DIFFERENTIAL CARRIER (fvoe R200)
REMOVAL
1
on safety stands Drain gear od
2 Remove exhaust tube
3
panion flange
4 Remove drive shafts
5 With differential carrier jacked up,
remove diff mounting insulator nuts
6 Loosen off four fitting bolts that
hold differential carrier onto suspen-
son member
7 Pull off differential carrier back-
ward together with jack
Jack up rear of car and support
Disconnect propeller shaft at com-
SPD511
After carner assembly IS removed,
support suspension member
on a stand
to prevent its insulators being twisted
or damaged
Note Do not place the center of
suspension member on the stand
before removal operation Other-
wse, it wll be &fficult to extract
the
gear carrier assembly
PRE- DISASSEMBLY
INSPECTION
Differential carrier should be in-
spected before parts except rear cover
are removed from it
These inspections are helpful in
finding the cause of the problem and
in determining necessary corrections
1 Using three 45 mm (I 77 in)
spacers, mount carrier
on Diff Attach-
ment KV38100800
LKV38100800
SPD512
2 Remove rear cover
3 Visually inspect parts for wear or
damage
4 Rotate gears checking for any
roughness whch would indicate dam-
aged bearings or chipped gears Check
gear teeth for scorlng or signs
of
abnormal wear Measure preload of
drive pinion
PD340
5 Set up a dial indicator and check
the backlash at several points around
ring gear
Ring gear-todrive pinion backlash-
0 13 -0 18 mm
(0 0051 . 0 0071 in)
SPD513
6 Check gear tooth contact with a
mxture of recommended powder and
Oll
For the tooth contact pattern, see
page PD-9
PD-4
DlSASS E MBLY
1
caps and carrier
2
remove bearing caps
Put match marks on side bearing
Loosen side bearing cap bolts and
3 Usmg Slide Hammer HT72400000
lift hfferential case assembly out
PD344
Note Care should be taken not to
confuse the left and nght hand
beanng caps and bearing outer races
SO that parts may be installed to the
ongmal position
4 Loosen dnve puuon nut, holdmg
compamon flange with Dnve
Plruon
Flange Wrench ST31520000 and pull
off companion flange usmg a suitable
Duller
~
~ DIFFERENTIAL
CARRIER (Tvw R200)
5 Extract drive piruon from carrier
using
a press Take out drive pinion
together with red bearing inner race,
bearing spacer and adjusting washer
6 Remove
od seal
Note Oil seal must not be reused
7 Remove pdot bearmg together
with pdot bearing spacer and front
bearing inner race using Pilot Bearing
Drift KV38100401
KV38100401
PD348
8 Remove side od seal
Note Oil seal must
not be reused
9 Hold rear bearmg inner race
with Puller ST30031000 and extract
from drive pinion with
a press
PO179 PO179
10 To remove front and rear bear-
ing outer races, put a drift to race
surface, and withdraw them by tap
ping the top of drift with
a hammer
P D 349
DIFFERENTIAL CASE
1 Extract bearing using Differential
Side Bearing Puller ST3306S001 (set
of ST33051001 and ST33061000)
ST
PD350
Note
a Securely attach puller to bearing
inner race, utilizing two grooves
in
ddferential case
b Be careful not to confuse the left
and nght hand parts
PD-5
2 Remove ring gear by loosening
ring gear bolts
Note
Loosen bolts dlagonally
3 Punch off pinion mate shaft lock
pin from ring gear side using Sold
Punch KV3
1 100300
Note Lock pin is caulked at pin hole
mouth
on differential case Do not
punch it off forcibly without
checking
how it is caulked
4 Draw out pimon mate shaft and
remove thrust block, pimon mate
gears, side gears and thrust washers
Note Put marks on gear and thrust
washer
so that they can be re-
installed in theu oripnal positions
from which they were removed
INSPECTION
Thoroughly clean all disassembled
parts, and examine them to see that
they are worn, damaged
or otherwise
fdulty and how they are affected
Repdir or replace all faulty parts,
whichever is necessary
1 Check gear teeth for scoring,
cracking or chipping, and make sure
that tooth contact pattern indicates
correct
meslung depth If any damaged
part is endent, replace parts
as re-
quired
Note. Drive pinion and drive gear are
supphed for replacement as a set,
therefore, should either part be
damaged, replace
as a set
2 Check pmion mate shaft, thrust
block, and pmion gears for scores and
signs of wear, and replace as required
Follow the same procedure for side
gears and their seats
on differential
case
3 Inspect all bearing races and
rollers for scoring, clupping or
evldence of excessive wear They
should be in tiptop condition such as
not worn and with rmrror-lke sur-
faces Replace if there
is a shadow of
doubt
on their efficiency, as an incor-
rect beanng operation may result
in
noise and gear seuure
