2 Pinion Differential

DISASSEMBLY

Typical 2 Pinion Differential Assembly:

1. Remove differential bearings using suitable puller.
2. Remove differential bearing cup from case and install over differential bearing.

Speedometer Drive Gear, Replacement:

3. Remove speedometer drive gear.
4. Remove differential side gears and thrust washers by rotating gears toward case window.
5. Remove pinion shaft retaining pin using suitable punch. Ensure speedometer gear has been removed before removing pin.
6. Remove pinion shaft, pinion gears and thrust washers.
7. Inspect final drive gear for damage and wear. If gear is to be replaced, remove rivets by drilling through rivet head with 5/16 in. drill, then chiseling off head. Punch rivet out of gear using suitable punch.

ASSEMBLY
1. Lubricate all thrust washers and thrust surfaces with suitable transmission fluid.

Installing Replacement Final Drive Gear Onto Differential Case:

2. If final drive gear was replaced, press new gear onto differential case, then install gear attaching nuts and torque nuts to 55-70 ft lbs (75-95 Nm).
3. Install pinion shaft, pinion gears and thrust washers.
4. Installation shaft retaining pin, then the differential side gears and thrust washers.
5. Install speedometer gear using suitable press and tool T80L-19703E or equivalent.
6. Install differential bearings using tool T81P-4221A or equivalent. Differential side gears must be aligned, and alignment maintained while installing differential assembly into transaxle case. Incorrect alignment of side gears will prevent installation of half shafts through side gears.
7. Adjust differential bearing preload as follows:
a. Remove differential seal from transaxle case using drift. Remove differential bearing cup from transaxle case using tool T77F-4222A or equivalent.
b. Remove preload shim located under bearing cup.

Installing Tool T81P-4451B Into Clutch Housing:

c. With differential installed position in clutch housing, install Height Gauge Spacers T81P-4451B or equivalent onto clutch housing dowels.

Installing Shim Selector Tool Over Differential Bearing Cup:

d. Position bearing cup removed from transaxle case onto differential bearing, then install shim selector tool T81P-4451B or equivalent over differential bearing cup.
e. Position transaxle case onto height gauge spacers. Install four bolts supplied with tool and torque bolts to 17-21 ft lbs (23-28 Nm).

Positioning Gauge Bar Tool Across Shim Selector Tool:

f. Position gauge bar tool T80L-77003A or equivalent across shim selector tool.

Differential Selective Shim Chart:

g. Using feeler gauge, measure gap between gauge bar and selector tool gauge surface. Obtain measurements from two positions around tool and take average of readings to determine necessary shim thickness. Refer to chart for available shim sizes. If shim size required is not on chart, select next thickest shim size.

Installing Bearing Cup Into Differential Case:

h. Install shim into transaxle case using tools T77F-1176A, T75T-1225A and T73T-4222B or equivalent. Ensure cups seats full into cover.
i. Install differential seal using suitable installation tool.