Pre-Disassembly Inspection

1. Check runout of drive pinion shaft. Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 inch) from the end of the shaft.
Maximum runout: 0.08 mm (0.0031 inch).
If the runout is greater than the maximum, replace the drive pinion and ring gear.
2. Remove differential carrier cover, as follows:
a. Remove the eight bolts from the carrier cover.
b. Using a brass bar and hammer, separate the cover and carrier.





3. Check ring gear runout. Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch).
If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.





4. Check ring gear backlash. Using a dial indicator, measure the backlash of the ring gear at three points at least and check that the average value is within the specification.
Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch).

NOTICE: The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 inch).

If the backlash is not within the specification, adjust the backlash.





5. Measure dive pinion preload. Using Special Service Tool (SST) 09229 - 55010 or equivalent, and a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.
Preload (at starting): 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).

NOTE: With vehicles which have run less than 8,000 km (5,000 miles), the preload may be large.

Maximum preload (at starting): 1.8 Nm (16.0 inch lbs.).
6. Measure total preload. Using SST 09229 - 55010 or equivalent, and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).
If necessary, disassemble and inspect the differential.





7. Check pinion gear backlash. Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch).
If the backlash is not within the specification, install the correct thrust washer.
8. Check tooth contact pattern.