Removal and Replacement

DIFFERENTIAL CARRIER REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
- Draining and Refilling of Differential Gear Oil.
- Removal and installation of Center Exhaust Pipe.

Removal steps
1. Drive shaft
2. Circlip
3. Propeller shaft connection
4. Feed tube (Vehicles with 4WS)
5. 0-ring (Vehicles with 4WS)
6. Rear oil pump (Vehicles with 4WS)
7. 0-ring (Vehicles with 4WS)
8. Differential support member installation nut
9. Stopper (lower)
10. Differential support member installation bolt
11. Dynamic damper (1990 models)
12. Differential support member
13. Differential support member installation bolt
14. Differential carrier





DIFFERENTIAL SUPPORT MEMBER BUSHING REPLACEMENT
Use the special tool to pull out and press in the differential support member bushing.

NOTE
Press in the bushing from the beveled part of the differential support member; press in until the end surface of the bushing outer cylinder is flush with the support member.





INSPECTION BEFORE DISASSEMBLY
Hold the working base in a vice, and attach the differential carrier to the working base.





FINAL DRIVE GEAR BACKLASH
With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on the drive gear.

NOTE
Measure at four points or more on the circumference of the drive gear.

Standard value: 0.11-0.16 mm (0.004-0.006 in.)





DRIVE GEAR RUNOUT
Measure the drive gear runout at the shoulder on the reverse side of the drive gear.

Limit: 0.05 mm (0.002 in.)





DIFFERENTIAL GEAR BACKLASH
While locking the side gear with the wedge, measure the differential gear backlash with a dial indicator on the pinion gear.

Standard value: 0-0.076 mm (0-0.003 in.)
Unit: 0.2 mm (0.008 in.)





FINAL DRIVE GEAR TOOTH CONTACT
Check the final drive gear tooth contact by following the steps below.

(1) Apply a thin. uniform coat of machine blue to both surfaces of the drive gear teeth.





(2) Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear, so that the revolution torque [approximately 2.5-3.0 Nm (28-33 in.lbs.)] is applied to the drive pinion.

Caution
If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.

(3) Check the tooth contact condition of the drive gear and drive pinion.





NOTE
(1) Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash. The adjustment of drive pinion height and final drive gear backlash should be repeated until tooth contact patterns bear a similarity to the standard tooth contact pattern.

(2) When adjustment is not able to obtain a correct pattern it may be judged that the drive gear and drive pinion have exceed their usage limits and both gears should be replaced as a set.