Disassembly and Assembly

Disassembly and Assembly

REMOVAL OF DRIVE GEAR AND DIFFERENTIAL CASE ASSEMBLY





1. Remove differential side shaft with a soft hammer.





2. Remove differential side flange with a soft hammer.





3. Remove extension tube and O-ring.





4. Place a small hole in seal case, using suitable punch or drill.





5. Assemble Tool as shown and remove seal.
Tool number: (SP8P)





6. Remove rear cover from gear carrier.





7. For proper reinstallation, paint matching mark on one side bearing cap.

NOTE: Bearing caps are line-board for initial assembly. The matching marks are used to replace them in their original positions.





8. Remove side bearing caps.





9. Remove side bearing adjust nuts.





10. Keep the side bearing outer races together with inner race. Do not mix them up.

REMOVAL OF DRIVE PINION ASSEMBLY





1. Put matching marks on companion flange and drive pinion with paint.
2. Loosen drive pinion nut using Tool.
Tool number: KV38108300 (J-44195)





3. Remove companion flange using a suitable puller.





4. Remove drive pinion (together with rear bearing inner race, collapsible spacer.)
5. Remove pinion front bearing inner race.





6. Place a small hole in case, using suitable punch or drill.





7. Assemble Tool as shown and remove seal.
Tool number: - (SP8P)





8. Turn nose of gear carrier down. Remove drive pinion front bearing outer race using Tool. Locate driver on back edge of outer race, then drive outer race out.

CAUTION: Do not nick gear carrier.

Tool number A: - (C-4171)
B: - (D-103)





9. Turn nose of gear carrier up. Remove drive pinion rear bearing outer race using Tool. Locate driver on back edge of outer race, then drive outer race out.

CAUTION: Do not nick gear carrier.

Tool number A: - (C-4171)
B: - (C-4307)





10. Remove drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.
Tool number: ST30021000 ( - )

DIFFERENTIAL CASE DISASSEMBLY





1. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove.
Tool number A: ST33081000 ( - )
Tool number B: ST30021000 ( - )

CAUTION:
^ To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
^ It is not necessary to remove side bearing except it is replaced.





^ Be careful not to confuse left-hand and right-hand parts. Keep bearing and bearing race for each side together.





2. Loosen drive gear bolts in a crisscross fashion.
3. Tap drive gear off the differential case with a soft hammer.
^ Tap evenly all around to keep the drive gear from bending.





4. Drive out pinion mate shaft lock pin using suitable punch from drive gear side.





5. Remove the pinion mate shaft.





6. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from the differential case.





7. Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft and thrust washers.

INSPECTION








^ Clean up the disassemble parts. Then, inspect if the parts are wear or damaged. If so, follow the measures below.

ADJUSTMENT OF DIFFERENTIAL CASE

Thrust Washer Selection





1. Apply gear oil to contact surfaces of each gear, thrust washers and differential case.
2. Install the removed thrust washer or same thickness washer to side gear.





3. Install the side gears, thrust washers, pinion mate gears and thrust washers into differential case.





4. Install pinion mate shaft to differential case so that it meets lock pin holes





5. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer. Use two feeler gauges to prevent leaning of side gear as showing figure.

Clearance between side gear thrust washer and differential case: 0.20 mm (0.0079 inch) or less





6. Make sure lock pin is flush with case, using a suitable punch.





7. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.
8. Install differential case assembly on drive gear.
^ Tighten bolts in a crisscross pattern, lightly tapping bolt head with a hammer.





9. Place differential case on drive gear. Tighten bolts in a crisscross fashion.





10. Press-fit side bearing inner race on differential case using Tools.
Tool number A: KV38100300 (J-25523)
Tool number B: ST33081000