ACURA RL KA9 1996 Service Repair Manual

8. Hol d th e driv e pinio n wit h a 1 1/4 " (3 2 mm ) he x bi t
an d socke t a s shown , the n carefull y tighte n th e pin -
io n locknu t unti l ther e is n o pla y in th e pinio n shaft .
Torque : 2 0 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
CAUTION : T o avoi d damagin g th e tapere d rolle r
bearing , d o no t overtighte n th e locknut .
1 1/4 " (3 2 mm ) HE X BI T an d SOCKE T
(Commerciall y available )
DIFFERENTIA L
CARRIE R
12. Instal l th e specia l too l a s shown , the n rotat e th e
driv e pinio n in bot h direction s s o tha t th e rin g gea r
rotat e on e ful l tur n i n bot h directions . Durin g thi s
operatio n resistanc e shoul d b e applie d t o th e rin g
gear .LOCKNU T SOCKET ,36 x 41 m m07HA A-SF1010 0
CORREC T TOOT H CONTAC T
13. Remov e th e differentia l cas e cover , an d chec k th e
toot h contac t patter n (hee l an d toe) . Adjus t th e rin g
gea r toot h contac t a s neede d (se e pag e 15-25 ).
14 . Afte r adjustin g th e rin g gea r toot h contact , remov e
th e driv e pinion , the n instal l a ne w pinio n space r
an d thrus t washer s o n th e driv e pinion .
PINION SPACE R
THRUS T WASHER S
DRIVE PINIO N
9. Clea n th e rin g gea r teeth , the n pain t the m lightl y an d
evenl y wit h Prussia n Blu e (o n bot h side s o f eac h
tooth) .
10 . Appl y lubrican t t o th e tapered roller bearings , instal l
th e differentia l carrie r int o th e differentia l case , the n
instal l th e differentia l cas e cover .
11 . Instal l th e bolt s an d tighte n in a crisscros s patter n in
severa l steps . 10 x 1.2 5 m m
44 N- m (4. 5 kgf-m , 3 3 Ibf-ft )
DIFFERENTIA L
CAS E COVE R
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Differential Assembl y
Reassembl y (cont'd )
15. Appl y lubrican t t o th e tapere d rolle r bearing , the n
instal l i t usin g th e specia l too l whil e holdin g th e
driv e pinio n a s shown .
DRIVER , 4 0 m m I.D .07746-003010 0
TAPERED ROLLE RBEARIN G
16. Instal l th e larg e thrus t washer , pinio n hub , smal l
thrust washe r an d locknut .
NOTE: Lubricat e th e locknu t an d driv e pinio n thread s
wit h gea r oil .
LOCKNU T
THRUS T WASHE R
PINION HU B
THRUS T WASHE R
17. Hol d th e driv e pinio n wit h a 1 1/4 " (3 2 mm ) he x bi t
an d socke t a s shown .
1 1/4" (32 mm ) HE X BI Tand SOCKE T(Commerciall y available )
18. Tighte n th e locknu t t o 21 6 N- m (2 2 kgf-m , 15 9 Ibf-ft) ,
and measur e th e tapere d rolle r bearin g preloa d
(Tp).
NOTE : Rotat e th e driv e pinio n severa l time s t o
assur e prope r tapere d rolle r bearin g contact .
Standard :
Ne w Bearing : 1.8 2 - 2.4 9 N- m
(18. 6 - 25. 4 kgf-cm , 16. 1 - 22. 0 Ibf-in )
Reuse d Bearing : 1.4 2 - 1.9 1 N- m
(14. 5 -19. 5 kgf-cm , 12. 6 - 16. 9 Ibf-in )
• I f th e tapere d rolle r bearin g preloa d exceed s th e stan -
dard , replac e th e pinio n spacer .
• I f th e tapere d rolle r bearin g preloa d i s les s tha n th e
standard , adjus t b y tightenin g th e locknu t a littl e a t a
time , bu t kee p th e torqu e withi n 21 6 - 31 3 N- m (2 2 -
3 2 kgf-m , 15 9 - 23 1 Ibf-ft) . I f thi s no t possible , replac e
th e pinio n spacer .
