Differential Assembly: Overhaul: Disassembly

1. Remove differential case cover bolts in a crisscross pattern. Remove differential case cover. Remove breather plate from differential case cover (if necessary). See Fig 1.
2. Remove differential carrier assembly from differential case. Remove oil guide pipe.
3. Using hammer and chisel, cut lock nut tab and pry away from drive pinion. Insert 32-mm hex bit socket into gear end of drive pinion.
4. Remove lock nut, thrust washer and drive pinion hub. Remove oil seal and thrust washer. Using soft-faced hammer, tap drive pinion from pinion bearing on front of drive pinion. Remove drive pinion, pinion spacer and thrust washers.
NOTE: If pinion bearings are replaced, bearing races must also be replaced.
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.
6. To remove pinion bearing races from differential case, heat differential case to 212°F (100°C) and remove bearing race. DO NOT heat differential case to more than 212°F (100°C). Remove thrust washers (located below bearing races) from differential case.
NOTE: If differential carrier bearings are replaced, bearing races must also be replaced.
7. Inspect differential carrier bearings. If replacing differential carrier bearings, use press and bearing remover to press bearing from differential carrier.
8. To remove differential carrier bearing races, heat differential case or differential case cover in area around bearing race with heat gun to 212°F (100°C) and removing bearing race. DO NOT heat differential case or differential case cover to more than 212°F (100°C). Remove thrust shim(s) (located below bearing races) 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 shaft and intermediate shaft inserted into side gears. See Fig 2. Using dial indicator, check pinion gear backlash. Pinion gear backlash should be .002-.006" (.05-.15 mm).
10. Replace differential carrier assembly if pinion gear backlash is not within specification. Remove ring gear (if necessary).

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.