Disassembly and Assembly

DISASSEMBLY




1. Remove final gear.




2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
4. Remove viscous coupling.




5. Drive out retaining pin and draw out pinion mate shaft.
6. Remove pinion mate gears and side gears.

ASSEMBLY




1. Attach side gear thrust washer to side gear and install them in differential case.
Then install pinion mate washers and pinion mate gears in place.




2. Insert pinion mate shaft.

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

Side Gear Thrust Washers For Differential Case Side:

3. Measure clearance between side gear and differential case with washers following the procedure below:
a. Set tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflection.

Clearance between side gear and differential case with washers:
0.1 - 0.2 mm (0.004 - 0.008 in)

c. If not within specification, adjust clearance by changing thickness of side gear thrust washers.

Side Gear Thrust Washers For Viscous Coupling Side:

4. Measure clearance between side gear and viscous coupling with washers following the procedure below.
a. Set remaining side gear with washer on pinion mate gears.
b. Measure distance "X".
- Side gear might be uneven, so measure it in at least 4 places along the circumference and take an average reading.
c. Measure dimension "Y".

Clearance between side gear and viscous coupling with washers can be obtained by "X + Y - 2A".
Specification: 0.1 - 0.2 mm (0.004 - 0.008 in)

d. If not within specification, adjust clearance by changing thickness of side gear thrust washer.




5. Install retaining pin.

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