Differential Installation
NOTE: If the differential case, bearing retainer or differential bearing is replaced, re-shimming will be required. Consult the appropriate Powertrain Car Shop Manual, Section 15-20.1. Position the jack under the rear oil pan rail of transaxle case. Place a wood block between jack and case to protect oil pan and case mating surface.
CAUTION: Extreme care must be taken not to damage transaxle case.
2. Raise the jack high enough to allow installation of bearing retainer.
NOTE: Inspect both differential seals for any evidence of damage and replace, if necessary, prior to differential installation.
Figure 25:
3. Refer to Figure 25.
Install differential, shims and bearing retainer using new O-ring seal or gasket.
Figure 26:
4. Refer to Figure 26.
Apply Threadlock and Sealer, E0AZ-19554-A (ESE-M4G204-A) or equivalent to threads of bearing retainer attaching bolts.
Install bolts and tighten to 20-26 N-m (15-19 ft.lbs.)
Figure 27:
5. Refer to Figure 27.
Lower the jack, Rotunda Number 014-00210, far enough to install the rear motor mount on the transaxle. Install the two (2) mount bolts and torque to 41-61 N-m (30-45 ft.lbs.)
Figure 28:
6. Refer to Figure 28.
Install the two (2) support bracket attaching nuts. Torque nuts 61-88 N-m (45-65 ft.lbs.) and remove jack.
Figure 29:
HALFSHAFT INSTALLATION
7. Refer to Figure 29.
Install new circlips on the inboard CV joint stub shafts.
The outboard CV joint stub shaft does not have a circlip.
NOTE: To install the circlip properly, start one end in the groove and work the circlip over the stub shaft end and into the groove. This will avoid over-expanding the circlip.
CAUTION: The circlip must not be reused. A new circlip must be installed each time the inboard CV joint is installed into the transaxle differential.
Figure 30:
8. Refer to Figure 30.
Carefully align the splines of the inboard CV joint stub shaft with the splines in the differential. Exerting some force, push the CV joint into the differential until the circlip is felt to seal in the differential side gear.
Use care to prevent damage to the differential oil seal.
CAUTION: Install shipping plug T81P-1177-B or equivalent to assure alignment of CV joint stub shaft with side gear.
NOTE: A non-metallic mallet may be used to aid in seating the circlip into the differential side gear groove. If a mallet is necessary, tap only on the outboard CV joint stub shaft.
Figure 31:
9. Refer to Figure 31.
Position a new seal on filter and install filter.
Install filter attaching bolts and tighten to 9-12 N-m (7-9 ft.lbs.)
Figure 32:
10. Refer to Figure 32.
Install new oil pan gasket.
Figure 33:
11. Refer to Figure 33.
Install oil pan and torque the thirteen (13) attaching bolts 16-23 N-m (12-17 ft.lbs.)
Figure 34:
12. Refer to Figure 34.
Connect control arm to the steering knuckle and install a new nut and bolt.
Tighten the nut to 50-60 N-m (37-44 ft.lbs.).
Repeat this step on the remaining side.
CAUTION: A new bolt and nut must be installed.
Figure 35:
13. Refer to Figure 35.
Position the brake hose routing clip on the suspension strut and install the attaching bolt.
Tighten the bolt to 11 N-m (8 ft.lbs.)
Figure 36:
14. Refer to Figure 36.
Reassemble the steering gear tie rod to the steering knuckle using a new nut and cotter pin.
Repeat this step on the remaining side.
Figure 37:
15. Refer to Figure 37.
Install the wheels and tires and lower the vehicle.
Tighten the wheel nuts to 108-144 N-m (80-105 ft.lbs.)
Figure 38:
16. Refer to Figure 38.
If equipped, install the bolts attaching the managed air valve to the ATX valve body cover.
Install the bolt that retains the thermactor hoses.
17. Fill the transaxle to the proper level with the specified automatic transmission fluid. Consult the appropriate model year Car Shop Manual for specifications and fill requirements.
Recheck fluid level at normal operating temperature.
OTHER APPLICABLE ARTICLES: 86-1-7
WARRANTY STATUS: "INFORMATION ONLY"