Bearing Adjustment Procedures

BEARING ADJUSTMENT PROCEDURES
1. Take extreme care when removing and installing bearing cups and cones. Use only an arbor press for installation, as a hammer may not properly align the bearing cup or cone. Burrs or nicks on the bearing seat will give a false end play reading, while gauging for proper shims. Improperly seated bearing cup and cones are subject to low-mileage failure.
2. Bearing cups and cones should be replaced if they show signs of pitting or heat distress.
3. If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.

NOTE: Bearing end play and drag torque specifications must be maintained to avoid premature bearing failures.

4. Used (original) bearing may lose up to 50 percent of the original drag torque after break-in.

NOTE: All bearing adjustments must be made with no other component interference or gear intermesh, except the transfer gear bearing.

5. Refer to the conversion chart in specifications to convert inches to millimeter measurements. Refer to bearing shim chart for proper shim thicknesses.

OUTPUT SHAFT BEARING
With output shaft gear removed, install a 13.65 min (0.537 inch) and a 1.34 min (0.053 inch) gauging shim on the planetary rear annulus gear hub using grease to hold the shim in place. The 13.65 min shim has a larger inside diameter and must be installed over the output shaft first. The 1.34 min shim pilots on the output shaft.
Install output shaft gear and bearing assembly, torque to 271 Nm (200 ft. lbs.).
To measure bearing end play:
1. Attach Tool L-4432 to the output shaft gear.
2. Mount a steel ball with grease into the end of the output shaft.
3. Push and pull the gear while rotating back and forth to insure seating of the bearing rollers.
4. Using a dial indicator mounted to the transaxle case, measure output shaft end play.
5. Once bearing end play has been determined, refer to the output shaft bearing shim chart.
6. The 12.65 min (0.498 inch), 13.15 mm (0.518 inch) or 13.65 mm (0.537 inch) shims are always installed first. These shims have lubrication slots that are necessary for proper bearing lubrication.
7. Shims thinner than 12.65 mm. listed in the chart are common to both the transfer shaft and output shaft bearings.
8. Use tool L-4434 to remove the retaining nut and washer. To remove the output shaft gear use tool L-4407.
9. Remove the two gauging shims and install the proper shim combination, making sure to install the 12.65, 13.15, or 13.65 mm shim first. Use grease to hold the shims in place. Install the output shaft gear and bearing assembly.
10. Install the retaining nut and washer, and torque to 271 Nm (200 ft. lbs.).
11. Using an inch-pound torque wrench, check the turning torque. The torque should be between 3 and 8 inch-pounds.
12. If the turning torque is too high, install a 0.05mm (0.002 inch) thicker shim. If the. turning torque is too low, install a 0.05 min (0.002 inch) thinner shim. Repeat until the proper turning torque is 3 to 8 inch pounds.

DIFFERENTIAL BEARING
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.
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. 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 the following steps,
a. Remove differential bearing retainer from the transaxle case.

Output Shaft Bearing Shim Chart:

Fig. 199:

b. Remove the bearing cup from the differential bearing retainer using Tool 6062A.
c. Remove the existing shim from under the cup.

Fig. 200:

d. Measure the existing shim.

NOTE: 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 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 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. The turning torque should be between 5 and 18 inch-pounds.

TRANSFER SHAFT BEARING
1. Use tool L-4434 to remove the retaining nut and washer. Remove the transfer shaft gear using tool L-4407.
2. Install a 2.29 mm (0.090 inch) and a 1.39 mm (0.055 inch) gauging shims on the transfer shaft behind the governor support.
3. Install transfer shaft gear and bearing assembly and torque the nut to 271 Nm (200 ft. lbs.).
To measure bearing end play:
a. Attach tool L-4432 to the transfer gear.
b. Mount a steel ball with grease into the end of the transfer shaft.
c. Push and pull the gear while rotating back and forth to insure seating of the bearing rollers.
d. Using a dial indicator, measure transfer shaft end play.

Shim Thickness:

e. Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain the proper bearing setting.
f. Use tool L-4434 to remove the retaining nut and washer. Remove the transfer shaft gear using tool L-4407.
g. Remove the two gauging shims and install the correct shim combination. Install the transfer gear and bearing assembly.
h. Install the retaining nut and washer and torque to 271 Nm (200 ft. lbs.). Measure transfer shaft end play, end play should be 0.05 to 0.25 mm (0.002 to 0.010 inch).
i. Measure bearing end play. End play should be between 0.05 mm and 0.25 mm (0.002 to 0.010 inch).

Transfer Bearing Shim Chart:

NOTE: If end play is too high, install a 0.05 mm (0.002 inch) thinner shim combination. If end play is too low, install a 0.05 mm (0.002 inch) thicker shim combination. Repeat until 0.05 to 0.25 mm (0.002 to 0.010 inch) end play is obtained.