Diferencial FUSO
Diferencial FUSO
Diferencial FUSO
com/
REDUCTION AND DIFFERENTIAL
Disassembly sequence
1 Lock plate 6 Differential (See later sections.)
2 Side bearing nut 7 Pinion (See later sections.)
3 Bearing cap 8 Shim
4 Side bearing outer race 9 Differential carrier
5 Side bearing inner race
CAUTION
• Keep side bearings, which have been removed, separately from each other and ensure that the correct
one is placed at the right place at installation.
• Be sure to replace the bearing cap, differential carrier and bolts as a differential carrier set.
• Be sure to replace the reduction gear of the differential and reduction pinion of the pinion as a reduction
gear set.
NOTE
• Record the number and thickness of shims to use them as reference at assembly.
Assembly sequence
Follow the disassembly sequence in reverse.
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REDUCTION AND DIFFERENTIAL
Special tools (Unit: mm {in.})
Mark Tool name and shape Part No. Application
Differential working
base assembly
H J K L
11 20 40 φ11
{0.43} {0.79} {1.57} {0.43}
Adapter
Removal of side bearing inner
A B MB999076 race (to be used in combination
with commercial bearing puller)
φ45 φ59
{1.77} {2.32}
Bearing installer
Installation of side bearing inner
A B MH061748
race
φ80 φ70
{3.15} {2.76}
Bearing retainer
guide pin
Installation of pinion (two pieces
MH061745
are used)
A B C D
18 85 12
M12 × 1.25
{0.71} {3.35} {0.47}
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REDUCTION AND DIFFERENTIAL
Inspection: Tooth contact of reduction gear
• Apply red lead to three to four teeth at three equally spaced
points of the reduction gear.
• Turn the reduction gear several times to check for tooth contact.
Removal procedure
Removal: Side bearing inner race
Removal: Pinion
• Screw two bolts evenly into the pinion removal screw holes to
remove the pinion.
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Adjustment procedure
Adjustment: Pinion
• Perform the following steps to adjust A, B and C within the spec-
ified dimensions.
• Calculate shim thickness D by using the following formula based
on the machining error data stamped on pinion assembly and
differential carrier.
• Formula:
D = 0.5 {0.020} – a + b + c
a = Deviation from standard dimension A
b = Deviation from standard dimension B
c = Deviation from standard dimension C
Unit: mm {in.}
Standard
Location How to calculate deviation
dimension
0.5
Shim thickness –
{0.020}
A numeral, multiplied by 100, is stamped
203
A {7.99}
on the outer periphery of the flange of the
differential carrier.
157 A numeral is stamped on the top of the
B {0.18} pinion assembly.
Measure deviation from dimension C us-
46.5 ing a dial gauge. Taking measurement is
C {1.8} usually not feasible and assume a value
from 0 to 0.2 mm.
Installation procedure
Installation: Pinion
• Apply sealant to the pilot bearing mounting surface of the differ-
ential carrier.
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REDUCTION AND DIFFERENTIAL
Inspection: Starting torque of pinion bearing
• After installing the pinion, measure the starting torque of the pin-
ion bearing.
• If the measured value deviates from the standard value, adjust.
<Reduction pinion>
A: Heel
B: Toe
C: Face
D: Flank
E: Clearance
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REDUCTION AND DIFFERENTIAL
NOTE
• When tooth contact is near the toe at no load, it becomes
middle area contact at load.
[Adjustment]
• Adjust by backlash between reduction gear and reduction pinion
(to be adjusted with the side bearing nut) and addition or reduc-
tion of rear bearing shims.
CAUTION
• Make sure you replace as a reduction gear set (reduction
gear and reduction pinion), when you replace the gear be-
cause of excessive teeth wear.
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M E M O
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REDUCTION AND DIFFERENTIAL
Differential
Disassembly sequence
1 Reduction gear
2 Differential case RH
3 Side gear washer
4 Side gear
5 Pinion washer
6 Differential pinion
7 Pinion spider
8 Differential case LH
CAUTION
• Be sure to replace the differential
case RH and the differential case
LH as a differential case set.
• Be sure to replace the side gear and
the differential pinion as a side gear
set.
Assembly sequence
Follow the disassembly sequence in re-
verse.
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Inspection procedure
Inspection: Backlash between side gear and axle shaft
• If the measured value exceeds the limit, replace defective parts.
Installation procedure
Installation: Differential case RH and differential case LH
• Apply rust preventive to the entire surface of the bolt.
• Apply thread lock cement to the bolt threads.
• Tighten the bolt to the specified torque.
CAUTION
• Make sure to apply rust preventive when tightening the bolt
to the specified torque.
• Wait at least one hour after installation before actually run-
ning the vehicle to let the thread lock cement harden.
