Inspection

INSPECTION BEFORE DISASSEMBLY





Hold the special tool in a vice, and attach the differential carrier to the special tool.

Drive Gear Backlash Check





1. With the drive pinion locked in place, measure the 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 (0.0043 - 0.0063 inch)

2. If the backlash is outside the standard value, adjust using the side bearing spacer.

NOTE: After adjustment, inspect the contact of the drive gear.

Drive Gear Runout Check





1. Measure the drive gear runout at the shoulder on the reverse side of the drive gear.

Limit: 0.05 mm (0.002 inch)

2. If the runout exceeds the limit value, check that there is no foreign material between the reverse side of the drive gear and the differential case, or that there is no looseness in the drive gear mounting bolt.
3. If step 2 is normal, change the assembly position of the drive gear and differential case, and then take another measurement.

NOTE: If adjustment is impossible, replace the differential case or the drive gear and drive pinion as a set.

Differential Gear Backlash Check





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

NOTE:
1. The measurement should be made for both pinion gears individually.
2. Measure the limited slip differential gear backlash.

Standard value: 0 - 0.076 mm (0 - 0.0030 inch)

Limit: 0.2 mm (0.008 inch)

2. If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear spacers.

NOTE: If adjustment is impossible, replace the side gear and pinion gear as a set.

Drive Gear Tooth Contact Check





Check the 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 special tool 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 (22-27 inch 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 drive gear backlash. The adjustment of drive pinion height and 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.