SA–82

SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of

Differential w/ A D D )

Disassembly and Assembly of Differential (with A.D.D.)

 SA–83
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

DISASSEMBLY OF DIFFERENTIAL
1. REMOVE ACTUATOR
(a) Remove the four bolts.
(b) Using a hammer, remove the actuator.

2. REMOVE DIFFERENTIAL CARRIER COVER

Remove the eight bolts and tap off the cover with a
plastic–faced hammer.

3. CHECK SIDE GEAR BACKLASH

Measure the side gear backlash while holding one pinion
gear toward the case.
Standard backlash: 0.05 – 0.20 mm
(0.0020 – 0.0079 in.)
If the backlash is out of specification, install the correct
thrust washers. (See page SA–90)

4. REMOVE LH SIDE GEAR SHAFT WITH TUBE

(a) Remove the four torx bolts.
Torx wrench: E14 (Part No. 09044–00010 or locally
manufactured tool)

(b) Using a plastic–faced hammer, tap on the tube to re–

move it.
SA–84
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

(c) Remove the sleeve.

(d) Remove the 0–ring from the tube.

5. REMOVE CLUTCH CASE

(a) Remove the two torx bolts.
Torx wrench: E14 (Part No. 09044–00010 or locally
manufactured tool)

(b) Using a plastic–faced hammer, tap on the clutch

case to remove it.

6. REMOVE RH SIDE GEAR SHAFT

Using SST, pull off the RH side gear shaft.
SST 09910–00015
(09911–00011, 09912–00010, 09914–00011)

7. REMOVE INTERMEDIATE SHAFT

Using SST, pull off the intermediate shaft.
SST 09350–20015 (09369–20040), 09950–20017
 SA–85
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

8. REMOVE RH SIDE OIL SEAL

Using SST, remove the oil seal.
SST 09308–00010

9. CHECK RING GEAR RUNOUT

Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 in.)
If the runout is greater than maximum, replace the ring
gear and drive pinion as a set.

10. CHECK RING GEAR BACKLASH

(a) Fix the dial indicator on the tooth surface at a 90

angle.
(b) Holding the drive pinion flange, measure the ring
gear backlash.
Ring gear backlash: 0.13 – 0.18 mm
(0.0051 – 0.0071 in.)
If the backlash is not within specification, adjust the ring
gear backlash.
HINT: Measure from three or more places on the cir–
cumference of the ring gear.

11. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND

DRIVE PINION (SEE STEP 7 ON PAGE SA–100)

12. MEASURE DRIVE PINION PRELOAD

Using a torque gauge, measure the preload of the back–
lash between the drive pinion and ring gear.
Preload (starting):
0.6 – 1.0 N–m (6 – 10 kgf–cm, 5.2 – 8.7 in.–Ibf )
13. CHECK TOTAL PRELOAD
Using a torque gauge, measure the total preload.
Total preload (starting):
Add drive pinion preload
0.4 – 0.6 N–m
(4 – 6 kgf–cm, 3.5 – 5.2 in.–Ibf)
SA–86
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

14. REMOVE COMPANION FLANGE

(a) Using a hammer and chisel, loosen the staked part
of the nut.

(b) Using SST to hold the flange, remove the nut.

SST 09330–00021

(c) Using SST, remove the companion flange.

SST 09557–22022 (09557–22030)

15. REMOVE OIL SEAL AND OIL SLINGER

(a) Using SST, remove the oil seal from the housing.
SST 09308–10010
(b) Remove the oil slinger.

16. REMOVE REAR BEARING AND BEARING SPACER

(a) Using SST, remove the rear bearing from drive pin–
ion.
SST 09556–30010
(b) Remove the bearing spacer.
If the rear bearing is damaged or worn, replace the bear–
ing.
 SA–87
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

17. REMOVE DIFFERENTIAL CASE AND RING GEAR

(a) Place matchmarks on the bearing cap and differen–
tial carrier.
(b) Remove the two bearing caps.

(c) Using SST and a hammer, remove the two side

bearing preload adjusting plate washers.
SST 09504–22011
HINT: Measure the adjusting plate washer and note
the thickness.

(d) Remove the differential case with bearing outer race

from the carrier.
HINT: Tag the bearing outer races to show the location
for reassembly.

18. REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER

INSPECTION AND REPLACEMENT OF

DIFFERENTIAL

1. REPLACE DRIVE PINION FRONT BEARING

(a) Using SST, press out the front bearing from the
drive pinion.
SST 09950–00020
HINT: If the drive pinion or ring gear are damaged, re–
place them as a set.

(b) Install the washer on the drive pinion.

(c) Using SST, press in the front bearing onto the drive
pinion.
SST 09506–30012
 SA–88
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

2. REPLACE DRIVE PINION FRONT AND REAR BEARING

OUTER RACES
(a) Using a brass bar and hammer, drive out the outer
race.
(b) Using SST, drive in a new outer race.
SST 09608–35014
Front outer race (09608–06020, 09608–06120)
Rear outer race (09608–06020, 09608–06110)

3. REMOVE SIDE BEARING FROM DIFFERENTIAL CASE

Using SST, remove the side bearing from the differential
case.
SST 09950–20017
HINT: Fix the claws of SST to the notches in the differ–
ential case.

4. REMOVE RING GEAR

(a) Remove the ring gear set bolts and lock plates.
(b) Place matchmarks on the ring gear and differential
case.
(c) Using a plastic–faced hammer, tap on the ring gear
to separate it from the differential case.

5. DISASSEMBLE DIFFERENTIAL CASE

(a) Using a hammer and punch, drive out the straight
pin. Remove the pinion shaft, two pinion gears, two
side gears and four thrust washers.

(b) Using a hammer and brass bar, drive out the needle
bearings.
 SA–89
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

6. ASSEMBLE DIFFERENTIAL CASE

(a) Using SST, press the new needle bearing into the
differential case.
NOTICE: Press in the bearings, with the engraved side
of each bearing facing outward from the differential case.

Bearing press in depth: 2.0 mm 10.079 in.)

SST 09950–20017

(b) Install the thrust washers to the side gears.

(c) Install the side gears with thrust washers and pinion
gears with thrust washers.
(d) Install the pinion shaft.
(e) Check the side gear backlash.
Measure the side gear backlash while holding one
pinion gear toward the case.
Backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.)
If the backlash is not within specification, install the side
gear thrust washers of different thickness.

HINT: Use washers of same thickness on both the

right and left sides.

(f) Using a hammer and punch, drive in the straight pin

through the case and hole in the pinion shaft.
SA–90
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

(g) Stake the case.

7. INSTALL RING GEAR ON DIFFERENTIAL CASE

(a) Clean the contact surfaces of the differential case
and ring gear.
(b) Heat the ring gear in boiling water.
(c) After the moisture on the ring gear has completely
evaporated, quickly install the ring gear to the differ–
ential case.

(d) Align the matchmarks on the ring gear and differen–

tial case.
(e) Coat the ring gear set bolts with gear oil.
(f) Temporarily install the lock plates and set bolts.
(g) After the ring gear cools down enough, tighten the
set bolts uniformly and a little at a time.
Torque: 97 N–m(985 kgf–cm, 71 ft–lbf)

(h) Using a hammer and drift punch, stake the lick

plates.
HINT: Stake one claw flush with the flat surface of
the nut. For the claw contacting the protruding por-
tion of the nut, stake only the half on the tightening
side.

8. INSTALL SIDE BEARINGS

Using a press and SST, install the side bearings to the dif
ferential case.
SST 09226–10010, 09950–20017
 SA–91
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

9. CHECK RING GEAR RUNOUT

(a) Install the differential case onto the carrier and in–
stall the plate washers to where there is no play in
the bearing. (See page SA–97)
(b) Install bearing caps. (See page SA–99)
(c) Using a dial indicator, measure the runout of ring
gear.
Maximum runout: 0.07 mm (0.0028 in.)

INSPECTION AND REPLACEMENT OF LH SIDE

GEAR SHAFT
1. INSPECT CLUTCH HUB AND CLUTCH SLEEVE
(a) Check the wear and damage of the clutch hub and
clutch sleeve.
If necessary, replace them.
(b) Check that the clutch sleeve slides smoothly on the
clutch hub.

2. REMOVE CLUTCH HUB

(a) Using a snap ring expander, remove the snap ring.
(b) Remove the clutch hub from the side gear shaft.

3. REMOVE SIDE GEAR SHAFT FROM TUBE

(a) Remove the three bearing retainer bolts.
(b) Remove the side gear shaft from the tube.

