Differential
DISASSEMBLY1. Remove differential side bearings:
a. Install button 8491-1 to differential case (Fig. 89).
b. Set up Tool 6048 (5048-1, -4, -6) as shown in (Fig. 90).
c. Remove differential side bearing (Fig. 91). Same procedure/tools work for both sides.
2. Remove ring gear-to-case bolts (Fig. 92) and remove ring gear.
3. Using three ring gear bolts as forcing screws (Fig. 93), separate differential support from case (Fig. 94).
4. Remove side gear thrust washer (Fig. 95).
5. Remove side gear (Fig. 96).
6. Remove long pinion shaft (Fig. 97).
7. Remove both short pinion shafts (Fig. 98).
8. Remove pinion shaft retainer (Fig. 99).
9. Remove four pinion gears and thrust washers (Fig. 100).
10. Remove side gear (Fig. 101).
11. Remove side gear thrust washer (Fig. 102).
ASSEMBLY
1. Install side gear thrust washer (Fig. 103).
2. Install differential side gear (Fig. 104).
3. Install four (4) pinion gears and thrust washers (Fig. 105).
4. Install pinion shaft retaining ring (Fig. 106).
5. Install two (2) short pinion shafts (Fig. 107).
6. Install one (1) long pinion shaft (Fig. 108).
7. Install differential side gear.
8. Install side gear thrust washer (Fig. 109).
9. Install differential support plate. Align support plate to differential case with alignment pins 8470 (Fig. 110).
10. Install thrust buttons 8491 to both bearing journals and press halves together using an arbor press (Fig. 111).
11. Install ring gear into position, start three ring gear-to-differential case bolts by hand (120° apart), and install alignment pins 8470 (Fig. 112).
12. Torque three ring gear bolts to draw ring gear into position. Remove alignment pins, install remaining ring gear-to-differential case bolts and torque to 95 Nm (70 ft. lbs.) (Fig. 113).
13. Install tapered roller bearings using installer 8473 and an arbor press (Fig. 114). Insert button 8491 on opposite journal to protect journal and/or bearing during press operation. Repeat the same operation on opposite side.
14. Measure and verify differential side gear end play.
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE
NOTE: Differential turning torque should only be measured with the geartrain out of the transaxle. If measurement is taken with transaxle assembled, an inaccurate measurement will result.
NOTE: All differential cover-to-case bolts and bearing plate-to-case bolts must be installed and torqued to obtain accurate measurement.
1. If transaxle is assembled, remove geartrain and leave differential in place.
2. Install differential cover and torque differential cover-to-case bolts to 54 Nm (40 ft. lbs.).
3. Install extension housing and torque extension housing-to-case bolts to 28 Nm (250 in. lbs.).
4. Place transaxle on work bench so axle centerline is parallel to the ground.
5. Install turning torque tool C-4995 to differential at side opposite extension housing.
6. Using in. lbs./Nm dial indicator, rotate differential case multiple times and record measurement (Fig. 115). Differential turning torque should be within 2.3 - 3.4 Nm (20 - 30 in. lbs.). Refer to shim chart for proper shim selection. If turning torque measured is less than 2.3 Nm (20 in. lbs.), install a thicker shim. If turning torque measured is greater than 3.4 Nm (30 in. lbs.), install a thinner shim.
DIFFERENTIAL BEARING SHIM CHART
ADJUSTMENT - DIFFERENTIAL SIDE GEAR END PLAY
Measure side gear end play: Insert feeler gauges 180° apart between differential side gear and thrust washer as shown in (Fig. 116). Measurement taken here applies to both sides. Side gear end play should be between 0.025 - 0.152 mm (0.001 - 0.006 in.). If clearance is greater than 0.152 mm (0.006 in.), install a thicker thrust washer (both sides). If clearance is less than 0.025 mm (0.001), install a thinner thrust washer (both sides). Refer to (Fig. 117) for available side gear shim thicknesses.
If end play measurement indicates a thrust washer change is necessary, the differential must be disassembled.