Differential Case
DIFFERENTIAL CASECOMPONENTS:
DISASSEMBLY
1. REMOVE SPEEDOMETER DRIVE GEAR
a. Remove the drive gear from the front differential case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR
a. Put matchmarks on the gear and front differential case.
b. Remove the 8 bolts.
c. Using a hammer, tap out the front differential ring gear from the case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the gear backlash.
Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not as specified, replace the pinion thrust washer and side gear thrust washers.
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a. Using a chisel and hammer, loosen the staked part of the front differential case.
b. Using a 3 mm pin punch and hammer, tap out the front differential pinion shaft straight pin from the front differential case.
5. REMOVE NO. 1 FRONT DIFFERENTIAL PINION SHAFT
a. Remove the front differential pinion shaft No. 1 from the front differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
a. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential No. 1 side gear thrust washers and 2 front differential side gears from the front differential case.
HINT: Revolving the front differential pinion, remove the 2 pinions and 2 side gears.
INSPECTION
1. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER
a. Using a micrometer, measure the thickness.
Minimum thickness: 0.94 mm (0.03701 inch)
If the thickness is less than the minimum, replace the front differential pinion thrust washer.
2. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT
a. Using a micrometer, measure the diameter of the front No. 1 differential pinion shaft.
Minimum diameter: 16.982 mm (0.6685 inch)
If the diameter is less than the minimum, replace the front No. 1 differential pinion shaft.
REASSEMBLY
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
a. Coat the sliding and rotating surface of the front differential side gear with gear oil.
b. Install the 2 front No. 1 differential side gear thrust washers to the 2 front differential side gears.
c. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential pinion thrust washers to the front differential case.
HINT: Revolving the front differential side gear, install the 2 front differential pinions and 2 front differential pinion thrust washers.
2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
a. Coat the front No. 1 differential pinion shaft with MP grease.
b. Install the front No. 1 differential pinion shaft to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.
3. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH
a. Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the gear backlash.
Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not within specification, replace the side gear thrust washer.
Standard thrust washer thickness:
Standard thrust washer thickness
HINT:
^ Because the thrust washer does not have any marks for distinction, measure the thickness with a micrometer to select a proper thrust washer.
^ Select washers of the same thickness for both the right and left side.
4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
a. Using a 3 mm pin punch and hammer, tap in the front differential pinion shaft straight pin to the front differential case.
b. Using a chisel and hammer, stake the front differential case hole.
5. INSTALL FRONT DIFFERENTIAL RING GEAR
a. Clean the contact surface of the front differential case and ring gear.
b. Using a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
c. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
d. Aligning both matchmarks, quickly install the front differential ring gear to the front differential case.
e. Install the 8 bolts.
Torque: 77 Nm (790 kgf-cm, 57 ft. lbs.)
6. INSTALL SPEEDOMETER DRIVE GEAR
a. Install the drive gear to the front differential case.