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19. Clea n th e rin g gea r teeth , the n pain t the m lightl y an d
evenl y wit h Prussia n Blu e (o n bot h side s of eac h
tooth) .
20 . Instal l th e differentia l carrie r int o th e differentia l
case , an d reinstal l th e differentia l cas e cover .
21 . Instal l th e bolt s an d tighte n in a crisscros s patter n in
severa l steps .
Torque : 4 4 N- m (4. 5 kgf-m , 3 3 Ibf-ft )
22. Instal l th e specia l too l a s shown . Rotat e th e driv e
pinio n i n bot h direction s s o tha t th e rin g gea r rotat e
on e ful l tur n i n bot h directions . Durin g thi s opera -
tio n resistanc e shoul d b e applie d to th e rin g gear .
LOCKNU T SOCKET ,36 x 41 m m07HAA-SF1010 0
DRIVEPINIO N
Remov e th e specia l tool , an d us e a dial-typ e torqu e
wrenc h o n th e driv e pinio n t o chec k tota l bearin g
preload . Th e tota l bearin g preloa d shoul d excee d
th e driv e pinio n bearin g preloa d b y th e amoun t
show n i n th e nex t column .
NOTE : Rotat e th e driv e pinio n severa l time s t o
ensur e prope r bearin g contact .
=0.94 -1.0 7 N- m (9. 6 -10. 9 kgf-cm , 8.3 3 - 9.4 6 Ibf-in )
If th e tota l bearin g preloa d i s no t withi n th e standard ,
correc t i t b y increasin g o r decreasin g th e preloa d o n th e
carrie r bearing s a s needed . I f ther e is to o muc h preload ,
decreas e th e shi m thicknes s equa l amount s o n bot h
sides . I f ther e i s no t enoug h preload , increas e th e shi m
thicknes s equa l amount s o n bot h sides .
NOTE : B e sur e th e sam e amoun t o f shi m thicknes s i s
adde d o r subtracte d fro m bot h sides , s o tha t th e toot h
contac t patter n an d backlas h ar e no t affected .
24 . Instal l th e oi l sea l usin g th e specia l tool s a s shown .
NOTE: Mak e sur e tha t distanc e i s correct .
DRIVER07749-001000 0
PINION COVE R DRIVE RATTACHMEN T07LAD-PW5050 0
15.5-16.0 m m(0.6 1 - 0.63 in)
OIL SEA L
Replace .
PROCES S SURFAC E
BAS E SURFAC E
PROCESS SURFAC E
= 1.0 4 -1.2 6 N- m (10. 6 -12. 8 kgf-cm , 9. 2 -11. 1 Ibf-in )
Reuse d differentia l carrie r tapere d rolle r bearing :
Tota l bearin g preloa d (fro m ste p 23 )
- T p (fro m ste p 18 )
Standard
:
Ne w differentia l carrie r tapere d rolle r bearing :
Tota l bearin g preloa d (fro m ste p 23 )
-Tp (fro m ste p 18 )
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Differential Assembl y
Reassembl y (cont'd )
25. Hol d th e differentia l assembl y usin g a benc h vise
wit h sof t jaw s a s shown .
Inspectio nhole
SOF T JAW S
LOCKNUT SOCKET ,
36 x 41 m m07HA A-SF1010 0
26. Alig n a backlas h inspectio n hol e wit h th e oi l fille r
plu g hole , an d instal l th e specia l tool s a s shown .
27 . Measur e backlas h o n th e differentia l carrie r usin g
th e specia l tool s a s shown . Afte r measuring , remov e
th e dia l gaug e an d tur n th e differentia l carrie r on e
ful l turn , the n remeasur e th e backlash .
Standard : 0.0 6 - 0.1 4 m m (0.00 2 - 0.00 6 in )
Th e differenc e betwee n th e tw o measurement s
take n mus t no t excee d 0.0 6 m m (0.00 2 in) .
