Differential Cage Assembly

DISASSEMBLY
1. Remove bolt.
2. Remove ring gear.





3. Remove lock pin, break staking on the lock pin, using a 5 mm (0.20 inch) diameter drill.





4. Remove the cross pin, using a soft metal rod and a hammer.
5. Remove pinion gear.
6. Remove side gear.
7. Remove thrust washer.

INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection.
Check the following parts:
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal

RING GEAR REPLACEMENT:
1. The ring gear should always be replaced with the drive pinion as a set.
2. Clean the ring gear threaded holes to remove the locking agent.
3. When installing the ring gear, apply LOCTITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt.
4. Discard used bolts and install new ones.
Torque: 108 Nm (80 ft. lbs.)





5. Tighten the fixing bolts in a diagonal sequence as illustrated.





CLEARANCE BETWEEN THE DIFFERENTIAL PINION AND THE CROSS PIN MEASUREMENT:
Standard: 0.06 - 0.12 mm (0.002 - 0.005 inch)
Limit: 0.2 mm (0.008 inch)





CLEARANCE BETWEEN THE SIDE GEAR AND THE DIFFERENTIAL BOX:
Standard: 0.03 - 0.10 mm (0.001 - 0.004 inch)
Limit: 0.15 mm (0.006 inch)





PLAY IN SPLINES BETWEEN THE SIDE GEAR AND THE AXLE SHAFT:
Standard: 0.08 - 0.36 mm (0.003 - 0.014 inch)
Limit: 0.5 mm (0.02 inch)

REASSEMBLY
1. Install thrust washer.
2. Install side gear.





3. Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction.
4. Install cross pin.





a. Be sure to install the cross pin so that it is in alignment with the lock pin hole in the differential cage.





b. Adjust the backlash between the side gear and the pinion gear.
Backlash: 0.03 - 0.08 mm (0.001 - 0.003 inch)
Thickness of thrust washers available:
1.00 mm, 1.05 mm, 1.10 mm (0.039 inch, 0.041 inch, 0.043 inch)





5. Install lock pin. After lock pin installation, stake the cage to secure the lock pin.
6. Clean the ring gear threaded holes to remove the locking agent. When installing the ring gear, apply LOCTITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt.





7. Tighten the bolts in diagonal sequence as illustrated.
Torque: 108 Nm (80 ft. lbs.)

NOTE: Discard used bolts and install new ones.