Differential: Service and Repair

DISASSEMBLY
1. Remove final gear.





2. Press out differential side bearings.





3. Remove speedometer drive gear.





4. Drive out pinion mate shaft retaining pin.





5. Draw out pinion mate shaft from differential case.
6. Remove pinion mate gears and side gears.

INSPECTION





Gear, Washer, Shaft And Case
- Check mating surfaces of differential case, side gears and pinion mate gears.
- Check washers for wear.





Bearings
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

ASSEMBLY
1. Install side gears and thrust washers in differential case.





2. Install pinion mate gears and thrust washers in the differential case while rotating them. Apply ATF to all parts.








3. Measure clearance between side gear and differential case with washers. If not within specification, adjust clearance by changing thickness of side gear thrust washers.
Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 inch)





- Refer to the illustration for side gear thrust washer availability.





4. Install retaining pin. Make sure that retaining pin is flush with case.





5. Install speedometer drive gear on differential case. Align projection of speedometer drive gear with groove of differential case.








6. Press differential side bearings on differential case.





7. Install final gear and tighten fixing bolts in numerical order.