1993 CHEVROLET PLYMOUTH ACCLAIM differential

GEAR SET
CAUTION: Tool 6252 must be used to remove or in-
stall this nut. Always install a NEW nut and tighten
to 258 N Im (190 ft. lbs.).
Fig. 7 Remove or Install Extension
Fig. 8 Remove or Install 3 Differential Bearing
Retainer Bolts
Fig. 9 Remove or Install Differential Bearing Retainer
Fig. 10 Differential Assembly Removed
Fig. 1 Rear End Cover Bolts
Fig. 2 Rear End Cover Removed
Ä TRANSAXLE 21 - 7

DIFFERENTIAL BEARING RETAINER
Fig. 1 Remove Differential Bearing Retainer Seal
Fig. 2 Install Differential Bearing Retainer Seal
Fig. 3 Remove Differential Bearing Retainer Cup
Fig. 4 Differential Bearing Retainer
Fig. 5 Install Oil Baffle
Fig. 6 Insert (Select) Shim and Differential Bearing Retainer Cup
21 - 24 TRANSAXLE Ä

CAUTION: Bolt on bearing support plate before in-
stalling input shaft rear bearing cup.
A-523, A-543 DIFFERENTIAL
Shim thickness need only be determined if any of
the following parts are replaced:
² Transaxle case
² Differential bearing retainer
² Extension housing
² Differential case
² Differential bearings
CAUTION: Differential covers are not interchange-
able from case to case.
Refer to Bearing Adjustment Procedure in rear
of this section to determine proper shim thickness for
correct bearing preload and proper bearing turning
torque.
Fig. 6 Install Input Shaft Rear Bearing Cup
Fig. 1 Remove Differential Bearing Cone
Fig. 2 Install Differential Bearing Cone
Fig. 3 Remove Differential Bearing Cone
Fig. 4 Install Differential Bearing Cone
Ä TRANSAXLE 21 - 27

CAUTION: Always install new ring gear bolts. Bolts
must be properly torqued (See Tightening Refer-
ence). After assembling the differential side gears, pinion
gears and pinion gears withthe pinion gear washers,
but without the side gear thrust washers. Rotate the
assembly two full revolutions both clockwise and
counterclockwise. Set up dial indicator as shown and record end play.
Rotate side gear 90 degrees and record another end
play. Again, rotate side gear 90 degrees and record a
final end play. Using the smallest end play recorded, shim that
side gear to within .001 to .013 inch. The other side
gear should be checked using the same procedure.
Fig. 5 Remove or Install Ring Gear Bolts and Ring Gear
Fig. 6 Remove Pinion Shaft Roll Pin
Fig. 7 Remove or Install Pinion Shaft
Fig. 8 Remove or Install Pinion Gears, Side Gears,and Thrust Washers by Rotating Side Gears to Opening in Case
Fig. 9 Differential Gears
21 - 28 TRANSAXLE Ä

CAUTION: Side gear end play must be within .001 to
.013 inch. Four select thrust washers are available:
.032, .037, .042, and .047 inch.
A-568 DIFFERENTIAL
Shim thickness need only be determined if any of the
following parts are replaced:
² Transaxle case
² Differential bearing retainer
² Extension housing
² Differential case
² Differential bearings
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness for
correct bearing preload and proper bearing turning
torque.
Fig. 1 Remove Differential Bearing Cone
Fig. 2 Install Differential Bearing Cone
Fig. 3 Remove Differential Bearing Cone
Fig. 10 Checking Side Gear End Play
Fig. 11 Checking Side Gear End Play
Ä TRANSAXLE 21 - 29

CAUTION: Always install new ring gear bolts. Bolts
must be properly torqued (See Tightening Refer-
ence).
Fig. 4 Install Differential Bearing Cone
Fig. 5 Remove or Install Ring Gear Bolts
Fig. 6 Remove Ring Gear
Fig. 7 Remove 3 Roll Pins
Fig. 8 Install 3 Roll Pins
Fig. 9 Ring Gear and Side Gear Removed
21 - 30 TRANSAXLE Ä

