Disassembly and Assembly

Disassembly




1. Remove final gear.
2. Remove speedometer drive gear by cutting it.




3. Press out differential side bearings with tool.

Note: Be careful not to mix up the right and left bearings.




4. Remove viscous coupling. (Models with 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 washers to side gears, 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. Apply automatic transmission fluid to any parts.




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. Always measure indicator deflection on both side gears.

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 washer: Service Data and Specifications (SDS)




4. Install retaining pin.

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




5. Install viscous coupling - Models with viscous coupling.




6. Install final gear.
7. Install speedometer drive gear.




8. Press on differential side bearings.