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2.Hold the following special tools in a vise, and install the differential carrier assembly
to the special tool.
- Working base (MB990909)
- Working base adapter (MB991116)
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1.With the drive pinion locked in place, use a dial gauge to measure the drive gear backlash
in four or more places on the drive gear.
Standard value: 0.11 - 0.16 mm
2.If the backlash is not within the standard value, adjust the final drive gear backlash
(Refer to  ).
3.After the adjustment, inspect the final drive gear tooth contact.
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1.Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
Limit: 0.05 mm
2.When the runout exceeds the limit value, check for foreign material between drive
gear rear side and differential case, and for loose drive gear installation bolts.
3.When check (2) gives normal results, reposition drive gear and differential case and
remeasure.
4.If adjustment is impossible, replace differential case, or replace drive gear and
pinion as a set.
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1.Insert a wedge between the side gear and the pinion shaft to lock the side gear.
2.While locking the side gear with the wedge, measure the differential gear backlash
with a dial indicator on the pinion gear.
Use the measurement procedure for the other pinion gear.
Standard value: 0.01 - 0.250 mm
3.If the backlash exceeds the standard value, adjust it by replacing the side gear spacers.
4.If adjustment is not possible, replace the side gears and pinion gears as a set.
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Check the tooth contact of drive gear by following the steps below.
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1.Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth.
| caution |
If the drive gear is rotated too much, the tooth contact pattern will become
unclear and difficult to check.
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2.Insert special tool brass bar (MB990939) between the differential carrier and the differential
case, and then rotate the companion flange by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive gear so that the revolution torque
(approximately 2.5 - 3.0 N·m) is applied to the drive pinion.
3.Check the tooth contact condition of the drive gear and drive pinion.
Standard tooth contact pattern
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Problem
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Solution
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1. Narrow tooth side
2. Drive-side tooth surface
(the side applying power during forward
movement)
3. Wide tooth side
4. Coast-side tooth surface
(the side applying power during reverse
movement)
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Tooth contact pattern resulting from excessive pinion height
The drive pinion is positioned too far from the centre of the drive gear.
|
Increase the thickness of the drive pinion rear shim, and position the drive pinion closer
to the centre of the drive gear. Also, for backlash adjustment, position the drive gear farther
from the drive pinion.
|
Tooth contact pattern resulting from insufficient pinion height.
The drive pinion is positioned too close to the centre of the drive gear.
|
Decrease the thickness of the drive pinion rear shim, and position the drive pinion farther
from the centre of the drive gear. Also, for backlash adjustment, position the drive gear closer
to the drive pinion.
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| note |
Check the tooth contact pattern to confirm that the adjustments of the pinion height and backlash
have been done properly. Continue to adjust the pinion height and backlash until the tooth contact
pattern resembles the standard pattern. If, even after adjustments have been made, the correct
tooth contact pattern cannot be obtained, it means that the drive gear and the drive pinion have
become worn beyond the allowable limit. Replace the gear set.
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Use the wooden handle of a hammer to remove the differential case assembly, differential
side bearing spacers and differential side bearing outer races.
| note |
Keep the right and left side bearings and side bearing adjusting spacers separate, so
that they do not become mixed during assembly.
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Use the following special tools to pull out the side bearing inner races.
- Side bearing puller (MB990810)
- Differential side bearing cap (MB990811)
| note |
There are two notches provided (at the differential case side) for the claw part of the
special tools; use special tools at that position.
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1.Make the mating marks to the differential case and the drive gear.
2.Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear.
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Drive out the lock pin with a punch.
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Use special tool front hub and flange yoke holder (MB990767) to hold the companion flange,
and then remove the companion flange self-locking nut.
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1.
| caution |
The mating mark made on the companion flange must not be on the coupling
surface of the flange yoke and the front propeller shaft.
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Make mating marks on the drive pinion and companion flange.
2.Drive out the drive pinion together with the drive pinion spacer and drive pinion
shims.
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Use the following special tools to pull out the front bearing inner race.
- Bearing puller (MB990339)
- Bearing remover (MB990648)
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Use special tool brass bar (MB990939) to remove the drive pinion front bearing outer race.
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Use special tool brass bar (MB990939) to remove the drive pinion rear bearing outer race.
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Use special tool rear axle shaft oil seal remover (MB990590) to remove the oil seal.
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