Differential: Service and Repair

PREINSPECTION OF BACKLASH OF SIDE GEAR AND PINION GEAR
1. Before disassembly, measure the backlash of the side gears. Backlash standard is 0.05 - 0.15 mm (0.0020 - 0.0059 inch) and the maximum is 0.50 mm (0.020 inch).
2. If the backlash exceeds the maximum, replace worn and damaged parts.

NOTE: The bearings do not need to be removed unless you are replacing them.





DISASSEMBLY
- Disassemble in the order shown in the illustration, referring to the following notes:





Roll Pin
1. Place the gear case in a vise.
2. Insert a 2.0 mm (0.079 inch) punch into the roll pin hole from the ring gear side, and remove the roll pin by using a hammer.





Bearing
1. Remove the bearing (speedometer drive gear side) from the gear case by using the Special Service Tool (SST).





2. Remove the bearing (ring gear side) by using a combination of parts from the SST.

ASSEMBLY
- Assemble in the reverse order of disassembly, referring to the following steps.





1. Install the ring gear to the gear case and tighten to 79 - 93 Nm (58 - 68 ft. lbs.).





2. Set the speedometer drive gear onto the gear case assembly.





3. Install the new bearings and bearing races by using the SST.
a. Press the new bearing (speedometer drive gear side) onto the gear case by using the SST.
b. Press on the other new bearing (ring gear side) in the same manner.
4. Apply ATF to the thrust washers and pinion shaft.
5. Install the pinion gears and thrust washers into the gear case.





6. Install the pinion shaft.





7. Install the roll pin, and crimp it to prevent it from coming out of the gear case.





8. Apply ATF to the thrust washers.
9. Install the thrust washers and side gears into the gear case, then turn the side gears and align them with the drive shaft holes.





10. Measure the backlash of the side gears as follows:
a. Install the left and right drive shafts in the differential assembly.
b. Support the drive shafts on V-blocks.
c. Measure the backlash of both side gears. Backlash standard is 0.05 - 0.15 mm (0.0020 - 0.0059 inch) and the maximum is 0.50 mm (0.020 inch).
11. If the backlash exceeds the maximum, rebuild or replace the differential assembly.