Differential And Ring Gear: Assembly: AWD

Clean the differential in suitable solvent and inspect components for damage or debris. Dry the components with regulated 344 kPa (50 psi) shop air. Do not free spin the bearings with shop air.

1. Apply transmission assembly lube on the lip and tension spring cavity on the open side of the seal.
   Fig 1: Seal & Installer

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2. Insert tool (special tool #C-293-3, Adapter, Bearing/Gear) into open side of the side gear lip seal.
   Fig 2: Special Tool #C-293-3

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   Fig 3: Differential Housing, Seal & Tool

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3. Insert the seal and tool into the bore in the differential housing.
   Fig 4: Tapping Seal Into Housing

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4. Using a suitable hammer, tap the seal into the differential housing bore until it seats against in inner lip.
   Fig 5: Side Gear Needle Bearing & Differential Housing

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5. Insert the side gear needle bearing into the bore in the differential housing.
   Fig 6: Tapping Seal Into Housing

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6. Using tool (special tool #6342, Installer, Seal) drive the needle bearing into the differential housing until it seats against the bottom of the bore.
   Fig 7: Special Tool #6342

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   Fig 8: Side Gear Thrush Washer & Differential

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7. Install the side gear thrush washer (1) into the differential (2).
   Fig 9: Differential Case & Side Gear

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8. Install the side gear (1) into the differential case (2).
   Fig 10: Conical Washers & Pinion Gears

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9. Install the conical washers (1) and pinion gears (2) into the differential case.
   Fig 11: Differential Case & Differential Link Shaft

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10. Slide the differential link shaft (1) into the differential case (3)
    Fig 12: Pin, Differential Case & Differential Link Shaft

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11. Install the pin (1) to hold the differential link shaft (3) into the differential case (2).
    Fig 13: Side Gear Thrust Washer, Side Gear & Differential

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12. Place the side gear (2) into the differential (3).
13. Place the side gear thrust washer (1) onto the side gear (2).
    Fig 14: Ring Gear Half & Differential

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14. Place the ring gear half (1) of the case onto the differential (2).
    Fig 15: Differential Case Halves & Screws

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15. Install the screws (1) to hold the differential case halves (2) together. Refer to SPECIFICATIONS .
    Fig 16: Differential, Ring Gear & Bearing

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16. Place the ring gear (1) in position on the differential (3).
    Fig 17: Differential & Ring Gear

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17. Install the bolts (2) to hold the ring gear (3) to the differential. Refer to SPECIFICATIONS .
18. Place the differential in position in the transaxle housing.
19. Assemble the transaxle. Refer to ASSEMBLY .
20. Install the transaxle in the vehicle. Refer to INSTALLATION .