REAR DIFFERENTIAL CARRIER ASSEMBLY INSPECTION


  1. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A017CDL

      Using a dial indicator, check the runout of the differential ring gear.

      Maximum runout
      0.07 mm (0.0028 in.)

      Check that there is no damage to the differential case. If the differential case is damaged, replace it.

  2. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A017CU0

      Using a dial indicator, check the backlash of the differential ring gear.

      Backlash
      0.13 to 0.18 mm (0.0051 to 0.0071 in.)

      If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

  3. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. A017ELF

      Using a dial indicator, check the backlash of the differential side gear while holding one of the pinion gears toward the differential case assembly.

      Backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      If the backlash is not within the specification, install the 2 differential side gear thrust washers of different thicknesses.

      Tech Tips

      Measure the backlash of the differential side gear with the rear differential pinion shaft installed.

  4. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A017F2PE02

      Using a dial indicator, measure the runout of the rear drive pinion companion flange sub-assembly vertically and horizontally.

      (A)
      30 mm (1.18 in.)
      Maximum runout
      0.10 mm (0.0039 in.)

      If the runout is greater than the maximum value, replace the companion flange sub-assembly.

  5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A017G9T

      Using a torque wrench, measure the preload of the differential drive pinion.

      Drive pinion preload (Initial)
      Item Preload
      New bearing 1.1 to 1.7 N*m (11.2 to 17.3 kgf*cm, 9.7 to 15.0 in.*lbf)
      Reused bearing 0.6 to 0.9 N*m (6.1 to 9.2 kgf*cm, 5.3 to 8.0 in.*lbf)

      If the preload is not within the specified range, adjust the total preload or repair as necessary.

  6. INSPECT TOTAL PRELOAD


    1. A017G9T

      Using a torque wrench, measure the total preload.

      Total preload (Initial)
      Drive pinion preload plus 0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to 4.4 in.*lbf)

      If the preload is not within the specified range, adjust the total preload or repair as necessary.

  7. INSPECT DIFFERENTIAL CASE ASSEMBLY


    1. A017DP2

      Install the rear differential case to the rear differential carrier sub-assembly.

    2. Install the right and left rear differential bearing caps with the 4 bolts.

      Torque:
      79 N*m  { 800 kgf*cm, 58 ft.*lbf }

    3. Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.07 mm (0.0028 in.)

      Tech Tips

      If the runout is greater than the maximum, replace the differential drive pinion, differential ring gear and rear differential case.

    4. Remove the rear differential case.

  8. INSPECT DIFFERENTIAL RING GEAR

    Tech Tips

    Perform this procedure only if the runout of the differential ring gear exceeds the specified maximum value.


    1. A017C5KE01

      Install the rear differential case to the rear differential carrier sub-assembly, and install the 2 rear differential side gear shaft plate washers so that there is no play in the bearing.

    2. Align the matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.

      Note

      Make sure the right and left bearing caps are not interchanged.

    3. Tighten both rear differential bearing caps with the 4 bolts.

      Torque:
      79 N*m  { 800 kgf*cm, 58 ft.*lbf }
    4. A017G0R

      Using a dial indicator, measure the runout of the differential ring gear.

      Maximum runout
      0.07 mm (0.0028 in.)

      If the runout is greater than the maximum value, replace the differential case assembly with a new one.

    5. A017ELW

      Remove the 2 rear differential bearing caps, 2 rear differential side gear shaft plate washers and differential case assembly.

  9. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A017DR5

      Coat 3 or 4 teeth at 3 different positions on the differential ring gear with Prussian blue.

    2. Hold the rear drive pinion companion flange sub-assembly firmly and rotate the differential ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A017CM8E05

      If the teeth are not contacting properly, use the following table to select a proper washer for correction.

      Washer thickness
      Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
      2.26 to 2.28 (0.0890 to 0.0898) 2.41 to 2.43 (0.0949 to 0.0957) 2.56 to 2.58 (0.1008 to 0.1016)
      2.29 to 2.31 (0.0902 to 0.0909) 2.44 to 2.46 (0.0961 to 0.0969) 2.59 to 2.61 (0.1020 to 0.1028)
      2.32 to 2.34 (0.0913 to 0.0921) 2.47 to 2.49 (0.0972 to 0.0980) 2.62 to 2.64 (0.1031 to 0.1039)
      2.35 to 2.37 (0.0925 to 0.0933) 2.50 to 2.52 (0.0984 to 0.0992) 2.65 to 2.67 (0.1043 to 0.1051)
      2.38 to 2.40 (0.0937 to 0.0945) 2.53 to 2.55 (0.0996 to 0.1004) 2.68 to 2.70 (0.1055 to 0.1063)