Differential Assembly: Testing and Inspection

INSPECTION





1. Check runout of companion flange. Using a dial indicator, measure the vertical and lateral runout of the companion flange. If the runout is greater than the maximum, replace the companion flange.

Maximum vertical and lateral runout: 0.09 mm (0.0035 inch).





2. Check the ring gear runout. Using a dial indicator, measure the ring gear runout.

Maximum runout: 0.05 mm (0.0020 inch).





3. Check ring gear backlash. Using a dial indicator, measure the ring gear backlash.

2 WD
Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch).

4 WD
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch).

If the backlash is not within specification, adjust the side bearing preload or repair as necessary.

NOTE: Measure from three or more places on the circumference of the ring gear.

4. Check tooth contact between ring gear and drive pinion.





5. Check side gear backlash. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch).
6. Measure drive pinion preload. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
Preload (at starting): 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).





7. Check total preload. Using a torque wrench, measure the total preload. If necessary, disassemble and inspect the differential.
Total preload (at starting): 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.).