Final Drive

40TE TRANSAXLE

FINAL DRIVE

DISASSEMBLY

NOTE: The transfer shaft should be removed for differential repair and bearing turning torque checking.








1. Remove the differential cover and bolts (Fig. 158) (Fig. 159).








2. Remove the differential bearing retainer and bolts (Fig. 160) (Fig. 161).

3. Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle.

WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING.

4. Remove differential assembly.








5. Set up dial indicator set C-3339 and tool C-4996 as shown in (Fig. 162) (Fig. 163) to measure side gear end play. Side gear end play must be within 0.001 - 0.013 inch.





6. Remove differential side bearing cone from ring gear side of differential. Install button L-4539-2, and Collets 5048-2 (Fig. 164).





7. Install 5048 as shown (Fig. 165), remove and discard bearing cone.





8. Remove differential side bearing cone from outboard end (opposite ring gear) of differential. Install Button L-4539-2 as shown (Fig. 166).





9. Install 5048 as shown (Fig. 167). Remove and discard bearing cone.





10. Remove pinion shaft retainer plate bolts (Fig. 168).





11. Remove pinion shaft retainer (Fig. 169).





12. Remove pinion shaft from differential case (Fig. 170).





13. Rotate pinion gears about case and remove (w/washer) (Fig. 171).





14. Remove differential side gears (Fig. 172).





15. Remove side gear thrust washers (Fig. 173).





16. Remove remaining differential ring gear-to-case bolts (Fig. 174).





17. Using a soft-faced hammer, remove ring gear from case (Fig. 175).
18. Using Miller Special Tool L-4518, remove the differential bearing race from the extension housing/adapter plate.








19. Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer (Fig. 176) (Fig. 177).





DIFFERENTIAL SERVICE TOOLS

ASSEMBLY

NOTE: Use Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to transaxle case.





1. Position differential case to ring gear. Install ring gear-to-differential case bolts and draw ring gear into position (Fig. 178). Torque bolts to 95 Nm (70 ft. lbs.).





2. Install side gear thrust washers (Fig. 179).





3. Install differential side gears (Fig. 180).





4. Install pinion gears and thrust washers 180° apart (Fig. 181).





5. Rotate pinion gears into position, ensuring the anti-rotate tabs are located into the differential case as shown (Fig. 182).





6. Install pinion shaft (Fig. 183).





7. Install pinion shaft retainer (Fig. 184).





8. Install pinion shaft retainer/ring gear-to-differential case bolts (Fig. 185) and torque to 95 Nm (70 ft. lbs.).





9. Position differential side bearing cone onto differential as shown (Fig. 186).





10. Using Tools 5052 and C-4171, install differential bearing to differential (ring gear side) (Fig. 187).





11. Using Tools L-4410 and C-4171, install differential bearing to differential (ring gear side) (Fig. 188).





12. Using Miller Special Tool 6061 and C-4171, install differential bearing race to bearing retainer (Fig. 189).
13. Using Miller Special Tool L-4520 and C-4171, install differential bearing cup to extension housing.
14. Measure and adjust differential bearing preload.
15. Install differential assembly to case. Install extension housing/adapter plate and bearing retainer.





16. Install bearing retainer with a bead of Mopar(R) Silicone Rubber Adhesive Sealant and torque bolts (Fig. 190) to 28 Nm (250 inch lbs.).
17. Install extension housing/adapter plate with a bead of Mopar(R) Silicone Rubber Adhesive Sealant and torque bolts to 28 Nm (250 inch lbs.).








18. Install differential cover with a bead of Mopar(R) Silicone Rubber Adhesive Sealant (Fig. 191) and torque bolts (Fig. 192) to 28 Nm (250 inch lbs.).

ADJUSTMENTS

DIFFERENTIAL BEARING PRELOAD MEASUREMENT AND ADJUSTMENT

NOTE: Perform all differential bearing preload measurements with the transfer shaft and gear removed.

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING EXISTING SHIM
1. Position the transaxle assembly vertically on the support stand, differential bearing retainer side up.





2. Install Tool L-4436A into the differential and onto the pinion mate shaft (Fig. 193).
3. Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated.





4. Using Tool L-4436A and an inch-pound torque wrench, check the turning torque of the differential (Fig. 194). The turning torque should be between 5 and 18 inch-pounds.
5. If the turning torque is within specifications, remove tools. Setup is complete.
6. If turning torque is not within specifications proceed with these steps.
a. Remove differential bearing retainer from the transaxle case.
b. Remove the bearing cup from the differential bearing retainer using Tool 6062A.
c. Remove the existing shim from under the cup.
d. Measure the existing shim.
e. If the turning torque was too high when measured, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is was too low, install a 0.05 mm (0.002 inch) thicker shim. Repeat until 5 to 18 inch-pounds turning torque is obtained. Oil Baffle is not required to be installed when making shim selection.
f. Install the proper shim under the bearing cup. Make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and cup.
g. Install the differential bearing retainer using Tool 5052 and C-4171. Seal the retainer to the housing with MOPAR(R) Adhesive Sealant and torque bolts to 28 Nm (250 inch lbs.).
7. Using Tool L-4436A and an inch-pound torque wrench, recheck the turning torque of the differential (Fig. 194). The turning torque should be between 5 and 18 inch-pounds.
Shim thickness need be determined only if any of these parts are replaced:
^ Transaxle case
^ Differential carrier
^ Differential bearing retainer
^ Extension housing
^ Differential bearing cups and cones





DIFFERENTIAL BEARING SHIM CHART

PRELOAD ADJUSTMENT W/O SHIM
1. Remove the bearing cup from the differential bearing retainer using Miller special Tool 6062A.
2. Remove existing shim from under bearing cup.
3. Reinstall the bearing cup into the retainer using Miller Special Tool 6061, and C-4171.

NOTE: Oil baffle is not required when making the shim calculation.

4. Install the bearing retainer into the case. Torque bolts to 28 Nm (250 inch lbs.).
5. Position the transaxle assembly vertically on the support stand and install Miller Special Tool L-4436-A into the bearing retainer.
6. Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated.
7. Attach a dial indicator to the case and zero the dial. Place the tip on the end of Special Tool L-4436-A.
8. Place a large screwdriver to each side of the ring gear and lift. Check the dial indicator for the amount of end play.

CAUTION: Do not damage the transaxle case and/or differential retainer sealing surface.

9. Using the end play measurement that was determined, add 0.18 mm (0.007 inch). This should give you between 5 and 18 inch pounds of bearing preload. Refer to the Differential Bearing Shim Chart to determine which shim to use.
10. Remove the differential bearing retainer. Remove the bearing cup.
11. Install the oil baffle. Install the proper shim combination under the bearing cup.
12. Install the differential bearing retainer. Seal the retainer to the housing with Mopar(R) Silicone Rubber Adhesive Sealant. Torque bolts to 28 Nm (250 inch lbs.).
13. Using Miller Special Tool L-4436-A and an inch-pound torque wrench, check the turning torque of the differential (Fig. 194). The turning torque should be between 5-18 inch-pounds.

NOTE: If turning torque is too high install a 0.05 mm (0.002 inch) thicker shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thinner shim. Repeat until 5-18 inch-pounds of turning torque is obtained.