Differential: Service and Repair

DISASSEMBLY
1. Inspect high speed output gear radial and thrust clearance, as follows:





a. Using a feeler gauge, measure the high speed output gear thrust clearance.
Standard clearance: 0.10-0.25 mm (0.0039-0.0098 inch)
Maximum clearance: 0.25 mm (0.0098 inch).





b. Using a dial indicator, measure the high speed output gear radial clearance.
Standard clearance: 0.035-0.091 mm (0.0014-0.0036 inch)
Maximum clearance: 0.091 mm (0.0036 inch).
2. Remove front drive gear piece, as follows:
a. Using a snap ring expander, remove the snap ring.





b. Using Special Service Tool (SST) 09950-00020, 09950-60010 (09951-00320) or equivalents, and a press, remove the front drive gear piece.

NOTICE: Be careful not to drop the center differential assembly.





3. Remove front taper roller bearing. Using SST 09950-00020 or equivalent, and a press, remove the front taper roller bearing.
4. Remove high speed output gear.
5. Remove needle roller bearing.
6. Remove high and low clutch sleeve assembly.
7. Remove high speed output gear bushing and clutch hub, as follows:





a. Using SST 09550-00020, 09950-00030, 09950-60010 (09951-00320) or equivalents, and a press, remove the high speed output gear bushing and clutch hub.
b. Using a magnetic finger, remove the straight pin from the differential front case.





8. Remove rear taper roller bearing. Using SST 09950-00020, 09950-60010 (09951-00320) or equivalents, and a press, remove the rear taper roller bearing.
9. Remove differential rear case. Remove the 12 bolts and differential rear case.
10. Remove rear side gear and thrust washer.
11. Remove pinion shaft, pinion gear and thrust washer, as follows:
a. Remove the straight pin from the pinion shaft.
b. Remove the pinion shaft, two pinion gears and two thrust washers.
c. Remove the front side gear and thrust washer.
12. Remove low gear. Using a plastic hammer, tap and remove the low gear.

NOTICE: Be careful not to damage the low gear.

13. Remove needle roller bearing, as follows:
a. Using a screwdriver, remove the snap ring.





b. Using SST 09223-00010, 09950-00010 (09951-00400), 09950-70010 (09951-07150) or equivalents, and a hammer, remove the needle roller bearing from the differential rear case.

ASSEMBLY

NOTE: Coat all of the sliding and rotating surfaces with gear oil before assembly.

1. Install needle roller bearing, as follows:





a. Using Special Service Tool (SST) 09612-24014 (09612-10050) or equivalents, and a press, install the needle roller bearing to the differential rear case.

NOTE: Install the bearing to the differential rear case, taking care that its stamped side comes in contact with SST.

b. Install the snap ring.
2. Install low gear, as follows:
a. Clean the contact surface of the differential case.
b. Heat the low gear in boiling water.
c. Carefully remove the low gear from the water.
d. After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.
3. Install pinion shaft, pinion gear and thrust washer, as follows:





a. Install the front side gear and thrust washer to the differential front case.





b. Install the pinion shaft, two pinion gears and thrust washers to the differential front case.





c. Using a dial indicator, measure the front case backlash.

NOTE: Push the pinion shaft.
Minimum backlash: 0.05 mm (0.0020 inch).





If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer.

d. In the same way, measure the rear case backlash.
4. Install straight pin to pinion shaft.
5. Install rear side gear and thrust washer.
6. Install differential rear case. Install the differential rear case and 12 set bolts.
7. Torque rear case set bolt, as follows:





a. Torque the rear case 12 set bolts.
Torque: 88 Nm (65 ft. lbs.).
b. Turn the pinion gear.
c. Loosen the rear case 12 set bolts.
d. Torque the rear case 12 set bolts.
Torque: 98 Nm (72 ft. lbs.).





8. Install rear taper roller bearing. Using SST 09316-12010 or equivalent, and a press, install the rear taper roller bearing.





9. Install clutch hub. Using SST 09316-12010, 09316-60011 (09316-00011) or equivalents, and a press, install the clutch hub.
10. Install high speed output gear bushing, as follows:
a. Apply Multi-Purpose (MP) grease to the straight pin.





b. Install the straight pin, as shown.





c. Using SST 09316-12010, 09316-60011 (09316-00011), as follows: and a press, install the high speed output gear bushing.

NOTICE: Before pressing, align the holes on the bushing and shaft so that the pin on the shaft aligned with the cutting portion of the bushing.





11. Install high and low clutch sleeve.

NOTE: Make sure to install the high and low clutch sleeve in the correct direction.

12. Install high speed output gear and needle roller bearing, as follows:
a. Apply gear oil to the needle roller bearing.
b. Install the high speed output gear and needle roller bearing.





13. Install front taper roller bearing. Using SST 09316-1201O, 09316-60011 (09316-00011) or equivalents, and a press, install the front taper roller bearing.





14. Install front drive gear piece. Using SST 09316-12010, 09316-60011 (09316-00011) or equivalents, and a press, install the front drive gear piece.
15. Install snap ring, as follows:








a. Select a snap ring that will allow minimum axial play.
b. Using a snap ring expander, install a new snap ring.
16. Inspect high speed output gear radial and thrust clearance.