Differential Cage Assembly

Part Of 2:

Part 2 Of 2:

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





3. Remove lock pin using a small drift.





4. Remove the differential shaft by using a hard metal rod and a hammer.
5. Remove pinion mate gear and thrust washer.
6. Remove side gear and 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:
- Ring gear, pinion gear
- Bearing
- Side gear, pinion mate gear, differential shaft
- Differential cage, carrier
- Thrust washer
- 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. Discard used bolts and install new ones.





4. When installing the ring gear, apply LOCITITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt.
Torque: 127 Nm (94 ft. lbs.)





Clearance between the differential pinion and the pinion shaft measurement.
Standard: 0.07 - 0.13 mm (0.003 - 0.005 inch)
Limit: 0.2 mm (0.008 inch)





Clearance between the side gear and the differential box.
Standard: 0.032 - 0.105 mm (0.001 - 0.004 inch)
Limit: 0.105 mm (0.004 inch)





Play in splines between the side gear and the axle shaft.
Standard: 0.07 - 0.38 mm (0.003 - 0.14 inch)
Limit: 0.05 mm (0.02 inch)

REASSEMBLY
Differential Cage / Thrust Washer/ Side Gear / Pinion Gear
1. Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction.





2. Install the pinion mate gear with thrust washer by engaging it with the side gears while turning both pinion mate gears simultaneously in the same direction.
3. Install differential shaft.





a. Be sure to install the differential shaft 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: 0.15 - 0.20 mm (0.006 - 0.008 inch)
Thickness of thrust washers available





4. Install lock pin.
Install the lock pin using small drift.
5. Install exciter ring (Of equipped with rear wheel antilock.)
Press the exciter ring on the differential cage using the ring gear as a pilot.





6. Tighten the bolts in diagonal sequence as illustrated.
Torque: 177 Nm (130 ft. lbs.)

NOTE: Discard used bolts and install new ones.