Differential Bearing Preload Adjustment

1. Remove bearing cup and existing shim from clutch bellhousing case.
2. Press in new bearing cup into bellhousing case (or use a cup that has been ground down on the outer edge for ease of measurement).
3. Press in new bearing cup into gear case side.
4. Oil differential bearings with transmission fluid. Install differential assembly in transaxle gear case. Install clutch bellhousing over gear case. Install and torque case bolts to 29 N.m (21 ft. lbs.).
5. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator.
   NOTE: Position of dial indicator in is for illustrative purposes only. The dial indicator should be parallel to T-Handle to obtain the most accurate reading. See Fig 1.
   Fig 1: Checking Differential Bearing End Play to Determine Shim Thickness

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - T-HANDLE

   2 - DIAL INDICATOR SET

   3 - TORQUE TOOL C-4995

6. Apply a medium load to differential with Torque Tool C-4995 (3) and a T-handle (1), in the downward direction. Roll differential assembly back and forth a number of times. This will settle the bearings. Zero the dial indicator (2). To obtain end play readings, apply a medium load in an upward direction while rolling differential assembly back and forth. Record end play. See Fig 1.
   Fig 2: Checking Differential Bearing Turning Torque

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - INCH-POUND TORQUE WRENCH

   2 - TORQUE TOOL C-4995

7. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18mm (0.007 in.).  Never combine shims to obtain the required preload.
8. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim(s) selected in step  7. Then press the bearing cup into clutch bellhousing.
9. Install clutch bellhousing. Install and torque case bolts to 26 N.m (19 ft. lbs.).
10. Using Torque Tool C-4995 (2) and an inch-pound torque wrench (1), check turning torque of the differential assembly. The turning torque should be 6 to 12 in. lbs. If the turning torque is too high, install a 0.05mm (0.002 inch) thinner shim. If the turning torque is too low, install a 0.05mm (0.002 inch) thicker shim. 
11. Recheck turning torque (1). See Fig 2. Repeat step  10. until the proper turning torque is obtained.

Once proper turning torque has been established, place gear case on the end plate. Draw a bead of Mopar® Gasket Maker, Loctite® 518, or equivalent, on the flat surface of the case mating flange. Install clutch bellhousing onto gear case. Install and tighten case bolts to 29 N.m (21 ft. lbs.).