differential ACURA RL KA9 1996 Service Repair Manual

Lubrication Points

For the details of lubrication points and types of lubricants to be applied, refer to the Illustrated Index and various work

procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

No.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22
LUBRICATION POINTS

Engine

Transmission

Brake line (Includes ABS line)

Power steering gearbox

Steering boots

Throttle cable end

Steering ball joints

Shift lever (Automatic transmission)

Pedal linkage

Intermediate shaft

Brake master cylinder pushrod

Fuel
fill
lid

Battery terminals

Trunk hinges and latch

Door hinges upper and lower

Door opening detents

Hood hinges and hood latch

Brake line joints (Front and rear wheelhouse)

Caliper Piston boot, caliper

Pins and boots

Power steering system

Differential

A/C compressor

API SERVICE LABEL API CERTIFICATION SEAL
LUBRICANT

API Service Grade: Use SJ "Energy Conserving" grade oil.

The oil container may also display the API Certification

seal shown below. Make sure it says "For Gasoline

Engines."

SAE Viscosity: See chart below.

Honda ATF-Z1 (ATF)*1

Genuine Honda DOT3 brake fluid*2

Steering grease P/N 08733 - B070E

Multi-purpose grease

Honda White Lithium Grease

Rust preventive

Silicone grease

Genuine Honda power steering fluid*3

Hypoid gear Oil API GL4 or GL5

Viscosity:

at above -18°C (0°F): SAE 90

at less than -18°C (0°F): SAE 80W-90

Compressor oil:

DENSO: ND-OIL8 (P/N) 38897 - PR7 - A01 AH or 38899 -

PR7-A01)

(For Refrigerant: HFC-134a (R-134a))

Recommended engine oil

viscosity for ambient

temperature ranges

*1: Always use Honda ATF-Z1 (ATF). Using a non-Honda ATF can affect shift quality.

*2: Always use Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the

life of the system.

*3: Always use Genuine Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmis-

sion fluid can cause increased wear and poor steering in cold weather.ProCarManuals.com

