Dodge Neon / Neon SRT-4. Manual — part 328
INSPECTION
Wash all components in a suitable solvent and
blow-dry with compressed air (except bearings).
Inspect all components for excessive wear. Minor
irregular wear and small gear chips are acceptable
and do not inhibit differential operation. However,
large gear chips or components discolored due to lack
of lubrication should result in differential replace-
ment.
ASSEMBLY
NOTE: The Quaife ATB Differential is serviced only
as a complete assembly. The only serviceable com-
ponents are the ring gear and tapered roller bear-
ings. No other component replacement will be
possible.
(1) Assemble and install differential components
as shown in (Fig. 104). Make sure center pack
(spring housing and belleville spring washers)
is assembled as shown in (Fig. 105).
Fig. 104 Differential Components
1 - GEAR BODY (SMALL SIDE)
6 - CENTER BLOCK
2 - SUN GEAR (2)
7 - GEAR BODY (FLANGE SIDE)
3 - PLANET PINION (12)
8 - BOLT (11)
4 - SPRING HOUSING (2)
9 - DOWEL
5 - BELLEVILLE WASHER (6)
21 - 96
T850 MANUAL TRANSAXLE
PL/SRT-4
DIFFERENTIAL (Continued)
(2) Noting
position
of
locating
dowel,
install
flanged gear body halve.
(3) Apply Mopar
t Lock & Seal Adhesive to the
eleven (11) gear body halve bolts. Install and torque
to 39 N·m (28 ft. lbs.).
(4) Install ring gear. Install and torque twelve (12)
bolts to 95 N·m (70 ft. lbs.) (Fig. 106).
(5) Using Tool 8473 and Tool 8491, install differen-
tial side bearings with arbor press (Fig. 107).
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE
NOTE: Differential turning torque should only be
measured with the geartrain out of the transaxle. If
measurement is taken with transaxle assembled, an
inaccurate measurement will result.
NOTE: All differential cover-to-case bolts and exten-
sion housing-to-case bolts must be installed and
torqued to obtain accurate measurement.
(1) If transaxle is assembled, remove geartrain
and leave differential in place. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/MANUAL - DISASSEMBLY)
Fig. 105 Quaife ATB Differential
1 - GEAR BODY (FLANGED SIDE)
2 - BOLT (11)
3 - SUN GEAR (2)
4 - PLANET PINION (12)
5 - CENTER PACK
6 - GEAR BODY (SMALL SIDE)
Fig. 106 Ring Gear-to-Case Bolts
1 - BOLT (12)
Fig. 107 Differential Bearing Installation
1 - TOOL C-4171
2 - TOOL 8473
3 - BEARING
4 - TOOL 8491
PL/SRT-4
T850 MANUAL TRANSAXLE
21 - 97
DIFFERENTIAL (Continued)
(2) Install differential cover and torque differential
cover-to-case bolts to 54 N·m (40 ft. lbs.).
(3) Install extension housing and torque extension
housing-to-case bolts to 28 N·m (250 in. lbs.).
(4) Place transaxle on work bench so axle center-
line is parallel to the ground.
(5) Install turning torque tool C-4995 to differen-
tial at side opposite extension housing.
(6) Using an in. lb./N·m dial indicator, rotate dif-
ferential case multiple times and record measure-
ment (Fig. 108). Differential turning torque should be
within 2.3-3.4 N·m (20-30 in. lbs.). Refer to shim
chart for proper shim selection. If turning torque
measured is less than 2.3 N·m (20 in. lbs.), install a
thicker shim. If turning torque measured is greater
than 3.4 N·m (30 in. lbs.), install a thinner shim.
DIFFERENTIAL BEARING SHIM CHART
PART NUMBER
SHIM THICKNESS
METRIC (MM)
STANDARD (STD)
4659242
0.50
0.0197
4659243
0.54
0.0213
4659247
0.58
0.0228
4659248
0.62
0.0244
4659249
0.66
0.0260
4659250
0.70
0.0276
4659251
0.74
0.0291
4659252
0.78
0.0307
4659253
0.82
0.0322
4659254
0.86
0.0339
4659255
0.90
0.0354
4659256
0.94
0.0370
4659257
0.98
0.0386
4659258
1.02
0.0402
4659259
1.06
0.0418
4659260
1.10
0.0434
4659261
1.14
0.0449
4659262
1.18
0.0465
4659263
1.22
0.0481
Fig. 108 Differential Turning Torque Measurement
1 - DIAL TORQUE WRENCH
2 - TOOL C-4995
21 - 98
T850 MANUAL TRANSAXLE
PL/SRT-4
DIFFERENTIAL (Continued)
PART NUMBER
SHIM THICKNESS
METRIC (MM)
STANDARD (STD)
4659264
1.26
0.0497
4659265
1.30
0.0512
4659266
1.34
0.0528
4659267
1.38
0.0544
4659268
1.42
0.0560
4659269
1.46
0.0575
4659270
1.50
0.0591
4659271
1.54
0.0607
4659272
1.58
0.0623
4659273
1.62
0.0638
4659274
1.66
0.0654
4659275
1.70
0.0670
4659276
1.74
0.0690
4659277
1.78
0.0701
4659278
1.82
0.0716
4659279
1.86
0.0732
4659280
1.90
0.0748
4659281
1.94
0.0763
4659282
1.98
0.0779
4659283
2.02
0.0795
4659284
2.06
0.0811
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
NOTE: For proper fluid level check intervals, (Refer
to LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopar
t
ATF+4 along with 0.12L (4 oz.) Mopar Limited Slip
Additive/Friction Modifier (P/N 04318060AB).. Use of
substitute fluids may result in improper transaxle
operation and/or failure.
(1) Raise vehicle on hoist.
(2) Remove transaxle fill plug (Fig. 109).
(3) Inspect fluid level. Fluid should be within 3/16”
below fill hole. Add Mopar
t ATF+4 as neccessary.
(4) Install fill plug, ensuring it is properly seated.
(5) Lower vehicle.
Fig. 109 Transaxle Fill Plug
1 - FILL PLUG
2 - END COVER
PL/SRT-4
T850 MANUAL TRANSAXLE
21 - 99
DIFFERENTIAL (Continued)
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