Differential

DISASSEMBLY





1. Remove oil seal from extension housing.





2. Remove differential cover bolts.





3. Remove differential cover.





4. Remove differential retainer bolts.





5. Loosen differential bearing retainer with Remover MB995046. Walk retainer out of housing using special tool.
6. Remove differential bearing retainer.





7. Remove bolts from extension housing.





8. Loosen extension housing with Remover MB995046. Walk housing out of transaxle case using special tool.





9. Remove extension housing.





10. Remove differential bearing cone from extension side using bearing puller MB995001, bearing puller MB995002 and button MB995049.
11. Remove differential bearing cone from bearing retainer side using bearing puller MB995001, bearing puller adapter MB995063 and button MB995049.





12. Remove ring gear bolts.





13. Remove pinion shaft roll pin by tapping out with a hammer and steel punch.





14. Remove pinion shaft.








15. Remove pinion gears, side gears and tabbed thrust washers by rotating pinion gears to opening in differential case.





16. Remove oil seal from differential bearing retainer with a small chisel and hammer.





17. Remove differential bearing race from extension housing using cup remover MB995048.
18. Remove differential bearing race from bearing retainer using bearing cup remover MB995064.

REASSEMBLY





1. Install a 0.50 mm (0.0197 inch) "test" shim and reinstall the bearing cup into the retainer. Install bearing cup, press in using Installer Bar MB990938 and Installer Adapter MB990933. Oil baffle is not required when making shim selection.





2. Install bearing retainer into the case and torque bolts to 28 Nm (20 ft. lbs.).





3. Install extension housing into the case and torque bolts to 28 Nm (20 ft. lbs.). Position transaxle assembly with oil pump facing up. Rotate ring gear one revolution to seal differential bearings.





4. Attach a dial indicator set MB995030 to the case and zero the dial indicator.
5. Place a large screwdriver to each side of the ring gear and lift. Check the dial indicator for the amount of end play.

CAUTION: Do not damage the transaxle case and/or differential cover sealing surface.

6. When the end play has been determined, refer to the Differential Bearing Shim Chart for correct shim combination.





DIFFERENTIAL BEARING SHIM CHART





7. Remove bolts from extension housing.





8. Loosen extension housing with Remover MB995046. Walk housing out of transaxle case using special tool.
9. Remove extension housing.





10. Remove differential retainer bolts.





11. Loosen differential bearing retainer with Remover MB995046. Walk retainer out of transaxle using special tool.
12. Remove differential bearing retainer.





13. Remove bearing cup with Cup Remover MB995064.
14. Remove the 0.50 mm (0.0197 inch) "test" shim.





15. Install the proper shim combination under the bearing cup.





16. Install bearing cup, and then press in using Installer Bar MB990938 and Installer Adapter MB990933.





17. Install differential bearing retainer into the case and torque bolts to 28 Nm (20 ft. lbs.).





18. Install extension housing into the case and torque bolts to 28 Nm (20 ft. lbs.).








19. Install Checking Tool MB995047 and a torque wrench to check differential bearings turning torque. The turning torque should be 0.56 to 2.03 Nm (5 to 18 inch lbs.). If the turning torque is too high, install a 0.05 mm (0.0020 inch) thinner shim. If the turning torque is too low, install a 0.05 mm (0.0020 inch) thicker shim. Repeat until proper turning torque is obtained.





20. Install proper shim.





21. Install bearing cup, and then press in using Installer Bar MB990938 and Installer Adapter MB990933.





22. Install new oil seal, press in using Installer Cap MB998812 and Installer Adapter (56) MB998827.








23. Using dial indicator MB995030 and Adapter MB995039, check side gear end play at ring gear side and differential case side.

NOTE: Side gear end play each side must be 0.025 to 0.330 mm (0.00098 to 0.01299 inch).

Four select thrust washers are available.
0.81, 0.93, 1.07 and 1.19 mm (0.0319, 0.0366, 0.0421 and 0.0469 inch).
If either side gear end play is not within specifications, remove appropriate side gear thrust washer.
Measure existing thrust washer and replace with new thrust washer that provides end play closest to center of end play specifications.








24. Install pinion gears, side gears and tabbed thrust washers by rotating pinion gears to opening in differential case.





25. Install pinion shaft.





26. Install pinion shaft roll pin by tapping in with a hammer and steel punch.





27. Install ring gear bolts.

NOTE: Always use new ring gear bolts and torque to 95 Nm (70 ft. lbs.).








28. Install differential bearing, and then press in using Installer Cap MD998812 and Installer Adapter (44) MD998821.





29. Install extension.

NOTE: Apply an 1/8 inch wide bead of Loctite 18718 or equivalent.





30. Install bolts to extension housing.





31. Install differential bearing retainer.

NOTE: Apply a 1/8 inch wide bead of Loctite 18718 or equivalent.





32. Install differential retainer bolts.





33. Install differential cover.

NOTE: Apply a 1/8 inch wide bead of Loctite 18718 or equivalent.





34. Install differential cover bolts.





35. Install new oil seal using Installer Cap MD998812 and Installer Adapter (56) MD998827.