Bearing Adjustment
42LE - Automatic TransaxleBEARING ADJUSTMENT PROCEDURE
The following steps will determine the correct shim thickness required to obtain proper pinion depth. All special tools described in this procedure must be used to obtain correct results.
CAUTION: Failure to adjust pinion depth correctly could cause gear noise or transaxle failure.
1. Install front transfer shaft bearing cup (Fig. 187). The transfer shaft bearing cup must be installed before making pinion depth measurement. Use special tool 6494 to install bearing cup. There are no shims located behind this bearing cup.
CAUTION: The bearing cup is seated in the case correctly if there is no clearance between the bottom of the bearing cup and case. If a 0.001" or 0.002" feeler gauge does not fit, the bearing cup is completely seated into transaxle case.
2. Install centering block (special tool 6549-2) into the transaxle case (Fig. 188). Screw centering block into inner adjuster hole of case until it bottoms. The pegs on the special tool are only used for installation. Orientation with in the case is not required.
3. Install new front bearing (actual bearing to be used during reassembly) onto gauge disc (special tool 6549-3) (Fig. 189).
4. Install gauge disc and bearing into case using gauge disc rod Tool 6549-4 (Fig. 190).
5. Install centering disc (special tool 6494-2) onto gauge disc rod (Fig. 191).
6. Install centering nut Tool 6549-5 as shown in (Fig. 192).
7. Hand tighten centering nut until all play in the tool has been removed.
8. Install dial indicator into locating block Tool 6549-1. Then screw extension rod onto dial indicator (Fig. 193).
NOTE: The dial indicator used to make this measurement must have a face that shows 0-50-0 (Special Tool C-3339) readings (Fig. 194). All steps from this point forward will reflect this assumption. This will give you proper shim thickness.
9. Before making a pinion depth measurement the dial indicator must be zeroed. This is done by placing the dial indicator in the zeroing fixture (special tool 6549-6). Then place the zeroing fixture on a flat surface. Adjust the dial face so the pointer on the dial indicator lines up with the zero (Fig. 195).
10. Compress the dial indicator slightly and insert dial indicator pin into centering block (Fig. 196).
11. Pivot dial indicator back and forth (Fig. 197) on centering pin to obtain the shortest distance measurement. This will be the lowest number reading on dial indicator. Record the number obtained. Now rotate the gauge disc clockwise 1/3 of a turn and recheck readings. Record number obtained. Rotate the gauge disc another 1/3 of a turn clockwise and take another reading. Average the three readings. Record this pinion depth measurement. If the readings differ by more than two thousandths recheck gauge disc installation, it may have been installed slightly cocked.
12. To determine the required shim thickness, the pinion depth measurement must be adjusted. The pinion shim adjustment number is the first of seven digits ink stamped on the shank of the transfer shaft (Fig. 198). Using the adjustment factor chart, convert the adjustment number to the corresponding adjustment factor. Utilizing the pinion depth measurement obtained in Step 11, add or subtract the adjustment factor to calculate the required shim thickness. Refer to pinion head shim chart for shim selections. This is the shim that will be installed between the transfer shaft pinion head and the front transfer shaft bearing. Refer to the following examples for further explanation:
13. Example 1 in (MM):
- Measured pinion shim depth: 0.789mm
- Adjustment number on transfer shaft: +2
- Adjustment factor (mm): -0.051mm
- Shim size needed: 0.789 - 0.051 = 0.738mm
14. Example 2 in (IN):
- Measured pinion shim depth: 0.032 inch
- Adjustment number on transfer shaft: -1
- Adjustment factor (in): +0.001
- Shim size needed: 0.032 + 0.001 = 0.033 inch
ADJUSTMENT FACTOR CHART:
PINION HEAD SHIM CHART:
15. Remove dial indicator, gauge disc and centering block from transaxle.
16. Install shim selected in Step 12 of this procedure onto the transfer shaft (Fig. 198).
17. Press front transfer shaft bearing onto transfer shaft (special tool 6052). The shim must be in place before pressing on bearing (Fig. 199).
18. At this point the pinion depth has been determined and the shim has been installed onto the transfer shaft. Before the pinion is installed into the transaxle case, bearing preload must be determined for the differential bearings. The following steps must be performed before the pinion is installed.
19. The following steps will determine how many foot pounds are required on the outer differential adjuster to obtain the correct turning torque.
CAUTION: Failure to set differential bearing preload correctly may cause bearing failure, gear noise and/or axle shaft seal failure.
20. Remove outer adjuster with special tool 6503 (Fig. 200).
21. Remove old stub shaft seals. Press inner adjuster seal out with special tool 6502B. Press outer adjuster seal out with special tool 6558.
22. Install new stub shaft seals in both adjusters using special tool 6558 (Fig. 201).
NOTE: To remove inner and outer adjuster races, use Tool 6062-A. To install inner and outer adjuster races, use Tool 6522 and Tool C-4171.
23. Lube adjuster threads and O-ring with gear oil before installing. Failure to lube threads will result in thread damage to the adjuster and transaxle case.
24. Screw in the inner adjuster using special tool 6502B (Fig. 202). The inner adjuster should be screwed in until under-flush with inside of the case (viewed from differential side).
If differential was not disassembled, refer to Differential Disassembly..