DISASSEMBLY







Disassembly steps


1.
Filler plug


2.
Gasket


3.
Drain plug


4.
Gasket


5.
Electronic control coupling


6.
Wave washer


7.
Differential cover assembly


8.
Vent plug


9.
Oil seal
<<A>>

·
Pre-disassembly check
<<B>>

10.
Differential case assembly
<<B>>

11.
Differential side bearing spacer
<<B>>

12.
Differential side bearing
<<C>>

13.
Drive gear
<<D>>

14.
Lock pin


15.
Pinion shaft


16.
Pinion gear


17.
Pinion washer


18.
Side gear


19.
Side gear spacer


20.
Differential case
<<E>>

21.
Differential nut


22.
Drive pinion assembly


23.
Drive pinion front shim (for drive pinion rotation torque adjustment)


24.
Drive pinion spacer
<<F>>

25.
Drive pinion rear bearing inner race


26.
Drive pinion rear shim (for drive pinion height adjustment)


27.
Drive pinion


28.
Oil seal


29.
Drive pinion front bearing inner race
<<G>>

30.
Drive pinion front bearing outer race
<<H>>

31.
Drive pinion rear bearing outer race


32.
Differential carrier

DISASSEMBLY SERVICE POINTS



<<A>> PRE-DISASSEMBLY CHECK


1.Remove the differential case assembly, differential side bearing spacer and differential side bearing.
2.Fix the following special tools in a vice, and install the differential carrier assembly.

  • Working base (MB990909)
  • Working base adapter (MB991116)

3.Use special tool side bearing holder (MB992111) to install the differential case assembly, differential side bearing spacer and differential side bearing to the differential carrier, then perform the following checks. Then tighten a flange bolt (M10 × 75 mm) to the specified torque.
Tightening torque: 43 ± 7 N·m

DRIVE GEAR BACKLASH



1.Set a dial gauge against the drive gear teeth edge and fix the drive pinion. Rotate the drive gear to measure the backlash at four or more points.
Standard value: 0.08 - 0.15 mm
2.When the backlash is not within the standard value range, adjust the final drive gear backlash. (Refer to .)
3.After the adjustment, check the final drive gear teeth contact.

DRIVE GEAR RUNOUT ON BACKSIDE



1.Set a dial gauge against the backside of the drive gear. Rotate the drive gear to measure the runout.
Limit : 0.05 mm
2.When the runout exceeds the limit, check for the foreign material between the backside of the drive gear and the differential gear case, and looseness of the drive gear mounting bolt.
3.When the runout measured in step 2 is normal, change the position of the drive gear and differential case, and measure the runout again.
4.If the adjustment is not possible, replace the differential case or the drive gear and the drive pinion as a set.

DIFFERENTIAL GEAR BACKLASH



1.Drive the wooden wage between one of the side gears and the pinion shaft to fix one side of the side gear. Then, set a dial gauge (with the measuring rod extended) against the pinion gear, and measure the backlash to check that it is within the standard value. Repeat the same procedure to measure the backlash at the other pinion gear.
Standard value: 0 - 0.076 mm
Limit : 0.2 mm
2.When the backlash exceeds the limit, adjust the backlash of the differential gear(Refer to ).
3.When the adjustment is not possible, replace the side gear and the pinion gear as a set.

FINAL DRIVE GEAR TEETH CONTACT ADJUSTMENT


Check the final drive gear teeth contact in the following steps:

1.Apply the bearing blue on the drive gear teeth (on both sides) thinly and evenly.

2.Insert special tool remover bar (MB990939) between the gear carrier and the drive gear installation side of the differential case. While applying load to the drive gear rotation so that approx. 2.5 to 2.9 N·m rotation torque is applied to the drive pinion, rotate the drive pinion by hand (360 degrees clockwise and anti-clockwise respectively).
caution Do not let the drive gear rotated over 360 degrees. It makes the gear contact pattern unclear.
3.Check contact of the final drive gear teeth.
Normal contact pattern
Cause
Measures
1. Small-end side
2. Drive-side tooth face (the side to which the force is applied while driving forward)
3. Large-end side
4. Coast-side tooth face (the side to which the force is applied while driving backward)

Contact pattern indicating that the drive pinion height is too high

Drive pinion is too much away from the centre of the drive gear.


Increase thickness of the drive pinion rear shim to bring the drive pinion closer to the centre of the drive gear. Then move the drive gear away from the drive pinion for the final drive gear backlash adjustment.
Contact pattern indicating that the drive pinion height is too low

Drive pinion is too close to the centre of the drive gear.


Reduce thickness of the drive pinion rear shim to bring the drive pinion away from the centre of the drive gear. Then move the drive gear closer to the drive pinion for the final drive gear backlash adjustment.
note
  1. Checking the contact pattern is the method to check that the drive pinion height and the final drive gear backlash are or are not adjusted properly. Repeat the adjustments of the drive pinion height and the final drive gear backlash until the contact pattern similar to the normal pattern.
  2. If the normal contact pattern cannot be obtained even after making the adjustments, the drive gear and the drive pinion have been worn exceeding the usage limit. Replace both gears as a set.

<<B>> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL SIDE BEARING SPACER/DIFFERENTIAL SIDE BEARING REMOVAL


caution When removing the differential case assembly, remove it slowly with care not to drop the differential side bearing spacer and the differential side bearing outer race.


  1. Remove the differential case assembly, differential side bearing spacer and differential side bearing outer race.
    note Identify the RH and LH side bearing spacers as a reference for the reassembly operation.
  2. Use special side bearing puller (MB990810) to remove the differential side bearing inner race.
    note Hook the claws of the special tool on the differential side bearing inner race through two cut-off parts on the differential case side.

<<C>> DRIVE GEAR REMOVAL



1.Put mating marks on the drive gear and differential case as a reference for the reassembly operation.
2.Loosen the drive gear tightening bolts in a diagonal order to remove the drive gear.

<<D>> LOCK PIN DRIVING OUT




<<E>> DIFFERENTIAL NUT REMOVAL



Use the following special tools to remove the differential nut:

  • Locking nut wrench (MB992112)
  • Drive pinion holder (MB992113)

<<F>> DRIVE PINION REAR BEARING INNER RACE REMOVAL



Use special rear axle shaft bearing remover (MB990560) to remove the drive pinion rear bearing inner race.

<<G>> DRIVE PINION FRONT BEARING OUTER RACE REMOVAL



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

<<H>> DRIVE PINION REAR BEARING OUTER RACE REMOVAL



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