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Preparation Before Servicing
1.Print out the measurement/adjustment value input sheet. (See MEASUREMENT/ADJUSTMENT VALUE INPUT SHEET [FW6A-EL/FW6AX-EL].)
Differential Backlash Measurement
1.Secure the ring gear and differential in a vise.
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2.Assemble the drive shaft and joint shaft to the ring gear and differential.
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3.Set the dial gauge and magnetic stand as shown in the figure.
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4.Set the dial gauge end to the pinion gear teeth.
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5.Secure the side gear on the front side by hand.
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6.Move the pinion gear with the dial gauge that has been set by hand and measure the backlash.
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7.Input the measured side gear on the front side and pinion gear backlash into the measurement/adjustment value input sheet.
8.Secure the side gear on the rear side by hand.
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9.Move the pinion gear with the dial gauge that has been set by hand and measure the backlash.
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10.Input the measured side gear on the rear side and the pinion gear backlash into the measurement/adjustment value sheet.
11.Set the dial gauge and magnetic stand to the pinion gear on the opposite side.
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12.Set the dial gauge end to the pinion gear teeth.
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13.Secure the side gear on the front side by hand.
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14.Move the pinion gear with the dial gauge that has been set by hand and measure the backlash.
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15.Input the measure side gear on the front side and the pinion gear backlash into the measurement/adjustment value sheet.
16.Secure the side gear on the rear side by hand.
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17.Move the pinion gear with the dial gauge that has been set by hand and measure the backlash.
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18.Input the measured side gear on the rear side and the pinion gear backlash into the measurement/adjustment value sheet.
19.Calculate the average value of the measured side gear on the front side and the pinion gear backlash.
20.Input the average value of the calculated side gear on the front side and the pinion gear backlash into the measurement/adjustment value sheet.
21.Calculate the average value of the measured side gear on the rear side and the pinion gear backlash.
22.Input the average value of the calculated side gear on the rear side and the pinion gear backlash into the measurement/adjustment value sheet.
23.Verify that the differential backlash on the front side and the differential backlash on the rear side satisfy the specification.
24.Remove the dial gauge and magnetic stand.
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25.Remove the drive shaft and joint shaft.
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26.Remove the ring gear and differential from the vise.
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Differential Backlash Adjustment
1.Remove the dial gauge and magnetic stand.
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2.Remove the drive shaft and joint shaft.
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3.Remove the ring gear and differential from the vise.
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4.Remove the roll pin shown in the figure using a pin punch.
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5.Remove the pinion shaft.
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6.Remove the pinion gears using the following procedure:
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7.Remove the thrust washers from the pinion gears.
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8.Remove the side gears.
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9.Remove the thrust washers from the side gears.
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10.Measure the thickness of the removed thrust washers from the side gears.
11.Input the measured thrust washer thickness into the measurement/adjustment value input sheet.
12.Perform the following calculation to calculate the differential backlash gap.
13.Input the differential backlash gap into the measurement/adjustment value sheet.
14.Perform the following calculation to calculate the gap in the thrust washer thickness.
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.
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:
| Selected thrust washer thickness |
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0.95 mm {0.037 in}
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0.90 mm {0.035 in}
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0.85 mm {0.033 in}
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0.80 mm {0.031 in}
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0.75 mm {0.030 in}
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19.Assemble the selected thrust washers to the side gears.
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20.Assemble the side gears which have the thrust washers assembled to them.
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21.Assemble the thrust washers to the pinion gears.
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22.Assemble the pinion gears which have the thrust washers assembled to them using the following procedure:
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23.Assemble the pinion shaft.
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24.Assemble a new roll pin to the position shown in the figure using a pin punch.
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25.Perform the differential backlash measurement. (See Differential Backlash Measurement.)