Overhaul
DISASSEMBLENOTE:
^ Mark differential components so their original positions relative to other components is maintained.
^ Bearing caps must not be interchanged.
1. Remove axle shafts then differential assembly tom axle.
2. Remove roll pin securing bearing nut locking fingers to bearing caps.
- Remove locking fingers.
3. Loosen bearing cap bolts and mark caps for assembly.
4. Using service tool LRT-54-508, remove bearing adjusting nuts.
5. Remove bearing cap bolts and bearing caps.
6. Remove crown wheel differential unit and bearings.
Remove pinion FRONT AXLE DIFFERENTIAL ONLY
7. Remove pinion flange nut using service tool LRT-51-003 to restrain flange.
8. Remove washer and pinion drive flange.
9. Remove pinion complete with bearing and outer bearing shims.
10. Remove pinion flange oil seal, spacer and bearing.
Remove pinion REAR AXLE DIFFERENTIAL ONLY
7. Remove pinion flange centralizing peg using service tool LRT-51-008.
8. Remove pinion flange nut using service tool LRT-51-003 to restrain flange.
9. Remove pinion complete with bearing and outer bearing shims.
10. Remove pinion flange oil seal and bearing.
All Differentials
11. Using service tool LRT-54-505, remove pinion head bearing race and shim and drive out outer bearing of differential housing.
12. Remove pinion head bearing with service tool LRT-99-002.
13. Remove bolts and washers securing crown wheel to differential flange.
- Remove crown wheel.
14. Remove differential carrier bearings.
15. Remove circlips and extract differential cross shaft.
16. Withdraw differential gears and pinions.
17. Clean all components.
INSPECTION
18. Check all bearings for wear and pitting.
19. Check ail gears for wear, scuffing, pitting and damaged teeth.
20. Supplied as matched sets are: crown wheel and pinion, pinion housing and bearing caps.
ASSEMBLE
Differential Gears
21. Install differential gears to differential housing.
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22. Install differential cross shaft and circlips.
23. Check gear for freedom of rotation and backlash.
- Nominal backlash should be present.
- Excess backlash necessitates replacement of gears or differential housing.
24. Check serial number marked on pinion end face matches that on crown wheel.
25. Clean and install crown wheel.
26. Install carrier bearings and assemble tracks to bearings.
27. Place differential housing with crown wheel and bearings in pinion housing.
28. Install bearing caps and bolts.
- Do not tighten bolts.
29. Install bearing adjusting nuts and adjust to obtain zero end float.
30. Tighten bearing cap bolts to 90 Nm.
31. Check crown wheel for run-out.
- This should not exceed 0.10 mm.
- If exceeded examine crown wheel and mounting flange for burrs, grit, etc.
- Install and recheck.
- A buckled or damaged differential housing flange is corrected by - replacing differential gear housing.
32. After checking run out remove differential housing from pinion housing.
33. Remove crown wheel bolts and install using Loctite "Studlock".
- Tighten to 58 Nm.
34. Install pinion head bearing race and original shim to pinion housing.
- Use service tools LRT-54-505 and LRT-54-506.
- If installation a new shim use minimum 1.27 mm thickness.
35. Install pinion outer bearing race to pinion housing.
- Use service tools LRT-54-505 and LRT-54-507.
36. Install pinion head bearing to pinion.
- Use service tool LRT-54-502.
37. Install pinion into its location without shims for bearing pre-load.
38. Install outer bearing, and spacer (front axle differential only).
39. Install driving flange, washer and nut.
40. Do not install oil seal at this stage.
41. Tighten pinion flange nut until force required to rotate pinion is 3.0 Nm if new bearings are installed.
- This will pre-load bearings to check pinion height dimension.
NOTE: If using original bearings, pre-load, figure is 1.5 Nm.
Drive Pinion Markings
NOTE: Markings on end face adjacent to serial number are of no relevance to servicing.
42. Figures marked on end face opposite to serial number show in thousandths of an inch, deviation from nominal, required to set pinion.
- Pinions marked plus (+) must be set below nominal.
- Pinions marked minus (-) must be set above nominal.
