Differential Carrier Assembly Disassembly
DISASSEMBLY
Required Special Tools:
- MB990560: Rear Axle Shaft Bearing Remover
- MB990810: Side Bearing Puller
- MB990909: Working Base
- MB990939: Remover Bar
- MB991116: Working Base Adapter
- MB992111: Side Bearing Holder
- MB992112: Lock Nut Wrench
- MB992113: Drive Pinion Holder
DISASSEMBLY SERVICE POINT
[[A]] INSPECTION BEFORE DISASSEMBLY
1. Remove the differential case assembly, differential side bearing spacer and differential side bearing.
2. Hold special tools MB990909 and MB991116 in a vise, and install the differential carrier assembly to the special tool.
3. Use special tool MB992111 to install the differential case assembly, differential side bearing spacer and differential side bearing to the differential carrier, then perform the following checks.
Tightening torque: 48± 6Nm (36± 4 ft-lb)
DRIVE GEAR BACKLASH
1. Set a dial gauge against the drive gear teeth edge and fix the drive pinion. Rotate the drive gear to measure the backlash at four or more points.
Standard value: 0.08 - 0.15 mm (0.003 - 0.006 inch)
2. When the backlash is not within the standard value range, adjust the final drive gear backlash. (Refer to Differential Carrier Assembly Reassembly.)
3. After adjustment, check the final drive gear teeth contact.
DRIVE GEAR RUNOUT ON BACKSIDE
1. Set a dial gauge against the backside of the drive gear. Rotate the drive gear to measure the runout.
Limit: 0.05 mm (0.002 inch)
2. When the runout exceeds the limit value, check for the foreign material between the backside of the drive gear and the differential gear case, and looseness of the drive gear mounting bolt.
3. When the runout measured in step 2 is normal, change the position of the drive gear and differential case, and measure the runout again.
4. If the adjustment is not possible, replace the differential case or the drive gear and the drive pinion as a set.
DIFFERENTIAL GEAR BACKLASH
1. Drive the wooden wedge between one of the side gears and the pinion shaft to fix one side of the side gear. Then, set a dial gauge (with the measuring rod extended) against the pinion gear, and measure the backlash to check that it is within the standard value. Repeat the same procedure to measure the backlash at the other pinion gear.
Standard value: 0 - 0.076 mm (0 - 0.0030 inch)
Limit: 0.2 mm (0.01 inch)
2. When the backlash exceeds the limit value, adjust the backlash of the differential gear.(Refer to Differential Carrier Assembly Reassembly.)
3. When the adjustment is not possible, replace the side gear and the pinion gear as a set.
FINAL DRIVE GEAR TEETH CONTACT ADJUSTMENT
Check the final drive gear teeth contact in the following steps:
1. Apply the bearing blue on the drive gear teeth (on both sides) thinly and evenly.
2. Insert special tool MB990939 between the differential carrier and the drive gear installation side of the differential case. While applying load to the drive gear so that the rotation torque [approximately 2.5 - 2.9 Nm (23 - 25 in-lb)] is applied to the drive pinion, rotate the drive pinion by hand (360 degrees clockwise and counterclockwise respectively).
CAUTION:
Do not let the drive gear rotated over 360 degrees. It makes the gear contact pattern unclear.
3. Check contact of the final drive gear teeth.
NOTE:
1. Checking the contact pattern is the method to check that the drive pinion height and the final drive gear backlash are or are not adjusted properly. Repeat the adjustments of the drive pinion height and the final drive gear backlash until the contact pattern similar to the normal pattern.
2. If the normal contact pattern cannot be obtained even after making the adjustments, the drive gear and the drive pinion have been worn exceeding the usage limit. Replace both gears as a set.
[[B]] DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL SIDE BEARING SPACER/DIFFERENTIAL SIDE BEARING OUTER RACE REMOVAL
CAUTION:
When removing the differential case assembly, remove it slowly with care not to drop the differential side bearing spacer and the differential side bearing outer race.
Remove the differential case assembly, differential side bearing spacer and differential side bearing outer race.
NOTE:
Identify the RH and LH side bearing spacers as a reference for the reassembly operation.
[[C]] DIFFERENTIAL SIDE BEARING INNER RACE REMOVAL
Use special tool MB990810 to remove the differential side bearing inner race.
NOTE:
Hook the claws of the special tool on the differential side bearing inner race through two cut-off parts on the differential case side.
[[D]] DRIVE GEAR REMOVAL
1. Put mating marks on the drive gear and differential case as a reference for the reassembly operation.
2. Loosen the drive gear tightening bolts in a diagonal order to remove the drive gear.
[[E]] LOCK PIN DRIVING OUT
Drive out the lock pin with a punch.
[[F]] DIFFERENTIAL NUT REMOVAL
Use special tools MB992112 and MB992113 to remove the differential nut:
[[G]] DRIVE PINION REAR BEARING INNER RACE REMOVAL
Use special tool MB990560 to remove the drive pinion rear bearing inner race.
[[H]] DRIVE PINION FRONT BEARING OUTER RACE REMOVAL
Use special tool MB990939 to remove the drive pinion front bearing outer race.
[[I]] DRIVE PINION REAR BEARING OUTER RACE REMOVAL
Use special tool MB990939 to remove the drive pinion rear bearing outer race.