Page 2249 of 4555

FINAL DRIVE
MT-93
D
E
F
G
H
I
J
K
L
MA
B
MT
FINAL DRIVEPFP:38411
Disassembly and Assembly (RS5F51A)ECS008CA
PRE-INSPECTION
Check the clearance between side gear and differential case as
follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
2. Put differential case vertically so that side gear to be measured faces upward.
3. Place the drift and a dial indicator onto side gear. Move side
gear up and down, and measure the clearance.
CAUTION:
There should be no resistance and gears should rotate
freely.
4. If not within specification, adjust the clearance by changing side
gear thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
DISASSEMBLY
1. Remove final gear mounting bolts, and then separate the final gear from differential case.
2. Remove differential side bearing (clutch housing side) using the
drift and pullers.
3. Remove differential side bearing (transaxle case side) using the
drift and pullers.
4. Remove speedometer drive gear. (For 2WD models)
PCIB0875E
Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SCIA1777E
SCIA0907E
Page 2250 of 4555

MT-94
FINAL DRIVE
5. Remove retaining pin from differential case using a pin punch,
and then remove pinion mate shaft.
6. Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case
Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
Bearing
Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
ASSEMBLY
1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
2. Install side gear thrust washers and side gears into differential
case.
3. While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
SCIA0908E
MTK0135D
SPD715
SMT839
Page 2251 of 4555

FINAL DRIVE
MT-95
D
E
F
G
H
I
J
K
L
MA
B
MT
4. Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.
5. Measure end play of side gears following the procedure below.
Then select side gear thrust washer.
a. Put differential case vertically so that its side gear to be mea-
sured faces upward.
b. Place the drift and a dial indicator onto side gears.
c. Move side gears up and down to measure end play, and select
thrust washer so that it satisfies the standard value. Refer to MT-
106, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .
CAUTION:
There should be no resistance and gears should rotate
freely.
Place differential case upside down. Measure the end
play for opposite side-gears likewise securely.
Only one thrust washer can be selected.
6. Install retaining pin into pinion mate shaft using a pin punch.
CAUTION:
Do not reuse retaining pin.
7. Press in differential side bearing (transaxle case side) to differ-
ential case using the drifts.
MTK0132D
PCIB0875E
End play standard value
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SCIA0908E
SCIA0910E
Page 2252 of 4555
MT-96
FINAL DRIVE
8. Align and install speedometer drive gear onto differential case.
(For 2WD models)
9. Press in differential side bearing (clutch housing side) to differ-
ential case using the drifts.
10. Install final gear into differential case, and tighten final gear
mounting bolts to the specified torque. Refer to MT-26, "
Final
Drive Components" .
SMT842D
SCIA1778E
SCIA0912E
Page 2253 of 4555

FINAL DRIVE
MT-97
D
E
F
G
H
I
J
K
L
MA
B
MT
Disassembly and Assembly (RS6F51A)ECS008CB
PRE-INSPECTION
Check the clearance between side gear and differential case as
follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
2. Put differential case vertically so that side gear to be measured faces upward.
3. Place the drift and a dial indicator onto side gear. Move side
gear up and down, and measure the clearance.
CAUTION:
There should be no resistance and gears should rotate
freely.
4. If not within specification, adjust the clearance by changing side
gear thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
DISASSEMBLY
1. Remove final gear mounting bolts, and then separate the final gear from differential case.
2. Remove differential side bearing (clutch housing side) using the
drift and pullers.
3. Remove differential side bearing (transaxle case side) using the
drift and pullers.
4. Remove speedometer drive gear. (For 2WD models)
PCIB0875E
Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SCIA1777E
SCIA0907E
Page 2254 of 4555

MT-98
FINAL DRIVE
5. Remove retaining pin from differential case using a pin punch,
and then remove pinion mate shaft.
6. Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case
Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
Bearing
Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
ASSEMBLY
1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
2. Install side gear thrust washers and side gears into differential
case.
3. While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
SCIA0908E
MTK0135D
SPD715
SMT839
Page 2255 of 4555

FINAL DRIVE
MT-99
D
E
F
G
H
I
J
K
L
MA
B
MT
4. Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.
5. Measure end play of side gears following the procedure below.
Then select side gear thrust washer.
a. Put differential case vertically so that its side gear to be mea-
sured faces upward.
b. Place the drift and a dial indicator onto side gears.
c. Move side gears up and down to measure end play, and select
thrust washer so that it satisfies the standard value. Refer to MT-
106, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .
CAUTION:
There should be no resistance and gears should rotate
freely.
Place differential case upside down. Measure the end
play for opposite side-gears likewise securely.
Only one thrust washer can be selected.
6. Install retaining pin into pinion mate shaft using a pin punch.
CAUTION:
Do not reuse retaining pin.
7. Press in differential side bearing (transaxle case side) to differ-
ential case using the drifts.
MTK0132D
PCIB0875E
End play standard value
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SCIA0908E
SCIA0910E
Page 2256 of 4555
MT-100
FINAL DRIVE
8. Align and install speedometer drive gear onto differential case.
(For 2WD models)
9. Press in differential side bearing (clutch housing side) to differ-
ential case using the drifts.
10. Install final gear into differential case, and tighten final gear
mounting bolts to the specified torque. Refer to MT-44, "
Final
Drive Components" .
SMT842D
SCIA1778E
SCIA0912E