LOCKNU T SOCKET ,36 x 41 m m07HA A-SF1010 0
28. I f th e backlas h i s les s tha n th e standard , adjus t th e
rin g gea r backlas h (se e pag e 15-25 ).
29 . Remov e th e differentia l cas e cover , an d chec k th e
toot h contac t patter n (fac e an d flank) . I f th e toot h
contac t i s no t correct , adjus t rin g gea r contac t (se e
page 15-25 ).
30 . Afte r al l adjustment s ar e made , instal l th e breathe r
plat e an d stak e th e scre w head s i n th e groov e a s
shown .
SCREW Replace .12 N- m (1. 2 kgf-m , 8. 7 Ibf-ft )
BREATHE RPLATE
31. Remov e th e differentia l carrier , the n instal l th e oi l
guid e pipe .
6 x 1. 0 m m
OIL GUID E 1 2 N- m (1. 2 kgf-m ,
PIP E 8.
7 Ibf-ft )
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32. Instal l th e differentia l carrie r i n th e differentia l case .
DIFFERENTIA LCARRIER
DIFFERENTIA LCASE
DIFFERENTIA LCARRIERDIFFERENTIA L CAS E
34. Instal l th e oi l sea l usin g th e specia l tool s a s shown .
DRIVER ATTACHMEN T
0796 5-SA0060 0 DRIVE
R
0774 9-001000 0
OI L SEA L
Replace .
PILOT, 3 2 x 50 m m
07MA D-PR9020 0
35. Stak e th e locknu t ta b int o th e groove .
1.0 m m (0.0 4 in)
3.5 m m (0.1 4 in)
33. Instal l th e differentia l cas e cover , an d tighte n th e
bolt s i n a crisscros s patter n i n severa l steps .
NOTE :
Us e liqui d gaske t (P/ N 0871 8 - 0001) .
Remov e an y dir t an d oi l fro m th e sealin g surface .
I f 2 0 minute s hav e passe d afte r applyin g liqui d
gasket , reappl y it , assembl e th e housings , an d
allo w it t o cur e a t leas t 2 0 minute s afte r assembl y
before fillin g differentia l wit h oil .
10 x 1.2 5 mm44 N- m (4. 5 kgf-m , 3 3 Ibf-ft )
DIFFERENTIA L
CAS E COVE R
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Drive Pinio n
Heigh t Adjustmen t
NOTE: I f th e driv e pinio n an d rin g gea r ar e replace d
(alway s a s a set) , th e heigh t ha s t o b e adjusted .
Selec t th e prope r shi m a s follows :
First , calculat e th e differenc e i n siz e betwee n th e ol d
shi m an d th e ne w pinion .
Th e las t numbe r (se e ill. ) o n eac h pinio n is th e plu s (+ ) o r
minu s (- ) toleranc e i n thousand s o f a millimeter . So , a
pinio n wit h +2 0 is 0.0 2 m m large r an d a pinio n wit h - 2 0
i s 0.0 2 m m smaller .
1 . I f th e numbe r o n th e ol d pinio n i s a plu s (+) , ad d i t
t o th e ol d shi m thickness . I f i t i s a minu s (-) , sub -
trac t i t fro m th e ol d shi m thickness .
2 . I f th e numbe r o n th e ne w pinio n i s a plu s (+) , sub -
trac t i t fro m th e numbe r yo u go t i n ste p 1 . I f i t i s a
minu s (-) , ad d it t o th e ste p 1 number .
3 . Selec t th e shi m tha t i s closes t (bu t no t mor e than )
th e fina l numbe r yo u go t fro m step s 1 an d 2 .
ETCHE D MAR K
eg: A1- 1
Exampl e 1:
Ol d shim : 2.0 0 m m thicknes s
Old pinion : +2 0 (0.0 2 mm )
New pinion : -1 0 (-0.0 1 mm )
2.00 + 0.0 2 + 0.0 1 = 2.03
Selec t th e 2.0 3 m m (0.079 9 in ) ne w shim .
