F300-DF-Front_and_Rear_Differential-Part1

F300-DF-Front_and_Rear_Differential-Part1.pdf

PART 1 - PART 2 - PART 3 - PART 4 - PART 5 - PART 6 - PART 7

FRONT/ REAR

DAIHATSU

GENERAL DESCRIPTION DF -2 IN-VEHICLE REPLACEMENT PROCEDURES

FOR OIL SEAL (FRONT) DF -3 TROUBLE SHOOTING

COMPONENTS ..

REMOVAL PRE-INSPECTIO

DISASSEMBLY _ INSPECTION A$SEMBLY INSTALLATION

FRONT DIFFERENTIAL

IN-VEHICLE REPLACEMENT PROCEDURES

FOR OIL SEAL (REAR) DF-29 REAR DIFFERENTIAL COMPONENTS DF-32 REMOVAL DF-33

DIFFERENTIAL

PRE-INSPECTION DISASSEMBLY INSPECTION

DF-38 ASSEMBLY

INSTALLATION DF-48

L.S.D. (Limited Slip Diflerential)

COMPONENTS DF-50 REMOVAL DF-51

DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION

FRONT/REAR DIFFERENTIAL

GENERAL DESCRIPTION

DIFFERENTIALS

The differential at both the front and rear employs a hypoid gear type. In the case ot ordinary differentials, there will be cases where the traction is lost when the wheel at one side is rotating idly on muddy roads or during a rapid cornering. To solve those problems, an 1..S.D. (Limited Slip Differential) is available as optional equipment on the rear differential.

Front differential W

Difiverenilal specifications

Final reduction gear ration W 7

V 7

5.285

5.265

Number of teeth

Differential fins; QW I ourerdiamaef 7

170 180

150

1 | Number of teeth

Hypoid pinion

Differential side gear Numbef Dfleeih K

Number of diherentiar pinion teeth

Pinion shaft oder diameter

FRONTIREAR DIFFERENT!AL

0 IN-VEHICLE REPLACEMENT

PROCEDURES FOR OIL SEAL FRONT FRONT DIFFERENTIAL (Drive Shaft Oil SEBI) REMOVAL 1. Remove the drive shaft from the front dmerential. (Refer

front axle and suspension). 2. Remove the oil seal at the drive shaft installation section, in

conjuction with the lollowing SSTS.

SST: 09517-87602-000 09308-1001 O-OOO

NOTE: - Never reuse the removed oil seal.

1. Drive the oil seal at the drive shafi installation section into

position, using the following SST.

SST: 09517-87601 -000

NOTE:

. Apply the lithium base multi purpose grease to the oil

seal lip section, prior to install.

2. install the drive shaft to the from differentiai.

(Refer front axle and suspension section).

FFIONT DIFFERENTIAL (Drive Piniun Oil Seal)

REMOVAL 1, Remove the propeller shaft.

CAUTION: - Prior to the removal, be sure to put a mating mark. Il this operaiion should fail to be performed, the propeller shaft may emit abnormal noise or vibration during the running.

(Right sine)

/LL

2. Release the staking ofthe lock nut of the drive pinion.

NOTE: o Insufficient releasing of the staking of the iock nut may cause the threaded portion of the drive pinion to be damaged.

Remove the lock nut and plate washer using the following

SST.

SST: 09330-00021 -000

NOTE: o Never reuse the removed lock nut.

4. Remove the companion flange

5. Remove the oil seai, using the following SST.

SST: 0951 7-87602-000

ENSTALLATION 1. Drive the oil seal into position, using the foliowing SST.

SST: 09517-87602-000

W :_ NOTE: _ 1%; Apply the lithium base multi purpose grease to the oil

seal lip seciion, prior to install. "Q 0

f-09330-00021000

2. Install the companion flange. 7

Install the Dlate washer and a new lock nur, Ti

W%0-DFD12

plate washer and a new lock nut. Tighten th

Tightening Torque:

157.0 - 196.0 Nm (16.0 - 20.0 kg!-m)

When staking the lock nut, point a suitable siaki

, point a suitable staking tool toward the drive pinion axis center and stake the lock nut securely, as shown in the figure below. (Poor staking may cause abnormal noise.)

