Side Case Replacement

Remove the rear differential (see REAR DIFFERENTIAL REMOVAL ).
Remove the rear differential front mounting brackets (A) from the rear differential (B).

Fig 1: Identifying Rear Differential And Front Mounting Brackets
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Disconnect the rear differential fluid temperature sensor 2P connector (A), then remove the rear differential fluid temperature sensor cover (B), the rear differential fluid temperature sensor (C), and the O-ring (D).

Fig 2: Identifying Rear Differential Fluid Temperature Sensor, Sensor Cover, 2P Connector And O-Ring
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Disconnect the left and right solenoid 4P connectors (A).

Fig 3: Identifying Solenoid 4P Connectors, Rear Differential Harness Bracket, Subharness And Ground Cable Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the ground cable bolt (B) and rear differential harness bracket D, then remove the rear differential subharness (C).
Remove the rear differential left side case (A) or the rear differential right side case (D), and the 10x12 mm dowel pins (E) from the rear differential center case (F).

Fig 4: Identifying Rear Differential Harness Bracket, Center, Left And Right Side Case
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove rear differential harness bracket B and rear differential harness bracket C.
Replace the rear differential left side case or the rear differential right side case.
Remove the ring gear (A), the needle bearing (B), and the 60.2 mm shim (C) from the differential side case (D).

Fig 5: Identifying Ring Gear, Needle Bearing, Shim And Differential Side Case
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the distance (1) between the end of the rear differential side case (A) and the 60.2 mm shim contact area (B) of the planetary gear with a straight edge (C) and a depth gauge (D). Measure at three locations, and average the reading.
NOTE:
- Carry out the measurement at normal room temperature.
- Clean the parts thoroughly before measure.
  
  Fig 6: Measuring Distance Between End Of Rear Differential Side Case And Shim Contact Area Of Planetary Gear With Straight Edge And Depth Gauge
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the distance between the end of the rear differential center case (A) and the ring gear contact area (B) of the taper roller bearing with a straight edge (C) and a depth gauge (D). Measure at three locations, and average the reading.
NOTE:
- Carry out the measurement at normal room temperature.
- Clean the parts thoroughly before measure.
  
  Fig 7: Measuring Distance Between End Of Rear Differential Center Case And Ring Gear Contact Area Of Taper Roller Bearing With Straight Edge And Depth Gauge
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the distance (3) between the needle bearing (A) and the taper roller bearing contact area (B) of ring gear with a depth gauge (C). Measure at three locations, and average the reading.
NOTE:
- Carry out the measurement at normal room temperature.
- Clean the parts thoroughly before measure.
  
  Fig 8: Measuring Distance Between Needle Bearing And Taper Roller Bearing Contact Area Of Ring Gear With Depth Gauge
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Shim Selection Formula

Select the proper 60.2 mm shim from the table. Follow the example below, and use the measurements you made in step 10 to 12.

(Basic Formula)

(1) + (2) - ((3) + 0.19) = shim thickness 0.19 mm (0.007 in): middle of the standard clearance.

Standard Clearance:

0.14- 0.24 mm (0.006- 0.009 in)

(For example)

(1) = 6.12 mm (0.241 in)

(2) = 15.3 mm (0.602 in)

(3) = 19.56 mm (0.770 in)

6.12 + 15.3 - (19.56 + 0.19) = 1.67 mm

Select the 1.60 mm shim from the table.

60.2 MM SHIM

No.	Thickness
A	1.10 mm (0.043 in)
B	1.20 mm (0.047 in)
C	1.30 mm (0.051 in)
D	1.40 mm (0.055 in)
E	1.50 mm (0.059 in)
F	1.60 mm (0.063 in)
G	1.70 mm (0.067 in)
H	1.80 mm (0.071 in)
I	1.90 mm (0.075 in)
J	2.00 mm (0.079 in)
K	2.10 mm (0.083 in)
L	2.20 mm (0.087 in)

Place one strip of plastigage (A) on the 60.2 mm shim contact area (B) of planetary gear. Install the 60.2 mm shim (C), the needle bearing (D), and the ring gear (E). Measure at three locations as shown.
NOTE:
- Carry out the measurement at normal room temperature.
- Clean the parts thoroughly before measure.
  
  Fig 9: Identifying Plastigage, Shim, Shim Contact Area, Needle Bearing And Ring Gear
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 10x12 mm dowel pins (A), the rear differential right side case (B) or the rear differential left side case (C), and the mounting bolts (D) onto the rear differential center case (E).

Fig 10: Rear Differential Center, Left, Right Side Case, Dowel Pins And Mounting Bolts With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the mounting bolts in a crisscross pattern in several steps, then tighten the bolts to the specified torque.
Remove the rear differential left side case (A) or the rear differential right side case (B), and the 10 x 12 mm dowel pins (C) from the rear differential center case

Fig 11: Identifying Rear Differential Center, Left, Right Side Case And Dowel Pins
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the ring gear (A), the needle bearing (B), and the 60.2 mm shim (C) from the differential side case (D).

Fig 12: Identifying Differential Side Case, Ring Gear, Needle Bearing And Shim
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the widest part of the plastigage.
Measure at three locations, and average the reading.
- If the clearance exceeds the standard, go to step 9.
- If the clearance is within the standard, go to step 20.
  Standard Clearance:
  
  0.14- 0.24 mm (0.006- 0.009 in)
  
  Fig 13: Measure Clearance Using Plastigage
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 60.2 mm shim (A), the needle bearing (B), and the ring gear (C) onto the rear differential side case (D).

Fig 14: Identifying Differential Side Case, Ring Gear, Needle Bearing And Shim
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the dirt and oil from the sealing surfaces. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009) to the sealing surface. Make sure you seal up to the inside edge of the bolt holes to prevent oil leakage.
NOTE:
- You must assemble the housings within 5 minutes after applying the liquid gasket. If you applied liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If not, the sealing surface must be cleaned, and the liquid gasket reapplied.
- Allow the liquid gasket to cure at least 30 minutes after assembly before filling the differential with fluid.
Left side case/Right side case

Fig 15: Identifying Sealing Surface
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 10x12 mm dowel pins (A), the rear differential right side case (D) or the rear differential left side case (E), and the mounting bolts (F) onto the rear differential center case (G).

Fig 16: Rear Differential Center, Left, Right Side Case, Dowel Pins And Mounting Bolts With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install rear differential harness bracket B and rear differential harness bracket C.
Tighten the mounting bolts in a crisscross pattern in several steps, then tighten the bolts to the specified torque.
Install the rear differential subharness (A) and rear differential harness bracket D, and install the ground cable (B).

Fig 17: Solenoid 4P Connectors, Rear Differential Harness Bracket, Subharness And Ground Cable With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Connect the left and right solenoid 4P connectors (C).
Install the rear differential fluid temperature sensor (A) with a new O-ring (B), and install the rear differential fluid temperature sensor cover (C).

Fig 18: Rear Differential Fluid Temperature Sensor, Sensor Cover, 2P Connector And O-Ring With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Connect the rear differential fluid temperature sensor 2P connector (D).
Install the rear differential front mounting brackets (A) with new bolts (B) on the rear differential (C).

Fig 19: Rear Differential, Rear Differential Front Mounting Brackets And Bolts With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the rear differential (see REAR DIFFERENTIAL INSTALLATION ).
Do the SH-AWD differential clutch torque memorization (see SH-AWD® DIFFERENTIAL CLUTCH TORQUE MEMORIZATION ).