REMOVAL OF THE DIFFERENTIAL CASE ASSEMBLY
Remove the differential case assembly slowly and carefully. Be caurful so that the side bearing outer race is not dropped.
Keep the right and left side bearings separate so that they are not mixed during reassembly.
REMOVAL OF THE SIDE BEARING INNER RACES
Fit the nut on top of the differential case, and then use the special tool to remove the side bearing inner race.
Attach the prongs of the special tool to the inner race of the side bearing through the notched section in the differentialcase.
REMOVAL OF DRIVE GEAR
Make the matchmarks to the differential case and the drive gear.
Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear.
REMOVAL OF LOCK PIN (FOR CONVENTIONAL DIFFERENTIAL)
REMOVAL OF SELF-LOCKING NUT
REMOVAL OF DRIVE PINION
Make the matchmarks to the drive pinion and companion flange.
Matchmarks should not be made to the contact surfaces of the companion flange and the propeller shaft.
Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims.
REMOVAL OF DRIVE PINION REAR BEARING INNER RACE
REMOVAL OF OIL SEAL / DRIVE PINION FRONT BEARING INNER RACE / DRIVE PINION FRONT BEARING OUTER RACE
REMOVAL OF DRIVE PINION REAR BEARING OUTER RACE
Check the companion flange for wear or damage.
Check the bearings for wear or discoloration.
Check the gear carrier for cracks.
Check the drive pinion and drive gear for wear or cracks.
Check the side gears, pinion gears and pinion shaft for wear or damage.
Check the side gear spline for wear or damage.
PRESS-FITTING OF OIL SEAL
With the special tool, press fit the oil seal to the end of the gear carrier.
Apply multipurpose grease to the oil seal lip.
Install the drive pinion rear bearing outer race and drive pinion front bearing outer race using the special tool.
Be careful not to press in the outer race when it is inclined.
Install the drive pinion inner and outer bearing races to the special tool in sequence shown in the illustration.
Apply a thin coat of the multipurpose grease on the mating face of the washer of the special tool.
Tighten the nut of the special tool slowly until the standard value of drive pinion turning torque is obtained.
Measure the drive pinion turning torque (without the oil seal) using the special tool.
Bearing division | Bearing lubrication | Rotation torque Nm (kg·cm) |
New | None (with anti-rust agent) | 0.6 ~ 0.9 (6 ~ 9) |
New or reused | Oil application | 0.4 ~ 0.5 (4 ~ 5) |
Gradually tighten the nut of the special tool while checking the drive pinion turning torque.
Because the special tool cannot be turned one rotation, turn it several times within the range that it can be turned. After obtaining smoothbearing operation, measure the rotation torque.
Position the special tool in the side bearing seat of the gear carrier and select a drive pinion rear shim of a thickness which corresponds to thegap between the special tools.
Clean the side bearing seat thoroughly. When positioning the special tool, confirm that the cut-out sections of the special tool touch the sidebearing seat very closely.
When selecting the drive pinion rear shims, use the fewest number of shims necessary.
Part No. | Shim thickness |
3000 4601 1 | 1.38 ± 0.01 |
3000 4602 9 | 1.41 ± 0.01 |
3000 4603 7 | 1.44 ± 0.01 |
3000 4604 5 | 1.47 ± 0.01 |
3000 4605 3 | 1.50 ± 0.01 |
3000 4606 1 | 1.53 ± 0.01 |
3000 4607 0 | 1.56 ± 0.01 |
3000 4608 8 | 1.59 ± 0.01 |
3000 4609 6 | 1.62 ± 0.01 |
3000 4610 0 | 1.65 ± 0.01 |
3000 4611 8 | 0.30 ± 0.013 |
Fit the selected drive pinion rear shim(s) to the drive pinion, and press-fit the drive pinion rear bearing inner race using the special tool.
Fit the drive pinion front shim(s) between the drive pinion spacer and the drive pinion front bearing inner race.
Tighten the companion flange to the specified torque using the special tool.
Do not install the oil seal.
Measure the drive pinion turning torque. (without the oil seal using the special tool)
Bearing use | Bearing lubrication | Rotation torque Nm (kg·cm) |
New | None (with anti-rust agent) | 0.6 ~ 0.9 (6 ~ 9) |
New or reused | Oil application | 0.4 ~ 0.5 (4 ~ 5) |
If the drive pinion turning torque is not within the range of the standard value, adjust the turning torque by replacing the drive pinion frontshim(s) or the drive pinion spacer.
When selecting the drive pinion front shim pack use the minimum number of shims.
Remove the companion flange and drive pinion once again.
Insert the oil seal into the gear carrier front lip using the special tool.
Apply multipurpose grease to the oil seal lip.
Apply a thin coat of multipurpose grease to the contacting surface of the oil seal in the companion flange and contacting surface of the washerof the flange before installing the drive pinion assembly.
Install the drive pinion assembly, shim packs and companion flange with matchmarks properly aligned, and tighten the companion flange self-lockingnut to the specified torque by using the special tool.
Measure the drive pinion turning torque (with oil seal) by using the special tool to verify that the drive pinion turning torque is withinthe standard value.
