Differential Case: Reassembly
- Coat thrust washers, side gears and pinion gears with oil. Install 2 thrust washers onto 2 differential side gears. Install 2 thrust washers with 2 side gears, and 2 thrust washers with pinion gears into differential case. Install pinion shaft, aligning lock pin holes on pinion shaft and differential case.
- Mount differential case in a soft-jawed vise. Using a dial indicator, check side gear backlash. Hold one pinion gear against case. Measure side gear backlash. See Figure. Backlash must be .002-.008" (.05-.20 mm). If backlash is not within specification, side gear thrust washers must be replaced.
- Select appropriate thrust washers to obtain correct side gear backlash. Thrust washers are available in thicknesses from .039" (1.0 mm) to .051" (1.3 mm) in .004" (.10 mm) increments. Install thrust washers and side gears in differential case. If possible, install same size thrust washers on both sides. Install pinion gears and pinion shaft. Check side gear backlash to ensure proper thrust washers are used.
- Using a pin punch and hammer, drive pinion shaft pin through transaxle case and pinion shaft. Stake differential case. Using appropriate press, install differential case tapered roller bearings.
- Clean contact surface of differential case and ring gear using cleaning solvent. Heat ring gear to 212°F (100°C) in water. DO NOT heat ring gear above 230°F (110°C).
- After moisture on ring gear has completely evaporated, quickly align match marks made during disassembly. Install ring gear on differential case. Install ring gear bolts and tighten to 78 ft. lbs. (106 N.m). Install NEW oil seals in transaxle housing and transaxle case. Coat lip of oil seals with lubricant.
- Adjust differential bearing preload. See DIFFERENTIAL BEARING PRELOAD under TRANSAXLE ADJUSTMENTS.