Exampl e 2 :
Ol d shim : 1.7 0 m m thicknes s
Old pinion : -1 0 (-0.0 1 mm )
New pinion : -2 0 (-0.0 2 mm )
1.70-0.0 1 +0.0 2 = 1.7 1
Selec t th e 1.7 0 m m (0.066 9 in ) ne w shim . 4
3 m m THRUS T SHI M
A
B
C
D
E
F
G
H
I
J
K
L
M
N
0
P
Q
R
S
T
U
V
Part Numbe r
41410 -PS D -00 0
41411-P5D-00 0
41412-P5D-00 0
41413-P5D-00 0
41414-P5D-00 0
41415-P5D-00 0
41416-P5D-00 0
41417-P5D-00 0
41418-P5D-00 0
41419-P5D-00 0
41420-P5D-00 0
41421-P5D-00 0
41422-P5D-00 0
41423-P5D-00 0
41424-P5D-00 0
41425-P5D-00 0
41426-P5D-00 0
41427-P5D-00 0
41428-P5D-00 0
41429-P5D-00 0
41430-P5D-00 0
41431-P5D-00 0Thicknes
s
1.6 4 m m (0.064 6 in )1.6 7 m m (0.065 7 in )
1.7 0 m m (0.066 9 in )
1.7 3 m m (0.068 1 in )
1.7 6 m m (0.069 3 in )
1.7 9 m m (0.070 5 in )
1.8 2 m m (0.071 7 in )
1.8 5 m m (0.072 8 in )
1.8 8 m m (0.074 0 in )
1.9 1 m m (0.075 2 in )
1.9 4 m m (0.076 4 in )
1.9 7 m m (0.077 6 in )
2.0 0 m m (0.078 7 in )
2.0 3 m m (0.079 9 in )
2.0 6 m m (0.081 1 in )
2.0 9 m m (0.082 3 in )
2.1 2 m m (0.083 5 in )
2.1 5 m m (0.084 6 in )
2.1 8 m m (0.085 8 in )
2.2 1 m m (0.087 0 in )
2.2 4 m m (0.088 2 in )
2.2 7 m m (0.089 4 in )
tolerance .
+/-20
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Ring Gea r Toot h Contac tRing Gea r Backlas h
Adjustmen t
1) Correc t Toot h Contac t
2 ) To e Contac t
Us e a thinne r driv e pinio n shi m (4 3 m m thrus t
shim ) t o mov e th e driv e pinio n awa y fro m th e rin g
gear .
3) Hee l Contac t
Us e a thicke r driv e pinio n shi m (4 3 m m thrus t
shim ) t o mov e th e driv e pinio n towar d th e rin g
gear .
4) Flan k Contac t
T o mov e th e rin g gea r awa y fro m th e driv e pin -
ion , us e a thicke r sid e bearin g shi m (79. 5 m m
thrus t shim ) o n th e driv e pinio n sid e an d a thinne r
on e o n th e rin g gea r side .
NOTE : Rechec k backlas h afte r replacin g th e sid e
bearin g shims . I f ou t o f specification , adjus t a s
describe d unde r To e Contact .
5) Fac e Contac t
To mov e th e rin g gea r towar d th e driv e pinion ,
us e a thinne r sid e bearin g shi m (79. 5 m m thrus t
shim ) o n th e driv e pinio n sid e an d a thicke r on e
o n th e rin g gea r side .
NOTE : Rechec k backlas h afte r replacin g th e sid e
bearin g shims . I f ou t o f specification , adjus t a s
describe d unde r Hee l Contact .
Adjustmen t
1. I f th e backlas h exceed s th e standard , correc t b y
decreasin g th e shi m thicknes s o n on e sid e an d
increasin g th e thicknes s o f th e othe r shi m th e sam e
amount .
NOTE:
• Th e tota l thicknes s o f bot h shim s mus t stil l equa l
th e tota l thicknes s o f th e origina l shims .
• I f ther e is to o muc h backlash , mov e th e rin g gea r
towar d th e driv e pinion . I f ther e i s no t enoug h
backlash , mov e th e rin g gea r awa y fro m th e
driv e pinion .
