Steps 31-62

31. Remove the differential cover, differential carrier assembly and inner adjuster.
32. At this point the amount of torque required on the outer differential adjuster has been determined. The transfer shaft can now be installed into the transaxle case. Perform the following steps to install transfer shaft into transaxle case.

Fig. 329:

33. Install transfer shaft into transaxle case (Fig. 329).

CAUTION: Bottom of support fixture must be flush with face of bell housing. If the support fixture is not flush, the seals and rear transfer shaft bearing cup will be pressed in cocked.

Fig. 330:

34. Install transfer shaft support fixture (special tool 6595) (Fig. 330).

Fig. 331:

35. Install transfer shaft seal protector (special tool 6592) (Fig. 331). Apply thin film of gear oil to protector.

Fig. 332:

36. Apply a small amount of lube to seal lips and install front transfer shaft seal. The serrated edges must face toward the rear of the transaxle (Fig. 332).

Fig. 333:

37. Install seal with special tool 6567A (Fig. 333). Use a press to install seal. The installation tool will set the seal depth. Do not use a hammer to install seal. The seal may be damaged if installed with a hammer.

Fig. 334:

38. Install rear transfer shaft seal. The seal must be installed so that the spring side of the seal faces the installation tool (Fig. 334). Use the same special tool (6567A) to install the seal. The installation tool will set the seal depth. Use a press to install this seal. Do not use a hammer.

Fig. 335:

39. Install rear transfer shaft cup into case (Fig. 335).

CAUTION: Properly seated cups are essential in correctly setting bearing preload.

Fig. 336:

40. Use special tool 6560 to press cup into case (Fig. 336).

Fig. 337:

41. Install Transfer shaft preload shim (Fig. 337). Use the original shim that was taken out of transaxle if possible. If original shim is not available, use the thickest shim as a starting point. Refer to Transfer Shaft Rear Shim Chart for available sizes.
42. Install rear transfer shaft cone. Press cone on transfer shaft using Special Tool MD998805.
43. Remove transfer shaft support fixture (special tool 6595).

CAUTION: Always use a new transfer shaft nut. Do not reuse old transfer shaft nut.





Transfer Shaft Rear Shim Chart

Fig. 338:

44. Install a new transfer shaft nut (Fig. 338). Tighten nut to 271 Nm (200 ft. lbs.). Use special tools 6497 holder and 6498 shaft socket to tighten nut.

CAUTION: Failure to set the transfer shaft turning torque correctly may cause transfer shaft bearings or seals to fail. Be sure transfer shaft does not have end play. If end play exists, install a thinner preload shim.

Fig. 339:

45. Check the turning torque of the transfer shaft using a torque wrench (Fig. 339). The turning torque should be 0.5 to 1.3 Nm (5 to 12 inch lbs.). If the turning torque is too high, install a thicker transfer shaft preload shim. If the turning torque is too low, install a thinner transfer shaft preload shim.

CAUTION: A press and special tool 6589 must be used when staking the transfer shaft nut. Do not use a hammer and the special tool to stake nut. If a hammer is used; seal, bearing, and/or tool damage may result. Also the stake will not be seated against the shaft correctly. This will allow the nut to loosen.

Fig. 340:

Fig. 341:

46. After the correct turning torque is obtained, use special tool 6589 to stake the new transfer shaft nut (Fig. 340). Be sure that the tool arms line up with slots in the transfer shaft. Use a press with the special tool to make the stakes in the nut.

CAUTION: Failure to stake the transfer shaft nut correctly may allow the nut to loosen during transaxle operation. This will cause transaxle failure.

47. At this point the transfer shaft, new oil seals, pinion depth and transfer shaft preload have been set. The following steps will set the backlash between the transfer shaft and the ring gear.
48. If the carrier requires reconditioning, refer to Differential Carrier Recondition.

Fig. 342:

49. Install vent baffle. Apply sealer as shown in (Fig. 342).
50. Install new inner adjuster O-ring. Lube inner adjuster threads and O-ring. Then install inner adjuster flush with differential side of case.

Fig. 343:

51. Install differential assembly (with ring gear attached) into transaxle case (Fig. 343).

Fig. 344:

52. Transfer shaft to ring gear backlash should be 0.006" to 0.009" thousands of an inch. To get the backlash close enough to measure, perform the following steps. Hold the transfer shaft with one hand and rock the ring gear back and forth (Fig. 344). You should feel some backlash between the gears. If no backlash is felt use special tool 6502B to turn the inner adjuster so that it raises the differential assembly. This will increase backlash. If there is to much backlash, use special tool 6502B to turn the inner adjuster so that it lowers the differential assembly. This will decrease backlash. Recheck the backlash after each adjustment.

Fig. 345:

53. Apply a 1/8 inch bead of sealant to differential cover flange. Then install differential cover with sealant (Fig. 345) and tighten cover bolts.

Fig. 346:

54. Install seal protector (special tool 6591) on shaft (Fig. 346).

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

Fig. 347:

55. Install outer adjuster with new O-ring (Fig. 347). Torque the outer adjuster (special tool 6503) to the torque reading recorded in Step 30. Then seat bearings, by turning differential three or four revolutions in both directions. Tighten adjuster a second time to same torque recorded in Step 30. Again reseat bearings. Repeat this sequence until correct adjuster torque is maintained.

Fig. 348:

56. To check and/or adjust backlash, remove the inspection plug from the top of the differential. Install dial indicator as shown in (Fig. 348). The tip of the dial indicator must be perpendicular against one of the ring gear teeth. Hold transfer shaft with locking pliers. Move ring gear back and forth with special tool 6548. Read the amount of backlash with dial indicator. Backlash should be 0.006" to 0.009" thousands of an inch.
57. If there is too much backlash, loosen the outer adjuster with special tool 6503. Then turn the inner adjuster so that it moves away from the ring gear. After adjusting the inner adjuster, retighten the outer adjuster to the torque recorded in Step 30. The inner adjuster should be turned in small increments.
58. If there is not enough backlash, loosen the outer adjuster with special tool 6503. Then turn the inner adjuster so that it moves towards the ring gear. After adjusting the inner adjuster, retighten the outer adjuster to the torque recorded in Step 30. The inner adjuster should be turned in small increments.
59. Once backlash is with in specifications, recheck backlash in four spots on t1le ring gear 90 degrees apart. All four readings should be within specifications.
60. Install inner and outer adjuster locking brackets.
61. Install new inspection plug. Use a wooden block to tap inspection plug into place.
62. It is easier to fill the differential prior to installing the transaxle back into the vehicle. The differential holds 32 ounces of fluid.

DIFFERENTIAL CARRIER-RECONDITION

Fig. 349:

Fig. 350:

Fig. 351:

Fig. 352:

Fig. 353:

Fig. 354:

Fig. 355:

Fig. 356:

CAUTION: Ring gear bolts are not reusable. When reassembling use new bolts.

NOTE: Mark ring gear location, if reusing ring gear.

NOTE: When reassembling differential, line up notches on side of carrier.

CAUTION: When reassembling use a new roll pin.

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.