Contents: Checking the gear clearance in…⇊ Bearing replacement ⇊ Replacing the differential cup ⇊ Removal the oil seal ⇊ Installing the seal ⇊ Checking the side clearance ⇊
Checking the gear clearance in engagement
1. Secure the differential assembly to the prisms and install both axle shafts.
2. Install the indicator.
3. Measure the clearance between both axle gears and satellites. Standard: 0.05-0.15 mm.
4. If the clearance differs from the standard, replace the differential cup.
Bearing replacement
Note: Check the bearings for wear and smooth rotation. If the bearing is OK, no removal is required.
1. Remove the bearings using a puller.
2. Install new bearings using a special tool and a press.
Replacing the differential cup
2WD models
1. Remove the final drive driven gear from the differential cup.
Note: The final drive driven gear bolts have left-hand threads.
2. Install the final drive driven gear with the beveled side facing the differential cup.
3. Tighten the mounting bolts to the required torque in a cross pattern.
4WD models
1. Remove the transfer case pinion gear and final drive driven gear from the differential housing.
Note: The final drive driven gear bolts have left-hand threads.
2. Install the final drive driven gear with the beveled side facing the differential cup, then install the transfer case drive gear onto the final drive driven gear.
3. Tighten the mounting bolts to the specified torque in a crisscross pattern.
Removal the oil seal
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 seal
1. Using a special tool, press the oil seal into the gearbox housing.
2. Using a special tool, press the oil seal into the flywheel housing.
Checking the side clearance
1. Install the 80mm, 2.50mm thick snap ring into the transmission housing.
2. Install the differential assembly onto the gearbox housing and, using a special tool, press it into the housing without tilting.
3. Install the flywheel housing with a new gasket, reference pin and connector bracket.
4. Tighten the bolts to the required torque.
5. Measure the side clearance between the 80mm snap ring and the outer ring of the ball bearing in the gearbox housing. Standard: 0-0.15mm.
6. If the clearance exceeds the specified limit, select a new retaining ring from the table and install it.
Retaining ring, 80 mm
| Catalogue 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 gap measured in step 5 is within the permissible limits, there is no need to perform 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.
[The article was copied from the website hondabook]