2 . Afte r adjustment , rechec k backlas h (se e page , 15-10 ).
Standard : 0.0 6 - 0.1 4 m m (0.00 2 - 0.00 6 in )
79. 5 m m THRUS T SHI M
AA
A B
AC
AD
AE
A F
AG
A H
A l
AJ
A K
AL
AM
A N
AO
A P
A Q
AR
AS
AT
A U
A V
AW
A X
Par t Numbe r
41460-P5D-00 0
41461-P5D-00 0
41462-P5D-00 0
41 46 3 -PS D -00 0
41464-P5D-00 0
41 46 5 -PS D -00 0
41466-P5D-00 0
4 1467 -PS D -00 0
41468-P5D-00 0
41 46 9 -PS D -00 0
41 47 0 -PS D -00 0
4147 1 -PS D -00 0
41 47 2 -PS D -00 0
41 47 3 -PS D -00 0
41 47 4 -PS D -00 0
41 47 5 -PS D -00 0
41 47 6 -PS D -00 0
41 47 7 -PS D -00 0
41 47 8 -PS D -00 0
41479-P5D-00 0
41 48 0 -PS D -00 0
41481-P5D-00 0
41 48 2 -PS D -00 0
41 48 3 -PS D -00 0
Thicknes s
0.66 m m (0.026 0 in )
1.1 7 m m (0.046 1 in )
1.2 0 m m (0.047 2 in )
1.2 3 m m (0.048 4 in )
1.2 6 m m (0.049 6 in )
1.2 9 m m (0.050 8 in )
1.3 2 m m (0.052 0 in )
1.3 5 m m (0.053 1 in )
1.38 m m (0.054 3 in )
1.4 1 m m (0.055 5 in )
1.4 4 m m (0.056 7 in )
1.4 7 m m (0.057 9 in )
1.5 0 m m (0.059 1 in )
1.5 3 m m (0.060 2 in )
1.5 6 m m (0.061 4 in )
1.5 9 m m (0.062 6 in )
1.6 2 m m (0.063 8 in )
1.6 5 m m (0.065 0 in )
1.6 8 m m (0.066 1 in )
1.7 1 m m (0.067 3 in )
1.7 4 m m (0.068 5 in )
1.7 7 m m (0.069 7 in )
1.8 0 m m (0.070 9 in )
1.8 3 m m (0.072 0 in )
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Differential Assembl y
Installation
NOTE: I f th e differentia l cas e i s replaced , th e 2 6 m m
shi m mus t b e adjuste d (se e ste p 1) . I f th e differentia l
cas e wa s no t replaced , g o to ste p 4 .
1 . Instal l th e differentia l assembly .
2 . Measur e th e clearanc e betwee n th e differentia l cas e
an d th e torqu e converte r housing .
26 m m SHI M
3. Selec t th e 2 6 m m shi m fro m th e followin g table .
2 6 m m SHI M
A
B
C
D
E
F
G
H
I
J
K
L
Part Numbe r
41432 -PY4 - 00 0
41433-PY4-00 0
41434-PY4-00 0
41435-PY4-000
41436-PY4-00 0
41437-PY4-00 0
41438-PY4-00 0
41439-PY4-00 0
41440-PY4-00 0
41441-PY4-00 0
41442-PY4-00 0
41443-PY4-00 0Thicknes
s
1.9 m m (0.0 7 48 in )
2.0 m m (0.078 7 in )
2.1 m m (0.082 7 in )
2.2 m m (0.086 6 in )
2.3 m m (0.090 6 in )
2.4 m m (0.094 5 in )
2.5 m m (0.098 4 in )
2.6 m m (0.102 4 in )
2.7 m m (0.106 3 in )
2.8 m m (0. 1 102 in )
2.9 m m (0. 1 142 in )
3.0 m m (0. 1 181 in )
Measuremen t
Value
1.99- 1.9 m m
2.0 9 - 2.0 m m
2.19-2. 1 m m
2.2 9 -2. 2 mm
2.39-2. 3 m m
2.4 9 -2. 4 mm
2.59-2. 5 m m
2.69-2. 6 m m
2.7 9 -2. 7 mm
2.89 - 2.8 m m
2.9 9 - 2.9 m m
3.09-3. 0 m m
4. Instal l th e tw o dowe l pin s o n th e differentia l assem -
bly.
