Inspection And Replacement Of Differential

1. REPLACE DRIVE PINION REAR BEARING

(a) Using SST and a press, pull out the rear bearing from the drive pinion.

SST 09950 00020

NOTE: If the drive pinion or ring gear are damaged replace them as a set.

(b) Install the washer on the drive pinion with the chamfered end facing the pinion gear.

(c) Using SST and a press, press the reused washer and rear bearing onto the drive pinion.

SST 09506 30011

2. REPLACE DRIVE PINION FRONT AND REAR BEARING OUTER RACE

(a) Using a hammer and brass barr drive out the outer race.

(b) Using SST, drive in a new outer race.

SST 09608-35014

(09608 06020, 09608 06110, 09608 06120)

Sst 09252 10010

3. REMOVE SIDE BEARINGS FROM DIFFERENTIAL CASE

Using SST, pull the side bearing from the differential case. SST 09950-20016

4. REMOVE RING GEAR

(a) Remove the ring gear set bolts and lock plates.

(b) Place matchmarks on the ring gear and differential case.

(c) Using a plastic or copper hammer, tap on the ring gear to separate it from the differential case.

5. DISASSEMBLE DIFFERENTIAL CASE

Using a hammer and punch, drive out the straight pin. Remove the pinion shaft, two pinion gears, two side gears and two thrust washers.

6. ASSEMBLE DIFFERENTIAL CASE

(a) Install correct thrust washer and side gears.

Select thrust washers from the table below that will ensure the backlash is within specification. Try to select washers of the same thickness for both sides.

Standard backlash: 0.05 - 0.20 mm

Thrust washer thickness mm jjn j

Thickness

0.96 -

1.04

(0.0378

- 0.0409)

1.06 -

1.14

(0.0417

- 0.0449)

1.16 -

1.24

(0.0457

- 0.0488)

1.26-

1.34

(0.0496

- 0.0528)

Install thrust washers and side gears in the differential case.

(b) Check the side gear backlash.

Measure the side gear backlash while holding one pinion gear toward the case.

Standard backlash: 0.05 - 0.20 mm

If the backlash is not within specification, install a thrust washer of different thickness.

&4074

(c) Install straight pin.

• Using a hammer and punch, drive the straight pcf through the case and hole in the pinion shaft.

• Stake the pin and differential case.

7. INSTALL NEW SIDE BEARING

Using SST and a press, drive a new side bearing into tft differential case.

SST 09550-10012

(09252-10010, 09557-10010, 09558-10010)

8. INSTALL RING GEAR ON DIFFERENTIAL CASE

(a) Clean the contact surface of the differential case.

(b) Heat the ring gear to about 100°C (212°F) in anal bath.

(c) Clean the contact surface of the ring gear with cleaning solvent.

(d) Then quickly install the ring gear on the different* case.

(e) Align the marks on the ring gear and differential case.

CAUTION: Do not heat the ring gear more than 110*0 (230° F).

(f) Coat the ring gear set bolts with gear oil.

(g) Install the lock plates and set bolts. Tighten the set bolts uniformly, a little at a time. Torque the bolts.

(h) Using a hammer and drift punch, stake the lock plates.

NOTE: Stake one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake only the half on the tightening side.

(i) Check the ring gear runout.

Install the differential case onto the carrier and tighten the adjusting nut just to where there is no play in the bearing.

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