Page 489 of 6000

4A2A–22
DIFFERENTIAL (REAR 220mm)
4. Remove the cross pin, using a soft metal rod and a
hammer.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove thrust washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Clean the ring gear threaded holes to remove the
locking agent.
3. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt.
4. Discard used bolts and install new ones.
Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)5. Tighten the fixing bolts in a diagonal sequence as
illustrated.
415RW036
Clearance between the differential pinion
and the cross pin measurement:
Standard: 0.06 – 0.12 mm (0.002–0.005 in)
Limit: 0.2 mm (0.008 in)
425RS045
Page 490 of 6000
DIFFERENTIAL (REAR 220mm)
4A2A–23
Clearance between the side gear and the
differential box:
Standard: 0.05–0.12 mm (0.002–0.005 in)
Limit: 0.15 mm(0.006 in)
425RS046
Legend
(1) Side Gear
(2) Differential Box
Play in splines between the side gear and
the axle shaft:
Standard: 0.07–0.38 mm(0.003 –0.014 in)
Limit:0.5m (0.02 in)
425RS047
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.
425RS048
4. Install cross pin.
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash:0.13 – 0.18 mm (0.005– 0.007 in)
Page 491 of 6000
4A2A–24
DIFFERENTIAL (REAR 220mm)
Thickness of thrust washers available:
0.80 mm, 0.90 mm, 1.00 mm 1.10 mm, 1.20 mm,
1.30 mm (0.031 in, 0.035 in, 0.039 in,0.043 in,
0.047 in, 0.051 in)
425RS050
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
6. Clean the ring gear threaded holes to remove the
locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.7. Tighten the bolts in diagonal sequence as illustrated.
Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)
NOTE: Discard used bolts and install new ones.
415RW036
Page 492 of 6000
DIFFERENTIAL (REAR 220mm)
4A2A–25
Limited Slip Differential
Disassembled View
425RS053
Legend
(1) Screw
(2) Differential cage A
(3) Thrust washer
(4) Spring disc
(5) Spring disc
(6) Friction plate
(7) Friction disc
(8) Friction plate
(9) Friction disc
(10) Pressure ring
(11) Side gear(12) Pinion and pinion shaft
(13) Side gear
(14) Pressure ring
(15) Friction disc
(16) Friction plate
(17) Friction disc
(18) Friction plate
(19) Spring disc
(20) Spring disc
(21) Thrust washer
(22) Differential cage B
Page 493 of 6000

4A2A–26
DIFFERENTIAL (REAR 220mm)
Disassembly
1. Using special tool, 5–8840–2381–0, grip it with a vice,
and set the differential.
425RS054
2. Gradually and evenly loosen the 4 fixing screws of the
differential cages A and B.
425RS055
3. Remove Differential cage A.
4. Remove Thrust washer.
5. Remove Spring disc.
NOTE: When removing the spring disc, friction disc, and
friction plate, place them in order for clear distinction of
left and right use.
6. Remove Spring disc.7. Remove Friction plate.
8. Remove Friction disc.
9. Remove Friction plate.
10. Remove Friction disc.
11. Remove Pressure ring.
12. Remove Side gear.
13. Remove Pinion and pinion shaft.
14. Remove Side gear.
15. Remove Pressure ring.
16. Remove Friction disc.
17. Remove Friction plate.
18. Remove Friction disc.
19. Remove Friciton plate.
20. Remove Spring disc.
21. Remove Spring disc.
22. Remove Thrust washer.
23. Remove Differential cage B.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
Visual check
Check the following parts for wear, damage, noise or any
other abnormal conditions.
Friction disc, friction plate and spring disc
425RS056
Legend
(1) Sliding surfaces
(2) Projections
Page 494 of 6000
DIFFERENTIAL (REAR 220mm)
4A2A–27
Pressure ring
425RS057
Legend
(3) Sliding surface with the friction disc. When
nicks or scratches are found, polish with an oil
stone and repair on a level block using a
compound.
(4) Sliding spherical surface with the pinion gear.
(5) Sliding surface with the side gear.
(6) V–shaped groove of the pressure ring and V
–shaped section of the pinion shaft.
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case. Repair burrs and nicks using
an oil stone.
Thrust washer
425RS058
Legend
(9) Sliding surface with the side gear or case.
(10) Peripheral groove of the side gear.
Repair light nicks and burrs using an oil stone.
Case
425RS059
Legend
(11) Contact surface with the spring disc.
(12) Inner groove of the differential cage B.
Repair light nicks and burrs using an oil stone.
425RS060
Page 495 of 6000
4A2A–28
DIFFERENTIAL (REAR 220mm)
Legend
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case.
Repair burrs and nicks using an oil stone.
(9) Sliding surface with the side gear or case.
(11) Contact surface with spring disc.
Measure the Deformation of the friction disc & plate.
Limit: 0.08 mm (0.003 in)
425RS061
Measure the wear of the friction plate & disc
Limit(A–B): 0.1 mm (0.004 in)
Remarks:
A=Inner or outer projections
B=Sliding surface subjected to abrasion
425RS062
Measure the wear of the thrust washer
Limit: 1.3 mm (0.05 in)
425RS063
Reassembly
Adjust the clearance between the friction disc and plate.
1. Measuring the depth of the differential cage.
Standard (A–B): 80.58 mm (3.17 in)
(C): 10.58 mm (0.41 in)
425RS064
2. Measuring the overall length of the pressurering,
friction disc and friction plate.
Mount the pinion shaft in the pressurering and then
install the friction disc & plate.
Page 496 of 6000

DIFFERENTIAL (REAR 220mm)
4A2A–29
Measure the length between the plates over the
V–groove. (D)
425RS065
3. After measuring dimensions A,B,C and D, make
adjustment in the following manner:
Measure the thickness (E) of the spring disc.
1.75mm (0.069in)
4discs
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness :1.75–1.85mm(0.069–0.073 in)
Backlash adjustment of the side gear in
the direction of the shaft
1. Measuring the depth of the differential cage.
(F–B): 82.03 mm (3.23 in)
(G): 12.03 mm (0.47 in)
425RS066
2. Measuring the dimension between the thrust washers
at both ends.
Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
Have the side gear contact to the pinion to make the
backlash 0.
Measure the dimension (H) between thrust
washers at both ends.
425RS067