4. REPLACE LH SIDE GEAR SHAFT BEARING

(a) Using a snap ring expander, remove the snap ring.
SA–92
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

(b) Using a press and SST, remove the bearing.

SST 09950–00020

(c) Remove the bearing retainer.

(d) Install the bearing retainer.

(e) Using a press and SST, install the new bearing.

SST 09316–60010 (09316–00040)
NOTICE: Be careful not to damage the bearing retainer.

5. REPLACE SIDE OIL SEAL

(See page SA–62)

6. INSTALL SIDE GEAR SHAFT

(a) Install the side gear shaft into the tube.
(b) Tighten the three bearing retainer bolts.

7. INSTALL CLUTCH HUB

(a) Install the clutch hub to the shaft.
 SA–93
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

(b) Using a snap ring expander, install the snap ring.

INSPECTION AND REPLACEMENT OF

ACTUATOR
1. MEASURE CLEARANCE OF SLEEVE FORK AND CLUTCH
SLEEVE
Using a feeler gauge, measure the clearance between the
sleeve fork and clutch sleeve.
Maximum clearance: 0.35 mm (0.0138 in.)
If the clearance exceeds the limit, replace the fork or
sleeve.
2. INSPECT A.D.D. ACTUATOR
(a) Check that the sleeve fork moves to the actuator
side when a vacuum of 500 mmHg (19.69 in.Hg,
66.7 kPa) is applied to port A. Also check that the
vacuum does not leak.
If not, replace the actuator.

(b) Check that the sleeve fork moves away from the ac–
tuator when a vacuum of 500 mmHg (19.69 in.Hg,
66.7 kPa) is applied to port B. Also check that the
vacuum does not leak.
If not, replace the actuator.

3. REMOVE A.D.D. INDICATOR SWITCH

SA–94
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

4. REMOVE SLEEVE FORK PIN

(a) Using SST, remove the screw plug.
SST 09313–30021

(b) Using a hammer and punch, drive out the pin

through the hole of clutch case cover.

5. SEPARATE ACTUATOR FROM CLUTCH CASE COVER

AND REMOVE SLEEVE FORK
(a) Remove the two bolts.

(b) Separate the actuator from clutch case cover anc

remove the sleeve fork.
(c) Remove the O–ring from actuator.

6. INSTALL SLEEVE FORK AND ACTUATOR INTO CLUTCH

CASE COVER
(a) Install a new 0–ring to the actuator.
(b) Coat the 0–ring with MP grease.
(c) Place the sleeve fork and install the actuator to the
clutch case cover.
 SA–95
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

(d) Tighten the two bolts.

Torque: 21 N–m (210 kgf–cm, 15 ft–lbf)

7. INSTALL SLEEVE FORK PIN

(a) Using a hammer and punch, drive in the pin through
the hole of clutch case cover.

(b) Coat the threads of screw plug with sealer.

Sealer: Part No. 08826–00090, THREE BOND 1281 or
equivalent
(c) Using SST, install the screw plug.
Torque: 20 N–m (200 kgf–cm, 14 ft–lbf)
SST 09313–30021

8. INSTALL A.D.
D. INDICATOR SWITCH
Install a new gasket and indicator switch.
Torque: 40 N–m (410 kgf–cm, 30 ft–lbf)
SA–96
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

ASSEMBLY OF DIFFERENTIAL
(See page SA–83)
1. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the following parts.
• Drive pinion
• Front bearing
HINT: Assemble the spacer and oil seal after adjusting
the gear contact pattern.

(b) Install the companion flange with SST.

Coat the threads of the nut with MP grease.
SST 09557–22022 (09557–22030)

(c) Adjust the drive pinion preload by tightening the

companion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330–00021

(d) Using a torque meter, measure the preload.

Preload (starting):
New bearing
1.2 – 1.9 N–m
(12 – 19 kgf–cm, 10.4 – 16.5 in.–Ibf )
Reused bearing
0.6 – 1.0 N–m
(6 – 10 kgf–cm, 5.2 – 8.7 in.–Ibf)

2. INSTALL DIFFERENTIAL CASE IN CARRIER

(a) Place the bearing outer races on their respective
bearings. Make sure the left and right outer races
are not interchanged.
(b) Install the differential case in the carrier.
 SA–97
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

3. ADJUST RING GEAR BACKLASH

(a) Install only the plate washer on the ring gear back
side.
HINT: Insure that the ring gear has backlash.