ATF DIPSTICK

RING GEAR/DRIVE PLATE

TORQUE

CONVERTER

4TH CLUTCH

1ST CLUTCH

2ND CLUTCH

MAINSHAFT

COUNTERSHAFT
DIFFERENTIAL

ASSEMBLY

EXTENSION

SHAFT

SECONDARY

DRIVEN GEAR

REVERSE

CLUTCH
1ST-HOLD

CLUTCH
3RD CLUTCHProCarManuals.com

MAINSHAFT 3RD

GEAR

MAINSHAFT 4TH

GEAR

4TH CLUTCH

1ST CLUTCH

MAINSHAFT 1ST

GEAR

MAINSHAFT 2ND

GEAR

2ND CLUTCH

MAINSHAFT REVERSE

GEAR
DIFFERENTIAL

EXTENSION SHAFT

SECONDARY DRIVE

GEAR

3RD CLUTCH

SECONDARY DRIVEN GEAR

COUNTERSHAFT 3RD

GEAR

COUNTERSHAFT 4TH

GEAR

1ST-HOLD CLUTCH

1ST-GEAR ONE-WAY

CLUTCH

COUNTERSHAFT 1ST GEAR

ONE-WAY CLUTCH HUB

COUNTERSHAFT 2ND GEAR

2ND-GEAR ONE-WAY

CLUTCH

PARK GEAR

REVERSE CLUTCH

COUNTERSHAFT REVERSE

GEAR

MAINSHAFT

COUNTERSHAFTProCarManuals.com

Differential
Troubleshootin g
NOTE: Mos t problem s i n th e uni t ar e t o b e diagnose d b y identifyin g noise s fro m th e gear s o r bearings .
Car e shoul d b e take n durin g diagnosi s no t t o confus e differentia l noise s wit h thos e fro m othe r drivetrai n components .
[Nois e symptom s wil l b e mos t prominent ]
Symptom
Consisten t nois e during
cruisin g
Gea r noise s whil e
acceleratin g
Gea r noise s whil e
coastin g o r acceleratin g
Bearin g noise s whil e
acceleratin g o r
coasting/deceleratio n
Abnormal noise s whe n
roundin g a curv e
Abnorma l noise s durin g
acceleratio n o r whe n firs t
drivin g awa y fro m a sto p
Oi l lea k
Overheatin g Probabl
e Caus e
• Lac k o f oi l
• Foreig n matte r stuc k in gears , etc .
• Imprope r toot h contac t betwee n rin g gea r an d
driv e pinio n
• Wor n o r damage d sid e bearin g
• Deforme d rin g gea r o r differentia l carrie r
• Lac k o f oi l
• Foreig n matte r stuc k in gears , etc .
• Imprope r driv e pinio n preloa d
• Chippe d o r damage d gear s
• Imprope r driv e pinio n preloa d
• Damage d o r chippe d gear s
Cracke d o r damage d driv e pinio n bearin g o r sid e
bearin g
• Wor n (excessiv e play ) o r damage d sid e bearin g
• Damage d sid e gear , pinion , o r pinio n shaf t
• Excessiv e backlas h betwee n rin g gea r an d
driv e pinio n
• Imprope r rin g gea r o r driv e pinio n preloa d
• Excessiv e pinio n backlas h
• Wor n differentia l spline s
• Loos e companio n flang e nut s an d othe r
fastener s
• Oi l leve l to o hig h
• Clogge d breathe r hol e
• Loos e cas e cove r o r inadequat e sealin g
• Wor n o r damage d oi l sea l
• Lac k o f oi l
• Insufficien t rin g gear-to-pinio n backlas h
• Excessiv e rin g gea r o r driv e pinio n preloa d Remed
y
• Replenis h oi l
• Clea n an d inspec t
• Adjus t o r replac e
• Replac e an y damage d o r
fault y part s
• Replenis h oi l
• Clea n an d inspec t
• Adjus t
• Replac e
Adjus t o r replac e
Replac e
Replace
• Adjus t
• Adjus t o r replac e
• Rechec k torqu e o r replac e
• Lowe r t o prope r leve l
• Clea n o r replac e
• Rechec k torqu e o r appl y sealan t
• Replac e
• Replenis h
• Adjus t
• Adjus t o r replac e
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Maintenance

Differential Oil

NOTE: Check the differential oil with engine OFF, and

the vehicle on level ground.

1. Remove the oil filler plug, then check the level and

condition of the oil.

WASHER

Replace.

Proper Lever

OIL FILLER PLUG

44 N-m (4.5 kgf-m, 33 Ibf-ft)

WASHER Replace.

2. The oil level must be up to the fill hole. If it is below

the hole, add oil until it runs out, then reinstall the

oil filler plug with a new washer.

3. If the differential oil is dirty, remove the drain plug,

and drain the oil.

DRAIN PLUG

39 N-m (4.0 kgf-m, 29 Ibf-ft)

WASHER Replace.

OIL FILLER PLUG

44 N-m (4.5 kgf-m, 33 Ibf-ft)

4. Reinstall the drain plug with a new washer, and refill

the differential with the recommended oil to the

proper level.

NOTE:

The drain plug washer should be replaced at every

oil change.

Clean the drain plug before reinstalling.
5. Reinstall the oil filler plug with a new washer.

Oil Capacity

1.05 (1.11 US qt, 0.92 Imp qt) at oil change

1.10 (1.16 US qt, 0.97 Imp qt) at overhaul

Recommended oil:

Hypoid gear oil

API Classification GL4 or GL5

viscosity:

SAE 90 above 0°F (-18°C)

