Dodge Neon / Neon SRT-4. Manual — part 311
ASSEMBLY
(1) Install side gears, pinion gears, and thrust
washers into case through opening and rotating into
position (Fig. 73) (Fig. 74).
(2) Install pinion shaft (Fig. 75).
(3) If previously removed, install ring gear to dif-
ferential case (Fig. 76).
(4) Install pinion shaft retainer (Fig. 77). Install
NEW ring gear-to-case bolts and torque to 81 N·m
(60 ft. lbs.) torque (Fig. 78).
Fig. 73 Side Gear and Washer
1 - SIDE GEAR
2 - WASHER
Fig. 74 Pinion Gear and Washer
1 - WASHER
2 - PINION GEAR
Fig. 75 Pinion Shaft Removal/Installation
1 - PINION SHAFT
2 - DIFFERENTIAL CASE
3 - PINION GEAR (2)
Fig. 76 Differential Ring Gear and Case
1 - DIFFERENTIAL CASE
2 - RING GEAR
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T350 MANUAL TRANSAXLE
PL/SRT-4
DIFFERENTIAL (Continued)
(5) Install speedometer drive gear to case (Fig. 79).
Note orientation of index tab.
(6) Using Steel Block and Tool L-4440, press
speedometer drive gear into position (Fig. 80).
Fig. 77 Pinion Shaft Retainer
1 - PINION SHAFT RETAINER
Fig. 78 Differential Ring Gear-to-Case Bolts
1 - DIFFERENTIAL CASE
2 - BOLT (12)
3 - RING GEAR
4 - PINION SHAFT RETAINER (2)
Fig. 79 Speedometer Drive Gear
1 - SPEEDOMETER GEAR
Fig. 80 Press Gear onto Differential
1 - STEEL STOCK
2 - TOOL L-4440
3 - SPEEDOMETER GEAR
4 - DIFFERENTIAL CASE
PL/SRT-4
T350 MANUAL TRANSAXLE
21 - 29
DIFFERENTIAL (Continued)
(7) Using an arbor press, Handle C-4171, and Tool
L-4410, install differential side bearings to ring gear
and case side (Fig. 81) (Fig. 82).
Measure and Adjust Side Gear End-Play
(1) Rotate the assembly two full revolutions both
clockwise and counterclockwise.Set up dial indicator
as shown and record end play (Fig. 83) (Fig. 84).
Rotate side gear 90 degrees and take another mea-
surement. Again, rotate side gear 90 degrees and
record a final measurement.
(2) Using the smallest end play recorded, shim
that side gear to within 0.001 to 0.013 inch. The
other side gear should be checked using the same
procedure.
CAUTION: Side gear end play must be within 0.001
to 0.013 inch. Five select thrust washers are avail-
able: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.
Fig. 81 Install Differential Bearing Cone to Ring
Gear Side
1 - ARBOR PRESS RAM
2 - BEARING CONE
3 - SPECIAL TOOL HANDLE C-4171
4 - SPECIAL TOOL L-4410
5 - DIFFERENTIAL ASSEMBLY
Fig. 82 Install Bearing Cone to Differential Case
Side
1 - TOOL C-4171
2 - TOOL L-4410
3 - BEARING CONE
Fig. 83 Checking Side Gear End Play (Typical)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
Fig. 84 Checking Side Gear End Play—Typical
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
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T350 MANUAL TRANSAXLE
PL/SRT-4
DIFFERENTIAL (Continued)
ADJUSTMENTS
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 transmission
fluid. Install differential assembly in transaxle gear
case. Install clutch bellhousing 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. 85). 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. 85). 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. 86). 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.
DIFFERENTIAL BEARING
CUPS
REMOVAL
(1) Remove differential assembly from gear case
using the procedure outlined in this group.
Fig. 85 Checking Differential Bearing End Play to
Determine Shim Thickness
1 - T-HANDLE
2 - DIAL INDICATOR SET
3 - SPECIAL TOOL C-4995
Fig. 86 Checking Differential Bearing Turning
Torque
1 - INCH-POUND TORQUE WRENCH
2 - SPECIAL TOOL C-4995
PL/SRT-4
T350 MANUAL TRANSAXLE
21 - 31
DIFFERENTIAL (Continued)
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