Differential Assembly (With A241H Transaxle)

COMPONENTS

DISASSEMBLY OF DIFFERENTIAL ASSEMBLY

1. CHECK DIFFERENTIAL END PLAY
Using a dial indicator, measure the differential end play.

End play: 0.18 - 0.82 mm (0.0071 - 0.0323 in.)

2. REMOVE OIL SEAL RINGS
Remove two oil seal rings from the ring gear mounting right case.

3. REMOVE SPEEDOMETER DRIVE GEAR
Using a screwdriver, remove the shaft snap ring and the speedometer drive gear.

4. REMOVE RING GEAR MOUNTING LEFT CASE
a. Place the matchmarks to the ring gear mounting left case and right case.
b. Remove the ten bolts and left case.

5. REMOVE RING GEAR
a. Place the matchmarks on the ring gear and left case.
b. Place the left case on SST.

SST 09350-32014 (09351-32090)

c. Using a plastic hammer, remove the ring gear from the left case.

6. REMOVE FRONT DIFFERENTIAL CASE

a. Remove the No.2 thrust washer.

b. Remove the front differential case from the ring gear mounting right case.

7. REMOVE FRONT DIFFERENTIAL LEFT CASE
a. Using a torx wrench, remove the eight screws from the left case.
b. Separate the left case and right case.

NOTE: Do not scratch the contact surface of the needle bearing.

8. REMOVE DRIVE PINIONS AND SIDE GEARS
Remove the following parts:
- Differential pinion shaft
- Shaft pin
- Two pinion gears
- Two pinion thrust washers
- Two side gears
- Two side gear thrust washers

9. REMOVE NO.1 THRUST WASHER

10. CHECK OPERATION OF DIFFERENTIAL LOCK CLUTCH PISTON
a. Plug one hole of the right case with your hand.
b. Apply compressed air into the other hole and confirm that the piston move.

11. REMOVE DIFFERENTIAL LOCK CLUTCH

a. Using a screwdriver, remove the snap ring.

b. Remove the flange, seven discs and seven plates.

c. Place SST, and compress the return spring.

SST 09350-32014 (09351-32070)

d. Using the snap ring pliers, remove the snap ring.

e. Apply compressed air to the right case hole to remove the No.1 piston.
f. Remove the O-ring from the No.1 piston.

g. Using a small screwdriver, remove the reaction sleeve and No.2 piston.
h. Remove the three O-rings from the reaction sleeve and No.2 piston.

12. REMOVE TRANSAXLE CASE OIL SEAL
Using a screwdriver, remove the oil seal from the transaxle case.

13. REMOVE TRANSMISSION OIL BAFFLE

REPLACEMENT OF RING GEAR MOUNTING CASE BEARINGS

1. REMOVE RING GEAR MOUNTING LEFT CASE BEARING
Using SST, remove the bearing.

SST 09950-00020, 09950-00030

2. INSTALL RING GEAR MOUNTING LEFT CASE BEARING
Using a press and SST, press in the bearing.

SST 09316-20011,09350-32014 (09351-32090)

3. REMOVE RING GEAR MOUNTING RIGHT CASE BEARING

a. Using a chisel and hammer, cut out the bearing cage.

NOTE: Do not damage to the case.

b. Using a press and SST, press out the bearing inner race.

SST 09350-32014 (09351-32090), 09950-00020

4. INSTALL RING GEAR MOUNTING RIGHT CASE BEARING
Using a press and SST, press in the new bearing.

SST 09316-60010 (09316-00010), 09502-12010

5. REMOVE RING GEAR MOUNTING CASE BEARING OUTER RACES

(Transaxle Housing Side)
Using a pin punch and hammer, drive out the outer race from the transaxle housing.

(Transaxle Case Side)
Using a brass bar and hammer, drive out the outer race and plate washer.

6. INSTALL RING GEAR MOUNTING CASE BEARING OUTER RACE

(Transaxle Housing Side)

Using a press and SST, press in the outer race.

SST 09608-35014 (09608-06020, 09608-06150)

(Transaxle Case Side)

a. Install the plate washer.

b. Using a press and SST, press in the outer race.

