Differential: Service and Repair

DISASSEMBLY
Follow disassembly steps outlined in illustration.

NOTE: Disassembly service points as follows:





A. Taper roller bearing removal. (3)
Using the special tool, remove the taper roller bearing.





B. Lock pin removal. (4)
1. Drive out the lock pin with a punch inserted in hole "A".
2. Remove the pinion shaft from the case, and remove the pinion gears and washers.
3. Remove the side gears and spacers from the case. Keep the removed gears and spacers for R.H. side use separated from those for L.H. side use.

ASSEMBLY
Assembly in reverse order as Disassembly.

NOTE: Assembly service points as follows:

A. Spacer / side gear / washer / pinion / pinion shaft installation. (5, 6, 7, 8 & 9)





1. With the spacers installed on the back of the differential side gears, install the gears in the differential case. When reusing the removed parts, install them in the original positions noted during disassembly. When using new differential side gears, install spacers of medium thickness 0.93 to 1.00 mm (.037 to .039 inch).
2. Install the washers to the back of the pinion gears, install the gears in the differential case, and then insert the pinion shaft.
3. Measure the backlash between the side gear and pinion gear. The backlash should be 0.025 to 0.150 mm (.00098 to .00591 inch) and the right and left gear pairs should have equal backlash. If the backlash is not within the standard value, disassemble, and reassemble them using spacers selected for correct backlash.
Standard value: 0.025-0.150 mm (.00098-.00591 inch)





B. Lock pin installation. (4)
Align the lock pin hole in pinion shaft with that in the case and install the lock pin.

CAUTION: The lock pin should be lower than the differential case flange surface.





C. Taper roller bearing installation. (3)





D. Bolt tightening. (1)
Apply automatic transmission fluid to the bolts and tighten the bolts to the specified torque in the sequence shown in the illustration.
Differential drive gear bolt: 135 Nm (98 ft. lbs.)