Model RE4F04V

DISASSEMBLY
1. Remove final gear.





2. Press out differential side bearings.





3. Remove differential side bearing outer race, and side bearing adjusting shim from transmission case.





4. Remove speedometer drive gear.





5. Remove viscous coupling.





6. Separate differential cases. Make paint marks to identify their original position.
7. Remove pinion mate shaft with gears.

INSPECTION





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





Viscous Coupling
^ Check case for cracks.
^ Check silicone oil for leakage.





Bearings
^ Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
^ When replacing taper roller bearing, replace outer and inner race as a set.

ASSEMBLY (Differential Case Side)
Measure clearance between side gear and differential case and viscous coupling with washers using the following procedure:





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 inch)





f. If not within specification adjust clearance by changing thickness of side gear thrust washer. Refer to the illustration.





ASSEMBLY (Viscous Coupling Side)
1. Proceed as follows:
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 inch)





g. If not within specification, adjust clearance by changing thickness of side gear thrust washer. Refer to the illustration.





2. Install viscous coupling.





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








4. Press differential side bearings on differential case.





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