DIFFERENTIAL CASE COMPONENTS MX 99 E350 MANUAL TRANSAXLE DIFFERENTIAL CASE FRONT DIFFERENTIAL PINION THRUST WASHER
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1 DIFFERENTIAL CASE TRANSMISSION E350 MANUAL TRANSAXLE COMPONENTS 99 THRUST WASHER FRONT NO. 1 DIFFERENTIAL SIDE GEAR THRUST WASHER FRONT DIFFERENTIAL SIDE GEAR FRONT DIFFERENTIAL SIDE GEAR FRONT NO. 1 DIFFERENTIAL PINION FRONT NO. 1 DIFFERENTIAL SIDE GEAR THRUST WASHER THRUST WASHER STRAIGHT PIN FRONT DIFFERENTIAL RING GEAR FRONT DIFFERENTIAL CASE N*m (kgf*cm, ft.*lbf) : Specified torque SPEEDOMETER 106 (1,080, 78) DRIVE GEAR FRONT DIFFERENTIAL RING GEAR SET BOLT C113292E03
2 100 REMOVAL 1. REMOVE SPEEDOMETER DRIVE GEAR (a) Remove the drive gear from the front differential C083559E01 Matchmark 2. REMOVE FRONT DIFFERENTIAL RING GEAR (a) Put matchmarks on the ring gear and the differential C083560E02 (c) Remove the 16 bolts. Using a plastic-faced hammer, tap out the differential C083561E01 C083562E01 3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH (a) Hold the differential pinion to the front differential case side. Using a dial indicator, measure the differential side gear backlash. Standard backlash: 0.10 to 0.20 mm ( to in.) If the backlash is out of specification, install proper side gear thrust washers. SST 4. REMOVE STRAIGHT PIN (a) Using SST and a hammer, unstake the staked part of the differential SST C092887E02
3 101 Using a pin punch and a hammer, tap out the straight pin from the differential C083564E01 5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION (a) Remove the No. 1 differential pinion shaft from the differential C083565E01 6. REMOVE FRONT DIFFERENTIAL SIDE GEAR (a) Remove the 2 differential pinions, 2 differential pinion thrust washers, 2 differential side gears and 2 No. 1 differential side gear thrust washers from the differential HINT: Remove the 2 pinion thrust washers and side gear thrust washers while turning the differential pinion. C083566E01 C083566E02 INSTALLATION 1. INSTALL FRONT DIFFERENTIAL SIDE GEAR (a) Coat the rotating surfaces of the differential side gears with gear oil. Install the 2 differential side gear thrust washers to the 2 differential side gears. (c) Install the 2 differential side gears, 2 differential pinions and 2 differential side gear thrust washers to the differential HINT: Install the 2 differential pinions with the differential pinion thrust washers while turning the differential pinion.
4 INSTALL FRONT NO. 1 DIFFERENTIAL PINION (a) Coat the rotating surface of the No. 1 differential pinion shaft with gear oil. Install the No. 1 differential pinion shaft to the differential case so that the hole for the differential pinion shaft straight pin is aligned with the hole in the differential C083565E02 3. INSTALL STRAIGHT PIN (a) Using a pin punch and a hammer, tap in the differential pinion shaft straight pin to the differential C083567E01 Using a chisel and hammer, stake the differential case hole. C083568E01 C083562E02 4. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH (a) Hold the differential pinion to the differential case side. Using a dial indicator, measure the differential side gear backlash. Standard backlash: 0.10 to 0.20 mm ( to in.) If the backlash is out of specification, select another differential side gear thrust washer and adjust it. Standard thrust washer thickness Part No. Mark Thickness mm ( in.) mm ( in.) mm ( in.) mm ( in.)
5 INSTALL FRONT DIFFERENTIAL RING GEAR (a) Clean the contact surface of the differential case and differential ring gear. Using a heater, heat the differential ring gear to 90 to 110 C (194 to 230 F). (c) After the moisture on the ring gear has completely evaporated, quickly install the differential ring gear to the differential C094319E02 Matchmark (d) Aligning the matchmarks, quickly install the front differential ring gear to the differential case with the 16 bolts. Torque: 106 N*m (1,080 kgf*cm, 78 ft.*lbf) C070796E02 6. INSTALL SPEEDOMETER DRIVE GEAR (a) Install the drive gear to the differential C070795E01 C068517E01 INSPECTION 1. INSPECT THRUST WASHER (a) Using a micrometer, measure the thickness of the thrust washer. Minimum thickness: 0.9 mm (0.035 in.) If the thickness is less than the minimum, replace the thrust washer. 2. INSPECT FRONT NO. 1 DIFFERENTIAL PINION (a) Using a micrometer, measure the outside diameter. Minimum diameter: mm ( in.) If the outside diameter is less than the minimum, replace the No. 1 differential pinion shaft. C068518E01
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