DIFFERENTIAL - Overhaul of Differential Carrier

CHECKS BEFORE DISASSEMBLING

DISASSEMBLING DIFFERENTIAL
DIFFERENTIAL
CARRIER
The following section explains the checks which must be
performed before disassembly of the differential . When
disassembling a malfunctioning differential, particular care
should be taken concerning these points.

  . IF SYMPTOMS OF TROUBLE SUCH AS BOOMING,

BEATING OR BODY VIBRATION OCCUR, CHECK THE
FOLLOWING:
  a ) Looseness of the drive pinion
  b ) Damag
Damage
e to the drive pinion bearings

(c) Check the runout of the companion flange

Maximum lateral runout   0 .10 mm 0.0039 in  

Maximum radial runout   0 .10 mm 0.0039 in  

OHP 10-

2 . IF ABNORMAL NOISE AND OTHER TROUBLE SYMP-

TOMS OCCUR, CHECK THE FOLLOWING:
(a) Ring gear runou
runoutt
. If the runout is greater than maximum, install a new
ring gear.
Maximum runout   0 .10 mm 0.0039 in .)

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DIFFERENTIAL - Overhaul of Differential Carrier

(b) Ring gear backlash

• If the backlash is not within specification, adjust the
side bearing preload or repair as necessary . (See
step 9 on page 3)
Backlash   0 .13 - 0.18 mm 0 .0051 - 0 .0071 in .)

(c) Inspect the tooth contact between the ring gear and
the drive pinion (See step 10 on page 41)
• Note the tooth contact position.
(d) Check for looseness of the side bearings, and for ab-
normal noise.

  e ) Check the side gear backlash

• Measure the side gear backlash while holding one
pinion gear against the case.
Standard backlash : 05 - 0 .20 mm
  0 .0020 - 0 .0079 in .)
If the backlash is not within specification, install the proper
thrust washers . (See page 34)

(f) Measure the drive pinion preload

• Using a torque meter, measure the preload of the

backlash between the drive pinion and ring gear.
Preload starting):
9 - 13 kg-cm 7 .8 - 11 .3 in .-lb, 0 .9 - 1 .3 N . m )
kg-cm

(g) Check the total preload

• Using a torque meter, measure the total preload.
Total preload starting) =
drive pinion preload + 4 to 6 kg-cm 3 .5 - 5 .2 in .-lb,
0 .4 - 0 .6 N•m) side bearing preload

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DIFFERENTIAL - Overhaul of Differential Carrier

ASSEMBLY OF DIFFERENTIAL

  . ASSEMBLY OF DIFFERENTIAL CASE

Apply sufficient hypoid gear oil to each sliding part and
rotating part.

  a ) Install the proper thrust washers on the side gears.

  b ) Install the side gears (with the thrust washer), pinion

gears, pinion thrust washers and pinion shaft in the
differential case.
Align the pinion shaft mounting hole with the hole in
the differential case.

(c) Check the side gear backlash.

Measure the side gear backlash while holding one
pinion gear against the case.
Standard backlash : .05 - 0 .20 mm
  0 .0020 - 0 .0079 in  
If the backlash is out of standard, select thrust washers
which are the same size for the right and left sides to
adjust until the backlash is within the standard.

THRUST WASHER THICKNESS mm (in  

.6  0 .063)
  .7  0 . 0 67)
  .8  0 .0 71)

  d) Install the straight pin.

• Using the hammer and punch, drive the straight pin
through the case and hole in thet he pinion shaft.
• Crimp the pin hole (in the differential case) slightly.

2 . INSTALL RING GEAR ON DIFFERENTIAL CASE

  a ) Clean the surface of the differential case where it
contacts the ring gear.
  b ) Heat the ring
r ing gear to about
abo ut 100°C (212
( 212°
°F) in an oil
bath.

NOTICE
Do not heat the
t he rin
ringg gear abov
abovee 110
110°
°C 230°F)

  c) Clean the contact surfaces of the ring gear with clean-

ing solvent  

35