### Differential Pinion Bearing Replacement on a Daihatsu Charade G10 #### Tools Needed: 1. click here for more details on the download manual…..
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### Differential Pinion Bearing Replacement on a Daihatsu Charade G10
#### Tools Needed:
1. **Socket Set** (Metric)
2. **Torque Wrench**
3. **Pry Bar**
4. **Bearing Puller/Installer**
5. **Slide Hammer**
6. **Seal Puller**
7. **Micrometer or Caliper**
8. **Impact Wrench** (optional)
9. **Clean Rags**
10. **Grease**
11. **Differential Oil**
12. **Safety Glasses**
13. **Gloves**
14. **Drain Pan**
#### Safety Precautions:
– Always wear safety glasses and gloves to protect yourself from debris and sharp components.
– Ensure the vehicle is on a stable surface and securely supported with jack stands.
– Disconnect the battery to prevent any electrical issues during the process.
#### Step-by-Step Procedure:
1. **Preparation**:
– Park the vehicle on a level surface and engage the parking brake.
– Disconnect the negative terminal of the battery.
2. **Drain Differential Oil**:
– Place a drain pan under the differential.
– Remove the drain plug and allow the oil to fully drain out.
3. **Remove the Driveshaft**:
– Unbolt the driveshaft from the differential.
– Slide the driveshaft out of the differential and secure it to prevent damage.
4. **Remove the Differential Cover**:
– Unbolt the differential cover using a socket wrench.
– Carefully pry the cover off and clean the mating surfaces.
5. **Extract the Differential**:
– Remove the ring gear if necessary.
– Carefully remove the differential assembly from the housing.
6. **Remove the Pinion Gear**:
– Using a socket set, unbolt the pinion gear from the differential housing.
– Carefully pull out the pinion gear and bearings.
7. **Remove Old Bearings**:
– Utilize a bearing puller to remove the old pinion bearings from the pinion shaft.
– Take care not to damage the pinion shaft during this process.
8. **Install New Bearings**:
– Preload the new bearings with a thin layer of grease.
– Using a bearing installer, press the new bearings onto the pinion shaft until fully seated.
9. **Reassemble the Pinion Gear**:
– Reinsert the pinion gear into the differential housing.
– Torque the pinion nut to the manufacturer’s specifications using a torque wrench.
10. **Install the Differential**:
– Carefully place the differential back into the housing.
– Reattach the ring gear if it was removed.
11. **Reattach Differential Cover**:
– Clean the mating surfaces and apply a new gasket or sealant.
– Bolt the differential cover back in place and torque to spec.
12. **Reinstall Driveshaft**:
– Slide the driveshaft back into the differential and bolt it securely.
13. **Fill Differential with Oil**:
– Replace the drain plug and fill the differential with the appropriate type and amount of oil.
14. **Reconnect Battery**:
– Reconnect the negative terminal of the battery.
15. **Test Drive**:
– Start the vehicle and take it for a short test drive, then check for leaks or unusual noises.
#### Common Pitfalls to Avoid:
– **Not Preloading the Bearings**: Ensure that the bearings are properly preloaded to avoid premature failure.
– **Incorrect Torque Specifications**: Always use a torque wrench to avoid over-tightening or under-tightening bolts.
– **Neglecting to Clean Surfaces**: Ensure all mating surfaces are clean to prevent oil leaks.
– **Failing to Replace the Seal**: Always replace the pinion seal when replacing the pinion bearings to prevent leaks.
#### Replacement Parts:
– **Pinion Bearings**: Ensure to get OEM or high-quality aftermarket bearings.
– **Pinion Seal**: Replace this to prevent oil leaks after reassembly.
– **Gasket/Sealant**: Use a new gasket for the differential cover.
By following these steps carefully, you can successfully replace the differential pinion bearing on a Daihatsu Charade G10.
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