- Unmarked pinions must be set at nominal.
43. Nominal setting dimension is represented by setting gauge block LRT-54-503.
- Referenced from pinion end face to bottom radius of differential bearing bore.
Drive Pinion Adjustment
44. Ensure pinion end face is free of burrs around etched markings.
45. Remove keep disc from magnetized base of dial gauge tool.
46. Place dial gauge and setting block on surface plate.
- Zero dial gauge trace pin on setting block.
NOTE:
^ Setting block has three height, settings marks.
^ Use 39.50 mm setting mark for this differential.
47. Position dial gauge centrally on pinion end face, register on lowest point on one differential bearing bore.
- Note dial gauge measurement from zeroed setting.
48. Repeat on other bearing bore.
- Add readings then halve sum to obtain mean reading.
- Note whether trace pin has moved up or down from zero.
- A. Where trace pin moves down, reading is equal to thickness of shims to remove, to bring pinion to nominal.
- B. Where trace pin moves up, reading is equal to thickness of shims to add, to bring pinion to nominal.
Pinion Height Shim Table:
49. Before adjusting shim thickness: check pinion face marking.
- If a plus (+) figure, subtract in thousandths of an inch from shim thickness figure.
50. If pinion has a minus (-) figure, add amount to shim thickness figure.
- Adjust shim thickness under pinion head bearing race as necessary.
Metric To Inch Conversion Table:
NOTE: Where dial indicator is metric, conversion must be made to inches when measuring and selecting shims.
51. Recheck pinion height setting.
- If setting is correct, mean reading of dial gauge will agree with figure marked on pinion end face.
- For example, with end face marking of +3, dial gauge reading should indicate pinion is +0.003 in.
Bearing Pre-load Adjustment
52. Remove the pinion flange, pinion, outer bearing and spacer.
53. Slide new shim, of same thickness as original (bearing pre-load) into position on pinion shaft.
- If installation a new shim use thickest shim 2.155 mm.
54. Install pinion to pinion housing and install outer bearing and spacer (front differential only).
55. Install driving flange, washer and nut.
56. Do not install oil seal at this stage.
Pinion Preload Shim Table:
57. Tighten pinion flange nut to 130 Nm.
- Force to rotate pinion shaft is 3.0 Nm using new bearings.
- Change shim as necessary to obtain reading.
- Thicker shim will reduce pre-load.
- Thinner shim will increase pre-load.
NOTE: If using original bedded in bearings, pre-load figure is 1.5 Nm.
58. Remove pinion flange.
Installing Pinion Oil Seal
59. Coat outer diameter of seal with grease.
- Install seal lip side leading flush with end face of housing using tool LRT-51-001.
Install pinion drive flange - FRONT AXLE DIFFERENTIAL ONLY
60. Lubricate seal lips with axle oil.
61. Install spacer and pinion drive flange to differential.
62. Secure flange with washer and nylon nut.
- Tighten to 130 Nm.
Install pinion drive flange - REAR AXLE DIFFERENTIAL ONLY
60. Lubricate seal lips with axle oil.
61. Install pinion drive flange to differential and secure with washer and nylon nut.
- Tighten to 130 Nm.
62. Coat centralizing peg with Loctite 601 or 638 and install over pinion retaining nut in drive flange.
CROWN WHEEL/PINION BACKLASH ADJUSTMENT
63. Place differential housing in pinion housing.
64. Install bearing caps and partly tighten bolts.
65. Install bearing adjusting nuts.
66. Mesh crown wheel to pinion.
- Using service tool LRT-54-508 loosen left bearing adjuster nut.
67. Tighten right nut until crown wheel/pinion backlash is just removed.
68. Tighten left nut until it contacts bearing.
- Continue turning until a backlash of 0,10 to 0,17 mm is met.
- DO NOT loosen right nut otherwise bearing preload will be affected.
69. Install locking fingers and roll pins.
- Align locking finger with a slot.
70. Evenly tighten bearing cap bolts to 90 Nm.
71. Recheck crown wheel/pinion backlash.
72. Lubricate bearings and gears.