Disassembly and Assembly

DISASSEMBLY

RS5F50A




1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.

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




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

RS5F5OV




1. Remove final gear.




2. Press out differential side bearings.




3. Remove speedometer drive gear.




4. Remove viscous coupling.




5. Separate differential cases.

Note: Make paint marks to identify their original positions.

6. Remove pinion mate shaft with 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.

RS5F5OA




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




4. Install retaining pin.

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




5. Install final gear.
6. Install speedometer drive gear.




7. Press on differential side bearings.

RS5F50V




3. Measure clearance between side gear and differential case & viscous coupling with washers using the following procedure:

Differential case side
a. Set tool on the differential case and lock gauging cylinder in place with set screw.




b. Install gauging plunger into cylinder.




c. Install pinion mate gears and side gear with thrust washer on differential case.
d. Set tool and allow gauging plunger to rest on side gear thrust washer.
e. Measure gap between plunger and cylinder.
This measurement should give exact clearance between side gear and differential case with washers.

Standard clearance: 0.1 - 0.2 mm (0.004 - 0.008 in)

f. If not within specification adjust clearance by changing thickness of side gear thrust washer. Side gear thrust washers for differential case side: Service Data and Specifications

Viscous coupling side




a. Place side gear and thrust washer on pinion mate gears installed on differential case.
b. Measure dimension X.
Measure dimension X in at least four places.
a. Set tool on viscous coupling and lock gauging cylinder in place with set screw.




b. Install gauging plunger into cylinder.




c. Install pinion mate gears and side gears with original washers on differential cases. Align paint marks.
d. Tighten differential case bolts.
e. Set tool and allow plunger to rest on side gear thrust washer.
f. Measure gap between plunger and cylinder.
This measurement should give exact clearance between side gear and differential case with washers.

Standard clearance: 0.1 - 0.2 mm (0.004 - 0.008 in)

g. If not within specification, adjust clearance by changing thickness of side gear thrust washer.
Side gear thrust washers for viscous coupling side: Service Data and Specifications




4. Install viscous coupling.




5. Install speedometer drive gear on differential case.

Note: Align the projection of speedometer drive gear with the groove of differential case.




6. Press differential side bearings on differential case.




7. Install final gear and tighten fixing bolts in a crisscross pattern.