Propeller Shaft,

Differential, Drive Shaft & Axle

step 2
TEAM Pub . No . TTM208EN
 DIFFERENTIAL - Overhaul of Differential Carrier

COMPONENTS

Pin Thrust washer

Adjusting nut

Side gear
Thrust washer

Outer race

Adjusting nut lock

Outer race

Differential carrier
♦ Collapsible spacer
Front bearing

♦ Nut

kg-cm (ft-lb, N•m) ♦ Non - reusable part

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DIFFERENTIAL - Overhaul of Differential Carrier

CHECKS BEFORE DISASSEMBLING DIFFERENTIAL

CARRIER
The following section explains the checks which must be
performed before disassembly of the differential . When
disassembling a malfunctioning differential, particular care
should be taken concerning these points.

1 . IF SYMPTOMS OF TROUBLE SUCH AS BOOMING,

BEATING OR BODY VIBRATION OCCUR, CHECK THE
FOLLOWING:
(a) Looseness of the drive pinion
(b) Damage to the drive pinion bearings

(c) Check the runout of the companion flange

Maximum lateral runout: 0 .10 mm (0.0039 in .)

Maximum radial runout : 0.10 mm (0.0039 in .)

OHP 10-

2 . IF ABNORMAL NOISE AND OTHER TROUBLE SYMP-

TOMS OCCUR, CHECK THE FOLLOWING:
(a) Ring gear runout
. If the runout is greater than maximum, install a new
ring gear.
Maximum runout : 0 .10 mm (0.0039 in .)

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DIFFERENTIAL - Overhaul of Differential Carrier

(b) Ring gear backlash

• If the backlash is not within specification, adjust the
side bearing preload or repair as necessary . (See
step 9 on page 3)
Backlash : 0 .13 - 0.18 mm (0 .0051 - 0 .0071 in .)

(c) Inspect the tooth contact between the ring gear and
the drive pinion (See step 10 on page 41)
• Note the tooth contact position.
(d) Check for looseness of the side bearings, and for ab-
normal noise.

(e) Check the side gear backlash

• Measure the side gear backlash while holding one
pinion gear against the case.
Standard backlash : 0 .05 - 0 .20 mm
(0 .0020 - 0 .0079 in .)
If the backlash is not within specification, install the proper
thrust washers . (See page 34)

(f) Measure the drive pinion preload

• Using a torque meter, measure the preload of the
backlash between the drive pinion and ring gear.
Preload (starting):
9 - 13 kg-cm (7 .8 - 11 .3 in .-lb, 0 .9 - 1 .3 N . m)

(g) Check the total preload

• Using a torque meter, measure the total preload.
Total preload (starting) =
drive pinion preload + 4 to 6 kg-cm (3 .5 - 5 .2 in .-lb,
0 .4 - 0 .6 N•m) side bearing preload

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ri DIFFERENTIAL - Overhaul of Differential Carrier

DISASSEMBLY OF DIFFERENTIAL
1 . REMOVE COMPANION FLANGE
(a) Using a hammer and chisel, loosen the crimped part
of the nut.
(b) Using the SST to hold the flange, remove the nut.
SST 09330-00021

(c) Using the SST, remove the companion flange.

SST 09557-22022
• Screw the bolt of the SST into the threaded portion
of the drive pinion.
• Mount the SST so that its flange is in contact with
the companion flange, than fasten it in place with
the joint bolt and nut.
• Hold the end of the SST bolt and turn the SST nut
counterclockwise to remove the companion flange.

2 . REMOVE OIL SEAL AND OIL SLINGER

(a) Using the SST, remove the oil seal from the housing.
SST 09308-10010
(b) Remove the oil stinger.

3 . REMOVE FRONT BEARING AND BEARING SPACER

(a) Using the SST, remove the front bearing from the
drive pinion.
SST 09556-30010
(b) Remove the bearing spacer.
If the front bearing is damaged or worn, replace the bear-
in g.
4 . REMOVE DIFFERENTIAL CASE AND RING GEAR
(a) Place matchmarks on the bearing cap and differential
carrier.
(b) Remove the two adjusting nut locks.
(c) Remove the two bearing caps and two adjusting nuts.
(d) Remove the bearing outer races.
(e) Remove the differential case from the carrier.
NOTICE
The bearing caps and carrier are manufactured as one unit,
and left and right caps, races, etc ., should not be inter-
changed.

