Overhaul

DISASSEMBLE





1. Hold the differential in a bench vise using a special tool, then remove the differential housing mounting bolts in a crisscross pattern in several steps.





2. Remove the differential housing, stop plate, washer, thrust needle bearing, and 65 mm shim.





3. Remove the 1 12 mm shim, clutch discs, clutch plates, and 102 mm washer.





4. Remove parts shown.





5. Screw two 8 x 1.0 mm bolts into the threaded holes in the differential housing cover to push it away from the final driven gear. Turn each bolt two turns at a time to prevent cocking the differential housing cover excessively.

REASSEMBLE

NOTE:
- If the limited slip differential clutch set was replaced, the 65 mm shim (differential housing cover side) and 112 mm shim (differential housing cover side) must be adjusted.
- Reassemble the parts in the same order and direction they were before disassembly.
- Lubricate the clutch disc surface with transmission oil.





1. Reassemble the parts as shown. Position the 65 mm shim with the thickness stamp mark facing up.





2. Install the carrier assembly.





3. Install the final driven gear. Align the mark on the differential housing cover with the mark on the final driven gear.





4. Install the washers, thrust needle bearing, and central gear.
5. Clean the gear end surface on the central gear.





6. Set the plastigauge (Blue) strip on the central gear at four points in a crisscross pattern.





7. Install the washer, thrust needle bearing, 65 mm shim, 112 mm shim, clutch disc, and spring plate. Be careful not to move the plastigauge when installing the washer. Position the 65 mm shim with the thickness stamp mark facing up.





8. Align the marks, then install the differential housing cover.





9. Tighten the mounting bolts in a crisscross pattern in several steps.





10. Remove the parts shown.





11. Measure the widest part of the plastigauge.
- Standard: 0.18 - 0.229 mm
- If the plastigauge measures within the standard go to step 14.
- If the plastigauge does not measure within the standard, continue with step 12.





12. Select the proper 65 mm shim based on the following table.
- If the measurement was less than 0.18 mm, install a thinner shim.
- If the measurement was more than 0.229 mm, install a thicker shim.
13. After installing a thinner or thicker shim, be sure to recheck the measurement with plastigauge.
- After installing a thinner shim: If the measured value is less than 0.18 mm, select the next thinner shim, and recheck. If the new value is more than 0.229 mm, the selected shim is OK.
- After installing a thicker shim: If the measured value is more than 0.229 mm select the next thicker shim, and recheck. If the new value is less than 0.18 mm, take the shim you chose at the step 12.





14. Install the washer, thrust needle bearing, 65 mm shim, 112 mm shim, clutch plate, clutch disc, and spring plate. Position the 65 mm shim with the thickness stamp mark facing up.





15. Align the marks, then install the differential housing cover.





16. Tighten the mounting bolts in a crisscross pattern in several steps.





17. Measure the preset torque.
- Standard: 59 - 137 Nm (43 - 101 ft. lbs.).
- If the preset torque is more than the standard, select a thinner 112 mm shim, and recheck the preset torque.
- If the preset torque is less than the standard, select a thicker 112 mm shim, and recheck the preset torque.