Front Differential
ASSEMBLY INSPECTION AND ADJUSTMENT^ Drain the differential gear oil before inspection and adjustment.
^ Remove and install the carrier cover as necessary for inspection and adjustment.
Total Preload Torque
1. Install the differential side shaft and differential side flange if necessary.
CAUTION: The differential side shaft and differential side flange must be installed in order to measure total preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
4. Measure total preload torque using Tool.
Tool number: ST3127S000 (J-25765-A)
Total preload torque: 2.98 - 4.76 Nm (0.31 - 0.48 kg-m, 27 - 42 in-lb)
NOTE: Total preload torque = Drive pinion bearing preload torque + Side bearing preload torque
^ If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion bearing preload torque first, then adjust the side bearing preload torque.
If the total preload torque is greater than specification
On drive pinion bearings: Replace the collapsible spacer.
On side bearings: Loosen the side bearing adjuster by the same amount on each side.
If the total preload torque is less than specification
On drive pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Tighten the side bearing adjuster by the same amount on each side.
Drive Gear Runout
1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout.
Runout limit: 0.08 mm (0.0031 in) or less
^ If the runout is outside of the limit, check the condition of the drive gear assembly. Foreign material may be caught between the drive gear and differential case, or the differential case or drive gear may be deformed.
CAUTION: Replace drive gear and drive pinion as a set.
Tooth Contact
1. Apply red lead to the drive gear.
NOTE: Apply red lead to both faces of three to four gears, at four locations evenly spaced on the drive gear.
2. Rotate the drive gear back and forth several times. Then check for correct drive pinion to drive gear tooth contact as shown.
CAUTION: Check tooth contact on drive side and reverse side.
3. If the tooth contact is improperly adjusted, follow the procedure below to adjust the drive pinion height (dimension X).
^ If the tooth contact is near the face (face contact), or near the heel (heel contact), use a thicker drive pinion height adjusting washer to move drive pinion closer to the drive gear.
^ If the tooth contact is near the flank (flank contact), or near the toe (toe contact), use a thinner drive pinion height adjusting washer to move the drive pinion farther from the drive gear.
Backlash
1. Fit a dial indicator to the drive gear face to measure the backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in)
^ If the backlash is outside of the specification, adjust each side bearing adjuster.
If the backlash is greater than specification:
Loosen side bearing adjuster A and tighten side bearing adjuster B by the same amount.
If the backlash is less than specification:
Loosen side bearing adjuster B and tighten side bearing adjuster A by the same amount.
CAUTION: Do not change the side bearing adjusters by different amounts as it will change the side bearing preload torque.
Companion Flange Runout
1. Rotate companion flange and check for runout on the companion flange face (inner side of the bolt holes) and companion flange inner side (socket diameter) using suitable tool.
Runout limit
Companion flange face: 0.10 mm (0.0039 in)
Companion flange inner side: 0.13 mm (0.0051 in)
2. If the runout is outside the runout limit, follow the procedure below to adjust.
a. Rotate the companion flange on the drive pinion by 90°, 180° and 270° while checking for the position where the runout is minimum.
b. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion bearing.
c. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion bearing or drive pinion bearing, replace the companion flange.