Differential: Service and Repair

OVERVIEW
Shim thickness need be determined only if any of the following parts are replaced:
- Transaxle gear case
- Clutch bell housing case
- Differential case
- Differential bearings
Refer to Bearing Adjustment Procedure in Manual Transmission/Transaxle, Adjustments to determine proper shim thickness. This will provide correct bearing preload and proper bearing turning torque.

DIFFERENTIAL BEARINGS

Fig. 116:

Fig. 117:

Fig. 118:

Fig. 119:

RING GEAR

Fig. 120:

CAUTION: Always install new ring gear bolts. Tighten ring gear bolts to 81 Nm (60 ft. lbs.) torque.

SPEEDOMETER DRIVE GEAR

NOTE: The plastic speedometer drive gear must be removed from the differential case in order to service the differential gears

REMOVAL

Fig. 121:

Fig. 122:

1. Pry the plastic speedometer drive gear off of the differential case using a flat blade pry tool (Fig. 121) (Fig. 122).

INSTALLATION

NOTE: A new speedometer drive gear must be installed on differential assembly. The lip on the speedometer drive gear must be positioned downward when installing onto differential assembly.

Fig. 122:

1. Position speedometer drive gear onto differential assembly (Fig. 123).

Fig. 124:

Fig. 125:

2. Using Miller Tool # L-4440 and steel stock, press speedometer drive gear onto differential (Fig. 124) (Fig. 125). Do not use a hammer.

DIFFERENTIAL GEARS

NOTE: The plastic speedometer drive gear must be removed from the differential case in order to service the differential gears.

REMOVAL

Fig. 126:

Fig. 127:

1. Remove pinion shaft retaining pin (Fig. 126) (Fig. 127).

Fig. 128:

2. Remove pinion shaft (Fig. 128).

Fig. 129:

3. Rotate side gears to opening in differential (Fig. 129).

Fig. 130:

4. Remove differential gears (Fig. 130).

INSTALLATION

1. Assemble the differential side gears, pinion gears and pinion gears with the pinion gear washers.

Fig. 131:

2. Install pinion shaft retaining pin (Fig. 131).

Fig. 132:

3. Stake pinion shaft retaining pin with a suitable chisel (Fig. 132).
4. Rotate the assembly two full revolutions both clockwise and counterclockwise.

Fig. 133:

Fig. 134:

5. Set up dial indicator as shown and record end play (Fig. 133) (Fig. 134). Rotate side gear 90 degrees and record another end play. Again, rotate side gear 90 degrees and record a final end play.
6. Using the smallest end play recorded, shim that side gear to within 0.001 to 0.013 inch. The other side gear should be checked using the same procedure.

CAUTION: Side gear end play must be within 0.001 to 0.013 inch. Five select thrust washers are available: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.

7. After the end play is measured and adjusted, replace speedometer drive gear with a new one. Install drive gear lip downward.