Final Drive

PRE-INSPECTION





Check the clearance between side gear and differential case using Tool and a dial indicator 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 faces upward.





3. Place final drive adapter and dial indicator 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)

CAUTION: There should be no resistance with the gears rotating freely.

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. Remove the differential side bearing (clutch housing side) using a puller and Tool (drift) as shown.





4. Remove the differential side bearing (transaxle case side) using a puller and Tool (drift) as shown.





5. Pull out the lock pin and pinion mate shaft using a pin punch.
6. Rotate pinion mate gears, and remove pinion mate gears, pinion mate thrust washers, side gears, and side gear thrust washers from the 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.

ASSEMBLY
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, 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 using the procedure below, then select a side gear thrust washer.
a. Upright the differential case so that its side gear to be measured face upward.
b. Place final drive adapter and dial indicator onto side gears.





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

CAUTION:
^ There should be no resistance with the gears rotating freely.
^ Place differential case upside down. Be sure to measure end play for opposite side-gears likewise.





Thrust washer

CAUTION: Only one thrust washer can be selected.





6. Drive a new lock pin into the pinion mate shaft using Tool (pin punch).

CAUTION: Do not reuse the lock pin.





7. Install differential side bearing (transaxle case side) using Tool (drift).





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





9. Install differential side bearing (clutch housing side) using Tool (drift).





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