Overhaul (Differential)

Component Location Index

Backlash Inspection

1. Install the driveshafts on the differential, then place the axles on V-blocks.
2. Check the backlash of the pinion gears (A) with a dial indicator (B).
Standard: 0.05 - 0.15 mm (0.002 - 0.006 inch)
3. If the backlash is out of standard, replace the differential carrier.

Carrier Bearing Replacement

Special Tools Required
- Attachment, 40 x 50 mm 07LAD-PW50601

NOTE:
- The bearing and bearing outer race should be replaced as a set.
- Inspect and adjust the carrier bearing preload whenever bearing is replaced.
- Check the bearing for wear and rough rotation. If the bearing is OK, removal is not necessary.

1. Remove the carrier bearing (A) with a commercially available puller (B), bearing separator (C), and stepped adapter (D).

2. Install the new bearings with the special tool using the small end and a press until it bottoms. Press the bearing on securely so there is no clearance between the bearing and the differential carrier.

Differential Carrier, Final Driven Gear Replacement
1. Remove the final driven gear from the differential carrier, and replace the differential carrier or final driven gear.

2. Install the final driven gear (A) in the direction shown on the differential carrier (B).

NOTE: Differential carrier bolts have left-hand threads.

Oil Seal Replacement

Special Tools Required
- Driver 07749-0010000
- Oil seal driver attachment 07947-SD90101
- Oil seal driver attachment 07JAD-PH80101

1. Remove the oil seal from the transmission housing.

2. Remove the oil seal from the torque converter housing.

3. Install the new oil seal (A) in the transmission housing with the special tools.

4. Install the new oil seal (A) in the torque converter housing with the special tools.

Carrier Bearing Outer Race Replacement

Special Tools Required
- Driver 07749-0010000
- Attachment, 78 x 90 mm 07GAD-SD40101
- Attachment, 72 x 75 mm 07746-0010600

NOTE:
- The bearing and bearing outer race should be replaced as a set.
- Replace the bearing with a new one whenever the outer race is replaced.
- Do not use the thrust shim on the torque converter housing.
- Adjust bearing preload after replacing the bearing and outer race.
- Coat all parts with ATF during installation.

1. Remove the bearing outer race (A), 76.2 mm thrust washer (B), and 76 mm thrust shim (C) from the transmission housing (D) by heating the housing to about 212°F (100°C) with heat gun (E). Do not heat the housing in excess of 212°F (100°C).

NOTE: Let the transmission housing cool to room temperature before installing the bearing outer race.

2. Remove the bearing outer race (A) and 80 mm thrust washer (B) from the torque converter housing (C).
3. Install the 80 mm thrust washer and the new bearing outer race in the torque converter housing.

4. Drive the bearing outer race to install securely in the housing with the special tools.

5. Install the 76 mm thrust shim (A), 76.2 mm thrust washer (B), and the new bearing outer race (C) in the transmission housing (D).

6. Drive the bearing outer race in securely so there is no clearance between the outer race, thrust washer, shim and housing with the special tools.

Carrier Bearing Preload Inspection

Special Tools Required
- Driver 07749-0010000
- Attachment, 72 x 75 mm 07746-0010600
- Preload inspection tool 07HAJ-PK40201

NOTE:
- If the transmission housing, torque converter housing, differential carrier, carrier bearing and outer race, or thrust shim were replaced, the bearing preload must be adjusted.
- Coat all parts with ATF during installation.
- Do not use the thrust shim in the torque converter housing.

2. Install the 76 mm thrust shim of 2.6 mm (0.102 inch) in thickness (P/N 41449-PK4-000) (A) in the transmission housing (B).
3. Install the 76.2 mm thrust washer (C) and the bearing outer race (D) in the transmission housing.

4. Drive the bearing outer race in securely so there is no clearance between the outer race, thrust washer, shim and housing with the special tools.

5. Install the differential assembly (A) in the torque converter housing (B), and install the gasket (C) and dowel pins (D) on the housing.
6. Install the transmission housing (E) and the transmission hanger (F), then tighten the bolts.
7. Rotate the differential assembly in both directions to seat the bearings.

8. Measure the starting torque of the differential assembly in both directions with the special tool, a torque wrench (A) and socket (B) at normal room temperature.
Standard:
New Bearing 2.7 - 3.9 Nm (28 - 40 kgf-cm, 24 - 35 inch lbs.)
Reused Bearing 2.5 - 3.6 Nm (25 - 37 kgf-cm, 22 - 32 inch lbs.)

9. If the measurement is out of standard, remove the thrust shim and select the thrust shim from table shown. Install the new thrust shim and recheck. To increase the starting torque, increase the thickness of the thrust shim. To decrease the starting torque, decrease the thickness of the shim. Changing the shim to the next size will increase or decrease starting torque about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2 - 3 inch lbs.).

THRUST SHIM, 76 MM