Page 755 of 1771
Rocker Arm Assembly
Removal
1. Loosen the adjusting screws, then remove the bolts
and the rocker arm assembly.
NOTE:
• Unscrew the camshaft holder bolts two turns at a
time, in a crisscross pattern, to prevent damaging
the valves or rocker arm assembly.
• When removing the rocker arm assembly, do not
remove the camshaft holder bolts. The bolts will
keep the camshaft holders, the springs and the
rocker arms on the shafts.
ADJUSTING SCREW
ADJUSTING SCREW
CAMSHAFT HOLDER BOLTS LOOSENING SEQUENCE:
6 mm BOLTS
8 mm BOLTSProCarManuals.com
Page 780 of 1771

Drive Plat e Connectin
g Ro d an dCrankshaf t
Replacemen tEnd Pla y
Remov e th e eigh t driv e plat e bolts , the n separat e th e
driv e plat e fro m th e crankshaf t flange . Afte r installation ,
tighte n th e bolt s i n a crisscros s pattern .
RING GEA R HOLDE R07LAB-PV00100
ENGINEBLOCK
RING GEA RInspec t rin g gea rteeth fo r wea rand damage .
RING GEA R HOLDE R07LAB-PV0010 0
12 x 1. 0 m m74 N- m(7.5 kgf-m , 5 4 Ibf-ft )
Connectin g Ro d En d Play :
Standar d (New) : 0.1 5 - 0.3 0 m m
(0.00 6 - 0.01 2 in )
Servic e Limit : 0.4 0 m m (0.01 6 in )
• I f out-of-tolerance , instal l a ne w connectin g rod .
• I f stil l out-of-tolerance , replac e th e crankshaf t
(se e page s 7- 9 an d 7-19 ).
Pus h th e crankshaf t firml y awa y fro m th e dia l indicator ,
an d zer o th e dia l agains t th e en d o f th e crankshaft . The n
pul l th e crankshaf t firml y bac k towar d th e indicator ; dia l
readin g shoul d no t excee d servic e limit .
SCREWDRIVE R
Crankshaft En d Play :
Standar d (New) : 0.1 0 - 0.3 5 m m
(0.004-0.01 4 in )
Servic e Limit : 0.4 5 m m (0.01 8 in )
• I f en d pla y i s excessive , inspec t th e thrus t wash -
er s an d thrus t surfac e o n th e crankshaft . Replac e
part s a s necessary .
NOTE : Thrus t washe r thicknes s i s fixe d an d mus t
no t b e change d eithe r b y grindin g o r shimming .
Thrus t washer s ar e installe d wit h groove d sid e fac -
ing outward .
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Page 1083 of 1771

27. Attach the torque converter to the drive plate with
eight bolts and torque:
Rotate the crankshaft as necessary to tighten the
bolts to 1/2 of the specified torque, then to the final
torque, in a crisscross pattern.
After tightening the last bolt, check that the crankshaft
rotates freely.
DRIVE PLATE/
RING GEAR
6 x 1.0 mm
12 N-m (1.2 kgf-m,
8.7 Ibf-ft)
6 x 1.0 mm
12 N-m (1.2 kgf-m,
8.7 Ibf-ft)
TORQUE CONVERTER
COVER
28. Install the torque converter cover.
29. Install the transmission ground cable.
TRANSMISSION GROUND CABLE
TRANSMISSION
SUB-HARNESS
CONNECTOR
30. Connect the transmission sub-harness connector.
31. Install the control box, then connect the connector.
CONTROL BOX
CONNECTOR
32. Install the lower heat shield cover.
33. Install the battery base and the upper heat shield.
6 x 1.0 mm
9.8 N-m (1.0 kgf-m,
7.2 Ibf-ft)
LOWER HEAT
SHIELD COVER
6 x 1.0 mm
9.8 N-m (1.0 kgf-m,
7.2 Ibf-ft)
UPPER HEAT
SHIELD COVER
8 x
1.25
mm
22 N-m (2.2 kgf-m,
16 Ibf-ft)
BATTERY
BASEProCarManuals.com
Page 1101 of 1771

