A540E & A540H

COMPONENTS

DISASSEMBLY OF DIFFERENTIAL CASE




1. REMOVE SIDE BEARING
Using SST, remove the two side bearings.

SST 09950-20017

2. REMOVE RING GEAR




a. Place the matchmarks on both the differential case and ring gear.




b. Remove the sixteen bolts.




c. Using a plastic hammer, tap out the ring gear.

3. DISASSEMBLE OF DIFFERENTIAL CASE




a. Place the matchmarks on the differential right and left case.




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




c. Using a plastic hammer, tap out the differential left case.
d. Remove the speedometer drive gear from the differential right case.




e. Remove the two differential side gears, two side thrust washers, differential spider, four differential pinions and four pinion washers from the differential left case.

4. DISASSEMBLE 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.




5. REMOVE RH OIL SEAL FROM RH RETAINER
Using a hammer and screwdriver, drive out the oil seal.

ASSEMBLY OF DIFFERENTIAL CASE




1. INSTALL RH OIL SEAL TO RH RETAINER
a. Using SST, drive in a new oil seal until its surface is flush with the surface of RH retainer.

SST 09316-60010 (09316-00010)

b. Coat the oil seal lip with MP grease.

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




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

HINT: 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)

HINT: Install the oil baffle and oil seal after adjusting the differential side bearing preload. Part 1

3. ASSEMBLE DIFFERENTIAL CASE

HINT: Coat all of the sliding and rotating surface with ATF 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 side gear.

Standard backlash: 0.05 - 0.20 mm
(0.0020 - 0.0079 in.)

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




f. Referring to the table, select the side gear 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 plastic hammer, carefully tap the differential right case.




j. Using a torx wrench, install and torque the sixteen torx screws.

Torque: 640 kg-cm (46 ft-lb, 63 N.m)

4. INSTALL RING GEAR




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

NOTE: 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 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)

5. INSTALL SIDE BEARINGS




a. Using SST and a press, install the RH side bearing to the differential case.

SST 09361-20011




b. Using SST and a press, install the LH side bearing.

SST 09316-60010 (09316-00010)