Rear Differential: Inspection: Notes

Wash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary.

1. Crown gear and drive pinion
   • If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment.
   • If crack, score, or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like.
2. Side gear and pinion mate gear
   • Replace if crack, score, or other defects are evident on tooth surface.
   • Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like.
3. Bearing

   Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident.

4. Thrust washers of side gear and pinion mate gear

   Replace if seizure, flaw, abnormal wear or other defect is evident.

5. Oil seal

   Replace if deformed or damaged, and at every disassembling.

6. Differential carrier

   Replace if the bearing bores are worn or damaged.

7. Differential case

   Replace if its sliding surfaces are worn or cracked.

8. Companion flange

   Replace if the oil seal lip contacting surfaces have flaws.

9. Rear differential oil temperature sensor (Turbo model for Europe)

   If the results of the following inspections are not satisfactory, replace rear differential temperature sensor.

   1. At room temperature, check for continuity between the sensor terminal and body.
   2. Soak the sensor in oil, then raise the oil temperature. Check that the continuity is cut off when the oil temperature is between 144°C (291°F) and 156°C (313°F). Then, check that the continuity resumes by the time the oil temperature drops to 135°C (275°F).
   CAUTION: The oil is hot, so be careful not to burn yourself when inspecting.