Differential: Service and Repair

DISASSEMBLY AND REASSEMBLY

SERVICE POINTS OF DISASSEMBLY

3. REMOVAL OF BALL BEARING - F5M21




Use the special tool as illustrated.

CAUTION: Do not reuse the bearing removed from the shaft.

4. REMOVAL OF TAPER ROLLER BEARING - F5M22




Use the special tool as illustrated.

CAUTION:
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.

5. REMOVAL OF LOCK PIN




Drive out the lock pin from the hole A using a punch.

SERVICE POINTS OF REASSEMBLY

10. INSTALLATION OF SPACER / 9. SIDE GEAR / 8. WASHER / 7. PINION / 6. PINION SHAFT




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

CAUTION: When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.037 - 0.039 in.)].




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 and 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 in.)

5. If the backlash is out of specification, disassemble again and using correct spacer, reassemble and adjust.

CAUTION: Adjust for same backlash of both side gears.

5. INSTALLATION OF LOCK PIN




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

CAUTION:
1. Do not reuse the lock pin.
2. The lock pin must not protrude more than 3 mm (0.118 in.).
3. The lock pin head must be sunk from the flange surface of the differential case.

4. INSTALLATION OF TAPER ROLLER BEARING - F5M22

Using special tools, install the taper roller bearings on both sides of the differential case.

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

3. INSTALLATION OF BALL BEARING - F5M21

Using special tools, install the ball bearings on both sides of the differential case.

1. INSTALLATION OF BOLTS

Apply specified adhesive to the entire threads of the bolts and quickly tighten in the order shown to specified torque.

Specified adhesive: 3M Stud Locking No. 4170

CAUTION: If a bolt is reused, remove traces of oil adhesive completely from the threads.