For 1990-2009 cars

#### Tools Required

• | DT 46462 (DW240-140) Transaxle Case Side Bearing Outer Race Adapter

• | DT 46465 (DW240-170) Adapter Handle

• | DT 46461 (DW240-130) Differential Preload Adapter

• | DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer

• | DT 47521 (DW260-031-02) Transaxle Case Oil Seal Installer

1. Using the DT 46462 (2) and the DT 46465 (1), install a new side bearing outer race into the transaxle housing.

Important: Install a shim of the same thickness as the one removed.

2. Install the shim to the transaxle case.
3. Install a new side bearing outer race into the transaxle case.
4. Coat the thrust washers, side gears, pinion gears, and pinion thrust washers with automatic transmission fluid (ATF).
5. Install the 2 differential side gear thrust washers to 2 differential side gears.
6. Install the 2 side gears with 2 thrust washers, 2 pinion gears, and 2 pinion thrust washers into the differential case.
7. Coat the pinion shaft with ATF.
8. Install the pinion shaft so as to align the lock pin holes on the pinion shaft and differential case.

Important: If the backlash is out of specification, install the correct thrust washer to the side gear.

9. Measure the side gear backlash while holding 1 pinion gear toward the case.

Specifications
The standard backlash is 0.05-0.2 mm (0.002-0.0079 in).

Important:

• | Try to select washers of the same size for both sides.

• | If the backlash is not within the specification, install a thrust washer of a different thickness.

10. Select thrust washers which will ensure that the backlash is within the specification. Refer to Transmission General Specifications .
11. Using a hammer and punch, drive in the pin through the case and holes in the pinion shaft.
12. Using a hammer and chisel, stake the differential case.
13. Using a press, install the tapered roller bearing into the differential case.
14. Using a press, install the tapered roller bearing into the differential case.
15. Remove any formed in place gasket (FIPG) material. Do not get oil on the contacting surfaces of the transaxle housing or transaxle case.
16. Install the differential to the transaxle case.
17. Install the transaxle housing and 16 bolts of the transaxle housing temporarily.

Notice: Refer to Fastener Notice in the Preface section.

18. Tighten 8 or 9 bolts out of the 16 bolts of the transaxle housing completely.

Tighten
Tighten the bolts to 29 N·m (22 lb ft).

19. Using the DT 46461 , turn the differential gear assembly right and left 2-3 times to allow the bearing to settle.

Important: If the preload is not within specifications, remove the differential from the transaxle case.

20. Using the DT 46461 and a small torque wrench, measure the preload of the differential gear.

Specifications

• | New bearing preload is 0.78-1.37 N·m (6.9-12.2 lb in).

• | Used bearing preload is 0.39-0.69 N·m (3.5-6.1 lb in).

21. Re-select the transaxle case side adjusting the shim according to the shim thickness table. Refer to Transmission General Specifications .
22. Using a plastic hammer, remove the 16 bolts and transaxle housing.
23. Remove the differential gear from the transaxle case.
24. Clean the contact surface of the differential case.
25. Heat the ring gear in water and boil for 10 minutes.
26. Carefully remove the ring gear from the water.
27. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
28. Install the 8 bolts.

Tighten
Tighten the bolts to 102 N·m (75 lb ft).

29. Using the DT 46471 (1) and a hammer, drive in a new transaxle housing oil seal.

Specifications
The oil seal in depth is 3.1 mm (0.122 in).

30. Using the DT 47521 (1), drive in a new transaxle case oil seal.

Specifications
The oil seal in depth is 4.3 mm (0.169 in).