• Wait at least four hours after installation before operating
the vehicle at full torque to let the thread lock cement hard-
en.
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REDUCTION AND DIFFERENTIAL
Installation: Reduction gear and differential case LH
• Apply rust preventive to the entire surface of the bolt.
• Apply thread lock cement at the entry of bolt holes on differential
case LH.
• Tighten the bolt to the specified torque.
CAUTION
• Make sure to apply rust preventive when tightening the bolt
to the specified torque.
• Wait at least one hour after installation before actually run-
ning the vehicle to let the thread lock cement harden.
• Wait at least four hours after installation before operating
the vehicle at full torque to let the thread lock cement hard-
en.
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M E M O
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REDUCTION AND DIFFERENTIAL
Pinion
Disassembly sequence
1 Lock nut
2 Companion flange
3 Dust cover
4 Collar
5 Rear bearing inner race
6 Lock ring
7 Pinion pilot bearing
8 Reduction pinion
9 Oil seal
10 Front bearing inner race
11 Front bearing outer race
12 Rear bearing outer race
13 Bearing retainer
: Non-reusable parts
NOTE
• Record the height of the collar to
use it as reference at assembly.
Assembly sequence
Follow the disassembly sequence in re-
verse.
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Pinion bearing
remover
Removal of rear bearing inner
A B MB999045
race
0.5 25.6
{0.020} {1.00}
Pinion bearing
installer
Installation of rear bearing inner
A B C MH061005
race and front bearing inner race
φ62 φ52 φ125
{2.44} {2.05} {4.92}
A B
MH061750 Installation of oil seal
φ112 φ88
{4.41} {3.46}
Pinion bearing
installer
Installation of front bearing outer
A B MH061977
race
φ89 φ78
{3.50} {3.07}
Pinion bearing
installer
Installation of rear bearing outer
A B MH061264
race
φ99 φ88
{3.90} {3.46}
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REDUCTION AND DIFFERENTIAL
Work before removal
Inspection: Starting torque of pinion bearing
• Apply the specified load to the companion flange or tighten the
lock nut to the specified torque.
• Measure the tangential force at outer periphery point of the bear-
ing retainer using a spring balancer.
CAUTION
• Securely fix the companion flange to measure.
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REDUCTION AND DIFFERENTIAL
Installation: Pinion pilot bearing
• Install the pinion pilot bearing with its retaining ring placed on the
gear.
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M E M O
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REDUCTION AND DIFFERENTIAL
LSD (Limited Slip Differential)
Disassembly sequence
1 Reduction gear 7 Friction disc 13 Pressure ring
2 LSD (Limited Slip Differential) 8 Friction plate 14 Side gear
3 Differential case LH 9 Friction disc 15 Differential pinion
4 Side gear washer 10 Friction plate 16 Pinion spider
5 Spring plate 11 Friction disc 17 Differential case RH
6 Friction plate 12 Friction plate
CAUTION
• Make sure to replace the side gear and the differential pinion as a side gear set.
Assembly sequence
Follow the disassembly sequence in reverse.
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REDUCTION AND DIFFERENTIAL
Special tools (Unit: mm {in.})
Mark Tool name and shape Part No. Application
D
20
{0.79}
Inspection procedure
Inspection: Rotation torque of LSD clutch plate
• After removing the reduction gear, carry out the following in-
spection.
• Measure the rotation torque to check for the friction force of the
clutch plate.
NOTE
• For measurement of rotation torque, rotate the side gears to
sufficiently smooth their operation and measure the value
during their rotation.
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REDUCTION AND DIFFERENTIAL
(3) Inspection of thickness
• Measure thickness of the friction surfaces and protrusions of
the spring plate, friction disc and friction plate, and find the differ-
ence. If it exceeds the limit, replace defective parts.
NOTE
• Take measurement at several points for each part.
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• Check that clearance in the side gear axial direction is within the
range of the standard value.
• If the clearance deviates from the standard value, adjust by
changing the side gear washer.
Thickness of side gear washer available
1.5, 1.6, 1.7 mm {0.059, 0.063, 0.067 in.} (three sizes)
NOTE
• Select side gear washers so that the right and left dimen-
sional difference from the back face of the pressure rings to
the end face of the side gear washers conforms to the stan-
dard value.
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REDUCTION AND DIFFERENTIAL
Assembly procedure
Assembly: LSD (Limited Slip Differential)
• Assemble each part into the differential case RH in the illustrat-
ed direction.
NOTE
• Take care not to install the friction discs and friction plates
in a wrong sequence and the spring plates in a wrong direc-
tion.
• When assembling, apply gear oil to each part. Especially,
apply gear oil carefully to contact surfaces and sliding sur-
faces.
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