Page 1569 of 2103
REAR AXLE Differential ‘Carrier
DISASSEMBLY SERVICE POINTS
DIFFERENTIAL CASE ASSEMBLY
Caution
the differential case slowly
fully so that the side bearing race is not
NOTE
Keep the right and left side bearings separate, so that they
do not become mixed at the time of reassembly.
BEARING INNER RACE REMOVAL
Place the nut on top of the differential case, and then use
the special tool to remove the side bearing inner r ace.
NOTE
Attach the prongs of the special tool to the inner ‘race of
the side bearing through the openings in the differential case.
DRIVE GEAR REMOVAL
(1) Make the mating marks to the differential case and the
drive gear.
(2) Loosen the drive gear attaching bolts in diagon al se-
quence to remove the drive gear.
LOCK PIN REMOVAL differential>
NUT REMOVAL
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Page 1570 of 2103
REAR AXLE Differential Carrier
Mating marks
I
(1) Make the mating marks to the drive pinion and companion
.
Caution
Mating marks should not be sur-
faces of companion shaft.“‘
(2) Drive out the drive pinion
spacer and drive pinion ,
. .
PINION REAR BEARING
REMOVAL
O I L
RACE/DRIVE PINION FRONT
OUTER RACE REMOVAL
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REAR BEARING
REMOVAL
INSPECTION
lCheck the companion flange for wear or damage.
lCheck the bearings for wear discoloration.
lCheck the gear carrier for cracks.
lCheck the drive pinion and drive gear or
lCheck the side gears, pinion gears and shaft for
wear or damage.
l Check the side gear
for damage
Page 1571 of 2103

AXLE Differential’
REASSEMBLY
Differential gear set
24
Final drive gear set
Reassembly steps
1. Gear carrier
2. Oil seal3. Drive pinion rear bearing outer race4. Drive pinion front bearing outer race l Pinion height adjustment
5. Drive pinion
6. Drive pinion rear shim (for pinion
height adjustment)7. Drive pinion rear bearing inner race
6. Drive pinion spacer
l Drive pinion preload adjustment
9. Drive pinion front shim (for preload
adjustment)10. Drive pinion assembly11. Drive pinion front bearing inner race
12. Oil 13. Companion flange
14. Washer
15. Self-locking nut
16. Differential case
17. Limited slip differential case assem- bly (Refer to
l Differential gear backlash adjustment differential> 18. Side
spacer
differential>
19. Side differential>20. Pinion washer21. Pinion gear differential>22. Pinion shaft 23. Lock pin
24. Drive gear 25. Side bearing race
26. Side bearing outer race
l
Drive gear backlash adjustment
27. Side bearing
28. Differential case assembly
29. Bearing cap
30. Vent plug
31. Differential cover assembly
NOTEl : Tightening torque with gear oil applied
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Page 1572 of 2103
2-3 mm in.)
Adhesive: Locking No.
or equivalent ,
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Page 1573 of 2103

REARAXLE Differential
Front bearingRear bearing1
SERVICE POINTS
(1) With the special fit the oil seal is. flush
with the end of
carrier.
(2)
grease to the lip.
PINION REAR BEARING
RACE/DRIVE PINION FRONT BEARING
RACE
Caution
careful not to press in the’ quter race at
PINION
Adjust the drive pinion height by the following pro cedures:
(1) Apply a thin coat of the grease to the mating
face of the washer of special tool.
(2) ‘Install special tools and drive front and rear bearing,
inner. races on the gear carrier in the sequence sh own
in the illustration.
NOTE
Apply a thin coat of the multipurpose grease to the mating
face of the washer of the special tool.
(3) Gradually’tighten the nut of the special tool checking’
the drive pinion turning torque until the value,
of drive pinion turning torque is
Standard value:’
Bearing Bearing lubrication
classification torque
torque)
N e wNone (with
ventiop oil)
New/reused
Gearoil--application
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Because the special be turned one turn, turn
it ‘several times within the range that it can turned;
then, after fitting to the bearing, measure the rot ation
torque.
Page 1574 of 2103

