Differential Assembly: Service and Repair

DISASSEMBLY

(A) Ball Bearing Removal

(B) Lock Pin Removal

(1) Drive out the lock pin with a punch inserted in hole "A".
(2) Remove the pinion shaft from the case, and remove the pinion gears and washers.
(3) Remove the side gears and spacers from the case. Keep the removed gears and spacers for R.H. side use separated from those for L.H. side use.

REASSEMBLY

(A) SPACER / SIDE GEAR / WASHER / PINION / PINION SHAFT INSTALLATION

(1) With the spacers installed on the back of the differential side gears, install the gears in the differential case. When reusing the removed parts, install them in the original positions noted during disassembly. When using new differential side gears, install spacers of medium thickness 1.0 mm (.039 in.).
(2) Install the washers to the back of the pinion gears, install the gears in the differential case, and then insert the pinion shaft.
(3) Measure the backlash between the side gear and pinion gear. The backlash should be 0.025 to 0.150 mm (.0010 to .0059 in.) and the right and left gear pairs should have equal backlash. If the backlash is not within the specified range, disassemble, and reassemble them using spacers selected for correct backlash.

Backlash: 0.025 - 0.150 mm (.0010 - .0059 in.)

Lock Pin Installation

(1) Align the lock pin hole in the pinion shaft with that in the case and press fit the lock pin until its protrusion is 3 mm (0.12 in.) or less.

Caution:
1. Do not reuse the lock pin.
2. Do not use a lock pin which requires only 2000 N (440 lbs.) or less force for installation.

(B) LOCK PIN INSTALLATION (F4A22)

(1) Align the lock pin hole in the pinion shaft with that in the case and press fit the lock pin until its sink from the differential case end is 1 mm (.04 in.) or more.

Caution:
1. Do not reuse the lock pin.
2. Do not use a lock pin which requires only 2000 N (440 lbs.) or less force for installation.

(B) LOCK PIN INSTALLATION (F4A23)

(1) Align the lock pin hole in pinion shaft with that in the case and install the lock pin.

Caution: The lock pin should be lower than the differential case flange surface.

(1) Apply automatic transmission fluid to the bolts and tighten the bolts to the specified torque in the sequence shown in the illustration.