>> A << Spacer/Side Gear/Washer/Pinion/Pinion Shaft Installation

WARNING: This page is about a different car, the 2005 Dodge Stratus. However, it is still accessible from the selected car via links, so may be relevant.

After a spacer has been mounted on the back surface of the side gear, install the side gear in the differential case.
NOTE: When a new side gear is to be installed, mount a medium thickness spacer [0.93 - 1.00 mm (0.0366 - 0.0395 inch].
Set the washer on the back of each pinion, and put both pinions simultaneously in mesh with the side gears. While rotating them, install them in position.

Fig 1: Putting Both Pinions Simultaneously In Mesh
Courtesy of DAIMLERCHRYSLER CORP.
Insert the pinion shaft.

Fig 2: Inserting Pinion Shaft
Courtesy of DAIMLERCHRYSLER CORP.
Measure the backlash between the side gear and pinion.
Standard value: 0.025 - 0.150 mm (0.0010 - 0.0059 inch)
If the backlash is out of specification, select a spacer and re-measure the backlash.
NOTE: Adjust until the backlashes on both sides are equal.

Fig 3: Measuring Backlash Between Side Gear And Pinion
Courtesy of DAIMLERCHRYSLER CORP.