(b) Snug down the washer and bearing by tapping on

the ring gear with a plastic–faced hammer.

(c) Hold the side bearing boss on the teeth surface of

the ring gear and measure the backlash.
Backlash (reference): 0.13 mm (0.0051 in.)

(d) Select a ring gear back plate washer, using the

backlash as reference. (See page SA–99)

(e) Select a ring gear teeth side washer with a thickness

which eliminates any clearance between the outer
race and case.
SA–98
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

(f) Remove the plate washers and differential case.

(g) Install the plate washer into the lower part of the
carrier.

(h) Place the other plate washer onto the differential

case together with the outer race, and install the dif–
ferential case with the outer race into the carrier.

(i) Using a plastic–faced hammer, snug down the

washer and bearing by tapping the ring gear.

(j) Using a dial indicator, measure the ring gear back–

lash.
Backlash: 0.13 – 0.18 mm (0.0051 – 0.0071 in.)

(k) If not within specification, adjust by either increas–

ing or decreasing the number of washers on both
sides by an equal amount.
HINT: There should be no clearance between the
plate washer and case.
Insure that there is ring gear backlash.
 SA–99
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

4. ADJUST SIDE BEARING PRELOAD

(a) Remove the ring gear teeth plate washer and mea–
sure the thickness.

(b) Using the backlash as a reference, install a new

washer of 0.06 – 0.09 mm (0.0024 – 0.0035 in.)
thicker than the washer removed.
HINT: Select a washer which can be pressed in 2/3
of the way with your finger.
(c) Using a plastic–faced hammer, tap in the side
washer.

(d) Recheck the ring gear backlash.

Backlash: 0.13 – 0.18 mm (0.0051 – 0.0071 in.)
(e) If not within standard, adjust by either increasing or
decreasing the washers on both sides by an equal
amount.
HINT: The backlash will change about 0.02 mm
(0.0008 in.) with 0.03 mm (o.0012 in.) alteration of
the side washer.
Washer thickness

5. INSTALL SIDE BEARING CAPS

Align the matchmarks on the cap and carrier.
Torque: 78 N–m (800 kgf–cm, 58 ft–lbf)
SA–100
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

6. MEASURE TOTAL PRELOAD

Using a torque wrench, measure the total preload.
Total preload (starting):
Add drive pinion preload
0.4 – 0.6 N–m (4 – 6 kgf–cm, 3.5 – 5.2 in.–lbf)

7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND

DRIVE PINION
(a) Coat 3 or 4 teeth at three different positions on the
ring gear with red lead.
(b) Hold the companion flange firmly and rotate the ring
gear in both directions.
(c) Inspect the tooth pattern.
If the teeth are not contacting properly, use the following
chart to select a proper washer for correction.
Washer thickness
 SA–101
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

8. REMOVE COMPANION FLANGE

(See step 14 on page SA–86)
9. REMOVE FRONT BEARING
(See step 16 on page SA–86)
10. INSTALL NEW BEARING SPACER AND FRONT BEARING
(a) Install a new bearing spacer on the drive pinion.
(b) Install the front bearing on the drive pinion.

11. INSTALL OIL SLINGER AND NEW OIL SEAL

(a) Install the oil slinger.
(b) Using SST, drive in a new oil seal.
SST 09554–30011
Oil seal drive in depth: 1.5 mm (0.059 in.)
(c) Apply MP grease to the oil seal lip.

12. INSTALL COMPANION FLANGE

(a) Using SST, install the companion flange on the
shaft.
SST 09557–22022 (09557–22030)

(b) Coat the threads of a new nut with MP grease.

