Adjusting and Selecting Washers

Exploded View RFD-15 (Part 1):

Exploded View RFD-15 (Part 2):

ADJUSTING AND SELECTING WASHERS
Side Gear Back Clearance
^ Assemble the differential parts if they are disassembled.





1. Place the differential case straight up so that the side gear to be measured is upward.





2. Using feeler gauges, measure the clearance between the side gear back and differential case at three different points, while rotating the side gear. Average the three readings to calculate the clearance. (Measure the clearance of the other side as well.)
Side gear back clearance: 0.20 mm (0.0079 in) or less.
^ If the side gear back clearance is outside of the specification, use a thicker or thinner side gear thrust washer to adjust.
If the side gear back clearance is greater than specification:
Use a thicker side gear thrust washer.
If the side gear back clearance is less than specification:
Use a thinner side gear thrust washer.

CAUTION:
^ Insert feeler gauges with the same thickness on both sides to prevent side gear from tilting.
^ Each gear should rotate smoothly without excessive resistance during differential motion.
^ Select a side gear thrust washer for right and left individually.

NOTE: Side gear back clearance is clearance between side gear and differential case for adjusting side gear backlash.

Side Bearing Preload Torque
^ A selection of side bearing adjusting washers is required for successful completion of this procedure.





1. Apply differential gear oil to the side bearings, and install the differential case assembly with the side bearing outer races into the gear carrier.

CAUTION: Do not reuse side bearing outer race when replacing side bearing inner race (replace as a set).





2. Insert the left and right original side bearing adjusting washers in place between side bearings and gear carrier.





3. Align the matching mark on the side bearing cap with the matching mark on the gear carrier.
4. Install the side bearing caps and tighten the side bearing cap bolts to the specified torque. Refer to Exploded View RFD-15.
5. Turn the differential assembly several times to seat the side bearings.





6. To determine side bearing preload torque, measure the pulling force of the differential assembly at the drive gear bolt using Tool.
Tool number: - (J-8129)
Specification: 34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) of pulling force at the drive gear bolt

NOTE: If pulling force of the differential assembly at the drive gear bolt is within specification, side bearing preload torque will also be within specification.





7. If the pulling force is outside the specification, use a thicker or thinner side bearing adjusting washer to adjust.
If the pulling force is less than the specification:
Use a thicker side bearing adjusting washer.
If the pulling force is greater than the specification:
Use a thinner side bearing adjusting washer.

CAUTION: Select a side bearing adjusting washer for right and left individually.

8. Record the total amount of washer thickness required for the correct side bearing preload torque.