Component Inspection

TOOLS REQUIRED
* 07HAJ-PK40201 Preload Inspection Tool
* Or Equivalent

PRELIMINARY INSPECTION
* To establish a starting point before disassembly, it is necessary to inspect the following:
- Ring gear backlash
- Total bearing preload
- Gear tooth contact

* Be sure the differential is at room temperature before inspecting.
* Record the results of the preliminary inspections as this information will become helpful during reassembly.

RING GEAR BACKLASH





1. Remove the 20 mm plug and the oil seal.
2. Secure the differential assembly in a vise using soft Jaws.





3. Align a differential carrier rib with the 20 mm plug hole, and install the special tools as shown.





4. Measure the backlash of the ring gear in 3 - 4 places on the differential carrier using the special tools as shown.
Standard: 0.04 - 0.10 mm (0.002 - 0.004 inch).
The difference among the 3 - 4 measurements taken must not exceed 0.04 mm (0.002 inch).





5. Remove the pinion collar oil seal by punching two holes in the seal 180° apart. Use the same pry point, and alternate between the two holes to lift the seal as shown.
NOTE: Use a wood block to protect the differential case.

BEARING PRELOAD
6. Remove the differential case cover and the differential carrier.





7. Use a dial-type torque wrench on the drive pinion to measure the drive pinion bearing preload.
Standard: 0.64 - 1.03 Nm (5.6 - 9.1 inch lbs.).

8. Reinstall the differential carrier and the differential case cover, then measure the total bearing preload.
Standard: (Drive pinion bearing preload from step 7) + (0.89 - 1.13 Nm; (7.90 - 9.98 inch lbs)).


GEAR TOOTH CONTACT





9. Remove the differential case cover and differential carrier.
NOTE: Loosen the bolts in a crisscross pattern, in several steps.
Clean and paint the ring gear teeth lightly and evenly with Prussian Blue (on both sides of each tooth)





10. Reinstall the differential carrier and the differential case cover, then torque the bolts in a crisscross pattern, in several steps.





11. Install the special tool as shown. Rotate the ring gear one full turn in both directions while applying resistance to the drive pinion.





12. Remove the differential case cover and the differential carrier, then check the tooth contact pattern.