32
DIFFERENTIAL - Overhaul of Differential Carrier

To case reassembly, tag the disassembled parts (side

bearing outer races and adjusting nuts) to show their
locations.

5 . REMOVE DRIVE PINION REAR BEARING

(a) Using a press and the SST, pull out the rear bearing
from the drive pinion.
SST 09950-00020

6 . REPLACE DRIVE PINION FRONT AND REAR BEARING

OUTER RACES
(a) Using a hammer and brass bar, drive out the outer
race.
(b) Using a press and the SST, drive in a new outer race.
SST 09608-35014

7 . REMOVE SIDE BEARINGS FROM DIFFERENTIAL CASE

Using the SST, pull the side bearing from the differential
case.
SST 09950-20017
Fix the claws of the SST to the notches in the differential
case.

8 . REMOVE RING GEAR

(a) Remove the ring gear set bolts and lock plates.
(b) Place alignment marks on the ring gear and differential
case.
(c) Using plastic or copper hammer, tap on the ring gear to
separate it from the differential case .

33
 DIFFERENTIAL - Overhaul of Differential Carrier

9 . 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.

INSPECTION

INSPECTION OF DIFFERENTIAL PARTS

Clean the disassembled parts and check them for wear,

damage, seizing, etc . If a defect is discovered, repair as
necessary or replace the part.

• Check for damage, wear or burning of bearing.

• Check for damage to or wear of bolts.
• Check for damage, wear or burning of the ring gear
or drive pinion.
• Check for cracks in the differential case.
• Check for wear in the side gear and side bearing in
the portions where they are fitted.
• Check for damage, wear or burning of the side
gears, pinion gears, thrust pinions and pinion shaft.

Adjusting nut

Adjusting nut lock

985 (71, 97)

♦ Bearing spacer
Front bearing
♦ Oil seal
Companion flange
Washer
Differential carrier
Bearing outer race
Oil slinger
Dust deflector
♦ Nut
kg-cm (ft-lb, N•m) : Specified torque ♦ Non-reusable part

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DIFFERENTIAL - Overhaul of Differential Carrier

ASSEMBLY OF DIFFERENTIAL

1 . ASSEMBLY OF DIFFERENTIAL CASE

Apply sufficient hypoid gear oil to each sliding part and
rotating part.
(a) Install the proper thrust washers on the side gears.

(b) Install the side gears (with the thrust washer), pinion
gears, pinion thrust washers and pinion shaft in the
differential case.
Align the pinion shaft mounting hole with the hole in
the differential case.

(c) Check the side gear backlash.

Measure the side gear backlash while holding one
pinion gear against the case.
Standard backlash : 0.05 - 0 .20 mm
(0 .0020 - 0 .0079 in .)
If the backlash is out of standard, select thrust washers
which are the same size for the right and left sides to
adjust until the backlash is within the standard.

THRUST WASHER THICKNESS mm (in .)

1 .6 (0 .063)
1 .7 (0 .067)
1 .8 (0 .071)

(d) Install the straight pin.

• Using the hammer and punch, drive the straight pin
through the case and hole in the pinion shaft.
• Crimp the pin hole (in the differential case) slightly.

2 . INSTALL RING GEAR ON DIFFERENTIAL CASE

(a) Clean the surface of the differential case where it
contacts the ring gear.
(b) Heat the ring gear to about 100°C (212°F) in an oil
bath.
NOTICE
Do not heat the ring gear above 110°C (230°F)

(c) Clean the contact surfaces of the ring gear with clean-
ing solvent .

