Part 2
Differential Backlash Measurement/Adjustment (Continued)14. Perform the following calculation to calculate the gap in the thrust washer thickness.
NOTE:
- The gap in the thrust washer thickness is the difference between the removed thrust washer thickness and the optimum thrust washer thickness.
- If the thrust washer thickness is thickened 0.1 mm {0.00394 in}, the differential backlash decreases approx. 0.08 mm {0.00315 in}.
Thrust washer thickness gap on front side = K x 0.1 mm {0.00394 in} / 0.08 mm {0.00315 in}
K: Differential backlash gap on front side
Note
Example
K : Differential backlash gap on front side is 0.075 mm {0.00295 in}
Thrust washer thickness gap on front side = 0.075 mm {0.00295 in} x 0.1 mm {0.00394 in} / 0.08 mm {0.00315 in} = 0.094 mm {0.00369 in}
Thrust washer thickness gap on rear side = L x 0.1 mm {0.00394 in} / 0.08 mm {0.00315 in}
L : Differential backlash gap on rear side
Note
Example
L : Differential backlash gap on rear side is 0.065 mm {0.00256 in}
Thrust washer thickness gap on rear side = 0.065 mm {0.00256 in} x 0.1 mm {0.00394 in} / 0.08 mm {0.00315 in} = 0.081 mm {0.00320 in}
15. Input the calculated thrust washer thickness gap into the measurement/adjustment value sheet.
16. Perform the following calculation to calculate the optimum thrust washer thickness.
Optimum thrust washer thickness on front side = H + M
H : Thickness of removed thrust washer on front side
M : Thrust washer thickness gap on front side
Note
Example
H : Thickness of removed thrust washer on front side is 0.810 mm {0.03189 in}
M : Thrust washer thickness gap on front side is 0.094 mm {0.00369 in}
Thickness of optimum thrust washer on front side = 0.810 mm {0.03189 in} + 0.094 mm {0.00369 in} = 0.904 mm {0.03559 in}
Thickness of optimum thrust washer on rear side = I + N
I : Thickness of removed thrust washer on rear side
N : Thrust washer thickness gap on rear side
Note
Example
I : Thickness of removed thrust washer on rear side is 0.795 mm {0.0313 in}
N : Thrust washer thickness gap on rear side is 0.081 mm {0.00320 in}
Thickness of optimum thrust washer on rear side = 0.795 mm {0.0313 in} + 0.081 mm {0.00320 in} = 0.876 mm {0.03449 in}
17. Input the calculated optimum thrust washer thickness into the measurement/adjustment value sheet.
18. Select the nearest thrust washer for the calculated optimum thrust washer thickness from the following table:
CAUTION: Select the same thickness of the thrust washers on the front and rear sides If the thrust washers of the same thickness are assembled on the front and rear sides, measure the differential backlash again, and if the measurement value does not satisfy the specification, thrust washers of varied thickness on the front and rear sides is alright.
19. Assemble the selected thrust washers to the side gears.
20. Assemble the side gears which have the thrust washers assembled to them.
21. Assemble the thrust washers to the pinion gears.
22. Assemble the pinion gears which have the thrust washers assembled to them using the following procedure:
1. Assemble the pinion gears which have the thrust washers assembled to them.
2 Rotate the pinion gears so that the pinion shaft holes of the differential gear case and the pinion gears are aligned as shown in the figure.
NOTE: If the pinion shaft holes of the differential gear case and the pinion gears are not aligned, remove the pinion gears, change the side gears combination, and reassemble.
23. Assemble the pinion shaft.
CAUTION: Assemble the pinion shaft so that the roll pin holes of the differential gear case and the pinion shaft are aligned.
24. Assemble a new roll pin to the position shown in the figure using a pin punch.
CAUTION: Assemble so that the end gap of the roll pin is positioned in the direction shown in the figure.
NOTE: Use a pin punch with an end outer diameter of 5 mm {0.197 in} or more, and within 8 mm {0.314 in}.
A : -0.5-0.5 mm {-0.01-0.01 in}
25. Perform the differential backlash measurement. (See Differential Backlash Measurement.)