Steps 1-30

The valve body and solenoid wiring connector must be removed from the transaxle in order to recondition the transaxle differential. The transfer shaft cannot be removed with the valve body in place. Refer to Valve Body Recondition for removal procedure.

If any bearings in the differential require replacement, all the bearings on the differential carrier and transfer shaft must be replaced. The differential adjusters must also be replaced when differential bearings are replaced.

Fig. 282:

Fig. 283:

Fig. 284:

Fig. 285:

Fig. 286:

Fig. 287:

Fig. 288:

Fig. 289:

Fig. 290:

Fig. 291:

Fig. 292:

Fig. 293:

Fig. 294:

Fig. 295:

Fig. 296:

DISASSEMBLY

CAUTION: The chain sprockets have a slip fit onto their shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly removal or installation will be difficult. Overspreading of the chain sprocket will also make sprocket removal difficult.

CAUTION: To ensure proper gear ratio, verify that the correct chain and sprocket ratio is selected.

CAUTION: When reinstalling drive chains, the blue link must face outward.

CAUTION: Driveshaft retainer clips and seals located on the stub shafts must be replaced before reinstalling driveshafts.

If the carrier requires reconditioning, refer to Differential Carrier Recondition.

CAUTION: Failure to grind and open stakes on the transfer shaft nut will result in thread damage to transfer shaft during nut removal.

WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.

Fig. 297:

Fig. 298:

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut as shown in (Fig. 297) and (Fig. 298). Do not grind through the transfer shaft nut into the shaft. There are two stakes on the nut.

Fig. 299:

Fig. 300:

Using a small chisel, carefully open stakes on nut (Fig. 299)
Remove the transfer shaft nut.

CAUTION: Do not reuse old transfer shaft nut because the removed stake weakens the nut flange.

CAUTION: The transfer shaft cannot be removed from the case at this time.

Fig. 301:

Install special tool 6577 to remove rear transfer bearing cup (Fig. 301).

Fig. 302:

Fig. 303:

Remove transfer shaft preload shim (Fig. 302). If transfer shaft bearings are to be reused, the original shim must also be reused.

CAUTION: If the transfer shaft is removed from the transaxle case for any reason, both seals must be replaced.

Fig. 304:

Remove transfer shaft seals (Fig. 304) using special tool 6310 and foot 6310-9 (Tar 960). Do not reuse old seals. The seals will be pulled out the rear of the case.

Fig. 305:

Remove the front transfer shaft bearing cup using special tool 6495 and handle C-4171 (Fig. 305). Use a press with special tools to remove cup.

Fig. 306:

Support special tool P-334 on press table so that pinion head of transfer shaft can be pressed through table (Fig. 306).
ASSEMBLE AND BEARING ADJUSTMENT PROCEDURE
The following steps will determine the correct shim thickness required to obtain proper pinion depth. All special tools described in this procedure must be used to obtain correct results.

CAUTION: Failure to adjust pinion depth correctly could cause gear noise or transaxle failure.

Fig. 307:

1. Install front transfer shaft bearing cup (Fig. 307). The transfer shaft bearing cup must be installed before making pinion depth measurement. Use special tool 6494 to install bearing cup. There are no shims located behind this bearing cup.

CAUTION: The bearing cup is seated in the case correctly if there is no clearance between the bottom of the bearing cup and case. If a 0.001" or 0.002" feeler gauge does not fit, the bearing cup is completely seated into transaxle case.

Fig. 308:

2. Install centering block (special tool 6549-2) into the transaxle case (Fig. 308). Screw centering block into inner adjuster hole of case until it bottoms. The pegs on the special tool are only used for installation. Orientation with in the case is not required.

Fig. 309:

3. Install new front bearing (actual bearing to be used during reassembly) onto gauge disc (special tool 6549-3) (Fig. 309).

Fig. 310:

4. Install gauge disc and bearing into case using gauge disc rod Tool 6549-4 (Fig. 310).

Fig. 311:

5. Install centering disc (special tool 6494-2) onto gauge disc rod (Fig. 311).

Fig. 312:

Fig. 313:

6. Install centering nut Tool 6549-5 as shown in (Fig. 312).
7. Hand tighten centering nut until all play in the tool has been removed.
8. Install dial indicator into locating block Tool 6549-1. Then screw extension rod onto dial indicator.

Fig. 314:

NOTE: The dial indicator used to make this measurement must have a face that shows 0-50-0 (Special Tool C-3339) readings (Fig. 314). All steps from this point forward will reflect this assumption. This will give you proper shim thickness.

