2001 > G 2.

0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

ADJUSTMENT OF PINION HEIGHT

1. Install the front bearing outer race with the SST.

2. Install the rear bearing outer race with the SST.

3. Adjust the mounting distance of drive pinion as follows by using the drive pinion model, pinion height
adjustment gauge body, and the gauge block.

4. Fit the spacer, rear bearing, and collar onto the drive pinion model. Secure the collar with the O-ring.

Use the spacer that was removed.

5. Install the pinion model assembly in the carrier.

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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

6. Attach the front bearing, collar, companion flange. washer, and lock nut.
7. Tighten the lock nut.

Tighten the nut to the extent that companion flange can be turned by hand.

8. Place the SST on the surface plate and set the dial indicator to "zero".

9. Place the SST atop the drive pinion model. ; then set the gauge body atop the gauge block.

10. Place the feeler of the dial indicator so that it contacts where the side bearing is installed in the
carrier. Measure the lowest position on both the left and right sides.
11. Add the two (left and right) values obtained by the measurements taken in step 10, and divide the
total by 2.

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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

STandard : -0.025 - 0.025 mm (-0.00098-0.00098in)

INSPECTION
DIFFERENTIAL OIL
1. Remove the filler plug and washer.
2. Verify that the oil is at the bottom of the filler plug hole. If it is low, add the specified oil.
3. Install the filler plug and a new washer.

Tightening torque : 39-54 N·m (4.0-5.5 kg·m, 29-40 lb·ft)

DRIVE PINION PRELOAD

1. Install the spacer.

2. Press the rear bearing on with the SST.

3. Install the distance piece.

4. Install the drive pinion.

5. Press the front bearing.
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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

6. Apply light coat of grease to the end face of the companion flange.

7. Install the companion flange, and tighten the locknut.

Do not install the oil seal.

8. Turn the companion flange by hand to seat the bearing.

9. Measure the drive pinion preload.
Adjust the preload by tightening the locknut and record the tightening torque.

Preload : 0.9-1.4 N·m (9-14 kg·cm, 7.8-12.2 lb·in)

Tightening torque : 128-284 N·m (13-29 kg·m, 94-210 lb·ft)

10. Remove the nut, washer, and companion flange.

11. Tap a new oil seal into the differential carrier with the SST.
12. Install the companion flange and washer, and tighten the locknut to set the preload.

Preload : 1.6-2.1 N·m (16-21 kg·cm, 13.9-18.2 lb·in)

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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

Tightening torque : 128-284 N·m (13-29 kg·m, 94-210 lb·ft)

Measure the run-out of the companion flange.

Run-out : below 0.06 mm (0.0024 in)

SIDE BEARING PRELOAD

1. Install the differential gear assembly in the carrier.

Tightening torque : 37-52 N·m (3.8-5.3 kg·m, 27-38 lb·ft)

2. Note the identification marks on the adjusters, and install the adjusters to their respective sides.

3. Install the differential bearing caps, making sure that the identification marks on the cap corresponds
with the one on the carrier.
4. Mark the ring gear at four points at approx. 90° intervals.
Mount a dial indicator to the carrier so that the feeler comes into contact at a right angle with one of
the ring gear teeth.
5. Turn both bearing adjusters equally with the SST until the backlash.

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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

Backlash : 0.12-0.14 mm (0.0047-0.0055 in)

6. Check the backlash at the three other marked points, and make sure the minimum backlash is above
0.05 mm (0.002 in) and the difference between the maximum and minimum is less than 0.07 mm
(0.0028 in)

7. Tighten the adjusters equally until the distance between the pilot sections on the bearing caps is as
specified.

Pilot diameter mm (in)

Front : 185.425-185.500 (7.3001-7.3031)
Rear : 185.425-185.500 (7.3001-7.3031)

When adjusting the differential bearing preload, be careful not to affect the backlash of the
drive and ring gear.

8. Tighten the bearing cap bolt.

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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

Tightening torque : 37-52 N·m (3.8-5.3 kg·m, 27-38 lb·ft)

9. Measure the backlash of the ring gear.

Backlash : 0.12-0.14 mm (0.0047-0.0055 in)

REPLACEMENT
DIFFERENTIAL OIL
1. Remove the plugs.
2. Drain the oil into a suitable container.
3. Wipe plugs clean.
4. Install the drain plug and a new washer.

Tightening torque : 39-54 N·m (4.0-5.5 kg·m, 29-40 lb·ft)

5. Add the specified oil from filler plug until the level reaches the bottom of the plug hole.
Above - 18℃ (0°F) : API GL-5, SAE 90
Type
Specified oil Below - 18℃ (0°F) : API GL-5, SAE 80
Capacity 1.2 liters (1.3 US qt, 1.1 lmp qt)

6. Install the filler plug and a new washer.

Tightening torque : 39-54 N·m (4.0-5.5 kg·m, 29-40 lb·ft)

OIL SEAL
1. Jack up the vehicle and support it with safety stands.

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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

2. Drain the differential gear oil.

3. Remove the propeller shaft.
4. Before loosening the flange locknut, measure and record the rotation starting torque of the drive
pinion (within range of the drive pinion and ring gear backlash).

Make a notation of the starting torque. At the time of installation tighten the locknut to this value.

5. Remove the locknut with the SST.

6. Remove the companion flange with the SST.

7. Remove the oil seal.

Apply front differential gear oil to the oil seal.

8. Install the new oil seal with the SST.

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 2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

9. Tighten a new locknut using the SST to get the starting torque as recorded in Step 4.

10. Install the propeller shaft.

11. Add the specified oil through the oil filler plug hole.
DIFFERENTIAL OIL SEAL (RH SIDE)
1. Jack up the vehicle and support it with safety stands.
2. Drain the differential gear oil.
3. Remove the drive shaft (Right side).
4. Remove the oil seal.
5. Install the new oil seal with the SST.
6. Install the drive shaft (Right side)
7. Add the specified oil.

REMOVAL
FRONT DIFFERENTIAL
1. Jack up the vehicle and support it with safety stands.

2. Drain the differential oil.

3. Make the joining marks between the front differential and propeller shaft.
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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

4. Remove the propeller shaft.

5. Remove the drive shaft. (Left side, Right side)

6. Jack up the front differential.

7. Remove the front differential mounting bracket.

8. Remove the front differential .
FRONT DIFFERENTIAL CASE RUBBER BUSHING
1. Remove the rubber bushing with the SST.

2. Install the rubber bushing.

INSTALLATION
1. Jack up the vehicle and support it with safety stands.
2. Install the front differential assembly.

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2001 > G 2.0 DOHC > Driveshaft and axle > Differential Carrier Assembly > Front Differential Carrier(4WD) > Repair procedures

Tightening torque :
M8 bolt : 23-26 N·m (2.3-2.7 kg·m, 17-20 lb·ft)
M10 bolt : 36-44 N·m (3.7-4.5 kg·m, 27-33 lb·ft)

3. Install the front differential mounting bracket.

Tightening torque :
(A) : 49-80 N·m (5.0-8.2 kg·m, 36-59 lb·ft)
(B) : 69-103 N·m (7.0-10.5 kg·m, 51-76 lb·ft)

4. Install the drive shaft (RH,LH)

5. Install the front propeller shaft.

6. Add the specified oil

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