Inspection of Differential Case
1. MEASURE DIFFERENTIAL LEFT CASE
Using a cylinder gauge, measure the inner diameter of the differential left case bushing.
Standard clearance: A 111.000 - 111.035 mm
(4.3701 - 4.3714 in.)
B 90.500 - 90.535 mm
(3.5630 - 3.5644 in.)
Maximum diameter: A 110.060 mm (4.3331 in.)
B 90.560 mm (3.5653 in.)
2. MEASURE DIFFERENTIAL NO.2 CASE
Using a micrometer, measure the outer diameter of differential No.2 case.
Standard clearance: A 110.929 - 110.964 mm
(4.3673 - 4.3686 in.)
B 90.429 - 90.464 mm
(3.5606 - 3.5615 in.)
C 35.000 - 35.025 mm
(1.3778 - 1.3789 in.)
Minimum diameter: A 110.850 mm (4.3642 in.)
B 90.350 mm (3.5571 in.)
Maximum diameter: C 35.030 mm (1.3791 in.)
3. MEASURE CONICAL SPRING WASHER
Using a caliper, measure the height of the conical spring washer.
Standard height:
Left conical spring washer
2.60 - 2.80 mm (0.102 - 0.110 in.)
Right conical spring washer
1.70 - 1.90 mm (0.067 - 0.075 in.)
Minimum height:
Left conical spring washer
2.50 mm (0.098 in.)
Right conical spring washer
1.60 mm (0.063 in.)
4. (Transmission Case Side)
IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE
a. Using a screwdriver, remove the oil seal.
b. Remove the transmission oil baffle.
c. Using a brass bar and hammer, drive out the bearing outer race lightly and evenly.
d. Remove the adjust shim.
e. Install the adjust shim.
HINT: First select and install a shim of lesser thickness than before.
f. Using SST and a press, install the tapered roller bearing outer race.
SST 09316-60010 (09316-00010, 09316-00040)
g. Install the transmission oil baffle.
HINT: Install the transmission oil baffle projection into the case side cutout.
h. Using SST, drive in a new oil seal.
SST 09223-15010
i. Coat the lip of the oil seal with MP grease.
5. (Transfer Case Side)
IF NECESSARY, REPLACE TAPERED ROLLER BEARING OUTER RACE
a. Using a brass bar and hammer, drive out the bearing outer race lightly and evenly through the cut-out portion on the transaxle case.
b. Using SST and a press, install the tapered roller bearing outer race.
SST 09316-60010 (09316-00010, 09316-00040)