Differential — disassembly and assembly

Special tool

	Adapter for 204-158 (thrust pad) 204-158-01 (14-038-01)
	Differential bearing installer 205-062 (15-025A)
	Bearing puller (main instrument) 205-295 (15-050A)
	Collet for 205-295 308-197 (16-062)

General equipment:

• Press
• punch

Name	Specification
Transmission Fluid for Manual Transmission	WSD-M2C200-C

Disassembly

1. Using the special tools, remove the differential bearings.

• 1. Install the special tool.
• 2. Remove differential bearings.
• 3. Remove the vehicle speed sensor ring (VSS).

2. Remove differential pinions and ring gear.

• 1. Rotate the differential pinions approximately 90 degrees in the differential box and remove them.
• 2. Remove the snap ring and discard it as no longer needed, using a suitable drift, remove the pin.
• Remove two differential satellites and plastic thrust elements.

3. Disconnect the ring gear from the differential case.

Assembly

1.

NOTE: Do not lubricate differential bearing.

Thoroughly clean and inspect all components and coat with clean manual transmission fluid before reassembly.

2.

NOTE: Install a new ring gear and differential pinion circlip.

Install the ring gear and differential pinions.

• 1. Using the old bolts, carefully connect the ring gear to the differential case.
• Install two differential pinion gears and plastic thrust pieces.
• 2. Using an appropriate drift, install the pin and circlip.
• 3. Install the differential pinions and rotate them 90 degrees in the differential box.

3.

NOTE: Install new ring gear bolts.

NOTE: Do not lean on the differential lower bearing.

Using the special tools, tighten the ring gear and install the differential bearings.

• 1. Install new ring gear bolts and tighten the bolts in a crosswise manner.
• 2. Install the vehicle speed sensor ring (VSS).
• 3. Using the special tools, install the differential bearings.