Front Differential Carrier Assembly

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): INSPECTION

1. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH

(a) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.

(b) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange by hand.

SST : 09564-32011

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

HINT
* Record the measured backlash to use as a reference for selecting a case washer.
* Inspect tooth contact to use the result as a reference for selecting a case washer.
* Select the case washer from the table below so that the backlash is within the specified range, and install the selected washer.

(c) If backlash is not within the specified range, change the thickness of the right and left case washers by equal amounts to adjust it.

Washer thickness

2. INSPECT FRONT DRIVE PINION COMPANION FLANGE

(a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

Maximum runout:

0.05 mm (0.0020 in.)

If the runout is greater than the maximum value, replace the companion flange.

3. INSPECT DRIVEN PINION PRELOAD

(a) Using a torque wrench, measure the preload using the backlash of the drive pinion and ring gear.

Preload (at starting):

New bearing
0.98 to 1.57 N*m (10.0 to 16.0 kgf*cm, 8.7 to 13.9 in.*lbf)

Reused bearing
0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm, 4.3 to 6.9 in.*lbf)

If the drive pinion preload is not within the specified range, adjust the drive pinion preload or repair as necessary.

4. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

Total preload (at starting):

New bearing
1.27 to 2.06 N*m (13.0 to 21.0 kgf*cm, 11.2 to 18.2 in.*lbf)

Reused bearing
0.78 to 1.27 N*m (8.0 to 13.0 kgf*cm, 6.9 to 11.2 in.*lbf)

If the total preload is not within the specified range, adjust the total preload or repair as necessary.

5. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Remove the 8 bolts and side bearing retainer.

(b) Remove the differential case from the differential carrier.

(d) Install the differential case to the differential carrier.

(e) Install the differential side bearing retainer with the 8 bolts.

Torque : 58 Nm (590 kgf-cm, 43 ft-lbf)

(f) Rotate the ring gear in both directions.

(g) Remove the 8 bolts and side bearing retainer.

(h) Remove the differential case from the differential carrier.

(i) Inspect the tooth contact pattern.

(j) If the teeth are not contacting properly, use the following table to select a proper adjust shim for correction.

NOTICE:
* If the contact pattern is either face contact or flank contact, the tooth contact may be adjustable while keeping the backlash within the specified range.
* If the thickness of the front adjust shim has been changed, adjust the backlash and measure the total preload.

Washer thickness:

6. INSPECT AND ADJUST DIFFERENTIAL SIDE GEAR BACKLASH

(a) Hold the differential case in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Measure the side gear backlash while holding 1 pinion gear toward the differential case.

Backlash:

0.05 to 0.20 mm (0.0020 to 0.0079 in.)

If the backlash is not within the specified range, install the 2 side gear thrust washers of different thicknesses.

HINT
Refer to the following table to select the 2 side gear thrust washers.

Washer thickness:

7. INSPECT DIFFERENTIAL PINION AND SIDE GEAR

(a) Check that there is no damage to the differential pinion gears and side gears.

If a differential pinion gear and/or side gear is damaged, replace them with new ones.

8. INSPECT DIFFERENTIAL CASE

(a) Check that there is no damage to the differential case.

If the differential case is damaged, replace it.