SAE 80 W - 90 below 0°F (-18°C)ProCarManuals.com

Differential Assembly
Removal
Make sur e jack s an d safet y stand s ar e place d properly ,
an d hois t bracket s ar e attache d to correc t position s o n
th e engine .
Appl y parkin g brak e an d bloc k rea r wheel s s o th e
vehicl e wil l no t rol l of f stand s an d fal l o n yo u whil e
workin g unde r it .
CAUTION : Us e fende r cover s to avoi d damagin g painte d
surfaces .
1. Remov e th e drai n plug , an d drai n th e differentia l oi l
(se e pag e 15-4 ).
2 . Remov e th e cotte r pin s an d castl e nuts , tha n sepa -
rat e th e bal l joint s fro m th e lowe r ar m usin g th e
specia l too l (se e sectio n 18 ).
3 . Remov e th e righ t dampe r pinc h bolt , the n separat e
th e dampe r for k an d dampe r (se e sectio n 18 ).
4 . Pr y th e driveshaft s ou t o f th e differentia l an d inter -
mediat e shaf t (se e sectio n 16 ).
CAUTION :
D o no t pul l o n th e driveshaft , a s th e inboar d
join t ma y com e apart .
Us e car e whe n pryin g ou t th e assembly , an d pul l
i t straigh t t o avoi d damagin g th e differentia l oi l
sea l o r th e intermediat e shaf t oute r seal .
5 . Pul l o n th e inboar d join t t o remov e th e righ t drive -
shaf t fro m th e differentia l an d t o remov e th e lef t
driveshaft from the intermediate shaft (see
section 16 ).
6 . Remov e th e intermediat e shaf t assembl y fro m th e
oi l pa n (se e sectio n 16 ).
7 . Ti e plasti c bag s ove r th e driveshaf t ends .
NOTE : Coa t al l precisio n finishe d surface s wit h
clea n engin e oil .
SE T RIN GReplace .
PLASTIC BA G
8. Remov e th e 3 6 m m sealin g bol t an d O-ring , the n
disconnec t th e extensio n shaf t fro m th e differentia l
usin g th e specia l tool .
NOTE : Shif t th e transmissio n int o th e B positio n t o
loc k th e secondar y gear .
36 m m SEALIN GBOLTSET RIN GReplace .
O-RINGReplace .
EXTENSIO N SHAF T PULLE R
07LAC-PW5010 0 o r
07LAC-PW5010 1 EXTENSIO
N SHAF T
9. Remov e th e splas h shield .
SPLAS HSHIELD
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Differential Assembl y
Removal (cont'd )
10. Remov e th e lowe r plate , the n reinstal l th e steerin g
gearbo x mountin g bolts .
STEERIN G GEARBO XMOUNTING BOLT S
5 9 N- m (6. 0 kgf-m ,
4. 3 Ibf-ft )
LOWE R PLAT E
11. Disconnec t th e vehicl e spee d senso r (VSS ) connec -
tor , the n remov e th e VSS/powe r steerin g spee d
sensor .
NOTE : D o no t disconnec t th e hoses .
VSS CONNECTO R
VSS/POWE R STEERIN G
SPEE D SENSO R
12. Remov e th e ai r cleane r housin g assembly .
AIR CLEANE RHOUSING ASSEMBL Y
13. Remov e th e powe r steerin g pump .
NOTE : D o no t disconnec t th e hoses .
POWER STEERIN G
PUM P
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Differential Assembl y
Removal (cont'd )
19. Remov e th e mountin g bolt s an d 2 6 m m shim , the n
remov e th e differential assembly.
O-RINGReplace .
DIFFERENTIA L
ASSEMBL Y
26 m m SHI M
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Differential Assembl y
Inspection
To establis h a startin g poin t befor e disassembly , inspec t
the following :
Ring gea r backlas h
Tota l bearin g preloa d
Gea r toot h contac t
NOTE:
Be sur e th e differential is a t roo m temperatur e befor e
inspecting .
Recor d th e result s o f th e preliminar y inspections .
Thi s informatio n wil l b e helpfu l durin g reassembly .
Rin g gea r backlas h
1 . Remov e th e oi l fille r plu g an d th e oi l seal .
OIL SEA LReplace .
OIL FILLE R PLU G
4 4 N- m (4. 5 kgf-m , 3 3 Ibf-ft )
WASHE R
Replace .
BENCHVISE LOCKNU
T SOCKET ,
36 x 4 1 m m07HAA-SF1010 0
3. Alig n th e differentia l gea r inspectio n hol e wit h th e
oi l fille r plu g hole . 4
. Measur e th e backlas h o f th e rin g gea r o n th e differ -
entia 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 dif -
ferentia 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 4 1 m m07HAA-SF1010 0
Total bearin g preloa d
5 . Remov e th e differentia l cas e cove r an d th e differen -
tia l carrier .
NOTE : Loose n th e bolt s i n a crisscros s pattern , i n
severa l steps .
10 x 1.2 5 mm44 N- m (4. 5 kgf-m , 3 3 Ibf-ft )
DIFFERENTIA L
CAS E COVE R
DIFFERENTIA L
CARRIER
2. Secur e th e differentia l assembly in a vis e wit h sof t
jaws .
SOFT JAW S
INSPECTIO NHOLE
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Differential Assembly

Disassembly

1. Remove the bolts in a crisscross pattern, in several

steps, then remove the differential case cover.

DIFFERENTIAL

CASE COVER

DIFFERENTIAL CASE

2. Remove the oil seal from the differential case cover.

OIL SEAL

Replace.

DIFFERENTIAL

CASE COVER
Remove the bearing outer race and the 79.5 mm

thrust shim(s) from the differential case cover by heat-

ing the differential case cover to about 212°F (100°C).

NOTE:

Do not heat the differential case cover in excess

of 212°F (100°C).

If the bearing outer race was removed by heat-

ing, allow the differential case cover to cool to

room temperature.

Replace the tapered roller bearing with a new

one whenever the bearing outer race is replaced.

BEARING OUTER

RACE

79.5
mm

THRUST SHIM

(1 or 2 shims)

DIFFERENTIAL CASE COVER

4. Remove the breather plate.

SCREW

Replace.

BREATHER PLATEProCarManuals.com