Differential

DIFFERENTIAL

DISASSEMBLY




1. Clamp the differential case in a vise
2. Remove the differential drive gear retaining bolts and remove the differential drive gear from the case




3. Remove the ball bearings using the special (09433-21000).

CAUTION: Do not reuse the bearing removed from the shaft.




4. Drive out the lock pin from the hole A using a punch.
5. Drive out the pinion shaft.
6. Remove the pinion gears, washers, side gears and spacers.

ASSEMBLY




1. Install the spacer on the back of the side gear and then install the gear in the differential case.

CAUTION:
1. When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.036-0.04 in)].
2. Do not reuse the lock pin.
3. The lock pin head must be sunk below the flange surface of the differential case.




2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them,with the side gears by turning them.
3. Inset the pinion shaft.




4. Measure the backlash between the side gears and pinions.

Standard value : 0.025-0.150 mm (0.001-0.006 in.)

5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.

CAUTION: Adjust the backlash of both side gears to the same specification.




6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

CAUTION:
1. Do not reuse the lock pin.
2. The lock pin head must not protrude more than 3 mm (0.118 in.).




7. Install the tapered roller bearings on both sides of the differential case using the special tool (09455-21100).

CAUTION: When press-fitting the bearings, press on the inner race only.




8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the illustration.

Specified sealant : 3M Stud Locking No.4170

CAUTION: If a bolt is reused, remove the old sealant from the threads.