(c) Using SST to hold the flange, tighten the nut.
Torque the nut.
SST 09330–00021
Torque: 120 N–m (1,225 kgf–cm, 89 ft–lbf)

13. CHECK FRONT BEARING PRELOAD

Using a torque meter, measure the preload of the back–
lash between the drive pinion and ring gear.
Preload (starting):
New bearing
1.2 – 1.9 N–m
(12 – 19 kgf–cm, 10.4 – 16.5 ft–lbf)
Reused bearing
0.6 – 1.0 N–m
(6 – 10 kgf–cm, 5.2 – 8.7 ft–lbf)
 SA–102
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

(a) If the preload is greater than specification, replace

the bearing spacer.
(b) If the preload is less than specification, retighten the
nut 13 N–m (130 kgf–cm,9 ft–lbf) a little at a time un–
til the specified preload is reached.
Maximum torque: 223 N–m (2,275 kgf–cm, 165 ft–lbf)
If the maximum torque is exceeded while retightening the
nut, replace the bearing spacer and repeat the preload
procedure. Do not back off the pinion nut to reduce the
preload.
14. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the vertical and lateral
runout of the companion flange.
Maximum vertical runout: 0.10 mm (0.0039 in.)

Maximum lateral runout: 0.10 mm (0.0039 in.)

If the runout is greater than maximum, inspect the
bearings.

15. STAKE DRIVE PINION NUT

16. INSTALL NEW RH SIDE GEAR SHAFT OIL SEAL

(a) Coat the oil seal lip with MP grease.
(b) Using SST, drive in the oil seal until it is flush with
the carrier end surface.
SST 09550–22011 (09550–00020, 09550–00031)
 SA–103
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

17. INSTALL RH SIDE GEAR SHAFT

(a) Install a new snap ring to the side gear shaft.
(b) Using a plastic–faced hammer, tap on the side gear
shaft to install it.
18. CHECK INSTALLATION OF SIDE GEAR SHAFT
(a) Check that there is 2 – 3 mm (0.08 – 0.12 in.) of
play in axial direction.
(b) Check that the side gear shaft will not come out by
trying to pull it completely out by hand.
19. INSTALL INTERMEDIATE SHAFT
(a) Install a new snap ring to the shaft.
(b) Using a plastic–faced hammer, tap on the shaft to in–
stall it.
20. CHECK INSTALLATION OF INTERMEDIATE SHAFT
(a) Check that there is 2 – 3 mm (0.08 – 0.12 in.) of
play in axial direction.
(b) Check that the shaft will not come out by trying to
pull it completely out by hand.
21. INSTALL CLUTCH CASE TO SIDE GEAR SHAFT TUBE
(a) Install a new O–ring to the tube.
(b) Coat the 0–ring with MP grease.

(c) Install the clutch case to the tube.

(d) Tighten the two torx bolts.
Torque: 78 N¿ m l800 kgf–cm, 58 ft¿ Ibf j
Torx wrench: E14 (Part No. 09044–00010 or locally
manufactured tool)

22. INSTALL CLUTCH SLEEVE

SA–104
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

23. INSTAL LH SIDE GEAR SHAFT TO DIFFERENTIAL

CARRIER
(a) Remove any packing material and be careful not to
get oil on the contacting surfaces of the differential
carrier and clutch case.
(b) Apply seal packing to the differential carrier as
shown.
Seal packing: Part No. 08826–00090, THREE BOND
1281 or equivalent
HINT: Install the side gear shaft within ten minutes af–
ter applying seal packing.
(c) Install LH side gear shaft to the differential carrier.
W Tighten the four torx bolts.
Torque: 78 N–m (800 kgf–cm, 58 ft–lbf)
Torx wrench: E14 (Part No. 09044–00010 or locally
manufactured tool)

24. INSTALL DIFFERENTIAL CARRIER COVER

(a) Remove any packing material and be careful not to
drop oil on the contacting surface of the differential
carrier or carrier cover.
(b) Apply seal packing to the carrier cover.
Seal packing: Part No. 08826–00090, THREE BOND
1281 or equivalent
HINT: Install the carrier cover within ten minutes after
applying seal packing.

(c) Install and torque the bolts.

Torque: 47 N–m (475 kgf–cm, 34 ft–lbf)

25. INSTALL ACTUATOR

(a) Remove any packing material and be careful not to
get oil on the contacting surfaces of the actuator
and clutch case.
(b) Apply seal packing to the clutch case as shown.
Seal packing: Part No. 08826–00090, THREE BOND
1281 or equivalent
HINT: Install the actuator within ten minutes after ap–
plying seal packing.
 SA–105
SUSPENSION AND AXLE – Front Differential (Disassembly and Assembly of
Differential w/ A D D )

(c) Tighten the four bolts.

Torque: 21 N–m (210 kgf–cm, 15 ft–lbf)