DIFFERENTIAL CASE INSPECTION

PROCEDURE


  1. INSPECT FRONT DIFFERENTIAL CASE


    1. A005JLAE02

      Install SST as shown in the illustration, and then rotate the front differential side gear as shown in the illustration.

      SST
      09528-52010   ( 09528-05040 )
      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 assembly.

  2. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT


    1. A005KH1E02
      Text in Illustration
      *a Front differential side gear thrust amount

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

      SST
      09528-52010   ( 09528-05040 )
      Front differential side gear thrust amount
      0.08 mm (0.00314 in.) or less

      Tech Tips


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

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

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

  3. INSPECT FRONT DIFFERENTIAL PINION BACKLASH


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

      SST
      09528-52010   ( 09953-05010, 09528-05020 )
      Torque:
      10 N*m  { 102 kgf*cm, 8 ft.*lbf }
      A005JQJE03
      Text in Illustration
      *a Turn *b Hold
    2. A005KROE02
      Text in Illustration
      *1 Front No. 1 Differential Pinion Shaft

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

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

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

      Tech Tips

      Make sure to measure the front differential pinion backlash for both of the 2 front differential pinions.

      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
      Mark Specified Condition
      14 0.95 mm (0.0374 in.)
      02 1.00 mm (0.0394 in.)
      15 1.05 mm (0.0413 in.)
      03 1.10 mm (0.0433 in.)
      16 1.15 mm (0.0452 in.)
      04 1.20 mm (0.0472 in.)

      Tech Tips

      Select washers of the same thickness for both the right and left sides.

  4. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER


    1. A005J32

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

      Standard thickness
      0.92 to 1.08 mm (0.0363 to 0.0425 in.)
      Minimum thickness
      0.92 mm (0.0363 in.)

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

  5. INSPECT FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A005IWGE01
      Text in Illustration
      *a Minimum Outer Diameter

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

      Standard outer diameter
      16.982 to 17.000 mm (0.6686 to 0.6692 in.)
      Minimum outer diameter
      16.982 mm (0.6686 in.)

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