Bearing use | Bearing lubrication | Rotation torque Nm (kg·cm) |
New | None (with anti-rust agent) | 0.8~1.15 (8~11.5) |
New or reused | Oil application | 0.65~0.77 (6.5~7.5) |
Assemble the side gears, side gear spacers, pinion gears, and pinion washers into the differential case.
Temporarily install the pinion shaft.
Do not install the lock pin yet.
Insert a wedge in the side gear and measure the differential gear backlash with a dial indicator on the pinion gear.
Measure both pinion gears separately.
0~0.076 mm (0~0.0003 in.) 0.2 mm (0.008 in.) |
If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear thrust spacers.
Measure the differential gear backlash once again, and confirm that it is within the limit.
After adjustment, check that the backlash is within the limit and the differential gear rotates smoothly.
When adjustment is impossible, replace the side gear and the pinion gear as a set.
Installation of the lock pin
Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin.
Fix the lock pin in place by staking two points around the lock pin hole with a punch.
Installation of the drive gear
Clean the drive gear attaching bolts.
Remove the adhesive on the threaded holes of the drive gear use a tap (M10 1.25), and then clean the threaded holes with compressed air.
Apply the specified adhesive to the threaded holes of the drive gear. See [Cf.] p.DS-4, SEALANTS AND ADHESIVE
Install the drive gear in the differential case with the matchmarks properly aligned. Tighten the bolts to the specified torque (800~900 kg●cm)in a diagonal sequence.
Press the side bearing inner race
Install side bearing spacers which are thinner than those removed, to the side bearing outer races, and then mount the differential case assemblyinto the gear carrier.
Select side bearing spacers with the same thickness for both the drive pinion side and the drive gear side.
Push the differential case to one side, and measure the clearance between the gear carrier and the side bearing with a feeler gauge.
Select two pairs of spacers which correspond to the value calculated according to the expression in the illustration. Install one pair each tothe drive pinion side and the drive gear side.
Install the side bearing spacers and differential case assembly, as shown in the illustration, to the gear carrier.
Tap the side bearing spacers with a brass bar to fit them to the side bearing outer race.
Align the matchmarks on the gear carrier and the bearing cap and tighten the bearing cap.
With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on the drive gear.
Measure at four points or more on the circumference of the drive gear.
0.08~0.13 mm (0.003~0.005 in.) |
Change the side bearing spacers as illustrated and then adjust the final drive gear backlash between the drive gear and the drive pinion.
When increasing the number of side bearing spacers, use the same number for each and as few as possible.
Check the drive gear and drive pinion for tooth contact. If poor contact is evident, adjust again.
Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
Limit : 0.05 mm (0.002 in.) |
If the drive gear runout exceeds the limit, reinstall by changing the position of the drive gear and differential case, and remeasure.
Fix the drive gear so it cannot move and measure the final drive gear backlash with a dial indicator.
Measure at four points or more on the circumference of the drive gear.
0.08~0.13 mm (0.003~0.005 in.) |
If the backlash is beyond the standard value, adjust by using the side bearing spacer.
After adjustment, inspect the contact of the final drive gear.
Place a dial gauge on the back-face of the drive gear and measure the runout.
0.05 mm (0.0020 in.) |
If the runout is beyond the limit, check that there are no foreign substances between the drive gear and differential case and, that the boltsfixing the drive gear are not loose.
If nothing is wrong in check (2), adjust the drive gear depth and remeasure.
If these adjustments are impossible, replace the case or install a new drive gear/drive pinion as a set.
Fix the side gear with a wedge so it cannot move and measure the differential gear backlash with a dial indicator on the pinion gear.
Take the measurements at two places (4 places for LSD) on the pinion gear.
0~0.076 mm (0~0.003 in.) 0.2 mm (0.008 in.) |
If the backlash exceeds the limit, adjust using side bearing spacers.
If adjustment is impossible, replace the side gear and pinion gears as a set.
Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth.
Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear so that some torque (approximately 25-30 kg●cm) is applied to thedrive pinion.
If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.
Check the tooth contact pattern.
Standard tooth contact pattern 1. Narrow tooth side 2. Drive-side tooth surface (the side receiving power during acceleration) 3. Wide tooth side 4. Coast-side tooth surface (the side receiving power during coast-down) |  |
Problem | Solution |
Tooth contact pattern resulting from excessive pinion height | |
 |  |
The drive pinion is positioned too far from the center of the drive gear. | Increase the thickness of the pinion height adjusting shim, and position the drive pinion closer tothe center of the drive gear. Also, for backlash adjustment, reposition the drive gear further from the drive pinion. |
Tooth contact pattern resulting from insufficient pinion height | |
 |  |
The drive pinion is positioned too close to the center of the drive gear. | Decrease the thickness of the pinion height adjusting shim, and position the drive pinion further fromthe center of the drive gear. Also, for backlash adjustment, reposition the drive gear closer to the drive pinion. |
Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash. The adjustment of drive pinion height and final drive gear backlash should be repeated until the tooth contact patterns are similar to the standard tooth contact pattern.
When you cannot obtain a correct pattern, the drive gear and drive pinion have exceeded their limits. Both gears should be replaced as a set.