REAR AXLE Differential Carrier
Fe gauge
Bearing cap
Al
the side bearing seat thoroughly..
Position. the special tool in the side bearing. se
at of the
gear carrier, and then install the bearing cap.
NOTE
When positioning tool’, be sure cutout
sections of the special ‘tool the. position shown
in the illustration.
And check that the tool is in
the side bearing seat.
.
(6)Use a feeler gauge to measure the clearance
the special tools.
(7) Remove the special tools
(8) Use a micrometer to measure the dimensions’(B)
(C) of the special tools.
(9) Install. the. bearing cap, and then use a gage
and the micrometer to measure the
of the bearing cap as shown in the
the thickness (E) of the drive rear shim
from the following equation, and select the shim th at is’
closest
to this value.
A m m
(11) Fit the selected drive pinion rear shim(s) the drive
and press-fit the drive pinion rear bearing inner
race by using the special tool.
P I N I O N P R E L O A D A D J U S T M E N T
Adjust the drive pinion turning torque by using the , following
procedures:
Fit the drive pinion front shim(s)
spacer and the drive pinion front bearing race.
(2) Tighten the companion flange to the specified ‘ torque, by
u s i n g t h e s p e c i a l t o o l s .
NOTE
Do not install the oil seal.
. .
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Page 1575 of 2103

REAR AXLE Differential Carrier
or
(3) Measure the drive pinion turning torque (without the
seal) by using the special tools.
Standard value:
BearingBearing lubrication ,
classification
torque) Nm
NewNone (with 0.9 1.2
oil)
New/reused Gear oil application0.4 0.5 (3-4)
(4)If the drive pinion turning torque is not within th e range
of the standard value, adjust the turning torque by replac-
ing the drive pinion front shim(s) or the drive pinion spacer.
NOTE
When selecting the drive pinion front shims, if the number
of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacers.
(5) Remove the companion flange and drive pinion on ce
again. Drive the oil
into the gear carrier front lip
by using the special tool. Apply multipurpose greas e to
the oil seal lip.
(6)Apply a thin coat of multipurpose grease to companion
flange contacting surface of the washer and oil sea l con-
tacting surface before installing drive pinion assembly.
(7) Install the drive pinion assembly and companion flange
with mating marks properly aligned, and tighten the com-
panion flange self-locking nut to the specified torque by
using the special tools.
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Page 1576 of 2103

REAR AXLE Differential Carrier
(8) Measure the drive pinion turning torque (with oil seal)
by using the special tools to verify that the drive pinion
turning torque complies with the standard value.
Standard value:
BearingBearing lubrication Rotation torque
classification (starting friction
torque)
NewNone (with
oil)
New/reusedGear oil application0.5 0.8 (4-5)
there is a deviation from the standard value, chec
k
whether or not there is incorrect tightening torque of the
companion flange tightening self-lock nut, or incor rect
fitting of the oil seal.
DIFFERENTIAL GEAR
differential>
Adjust the differential gear backlash by the follow ing proce-
dures:
(1) Assemble the side gears, side gear spacers, pin ion gears,
and pinion washers into the differential case.
(2) Temporarily install the pinion shaft.
NOTE,
Do not drive in the lock pin yet.,
(3) While locking the side gear with the wedge,. me asure
the differential gear backlash with a
on the’
pinion gear.
NOTE
(1) The measurement should be made for both pinion
gears individually.
(2) Refer to for measurement of slip
differential gear backlash.
Standard value: 0 0.076 mm in.)
Limit: 0.2 mm
in.)
(4) If the differential gear backlash exceeds the l imit, adjust
the backlash by installing thicker side gear spacer s.
(5) Measure the differential gear backlash once aga in, and
confirm that it is within the limit.
NOTE
1. After adjustment, check that is less than
the limit and differential “gear rotates smoothly.
2. When adjustment is impossible,’ replace the side gear
and the pinion gear as a set.
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