DOWE L PIN S
5. Attac h th e differentia l assembl y t o th e engine , the n
tighte n th e fou r mountin g bolt s t o th e specifie d
torque .
O-RING .Replace .
12 x 1.2 5 mm64 N- m (6. 5 kgf-m ,
4 7 Ibf-ft )
26 m m SHI M
6. Instal l th e 2 6 m m shim , the n tighte n th e mountin g
bolt s t o th e specifie d torque .
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7. Instal l th e righ t engin e mount .
RIGHT ENGIN EMOUNT10 x 1.2 5 mm38 N- m (3. 9 kgf-m ,
2 8 Ibf-ft )
10 x 1.2 5 mm38 N- m (3. 9 kgf-m ,
2 8 Ibf-ft )
8. Instal l th e righ t engin e moun t bracket , the n righ t
an d lef t engin e moun t bracke t nuts .
10 x 1.2 5 mm38 N- m (3. 9 kgf-m ,
2 8 Ibf-ft )
12 x 1.2 5 mm64 N- m (6. 5 kgf-m ,
4 7 Ibf-ft )
RIGH T ENGIN E
MOUN T BRACKE T
Appl y liqui d gaske t
(P/N 0871 8 -0001 )
12 x 1.2 5 mm64 N- m (6. 5 kgf-m ,
4 7 Ibf-ft )
9. Remov e th e chai n hoist .
10 . Instal l th e engin e sto p moun t bracke t bolts .
ENGIN E STO PMOUNT S
12 x 1.2 5 mm74 N- m (7. 5 kgf-m ,
5 4 Ibf-ft )
11. Appl y Supe r Hig h Tem p Ure a Greas e (P/ N 0879 8 -
9002 ) t o th e spline s o f th e extensio n shaft , the n
instal l th e ne w se t ring .
SET RIN GReplace .
15-27ProCarManuals.com

Differential Assembl y
Installation (cont'd )
12. Instal l th e extensio n shaf t usin g th e specia l too l a s
shown .
NOTE : Pus h th e extensio n shaf t i n th e secondar y
drive n gea r shaf t unti l th e extensio n shaf t stops .
EXTENSIO N
SHAF T
EXTENSIO N SHAF T
INSTALLE R
07MAF-PY40100 or07MAF-PY4010 1
13. Fil l th e secondar y gea r wit h Supe r Hig h Tem p Ure a
Greas e (P/ N 0879 8 - 9002) .
O-RIN GReplace .12- 1 4 g (0. 4 -0. 5 oz)
36 m m SEALIN G BOL T
7 8 N- m (8. 0 kgf-m , 5 8 Ibf-ft )
14. Instal l th e ne w O-rin g i n th e groov e o f th e 3 6 m m
sealin g bolt , the n instal l th e 3 6 m m sealin g bolt .
NOTE : Shif t th e transmissio n int o th e [P ] positio n t o
loc k th e secondar y gear . 15
. Instal l th e righ t exhaus t manifol d cover , the n instal l
th e breathe r tub e to th e clamp .
8 x 1.2 5 mm22 N- m (2. 2 kgf-m ,
1 6 Ibf-ft ) CLAM
P
BREATHE RTUBE
RIGH T EXHAUS TMANIFOL D COVE R
16. Instal l th e powe r steerin g pump , the n adjus t th e
bel t tensio n o f pum p bel t (se e sectio n 17 ).
2 2 N- m (2. 2 kgf-m , 1 6 Ibf-ft )
POWE RSTEERIN G
PUM P
ADJUSTIN GBOLT44 N- m (4. 5 kgf-m ,
3 3 Ibf-ft )
SE
T RIN G
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