Differential

Shim thickness need be determined only if any of the following parts are replaced:
- Transaxle gear case
- Clutch bellhousing case
- Differential case
- Differential bearings
Refer to Bearing Adjustment Procedure. This will provide correct bearing preload and proper bearing turning torque.

Remove Differential Bearing Cone:

Install Differential Bearing Cone:

Remove Differential Bearing Cone:

Install Differential Bearing Cone:

DIFFERENTIAL BEARINGS

Remove Or Install Ring Gear Bolts And Ring Gear:

RING GEAR

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

Pry Off Speedometer Drive Gear:

Speedometer Drive Gear Removed:

Removal
1. Pry the plastic speedometer drive gear off of the differential case using a flat blade pry tool.

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.

Speedometer Drive Gear:

1. Position speedometer drive gear onto differential assembly.

Press Gear Onto Differential:

Drive Gear Pressed Onto Differential:

2. Using Miller Tool # L-4440 and steel stock, press speedometer drive gear onto differential. 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.

Remove Pinion Shift Retaining Pin:

Retaining Pin Removed:

Removal
1. Remove pinion shaft retaining pin.

Pinion Shaft Removal:

2. Remove pinion shaft.

Remove Pinion Gears, Side Gears, And Thrust Washers By Rotating Side Gears To Opening In Case:

3. Rotate side gears to opening in differential.

Differential Gears:

4. Remove differential gears.

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

Install Retaining Pin:

2. Install pinion shaft retaining pin.

Staking Retaining Pin:

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

Checking Side Gear End Play (Typical):

5. Set up dial indicator as shown and record end play. 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. Meter the end play is measured and adjusted, replace speedometer drive gear with a new one. Install drive gear lip downward.