Part 3

REMOVAL OF DIFFERENTIAL COMPONENT PARTS




1. MEASURE DIFFERENTIAL TOTAL PRELOAD
Using a torque meter measure the total preload, and make a note of it.

2. REMOVE LH BEARING RETAINER




a. Remove the six bolts.




b. Using a large screwdriver, remove the LH bearing retainer.

NOTE: Wrap the screwdriver in a rag, etc. to avoid damage to the case and retainer.

3. (A540E) REMOVE RH RETAINER




a. Remove the six bolts.




b. Using a large screwdriver, remove the RH retainer.

NOTE: Wrap the screwdriver in a rag, etc. to avoid damage to the case and retainer.

4. REMOVE CARRIER COVER







a. Remove the eleven bolts.







b. Tap the carrier cover with a plastic hammer to remove it.

5. REMOVE DIFFERENTIAL CASE




a. (A540E)
Remove the differential case, outer race and shim from the transaxle case.




(A540H)
Remove the differential assembly.




b. Remove the two apply gaskets.

6. REMOVE DRIVE PINION CAP




a. Remove the bolt.




b. Using pliers, pull out the drive pinion cap.
c. Remove the O-rings from the cap.




7. MEASURE DRIVE PINION PRELOAD
Using a torque meter, measure the drive pinion preload.

Preload (at starting): Reused bearing
5 - 8 kg-cm (4.3 - 6.9 in.-lb, 0.5 - 0.8 N.m

The total preload measured in step 1 minus the drive pinion preload equals 1.3 - 2.0 kg-cm (1.1 - 1.7 in-lb, 0.1 - 0.2 N.m). If the result is not within this specification, the side bearing preload is bad.




8. REMOVE COUNTER DRIVEN GEAR
a. Using a chisel, loosen the staked part of the nut.




b. Using SST to hold the gear, remove the nut.

SST 09330-00021,09350-32014 (09351-32032)




c. Using SST, remove the gear and bearing.

SST 09350-32014 (09351-32061)




a. Using SST, remove the outer race.
SST 09350-32014 (09308-10010)




b. Remove the spacer and oil slinger




10. (A540E) REMOVE SENSOR ROTOR




11. (A540H)
REMOVE DRIVE PINION BEARING NO.2 SPACER

12. REMOVE DRIVE PINION




a. Using SST, remove the snap ring.

SST 09350-32014 (09351-32050)

CAUTION: Take care not to scratch the inside of the transaxle.




b. Insert the bar into the case hole to drive out the drive pinion.
c. Using a press, drive out the drive pinion from transaxle case.

CAUTION: Take care not to scratch the inside of the transaxle case when driving out the drive pinion.




d. (A540E)
Remove the two O-rings from the bearing cage.




e. Remove the bearing cage from drive pinion.