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REAR AXLE Differential Carrier
LOCK PIN INSTALLATION
(1) Align the pinion shaft lock pin hole with the ‘ differential
case lock pin hole, and drive in the
pin.
(2) Stake the lock pin with a punch at, two points.
DRIVE GEAR INSTALLATION
(1) Clean the drive gear attaching bolts.
(2) Remove the adhesive adhering to the threaded ho les
of the drive gear by turning
0 and then
clean the threaded holes by applying compressed air .
(3) Apply the specified adhesive to the threaded holes of
the drive gear.
Specified adhesive:
Stud Locking Part No. 4170’ or equivalent
(4) Install the drive gear onto the differential ca se with the
mating marks properly aligned: Tighten the. bolts t o
specified torque 90 Nm (58-65 in a diagonal
sequence.
BEARING INNER RACE .
DRIVE GEAR BACKLASH ADJUSTMENT’
Adjust the drive gear backlash by the procedures:
(1) Install the side bearing spacers,’
are thinner than
those removed, to the side bearing outer races,, an d then
mount the differential case assembly into the
NOTE
Select side bearing spacers with the thickness for’
both the drive pinion side and the drive gear side.
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REAR AXLE Differential
2 0.05 mm in.) Thickness of the spacer on
one side
(2) Push the differential case to ‘one and measure the
clearance between the gear carrier and the bearing.
(3) Measure the thickness the side bearing on
one side, select two pairs of spacers which corresp ond
to that thickness plus one half of the clearance pl us 0.05
mm, and then install one pair each to the drive pin ion
side and the drive gear side.
(4) Install side bearing spacers and differential case as-
sembly, as shown in the illustration;’
the
, .
,.
(5) Tap the side bearing spacers with a brass bar t o fit them
to the side bearing outer race.
(6)Align the mating marks on the gear carrier and the bearing’:
cap, and then tighten the bearing cap.
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REAR AXLE Differential
If backlash is too small
spacer spacer
If backlash is too large
With the drive in place, measure’ the
gear backlash with a dial the drive gear.
Measure at four points or more on
of the drive gear.Standard value: 0.11
0.16 mm In.)
(8) Change the side bearing spacers as illustrated, and then
adjust the drive gear backlash between the drive ge ar
and the drive pinion.
NOTE
When increasing the number of bearing spacers,
use the same number for each, and as few
(9) Check the drive gear and drive pinion for tooth contact;
If poor contact is evident, make adjustment. (Refer to
(lO)Measure the drive gear at the shoulder on the
reverse side of the drive gear.
L i m i t : 0 . 0 5 m m
(11) If the gear exceeds limit, reinstall by
changing the phase of the drive gear and differenti al case,
and remeasure.
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REAR AXLE Assembly, . . .
Feeler
Feelergauge
gear (R.H.) washer .
A
INSPECTION BEFORE
DIFFERENTIAL
(1) Hold the limited a
the differential side
Caution
When the limited slip in
vice, do not tighten
(2)Install two 0.03 ih.)
between the differential case
Caution
Do not insert the feeler
i n t h e d i f f e r e n t i a l
.
. .
I the special in the splined of the
tial’ side gear (R.H.) and make the side gear
(R.H.) turns.
the feeler gauges with in.) feeler:
“gauges..
the special tool in the
gear (R.H.) and make gear’
(R.H.) does not turn.,,
Standard value:
mm in.)
NOTE
The differential gear backlash is normal if the side gear
clearance in the direction of thrust is within the standard
value.
(6) If the side gear clearance in the direction of thrust
not within the standard value, remove the differential case
(A) and adjust by means of thrust washer (L.H.).
Thrust washer (L.H.)
Part No.Thickness mm (in.)
0.8
0.9
1
1.1
1.15
1.2
1.25
1.3
I1.35
1.4
1.5
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REAR AXLE LSD Case Assembly
Thrust washer (R.H.) [Reference]
Part No.Thickness mm (in.)
0.8
NOTE
The thrust washers (L.H.) are a
one appropriate thrust washer from 11 wash-,ers.
DISASSEMBLY AND REASSEMBLY27300140011
Disassembly steps
l Inspection before disassembly, t o
Differential case (A) 3. Thrust washer (L.H.)
4. Viscous coupling (with differential
side gear: L.H.)
5. Pinion mate washer
6. Differential pinion mate
7. Differential pinion shaft
8. Differential side gear
9. Thrust washer (R.H.) 10. Differential case (B)
NOTELSD: Limited slip differential
DISASSEMBLY SERVICE POINT
WASHER (R.H.)
The thrust washer (L.H.) differs from the thrustwasher (R.H.)
in thickness.
Keep them separately from each other for reference in assem-
bly.
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REAR AXLE LSD Case Assembly
l - - c a s e ( B )
Pinion mate
washer
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REASSEMBLY SERVICE POINTS
DIFFERENTIAL CASE CASE
(A) INSTALLATION
Install the differential cases (A) and (B) with the ir mating
marks in alignment.
DIFFERENTIAL PINION
WASHER INSTALLATION
Attach the differential pinion mate to the pinion s haft with
the pinion washers directed as shown, then assemble them
into the differential case (B).
THRUST WASHER (L.H.) SELECTION
When the differential side gear and pinion mate gea r have
been replaced, select the thrust washer (L.H.) by the following
procedure.
(1) Wash the differential side gear and pinion mate gear
with unleaded gasoline and degrease.
(2) Assemble the thrust washers so far used, withou t
confusing the R.H. part with the L.H. part and toge ther
with each gear, VCU, pinion mate washer and pinion
shaft, to the differential cases (A) and (B), and l oosely
tighten the screws.
(3)Check the differential backlash, and select a thrus t washer
(L.H.) to obtain its standard value. (Refer to
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REAR AXLE LSD Case
Differential sideDifferential
pinion mate
Differential
case (A)
in slidingcontact withdifferential case
Splined portion
INSPECTION
(1) Check each gear and the differential pinion sha ft for wear
and damage.
(2) Check the portion of the differential side gear
(R.H.) for damage and shoulder.
(3)Check the sliding surfaces of the thrust washer and pinion
mate washer for wear, seizure and damage.
(4) Check the sliding surfaces of the differential cases (A)
and (B) for wear, seizure and damage.
A. Surface in sliding contact with VCU
B. Surface in sliding contact with pinion mate wash er
C. Surface in sliding contact with thrust washer D. Surface in sliding contact with thrust washer
(5) Check the spline of VCU for damage and shoulder and
check the surface in sliding contact with the diffe rential
case (B).
(6) Check the side gear (L.H.) of VCU for wear and damage.
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