Differential: Service and Repair

FINAL DRIVE





Disassembly




1. Remove final gear.




2. Drive out pinion mate shaft lock pin and draw out pinion mate shaft.




3. Remove governor shaft drive gear.




4. Drive out differential side bearing outer race and inner cone.

Inspection




1. Check mating surface of differential case, side gears and pinion mate gears. Replace as required.




2. Check clearance between side gear and differential case with washer following the procedure below.
a. Set Tool and dial gauge on side gear.




b. Move side gear up and down to measure dial gauge deflection. Always measure gauge deflection on both side gears.
Clearance between side gear and differential case with washer:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. if clearance exceeds the specified value, check for wear and replace necessary parts.
3. Check tapered roller bearings for wear, scratches, pitching or flaking.

Assembly




1. Install the side gear and thrust washer in the differential case.
2. Install the pinion mate gear and thrust washer in the differential case while rotating them.




3. Insert pinion mate shaft.

Note: When inserting, be careful not to damage pinion mate washers.

4. Measure clearance between side gear and pinion mate gear referring to "Inspection". If necessary adjust.
Side gear to pinion mate clearance:
0.1 - 0.2 mm (0.004 - 0.008 in)
5. Install pinion mate shaft lock pin using a punch.

Note: Make sure that lock pin is flush with case.




6. Install governor shaft drive gear.




7. Press on differential side bearing inner cone and outer race.
8. Install final gear.