Differential Case: Service and Repair
INSPECTION BEFORE DISASSEMBLYDifferential Gear Backlash Check
1. Hold the limited slip differential case assembly in a vice with the differential side gear (R.H.) up.
CAUTION: When the limited slip differential case is held in a vice, do not tighten excessively.
2. Install two 0.03 mm (.001 inch) feeler gauges diagonally between the differential case (B) and the thrust washer (R.H.).
CAUTION: Do not insert the feeler gauge in the oil groove provided in the differential case (B).
3. Insert the special tool in the splined portion of the differential side gear (R.H.) and make sure that the side gear (R.H.) turns.
4. Replace the feeler gauges with 0.09 mm (.004 inch) feeler gauges.
5. Insert the special tool in the splined portion of the differential side gear (R.H.) and make sure that the side gear (R.H.) does not turn.
Standard value: Differential gear backlash 0.03-0.09 mm (.001-.004 inch)
NOTE: The differential gear backlash is normal if the side gear clearance in the direction of thrust is within the standard value.
6. If the side gear clearance in the direction of thrust is not within the standard value, remove the differential case (A) and adjust by means of thrust washer (L.H.).
DISASSEMBLY
Follow disassembly steps outlined in illustration.
NOTE: Disassembly service points as follows:
A. Thrust washer (L.H.)/thrust washer (R.H.) removal. (3 & 9)
The thrust washer (L.H.) differs from the thrust washer (R.H.) in thickness. Keep them separately from each other for reference in assembly.
INSPECTION
1. Check each gear and the differential pinion shaft for wear and damage.
2. Check the splined portion of the differential side gear (R.H.) for damage and shoulder.
3. Check the sliding surfaces of the thrust washer and pinion mate washer for wear, seizure and damage.
4. Check the sliding surfaces of the differential cases (A) and (B) for wear, seizure and damage.
A: Surface in sliding contact with Viscous Unit (VCU).
B: Surface in sliding contact with pinion mate washer.
C: Surface in sliding contact with thrust washer.
D: Surface in sliding contact with thrust washer.
5. Check the spline of VCU for damage and shoulder and check the surface in sliding contact with the differential case (B).
6. Check the side gear (L.H.) of VCU for wear and damage.
ASSEMBLY
Assembly in reverse order as Disassembly.
NOTE: Assembly service points as follows:
A. Differential case (b)/differential case (a) installation. (2 & 10)
Install the differential cases (A) and (B) with their mating marks in alignment.
B. Differential pinion mate/pinion mate washer installation. (5 & 6)
Attach the differential pinion mate to the pinion shaft with the pinion washers directed as shown, then assemble them into the differential case (B).
C. Thrust washer (L.H.) selection. (3)
When the differential side gear and pinion mate gear have been replaced, select the thrust washer (L.H.) by the following procedure.
1. Wash the differential side gear and pinion mate gear with unleaded gasoline and degrease.
2. Assemble the thrust washers so far used, without confusing the R.H. part with the L.H. part and together with each gear, VCU, pinion mate washer and pinion shaft, to the differential cases (A) and (B), and loosely tighten the screws.
3. Check the differential backlash, and select a thrust washer (L.H.) to obtain its standard value.