DISASSEMBLY AND REASSEMBLY







Disassembly steps

>>D<<
1.
Differential drive gear
<<A>>
>>C<<
2.
Ball bearing
<<B>>
>>C<<
3.
Ball bearing
<<C>>
>>B<<
4.
Lock pin

>>A<<
5.
Pinion shaft

>>A<<
6.
Pinion

>>A<<
7.
Washer

>>A<<
8.
Side gear

>>A<<
9.
Spacer


10.
Differential case

DISASSEMBLY SERVICE POINT



<<A>> BALL BEARING REMOVAL



Use the special tool bearing remover (MD998917) and the press to remove the ball bearing.

<<B>> BALL BEARING REMOVAL



Use the special tool bearing remover (MD998917) and the press to remove the ball bearing.

<<C>> LOCK PIN REMOVAL



Pull the lock pin from the hole A.

ASSEMBLY SERVICE POINT



>>A<< SPACER / SIDE GEAR / WASHER / PINION / PINION SHAFT INSTALLATION



1.Install the spacer to the back side of the side gear and then install the side gear within the differential case
2.Combine the washer to the back side of the pinion to engage the both of them with side gear at the same time. Rotate it to be installed to the specified position.
3.Insert the pinion shaft.

4.Measure the backlash of the side gear and of the pinion.
Standard value: 0.025 - 0.050 mm
(Backlash of differential gear and pinion)
5.When the backlash is different from the standard value, select the spacer. Overhaul, install and adjust the gear again.
note Adjust the backlash to be even at the both sides.

>>B<< LOCK PIN INSTALLATION


caution
  • Do not re-use the lock pin.
  • If your can press in the lock pin too easily with a light force, you must replace the differential case.

Align the lock pin hole of the pinion shaft with the lock pin hole of the case to press fit the lock pin.

>>C<< BALL BEARING INSTALLATION



Use the following special tools to press-fit the ball bearing to the both sides of the differential case.

  • Installer cap (MD998812)
  • Installer 100 (MD998813)
  • Installer adapter (MD998820)

Use the following special tools to press-fit the ball bearing to the both sides of the differential case.

  • Installer cap (MD998812)
  • Installer 100 (MD998813)
  • Installer adapter (MD998820)

>>D<< DIFFERENTIAL DRIVE GEAR INSTALLATION


1.Install the differential drive gear to the differential case.
2.Apply sealant to the bolt threads.
SEALANT
    Brand name: Three bond 1303, LOCTITE 648 or equivalent

3.Tighten the bolts to the specified torque of 133 ± 5 N·m in numerical order shown in the illustration.