Final Drive

DISASSEMBLY





1. Remove final gear.





2. Press out differential side bearings.
- Be careful not to mix up the right and left bearings.
3. Remove viscous coupling-RE4F04W.





a. Remove viscous coupling.
b. Make alignment marks with paint on differential cases A and B.





c. Remove the bolts holding the differential cases, and remove the pinion mate gears and side gears.





4. Remove speedometer drive gear.





5. Drive out pinion mate shaft lock pin.





6. Draw out pinion mate shaft lock pin.
7. Remove pinion mate gears and side gears.

INSPECTION
Gear, Washer, Shaft and Case





- Check mating surfaces of differential case, side gears and pinion mate gears.
- Check washers for wear.

Viscous Coupling - RE4F04W





- Check case for cracks.
- Check silicone oil for leakage.

Bearings





- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing taper roller bearing, replace outer and inner race as a set.

ASSEMBLY





1. Attach side gear thrust washers to side gears, then install pinion mate thrust washers and pinion mate gears in place.
- Apply ATF to any parts.





2. Insert pinion mate shaft.
- When inserting, be careful not to damage pinion mate thrust washers.

-RE4F04B-
1. Measure clearance between side gear and differential case with washers following the procedure below:





a. Set Tool and dial indicator on side gear.





b. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case with washer: 0.1 - 0.2 mm (0.004 - 0.008 inch)
c. If not within specification, adjust clearance by changing thickness of differential side gear thrust washers.
Differential side gear thrust washers: Refer to Application and ID.

-RE4F04W-
Differential Case Side
1. Measure clearance between side gear and differential case & viscous coupling with washers using the following procedure:





a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflection.
Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 inch)
c. If not within specification adjust clearance by changing thickness of side gear thrust washer. Differential side gear thrust washers for differential case side:
Refer to Application and ID.

Viscous Coupling Side
1. Measure clearance between side gear and differential case & viscous coupling with washers using the following procedure:





a. Place side gear and thrust washer on pinion mate gears installed on differential case.
b. Measure dimension X.
- Measure dimension X in at least two places.





c. Measure dimension Y.
- Measure dimension Y in at least two places.
Clearance between side gear and viscous coupling = X + Y - 2A:
0.1 - 0.2 mm (0.004 - 0.008 inch)
A: Height of gauge
d. If not within specification, adjust clearance by changing thickness of side gear thrust washer.
Differential side gear thrust washers for viscous coupling side: Refer to Application and ID.





3. Install lock pin.
- Make sure that lock pin is flush with case.
4. Install viscous coupling-RE4F04W.





a. After choosing the side gear washer, tighten down differential cases A and B. Tighten bolts to the specified torque. Refer to the image at the top of this article.

CAUTION: Make sure that A and B alignment marks are positioned correctly.

b. Install viscous coupling.





5. Install speedometer drive gear on differential case.
- Align the projection of speedometer drive gear with the groove of differential case.





6. Press on differential side bearings.





7. Install final gear and tighten fixing bolts in a crisscross pattern. Tighten final gear bolts to the specified torque. Refer to the image at the top of this article.