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DIFFERENTIAL - Overhaul of Differential Carrier

(d) Then quickly place the ring gear on the differential

case, and align the matchmarks on the ring gear and
differential case.
(e) Coat the ring gear set bolts with gear oil.
(f) Temporarily install the lock plates and set bolts.
(g) After the ring gear cools down enough, tighten the set
bolts uniformly, a little at a time.
Torque : 985 kg-cm (71 ft-lb, 97 N•m)

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

NOTE : Stake one claw flush with one of the flats of the
bolt head (arrow A), and stake half of the other claw on
the trailing side (arrow B) of the bolt head corner.

3 . INSTALL SIDE BEARING

Using a press and the SST, press the side bearings on
the differential case.
SST 09550-10012

4 . CHECK RING GEAR RUNOUT

(a) Install the differential case onto the carrier and tighten
the adjusting nut just to where there is no play in the
bearings.
(b) Check the ring gear runout.
Maximum runout : 0 .10 mm (0.0039 in .)

5 . INSTALL DRIVE PINION REAR BEARING

(a) Install the washer on the drive pinion with the cham-
fered end facing the pinion gear.
(b) Using a press and the SST, press the reused washer
and new rear bearing on the drive pinion.
SST 09506-30012

36
DIFFERENTIAL - Overhaul of Differential Carrier

6 . TEMPORARILY ADJUST DRIVE PINION PRELOAD

(a) Install following parts:
▪ Drive pinion
. Front bearing
NOTE : Assemble the spacer, oil slinger and oil seal af-
ter adjusting the gear contact pattern.

(b) Install the companion flange with the SST.

SST 09557-22022 (09557-22050)

(c) Adjust the drive pinion preload by tightening the com-

panion flange nut.
Using the SST to hold the flange, tighten the nut.
SST 09330-00021
NOTICE
As there is no spacer, tighten a little at a time, being
careful not to overtighten.

(d) Using a torque meter, measure the preload.

Preload (starting):
New bearing
19 - 26 kg-cm
(16 .5 - 22 .6 in .-lb, 1 .9 - 2.5 N•m)
Reused bearing
9 - 13 kg-cm
(7 .8 - 11 .3 in .-lb, 0 .9 - 1 .3 N•m)
• In order to get the bearing seated properly, turn the
drive pinion several times clockwise and counter-
clockwise, then measure the preload.
. In order to measure the total preload, keep a rec-
ord of each preload value .

37
 DIFFERENTIAL - Overhaul of Differential Carrier

7 . INSTALL DIFFERENTIAL CASE IN CARRIER

(a) Place the bearing outer races on their respective bear-
ings . Make sure the left and right outer races are not
interchanged.
(b) Install the case in the carrier.
Make sure that there is backlash between the ring gear
and drive pinion.
(c) Install the adjusting nuts on their respective carriers,
making sure the nuts are threaded properly.

8. INSTALL BEARING CAPS

Aligh the matchmarks on the cap and carrier . Screw in
the two bearing cap bolts two or three turns and press
down the bearing cap by hand.

NOTICE
If the bearing cap does not fit tightly on the carrier, the
adjusting nuts are not threaded properly . Reinstall the ad-
justing nuts of necessary.

9 . ADJUST SIDE BEARING PRELOAD

(a) Tighten the four bearing cap bolts to the specified
torque, then loosen them to the point where they can
be turned by hand.
Torque : 800 kg-cm (58 ft-lb, 78 N .m)
(b) Fully tighten the four bearing cap bolts by hand.

(c) Using the SST, tighten the adjusting nut on the ring
gear side until the ring gear has a backlash of about
0 .2 mm (0 .008 in .).
SST 09504-00011

(d) While turning the ring gear, use the SST to fully
tighten the adjusting nut on the drive pinion side. After
the bearing are settled, loosen the adjusting nut on the
drive pinion side.
SST 09504-00011

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DIFFERENTIAL - Overhaul of Differential Carrier

(e) Place a dial indicator on the top of the adjusting nut

on the ring gear side.
(f) Adjust the side bearing for zero preload by tightening
the other adjusting nut until the pointer on the indica-
tor begins to move.

(g) Tighten the adjusting nut 1 - 1 1/2 notches from the

zero preload position.

