Differential Case ASSY (MTM): Overhaul

1. Remove the speedometer drive (MTM) gear from the front differential case.

Fig 1: Removing Speedometer Drive Gear

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1. Put matchmarks on the front differential ring gear and front differential case.
   Fig 2: Putting Matchmarks

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2. Remove the 8 bolts. Using a hammer, remove the front differential ring gear.

Fig 3: Removing Bolts

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1. Fixing the front differential pinion from the front differential case side. Using a dial indicator, measure the backlash of the front differential side gear.

   Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

Fig 4: Inspecting Front Differential Side Gear Backlash

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If backlash is out of specification, install proper side gear thrust washers.

1. Using a chisel and a hammer, loosen the staked part of the front differential case.
   Fig 5: Loosening Staked Part

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2. Using a pin punch (phi 3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.

Fig 6: Removing Front Differential Pinion Shaft Straight Pin

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1. Remove the front differential pinion shaft No.1 from the front differential case.

Fig 7: Removing Front Differential Pinion Shaft

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1. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential side gear thrust washers and 2 front differential side gears from the front differential case.

HINT:

Turning the front differential pinion, remove the 2 pinions and 2 side gears.

Fig 8: Removing Front Differential Side Gear

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1. Using a micrometer, measure the thickness of the front differential pinion thrust washer.

   Minimum thickness: 0.92 mm (0.0362 in.) 

If the clearance is below the minimum, replace the front differential pinion thrust washer.

Fig 9: Measuring Thickness

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1. Using a micrometer, measure the outer diameter of the front differential pinion shaft No.1.

   Minimum outer diameter: 16.982 mm (0.6686 in.) 

If the outer diameter is less than the minimum, replace the front differential pinion shaft No.1.

Fig 10: Measuring The Outer Diameter

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1. Coat the sliding and rotating surface of the 2 front differential side gears with gear oil.
2. Install the 2 front differential side gear thrust washers to the 2 front differential side gears.
   Fig 11: Installing Front Differential Side Gear

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   HINT:

   Install the front differential side gear thrust washer that has the same thickness as the removed one.

3. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential side pinion thrust washers to the front differential case.

HINT:

Turning the front differential side gear, align the 2 front differential pinions with the hole of the front differential case.

1. Coat the rotating surface of the front differential pinion shaft No.1 with gear oil.
2. Install the front differential pinion shaft No.1 to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.

Fig 12: Installing Front Differential Pinion Shaft

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1. Fixing the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

   Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

If the backlash is out of specification, replace the side gear thrust washer.

Fig 13: Adjusting Front Differential Side Gear Backlash

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HINT:

• Because the thrust washer does not have any identification mark, measure the front thickness with a micrometer to select a proper thrust washer.
• Select washers that has the same thickness as both the right and left.

1. Using a pin punch (phi 3 mm) and a hammer, install the front differential pinion shaft straight pin to the front differential case.
   Fig 14: Installing Front Differential Pinion Shaft Straight Pin

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2. Using a chisel and a hammer, stake the front case hole.

Fig 15: Staking Front Case Hole

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1. Clean the contact surface of the front differential case and front differential ring gear.
2. Using a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F)
3. After the moisture on the ring gear has completely evaporated, quickly install the front differential ring gear to the front differential case.
   Fig 16: Heating Front Differential Ring Gear

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4. Align the both matchmarks, quickly install the 8 bolts with the front differential ring gear to the front differential case.

   Torque: 77 N.m (789 kgf.cm, 57 ft.lbf) 

Fig 17: Aligning Both Matchmarks

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1. Install the speedometer drive (MTM) gear to the front differential case.

Fig 18: Installing Speedometer Drive Gear

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