Front Differential Carrier

Repair Procedures

Removal

1. 1

   Remove the propeller shaft.

   (Refer to Drive Shaft and Axle — "Front Propeller Shaft")

2. 2

   Remove the subframe.

   (Refer to Suspension System — "Subframe")

3. 3

   Separate the compressor. [LAMBDA II 3.3 T-GDI only]

   (Refer to Heating, Ventilation and Air Conditioning - "Compressor").

4. 4

   Remove the front drive shaft.

   (Refer to Drive Shaft and Axle - "Front Drive Shaft")

5. 5

   Remove the engine support bracket (A). [RH]

   Tightening Torque: 49.0–59 N·m

   

6. 6

   Loosen the front differential bolts (B) and remove the front differential (A).

   Tightening torque: 58.8–64 N·m

   

7. 7

   Install in the reverse order of removal.

8. 8

   Inspect the front wheel alignment.

   (See Suspension System - Alignment)

Disassembly

[Differential Case Assembly]

1. 1

   Drain the oil by removing the drain plug (A).

   

2. 2

   Place the front differential assembly on SST (09474-4E400).

   

3. 3

   Remove the side seal (A) using a screwdriver.

   

4. 4

   Loosen the bolts and remove the cover (B) from the differential case.

   

5. 5

   Using a hammer and chisel, remove the spacer (A) and side bearing race (B).

   

6. 6

   Separate the differential case assembly from the differential carrier.

   

   

7. 7

   Remove the seal (A) from the differential carrier.

   

8. 8

   Using SST (09452-2W300), remove the shim and bearing ring from the differential carrier.

   

9. 9

   Using SST (09474-4E200), remove the side bearing.

   

10. 10

    Attach "LH" or "RH" tags to each bearing.

11. 11

    Loosen the bolts and remove the differential carrier (A) and the ring gear (B).

    

[Drive Pinion Assembly]

1. 1

   Remove the pinion bearing race.

   1. Using SST (09474-4E400), position the front differential carrier.

   2. Loosen the lock nut and remove the companion flange (A).

      

2. 2

   Loosen the bolts and remove the bearing retainer (A).

   Tightening torque: 34.3–37 N·m

   

3. 3

   Using a press, remove the drive pinion from the drive pinion assembly.

   

4. 4

   Remove the pinion oil seal (A) and the front pinion bearing from the cage using a screwdriver.

   

5. 5

   Using a hammer and chisel, remove the rear pinion bearing race (A).

   

6. 6

   Separate the pinion bearing spacer (A) and the front pinion bearing (B).

   

7. 7

   Using a press, remove the pinion rear bearing.

   

Inspection

1. After cleaning, inspect the parts for damage or wear. If any is found, follow the procedure below.

   Item		Identify
   Gear Set (Drive Pinion and Ring Gear)		Replace the gear set with a new one if the gear teeth are damaged (cracks/pits/dents).
   Bearing		Replace the bearing with a new one if the roller or race is damaged (cracks/pits/dents).
   Seal		Replace the seal with a new one whenever the differential is disassembled.
   Differential Case		Replace the carrier with a new one if the inside bearing bore is damaged (cracks, pits, or dents), or if a crack is found inside or outside.
   Companion Flange		Replace the pinion seal with a new one if the contact surface is damaged (cracks/pits/dents).
   Open Type	Differential Gear Set (Differential Side Gear and Differential Pinion Gear)	Replace the gear set with a new one if the gear tooth or tooth surface is damaged (cracks/pits/dents).
   	Differential Washer (Differential Side Gear Washer and Differential Pinion Gear Washer)	Replace the washer with a new one if the washer surface is damaged (cracks/pits/dents).

Installation

[Drive Pinion Assembly]

1. 1

   Using a round pipe (A), press in the rear pinion bearing (B).

   

2. 2

   Install the pinion bearing spacer (B) onto the drive pinion (A).

   

3. 3

   Using SST (09474-4E500), install the front pinion bearing race.

   

4. 4

   Using SST (09432-33700), install the pinion rear bearing race.

   

5. 5

   After installing the pinion oil seal (A), install the pinion assembly (B) into the bearing retainer (C).

   

6. 6

   Install the companion flange.

   

7. 7

   Tighten the pinion lock nut.

   Pinion bearing preload:

   1,2–1.8 N·m

   

8. 8

   Install the pinion O-ring.

   

9. 9

   Install the pinion assembly (A).

   Tightening torque: 34.3–37 N·m

   

[Differential Case Assembly]

1. 1

   Install the differential carrier and ring gear.

   Torque: 78.4–88 N·m

   

2. 2

   Using SST (09432-3D500), install the side bearing.

   

3. 3

   Using SST (09474-4E100), install the differential case oil seal.

   

4. 4

   Using SST (09432-3D900), install the shim and run the differential carrier.

   

5. 5

   Using SST (09432-3D900), install the shim and run the differential carrier cover.

   

6. 6

   Install the differential case assembly onto the differential carrier.

   

7. 7

   Check the backlash on the companion flange.

   Backlash:

   Standard: 0.07–0.15 mm (0.003–0.006 in.)

   Companion flange equivalent to PCD:

   0.11–0.23 mm (0.004–0.009 in.)

   Standard companion flange torque: 30 kgf·cm

   

8. 8

   Install the differential carrier cover, then install the oil seal.

   Tightening torque:

   39,2–49 N·m

   Sealant: LIQUID GASKET LT5060 or equivalent

   

9. 9

   Measure the total preload.

   Total preload: Pinion bearing preload (12.0–18.3 kgf·cm) + (15.0–45.0 kgf·cm) / Gear ratio

   

10. 10

    Install the drain plug (A).

    Tightening Torque: 49.0–69 N·m

    

11. 11

    Install the rear differential assembly on the vehicle. Loosen the filler plug (A) and fill with oil.

    Tightening Torque: 44.1–54 N·m

    Oil type: Hypoid gear oil MS517-15 GT 75W/85 (GL-5)

    (equivalent to SK HK SYN GEAR OIL 75W/85)

    Oil capacity (L): 0.7 ± 0.05