Differential

Differential
Pre-Inspection
Backlash of side gear and pinion gear





1. Before disassembly, measure backlash of side gears and pinion gears. If not within specification, replace differential assembly.
Backlash:
Standard: 0.001 - 0.004 inch (0.025 - 0.1 mm)
Maximum: 0.020 inch (0.5 mm)

Disassembly





Notice: Do not remove side bearings unless necessary.

1. Remove two side gears and two thrust washers.

Notice:
a) Use protective plates in vise to prevent damage to differential.
b) Insert punch into spring pin hole from ring gear side.





2. Place gear case on a vise and knock pin out with suitable pin punch and hammer. Then remove two thrust washers, two pinion gears and pinion shaft.
3. Remove side bearing inner race (side opposite ring gear) from gear case with SST (OK130 171 013) or equivalent.





4. Remove speedometer drive gear.





5. Remove side bearing (ring gear side) from gear case with SST (OK670 990 AAO) or equivalent.

Re-assembly





1. Set speedometer drive gear onto ring gear and case assembly.

Notice: Do not reuse side bearings if they were removed.

2. Press side bearing (side opposite ring gear) into ring gear and case assembly with SST (OK990 175 AA1) or equivalent.





3. Press on other side bearing (ring gear side) in same manner.
4. Install pinion gears and thrust washers into case.





5. Install pinion shaft.





6. Install spring pin, and stake hole to prevent spring pin from coming out of gear case.





7. Install thrust washers and side gears into gear case at same time, then rotate them around pinion gears and align them with driveshaft holes.

Notice: Be certain that both side gears are centered in their respective driveshaft holes. If not, remove both side gears and re-install them.

8. Measure backlash of side gears and pinion gears as follows:
a. Install left and right driveshafts in differential assembly.
b. Support driveshafts on V-blocks.
c. Measure backlash of both pinion gears.
Backlash:
Standard: 0.001 - 0.004 inch (0.025 - 0.1 mm)
Maximum: 0.020 inch (0.5 mm)





9. If backlash is not within specification, replace differential assembly.