Rear Differential

INSPECTION

Wash all the disassembled parts clean, and examine them for wear, damage or other defects. Repair or replace defective parts as necessary.
1. Crown gear and drive pinion:
^ If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment.
^ If crack, score or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like.
2. Side gear and pinion mate gear:
^ Replace if crack, score or other defects are evident on tooth surface.
^ Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like.
3. Bearing:
Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident.
4. Thrust washers of side gear and pinion mate gear:
Replace if seizure, flaw, abnormal wear or other defect is evident.
5. Oil seal:
Replace if deformed or damaged, and at every disassembling.
6. Differential carrier:
Replace if the bearing bores are worn or damaged.
7. Differential case:
Replace if its sliding surfaces are worn or cracked.
8. Companion flange:
Replace if the oil seal lip contacting surfaces have flaws.





1. SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of the side gear.
Side gear backlash: 0.1 - 0.2 mm (0.004 - 0.008 inch)
If the side gear backlash is not within the specification, adjust clearance as specified by selecting side gear thrust washer.





2. CROWN GEAR BACKLASH
Using a dial gauge, check the backlash of the crown gear.
Crown gear backlash: 0.1 - 0.2 mm (0.004 - 0.008 inch) If the crown gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.





3. CROWN GEAR RUNOUT
Using a dial gauge, check the crown gear runout.
Crown gear runout: Less than 0.05 mm (0.0020 inch)
If the crown gear runout exceeds 0.05 mm (0.0020 inch), replace the crown gear.
4. TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION
Inspect the tooth contact between crown gear and driven pinion.





5. TOTAL PRELOAD
Using a gauge, check the turning resistance increase.
Total preread: 2.9 - 10.8 Nm (0.3 - 1.1 kgf, 0.7 - 2.4 lbs.)
If the increase of the resistance is not within the specification, adjust the side bearing retainer shims.