Differential: Service and Repair

DISASSEMBLY





1. Remove snap ring (1) (Inner-110) using flat bladed screwdriver.
2. Remove center differential cover (2).
3. Remove snap ring (4) and roller bearing (3).
4. Remove viscous coupling (5).
5. Remove needle bearings (6).
6. Remove adjusting washer (7) (45 x 62 x t).
7. Remove pinion shaft (8), bevel pinions (9) and retainers (10).
8. Remove side gear (11).
9. Remove thrust washer (12).





10. Remove ball bearing (13) using Special Tool (ST).
ST 498077300 Center Differential Bearing Remover, or equivalent

CAUTION: Do not reuse ball bearing.

ASSEMBLY





Assembly is in the reverse order of disassembly. Do the following:
- Install thrust washer with chamfered side of inner perimeter facing the side gear.
- Install adjusting washer with chamfered side of inner perimeter facing the viscous coupling using Special Tool (ST).
ST 499547300 Installer Set, or equivalent





1. Selection of snap ring (Inner-110)
a. After assembling, using a thickness gauge measure clearance between snap ring (1) and center differential case. Clearance: should be within 0 - 0.15 mm (0 - 0.0059 inch).





b. If the measurement is not within the specification, select suitable snap ring.





2. Selection of adjusting washer (Backlash adjustment)
a. After assembling, set up a ST1 and ST2 to end of viscous coupling shaft. Move viscous coupling up and down, and measure backlash in the axial direction.
ST1 498247001 Magnet Base, or equivalent
ST2 498247100 Dial Gauge, or equivalent





b. If the measurement is not within 0.62 - 0.86 mm (0.0244 - 0.0339 inch), select suitable washer.