(h) Using a dial indicator, adjust the ring gear backlash

until it is within specification.
Backlash : 0 .13 - 0 .18 mm (0 .0051 - 0 .0071 in .)
NOTE : The backlash is adjusted by turning the left and
right adjusting nuts equal amounts . For example, loosen
the nut on the left side one notch and tighten the nut on
the right side one notch.
Measure the backlash at three or more places around the
ring's circumference.

(i) Tighten the bearing cap bolts.

Torque : 800 kg-cm (58 ft-lb, 78 N•m)
(j) Recheck the ring gear backlash.
Backlash : 0 .13 - 0 .18 mm (0 .0051 - 0.0071 in .)

(k) Using a torque meter, measure the total preload.

Total preload (starting) =
drive pinion preload + 4 to 6 kg-cm (3 .5 - 5 .2 in-lb,
0.4 - 0 .6 N•m) side bearing preload
If the preload value is out of standard, adjust it with the
adjusting nut on the ring gear teeth side .

39
 DIFFERENTIAL - Overhaul of Differential Carrier

NOTE
BACKLASH
If there is too much backlash, each time the
Backlash is the play in the direction of rota-
tion of the ring gear and drive pinion . No vehicle starts out or changes between driving
matter what the driving conditions, the gears and coasting, shock is generated by the gears
are protected with a coating of lubricating oil hitting each other, resulting in damage to the
and a gap is provided between the teeth in the gears.
gears so that no matter how much undue Conversely, if the backlash is too small, the
force is brought to bear on them, they will not gears will make a whining noise.
be damaged.
7- REFERENCE
ADJUSTING SIDE BEARING PRELOAD IN DIFFERENTIAL OF AN INDEPENDENT REAR SUSPENSION
MODEL
(a) Select and install a plate washer in the ring gear side.
The washer should be of a size that will bring the
backlash to within the standard.
(b) Using a plastic hammer, tap the ring gear lightly so
that the bearing and washer will settle into place.

(c) Bring a dial indicator in contact with the ring gear at

right angles to the end of the tooth surface, then fas-
ten the companion flange and move the ring gear.
Measure the backlash.
Backlash (reference) : 0 .10 mm (0 .0039 in .)

(d) Select a pinion gear side plate washer of a thickness

which will eliminate any clearance between the outer
race and the differential carrier.
(e) Replace the plate washer selected in (d) with a plate
washer with a thickness of 0 .06 - 0 .09 mm (0 .0024 -
0 .0035 in .), then drive it into place using the SST.
SST 09504-22011
(f) Align the matchmark on the side bearing cap and
install it.
(g) Check the ring gear backlash again . If the backlash
is out of standard, increase or decrease the thickness
of the right and left plate washers by the same thickness
so as to bring it to within the standard.

ADJUSTING DIFFERENTIAL SIDE BEARING PRELOAD IN FF VEHICLES (FOR TRANSVERSELY-

MOUNTED ENGINE)
• See Step 2 Training Manual, Vol . 7, "Clutch & Manual Transaxle/Transmission" (Pub . No . TTM207E),
for adjustment of the side bearing preload.

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DIFFERENTIAL - Overhaul of Differential Carrier

10 . INSPECT TOOTH CONTACT BETWEEN RING GEAR AND

DRIVE PINION
(a) Coat three or four teeth at three different positions on
the ring gear with red lead.
(b) Hold the companion flange firmly and rotate the ring
gear in both directions.
(c) Inspect the tooth pattern.

Heel Contact Face Contact

Select an adjusting shim that will bring the drive

Proper Contact pinion closer to the ring gear.

Toe Toe Contact Flank Contact

Driven side Drive side

Select an adjusting shim that will shift the drive

Heel pinion away from the ring gear.

PROPER AND IMPROPER TOOTH CONTACT

OHP 12
If tooth contact is improper, select a washer for adjusting
the position of the drive pinion and reinstall the drive
pinion.
NOTE : In the case of face contact and flank contact, ad-
justment may be possible within the ring gear backlash
standard.
(--- NOTE
A helical gear is used for the ring gear in differentials for
FF vehicles (with engines mounted transversely), so there
is no need to check the tooth contact .

41