Part 1
DIFFERENTIAL BACKLASH MEASUREMENT/ADJUSTMENTPreparation Before Servicing
1. Print out the measurement/adjustment value input sheet. (See MEASUREMENT/ADJUSTMENT VALUE INPUT SHEET.)
NOTE:
- When performing the measurement/adjustment, input the measured and calculated values into the measurement/adjustment value input sheet.
- When performing the other measurements/adjustments, if the measurement/adjustment value input sheet has been printed out, use the printed sheet.
Differential Backlash Measurement
NOTE: Measure the tooth play (gap) between the side gear and pinion gear as the differential backlash.
1. Secure the ring gear and differential in a vise.
A : Vise
CAUTION: Insert a protective plate between the vise and the part so as not to damage the part.
2. Assemble the drive shaft (LH) and joint shaft to the ring gear and differential.
A : Drive shaft (LH)
B : Joint shaft
CAUTION: Because the drive shaft (LH) clip is not required for the differential backlash measurement, do not assemble it.
3. Set the dial gauge and magnetic stand as shown in the figure.
A : Dial gauge
B : Magnetic stand
CAUTION: To reduce error during the backlash measurement, set the dial gauge so that it is perpendicular to the teeth of the pinion gear.
4. Set the dial gauge end to the pinion gear teeth.
A : Area in which dial gauge end is set
CAUTION: To reduce error during the backlash measurement, set the dial gauge end to within the area shown in the figure.
5. Secure the side gear on the front side by hand.
A : Secure by hand
6. Move the pinion gear with the dial gauge that has been set by hand and measure the backlash.
A : Secure by hand
B : Move the pinion gear by hand such that the secured side gear does not move.
CAUTION: Because a difference occurs in the backlash measurement value if the secured side gear moves, move the pinion gear by hand so that the secured side gear does not move.
7. Input the measured side gear on the front side and pinion gear backlash into the measurement/adjustment value input sheet.
NOTE: Input into section A in the measurement/adjustment value input sheet.
8. Secure the side gear on the rear side by hand.
A : Secure by hand
9. Move the pinion gear with the dial gauge that has been set by hand and measure the backlash.
A : Secure by hand
B : Move the pinion gear by hand such that the secured side gear does not move.
CAUTION: Because a difference occurs in the backlash measurement value if the secured side gear moves, move the pinion gear by hand so that the secured side gear does not move.
10. Input the measured side gear on the rear side and the pinion gear backlash into the measurement/adjustment value sheet.
NOTE: Input into section B in the measurement/adjustment value sheet.
11. Set the dial gauge and magnetic stand to the pinion gear on the opposite side.
A : Dial gauge
B : Magnetic stand
CAUTION: To reduce error during the backlash measurement, set the dial gauge so that it is perpendicular to the teeth of the pinion gear.
12. Set the dial gauge end to the pinion gear teeth.
A : Area in which dial gauge end is set
CAUTION: To reduce error during the backlash measurement, set the dial gauge end to within the area shown in the figure.
13. Secure the side gear on the front side by hand.
A : Secure by hand
14. Move the pinion gear with the dial gauge that has been set by hand and measure the backlash.
A : Secure by hand
B : Move the pinion gear by hand such that the secured side gear does not move.
CAUTION: Because a difference occurs in the backlash measurement value if the secured side gear moves, move the pinion gear by hand so that the secured side gear does not move.
15. Input the measure side gear on the front side and the pinion gear backlash into the measurement/adjustment value sheet.
NOTE: Input into section A in the measurement/adjustment value sheet.
16. Secure the side gear on the rear side by hand.
A : Secure by hand
17. Move the pinion gear with the dial gauge that has been set by hand and measure the backlash.
A : Secure by hand
B : Move the pinion gear by hand such that the secured side gear does not move.
CAUTION: Because a difference occurs in the backlash measurement value if the secured side gear moves, move the pinion gear by hand so that the secured side gear does not move.
18. Input the measured side gear on the rear side and the pinion gear backlash into the measurement/adjustment value sheet.
NOTE: Input into section B in the measurement/adjustment value sheet.
19. Calculate the average value of the measured side gear on the front side and the pinion gear backlash.
20. Input the average value of the calculated side gear on the front side and the pinion gear backlash into the measurement/adjustment value sheet.
NOTE: The average value of the calculated side gear on the front side and the pinion gear backlash is the differential backlash on the front side.
21. Calculate the average value of the measured side gear on the rear side and the pinion gear backlash.
22. Input the average value of the calculated side gear on the rear side and the pinion gear backlash into the measurement/adjustment value sheet.
NOTE: The average value of the calculated side gear on the rear side and the pinion gear backlash is the differential backlash on the rear side.
23. Verify that the differential backlash on the front side and the differential backlash on the rear side satisfy the specification.
Specification
0.030-0.150 mm {0.0012-0.0059 in}
- If not within the specification, perform the differential backlash adjustment. (See Differential Backlash Adjustment.)
- If it exceeds the specification even if the thrust washer with a thickness of 0.95 mm {0.037 in}, which is the thickest, is assembled after performing the differential backlash adjustment, disassemble the ring gear and differential and replace the differential gear case with a new one.
(See RING GEAR AND DIFFERENTIAL DISASSEMBLY.)
(See RING GEAR AND DIFFERENTIAL ASSEMBLY.)
24. Remove the dial gauge and magnetic stand.
A : Dial gauge
B : Magnetic stand
25. Remove the drive shaft (LH) and joint shaft.
A : Drive shaft (LH)
B : Joint shaft
26. Remove the ring gear and differential from the vise.
A : Vise
Differential Backlash Adjustment
1. Remove the dial gauge and magnetic stand.
A : Dial gauge
B : Magnetic stand
2. Remove the drive shaft (LH) and joint shaft.
A : Drive shaft (LH)
B : Joint shaft
3. Remove the ring gear and differential from the vise.
A : Vise
4. Remove the roll pin shown in the figure using a pin punch.
NOTE: Use a pin punch with an end outer diameter of 3 mm {0.119 in} or more, and within 4 mm {0.157 in} and an end length of 50 mm {2.0 in} or more.
5. Remove the pinion shaft.
6. Remove the pinion gears using the following procedure:
1. Rotate the pinion gears as shown in the figure.
2. Remove the pinion gears.
7. Remove the thrust washers from the pinion gears.
8. Remove the side gears.
9. Remove the thrust washers from the side gears.
10. Measure the thickness of the removed thrust washers from the side gears.
NOTE: Recommended measuring instrument: Micrometer
11. Input the measured thrust washer thickness into the measurement/adjustment value input sheet.
12. Perform the following calculation to calculate the differential backlash gap.
NOTE: The differential backlash gap is the difference between the differential backlash and the median value of the differential backlash specification.
Differential backlash gap on front side = C - J
C : Differential backlash on front side
J : Median value of differential backlash specification (0.090 mm {0.00354 in})
Note
Example
C : Differential backlash on front side is 0.165 mm {0.00650 in}
Differential backlash gap on front side = 0.165 mm {0.00650 in} - 0.090 mm {0.00354 in} = 0.075 mm {0.00295 in}
Differential backlash gap on rear side = D - J
D : Differential backlash on rear side
J : Median value of differential backlash specification (0.090 mm {0.00354 in})
Note
Example
D : Differential backlash on rear side is 0.155 mm {0.00610 in}
Differential backlash gap on rear side = 0.155 mm {0.00610 in} - 0.090 mm {0.00354 in} = 0.065 mm {0.00256 in}
13. Input the differential backlash gap into the measurement/adjustment value sheet.