Differential Backlash Adjustment: Notes

Secure the differential in a vice.

Fig 1: Securing Differential In Vice
Assemble the drive shaft and the joint shaft to the differential.

Fig 2: Assembling Drive Shaft And Joint Shaft To Differential
Set the dial gauge with the measuring probe attached perpendicularly to the area shown in the figure for the pinion gear.

Fig 3: Setting Dial Gauge With Measuring Probe Attached Perpendicularly
Measure the side gear on the joint shaft side and the pinion gear backlash using the following procedure:
1. Affix the side gear on the joint shaft side by hand.
  
  Fig 4: Measuring Side Gear On Joint Shaft Side And Pinion Gear Backlash
2. Measure the backlash by moving the pinion gear with the dial gauge that has been set and determine measured value A.
  CAUTION:
  - Because a difference occurs in the backlash measurement value if the secured side gear moves, move the pinion gear by hand so that the secured side gear does not move.
  Fig 5: Measuring Backlash By Moving Pinion Gear With Dial Gauge
3. Measure the opposite of the pinion gear backlash in the same way as procedure 2 in Step 4 and determine measured value B.
4. Calculate the average value of measured values A and B using the following formula and determine the backlash measurement value on the joint shaft side of the pinion gear.
  - (Measured value A + measured value B)/2 = backlash measurement value on joint shaft side
    
    Fig 6: Measuring Opposite Of Pinion Gear Backlash
Measure the side gear on the drive shaft side and the pinion gear backlash using the following procedure:
1. Affix the side gear on the drive shaft side by hand.
  
  Fig 7: Measuring Side Gear On Drive Shaft Side And Pinion Gear Backlash
2. Measure the backlash by moving the pinion gear that the dial gauge has been set and determine measured value C.
  CAUTION:
  - Because a difference occurs in the backlash measurement value if the secured side gear moves, move the pinion gear by hand so that the secured side gear does not move.
  Fig 8: Measuring Backlash By Moving Pinion Gear
3. Measure the opposite of the pinion gear backlash in the same way as procedure 2 in Step 5 and determine measured value D.
4. Calculate the average value of measured values C and D using the following formula and determine the backlash measurement value on the drive shaft side of the pinion gear.
  - (Measured value C + measured value D) / 2 = backlash measurement value on drive shaft side
    
    Fig 9: Measuring Opposite Of Pinion Gear Backlash
Verify that the backlash on the joint shaft and drive shaft sides is within the specification.
Differential pinion gear backlash

Specification: 0.05-0.15 mm {0.002-0.005 in}
- If the measured backlash for each is within the specification, the thrust washer thickness is the same as the removed one and there is no problem, therefore the "DIFFERENTIAL BACKLASH ADJUSTMENT" procedure is finished.
- If not within the specification, perform "Thrust Washer Selection Calculation". (See THRUST WASHER SELECTION CALCULATION .)
- If it exceeds the specification even when a 0.95 mm {0.037 in} thick thrust washer is used, replace the differential case.