Differential Lock: Service and Repair

DISASSEMBLY
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case.
3. Remove Actuator Assembly and draw out actuator ASM.
4. Remove housing.
5. Remove sleeve.
6. Remove clutch gear.





7. Remove snap ring from front axle case by using snap ring pliers.
8. Take out inner shaft from front axle case.





9. Remove snap ring from inner shaft by using snap ring pliers.





10. Remove inner shaft bearing by using a remover J-37452 and press.

NOTE: Be careful not to damage the shaft.





11. Remove needle bearing from inner shaft by using a remover J-26941 and sliding hammer J-2619-01.

NOTE: Be careful not to damage the shaft.

12. Remove oil seal from front axle case.

NOTE: Be careful not to damage the front axle case.

INSPECTION AND REPAIR
Inspect the removed parts. If there are abnormalities such as wear and damage, take corrective action or replace.

Visual Check





1. Check and see if the inner shaft has any abnormalities such as wear and damage.





2. When inspecting the inner shaft, be sure to check and see if its splined part is twisted, worn, or cracked. If so replace with a new shaft. In case of an abnormality in its gear part (a slide with sleeve), replace the shaft.

Inner Shaft Run-out





With both end centers supported, rotate the shaft slowly and measure deflection with a dial gauge.

Limit: 0.5 mm (0.02 inch)

NOTE: Do not heat the shaft to correct its bend.

Inner Shaft Bearing





1. Inspect the state of inner shaft bearing. If any abnormality such as roughness is found, replace with a new inner shaft bearing.
2. Insert a clutch gear and check the state of needle bearing.
3. If there is an abnormality such as roughness, replace the needle bearing.

Sleeve Condition
Check and see that there is no wear, damage, or cracking in the sleeve.

NOTE: Close inspection of the groove and inner gear are required because those are important parts.

Sleeve Function





Operate the sleeve with the inner shaft combined with the clutch gear. If roughness is felt, replace the sleeve.

NOTE: Gear oil should be applied to the contact surface of gear.





Check the width of sleeve center groove.

Limit: 7.1 mm (1.28 inch)

Clutch Gear Condition
Check and see that there is no wear, damage, cracking, or any other abnormality in the clutch gear.

Clutch Gear Function





If there is an abnormality such as roughness when operated in combination with sleeve, replace the clutch gear.

NOTE: When inspecting, gear oil should be applied to the contact surface of gear.

Clutch Gear Journal Diameter





Make sure of the size illustrated.

Limit: 36.98 mm (1.456 inch)

Actuator
Check and see that there is no damage, cracking, or other abnormality.











Functional Check





Disconnect the shift position switch and make sure of function with a vacuum of -400 mmHg applied to Ports A and B, in accordance with the table provided.

If there is an abnormality, replace the actuator as an assembly.

NOTE:
1. If the actuator works under -400mmHg or less, there is no functional problem.

2. Be careful not to permit the entry of water or dust into the ports of the actuator.

Dimensional Check





Measure illustrated sizes 1, 2, and 3.
Limit
1=64.1 mm (2.52 inch)
2=6.7 mm (0.26 inch)
3=6.7 mm (0.26 inch)

REASSEMBLY





1. Install the new oil seal which has been immersed in differential gear oil, by using an oil seal installer J-41693 and grip J-8092.





2. Force a new needle bearing into inner shaft by using a installer J-41694 and grip J-8092.





3. Place a new snap ring(internal) in inner shaft. Force a new inner shaft bearing into the inner shaft by using a installer J-37452 and press.
4. Install snap ring(external).

NOTE: Be careful not to damage the inner shaft.

5. Clean the housing contact surface of the front axle case and insert inner shaft assembly into the front axle case.

NOTE: Be careful not to damage seal.





6. Install snap ring (internal) in the groove of front axle case.

NOTE: Be sure to install the snap ring properly.

7. Apply differential gear oil to clutch gear, then install clutch gear.
8. Apply differential gear oil to sleeve, then install sleeve.





9. Clean contact surface with the front axle and actuator mounting surface. Apply liquid gasket to the contact surface on the front axle case, then install in the housing.
10. Tighten bolts to specified torque.

Torque: 116 Nm (85 ft. lbs.)

11. Clean the actuator contact surface with the housing then Install and tighten shift position switch to specified torque.

Torque: 39 Nm (29 ft. lbs.)





12. Apply liquid gasket to the contact surface on the actuator side.

13. Align shift arm with the groove of sleeve and install the actuator.
14. Tighten bolts to specified torque.

Torque: 13 Nm (113 ft. lbs.)

15. Install front axle drive shaft and mounting bracket. Tighten fitting bolts to specified torque.

Torque: 116 Nm (85 ft. lbs.)

16. Pour specified amount of differential gear oil to filler plug.

Front Differential Oil Capacity: 1.4 liters (1.48 quarts)
Actuator Housing Oil Capacity: 0.12 liters (0.13 quarts)

17. Install filler plug through gasket and tighten to specified torque.

Torque: 7.8 Nm (58 ft lbs.)