Differential: Service and Repair

DISASSEMBLY
1. Using a press, remove the taper roller bearing. Be careful not to damage the speedometer drive gear.





2. Secure the case in a vise and remove the crown gear tightening bolts, then separate the crown gear, case (RH) and case (LH).





3. Pull out the straight pin and shaft, and remove the differential bevel gear, washer, and differential bevel pinion.

INSPECTION
Check each component for harmful cuts, damage and other faults.

ASSEMBLY
1. Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft, and fit the straight pin. Make sure that the case (RH) is staked in order to lock the straight pin.
2. Install the washer and differential bevel gear to the differential case (LH). Then put the case over the differential case (RH), and connect both cases.
3. Install the crown gear and secure by tightening the bolt.
- Standard tightening torque: 59-65 Nm (43-48 ft.lb)

4. Measurement of backlash (Selection of washer).





a. Measure the gear backlash by inserting a dial gauge through the access window of the case.
- Standard value: 0.13-0.18 mm (0.0051-0.0071 in)

b. Measure the backlash by applying a pinion tooth between two bevel gear teeth.





5. Install the speedometer drive gear. Then force-fit the taper roller bearing with a press.
- Be sure to position correctly the locking end of the speedometer drive gear.