Differential Overhaul

Shim thickness need only be determined it any of the following parts are replaced:
Transaxle gear case
Clutch bellhousing case
Differential case
Differential bearing




Refer to Bearing Adjustment Procedure at the end of this section to determine proper shim thickness. This will provide correct bearing preload and proper bearing turning torque.




Install the bearing cone using the special tool.




Install the differential bearing cone using the special tool.








Install the bearing cone using the special tool.

CAUTION: Always install new ring gear bolts. Tighten ring gear bolts to 81 N.m (60 ft-lbs.) torque.




Remove the roll pin using a pin punch, etc.




Remove the pinion shaft.




Remove the pinion gear, side gear and thrust washer.




Assemble the differential side gears, pinion gears and pinion gears with the pinion gear washers. Rotate the assembly two full revolutions both clockwise and counterclockwise.







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 final end play. Using the smallest end play recorded, shim that side gear to within 0.25 mm (.0098 in) to 0.33 mm (.0130 in). The other side gear should be checked using the same procedure.

CAUTION: Side gear end play must be within 0.25 - 0.33 mm (.0098 - .0130 in). Five select thrust washers are available: 0.69 mm (.0272 in.), 0.81 mm (.0319 in), 0.94 mm (.0370 in), 1.07 mm (.0421 in) and 1.19 mm (.0469 in).