Differential Assembly: Reassembly
WARNING: This page is about a different variant/trim than selected.
- Install original shim (if removed) into transaxle case. Using appropriate race installer and hammer, install outer race into transaxle housing and transaxle case (if removed). Drive outer races in until shim and outer race contact housing or case surface.
- Coat thrust washers, side gears and pinion gears with ATF. Install 2 thrust washers onto 2 differential side gears. Install 2 thrust washers with 2 side gears, and 2 thrust washers with pinion gears into differential case. Install pinion shaft, aligning lock pin holes on pinion shaft and differential case.
- Mount differential case in a soft-jawed vise. Using a dial indicator, check side gear backlash. Hold one pinion gear against case. Measure side gear backlash. See Figure. Backlash must be .002-.008" (.05-.20 mm). If backlash is not within specification, side gear thrust washers must be replaced.
- 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 side gear backlash to ensure proper thrust washers are used.
- Using a pin punch and hammer, drive pinion shaft pin through transaxle case and pinion shaft. Stake differential case. Using appropriate press, install differential case tapered roller bearings.
- Remove any material from transaxle housing and case mating surfaces. DO NOT allow oil to contact surfaces. Install differential assembly into transaxle case. Install transaxle housing onto transaxle case. Install 14 bolts and tighten all bolts except 3 lower bolts ("A") inside transaxle housing to 22 ft. lbs. (29 N.m). Tighten 3 lower bolts ("A") inside transaxle housing to 16 ft. lbs. (22 N.m). Ensure bolts are in correct locations. See Figure.
- Using appropriate adapter and ratchet, rotate differential assembly in both directions to seat bearings. Using an INCH-lb. torque wrench, measure differential side bearing preload. See Fig 1. Preload should be 8.7-13.9 INCH lbs. (.98-1.57 N.m) for NEW bearings and 4.3-6.9 INCH lbs. (.5-.8 N.m) for used bearings.
- If preload is not within specifications, remove 14 transaxle housing bolts. Using a plastic hammer, remove transaxle housing from transaxle case. Remove differential assembly from transaxle case and replace shim at rear tapered roller bearing with appropriate shim.
- Adjustment shims are marked in numeric order and are available in thicknesses from .075 (1.90 mm), marked with a "01", to .110" (2.80 mm), marked with the number "19". Shims increase in increments of .002" (.05 mm). Recheck preload after shim replacement.
- Clean contact surface of differential case and ring gear using cleaning solvent. Heat ring gear to 212°F (100°C) in water. DO NOT heat ring gear greater than 230°F (110°C).
- After moisture on ring gear has completely evaporated, quickly align match marks made during disassembly. Install ring gear on differential case. Install ring gear bolts and lock plates and tighten bolts to 65 ft. lbs. (88 N.m).
- Install NEW oil seals in transaxle housing and transaxle case. On U340E transaxle, transaxle housing oil seal installed depth is .059-.098" (1.50-2.50 mm). On U341E transaxle, transaxle housing oil seal installed depth is -.020-.020" (-.50-.50 mm). On U340E transaxle, transaxle case oil seal installed depth is .213-.252" (5.40-6.40 mm). On U341E transaxle, transaxle case oil seal installed depth is .087 to .126" (2.20-3.20 mm). On both transaxles, coat lip of oil seals with lubricant.