Differential Case Assembly

DIFFERENTIAL CASE ASSEMBLY (E350 TRANSAXLE)
OVERHAUL





1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR
a. Remove the speedometer drive (MTM) gear from the front differential case assembly.





2. REMOVE FRONT DIFFERENTIAL RING GEAR
a. Put matchmarks on the front differential ring gear and the front differential case.





b. Remove the 16 bolts. Using a plastic hammer, remove the front differential case.





3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Hold the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.
Standard backlash: 0.10 to 0.20 mm (0.0039 to 0.0079 inch)
If backlash is out of specification, install proper side gear thrust washers.





4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a. Using SST and a hammer, unstake the staked part of the front differential case.
SST 09930-00010





b. Using a pin punch and a hammer, remove the front differential pinion shaft straight pin from the front differential case.





5. REMOVE FRONT DIFFERENTIAL PINION SHAFT NO.1
a. Remove the front differential pinion shaft No.1 from the front differential case.





6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
a. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential side gears and 2 front differential side gear thrust washers No. 1 from the front differential case.

HINT: Remove the 2 pinion thrust washers and side gear thrust washers while turning the front differential pinion.





7. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER
a. Using a micrometer, measure the thickness of the front differential pinion thrust washer.
Minimum thickness: 0.9 mm (0.035 inch)
If the thickness is less than the minimum, replace the front differential pinion thrust washer.





8. INSPECT FRONT DIFFERENTIAL PINION SHAFT NO.1
a. Using a micrometer, measure the outside diameter of the front differential pinion shaft No.1.
Minimum diameter: 17.975 mm (0.70768 inch)
If the outer diameter is less than the minimum, replace the front differential pinion shaft No.1.





9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
a. Coat the rotating surfaces of the front differential side gears with gear oil.
b. Install the 2 front differential side gear thrust washers to the 2 front differential side gears.
c. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential side gear thrust washers to the front differential case.

HINT: Install the 2 front differential pinions with the front differential pinion thrust washers while turning the front differential pinion.





10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
a. Coat the rotating surface of the front differential pinion shaft No. 1 with gear oil.
b. Install the front differential pinion shaft No.1 to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.





11. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a. Using a pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.





b. Using a chisel and hammer, stake the front differential case hole.





12. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Hold the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.
Standard backlash: 0.10 to 0.20 mm (0.0039 to 0.0079 inch)
b. If backlash is out of specification, select another front differential side gear thrust washer and adjust it.





Thrust washer: mm (inch)





13. INSTALL FRONT DIFFERENTIAL RING GEAR
a. Clean the contact surface of the front differential case and front differential ring gear.
b. Using a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).
c. After the moisture on the ring gear has completely evaporated, quickly install the front differential ring gear to the front differential case.





d. Aligning the matchmarks, quickly install the front differential ring gear to the front differential case with the 16 bolts.
Torque: 106 Nm (1,080 kgf-cm, 78 ft. lbs.)





14. INSTALL SPEEDOMETER DRIVE (MTM) GEAR
a. Install the speedometer drive (MTM) gear to the front differential case.