Differential: Service and Repair

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

INSPECTION





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





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





ASSEMBLY
1. Attach side gear thrust washers to side gears and install in differential case.
2. Install pinion mate washers and pinion mate gears.





3. Insert pinion mate shaft. When inserting, be careful not to damage pinion mate thrust washers.





4. 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 inch) or less.





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





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





6. Install final gear. Apply locking sealant to final gear fixing bolts before installing them.
7. Install speedometer drive gear and stopper.





8. Press on differential side bearings.