Differential Assembly: Adjustments

Fig. 20 Differential bearing shim chart:

When making adjustments, ensure there is no gear interference from other components.

1. Remove bearing cup and shim from differential bearing retainer (if not previously done).
2. Select a suitable gauging shim that will give 0.001-0.010 inch endplay. If original shim is available, measure it, then select a shim 0.015 inch less than measurement.
3. Install selected gauging shim in differential bearing retainer, then press in bearing cup. It is not necessary to install oil baffle at this time.
4. Lubricate differential bearings with SAE 5W-30 motor oil, then install differential in transaxle case. Inspect extension housing O-ring for damage and replace as necessary. Apply a 1/16 inch bead of RTV to extension housing flange.
5. Install extension housing and differential bearing retainer. Torque attaching bolts to 21 ft. lbs.
6. Position transaxle case on workbench with bellhousing facing downward. Secure with suitable C-clamps. Install suitable dial indicator in such a way as to measure differential endplay.
7. Apply medium load to differential with tool No. C-4995 and T-handle in downward direction while rotating differential assembly back and forth several times to seat bearings. Zero dial indicator, then to obtain endplay reading, apply medium load in upwards direction while rolling differential assembly back and forth several times to settle bearings. Measure and record endplay.
8. The required shim for bearing preload is determined by adding gauging shim thickness, endplay and preload of 0.010 inch. After determining proper thickness. Shims can be combined as necessary to be within 0.002 inch of required dimension.
9. Remove differential bearing retainer, bearing cup and gauging shim. Install oil baffle, ensuring it is not damaged. Install shims, then press bearing cup into retainer.
10. Using tool NO. C-4995 and suitable inch lbs. torque wrench, check turning torque of differential assembly in both directions. Turning torque should be 9-14 ft. lbs. for new bearings, or 6 inch lbs. for used bearings. If turning torque is too high, install 0.002 inch thinner shim. If turning torque is too low, install a 0.002 inch thicker shim.
11. Repeat step 10 until proper turning torque is established.