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Fig. 9 Differential Gears

After assembling the differential side gears, pinion gears and pinion gears with the pinion gear washers, but without the side gear thrust washers. Rotate the assembly two full revolutions both clockwise and counterclockwise.

Set up dial indicator as shown and record end play. Rotate side gear 90 degrees and record another end play. Again, rotate side gear 90 degrees and record a final end play.

Using the smallest end play recorded, shim that side gear to within .001 to .013 inch. The other side gear should be checked using the same procedure.

Fig. 10 Checking Side Gear End Play

CAUTION: Side gear end play must be within .001 to

.013 inch. Four select thrust washers are available:

.032, .037, .042, and .047 inch.

CAUTION: Side gear end play must be within .001 to

.013 inch. Four select thrust washers are available:

.032, .037, .042, and .047 inch.

Fig. 11 Checking Side Gear End Play

A-568 DIFFERENTIAL

Shim thickness need only be determined if any of the following parts are replaced:

²Transaxle case

²Differential bearing retainer

²Extension housing

²Differential case

²Differential bearings

Refer to Bearing Adjustment Procedure in rear of this section to determine proper shim thickness for correct bearing preload and proper bearing turning torque.

Fig. 1 Remove Differential Bearing Cone

21 - 30 TRANSAXLE

Fig. 2 Install Differential Bearing Cone

Fig. 3 Remove Differential Bearing Cone

Fig. 4 Install Differential Bearing Cone

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Fig. 5 Remove or Install Ring Gear Bolts

CAUTION: Always install new ring gear bolts. Bolts must be properly torqued (See Tightening Reference).

Fig. 6 Remove Ring Gear

Fig. 8 Install 3 Roll Pins

Fig. 9 Ring Gear and Side Gear Removed

CAUTION: See Figure 12 to determine side gear thrust washer thickness. Side gear end play must be within.001 to .013 inch.

Four select thrust washes are available: .032,

.037, .042, and .047 inch.

Fig. 11 Remove or Install 4 Pinion Gears and 2 Side Gears

Fig. 12 Differential Gears

Side gear thrust washers are available in 4 select thicknesses: .032, .037, .042, and .047 inch.

Measure the depth from the differential case to the machined surface in 3 places, as shown in Figure 13. Then measure the height of raised step on the ring gear. The difference, minus the proper side gear end play (.001 to .013 inch) is the proper thrust washer thickness.

For the other side gear: After assembling the differential side gears, pinion gears, and pinion gears with the pinion gear washers but without the side gear thrust washers. Rotate the assembly two full revolutions both clockwise and counterclockwise.

Set up dial indicator as shown in Figure 14 and record end play. Rotate side gear 90 degrees and record another end play. Again, rotate side gear 90 degrees and record a final end play.

Using the smallest end play recorded, shim that side gear to within .001 to .013 inch.

Fig. 13 Determine Proper Side Gear Thrust Washer

Thickness

CAUTION: After reassembly of the differential assembly, insert the inner joint housing spline from a drive shaft into the side gear. By hand, turn the side gear with the joint housing spline. If the side gear will NOT turn, or it feels very tight, remove the ring gear and install a thinner side gear thrust washer.

Fig. 14 Checking Side Gear End Play

Side gear thrust washers are available in four select thicknesses: .032, .037, .042, and .047 inch.

BEARING ADJUSTMENT PROCEDURE

GENERAL RULES ON SERVICING BEARINGS

(1)Take extreme care when removing and installing bearing cups and cones. Use only an arbor press for installation, as a hammer may not properly align the bearing cup or cone. Burrs or nicks on the bearing seat will give a false end play reading while gauging for proper shims. Improperly seated bearing cups and cones are subject to low mileage failure.

(2)Bearing cups and cones should be replaced if they show signs of pitting or heat distress. If distress

is seen on either the cup or bearing rollers, both cup and cone must be replaced.

(3)Bearing preload and drag torque specifications must be maintained to avoid premature bearing failures. Used (original) bearing may lose up to 50% of the original drag torque after break in. All bearing adjustments must be made with no other component interference or gear intermesh.

