Differential End Play Measurement

This is a variation on the manual method, using stuff I found in the garage and my new Harbor Freight digital caliper (claimed accurate to +/- 0.001").

First assemble the differential and install the extension housing:




Then I rested this thick, flat metal plate thing with a hole in the middle over the center of the seal:


Then extend the depth finder on the caliper and zero out the distance between the top of the plate and the pinion:


Hold the body of the caliper firmly while prying up the diff through all its travel with a big screwdriver through the VSS hole:



Full travel measured 0.016":


Spec for play is 0.005" to 0.025", so no need to swap in a different thickness selective washer. Test OK.