Differential: Service and Repair

DIFFERENTIAL ASSEMBLY
Servicing procedure for differential assembly is similar to that for manual transmission.

DISASSEMBLY





1. Remove differential side bearing (L). Use special tool (A): 09925-88210 or equivalent, and puller for its removal.
2. Remove final gear. Hold differential case with soft jawed vise and remove eight bolts then take out final gear.





3. Remove cliff. side bearing R. Drive it out by using special tool (B) 09913-80112 or equivalent, bearing puller and press.
4. Remove speedometer drive gear.





5. Remove side pinion shaft pin. Use special tool (C) 09922-85811 or equivalent, and hammer for its removal.
6. Remove side pinion shaft, differential pinions with each washer, differential gears with each washer.

ADJUSTMENT AND REASSEMBLY
Prepare replacing parts as required and proceed to reassembly. Make sure that all parts are clean.
1. Install differential gears. Measure and adjust thrust play, and then assemble them with suitable thrust washers.
2. Drive in side pinion shaft pin from right side till it is flush with cliff. case surface.





3. Install differential side bearing (L). Face its seal side inward (differential case side) and press-fit by using the same special tool with right hand bearing in step (5).
4. Install speedometer drive gear.
5. Install differential side bearing R. Face its seal side inward and press-fit it by using special tool with copper hammer. While press-fitting, support cliff. assembly as illustrated so that left hand bearing is floating.
Special Tool:
(A): 09951-76010 or equivalent.
(B): 09951-16060 or equivalent.





6. Hold differential assembly with soft jawed vise, install final gear and then tighten it with eight bolts to specified torque.
Tightening Torque (a): 80 - 90 Nm (58.0 - 65.0 ft. lbs.).

NOTE: Place offset side of final gear flange toward differential case.

CAUTION: Use of any other bolts than specified ones is prohibited.

SHIM ADJUSTMENT FOR DIFFERENTIAL SIDE BEARING





Before installing differential assembly to transmission case, select a differential side bearing shim as follows.





1. With gasket removed, measure dimension "a" of transmission case housing (from mating surface to bearing bore bottom) by using straightedge and vernier caliper. The dimension "a" can be obtained by subtracting straightedge width "d" from measured value.
Dimension "a"=measured value-straightedge width "e".





2. In the same manner as the above (1), measure dimension "b" of transmission case (from mating surface to bearing bore bottom).
Dimension "b"= measured value-straightedge width "e".





3. Place differential assembly on surface plate and measure dimension "c" (bearing-to-bearing).
Dimension "c"=measured value-straightedge width "d"
4. Obtain case-to-bearing clearance "d" in following calculation:"d"=("a"+"b"+ 0.4) - ("c"+ 0.2)
Gasket thickness: 0.4 mm (0.016 inch)
Intended to absorb the measurement error: 0.2 mm (0.008 inch).
5. Select a shim from among available sizes and install it between transmission case and side bearing.

CAUTION: Installing of over sized shim beyond specification may cause tight rotation and consequential bearing damage.