Inspection
INSPECTIONWash all the disassembled parts clean, and examine them for wear, damage and other defects. Repair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
^ If there is evidently an abnormal tooth contact, find out the cause and adjust until the teeth contact correctly. Replace the gear if there is an excessive worn or an incapable adjustment.
^ If crack, cutout or seizure is found, replace the parts as a set. Slight damage of some teeth can be corrected by oil stone or the like.
2) Side gear and pinion mate gear
^ Replace if cracks, scoring or other defects are evident on the tooth surface.
^ Replace if thrust washer contact surface is worn or seized. Slight damages of the surface can be corrected by oil stones or equivalent.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging during rotation, noise or other defect is evident.
4) Thrust washer of the side gear and pinion mate gear
Replace if seized, flawed, abnormally worn or having other defects.
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 sliding surfaces are abnormally worn, burned, or cracked.
8) Companion flange
Replace if the oil seal lip contact surface shows cracking.
9) Rear differential oil temperature switch (T-type (H3))
Check the rear differential oil temperature switch for continuity.
SIDE GEAR BACKLASH (T-TYPE (B2))
Using a dial gauge, check the backlash of side gear.
Side gear backlash:
0.10 - 0.20 mm (0.004 - 0.008 in)
If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash to the specification.
HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid driven gear.
Hypoid driven gear backlash:
0.10 - 0.20 mm (0.004 - 0.008 in)
If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE
Using a dial gauge, check the hypoid driven gear back surface runout.
Hypoid driven gear back surface runout:
0.05 mm (0.002 in)
If the hypoid driven gear runout exceeds specification, replace the hypoid driven gear.
TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between the hypoid driven gear and drive pinion.
TOTAL PRELOAD
Using a spring scale, check the total preload.
Total preload:
T-type (B2):
20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lbf)
T-type (H3):
26.5 - 53 N (2.7 - 5.4 kgf, 6.0 - 11.9 lbf)
If the total preload is not within the specification, adjust the side retainer shim.
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.
Limit of runout:
0.08 mm (0.003 in)
3) Set the gauge inside of the companion flange, and measure the runout.
Limit of runout:
0.08 mm (0.003 in)
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.