Differential Assembly: Service Precautions

Differential system

Precautions

1. Wash the outside of the rear differential ASSY to remove sand, mud, etc. before disassembly so that they will not enter the inside of the rear differential during disassembly and installation.
2. When disassembling the joint sections of light alloy parts such as the differential carrier cover, disassemble them by slightly tapping with a plastic hammer. Do not pry apart with a screwdriver or other tools.
3. Keep the disassembled parts in order, and protect them from dust and dirt covering with a cloth.
4. Before installation, all disassembled parts should be thoroughly washed and dried, and then apply grease or oil to the necessary sections. When washing aluminum and rubber parts, bolts with lubricant, etc., do not use alkaline chemical solvent. In addition, do not wash rubber base parts such as O-rings and oil seals with wash oil (white gasoline, etc.).
5. Before installation, apply sufficient amount of differential oil used for each differential ASSY to the sliding surfaces and rotating sections.
6. When fixing the parts in a vise, do not place the parts directly in a vise but use an aluminum plates in between.
7. Be careful of handling the mating surfaces of the case. If they are damaged, oil leakage may occur.
8. Before applying seal material, completely remove the old seal material adhering to the sealing portions, and then wash the sealing portion with wash oil (white gasoline, etc.).
9. After assembling the parts with seal material, leave them for 1 hour or more, and then fill them with oil. Avoid rapid acceleration and deceleration for 12 hours or more.
10. Be careful of handling the contact surfaces to the oil seals, O-rings and gaskets. If they are damaged, oil leakage may occur.
11. When press-fitting the oil seal farther than the end face of the differential carrier, oil leakage may occur. To avoid oil leakage, measure the press-fitting amount at more than 3 points on the oil seal circumference. Then, make sure that the difference between the maximum and the minimum of the measured values is within the specification.
12. Be careful not to damage the oil seal lip and outer circumference while press-fitting the oil seal.
13. When replacing the bearing, replace the outer race and the inner race as a set.
14. When replacing the bearing, do not apply excessive force to the roller, the holder and the rolling contact surface.
15. Anti-rust oil is applied to a new bearing. Do not wash off this oil.
16. If the seat or the thread of the bolt is heavily rusted, replace it with a new part.