SERVICE MANUAL &
TECHNICAL BULLETIN
SERVICE MANUALTECHNICAL BULLETINMODEL
DX
SERIES
MODEL D01/D02 SERIES
DIFFERENTIAL CARRIER
SECTIONDF
CONTENTS
SERVICE DATA AND SPECIFICATIONS .......................2
General Specifications.................................................2
Inspection and Adjustment ..........................................3
Tightening Torque ........................................................3
TROUBLE DIAGNOSES AND CORRECTIONS.............4
DIFFERENTIAL CARRIER ..............................................5
Construction.................................................................5
SPECIAL SERVICE TOOLS............................................7
General Specifications
D01 SERIES
Applied model
FD01A15-18
PD01A15-18
Model
H263
Gear ratio
5.286
5.857
Number of teeth (Ring gear/Drive pinion)
37/7
41/7
Differential gear
2-pinion
Number of teeth (Side gear/Pinion mate gear)
16/10
Oil capacity
(US qt, Imp qt)
2.7 (2-7/8, 2-3/8)
D02 SERIES
Applied model
UD02A20-25
FD02A20-25
UGD02A30
Model
H296
H310
Gear ratio
5.857
6.166
Number of teeth
(Ring gear/Drive pinion)
41/7
37/6
Differential gear
4-pinion
Number of teeth
(Side gear/Pinion mate gear)
18/10
16/10
Oil capacity
(US qt, Imp qt)
3.0 (3-1/8, 2-5/8)
5.5 (5-7/8, 4-7/8)
SERVICE DATA AND SPECIFICATIONS
DF-2
Inspection and Adjustment
Drive pinion starting torque
N⋅m (kg-cm, in-lb)
A/T models
1.8 - 2.3 (18 - 23, 16 - 20)
Backlash
mm (in)
Side gear to pinion mate gear
0.15 - 0.20 (0.0059 - 0.0079)
Drive pinion to ring gear
H263
0.18 - 0.23 (0.0071 - 0.0091)
H296 & H310
0.20 - 0.28 (0.0079 - 0.0110)
Distance between left and right
bearing caps
(Side bearing preload)
mm (in)
H263
262.88 - 262.93
(10.3496 - 10.3516)
H296
282.86 - 282.93
(11.1358 - 11.1390)
H310
302.85 - 302.93
(11.9232 - 11.9264)
SIDE GEAR THRUST WASHER
Unit: mm (in)
H263
H296
H310
1.55 (0.0610)
1.60 (0.0630)
1.65 (0.0650)
—
—
—
1.54 (0.0606)
1.57 (0.0618)
1.60 (0.0630)
1.63 (0.0642)
1.66 (0.0654)
1.69 (0.0665)
DRIVE PINION BEARING ADJUST SHIM
Unit: mm (in)
0.15 (0.0059)
0.