Fig. 315:

9. Before making a pinion depth measurement the dial indicator must be zeroed. This is done by placing the dial indicator in the zeroing fixture (special tool (3549-6). Then place the zeroing fixture on a flat surface. Adjust the dial face so the pointer on the dial indicator lines up with the zero (Fig. 315).

Fig. 316:

10. Compress the dial indicator slightly and insert dial indicator pin into centering block (Fig. 316).

Fig. 317:

11. Pivot dial indicator back and forth (Fig. 317) on centering pin to obtain the shortest distance measurement. This will be the lowest number reading on dial indicator. Record the number obtained. Now rotate the gauge disc clockwise 1/3 of a turn and recheck readings. Record number obtained. Rotate the gauge disc another 1/3 of a turn clockwise and take another reading. Average the three readings. Record this pinion depth measurement. If the readings differ by more than two thousandths recheck gauge disc installation, it may have been installed slightly cocked.

Fig. 318:

12. To determine the required shim thickness, the pinion depth measurement must be adjusted. The pinion shim adjustment number is the first of seven digits ink stamped on the shank of the transfer shaft (Fig. 318). Using the adjustment factor chart, convert the adjustment number to the corresponding adjustment factor. Utilizing the pinion depth measurement obtained in Step 11, add or subtract the adjustment factor to calculate the required shim thickness. Refer to pinion head shim chart for shim selections. This is the shim. that will be installed between the transfer shaft pinion head and the front transfer shaft bearing. Refer to the following examples for further explanation:
13. Example 1 in (MM):
- Measured pinion shim depth: 0.789 mm
- Adjustment number on transfer shaft: +2
- Adjustment factor (mm): -0.051 mm
- Shim size needed: 0.789 - 0.051 = 0.738 mm
14. Example 2 in (IN):
- Measured pinion shim depth: 0.032 inch
- Adjustment number on transfer shaft: -1
- Adjustment factor (in): + 0.001
- Shim size needed: 0.032 + 0.001 = 0.033 inch








15. Remove dial indicator, gauge disc and centering block from transaxle.
16. Install shim selected in Step 12 of this procedure onto the transfer shaft (Fig. 318).

Fig. 319:

17. Press front transfer shaft bearing onto transfer shaft (special tool 6052). The shim must be in place before pressing on bearing (Fig. 319).
18. At this point the pinion depth has been determined and the shim has been installed onto the transfer shaft. Before the pinion is installed into the transaxle case, bearing preload must be determined for the differential bearings. The following steps must be performed before the pinion is installed.
19. The following steps will determine how many foot pounds are required on the outer differential adjuster to obtain the correct turning torque.

CAUTION: Failure to set differential bearing preload correctly may cause bearing failure, gear noise and/or axle shaft seal failure.

Fig. 320:

20. Remove outer adjuster with special tool 6503 (Fig. 320).
21. Remove old stub shaft seals. Press inner adjuster seal out with special tool 6502B. Press outer adjuster seal out with special tool 6558.

Fig. 321:

22. Install new stub shaft seals in both adjusters using special tool 6558 (Fig. 321).

NOTE: To remove inner and outer adjuster races, use Tool 6062-A. To install inner and outer adjuster races, use Tool 6522 and Tool C-4171.
23. Lube adjuster threads and O-ring with gear oil before installing. Failure to lube threads will result in thread damage to the adjuster and transaxle case.

Fig. 322:

24. Screw in the inner adjuster using special tool 6502B (Fig. 322). The inner adjuster should be screwed in until under-flush with inside of the case (viewed from differential side).

Fig. 323:

25. Install differential assembly into the transaxle case (Fig. 323).

Fig. 324:

26. Install differential cover (Fig. 324). Do not apply silicone sealant at this time. All bolts should be installed and tightened.

Fig. 325:

27. Install seal protector (special tool 6591) as shown in (Fig. 325). Apply a thin film of gear oil on the protector.

CAUTION: Lube threads and O-ring on adjuster before installing. Failure to due so will result in thread damage to the adjuster and transaxle case.

Fig. 326:

28. Screw on outer adjuster and tighten adjuster down finger tight (Fig. 326).

Fig. 327:

29. Insert special tool 6548 (Fig. 327). This tool will be used to check turning torque of the differential assembly.

CAUTION: Differential bearings must be seated before talking turning torque readings. This is done by rotating the differential three or four turns in both directions.

CAUTION: Turning torque of 19 to 23 inch lbs. can only be obtained when using new bearings. Do not attempt to obtain this turning torque with used bearings.

Fig. 328:

30. Tighten outer adjuster with tool 6503 until 19 to 23 inch lbs. of turning torque is obtained on tool 6548. Record how many foot pounds were required on the outer adjuster to obtain the correct turning torque (Fig. 328). Record the foot pound reading. The reading that you are recording will be used in Step 55 of this procedure.