W/2 Pinion Differential

DISASSEMBLE

Typical 2 Pinion Differential Assembly:

1. Remove lefthand differential roller bearing using differential bearing cone remover tool No. T77F-4220-B1 and step plate tool No. T81P-4220-A, or equivalents.
2. Remove righthand differential bearing cup from case, then install over righthand differential bearing.
3. With bearing cup in position, remove bearing from speedometer side of differential using differential bearing remover tool No. T57L-4220-A and step plate tool No. T81P-4220-A, or equivalents.

CAUTION: Failure to use bearing cup will result in damage to bearing.

Speedometer Drive Gear Replacement:

4. Remove speedometer drive gear. Speedometer drive gear is plastic and is not pressed onto differential case.
5. Remove differential side gears by rotating gears toward case window.
6. Remove pinion shaft retaining pin using a 5/32 inch punch.

NOTE: Ensure speedometer gear has been removed before removing pin.

7. Remove pinion shaft, pinion gears, and thrust washers.
8. Inspect final drive gear for damage and wear. If gear is to be replaced, remove rivets by drilling through rivet head with 5/16 inch drill, then chiseling off head and punching rivet out of gear using punch.

ASSEMBLE
1. Lubricate all thrust washers and thrust surfaces on gears and case with transaxle fluid.

Final Drive Gear To Differential Case Installation:

2. If final drive gear was removed, press new gear onto differential case, then install gear attaching bolts.
3. Install pinion shaft, pinion gears, and thrust washers.
4. Install pinion shaft retaining pin, then the differential side gears and thrust washers.
5. Install speedometer gear.

NOTE: Speedometer drive gear is plastic and is not pressed onto differential case. Ensure chamfer on drive gear inside diameter faces differential case.

6. Install differential bearings using differential bearing cone installer tool No. T83P-4220-CH, or equivalent.

CAUTION: 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 halfshafts through side gears.

7. Adjust differential bearing preload as follows:
a. Remove differential seal from transaxle case using drift, then the differential bearing cup from transaxle case using differential bearing cup replacer tool T77F-4222-A, or equivalent.
b. Remove preload shim located under bearing cup.

Height Gauge Spacer Tool Installation In Clutch Housing:

c. With differential installed in clutch housing, then install height gauge spacer tool Nos. T81P-4451-B2 and T83P-4451-AH2, or equivalents, onto clutch housing dowels.

Shim Selector Tool Installation:

d. Position bearing cup from transaxle case onto differential bearing, then install shim selector tool No. T83P-4451-AH1, or equivalent, over differential bearing cup.
e. Position transaxle case onto height gauge spacers, then install four bolts supplied with tool. Torque bolts to 17-21 ft lbs.
f. Rotate differential several times to ensure seating of differential bearing.

Gauge Bar Tool Installation Across Shim Selector Tool:

g. Position gauge bar tool No. T80L-77003A, or equivalent, across shim selector tool.

Differential Selective Shim Chart:

h. Using feeler gauge, measure gap between gauge bar and selector tool gauge surface. Obtain measurements from two more positions around tool and take average of readings to determine necessary shim thickness. Refer to the Differential Selective Shim Chart for available shim sizes. If shim size required is not on chart, select next thinner shim.
i. Install shim into transaxle case, then apply light film of transaxle fluid to bearing bores in transaxle case and clutch housing.

Bearing Cup Installation In Differential Bearing Case:

j. Using draw bolt tool No. T77F-1176-A, differential bearing cup replacer tool No. T75T-1225-A, and differential bearing cup replacer tool No. T73T-4222-A, or equivalents, install bearing cup in transaxle case.

NOTE: Ensure cups seat fully into cover.

k. Install differential seal using differential seal replacer tool No. T81P-1177-A, or equivalent.