For 1990-2009 cars only
Housings Clean and Inspect
- Carefully and thoroughly inspect all drive unit components before assembly. Thorough inspection of the drive components for wear or stress with subsequent replacement of worn components eliminates costly drive component repair after assembly.
- Clean the housings in solvent and remove all sealant material from the sealing surfaces.
- Inspect the clutch and differential housings for the following:
- Clean and inspect the vent passage (1) and oil return passage (2).
- Clean and inspect the vent passage (1) in the rear cover.
- Clean and inspect the drain plug threads (1), and check the welch plug (2) for leakage, rust holes and looseness.
| • | Damaged sealing surfaces |
| • | Worn or scored bearing race bores |
| • | Damaged bolt, drain plug, or fill plug hole threads |
| • | Porosity |
| • | Damage to the exterior of the housings |
| • | Damaged, restricted or missing vent tube |
| • | Worn mounting bracket bushings |
Gears and Shafts Clean and Inspect
- Clean the gears and shafts in solvent.
- The ring gear and pinion must be inspected for the proper wear pattern.
- Inspect the pinion shaft for the following:
- Inspect the bearings for a bent bearing cage.
| • | The end of the gear tooth farthest away from the center of the ring gear (1) is the "heel" end of the tooth. |
| • | The end of the gear tooth nearest the center of the ring gear (2) is the "toe" end of the tooth. |
| • | The side of the tooth that curves inward or is concave (3) is considered the "coast" side of the tooth. |
| • | The side of the tooth that curves outward or is convex (4) is considered the "drive" side of the tooth. |
| • | Worn or damaged splines (1) |
| • | Worn bearings (2) |
| • | Wear, pitting or discoloration by heat (3) |
| • | Damaged threads (4) |
| • | Worn or scored shaft (5) |
Bearings and Races Clean and Inspect
- Inspect the bearing rollers and races for the following:
- Inspect the bearing rollers and races for heat discoloration. Heat discoloration ranges from a faint yellow to a dark blue color. This discoloration may result from an overload or improper lubrication. Excessive heat causes softening of the rollers and races.
- Inspect the pinion flange sealing surface (1) for wear, damaged bolt threads (2) and worn or damaged splines (3).
- Wipe with a clean lint free towel and inspect the following:
- Clean the differential case in solvent.
- Inspect the following for cracking or scoring:
- Replace the differential carrier assembly as necessary.
- Clean the following parts in solvent.
- Inspect the following for scoring, pitted teeth and cracks:
| • | Pitting |
| • | Scoring or grooves |
| • | Excessive wear or other damage |
Important: Bearing races with signs of heat discoloration must be replaced.
Notice: Do not submerge the clutch drum in solvent. Solvents will damage the friction material and gerotor pump.
Important: The clutch drum is not serviceable. If inoperative conditions are found, replace the unit.
| • | The pinion nut threads (1) |
| • | The pinion splines (2) |
| • | The bearing surface (3) |
| • | The front sealing surface (4) |
| • | The rear sealing surface (5) |
| • | The side bearing mounting surfaces (1) |
| • | The differential pin bores (2) |
| • | The ring gear mounting surfaces (3) |
| • | The side and spider gear thrust washer surfaces (4) |
| • | Side gear thrust washers (1) |
| • | Side gears (2) |
| • | Spider gear thrust washers (3) |
| • | Pinion gears (4) |
| • | Pinion shaft pin (5) |
| • | Lock pin (6) |
