A/T A/T Differential14-264

A/T Differential14-264

Component Location Index

4WD:

1	THRUST SHIM, 75 mm	Preload Inspection, page 14-271
2	THRUST WASHER, 76.2 mm
3	BEARING OUTER RACE	Replacement, page 14-269
4	CARRIER BEARING	Replacement, page 14-266
5	FINAL DRIVEN GEAR	Replacement, page 14-267
6	DIFFERENTIAL CARRIER	Backlash Inspection, page 14-266 Replacement, page 14-267
7	TRANSFER DRIVE GEAR	Replacement, page 14-267
8	CARRIER BEARING	Replacement, page 14-266
9	BEARING OUTER RACE	Replacement, page 14-269
10	THRUST WASHER, 80 mm

2WD:

1	THRUST SHIM, 76 mm	Preload Inspection, page 14-271
2	THRUST WASHER, 76.2 mm
3	BEARING OUTER RACE	Replacement, page 14-269
4	CARRIER BEARING	Replacement, page 14-266
5	FINAL DRIVEN GEAR	Replacement, page 14-267
6	DIFFERENTIAL CARRIER	Backlash Inspection, page 14-266 Replacement, page 14-267
7	CARRIER BEARING	Replacement, page 14-266
8	BEARING OUTER RACE	Replacement, page 14-269
9	THRUST WASHER, 80 mm

Backlash Inspection14-265

NOTE: The illustration shows the 4WD model; 2WD is similar.

1. Install the driveshaft and intermediate shaft 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 in.)

3. If the backlash is out of standard, replace the differential carrier.
   

Carrier Bearing Replacement14-265

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.

The illustration shows the 4WD model; 2WD is similar.

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

   

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

   

   
   

Differential Carrier/Final Driven Gear Replacement14-266

4WD:

1. Remove the final driven gear (A) and transfer drive gear (B) from the differential carrier (C).
   

   NOTE: The final driven gear bolts have left-hand threads.

   

   
   

2. Install the final driven gear with the chamfered side on the inner bore facing the differential carrier.
   
3. Tighten the bolts to the specified torque in a crisscross pattern.
   

2WD:

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 Replacement14-267

Special Tools Required

Handle driver 07749-0010000

Oil seal driver attachment 07947-SD90101

Oil seal driver attachment 07JAD-PH80101

NOTE: The illustration shows the 4WD model; 2WD is similar.

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 Replacement14-268

Special Tools Required

Handle driver 07749-0010000

Driver attachment, 78 x 90 mm 07GAD-SD40101

Driver 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.

The illustration shows the 4WD model; 2WD is similar.

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.
   

   

   
   

14-269

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 to install securely so there is no clearance between the outer race, thrust washer, shim and housing with the special tools.
   

   

   
   

Carrier Bearing Preload Inspection14-270

Special Tools Required

Handle driver 07749-0010000

Driver 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.

The illustration shows the 4WD model; 2WD is similar.

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 adjusting the bearing preload.

   

   
   

2. Install the 76 mm thrust shim (A) in the transmission housing (B).
   If you replace the 76 mm thrust shim with new one, use the same thickness shim as the old one.
   

   

   
   
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 to install securely so there is no clearance between the outer race, thrust washer, shim and housing with the special tools.
   

   

   
   

14-271

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) with the transmission hanger (F) and harness clamp brackets (G), 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 with the special tool, a torque wrench (A) and socket (B). Measure the starting torque at normal room temperature in both directions.
   

STANDARD:

New Bearing: 2.7 - 3.9 N·m

(28 - 40 kgf·cm, 24 - 35 lbf·in)

Reused Bearing: 2.5 - 3.6 N·m

(25 - 37 kgf·cm, 22 - 32 lbf·in)

Carrier Bearing Preload Inspection (cont'd)14-272

9. If the measurement is out of standard, remove the thrust shim and select the thrust shim from table below. 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 N·m (3 - 4 kgf·cm, 3 - 3 lbf·in).
   

