Differential Assembly

Differential bearing preload must be adjusted if any of the following components have been replaced:

• Transaxle Case
• Differential Carrier
• Differential Bearing Retainer
• Extension Housing
• Differential Bearings

If none of these parts are replaced, differential may be reassembled using the original adjusting shims.

1. Remove differential bearing outer race and preload adjusting shim from differential bearing retainer. If differential bearings have been replaced, also replace outer race in extension housing.
2. Install .020 (.50 mm) gauging shim in differential bearing retainer and reinstall bearing outer race. Install a new outer race in extension housing (if removed).
3. Position differential assembly in transaxle case. Install extension housing on case and tighten attaching bolts. Install differential bearing retainer and tighten attaching bolts.
4. Position transaxle assembly vertically in support stand and install Adapter (L-4436 ) into extension housing. Rotate differential at least one full turn to ensure tapered roller bearings are fully seated.
   NOTE: Adapter (L-4436 ) fits through extension housing and rests on pinion shaft.
5. Attach dial indicator to case. See Fig 1 . Position indicator tip on end of adapter and zero dial indicator.
   Fig 1: Measuring Differential End Play

   Courtesy of CHRYSLER MOTORS.
6. Place a large screwdriver under each side of ring gear and lift. Check dial indicator for amount of end play.
   CAUTION: DO NOT  damage transaxle case or differential cover sealing surface when lifting ring gear.
7. To determine shim combination required to obtain correct differential bearing preload, see the DIFFERENTIAL BEARING SHIM  table.
8. Remove differential bearing retainer.Remove differential bearing outer race and gauging shim from retainer. Install proper shim combination, as determined in step 7), under bearing race. Ensure oil baffle is installed properly in retainer, below bearing shims and race. Reinstall bearing retainer in case. Use RTV sealant between retainer and case.
9. To check adjustment, oil differential bearings. Insert Adapter (L-4436) through extension housing to engage differential assembly.
10. Using an INCH lb torque wrench, check differential turning torque. Turning torque with differential bearing preload correctly adjusted should be 5-18 INCH lbs. (.55-2.0 N.m). If not, install a .002" (.05 mm) thinner shim to decrease torque or a .002" (.05 mm) thicker shim to increase torque.
11. When correct torque has been obtained, remove torque wrench, apply 1/8" bead of RTV sealant around differential cover and install cover on case. Install and tighten attaching bolts. Oil and install a new extension housing oil seal.