DISASSEMBLY

Disassembly steps <<A>> · Inspection before disassembly 1. Cover 2. Bearing cap <<B>> 3. Differential case assembly 4. Side bearing spacer 5. Side bearing outer race <<C>> 6. Side bearing inner race <<D>> 7. Drive gear <<E>> 8. Self-locking nut 9. Washer <<F>> 10. Drive pinion assembly 11. Companion flange 12. Drive pinion spacer 13. Drive pinion front shim (for turning torque adjustment) <<G>> 14. Drive pinion rear bearing inner race 15. Drive pinion rear shim (for pinion height adjustment) 16. Drive pinion <<H>> 17. Oil seal <<H>> 18. Drive pinion front bearing inner race <<H>> 19. Drive pinion front bearing outer race <<I>> 20. Drive pinion rear bearing outer race 21. Oil seal 22. Differential carrier <<J>> 23. Lock pin 24. Pinion shaft 25. Pinion gear 26. Pinion washer 27. Side gear 28. Side gear spacer 29. Filler plug 30. Gasket 31. Drain plug 32. Packing 33. Differential case

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)

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.

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.

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 - 0.250 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.

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. 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 PROBLEM SOLUTION 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) 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. 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.

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.

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.

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.

Use special tool front hub and flange yoke holder (MB990767) to hold the companion flange, and then remove the companion flange self-locking nut.

2.Pull out the drive pinion together with special tool side bearing puller(MB990810).

Use the following special tools to pull out the rear bearing inner race. Bearing puller (MB990339) Bearing remover (MB990648)

Use special tool remover bar (MB990939) to remove the drive pinion front bearing outer race.

Use special tool remover bar (MB990939) to remove the drive pinion rear bearing outer race.

Drive out the lock pin with a punch.