Differential: Service and Repair

DISASSEMBLY





1. Inspect the differential:
1 Differential gear case
2 Speedometer drive gear
3 Differential bearing shim
4 Differential case bearing
5 Pinion shaft roll pin
6 Pinion shaft
7 Pinion thrust washer
8 Pinion gear
9 Side gear thrust washer
10 Differential side gear

NOTE: If a fault is detected during the checking procedure, the differential should be replaced.





2. Remove the differential pinion shaft.
1 Remove the pinion shaft roll pin.
2 Remove the differential pinion shaft.

NOTE: Do not remove the final drive pinion shaft retaining ring.





3. Remove the pinion gears and thrust washers.
- Turn the differential pinion gears 90 degrees and remove.





4. Remove the differential side gears and differential side gear thrust washers.
5. Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
6. Inspect the differential parts for damage and wear.
- Gear teeth
- Thrust washer surface
- Thrust bearing surface
- Pinion shaft





7. Inspect the final drive planet and carrier.
1 Pinion gear teeth
2 Thrust bearing surfaces
3 Bushing surfaces





8. Measure the final drive planet gear end play with a feeler gauge.

CAUTION: Do not disassemble the planet carrier.

NOTE: If the measurement exceeds specification, replace the complete final drive carrier.


ASSEMBLY





1. Install the differential side gears and thrust washers.





2. Install the differential pinion gears and thrust washers.
- Rotate the differential pinion gears 90 degrees.





3. Install the differential pinion shaft.
1 Push the pinion shaft in place.
2 Install the roll pin.