Inspection
INSPECTIONWash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary.
1) Hypoid driven gear and drive pinion
^ If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment.
^ If crack, score, or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like.
2) Side gear and pinion mate gear
^ Replace if crack, score, or other defects are evident on tooth surface.
^ Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident.
4) Thrust washers of side gear and pinion mate gear
Replace if seizure, flaw, abnormal wear or other defect is evident.
5) Oil seal
Replace if deformed or damaged, and at every disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting surfaces have flaws.
9) Rear differential oil temperature switch
If the results of the following inspections are not satisfactory, replace rear differential temperature switch.
(1) At room temperature, check for continuity between the sensor terminal and body.
(2) Soak the sensor in oil, then raise the oil temperature. Check that the continuity is cut off when the oil temperature is between 144°C (291°F) and 156°C (313°F). Then, check that the continuity resumes by the time the oil temperature drops to 135°C (275°F).
SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of the side gear.
Side gear backlash: 0. 1 - 0.2 mm (0.004 - 0.008 inch)
If the side gear backlash is not within the specification, adjust clearance as specified by selecting the side gear thrust washer.
HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of the hypoid driven gear.
Hypoid driven gear backlash: 0. 1 - 0.2 mm (0.004 - 0.008 inch)
If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
HYPOID DRIVEN GEAR RUNOUT
Using a dial gauge, check the hypoid driven gear runout.
Hypoid driven gear runout: Less than 0.05 mm (0.0020 inch)
If the hypoid driven gear runout exceeds 0.05 mm (0.0020 inch), replace the hypoid driven gear.
TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between hypoid driven gear and driven pinion.
TOTAL PRELOAD
Using a gauge, check the turning resistance increase.
Total preload:
Except STI model: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lbs.)
STI model: 27 - 54 N (2.8 - 5.50 kgf, 6.1 - 12.2 lbs.)
If the total preload is not within the specification, adjust the side bearing retainer shims.
COMPANION FLANGE
1) If rust or dirt is attached to the companion flange, remove them.
2) Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout.
3) Set the gauge inside of the companion flange, and measure the runout.
4) If either runout exceeds the limit, move the phase of companion flange and drive pinion 90° each, and find the point where the runout is within the limit.
5) If the runout exceeds the limit after changing the phase, replace the companion flange and recheck the runout.
6) If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.