DIFFERENTIAL CASE INSPECTION

PROCEDURE

1. INSPECT FRONT DIFFERENTIAL CASE ASSEMBLY WITH RING GEAR

   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.

      • 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. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

   1. 

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

      09528-52010

      09528-05040

      Front differential side gear thrust amount

      0.08 mm (0.00315 in.) or less

      Table 1. Text in Illustration

      *a	Front Differential Side Gear Thrust Amount

      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, 2 front differential pinion thrust washers and 2 conical springs.

3. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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

      09528-52010

      09528-05020

      09953-05010

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      

      Table 2. Text in Illustration

      *a

      Turn

      *b

      Hold

   2. Secure the front differential case assembly with ring gear in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

   3. 

      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

   4. 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

      Mark	Specified Condition
      19	0.90 mm (0.0354 in.)
      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 (0.0453 in.)
      04	1.20 mm (0.0472 in.)

      Tip:

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

4. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER

   1. 

      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.)

      Tip:

      Measure the most worn portion of the front differential pinion thrust washer.

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

5. INSPECT FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   1. 

      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.)

      Tip:

      Measure the mast worn portion of the front No. 1 differential pinion shaft.

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