Checking gear engagement clearance
1. Fix differential in gathering on prisms and establish both semiaxes.
2. Install the indicator.
3. Measure the clearance between both side gears and satellites. Standard: 0.05-0.15 mm.
4. If the gap differs from the standard, replace the differential cup.
Bearing replacement
Note: Check bearings for wear and smooth running. If the bearing is in order, removal is not required.
1. Remove the bearings with a puller.
2. Install new bearings using the special tool and a press.
Replacing the differential cup
2WD Models
1. Remove final drive driven gear from differential cup.
Note: Final drive pinion bolts are left hand threaded.
2. Install the final drive driven gear with the beveled side toward the differential cup.
3. Tighten the fixing bolts to the required torque crosswise.
4WD Models
1. Remove the transfer case drive gear and final drive driven gear from the differential cup.
Note: Final drive pinion bolts are left hand threaded.
2. Install the final drive driven gear with the beveled side toward the differential cup, then install the transfer case drive gear onto the final drive driven gear.
3. Tighten the fixing bolts to the required torque crosswise.
Removing the gland
1. Remove the differential assembly.
2. Knock out the oil seal from the gearbox housing.
3. Knock out the oil seal from the flywheel housing.
Installing the gland
1. Using the special tool, press the oil seal into the gearbox housing.
2. Using the special tool, press the oil seal into the flywheel housing.
Side clearance check
1. Install an 80mm 2.50mm thick circlip into the transaxle case.
2. Install the differential assembly on the gearbox housing and, using the special tool, press it into the housing without distortion.
3. Install the flywheel housing with a new gasket, dowel pin, and connector bracket.
4. Tighten the bolts to the required torque.
5. Measure the side clearance between the 80 mm circlip and the ball bearing outer race in the gearbox housing. Standard: 0-0.15 mm.
6. If the clearance exceeds the specified limit, select a new retaining ring from the table and install it.
Retaining ring, 80 mm
catalog no | Thickness |
90414-689-00 | 2.50 mm |
90415-689-00 | 2.60 mm |
90416-689-00 | 2.70 mm |
90417-689-00 | 2.80 mm |
90418-689-00 | 2.90 mm |
90419-RN8-00 | 3.00 mm |
Note: If the clearance measured in step 5 is within the allowable limits, it is not necessary to carry out steps. 7 and 8.
7. Remove the flywheel housing.
8. Replace the 2.50 mm retaining ring with an 80 mm ring of the required thickness selected in step 5.