RS5F51A

Pre-Inspection





- Check the clearance between side gear and differential case as follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust washer, differential case, side gear, and other parts from sticking by gear oil.





2. Upright the differential case so that the side gear to be measured
3. Place final drive adapter and dial gauge onto side gear. Move side gear up and down, and measure the clearance.
Clearance between side gear and differential case: 0.1 - 0.2 mm (0.004 - 0.008 inch)
4. If not within specification, adjust the clearance by changing thrust washer thickness.
5. Turn differential case upside down, and measure the clearance between side gear and differential case on the other side in the same way.

Disassembly





1. Remove mounting bolts. Then, separate the final gear from differential case.
2. Remove speedometer drive gear.
3. Using a drift and puller, remove differential side bearing (clutch housing side).





4. Using a drift and puller, remove differential side bearing (transaxle case side).





5. Using a pin punch, pull out lock pin and pinion mate shaft.
6. Rotate pinion mate gears, and remove pinion mate gears, pinion mate thrust washers, side gears, and side gear thrust washers from differential case.

Inspection After Disassembly
Gear, Washer, Shaft and Case





- Check side gears, side gear thrust washers, pinion mate shaft, pinion mate gears, pinion mate thrust washers and differential case. If necessary, replace with a new one.

Bearing





- Check for bearing damage and rough rotation. If necessary, replace with a new one.

CAUTION: When replacing tapered roller bearing, replace outer and inner races as a set.

Reassembly





1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
2. Install side gear thrust washers and side gears into differential case.
3. While rotating pinion mate thrust washers and pinion mate gears, and aligning them diagonally, install them into differential case.





4. Insert pinion mate shaft into differential case.

CAUTION: Be sure not to damage pinion mate thrust washers.

5. Measure end play of side gears following procedure below. Then select side gear thrust washer.





a. Upright the differential case so that its side gear to be measured faces upward.
b. Place final drive adapter and dial gauge onto side gears.





c. Move side gears up and down to measure end play, and select thrust washer so that it meets specification.
End play standard value: 0.1 - 0.2 mm (0.004 - 0.008 inch)

CAUTION: Place differential case upside down. Be sure to measure end play for opposite side-gears in the same way.





Thrust washer

CAUTION: Only 1 thrust washer can be selected.





6. Drive a lock pin into the pinion mate shaft using tool.

CAUTION: Do not reuse the lock pin.





7. Install differential side bearing (transaxle case side) using tool.





8. Align and install speedometer drive gear onto differential case.





9. Install differential side bearing (clutch housing side) using tool.





10. Install differential gear into differential case, and tighten final gear mounting bolts.