Differential: Service and Repair

DISASSEMBLY
1. Clamp the differential case in a vise.





2. Remove the differential drive gear retaining bolts and remove the differential drive gear from differential case.





3. Remove the taper roller bearing using the special tool (09433 - 21000, 09532 - 11301) or equivalents.





4. Drive out the lock pin from the hole A using a punch.
5. Drive out the pinion shaft.
6. Remove the pinion gears, washers, side gears and spacers.

ASSEMBLY





1. Install the spacer on the back of the side gear and then install the gear in the differential case.

CAUTION:
a. When installing a new side gear, use a spacer of medium thickness 0.93-1.00 mm (0.036-0.04 inch).
b. Do not reuse the lock pin.
c. The lock pin head must be sunk below the flange surface of the differential case.





2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears by turning them.
3. Insert the pinion shaft.





4. Measure the backlash between the side gears and pinions.
Standard value: 0.025-0.150 mm (0.001-0.006 inch).
5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.

CAUTION: Adjust the backlash of both side gears to the same specification.





6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

CAUTION:
a. Do not reuse the lock pin.
b. The lock pin head must be below the flange surface of the differential case.





7. Install the taper roller bearings on both sides of the differential case using the special tool (09455 - 21100) or equivalent.

CAUTION: When press-fitting the bearings, push the inner race only.





8. Apply specified sealant to the entire threads of the bolt and tighten in the order shown in figure to the specified torque with the differential case clamped in a vise.
Specified sealant: Three bond 1303 or LOCTITE 648

CAUTION: If a bolt is reused, remove the old sealant from the threads.