D), 40 mm I.D. driver (E), and 30 mm I.D. attachment (F) as shown.
5. Install the bearing outer races (A) into the differential carrier using the 45 x 55 mm I.D. attachment (B), 40 mm I.D. driver (C), 78 x 80 mm attachment (D), and driver (E) as shown.
6. Apply the recommended fluid to the tapered roller bearing (A), then install the drive pinion gear (B) and new pinion spacer (C) into the differential carrier (D).
7. Apply the recommended fluid to the tapered roller bearing, then install the tapered roller bearing and spacer (A) using the 40 mm I.D. driver (B) and 30 mm I.D. attachment (C) while holding the drive pinion gear (D).
8. Install the new oil seal using the companion flange and 40 mm I.D. driver (A) as shown.
9. Apply molybdenum grease to the surface end of the companion flange, then install the companion flange (A), drive pinion washer (B), and new locknut (C).
10. Install the holder handle (A) and companion flange holder (8) to the companion flange, then tighten the locknut to 20 Nm (2.0 kgf-m, 14 lbf-ft).
11. Rotate the drive pinion several times to ensure proper tapered roller bearing contact. Measure the drive pinion turning torque before tightening the locknut to the specified torque.
12. Tighten the locknut to 127 Nm (13.0 kgf-m, 94 lbf-ft), then remove the holder handle (A) and companion flange holder (B).
13. Rotate the drive pinion several times to assure proper tapered roller bearing contact. Measure the drive pinion turning torque.
^ If the drive pinion turning torque exceeds the standard, replace the pinion spacer.
^ If the drive pinion turning torque is less than the standard, adjust by tightening the locknut a little at a time, but keep the torque within 127 - 284 Nm (13.0 - 29.0 kgf-m, 94 - 210 lbf-ft). If this is not possible, replace the pinion spacer.
Turning Torque: 0.88 - 1.37 Nm (9.0 - 14.0 kgf-cm, 7.8 - 12.1 lbf-in) + Tp (from step 11)
Tp: Actual measurement of drive pinion turning torque
14. Install the Torsen LSD assembly (A), bearing outer races (B), and adjustment screws (C) onto the differential carrier.
15. Install the bearing caps (A) while aligning both the marks (B) on the threads of the adjustment screws and bearing caps, then install the mounting bolts finger-tight.
16. Measure the backlash of the ring gear.
17. Tighten the bearing cap mounting bolts.
18. Thoroughly clean the ring gear teeth (A) and drive pinion gear teeth, and paint the ring gear teeth (B) with Prussian Blue lightly and evenly.
19. Rotate the companion flange (C) three full turns forward and then backward to produce a contact pattern on the ring gear. During this operation, resistance should be applied to the ring gear.
20. Check the tooth contact pattern and adjust it if needed.
^ Toe Contact: Use a thinner thrust washer to move the drive pinion gear away from the ring gear.
^ Heel Contact: Use a thicker thrust washer to move the drive pinion gear toward from the ring gear.
^ Flank Contact: To move the ring gear away from the drive pinion gear, tighten the adjustment screw on the drive pinion gear side and loosen the adjustment screw on the ring gear side. Recheck backlash after adjusting the adjustment screws. If out of specification, adjust as described under Toe Contact.
^ Face Contact: To move the ring gear toward the drive pinion gear, tighten the adjustment screw on the ring gear side, and loosen the adjustment screw on the drive pinion gear side. Recheck backlash after adjusting the adjustment screws. If out of specification, adjust as described under Heel Contact.
21. Rotate the Torsen LSD assembly several times to ensure proper tapered roller bearing contact. Measure the Torsen LSD assembly preload using the push/pull gauge.
^ If the Torsen LSD assembly preload exceeds the standard, adjust by loosening the adjustment screws a notch at a time.
^ If the Torsen LSD assembly preload is less than the standard, adjust by tightening the adjustment screws a notch at a time.
22. Install the lock plates (A).
23. Install the new oil seal using the oil seal driver (A) as shown.
24. Install the breather plate (A), drain plug (B), and new sealing washers (C). Install the filler plug (D) finger-tight.
25. Clean the dirt and oil from the mating surfaces. Apply liquid gasket, P/N 08718-0001 evenly to the mating surface of the differential case and the differential carrier. Install the component within 5 minutes of applying the liquid gasket.
26. Install the differential case.
27. Tighten the ten mounting bolts in a crisscross pattern in several steps.
28. Install the new clips (A) on the output shafts, then install the output shafts (B).
