Assembly of Differential Case

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




1. INSTALL SIDE BEARING
a. Using SST and a press, install the side bearing to the differential No.1 case.
SST 09316-60010 (09316-00010, 09316-00020), 09316-20011




b. Using SST and a press, install the side bearing to the differential No.2 case.
SST 09309-36010,09316-60010 (09316-00010)




2. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR BACKLASH
(Differential Side Gear Subassembly)
a. install the No.2 side gear thrust washer, (temporarily install) 1.0 mm (0.039 in.) size thrust washer, differential side gear subassembly, four pinions, four thrust washers, pinion shaft holder and four shafts to the differential No.1 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 subassembly toward the case.

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

HINT: 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 No.1 case.




3. ASSEMBLE DIFFERENTIAL NO.1 CASE
a. Install the No.2 side gear thrust washer (previously selected), conical spring washer and differential side gear subassembly to the No.1 case.

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




b. Install spacer to the differential No.1 case.




c. Install the four pinion thrust washers, four differential pinions, shaft holder and four shafts to the No.1 case.




4. INSTALL SPEEDOMETER DRIVE GEAR
a. Install spacer to the differential No.1 case.
b. Using snap ring pliers, install snap ring.




c. Align the projection on the differential No.1 case and speedometer drive gear.
d. Using snap ring pliers, install snap ring.




5. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Install the front differential side gear thrust washer, side gear, shaft holder, four pinions, four thrust washers, No.2 shaft and two shafts to the front differential case.




b. 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, 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 to as shown.

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




7. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR THRUST CLEARANCE
(Differential No.2 Case)
a. Install the No.2 side gear thrust washer, front differential side gear thrust washer, side gear and front differential case assembly to the differential No.2 case.

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: 0.17 - 0.26 mm
(0.0067 - 0.0102 in.)

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




Referring to the table, 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 No.2 case.




8. INSTALL RING GEAR
a. Clean the contact surface of the differential No.2 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 differential No.2 case.

HINT: Align the matchmarks on the differential No.2 case and connect the ring gear.




9. SELECT CENTER DIFFERENTIAL SIDE GEAR THRUST WASHER
a. Install the front differential case assembly, side gear, thrust washer, (temporarily install) 1.0 mm (0.039 in.) size No.2 thrust washer and No.2 thrust washer to the differential No.1 case assembly.

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

Engage the front differential side gear and pinion gear of No.1 case.




b. Clean the No.2 side gear thrust washer and No.2 case.
c. Place the plastic gauge onto the No.2 thrust washer as shown in the image.

HINT: Place the plastigauge in four positions on top of the side gear thrust washer so that they are above the axes of the three pinion shafts inside the differential No.1 case.
Place the plastigauge so that is as close as possible to the outer side of the No.2 thrust washer.




d. Install the No.2 case.

HINT: Align the matchmarks on the differential No.1 case and connect the No.2 case.
Do not turn the No.2 case.




e. Install and torque the sixteen bolts.

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




f. Remove the sixteen bolts and differential No.2 case up ward.
g. Measure the plastigauge at its widest point.

Standard clearance: 0.155 - 0.250 mm
(0.0061 - 0.0098 in.)




HINT: 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.

h. Remove the differential No.2 case. No.2 thrust washer and (temporarily install) 1.0 mm (0.039 in.) thrust washer.




10. INSTALL DIFFERENTIAL NO.2 CASE
a. Install the conical spring washer and No.2 side gear thrust washer (previously selected).

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




b. Install the differential No.2 case to the No.1 case.

HINT: Align the matchmarks on the differential No.1 case and connect the No.2 case.




c. Install and torque the sixteen bolts.

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




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




12. 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)




13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a. Turn the differential case assembly counterclockwise and clockwise several time.
b. Using a spring tension gauge, measure the differential case assembly preload.

Preload (at starting):
New bearing
3.2 - 6.3 kg
(7.1 - 13.9 lb, 31.4 - 61.8 N)
Reused bearing
2.0 - 4.0 kg
(4.4 - 8.8 lb, 19.6 - 39.2 N)




If the preload is not within specification, select the shims.




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




15. REMOVE DIFFERENTIAL CASE ASSEMBLY