Removal and Installation

This document has been updated by TSB# 09-27-001.







REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS
[A] PROPELLER SHAFT REMOVAL

CAUTION: Suspend the propeller shaft from the body with wire, etc. to avoid spilling transmission fluid and to avoid injury from failing propeller shaft when not secured.





Make the mating marks on the flange yoke of the propeller shaft and the companion flange of the differential case.

[B] DIFFERENTIAL CARRIER REMOVAL

CAUTION: Use care not to strike the companion flange.





Remove the attaching nuts. Strike the lower part of differential carrier assembly with a piece of wood several times to loosen the assembly. Remove the assembly.

INSTALLATION SERVICE POINT
]A[ PROPELLER SHAFT INSTALLATION





Align the mating marks on the flange yoke and the companion flange to install the propeller shaft.

INSPECTION BEFORE DISASSEMBLY





Secure special tool MB990909 in a vice. Install the differential carrier assembly with the attachment. Then carry out the following inspection.

DRIVE GEAR BACKLASH





1. Place a dial gauge against the end of a drive gear tooth and secure the drive pinion. Then turn the drive gear and take measurements at four places or more to check the backlash.
Standard value: 0.13 - 0.18 mm (0.005 - 0.007 inch)
2. If the backlash is not within the standard value, adjust the drive gear backlash.

DRIVE GEAR RUNOUT





1. Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
Limit: 0.05 mm (0.002 inch)
2. If the runout exceeds the limit value, check that there is no foreign material between the reverse side of the drive gear and the differential case, or that there is no looseness in the drive gear mounting bolt.
3. If step (2) is normal, change the assembly position of the drive gear and differential case, and then take another measurement.
4. If adjustment is impossible, replace the differential case or the drive gear and drive pinion as a set.

DIFFERENTIAL GEAR BACKLASH





1. Tap in a wooden wedge between the side gear and the pinion shaft and secure one side gear. Then place a dial gauge (with the measuring probe extended) against the pinion gear and measure the backlash.
Standard value: 0.01 - 0.25 mm (0.0004 - 0.0098 inch)
Check the other pinion gear by the same procedure.
2. If the backlash exceeds the standard, adjust the differential gear backlash.
3. If adjustment is not possible, replace the side gears and pinion gears as a set.

DRIVE GEAR TOOTH CONTACT
Check the drive gear tooth contact by the following steps.





1. Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth.

CAUTION: If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.





2. Insert special tool MB990939 between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear, so that the revolution torque [approximately 2.5 - 3.0 Nm (22 - 27 inch lbs.)] is applied to the drive pinion.





3. Check the tooth-contact condition of the drive gear and drive pinion.

NOTE: Checking the tooth contact pattern is the way to confirm that the adjustments of the pinion height and backlash have been done properly. Continue to adjust the pinion height and backlash until the tooth contact pattern resembles the standard pattern.
If, even after adjustments have been made, the correct tooth contact pattern cannot be obtained, it means that the drive gear and the drive pinion have become worn beyond the allowable limit. Replace the gear set.