Front Differential Carrier
FRONT DIFFERENTIAL CARRIER
COMPONENTS
REMOVAL
1. Drain oil.
2. Remove the drive shaft and the output shaft.
CAUTION: When removing the driveshaft, be careful not to damage the differential carrier oil seal by interference of spline part.
3. Remove the front propeller shaft.
NOTE: Make matchmark on the flange yoke and differential companion flange to avoid any mistake when installing them again.
4. Remove the power steering tube mounting bracket.
Tightening torque: 18 - 23 Nm (1.8 - 2.3 kg-m, 13 - 16 ft. lbs.)
5. Remove the differential mounting bracket.
6. Remove the front member.
7. Remove the differential mounting bolt.
8. Remove the differential carrier.
INSPECTION BEFORE DISASSEMBLY
Mount the differential carrier on the special tool (09517-43401).
FINAL DRIVE GEAR BACKLASH
1. Fix the drive gear so it cannot move and measure the final drive gear backlash with a dial indicator.
NOTE: Measure at four points or more on the circumference of the drive gear.
Standard value: 0.09 - 0.11 mm (0.0035 - 0.0043 inch)
2. If the backlash is beyond the standard value, adjust it using the side bearing spacer.
NOTE: After adjustment, inspect the contact of the final drive gear.
DRIVE GEAR RUNOUT
Check the back-face lash as follows:
1. Place a dial gauge on the back-face of the drive gear and measure the runout.
Limit: 0.05 mm (0.0020 inch)
2. If the runout is beyond the limit, check that there are no foreign substances between the drive gear and differential case and, that the bolts fixing the drive gear are not loose.
3. If nothing is wrong in check (2), adjust the drive gear depth and remeasure.
NOTE: If these adjustments are impossible, replace the case or install a new drive gear/drive pinion as a set.
DIFFERENTIAL GEAR BACKLASH
1. Fix the side gear with a wedge so it cannot move and measure the differential gear backlash with a dial indicator on the pinion gear.
NOTE: Take the measurements at two places (4 places for LSD) on the pinion gear.
Standard value: 0 - 0.1 mm (0 - 0.0039 inch)
2. If the backlash exceeds the limit, adjust using side bearing spacers.
NOTE: If adjustment is impossible, replace the side gear and pinion gears as a set.
FINAL DRIVE GEAR TOOTH CONTACT
Check the final drive gear tooth contact by following the steps below:
1. Apply the same amount of machine blue slightly to both surfaces of the drive gear teeth.
2. Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear so that some torque (approximately 25 - 30 kg-cm) is applied to the drive pinion.
CAUTION: If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.
3. Check the tooth contact pattern.
NOTE:
^ Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash. The adjustment of drive pinion height and final drive gear backlash should be repeated until the tooth contact patterns are similar to the standard tooth contact pattern.
^ When you cannot obtain a correct pattern, the drive gear and drive pinion have exceeded their limits. Both gears should be replaced as a set.
INSTALLATION
1. Installation is the reverse of removal.
2. Align the matchmark on the flange yoke and the companion flange.
Tighten the propeller shaft and the front differential carrier.
4WD CONTROL SYSTEM (PART TIME 4WD) INSPECTION
FUNCTION CHECK
1. Air pressure gauge is attached in between air hoses that connect differential (actuator) with air pump motor assy. Air pressure gauge adjustment screw shall be fastened until it stops ultimately. And make a blind stopper at air check side by using fuel hose etc.
CAUTION:
^ Air pressure gauge shall be installed by using 3-way union etc.
^ Take heed not to snap or bend the piping hose.
2. Turn the ignition switch on and shift the transfer lever 2H - 4H.
3. Check that the motor starts to revolve in 1 second and stops when Air pressure gauge value displayed with in the specified value.
Specified pressure: 37 - 57 kPa (5.4 - 8.2 inch lbs.2, 0.38 - 0.58 kg-f/cm2).
CAUTION: Check also air leak.
4. Check that if transfer lever is shifted to 2H then promptly Air pressure gauge value drops down.
5. Confirm that motor returns when Air pressure adjustment screw has been loosened to lower the gauge pressure value after motor had started to revolve by shifting transfer lever to 4H. And also check that the motor stops after several seconds since it started to run.
ACTUATOR CHECK
1. Detach air hose from air pump motor assy. and then attach Air pressure gauge at air hose as in figure.
2. Attach compressor air hose to Air pressure gauge and then set to specified pressure by fastening adjustment screw. Whence check that actuator is operated to effect the axle lock.
Specified pressure: 37 kPa (5.4 inch lbs. 2, 0.38 kgf/cm2).
CAUTION: Take heed that there is potential for diaphragm breakage if pressure beyond 200 kPa (28 inch lbs. 2, 2.0 kgf/cm2) is applied.
Do not use the air gun.
AIR PUMP MOTOR CHECK
1. Attach air pressure gauge, voltmeter and battery to air pump motor. as in figure. Air pressure gauge adjustment screw shall be fastened until it stops ultimately. And make a blind stopper at air check side by using fuel hose etc.
2. Confirm that motor runs when battery has been connected. And check that motor stops when returned to specified pressure.
Specified pressure: 37 - 57 kPa (5.4 - 8.2 inch lbs.2, 0.38 - 0.58kgf/cm2).
CAUTION: Check also air leak.
3. Read voltmeter indication value so as to check if it is within specified range.
Voltage: about 0 V (when motor runs) 10 - 14 V (when motor stopped)