92Rocky-DF-Front_and_Rear_Differential-Part1
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PART 1 - PART 2 - PART 3 - PART 4 - PART 5 - PART 6 - PART 7
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DAIHATSU Rocky
FRONT/REAR DIFFERENTIAL
GENERAL DESCRIPTION DF -2 IN-VEHICLE REPLACEMENT PROCEDURES
FOR OIL SEAL (FRONT) DF -3 TROUBLE SHOOTING DF -6 FRONT DIFFERENTIAL
COMPONENTS DF -7 REMOVAL DF -8 PRE-INSPECTION DF-10
DISASSEMBLY DF-12 INSPECTION DF-15 ASSEMBLY DF-16 INSTALLATION DF-26 IN-VEHICLE REPLACEMENT PROCEDURES
FOR OIL SEAL (REAR) DF-29 REAR DIFFERENTIAL COMPONENTS DF-32 REMOVAL DF-33 PRE-INSPECTION DF-34 DISASSEIVIBLY DF-35 ENSPECTION DF-38 ASSEMBLY DF-39 iNSTAl_LATlON DF-49 L.S.D, (Limited Slip Differential)
COMPONENTS DF-51 REMOVAL DF-52 DISASSEMBLY DF-52 INSPECTION DF-55 ASSEMBLY DF-55 INSTALLATION DF'-61
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FRONT/REAR DIFFERENTIAL
GENERAL DESCRIPTION
The differential at both the front and rear employs a hypoid gear type.
In the case of 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 L.S.D. (Limited Slip
Differential) is avaiiabie as optional equipment on the rear differential.
Front differential Rear differential
Differential specifications
K' d
in Front Item
Rear
Rear (LSD)
Final reduction gear ration 5.285
5.285
5.285
Number of teeth 37
Differential ring gear Outer diameter mm (imh) 170 (6.69)
180 (7.09)
180 (7.09)
Gear type I-lypoid gear
HYDOICI gear
Number of teeth 7
7
7
Final reduction gear Qufer diameter mm (inch) 55 (2.17)
Gear type Hypoid pinion
14
14
_ _ _ Number of teeth 18 Drfferentlal s1de gear
Number of inner spline teeth 25
27
27
Number of differential pinion teeth 10
10
10
Pinion shafc outer diameter mm (inch) 0516 (0.63)
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FRONT/REAR DIFFERENTIAL
PROCEDURES FOR OIL SEAL FRONT FRONT D|FFERENT|AL (Drive shaft cn seal) REMOVAL
1. Remove the drive shaft from the front differential. (Refer
front axle and suspension section)
INSTALLATION
NOTE: v Apply the lithium base multi purpose grease to the oil
seal lip section, prior to install.
2. Install the drive shaft to the front differential.
(Refer front axle and suspension section).
(Righf Side) 09517-87601-060
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FRONT DIFFERENTIAL (Drive Pinion Oil Seal)
REMOVAL 1. Remove the propeller shaft.
CAUTION: 0 Prior to the removal, be sure to put a mating mark. If this operation should fall to be performed, the propeller shaft may emit abnormal noise or vibration during the running.
(Right side)
Mating mark
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FRONT/REAR DIFFERENTIAL
2. Release the staking of the lock nut ofthe drive pinion.
NOTE:
~ Insufficient releasing of the staking of the lock nut may cause the threaded portion of the drive pinion to be damaged.
Hemove the lock nut and plate Washer using the following
SST.
WRUQO-DFO09 5. Remove the oil seal, using the following SST.
SST: 09308-10010-OOO
Drive the oil seal into position, using the following SST.
SST: 09517-87601-OOO
NOTE:
o Apply the lithium base multi purpose grease to the oil
seal lip section, prior to install.
09308-10010
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FRONT/REAR DIFFERENTIAL
3. Install the plate washer and a new lock nut. Tighten the nut, , / F1
using the following SST. Q
NOTE:
(2) New nut (3) Drive pinion
0 When staking the lock nut, point a suitable staking tool toward the drive pinien axis center and stake the lock nut securely, as shown in the figure below. (P99/reieking may cause abnormal noise.)
4. Install the propeller shaft.
CAUTION: 0 While installing the propeller shaft, align the mating marks put during the removal with each other. If this operation should fail to be performed correctly, the propeller shaft may emit abnormal noise or vibration during the running. Tightening Torque: 6.0 - 8.0 kg-m
(43.4 - 57.9 ft-lb, 58.8 - 78.5 N-m)
5. After the propeller shaft has been installed, apply black paint to the exposed machined surface (slant line section in the right figure).
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FRONT/REAR DIFFERENTIAL
TROUBLE SHOOTING
Symptoms
Possible causes
Checking points
Abnormal noise
Differential tapping noise
Improper backlash of hypoid gea
ring gear.
r Check backlash between drive pinion and
Differential clunk noise
The same above
The same above
Differential cionking noise
Drive pinion improperly adjusted
Check preload. Check backlash.
Differential chuckle noise
Abnormal wear in side gear and differential case
Check side gear. Check differential case.
Differential noise
Improper tooth Contact at hypoid gear
ring gear.
Check tooth Contact between drive pinion and
OH leakage
Check each oil seal.
Oil leakage at differential carrier installation section
housing.
Check installation surface with rear axle
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FRONT/REAR DIFFERENTIAL
FRONT DIFFERENTIAL
COMPONENTS
Differential pinion thrust washer ® Differential pinion Differential pinion shaft Differential side gear Differential side gear thrust washer
Tapered roller bearing
(Inner & Outer) Shim
Differential drive pinion bearing
Tapered roller bearing (Inner & Outer)
16,0 - 20.0
Oii seal Differential bearing adjusting nut Bearing Differential drive pinion Differential ring gear Differential case S/A Bolt Differential carrier support stopper Spacer Differential mounting lower insulator Differential _carrier support BKT Differential mounting upper insulator Drive pinion companion flange S/A Dust cieflector
Drain plug Breather hose
4.0 - 5.5
39.8, 39.2 - 53.9)
Tightening torque kg-m (ft-Ib, Non-reusable parts Selection parts
Differential carrier S/A Bearing cap
Differential bearing adjusting nut
Differentiai carrier gasket Front axle housing cover S/A
Differential carrier support BKT Differential carrier support BKT
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7. Remove the propeller shaft.
_ wi/ 8. Hold the propeiier shaft in a suspended state.
R
9. Remove the differential mounting.
FRONT/REAR DIFFERENTIAL
REMOVAL
4. Hemove the englne undercover by removmg the Tour bolts. J 5. Remove the front drive shafts and stabilizer.
6. Disconnect the breather hose by removing the clamp.
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Support the differential with a transmission jack or the like. Remove the differential from the chassis frame by removing the three bolts of the differential mounting brackets. Remove the differential from the vehicle, while supporting the differential with a jack. _
Remove the ten bolts of the front axle housing cover sub- assembly.
Remove the front axle housing cover subassembly, using the standard tool of the scraper. NOTE: o Never reuse the removed gasket.
FRONT/REAR DIFFERENTIAL
EL
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FRONT/REAR DIFFERENTIAL
15. Remove the three differentia! carrier support brackets from Side) E
the differential by removing the three bolts. Q
16. Install the differential assembly removed from the vehicle 09548_872O1_O00
on the following SSTS
PRE-INSPECTION
NOTE: o Prior to the disassembling of the differential, be sure to check the following items and record the 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 (0.004 inch)
If the runout exceeds the allowable limit, replace the final gear as a set.
DF-10
(Right side)
