Assembly of Differential Case

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




1. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR BACKLASH
(Differential Side Gear Sub Assembly)
a. Install the No.2 side gear thrust washer, (Temporarily install) 1.0 mm (0.039 in.) size thrust washer, differential side gear subassembly, spider, five pinions and pinion thrust washers to the differential right case.

HINT: Thrust washer 1.0 mm (0.039 in.) size is for check of backlash.







b. Using a dial indicator, measure the backlash of one pinion gear while holding the differential side gear sub assembly toward the case.

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

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

Referring to the table, select the No.2 thrust washer which will ensure that the backlash is within specification. Try to select a washer of the same size.

c. Remove the differential right case.
(No.2 Differential Case)




a. Install the No.2 side gear thrust washer, (Temporarily install) 1.0 mm (0.039 in.) size thrust washer and differential No.2 case to the differential left case.

HINT: Thrust washer 1.0 mm (0.039 in.) size is for check of backlash.




b. Using four transmission case cover bolts, install the differential intermediate case to the left case.

HINT: Align the alignment marks on the differential left case and connect the intermediate case.




c. Install the differential spider, five pinions and pinion thrust washers to the differential intermediate 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 differential intermediate case.

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

c. Remove the differential case.




2. ASSEMBLY DIFFERENTIAL RIGHT CASE
a. Install the No.2 side gear thrust washer (previously selected), conical spring washer and differential side gear subassembly to the right case.

HINT: Be careful not to mistake the direction of conical spring washer.




b. Install the differential spider, five pinion and pinion thrust washers to the differential right case.




3. INSTALL SPEEDOMETER DRIVE GEAR
Install the speedometer drive gear to the differential right case.




4. INSTALL DIFFERENTIAL INTERMEDIATE CASE
a. Align the alignment marks on the right case and connect the intermediate case.
b. Install the fifteen torx screws Using a torx wrench, tighten the screws uniformly and a little at a time in succession. Torque the screws.

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




5. CHECK AND ADJUST FRONT SIDE GEAR BACKLASH (Differential No.2 Case)
a. Install the front differential side gear thrust washer, side gear, pinion shaft holder, four pinions and thrust washers.




b. Fit No.2 case pin hole and pinion shaft pin hole, install the No.2 pinion shaft and two pinion shafts to the No.2 case.
c. Install the three straight pins.







d. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.

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

HINT: Do not mount the surface of No.2 differential case which contacts with bushing in a vise.

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.




6. INSTALL SNAP RING
Using snap ring pliers, install the shaft snap ring toward as shown.

HINT: Before installing the shaft snap ring, wrap vinyl tape around the case prevent from damage.




7. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR THRUST CLEARANCE
(Differential Left Case)
a. Install the No.2 side gear thrust washer, (Temporarily install) 1.0 mm (0.039 in.) size No.2 side gear thrust washer, front differential side gear thrust washer, side gear and No.2 case assembly.

HINT: Engage the front differential side gear and pinion gear of No.2 case.







b. Using a dial indicator, measure the thrust clearance of front differential side gear while holding the No.2 case on the left side.

Standard clearance: 0.14 - 0.21 mm
(0.006 - 0.008 in.)

HINT: Turning the side gear a bit, check the maximum value of thrust clearance.

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

c. Remove the differential left case.




8. ASSEMBLY DIFFERENTIAL LEFT CASE
a. Install the No.2 side gear thrust washer (previously selected) and conical spring washer to the left case.

HINT: Be careful not to mistake the direction of conical A spring washer.




b. Install the front differential side gear thrust washer and side gear to the left case.
c. Install the differential No.2 case assembly.

HINT: Engage the front differential side gear and pinion gear of No.2 case.




d. Turning the differential No.2 case, check the turns smoothly.




e. Install the intermediate case to the differential left case.

HINT: Align the matchmarks on the differential left case and connect the intermediate case.




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

NOTE: Do not heat the ring gear above 11 °C (230 °F)

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




d. Then quickly install the ring gear on the differential case.

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

e. Install the sixteen set bolts. Tighten the set bolts uniformly and a little at a time in succession. Torque the bolts.

Torque: 1260 kg-cm (91 ft-lb. 124 N-m)




10. INSTALL SIDE BEARING
Using SST and a press install the side bearing to the differential case.
SST 09316-20011 and 09316-60010 (09316-00010)
11. ADJUST OUTPUT SHAFT PRELOAD




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




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




14. 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)




15. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER BEARING OUTER RACE




16. INSTALL ADJUST SHIM

HINT: Install the previously selected shim.




17. INSTALL REAR BEARING RETAINER
Using a torx wrench, install and torque the seven torx screws.

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







18. 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
1.9 - 3.7 kg-cm
(1.6 - 3.2 in-lb, 0.2 - 0.4 N-m)
Reused bearing
Add output shaft preload
1.2 - 2.3 kg-cm
(1.0 - 2.0 in-lb, 0.1 - 0.2 N-m)

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

HINT: The preload will change about 1.3 kg-cm (1.13 in-lb, 0.13 N-m) with each shim thickness.




19. REMOVE REAR BEARING RETAINER
Using torx wrench, remove the seven torx screws and rear bearing retainer.




20. REMOVE ADJUST SHIM
21. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with a plastic hammer.




22. REMOVE OUTPUT SHAFT ASSEMBLY
23. REMOVE DIFFERENTIAL CASE ASSEMBLY