Differential: Service and Repair

DISASSEMBLE
1. On Capri models, measure and record the backlash of the pinion gears before disassembling the differential as follows:
a. Install both driveshafts on differential assembly.
b. Support driveshafts on V-blocks, then measure backlash of both pinion gears. Correct measurement is 0.000-0.004 inch.
c. Remove eight bolts securing ring gear to gear case.
d. Tap ring gear around its circumference with soft mallet to loosen, then remove ring gear from gear case.
2. On all models, mount gear case in vise equipped with soft jaws. Do not exert excess pressure on vise.
3. Remove pinion shaft roll pin using 4 mm diameter rod, at least 3 inches long, and hammer. Drive roll pin free of gear case.
4. Press front differential bearing from gear case using bearing puller attachment tool No. D84L-1123-A and step plate adapter tool No. D80L-630-3, or equivalents.
5. On non-turbo models, remove speedometer drive gear from gear case.
6. On all models, remove rear differential bearing from gear case using puller tool No. T77F-4220-B and step plate adapter tool No. D80L-630-3, or equivalents.
7. On turbo models, perform the following:

Pinion Gear And Thrust Washer Removal:

a. Slide pinion shaft out of gear case, then remove pinion gears and thrust washers by rotating them out of gear case. Keep pinion and side gear thrust washers with their respective gears for reinstallation.
b. Remove side gears, thrust washers, and speedometer from gear case.

ASSEMBLE

NOTE: Before assembly, wash all parts and dry with compressed air. Apply Mercon transaxle fluid to all surfaces following assembly.

1. Install speedometer drive gear to gear case, aligning locating tang on gear with groove in case.
2. Install new front differential bearing to gear case with a press and driver handle tool No. T80T-4OOO-W and bearing cone replacement tool No. T87C-77000-C, or equivalents.
3. Install rear differential bearing to gear case with a press, using driver handle tool No. T80T-4000-W and bearing cone replacement tool No. T87C-77000-C, or equivalents.

Side Gear Thrust Washer Thickness Selection Chart:

4. On models equipped with turbo-charged engine, locate and record identification numbers on each side gear thrust washer. The Side Gear Thrust Washer Thickness Selection Chart shows thickness of thrust washers. This information may be used when setting backlash of side and pinion gears.
5. On all models, coat differential side gears and thrust washers with transaxle fluid.
6. Install differential side gear thrust washers to side gears, then the side gears into gear case.
7. Coat differential pinion gear thrust washers with transaxle fluid, then install thrust washers to pinion gears and pinion gear assemblies to gear case. Install differential pinion gears to gear case so they are parallel to each other.
8. After installing thrust washers on pinion gears, turn gears back on side gear and install them into gear case.

NOTE: Pinion gears and pinion shaft hole must be aligned on both sides of gear case. If gears and gear case shaft hole do not line up, remove pinion gears and install into case.

Pinion Shaft Installation:

9. Install pinion shaft into gear case.
10. Install roll pin through gear case and into the pinion shaft using suitable drift and hammer. Sink pin until it is approximately 1/6 inch below gear case surface.
11. Stake gear case to prevent pin from coming out, then install ring gear to gear case with depression on gear toward gear case.
12. Align threaded holes in gear with holes in case, then install and hand-tighten ring gear bolts.
13. Torque bolts to 51-61 ft lbs in two stages. Mark first bolt tightened and work in clockwise direction until all bolts have been properly tightened.
14. Check and adjust side gear and pinion gear backlash as follows:
a. Install both axle shafts into differential assembly.
b. Support axle shafts on V-blocks.
c. Measure backlash of both pinion gears. Correct backlash measurement is less than 0.004 inch.
d. If backlash is more than specified, adjust by selecting thrust washer from Side Gear Thrust Washer Thickness Selection Chart.
e. Thrust washer should be same thickness at each side gear.