(4)Replace bearings as a pair. For example, if one differential bearing is defective, replace both differential bearings. If one input shaft bearing is defective, replace both input shaft bearings.

(5)Bearing cones must not be reused if removed.

(6)Turning torque readings should be obtained while smoothly rotating in either direction (breakaway reading is not indicative of the true turning torque).

(7)Replace oil baffle, if damaged.

INPUT SHAFT BEARING END PLAY

ADJUSTMENT

(1)Using Tool C-4656 with Handle C-4171, press input shaft front bearing cup slightly forward in case. Then, using Tool C-4655 with Handle C-4171, press bearing cup back into case from the front. Properly position bearing cup, before checking input shaft end play (see input shaft front bearing cup replace in

Subassembly Recondition section). This step is not necessary if Tool C-4655 was previously used to install input shaft front bearing cup in the case. Also no input shaft shim has been installed since pressing cup into case.

(2)Select a gauging shim which will give 0.025 to 0.254mm (.001 to .010 inch) end play. SUGGES-

TION: Measure original shim from input shaft seal retainer and select a shim 0.254mm (.010 inch) thinner than original for the gauging shim.

(3)Install gauging shim on bearing cup and install input shaft seal retainer.

CAUTION: The input shaft seal retainer is used to draw the input shaft front bearing cup the proper distance into the case bore during this step. Alternately tighten input shaft seal retainer bolts until input shaft seal retainer is bottomed against case. Tighten bolts to 28 NIm (21 ft. lbs.).

(4)Oil input shaft bearings with SAE 5W-30 engine oil and install input shaft in case. Install bearing retainer plate with input shaft rear bearing cup

pressed in and bearing support plate installed. Tighten all bolts and nuts to 28 NIm (21 ft. lbs.).

(5)Position dial indicator to check input shaft end play. Apply moderate load, by hand, to input shaft splines (Fig. 1). Push toward rear while rotating input shaft back and forth a number of times to settle out bearings. Zero dial indicator. Pull input shaft to-

tained. Observe CAUTION in step (8).

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

(1)Remove bearing cup and existing shim from differential bearing retainer. (See Differential Bearing Retainer in Subassembly Recondition section).

(2)Select a gauging shim which will give 0.025 to 0.254mm (.001 to .010 inch) end play. SUGGESTION:

Measure original shim from differential bearing retainer and select a shim 0.381mm (.015

Install gauging shim in differential bearing retainer and press in bearing cup. Installation of oil baffle is not necessary when checking differential assembly end play.

(3) Oil differential bearings with SAE 5W-30 engine oil and install differential assembly in transaxle case. Check extension housing O-ring for damage (replace if necessary). Add a 1/16 inch bead of MOPARt Gasket Maker, Loctite 518, or equivalent to exten-

Fig. 3 Checking Differential Bearing End Play to Determine Shim Thickness

(6)The Shim required for proper bearing preload is the total of the gauging shim thickness, plus end play, plus (constant) preload of 0.254mm (.010 inch). Combine shims, if necessary, to obtain a shim within .05mm (.002 inch) of the required shim (see Shim Chart for proper shims).

(7)Remove differential bearing retainer. Remove bearing cup and gauging shim. Properly install oil baffle. Be sure oil baffle is not damaged. Install shim(s) selected in step (6). Then press in the bearing cup into differential bearing retainer.

(8)Using a 1/16 inch bead of MOPARt Gasket Maker, Loctite 518, or equivalent for gasket, install differential bearing retainer. Torque all bolts (See Tightening Reference).

(9)Using Special Tool C-4995 and an inch-pound torque wrench, check turning torque of the differential assembly in clockwise and counterclockwise directions (Fig. 4). The turning torque should be 9 to

14 in. lbs. for new bearings or a minimum of 6

Fig. 4 Checking Differential Bearing Turning Torque

DIFFERENTIAL BEARING SHIM CHART

in. lbs. for used bearings. If the turning torque is too high, install a .05mm (.002 inch) thinner shim. If the turning torque is too low, install a

.05mm (.002 inch) thicker shim.

(10) Recheck turning torque. Repeat Step (9) until the proper turning torque is obtained.