Hi i have a 1991 Honda 300 4x4 that needs a rear differential rebuild.Was wondering if anyone has done one.I have all new bearings and new pinion and ring gears but no shims.Was asking the local ATV mechanic and he said it could cost a fortune to put it back together properly because there is no way of knowing what shim combination will work and each shim is aprox. $15 CDN. and there are like 40 different shims.My old diff. has no signs of any shims left.There must be an easier way to figure this out without having to by all these shims.It just doesn't make any sense.Thanks in advance for all anwers.

 

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These are the Honda rear end tools ..
http://img526.imageshack.us/my...copyofdscn3673ih0.jpg

This is the rear end with ring gear removed..
http://img526.imageshack.us/my...copyofdscn3672os1.jpg

Pop out the seal..
http://img526.imageshack.us/my...copyofdscn3674nk8.jpg

Remove the large retainer nut..
http://img526.imageshack.us/my...copyofdscn3675ww8.jpg

http://img266.imageshack.us/my...copyofdscn3681cs5.jpg

Using the holder remove the pinion nut ..
http://img178.imageshack.us/my...copyofdscn3676nz3.jpg

http://img266.imageshack.us/my...copyofdscn3677gs3.jpg

Then pull the pinion ..
http://img513.imageshack.us/my...copyofdscn3683it9.jpg

http://img178.imageshack.us/my...copyofdscn3684eq5.jpg

The small pinion bearing comes out by working the retainer ring to the hole
and bending the tip up and pulling it out with needle nose plyers or needle
nose vice grips..The hole can be just seen thru the dirt..
http://img512.imageshack.us/my...copyofdscn3686el7.jpg

http://img512.imageshack.us/my...copyofdscn3685fc7.jpg

This rear end had All ***** rear end kit installed..
http://img178.imageshack.us/my...=copyofdscn3687gt1.jpg

 

Hi and thanks for the super pics.I have had no problem taking the diff apart.I have it all cleaned up with new bearing kit and new gears.I need to know what shims to use or how to measure to find out how.

 

If you need the rear end section from the 1991 PDF shop manual PM your email address... We get a couple of rearends in a year that have no or missing shims ,
side clearance is more inportant than tooth pattern ..

 

The shims are $8.62 CDN (dealer cost) and sell for $14.09 CDN each ...

 

<div class="FTQUOTE"><begin quote>Originally posted by: HondaMechanic

side clearance is more inportant than tooth pattern ..</end quote></div>

HondaMechanic, Why would you say the side clearance is more important? Isn't the reason for the shims is to set the gear mesh so you don't end up with a gearbox that is sloppy or tight?

We've always used prussian blue on our gears to check the mesh, adjusting shims for a mesh closest to the middle of the gear tooth face - this should have the backlash set properly.

Although you did a fine job of presenting the OEM Honda tools and the Snap On tools (we just can't be proper grease-monkeys without having Snap On tools [img]i/expressions/face-icon-small-wink.gif[/img] ) One tool I noticed you did not show was the propane torch - heating around the pinion bearing lock nut makes it come loose a lot easier, and once you get the clip from the pinion needle bearing, heating the aluminum around it makes it slide right out.

 

The reason I said that side clearance is the most important is that most of the forum users and looking for the fastest way to get back on the trail ,
if you put 2 thin shims on the ringgear then it will move back & forth against the pinion and it won't last long ..

If your going to assemble the rearend using prussian blue then you will need the 25 shims from U to X and from A to T .. As well as the pinion shims
from A to G .. Which will cost approx. $450.00 + taxes ..

Now as for the pictures that rearend was (an still is) junk , the pictures were only for forum users information and to show the parts & special tools needed ..

As far as Snap-On tools go , well I have approx. 30 thousand in Snap-On tools because that is the only tool truck that comes to our shop ..

The retaining ring in the pinion bearing isn't to bad getting out if you first inlarge (bevel the sides) the hole with a die grinder then use an awl to get the
end into the hole..

 

So i should use no spacers on the ring gear and adjust side clearance with correct size spacer on pinion?What can i use to measure clearance?Thanks

 

Does anyone know where I can get the tool to remove the pinion lock not?