Differential Assembly

DIFFERENTIAL ASSEMBLY

Components





Differential Case Disassembly




1. REMOVE SIDE BEARING
Using SST, remove the 2 side bearings.
SST 09608 - 16011, 09550 - 4001001.

2. REMOVE RING GEAR



a. Place matchmarks on both the differential case and ring gear.




b. Remove the 12 bolts.




c. Using a plastic hammer, tap out the ring gear.




3. CHECK SIDE GEAR BACKLASH
Using a dial gauge, measure the backlash of each side gear while holding one pinion toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)

4. DISASSEMBLE DIFFERENTIAL CASE



a. Drive out the pinion shaft lock pin from the side on which the ring gear is installed.




b. Remove the pinion shaft from the case.
c. Remove the 2 pinions and side gears with the 4 thrust washers.


Differential Case Assembly

1. ASSEMBLE DIFFERENTIAL CASE



a. Install the removed thrust washers to the side gears.




b. Install the side gears with thrust washers, pinion thrust washers and pinion gears.




c. Install the pinion shaft.




d. Check the side gear backlash. Measure the side gear backlash while holding one pinion gear toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)

Refering to the table below, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides.

Thrust washer thickness





If the backlash is not within specification, install a thrust washer of a different thickness.




e. Using a pin punch and hammer, drive the lock pin through the case and hole in the pinion shaft.
f. Stake the differential case.

2. INSTALL RING GEAR



a. Clean the contact surface of the differential case.
b. Heat the ring gear to about 1OO°C (212°F) in an oil bath.

NOTICE: Do not heat the ring gear above 110°C (230° F).

c. Carefully remove the ring gear from the oil bath.
d. Clean the contact surface of the ring gear with cleaning solvent.




e. Quickly install the ring gear on the differential case. Install the 12 bolts.

HINT: Align the matchmarks on the differential left case and contact the ring gear.

f. Tighten the set bolts uniformly a little at a time. Torque the bolts.

Torque: 124 Nm (1,260 kgf.cm, 91 ft. lbs.)

3. INSTALL SIDE BEARING



a. Install the speedometer drive gear onto the differential case.




b. Using SST and a press, press in the RH side bearing onto the differential case.
SST 09316 - 20011




c. Using SST and a press, press in the LH side bearing onto the differential case.
SST 09316 - 60010 (09316 - 00010)