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Manual Transaxle: Differential: Assembly

  1. Install side gear thrust washer (Fig 1 ).
    Fig 1: Installing Side Gear Thrust Washer
    G02692933Courtesy of DAIMLERCHRYSLER CORP.
  2. Install differential side gear (Fig 2 ).
    Fig 2: Installing Differential Side Gear
    G02692934Courtesy of DAIMLERCHRYSLER CORP.
  3. Install four (4) pinion gears and thrust washers (Fig 3 ).
    Fig 3: Installing Pinion Gear And Thrust Washer
    G02692935Courtesy of DAIMLERCHRYSLER CORP.
  4. Install pinion shaft retaining ring (Fig 4 ).
    Fig 4: Installing Pinion Shaft Retaining Ring
    G02692936Courtesy of DAIMLERCHRYSLER CORP.
  5. Install two (2) short pinion shafts (Fig 5 ).
    Fig 5: Installing Short Pinion Shaft (2)
    G02692937Courtesy of DAIMLERCHRYSLER CORP.
  6. Install one (1) long pinion shaft (Fig 6 ).
    Fig 6: Installing Long Pinion Shaft
    G02692938Courtesy of DAIMLERCHRYSLER CORP.
  7. Install differential side gear.
  8. Install side gear thrust washer (Fig 7 ).
    Fig 7: Installing Side Gear Thrust Washer
    G02692939Courtesy of DAIMLERCHRYSLER CORP.
  9. Install differential support plate. Align support plate to differential case with alignment pins 8470 (Fig 8 ).
    Fig 8: Aligning Differential Support To Case
    G02692940Courtesy of DAIMLERCHRYSLER CORP.
  10. Install thrust buttons 8491 to both bearing journals and press halves together using an arbor press (Fig 9 ).
    Fig 9: Installing Differential Support
    G02692941Courtesy of DAIMLERCHRYSLER CORP.
  11. Install ring gear into position, start three ring gear-to-differential case bolts by hand (120° apart), and install alignment pins 8470 (Fig 10 ).
    Fig 10: Installing Ring Gear
    G02692942Courtesy of DAIMLERCHRYSLER CORP.
  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 N.m (70 ft. lbs.) (Fig 11 ).
    Fig 11: Installing Ring Gear-To-Differential Case Bolts
    G02692943Courtesy of DAIMLERCHRYSLER CORP.
  13. Install tapered roller bearings using installer 8473 and an arbor press (Fig 12 ). Insert button 8491 on opposite journal to protect journal and/or bearing during press operation. Repeat the same operation on opposite side.
    Fig 12: Installing Differential Side Bearing Installation
    G02692944Courtesy of DAIMLERCHRYSLER CORP.
  14. Measure and verify differential side gear end play. (Refer to DIFFERENTIAL - ADJUSTMENTS  ).
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