Differential: Service and Repair

DISASSEMBLY
Follow disassembly steps outlined in illustration.

NOTE: Disassembly service points as follows:





A. Ball bearings removal. (3)

CAUTION: Do not reuse the bearing removed from the shaft.





B. Taper roller bearing removal. (4)

CAUTION:
- Do not reuse the bearing removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.





C. Lock pin removal. (5)
Drive out the lock pin from the hole A using a punch.

ASSEMBLY
Assembly in reverse order as Disassembly.

NOTE: Assembly service points as follows:

A. Spacer/side gear/washer/pinion/pinion shaft installation. (6, 7, 8, 9 & 10)





1. Install the spacer on the back of the side gear and then install the gearing the differential case.

CAUTION: When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.0366-0.0394 inch)].





2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears and turning them.
3. Insert the pinion shaft.





4. Measure the backlash between the side gears and pinions.
Standard value: 0.025-0.150 mm (0.00098-0.00591 inch)

5. If the backlash is out of specification, disassemble again and using correct spacer, reassemble and adjust.

CAUTION: Adjust for same backlash of both side gears.





B. Lock pin installation. (5)
Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

CAUTION:
- Do not reuse the lock pin.
- The lock pin head must be sunk from the flange surface of the differential case.





C. Taper roller bearings installation. (4)

CAUTION: Apply the special tool to the inner race only.





D. Ball bearings installation. (3)
E. Bolts installation. (1)





1. Apply the specified sealant to the bolt threads.
Specified sealant: 3M Stud Locking No.4170 or equivalent.





2. Tighten to the specified torque while following the order given in the illustration.