DIFFERENTIAL CASE INSPECTION

PROCEDURE

1. Click here

   INSPECT FRONT DIFFERENTIAL CASE (w/ Pre-torque Mechanism)

   
   
   1. 

      Using SST, rotate the front differential side gear as shown in the illustration.

      09528-52010

      09528-05040

      Standard
      The front differential side gear does not lock when rotated in either direction.

      Tip:
      

      • If the front differential side gear locks, perform all inspections.

      • If the front differential side gear still locks even after replacing the malfunctioning parts, replace the front differential case assembly with ring gear.

2. Click here

   INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT (w/ Pre-torque Mechanism)

   
   
   1. 

      Using SST and a dial indicator, measure the thrust amount of the front differential side gear.

      Table 1. Text in Illustration

      *a	Front Differential Side Gear Thrust Amount

      09528-52010

      09528-05040

      Front differential side gear thrust amount
      0.08 mm (0.00314 in.) or less

      Tip:
      

      • Measure the front differential side gear thrust amount while slowly rotating the front differential side gear.

      • Make sure to measure the front differential side gear thrust amount for both of the 2 front differential side gears.

      • If the result is not as specified, replace the 2 front differential side gears, 2 front differential pinions and 2 front conical spring washers.

3. Click here

   INSPECT FRONT DIFFERENTIAL PINION BACKLASH (w/ Pre-torque Mechanism)

   
   
   1. 

      Set SST as shown in the illustration and tighten it.

      Table 2. Text in Illustration

      *a

      Turn

      *b

      Hold

      09528-52010

      09953-05010

      09528-05020

      10 N*m

      102 kgf*cm

      7 ft.*lbf

   2. 

      Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.

      Table 3. Text in Illustration

      *1	Front No. 1 Differential Pinion Shaft

   3. Using a dial indicator, measure the front differential pinion backlash.

      Standard backlash
      0.20 mm (0.00787 in.) or less

      If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select a front No. 1 differential side gear thrust washer which will ensure that the backlash is within the specification.

      Front No. 1 Differential Side Gear Thrust Washer Thickness
      Part No. Mark Thickness mm (in.) 41361-48010 19 0.90 (0.0354) 41361-22140 14 0.95 (0.0374) 41361-22020 02 1.00 (0.0394) 41361-22150 15 1.05 (0.0413) 41361-22030 03 1.10 (0.0433) 41361-22160 16 1.15 (0.0453) 41361-22040 04 1.20 (0.0472)

      Tip:

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

4. Click here

   INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH (w/o Pre-torque Mechanism)

   
   
   1. 

      Install the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      If the backlash is out of specification, replace the 2 front No. 1 differential side gear thrust washers.

      Front No. 1 Differential Side Gear Thrust Washer Thickness
      Part No. Mark Thickness mm (in.) 41361-22140 14 0.95 (0.0374) 41361-22020 02 1.00 (0.0394) 41361-22150 15 1.05 (0.0413) 41361-22030 03 1.10 (0.0433) 41361-22160 16 1.15 (0.0453) 41361-22040 04 1.20 (0.0472)

      Tip:

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

5. Click here

   INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER

   
   
   1. 

      Using a micrometer, measure the thickness of the front differential pinion thrust washer.

      Minimum thickness
      0.92 mm (0.0362 in.)

      If the thickness is less than the minimum, replace the front differential pinion thrust washer.

6. Click here

   INSPECT FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   
   
   1. 

      Using a micrometer, measure the outer diameter of the front No. 1 differential pinion shaft.

      Minimum outer diameter
      16.982 mm (0.669 in.)

      If the outer diameter is less than the minimum, replace the front No. 1 differential pinion shaft.