ADJUSTMENT OF DIFFERENTIAL GEAR BACKLASH
Adjust the differential gear backlash according to the following procedures
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- Assemble the side gears, side gear spacers, pinion gears, and pinion washers into the differential case.
- Temporarily, install the pinion shaft. NOTE: Do not install the lock pin yet.
- Insert a wedge in the side gear and measure the differential gear backlash with a dial indicator on the pinion gear. NOTE: Measure both pinion gears separately. Standard value: 0-0.1 mm (0-0.0039 in.) Limit: 0.2 mm (0.008 in.)
- If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear thrust spacers.
- Measure the differential gear backlash once again, and confirm that it is within the limit. NOTE: After adjustment, check that the backlash is within the limit and the differential gear rotates smoothly. When adjustment cannot be made, replace the side gear and the pinion gear as a set.
- Install the drive gear as follows: Clean the drive gear attaching bolts. Remove the adhesive on the threaded holes of the drive gear with a tap (M12 x 1.5), and then clean the threaded holes with compressed air. Apply the specified adhesive to the threaded holes of the drive gear. Specified adhesive: LOCTITE #262 or equivalent Install the drive gear in the differential case with the match marks properly aligned. Tighten the bolts to the specified torque (11-15 kg. m) in a diagonal sequence.
- Press-fit the side bearing inner race.
- Align the match mark on the gear carrier and the bearing cap, and then tighten the bearing cap.
- Adjust final drive gear backlash as follows: Using the special tool (09521-43001), temporarily tighten the side bearing nut until it is in the state just before preloading of the side bearing. Measure the final drive gear backlash. Standard value: 0.13-0.18 mm (0.0051-0.0071 in.) NOTE: Measure at least 4 points on the drive gear periphery. Using the special tool (09521-43000), adjust the backlash to standard value by moving the side bearing nut as shown in illustration. NOTE: First turn the side bearing nut for loosening, and then turn (by the same amount) the side bearing nut for tightening. Using the special tool (09521-43001) to apply the preload, turn both right and left side bearing nuts half the distance between centers of two neighboring holes. Choose and install the appropriate lock plate. Check the final drive gear tooth contact. If poor contact is evident, make adjustment. Measure the drive gear runout. Limit: 0.05 mm (0.0020 in.) When drive gear runout exceeds the limit, remove the differential case and then the drive gears, moving them to different positions and reinstalling them.
