Assembly of Differential Case

1. ASSEMBLE DIFFERENTIAL CASE

HINT: Coat all of the sliding and rotating surface with gear oil before assembly.

a. Install the thrust washer to the side gear.




b. Install the four pinions and thrust washers to the spider.
c. Install the side gear and spider with four pinions to the differential left case.




d. Using a dial indicator, measure the backlash of one pinion gear while holding the No.2 differential case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)

HINT: Push the pinion gear of the left side of the differential case.

e. Install the side gear and spider with four pinions to the right side of the differential case.
Check the side gear backlash.




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




g. Install the speedometer driven gear.




h. Align the matchmarks on the differential cases.




i. Using a plastic hammer, carefully tap the differential case.




j. Using a torx wrench, install and torque the sixteen torx screws.
Torx wrench T50 09042-00040
Torque: 640 kg-cm (46 ft-lb, 63 N.m)




2. INSTALL RING GEAR
a. Clean the contact surface of the differential case.
b. Heat the ring gear to about 100°C (212°F) in an oil bath.

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

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




d. Quickly install the ring gear on the differential case. Install the sixteen bolts.

HINT: Align the matchmarks on the differential left case and contact the ring gear.

e. 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)




3. INSTALL SIDE BEARING
Using SST and a press, install the side bearings onto the differential case.
SST 09316-20011, 09506-35010

HINT: Press the bearing on the ring gear side first.

4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See "Installation of Component Parts")




5. INSTALL DIFFERENTIAL CASE ASSEMBLY
Install the differential case assembly to the transaxle case.




6. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case, install the output shaft assembly.




7. INSTALL TRANSMISSION CASE
a. Install the transmission case.

HINT: If necessary, tap on the case with a plastic hammer.

b. Install and torque the seventeen bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)




8. INSTALL OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.




9. INSTALL SHIM
(See "Installation of Component Parts")

HINT: Install the previously selected shim.




10. INSTALL REAR BEARING RETAINER
Using a torx wrench, install and torque the seven torx screws.
Torx wrench T45 09042-00050

Torque: 430 kg-cm (31 ft-lb, 42 N.m)

11. ADJUST DIFFERENTIAL CASE PRELOAD
a. Install the new lock nut to the output shaft.
b. Turn the output shaft right and left two or three times to allow the bearings to settle.




c. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Add output shaft preload) 2.0 - 4.1 kg-cm (1.7 - 3.6 in.-lb, 0.2 - 0.4 N.m)
Reused bearing (Add output shaft preload) 1.3 - 2.5 kg-cm (1.1 - 2.2 in.-lb, 0.1 - 0.2 N.m)




If the preload is not within specification, select the thrust washers.

HINT: The total preload will change about 1 - 2 kg-cm (0.9 - 1.7 in.-lb, 0.1 - 0.2 N.m) with each shim thickness.




12. REMOVE REAR BEARING RETAINER
Using torx wrench, remove the seven torx screws and rear bearing retainer.
Torx wrench T45 09042-00050
13. REMOVE SHIM




14. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with a plastic hammer.




15. REMOVE OUTPUT SHAFT ASSEMBLY
16. REMOVE DIFFERENTIAL CASE ASSEMBLY