Differential Case Assembly
DIFFERENTIAL CASECOMPONENTS:
REMOVAL
1. REMOVE SPEEDOMETER DRIVE GEAR
a. Remove the drive gear from the front differential case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR
a. Put matchmarks on the ring gear and the differential case.
b. Remove the 16 bolts.
c. Using a plastic-faced hammer, tap out the differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Hold the differential pinion to the front differential case side. Using a dial indicator, measure the differential side gear backlash.
Standard backlash: 0.10 to 0.20 mm (0.0039 to 0.0079 inch)
If the 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 differential case.
SST 09930-00010
b. Using a pin punch and a hammer, tap out the straight pin from the differential case.
5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT
a. Remove the No. 1 differential pinion shaft from the differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
a. Remove the 2 differential pinions, 2 differential pinion thrust washers, 2 differential side gears and 2 No. 1 differential side gear thrust washers from the differential case.
HINT: Remove the 2 pinion thrust washers and side gear thrust washers while turning the differential pinion.
INSTALLATION
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
a. Coat the rotating surfaces of the differential side gears with gear oil.
b. Install the 2 differential side gear thrust washers to the 2 differential side gears.
c. Install the 2 differential side gears, 2 differential pinions and 2 differential side gear thrust washers to the differential case.
HINT: Install the 2 differential pinions with the differential pinion thrust washers while turning the differential pinion.
2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
a. Coat the rotating surface of the No. 1 differential pinion shaft with gear oil.
b. Install the No. 1 differential pinion shaft to the differential case so that the hole for the differential pinion shaft straight pin is aligned with the hole in the differential case.
3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a. Using a pin punch and a hammer, tap in the differential pinion shaft straight pin to the differential case.
b. Using a chisel and hammer, stake the differential case hole.
4. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Hold the differential pinion to the differential case side. Using a dial indicator, measure the differential side gear backlash.
Standard backlash: 0.10 to 0.20 mm (0.0039 to 0.0079 inch)
If the backlash is out of specification, select another differential side gear thrust washer and adjust it.
Standard thrust washer thickness:
Standard thrust washer thickness
5. INSTALL FRONT DIFFERENTIAL RING GEAR
a. Clean the contact surface of the differential case and differential ring gear.
b. Using a heater, heat the differential ring gear to 90 to 110°C (194 to 230°F).
c. After the moisture on the ring gear has completely evaporated, quickly install the differential ring gear to the differential case.
d. Aligning the matchmarks, quickly install the front differential ring gear to the differential case with the 16 bolts.
Torque: 106 Nm (1,080 kgf-cm, 78 ft. lbs.)
6. INSTALL SPEEDOMETER DRIVE GEAR
a. Install the drive gear to the differential case.
INSPECTION
1. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER
a. Using a micrometer, measure the thickness of the thrust washer.
Minimum thickness: 0.9 mm (0.035 inch)
If the thickness is less than the minimum, replace the thrust washer.
2. INSPECT FRONT NO. 1 DIFFERENTIAL PINION SHAFT
a. Using a micrometer, measure the outside diameter.
Minimum diameter: 17.975 mm (0.70768 inch)
If the outside diameter is less than the minimum, replace the No. 1 differential pinion shaft.