Component Disassembly & Reassembly: Differential: Reassembly

Install bearing outer races and original shims in transaxle housing and case. Select thrust washers that will ensure correct side gear backlash. Thrust washers are available in thicknesses of .037-.047" (.95-1.20 mm) in .002" (.05 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 gear backlash to ensure proper thrust washers are used. When backlash is correct, drive lock pin through differential case and into pinion shaft. Stake differential case to retain lock pin.
Press side bearing on differential case. Install speedometer drive gear on differential case. Install remaining side bearing on differential case.
Install differential in transaxle case. Install transaxle housing. Install bolts in correct locations and tighten bolts to 21 ft. lbs. (29 N.m). See Fig 3-72. Measure differential bearing preload, using Differential Preload Adapter (09564-32011) and an INCH-lb. torque wrench. See Fig 6.
Preload must be within specification. Refer to the DIFFERENTIAL PRELOAD SPECIFICATIONS table. If preload is incorrect, remove differential from transaxle case and replace adjusting shim under bearing. Adjusting shims are available in thicknesses of .079" (2.00 mm) to .114" (2.90 mm) in .002" (.05 mm) increments. Preload will change approximately 2.6-3.5 INCH lbs. (.3-.4 N.m) with each shim thickness.
When correct preload is obtained, remove differential from transaxle case. Install ring gear on differential case. Clean ring gear and mounting surface. Heat ring gear to 212°F (100°C) in an oil bath. DO NOT heat ring gear at temperatures greater than 230°F (110°C). Align ring gear on differential case and install NEW bolts. Tighten bolts evenly in crisscross pattern to 72 ft. lbs. (97 N.m).
Stake locking tabs. Stake one tab flush with flat surface of nut. Stake 2nd tab against corner of nut on tightening side. Coat lip of oil seals with multipurpose grease.

DIFFERENTIAL PRELOAD SPECIFICATIONS

Application	INCH Lbs. (N.m)
New Bearings	7.1-12.4 (.8-1.4)
Used Bearings	3.5-6.2 (.4-.7)

Fig 1: Measuring Differential Pinion Gear Backlash

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Fig 2: Exploded View Of Differential Assembly

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Fig 3: Installing Transaxle Housing Bolts (A-242L)

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Fig 4: Installing Transaxle Housing Bolts (A-241E & A-244E)

Fig 5: Installing Transaxle Housing Bolts (A-245E & A-246E)

Fig 6: Measuring Differential Bearing Preload