SST 09608-35014 (09608-06020,09608-06180)

INSPECTION OF DIFFERENTIAL LOCK CLUTCH

INSPECT DISCS, PLATES AND FLANGE
Check that the sliding surface of disc, plate and flange worn or burnt. If necessary, replace them.

HINT:
- If the lining of the disc is exfoliated or discolored, or even a part of the printed number are defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least two hours.

ASSEMBLY OF DIFFERENTIAL ASSEMBLY

1. INSTALL DIFFERENTIAL LOCK CLUTCH PISTON

a. Coat the four O-rings with ATF.
b. Install the four O-rings to the reaction sleeve and pistons.

c. Install the No.1, No.2 pistons and reaction sleeve to the ring gear mounting right case.

2. INSTALL RETURN SPRING
a. Place the spring on the piston.
b. Place SST on the spring retainer, and compress the spring with a press.

SST 09350-32014(09351-32070)

c. Using snap ring pliers, install the snap ring.

3. INSTALL PLATE, DISCS AND FLANGE

a. Install the plate and discs.

Install in order: P = Plate D = Disc
P - D - P - D - P - D - P - D - P - D - P - D - P - D

b. Install the flange with a facing the flat end downward.

c. Using a screwdriver, install the snap ring.

4. CHECK OPERATION OF DIFFERENTIAL LOCK CLUTCH PISTON
a. Plug the one hole with your hand.
b. Apply compressed air into the other hole and be sure that the piston move.

5. INSTALL NO.1 THRUST WASHER

6. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH

(Front Differential Left Case)

a. Install the following parts:
- Side gear thrust washer
- Side gear
- Two differential pinion gear
- Two pinion gear thrust washer
- Pinion shaft
- Pinion shaft pin

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

Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)

If not within specification select the side gear thrust washer.

NOTE: Do not tighten the vise too tight.

(Front Differential Right Case)

a. Install the following parts:
- Side gear thrust washer
- Side gear
- Two differential pinion gear
- Two pinion gear thrust washer
- Pinion shaft
- Pinion shaft pin

7. INSTALL FRONT DIFFERENTIAL LEFT CASE
a. Install the left case to the right case.
b. Using a torx wrench, torque the eight torx screws.

Torque: 340 kg-cm (25 ft-lb, 33 N.m)

NOTE: Do not scratch the contact surface of the needle bearing.

8. INSTALL FRONT DIFFERENTIAL CASE

a. Install the front differential case to the ring gear mounting right case.

b. Install the No.2 thrust washer.

9. INSTALL RING GEAR
a. Clean the contact surface of the ring gear mounting 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 110 °C (230 °F)

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

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

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

e. Torque the ten bolts.

Torque: 1,260 kg-cm (91 ft-lb, 124 N.m)

10. CHECK OPERATION OF FRONT DIFFERENTIAL
Check that the front differential turns smoothly.

11. INSTALL SPEEDOMETER DRIVE GEAR
a. Place the speedometer drive gear on the ring gear mounting case.
b. Install the snap ring.

12. CHECK AND ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

a. Install the differential assembly to the transaxle case.

b. Install the transaxle housing to the transaxle case.

Torque: 300 kg-cm (22 ft-lb, 29 N.m)

c. Turn the differential assembly counterclockwise and clockwise several time
d. Using a spring tension gauge, measure the differential side bearing preload.

Preload (at starting):
New bearing 2.5 - 4.4 kg (5.5 - 9.7 lb, 24.5 - 43.1 N)
Reused bearing 1.3 - 2.2 kg (2.9 - 4.9 lb, 12.7 - 21.6 N)

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

e. Remove the differential assembly from the transaxle case.

13. INSTALL DIFFERENTIAL OIL SEAL RINGS
Install the two oil seal rings to the ring gear mounting case lower side grooves.

14. INSTALL TRANSMISSION OIL BAFFLE

15. INSTALL OIL SEAL
a. Using SST, drive in a new oil seal to the transaxle case.

SST 09223-15010

b. Coat the oil seal lip with MP grease.