Differential Assembly: Disassembly

1. Remove differential case cover. Remove breather plate from differential case cover (if necessary). See Fig 1 .
2. Remove differential carrier assembly. Remove coolant pipe joint bolts, seal washers and coolant pipes. Remove oil cooler nuts, oil cooler, "O" rings and oil guide pipe.
3. Using hammer and chisel, cut lock nut tab and pry away from drive pinion. Insert 17-mm Allen wrench into gear end of drive pinion. Secure long end of Allen wrench in vise.
4. Remove lock nut, thrust washer and drive pinion hub. Remove oil seal, thrust washer and pinion bearing. Remove drive pinion, pinion spacer and thrust washers.
5. Inspect pinion bearings. If replacing pinion bearing on drive pinion, use press and bearing remover to press bearing from drive pinion. Remove drive pinion thrust shim from drive pinion.
   NOTE: If pinion bearings are replaced, bearing races must also be replaced.
6. To remove pinion bearing races from differential case, tap out bearing race using hammer and drift. Remove thrust washers, located below bearing races, from differential case.
7. Inspect differential carrier bearings. If replacing differential carrier bearings, use press and bearing remover to press bearing from differential carrier.
   NOTE: If differential carrier bearings are replaced, bearing races must also be replaced.
8. To remove differential carrier bearing races, tap out bearing race from differential case and differential case cover using hammer and drift. Remove thrust shim, located below bearing race, from differential case or differential case cover.
   NOTE: Thrust shim must be replaced if bearing race was removed from differential case or differential case cover.
   NOTE: Pinion gear backlash must be checked to determine if differential carrier assembly must be replaced. Differential carrier bearings must be removed from differential carrier to measure pinion gear backlash.
9. Mount differential carrier in "V" blocks with axle shafts inserted into side gears. See Fig 2 . Using dial indicator, check pinion gear backlash. Pinion gear backlash should be .002-.012" (.05-.30 mm).
10. If pinion gear backlash is not within specification, replace differential carrier assembly. Remove ring gear (if necessary).
11. Drive pin for pinion shaft from differential carrier. Remove pinion shaft, side gears, pinion gears and thrust washers. See Fig 1 .

Fig 1: Exploded View Of Differential Assembly

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 2: Checking Pinion Gear Backlash

Courtesy of AMERICAN HONDA MOTOR CO., INC.