Dodge Neon 2001, Service Manual

Page: 530 / 743

DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT / SHIM SELECTION
Measure and adjust differential side bearing pre-
load during any transaxle service, especially when
the following components are replaced:
•
Transaxle gear case
•
Clutch bellhousing case
•
Differential case
•
Differential bearings
NOTE: True bearing turning torque readings can be
obtained only with the geartrain removed from the
case.
(1) Remove bearing cup and existing shim from
clutch bellhousing case.
(2) Press in new bearing cup into bellhousing case
(or use a cup that has been ground down on the
outer edge for ease of measurement).
(3) Press in new bearing cup into gear case side.
(4) Oil differential bearings with Mopar
t
type M.S.
9417 Manual Transaxle Fluid. Install differential
assembly in transaxle gear case. Install clutch bell-
housing over gear case. Install and torque case bolts
to 29 N·m (21 ft. lbs.).
(5) Position transaxle with bellhousing facing
down on workbench with C-clamps. Position dial
indicator.
NOTE: Indicator is set up as shown for illustrative
purposes only (Fig. 32). Indicator must be parallel
to T-Handle to obtain the most accurate reading.
(6) Apply a medium load to differential with Tool
C-4995 and a T-handle, in the downward direction.
Roll differential assembly back and forth a number of
times. This will settle the bearings. Zero the dial
indicator. To obtain end play readings, apply a
medium load in an upward direction while rolling
differential assembly back and forth (Fig. 32). Record
end play.
(7) The shim required for proper bearing preload is
the total of end play, plus (constant) preload of
0.18 mm (0.007 in.). Never combine shims to obtain
the required preload.
(8) Remove case bolts. Remove clutch bellhousing
differential bearing cup. Install shim(s) selected in
Step 7. Then press the bearing cup into clutch bell-
housing.
(9) Install clutch bellhousing. Install and torque
case bolts to 26 N·m (19 ft. lbs.).
(10) Using Special Tool C-4995 and an inch-pound
torque wrench, check turning torque of the differen-
tial assembly (Fig. 33). The turning torque should
be 6 to 12 in. lbs. If the turning torque is too
high, install a 0.05 mm (0.002 inch) thinner
shim. If the turning torque is too low, install a
0.05mm (0.002 inch) thicker shim.
(11) Recheck turning torque. Repeat Step 10 until
the proper turning torque is obtained.
Fig. 32 Checking Differential Bearing End Play to
Determine Shim Thickness
1 - T-HANDLE
2 - DIAL INDICATOR SET
3 - SPECIAL TOOL C-4995
Fig. 33 Checking Differential Bearing Turning
Torque
1 - INCH-POUND TORQUE WRENCH
2 - SPECIAL TOOL C-4995
PL
A578 MANUAL TRANSMISSION 21s - 15
DIFFERENTIAL (Continued)
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2001 NEON