Differential: Service and Repair

DIFFERENTIAL CASE
DISASSEMBLY





1. REMOVE SIDE BEARING FROM DIFFERENTIAL CASE
a) Using SST, remove the bearings from both sides of the differential case.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)
b) Remove the vehicle speed sensor drive gear from the RH side.





2. REMOVE RING GEAR
a) Place matchmarks on the ring gear and differential case.
b) Remove the 6 bolts.
c) Using a plastic hammer, tap on the ring gear to remove it from the differential case.





3. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the differential case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specification, install the correct thrust washer to the side gears.





4. DISASSEMBLE DIFFERENTIAL CASE
a) Using a pin punch and hammer, drive out the straight pin.
b) Remove the pinion shaft from the differential case.
c) Remove the 2 pinion gears and side gears with the 4 thrust washers from each gear.





5. Transmission case side:
IF NECESSARY, REPLACE OIL SEAL AND SIDE BEARING OUTER RACE
a) Using a screwdriver and hammer, drive out the oil seal.
b) Using SST, pull out the outer race and shim.
SST 09612-65014
c) Place the shim into the differential case.





d) Using SST and a hammer, drive in a new outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)

NOTICE: When replacing the side bearing outer race, replace the side bearing along with it.





e) Using SST and a hammer, drive in a new oil seal.
SST 09350-32014 (09351-32111), 09950-70010 (09951-07150)
Drive in depth: 2.4 ± 0.3 mm (0.094 ± 0.012 inch)
f) Coat the lip of the oil seal with MP grease.





6. Transaxle case side:
IF NECESSARY, REPLACE OIL SEAL AND SIDE BEARING OUTER RACE
a) Using a screwdriver and hammer, drive out the oil seal.
b) Using SST pull out the outer race and plate washer.
SST 09612-65014
c) Place the plate washer into the differential case.





d) Using SST and a hammer, drive in a new outer race.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)

NOTICE: When replacing the side bearing outer race, replace the side bearing along with it.





e) Using SST and a hammer, drive in a new oil seal.
SST 09350-32014 (09351-32130, 09351-32150)
Drive in depth: 1.9 ± 0.3 mm (0.075 ± 0.012 inch)
f) Coat the lip of the oil seal with MP grease.

REASSEMBLY





1. ASSEMBLE DIFFERENTIAL CASE
a) Install the correct thrust washers and side gears.
Refer to the table above, select thrust washers which will ensure that the backlash is within the specification. Try to select washers of the same size for both sides.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 inch)





b) Install the thrust washers and side gears in the differential case.
c) Install the pinion shaft.





d) Using a dial indicator, check the side gear backlash.
Measure the side gear backlash while holding one pinion gear toward the differential case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specification, install a thrust washer of different thickness.
e) Using a pin punch and hammer, drive in the straight pin through the differential case and hole in the pinion shaft.
f) Using a chisel and hammer, caulk the pin holes around the circumference of the differential case.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
a) Clean the contact surface of the differential case.
b) Heat the ring gear in boiling water.
c) Carefully remove the ring gear from the water.
d) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





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

e) Install the 6 set bolts. Tighten each set bolt uniformly, a little at a time in succession. Torque the bolts.
Torque: 124 Nm (1,260 kgf-cm, 91 ft. lbs.)





3. INSTALL SIDE BEARING
a) Install the vehicle speed sensor drive gear to the RH side.
b) Using SST and a press, install new side bearings to the both sides of the differential case.
SST 09350-32014 (09351-32090, 09351-32120)

NOTICE: When replacing the side bearing outer race, replace the side bearing along with it.





4. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD

NOTICE: Perform this only when replacing the side bearing and outer race of the differential case.

a) Install the differential case assembly to the transaxle case.
b) Install the transmission case.
c) Install and torque the case bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





d) Using SST and a torque wrench, turn the differential case assembly right and left 2 or 3 times to allow the bearings to settle.
SST 09564-32011
e) Using SST and a torque wrench, measure the preload.
SST 09564-32011
Preload (at starting):
New bearing: 0.8 - 1.6 Nm (8 - 16 kgf-cm, 6.9 - 13.9 inch lbs.)
Reused bearing: 0.5 - 1.0 Nm (5 - 10 kgf-cm, 4.3 - 8.7 inch lbs.
If the preload is not within the specification, remove the transmission case side outer race of the side bearing with SST.
f) Select an appropriate shim.





HINT: The preload will change by about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.6 - 3.5 inch lbs.) corresponding to a change of 0.05 mm (0.0020 inch) in shim thickness.