Disassembly

C59 MANUAL TRANSMISSION / TRANSAXLE: DIFFERENTIAL CASE: DISASSEMBLY

DISASSEMBLY

1. REMOVE SPEEDOMETER DRIVE GEAR





(a) Remove the speedometer drive gear from the front differential case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR





(a) Place matchmarks on the front differential ring gear and the front differential case.
(b) Remove the 8 bolts.





(c) Using a plastic hammer, remove the front differential ring gear from the front differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH





(a) Secure the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.
Standard backlash:
0.05 to 0.20 mm (0.00197 to 0.00787 in.)
If the backlash is out of specification, adjust it using new side gear thrust washers Differential Case.
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN





(a) Using a chisel and a hammer, loosen the staked part of the front differential case.





(b) Using a pin punch (dia3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT





(a) Remove the front No. 1 differential pinion shaft from the front differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR





(a) Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 No. 1 front differential side gear thrust washers, and 2 front differential side gears from the front differential case.
HINT: While rotating the front differential pinion, remove the 2 pinions and 2 side gears.