CAUTION: See Figure 14 to determine side gear
thrust washer thickness. Side gear end play must be
within.001 to .013 inch.Four select thrust washes are available: .032, .037,
.042, and .047 inch.
Side gear thrust washers are available in 4
select thicknesses: .032, .037, .042, and .047 inch. Measure the depth from the differential case to the
machined surface in 3 places, as shown in Figure 13.
Then measure the height of raised stepon the ring
gear. The difference, minus the proper side gear end
play (.001 to .013 inch) is the proper thrust washer
thickness. For the other side gear: After assembling the differ-
ential side gears, pinion gears, and pinion gears with
the pinion gear washers but withoutthe side gear
thrust washers. Rotate the assembly two full revolu-
tions both clockwise and counterclockwise. Set up dial indicator as shown in Figure 14 and
record end play. Rotate side gear 90 degrees and record another end play. Again, rotate side gear 90
degrees and record a final end play.
Using the smallest end play recorded, shim that side
gear to within .001 to .013 inch.
CAUTION: After reassembly of the differential assem-
bly, insert the inner joint housing spline from a drive
shaft into the side gear. By hand, turn the side gear
with the joint housing spline. If the side gear will NOT
turn, or it feels very tight, remove the ring gear and
install a thinner side gear thrust washer.
Side gear thrust washers are available in four
select thicknesses: .032, .037, .042, and .047 inch.
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Take extreme care when removing and installing
bearing cups and cones. Use only an arbor press for
installation, as a hammer may not properly align the
bearing cup or cone. Burrs or nicks on the bear-
Fig. 12 Differential Gears
Fig. 13 Determine Proper Side Gear Thrust Washer Thickness
Fig. 10 Remove or Install Pinion Shafts
Fig. 11 Remove or Install 4 Pinion Gears and 2 Side Gears
Ä TRANSAXLE 21 - 31

ing seat will give a false end play reading while
gauging for proper shims. Improperly seated bearing
cups and cones are subject to low mileage failure.(2) Bearing cups and cones should be replaced if they
show signs of pitting or heat distress. If distress is seen
on either the cup or bearing rollers, both cup and cone
must be replaced. (3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing
failures. Used (original) bearing may lose up to 50% of
the original drag torque after break in. All bearing
adjustments must be made with no other compo-
nent interference or gear intermesh. (4) Replace bearings as a pair. For example, if one
differential bearing is defective, replace both differen-
tial bearings. If one input shaft bearing is defective,
replace both input shaft bearings. (5) Bearing cones must notbe reused if removed.
(6) Turning torque readings should be obtained
while smoothly rotating in either direction (break-
away reading is not indicative of the true turning
torque). (7) Replace oil baffle, if damaged.
INPUT SHAFT BEARING END PLAY ADJUST-MENT
(1) Using Tool C-4656 with Handle C-4171, press
input shaft front bearing cup slightly forward in case.
Then, using Tool C-4655 with Handle C-4171, press
bearing cup back into case from the front. Properly
position bearing cup, before checking input shaft end
play (see input shaft front bearing cup replace in
Subassembly Recondition section).This step is
not necessary if Tool C-4655 was previously used
to install input shaft front bearing cup in the
case. Also no input shaft shim has been installed
since pressing cup into case. (2) Select a gauging shim which will give 0.025 to
0.254mm (.001 to .010 inch) end play. SUGGESTION:
Measure original shim from input shaft seal retainer and select a shim 0.254mm (.010
inch) thinner than original for the gauging shim.
(3) Install gauging shim on bearing cup and install
input shaft seal retainer.
CAUTION: The input shaft seal retainer is used to
draw the input shaft front bearing cup the proper
distance into the case bore during this step. Alter-
nately tighten input shaft seal retainer bolts until
input shaft seal retainer is bottomed against case.
Tighten bolts to 28 N Im (21 ft. lbs.).
(4) Oil input shaft bearings with SAE 5W-30 engine
oil and install input shaft in case. Install bearing
retainer plate with input shaft rear bearing cup
pressed in and bearing support plate installed. Tighten
all bolts and nuts to 28 N Im (21 ft. lbs.).
(5) Position dial indicator to check input shaft end
play. Apply moderate load, by hand, to input shaft
splines (Fig. 1). Push toward rear while rotating input
shaft back and forth a number of times to settle out
bearings. Zero dial indicator. Pull input shaft toward
the front while rotating input shaft back and forth a
number of times to settle out bearings. Record end play.
(6) The shim required for proper bearing end play is
the total of the gauging shim thickness, plus end play,
minus (constant) end play of 0.051mm (.002 inch).
Combine shims, if necessary, to obtain a shim within
.04mm (.0016 inch) of the required shim (see Shim
Chart for proper shim). (7) Remove input shaft seal retainer and gauging
shim. Install shim(s) selected in step (6). Then reinstall
input shaft seal retainer with a 1/16 inch bead of
MOPAR tGasket Maker, Loctite, or equivalent for a
gasket. Record end play. Observe the CAUTIONin
step (3). Tighten input shaft seal retainer bolts to 28
N Im (21 ft. lbs.).
Fig. 14 Checking Side Gear End Play
Fig. 1 Checking Input Shaft Bearing End Play to De-
termine Shim Thickness
21 - 32 TRANSAXLE Ä