Differential Assembly: Service and Repair
DIFFERENTIAL CARRIER (4WD)COMPONENT:
REMOVAL
1. Drain the differential gear oil.
2. Remove the rear drive shaft.
3. Remove the propeller shaft.
4. Support the differential assembly (A) with the jack (B).
5. Disconnect the coupling control connector (A).
6. After loosen the differential mounting bolts (A), and remove the differential (B).
7. After loosen the cover bolts (A), and remove the differential cover (B).
INSPECTION
Install the differential carrier assembly (A) with the special tools (09517-43101 & 09517-43500). Then carry out the following inspection.
1. Check the final drive gear backlash by the following procedure.
1) Place the drive pinion and move the drive gear to check backlash is within the standard range.
NOTE: Measure at 4 points on the gear periphery.
2. Check the drive gear back-face lash by the following procedure.
1) Place a dial gauge on the back-face of the drive gear and measure the runout.
2) If the runout is beyond the limit, check that there are no foreign substances between the drive gear and differential case and, that the bolts fixing the drive gear are not loose.
3. Check the differential gear backlash by the following procedure.
1) Fix the side gear with a wedge so it cannot move and measure the differential gear backlash with a dial indicator on the pinion gear.
Standard value: 0 - 0.05 mm (0 - 0.002 in)
NOTE: Take the measurements at two places on the pinion gear.
2) If the backlash exceeds the limit, adjust using side bearing spacers.
NOTE: If adjustment is impossible, replace the side gear and pinion gear as a set.
4. Check the tooth contact of the final drive gear by the following procedure.
1) Apply the same amount of machine blue slightly to both surfaces of the drive gear teeth.
2) Insert a brass rod 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 some torque (approximately 25-30Nm) 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 pattern.
NOTE:
^ Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash. The adjustment of drive pinion height and final drive gear backlash should be repeated until the tooth contact patterns are similar to the standard tooth contact pattern.
^ When you cannot obtain a correct pattern, the drive gear and drive pinion have exceeded their limits. Both gears should be replaced as a set.
5. Check the oil leaks and the lip part for chew or wear.
6. Check the bearings for wear or discoloration.
7. Check the gear carrier for cracks.
8. Check the drive pinion and drive gear for wear or cracks.
9. Check the side gears, pinion gears and pinion shaft for wear or damage.
10. Check the side gear spline for wear or damage.
INSTALLATION
1. After apply liquid gasket, install the differential cover (B), and install the mounting bolts (A).
2. After install the differential (B), and install the mounting bolts (A).
3. Using the transaxle jack (B), install the differential assembly (A).
4. Connect the coupling control connector (A).
5. Install the propeller shaft.
6. Install the rear drive shaft.
7. Fill the gear oil.
