Assembly

DIFFERENTIAL

ASSEMBLY








1. Install side gears, pinion gears, and thrust washers into case through opening and rotating into position (Fig. 61) (Fig. 62).





2. Install pinion shaft (Fig. 63).





3. If previously removed, install ring gear to differential case (Fig. 64).








4. Install pinion shaft retainer (Fig. 65). Install NEW ring gear-to-case bolts and torque to 81 Nm (60 ft. lbs.) torque (Fig. 66).





5. Install speedometer drive gear to case (Fig. 67). Note orientation of index tab.





6. Using Steel Block and Tool L-4440, press speedometer drive gear into position (Fig. 68).








7. Using an arbor press, Handle C-417 1, and Tool L-4410, install differential side bearings to ring gear and case side (Fig. 69) (Fig. 70).

Measure and Adjust Side Gear End-Play








1. Rotate the assembly two full revolutions both clockwise and counterclockwise. Set up dial indicator as shown and record end play (Fig. 71) (Fig. 72). Rotate side gear 90 degrees and take another measurement. Again, rotate side gear 90 degrees and record a final measurement.
2. 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.

ADJUSTMENTS

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT /SHIM SELECTION
Measure and adjust differential side bearing preload during any transaxle service, especially when these components are replaced:
^ Transaxle gear case
^ Clutch bellhousing case
^ Differential case
^ Differential bearings

NOTE: True bearing turning torque readings can be obtained only with the geartrain removed from the case.

1. Remove bearing cup and existing shim from clutch bellhousing case.
2. Press in new bearing cup into bellhousing case (or use a cup that has been ground down on the outer edge for ease of measurement).
3. Press in new bearing cup into gear case side.
4. Oil differential bearings with transmission fluid. Install differential assembly in transaxle gear case. Install clutch bellhousing over gear case. Install and torque case bolts to 29 Nm (21 ft. lbs.).
5. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator.





NOTE: Indicator is set up as shown for illustrative purposes only (Fig. 73). Indicator must be parallel to T-Handle to obtain the most accurate reading.

6. Apply a medium load to differential with Tool C-4995 and a T-handle, in the downward direction. Roll differential assembly back and forth a number of times. This will settle the bearings. Zero the dial indicator. To obtain end play readings, apply a medium load in an upward direction while rolling differential assembly back and forth (Fig. 73). Record end play.
7. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18 mm (0.007 inch). Never combine shims to obtain the required preload.
8. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim(s) selected in Step 7. Then press the bearing cup into clutch bellhousing.
9. Install clutch bellhousing. Install and torque case bolts to 26 Nm (19 ft. lbs.).





10. Using Special Tool C-4995 and an inch-pound torque wrench, check turning torque of the differential assembly (Fig. 74). The turning torque should be 6 to 12 inch lbs. If the turning torque is too high, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thicker shim.
11. Recheck turning torque. Repeat Step 10 until the proper turning torque is obtained.