Differential Case Assembly
DIFFERENTIAL CASE ASSY (C50)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR
a. Remove the speedometer drive gear from the front differential case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR
a. Put matchmarks on the front differential ring gear and the front differential case.
b. Remove the 8 bolts. Using a hammer, remove the front differential ring gear from the front differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Fixing the front differential pinion to the front differential case side. Using a dial gauge, measure the front differential side gear back lash.
Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a. Using a chisel and a hammer, loosen the staked part of the front differential case.
b. Using a pin punch ([diameter]3mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT NO.1
a. Remove the front differential pinion shaft No.1 from the front differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
a. Remove the 2 front differential pinions, front differential pinion thrust washers and front differential side gear thrust washer No.1 from the front differential case.
HINT: Revolving the front differential pinion, remove the 2 pinions, pin ion thrust washers and side gear thrust washers.
7. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER
a. Using a micrometer, measure the thickness of the front differential pinion thrust washer.
Minimum thickness: 0.94 mm (0.03701 inch)
If the thickness exceeds the minimum, replace the front differential pinion thrust washer.
8. INSPECT FRONT DIFFERENTIAL PINION SHAFT NO.1
a. Using a micrometer, measure the outer diameter of the front differential pinion shaft No.1.
Minimum outer diameter: 16.982 mm (0.6685 inch)
If the outer diameter exceeds the minimum, replace the front differential pinion shaft No.1.
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
a. Coat the sliding and rotating surface of the front differential side gear with UP greases.
b. Install the 2 front differential side gear thrust washers to the 2 front differential side gear.
c. Install the 2 front differential pinions with front differential pinion thrust washers to the front differential case.
HINT: Revolving the front differential pinion, install the 2 front differential pinions with front differential pinion thrust washers.
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
a. Coat the front differential pinion shaft No.1 with MP grease.
b. Install the front differential pinion shaft No.1 to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.
11. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Fix the front differential pinion to the front differential case side. Using a dial gauge, measure the front differential side gear backlash.
Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
HINT:
^ Because the thrust washer does not have any marks for distinction, measure the thickness with a micrometer to select a proper thrust washer.
^ Select washers of the same thickness for both the right and left.
Thrust washer thickness
12. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a. Using a pin punch ([diameter]3 mm) and a hammer, install the front differential pinion shaft straight pin to the front differential case.
b. Using a chisel and a hammer, stake the front differential case hole.
13. INSTALL FRONT DIFFERENTIAL RING GEAR
a. Using a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F)
b. Clean the contact surface of the front differential case.
c. Aligning the both matchmarks, quickly install the front differential ring gear to the front differential case.
d. Install the 8 bolts.
Torque: 77 Nm (790 kgf-cm, 57 ft. lbs.)
14. INSTALL SPEEDOMETER DRIVE (MTM) GEAR
a. install the speedometer drive gear to the front differential case.