Differential: Service and Repair

Disassembly

1. Remove the sealing bolts (A) of the differential drive gear.




2. Disassemble the differential drive gear (A) from the differential case by using a rubber hammer or a gear pulley.




3. Remove the lock pin by using a chisel (A).




4. Remove the pinion shaft (A).




5. Remove the two differential pinion gears (A) with washer (B).




6. Remove the two differential side gears (A) with the differential spacer.




7. Remove the speedometer drive gear (A) by using a chisel (B).




8. Remove the taper roller bearing (A) by using a puller (B).






Reassembly

1. Install the speedometer drive gear (A).




2. Insert the taper roller bearing(A) and press in by using a hammer or a pressing tool and the special tool (09493-2F200).




3. Install the differential side gear, pinion gear , and pinion shaft and then measure the clearance(T) which a snap is being placed and choose the differential gear spacer in the chart below.

Allowable Backlash: 0.1L Max mm (0.00394L Max in)
Spacer thickness = T - [Allowable backlash]






4. After removing the pinion shaft, differential side gear, and pinion gear, install the differential gear spacer determined and the differential side gear.
5. Install the differential pinion gear (A) with washer (B).




6. Install the pinion shaft and then insert the two lock pins (A).




7. Install the sealing bolts (A) of the differential drive gear.

Tightening torque :
130 - 140 Nm (13 - 14 kgf.m, 94 - 101 lb-ft)