Reassembly (Differential & Drive Pinion)
- Install NEW counter driven gear bearing (if necessary). Press in shaft bearing outer race into cage. Press bearing onto drive pinion shaft. Install drive pinion into transaxle case. See Fig 1 and Fig 2 . Place bearing cage onto drive pinion shaft. DO NOT damage oil seals with pinion shaft. Using brass drift and hammer, lightly tap bearing cage into transaxle case until snap ring groove in bore is visible. Install snap ring into bore.
- On A-540E transaxle, install sensor rotor. On all transaxles, install oil slinger and NEW spacer (crush sleeve). Install spacer with small end downward. Press outer race into case. Place transaxle case with converter side facing down. Support drive pinion shaft with brass bar. See Fig 3. Using press, install driven gear until bearing almost touches counter gear.
- Install NEW lock nut. Secure gear from turning. Tighten nut to 207 ft. lbs. (280 N.m). Rotate gear both directions while tightening nut. Using a INCH-lb. torque wrench, measure starting preload of drive pinion.
- Starting preload with new bearing should be 8.7-13.9 INCH lbs. (1.0-1.6 N.m). With used bearing, preload should be 4.3-6.9 INCH lbs. (.5-.8 N.m). If preload exceeds specification, replace bearing spacer (crush sleeve). DO NOT loosen nut to adjust starting preload.
- If starting preload is less than specification, retighten shaft nut 115 INCH lbs. (13 N.m) at a time until specified preload is reached. Maximum shaft nut torque is 260 ft. lbs. (353 N.m). If maximum torque is exceeded while tightening shaft nut, replace bearing spacer. Repeat preload procedure. DO NOT loosen nut to reduce preload. Stake lock nut.
- Install apply gasket(s) in transaxle case. On A-540E and A-541E transaxles, place outer race and selected adjusting shim on right side bearing. On all transaxles, place differential case in transaxle case. On A-540E and A-541E transaxles, ensure shim is properly installed. On A-540H transaxle, ensure ring gear mount case sleeve and outer race are properly installed.
- On all transaxles, ensure bearing contact surfaces of differential (carrier) cover and transaxle case are oil free. Apply appropriate sealer to case and carrier cover. Install cover. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
- Install left bearing retainer by tapping with soft-faced hammer while keeping carrier centered with retainer. Tighten bolts to 14 ft. lbs. (19 N.m). Seat bearings by turning differential assembly several times.
- Using a INCH-lb. torque wrench, measure total preload. See Figure. Drive pinion starting preload with new bearings should be 2.2-3.8 INCH lbs. (.2-.4 N.m) greater than drive pinion shaft preload previously measured in step 4.
- If used bearings are used, preload should be 1.2-1.9 INCH lbs. (.1-.2 N.m) greater than drive pinion shaft preload previously measured. If preload exceeds specifications, replace adjusting shim in left bearing retainer. Remove left bearing retainer. Remove bearing race from retainer. Select shim from DIFFERENTIAL SIDE BEARING ADJUSTING SHIM SELECTION table.DIFFERENTIAL SIDE BEARING ADJUSTING SHIM SELECTION
ID Mark Thickness - In. (mm) 0 .0787 (2.000) 1 .0807 (2.050) 2 .0827 (2.100) 3 .0846 (2.150) 4 .0866 (2.200) 5 .0886 (2.250) 6 .0906 (2.300) 7 .0925 (2.350) 8 .0945 (2.400) 9 .0965 (2.450) A .0984 (2.500) B .1004 (2.550) C .1024 (2.600) D .1043 (2.650) E .1063 (2.700) F .1083 (2.750) G .1102 (2.800) H .1122 (2.850) - Install selected shim in retainer. Install bearing race. Install left bearing retainer by tapping with soft-faced hammer while keeping carrier centered with retainer. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Recheck total starting preload.
- If starting preload is within specification, remove left bearing retainer. Apply appropriate sealant to retainer mounting surface. Apply thread sealer to bolts. Install retainer.
- Place oil baffle on left bearing retainer. Press in oil seal until flush with surface of retainer. Apply sealant to right retainer. Coat bolt threads with sealer. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install drive pinion cap to converter side of transaxle case.