(1) E

(1) Suitable staking tool (2) New nut (3) Drive pinion A (2)

While installing the propeller shaft, align the mating marks pu! during the removal with each other. I

er. If this operation should fail to be performed correctly, the

propeller shaft may emit abnormal noise or vibration during the running.

5. After the propeller shaft has been installed, aonl

, apply black paint to the exposed machined surface (slant line section in the riuht fi

e right figure).

DF-5

FRONTIHEAFI DIFFERENTIAL

TROUBLE SHOOTING

Symptoms

Possible causes Checking points

Abnormal noise

Differential tapping noise

Improper backlash of hypoid gear Check backiash between drive pinion and

ring gear

Differential ciunk noise

The Same above

The same above

Differential clonking noise

Drive pinion improperly adjusted

l Check preload. Check bacmasn.

Differential chuckle noise

Abnormal wear in side gear and differential case

Check side gear.

Check differential case.

Differemiai noise

Improper tooth contact at hypoid gear

ring gear.

Check tooth contact between drive pinion and

1 Oil leakage

OH leakage at dilferential earner instahation section

housing.

1 Check installation surface with rear axle

FRONT DIFFERENTIAL

COMPONENTS

29.4 f 49.0 (3.0 - 5.0)

39.2 - 58.8 (4.0 - 6.0)

39.2 - 53.9

(4.0 - 5.5)

Differential pinion thrust washer Differential pinion Differentiai pinion shaft Differential side gear Difierantiai side gear thrust washer Slotted pin Tapered roller bearing (inner G Outer) Shim Differential drive pinion bearing spacer Shim Tapered roller bearing (Inner 8. Outer)

18.5 - 88.3 8.0 - 9.0)

Oil seal Differential bearing adiusting nut Bearing Differential drive pinion Differential ring gear Differential case SIA Boli Differential carrier support stopper Spacer <21) Differential mounting lower insulator Differential carrier support BKT Differential mounting upper

insulator Drive pinion companion flange SIA Dust defiector

39,2 - sas (40 - 5.5)

I: : Tighlening torque Unit : N-m if : Non-reusable parts ,f : Selection parts

Oil seal Differential carrier SIA Bearing cap Bolt Differential bearing adjusting nut

iock Difierentiai carrier gasket Front axle housing cover SIA Gasket G) Drain plug Breather hose GB Clip Union Differentia\ carrier support BKT Differ:-:ntia\ carrier support BKT

FRONTIREAR DIFFERENTIAL

REMOVAL '

.Jack up the vehicle and support it with safety stands, (As iacking-up points and support points for safety

for the jacking-up points and support points for safe stands. refer GI-section.)

Remove the front wheel. Drain the oil from the differential.

Remove the engine undercover by removing the four bolts

Remove the front drive shafts and stabilizer. (Refer Front Axle & Suspension section)

6. Disconnect the breather hose by removing the clamp.

NOTE:

Before the propeller shaft is removed, be sure to put a

mating mark as a guide during me installation.

Hold the propeller shaft in a suspended state. X ; ‘k W

Remove the differential rnountinu. rnlanuiaem ,... , , -_ f

Temporariiy loosen the three bolts of the differential mount

ing brackets.

Support the differential with a transmission jack or the like. Remove the differential from the chassis frame by removing the three bolts ofthe differential mounting brackets. Remove the differential from the vehicle, while supporting the differentiai with a jack.

Remove the ten bolts of the front axle housing cover sub- assembly.

FRONT/REAR DIFFERENTIAL

15. Remove the three differential carrier support brackets from

the differential by removing the three bolts.

16. Install the differential assembly removed from the vehicle

on the following SSTS.

SSTs: 09219-87202-000 09458-87601 -O00

0 Prior to the disassembling of the differential, be sure to check the following items and reoord ihe values. (These values are used as reference which assures the correct assembling.)

1. Ring gear runout check

Measure the runout at the back surface of the ring gear, using a dial gauge.

Allowable Limit: 0.1 mm

Il the runout exceeds the allowable limlt, replace the final gear as a ser.

DF-10

(Front Side) cv:

(Len side)

PRE-INSPECTION

NOTE;

F300-DF-Front_and_Rear_Differential-Part1

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