Differential: Service and Repair

DIFFERENTIAL - FOUR WHEEL DRIVE (4WD) DISASSEMBLY/ASSEMBLY









Disassembly





1. Using the special tool, measure and record the backlash for the differential side gears. Install a new differential if beyond specification.

NOTE:Backlash specification: 0.02-0.08 mm (0.0008-0.0031 in).
2. Remove the 10 reduction gear bolts.

3. Remove the reduction gear.

4. Remove the 10 final drive gear bolts.

5. Remove the final drive gear.





6. Using the special tools, remove the differential side bearing.

- Discard the differential side bearing.

7. Remove the spacer.

8. Remove the vehicle speed sensor (VSS) drive gear.





9. Using the special tools, remove the differential side bearing.

- Discard the differential side bearing.

Assembly





1. Using a suitable press, install a new differential side bearing. Only use the inner bearing race to install.

2. Install the VSS drive gear.

3. Install the spacer.





4. Using a suitable press, install a new differential side bearing. Only use the inner bearing race to install.

5. Install the final drive gear.





6. Install the 10 final drive gear bolts.

- Tighten in the sequence shown to 120 Nm {12.0 kgf-m, 89 ft-lbf}.

7. Install the reduction gear.





8. Install the 10 reduction gear bolts.

- Tighten in the sequence shown to 96 Nm {9.6 kgf-m, 71 ft-lbf}.