Differential: Service and Repair

NOTE: Whenever a differential bearing is removed, a new differential bearing must be installed.

1. Remove the roll pin.
2. Remove the differential pinion shaft.





3. Remove the differential pinion gears and differential pinion thrust washers by rotating them out of the differential.
4. Remove the differential side gears and differential side gear thrust washers.





5. Use Gear and Pulley, Pull D80L-522-A Step Plate Adapter D80L-630-3 (part of D80L-630-A), Bearing Pulling Attachment D84L-1123-A, and the Legs from Push-Pull Set D80L-927-A or equivalents to remove the rear differential bearing (speedometer drive gear end).
6. Remove the speedometer drive gear.





7. Use Differential Bearing Cone Remover/Replace T77F-4220-B3 and Step Plate Adapter D80L-630-3 (part of D80L-630-A) or equivalent to remove the front differential bearing (ring gear end).
8. Check for damaged or worn gears.
9. Check for a cracked or damaged transaxle case.





10. Make sure that movement within the differential is less than 0.10 mm (0.004 inch) in all directions. If movement is greater than 0.10 mm (0.004 inch) in any direction, determine whether the differential pinion shaft or trans axle case is causing the concern. Replace as necessary.





11. Check the differential side gear and differential pinion shaft backlash as follows:
a. Install the LH front wheel driveshaft and joint and RH front wheel driveshaft and joint into the differential.
b. Support the LH front wheel driveshaft and joint and RH front wheel driveshaft and joint on V-blocks.
c. Use Dial Indicator with Bracketry T50T-4201-C or equivalent to measure the backlash of both differential pinion gears. If the backlash is more than allowable, replace the differential as an assembly.
^ The standard backlash measurement is between 0.05-0.15 mm (0.0020-0.0059 inch).
^ The maximum backlash measurement is 0.50 mm (0.020 inch).





ASSEMBLY
1. Use either Driver Handle T80T-4000-W or a press, and Differential Bearing Cone Replace T88C-77000-EH to install the speedometer drive gear and rear differential bearing.





2. Use either Driver Handle T80T-4000-W or a press, and Differential Bearing Cone Replace T88C-77000-EH and install the front differential bearing (ring gear end).
3. Install the differential pinion thrust washers and differential pinion gears.
4. Install the differential pinion shaft.
5. Install the roll pin, then crimp it so it cannot come out of the gear case.
6. Install the differential side gear thrust washer and differential side gears.