   No.	Part Number	Thickness
   S	41438-PX4-700	2.05 mm (0.080 in.)
   T	41439-PX4-700	2.10 mm (0.082 in.)
   U	41440-PX4-700	2.15 mm (0.084 in.)
   A	41441-PK4-000	2.20 mm (0.086 in.)
   B	41442-PK4-000	2.25 mm (0.088 in.)
   C	41443-PK4-000	2.30 mm (0.090 in.)
   D	41444-PK4-000	2.35 mm (0.092 in.)
   E	41445-PK4-000	2.40 mm (0.094 in.)
   F	41446-PK4-000	2.45 mm (0.096 in.)
   G	41447-PK4-000	2.50 mm (0.098 in.)
   H	41448-PK4-000	2.55 mm (0.099 in.)
   I	41449-PK4-000	2.60 mm (0.101 in.)
   J	41450-PK4-000	2.65 mm (0.103 in.)
   K	41451-PK4-000	2.70 mm (0.105 in.)
   L	41452-PK4-000	2.75 mm (0.107 in.)
   M	41453-PK4-000	2.80 mm (0.109 in.)
   N	41454-PK4-000	2.85 mm (0.111 in.)
   O	41455-PK4-000	2.90 mm (0.113 in.)
   P	41456-PK4-000	2.95 mm (0.115 in.)
   Q	41457-PK4-000	3.00 mm (0.117 in.)
   R	41458-PK4-000	3.05 mm (0.119 in.)
   0A	41428-PRP-000	1.55 mm (0.061 in.)
   0B	41429-PRP-000	1.60 mm (0.063 in.)
   0C	41430-PRP-000	1.65 mm (0.065 in.)
   0D	41431-PRP-000	1.70 mm (0.067 in.)
   0E	41432-PRP-000	1.75 mm (0.069 in.)
   0F	41433-PRP-000	1.80 mm (0.071 in.)
   0G	41434-PRP-000	1.85 mm (0.073 in.)
   0H	41435-PRP-000	1.90 mm (0.075 in.)
   0I	41436-PRP-000	1.95 mm (0.077 in.)
   0J	41437-PRP-000	2.00 mm (0.079 in.)

   
   

   
   

   
   

No.	Part Number	Thickness
A	41428-PAX-000	1.575 mm (0.062 in.)
B	41429-PAX-000	1.625 mm (0.064 in.)
C	41430-PAX-000	1.675 mm (0.066 in.)
D	41431-PAX-000	1.725 mm (0.068 in.)
E	41432-PAX-000	1.775 mm (0.070 in.)
F	41433-PAX-000	1.825 mm (0.072 in.)
G	41434-PAX-000	1.875 mm (0.074 in.)
H	41435-PAX-000	1.925 mm (0.076 in.)
I	41436-PAX-000	1.975 mm (0.078 in.)
J	41437-PAX-000	2.025 mm (0.080 in.)
K	41438-PAX-000	2.075 mm (0.082 in.)
L	41439-PAX-000	2.125 mm (0.084 in.)
M	41440-PAX-000	2.175 mm (0.086 in.)
N	41441-PAX-000	2.225 mm (0.088 in.)
O	41442-PAX-000	2.275 mm (0.090 in.)
P	41443-PAX-000	2.325 mm (0.092 in.)
Q	41444-PAX-000	2.375 mm (0.094 in.)
R	41445-PAX-000	2.425 mm (0.095 in.)
S	41446-PAX-000	2.475 mm (0.097 in.)
T	41447-PAX-000	2.525 mm (0.099 in.)
U	41448-PAX-000	2.575 mm (0.101 in.)
V	41449-PAX-000	2.625 mm (0.103 in.)
W	41450-PAX-000	2.675 mm (0.105 in.)
X	41451-PAX-000	2.725 mm (0.107 in.)
Y	41452-PAX-000	2.775 mm (0.109 in.)
Z	41453-PAX-000	2.825 mm (0.111 in.)
0A	41454-PAX-000	2.875 mm (0.113 in.)
0B	41455-PAX-000	2.925 mm (0.115 in.)
0C	41456-PAX-000	2.975 mm (0.117 in.)
0D	41457-PAX-000	3.025 mm (0.119 in.)

A/T A/T Differential14-264