DIFFERENTIAL CASE INSPECTION

PROCEDURE

1. INSPECT FRONT DIFFERENTIAL CASE

   1. 

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

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      Standard

      The front differential side 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, replace the front differential case assembly.

2. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

   1. 

      *a	Front Differential Side Gear Thrust Amount

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

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      09528-05030

      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 front differential side gears.

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

3. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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

      09528-52010

      09528-05010

      09953-05010

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      

      *a

      Turn

      *b

      Hold

   2. 

      *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

      0.20 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
      1	1.00 mm (0.0394 in.)
      2	1.10 mm (0.0433 in.)
      3	1.20 mm (0.0472 in.)
      4	1.30 mm (0.0512 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.

      Minimum Thickness

      0.9 mm (0.0354 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. 

      *a	Outer Diameter

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

      Minimum Outer Diameter

      17.975 mm (0.708 in.)

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