DIFFERENTIAL CASE INSPECTION

PROCEDURE

1. INSPECT FRONT NO.1 DIFFERENTIAL CASE SUB-ASSEMBLY

   
   

   1. 

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

      SST

      09528-52010   ( 09528-05030 )

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

      
      

      • If the front differential side gear locks, perform all remaining inspection procedures.

      • Replace any parts that do not meet the specifications.

      • If the front differential side gear locks after performing the inspection procedures again, replace the front No. 1 differential case sub-assembly.

2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

   
   

   1. Set SST as shown in the illustration and tighten it.

      SST

      09528-52010   ( 09953-05010, 09528-05010 )

      Torque:

      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      

      Text in Illustration

      *a

      Turn

      *b

      Hold

   2. 

      Text in Illustration

      *1	Front No. 1 Differential Pinion Shaft

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

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

      Standard backlash
      0.15 mm (0.00590 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.

      Thrust Washer Thickness
      Specified Condition Specified Condition 1.25 mm (0.0492 in.) 1.65 mm (0.0650 in.) 1.30 mm (0.0512 in.) 1.70 mm (0.0669 in.) 1.35 mm (0.0531 in.) 1.75 mm (0.0689 in.) 1.40 mm (0.0551 in.) 1.80 mm (0.0709 in.) 1.45 mm (0.0571 in.) 1.85 mm (0.0728 in.) 1.50 mm (0.0591 in.) 1.90 mm (0.0748 in.) 1.55 mm (0.0610 in.) 1.95 mm (0.0768 in.) 1.60 mm (0.0630 in.) -

      Tech Tips

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

3. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER

   
   

   1. 

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

      Minimum thickness
      0.54 mm (0.0213 in.)

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

4. INSPECT FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   
   
   1. 

      Text in Illustration

      *a	Minimum Outer Diameter

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

      Minimum outer diameter
      20.499 mm (0.8071 in.)

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