Reassembly

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: DIFFERENTIAL CASE: REASSEMBLY

REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR





(a) Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.
2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT





(a) Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.
3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN





(a) Using a pin punch and hammer, install the pinion shaft straight pin.





(b) Using a chisel and hammer, stake the differential case.
NOTE: Stake it after adjusting the backlash Differential Case.

4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING





(a) Using SST and a press, install the front differential case front tapered roller bearing to the differential case.
SST: 09550-60010
09951-00480
SST: 09950-70010
09951-07100
SST: 09710-04081
NOTE: Do not damage the bearing cage during installation of the bearing inner race.





(b) Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing.
SST: 09950-60020
09951-00750
SST: 09950-70010
09951-07200
5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING





(a) Using SST and a press, install the front differential case rear tapered roller bearing to the differential case.
SST: 09710-04081
SST: 09550-60010
09951-00480
SST: 09950-70010
09951-07100
NOTE: Do not damage the bearing when installing the bearing inner race.





(b) Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle housing.
SST: 09550-60010
09951-00790
SST: 09950-70010
09951-00710
NOTE: Make sure that there is no clearance between the bearing and transaxle housing.

6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD





(a) Install the differential assembly to the transaxle case.
(b) Clean the contact surfaces of the transaxle case and transaxle housing.





(c) Install the transaxle housing to the transaxle case and tighten the 18 bolts.
Bolt A - Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
Bolt B - Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
Bolt C - Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
Bolt D - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
Bolt E - Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
Bolt F - Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
Bolt length:
Bolt B, C, D, F
50 mm (1.969 in.)
Bolt A, E
42 mm (1.654 in.)





(d) Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing.
SST: 09564-32011
(e) Using SST and a torque wrench, measure the rotating torque of the differential.
SST: 09564-32011
Rotating torque at 60 rpm:
New bearing
0.20 to 1.0 N*m (2.0 to 10.2 kgf*cm, 1.8 to 8.9 in.*lbf)
Used bearing
0.10 to 0.50 N*m (1.0 to 5.1 kgf*cm, 0.9 to 4.4 in.*lbf)
HINT: If the rotating torque is not within the specified range, refer to the table below to select a thrust washer so that the rotating torque is within the specified range.

Flange Thickness









(f) Remove the 18 bolts and the transaxle housing.





(g) Remove the differential assembly.
7. INSTALL FRONT DIFFERENTIAL RING GEAR





(a) Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
NOTE: Do not heat the ring gear to over 110°C (230°F).

(b) Clean the contact surface of the front differential case.





(c) Align the matchmarks, and install the front differential ring gear case quickly.
NOTE: Do not install the bolts while the ring gear is hot.





(d) Tighten the 10 bolts.
Torque: 95 Nm (970 kgf-cm, 70 ft-lbf)
NOTE: Tighten the bolts one at a time in diagonal order.

8. INSTALL TRANSAXLE HOUSING OIL SEAL





(a) Using SST and a hammer, drive in a new oil seal.
SST: 09316-60011
09316-00011
(b) Coat the lip of the oil seal with a small amount of MP grease.
Oil seal drive in depth:
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL





(a) Using SST and a hammer, drive in a new oil seal.
SST: 09649-17010
SST: 09950-70010
09951-07150
(b) Coat the lip of the oil seal with a small amount of MP grease.
Oil seal drive in depth:
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)