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1.Remove the cover and gasket.
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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 drive gear backlash (Refer
to  ).
3.After the adjustment, inspect the 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 runout exceeds the limit value, check for foreign material between drive gear
rear side and differential case, or for loose drive gear installation bolts.
3. When step (2) gives normal results, reposition the drive gear and differential case
and remeasure.
4.If adjustment is impossible, replace the differential case, or replace the drive gear
and pinion as a set.
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1.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 both pinion gears.
Standard value : 0.01 - 0.25 mm
2.If the backlash exceeds the limit, adjust by using the side gear thrust spacers (Refer
to ).
3.If adjustment is impossible, replace the side gear and pinion gear 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.
2.
| caution |
If the drive gear is rotated too much, the tooth contact pattern will
become unclear and difficult to check.
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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 - 2.9 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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- Narrow tooth side
- Drive-side tooth surface (the side applying power during forward movement)
- Wide tooth side
- 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.
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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.
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Tooth contact pattern resulting from insufficient pinion height.
The drive pinion is positioned too close to the centre of the drive gear.
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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.
| note |
Keep the right and left side bearings and side bearing adjusting spacers separate, so
that they do not become mixed during reassembly.
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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 a diagonal sequence to remove the drive gear.
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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.Make mating marks on the drive pinion and companion flange.
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2.Pull out the drive pinion together with special tool side bearing puller(MB990810).
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Use the following special tools to pull out the rear bearing inner race.
- Bearing puller (MB990339)
- Bearing remover (MB990648)
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Use special tool remover bar (MB990939) to remove the drive pinion front bearing outer
race.
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Use special tool remover bar (MB990939) to remove the drive pinion rear bearing outer
race.
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Drive out the lock pin with a punch.
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