Differential Assembl y
Inspection (cont'd )
Bearing preloa d
6 . Remov e th e differentia l cas e cove r an d th e differen -
tia l carrier .
7 . Us e a dial-typ e torqu e wrenc h o n th e driv e pinio n t o
measur e th e driv e pinio n bearin g preload .
Standard: 0.64-1.03 N-m
(6.5-10.5 kgf-cm, 5.6-9.1 Ibf-in)
8. Reinstal l th e differentia l carrie r an d th e differentia l
cas e cover , the n measur e th e tota l bearin g preload .
Standard: Tp* + 0.89-1.13 N-m
(9.1-11.5 kgf-cm, 7.90-9.98 Ibf-in)
*: Driv e pinio n bearin g preloa d i n ste p 7 .
Gea r toot h contac t
9 . Remov e th e differentia l cas e cove r an d differentia l
carrier . Clea n an d pain t th e rin g gea r teet h lightl y an d
evenl y with Prussia n Blu e (o n bot h side s o f eac h
tooth) .
NOTE : Loose n th e bolt s i n a crisscros s pattern , i n
severa l steps .
DIFFERENTIA LCARRIER
DIFFERENTIA L
CAS E
10. Reinstal l th e differentia l carrie r an d th e differentia l
cas e cover , the n torqu e th e bolt s in a crisscros s pat -
tern , i n severa l steps .
10 x 1.2 5 mm47 N- m (4. 8 kgf-m , 3 5 Ibf-ft )
11. Instal l th e specia l too l a s shown . Rotat e th e rin g gea r
one ful l tur n i n bot h direction s whil e applyin g
resistanc e t o th e driv e pinion .
PRELOA D INSPECTIO N TOO L07HAJ-PK40201
DRIVE PINIO N
12. Remov e th e differentia l cas e cove r an d th e differen -
tia l carrier , the n chec k th e toot h contac t pattern .
CORREC T TOOT H CONTAC T
TOE CONTAC T HEE L CONTAC T
FLANK CONTAC T FAC E CONTAC T
DIFFERENTIA L
CAS E COVE R
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Page 1102 of 1771

Disassembly
1. Remov e th e bolt s in a crisscros s pattern , i n severa l
steps , the n remov e th e differentia l cas e cover .
DIFFERENTIA L
CAS E COVE R
DIFFERENTIA L CAS E
2. Remov e th e oi l sea l fro m th e differentia l cas e cover .
OIL SEA LReplace .
DIFFERENTIA L
CAS E COVE R
3. Remov e th e bearin g oute r rac e an d th e 7 5 m m thrus t
shim fro m th e differentia l cas e cove r b y drivin g the m
out o r b y heatin g th e differentia l cas e cove r t o abou t
212°F (100°C) .
CAUTION : D o no t reus e th e 7 5 m m thrus t shi m if
th e bearin g oute r rac e wa s drive n out .
NOTE :
• D o no t hea t th e differentia l cas e cove r i n exces s
of 212° F (100°C) .
• I f th e bearin g oute r rac e wa s remove d b y heat -
ing , allo w th e differentia l cove r t o coo l t o roo m
temperature .
• Replac e th e tapere d rolle r bearin g wit h a ne w on e
wheneve r th e bearin g oute r rac e i s replaced .
BEARING OUTE RRACE
75 m mTHRUS T SHI M
DIFFERENTIA L
CAS E COVE R
4. Remov e th e breathe r chambe r plat e an d th e oi l col -
lec t plate .
FLAT SCRE W
Replace .
BREATHER
CHAMBE R
PLATE
OIL COLLEC T
PLAT E DIFFERENTIA
L
CAS E COVE R
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Page 1107 of 1771
Backlash Inspectio n
1. Remov e th e tapere d rolle r bearing s (se e pag e 15-14 ).
2 . Instal l th e lef t driveshaf t an d th e intermediat e shaf t
i n th e sid e gears .
3 . Measur e th e backlas h o f bot h pinio n gears .
Standard: 0.05-0.15 mm (0.002-0.006 in)
Service Limit: 0.30 mm (0.012 in)
PINION GEAR S
If th e backlas h exceed s th e servic e limit , replac e th e
differentia l carrier .
Ring Gea r Replacemen t
1. Remov e th e bolt s in a crisscros s pattern , i n severa l
steps, an d remov e th e rin g gear .
12 x 1. 0 m m135 N- m (13. 8 kgf-m ,
99. 8 Ibf-ft )
DIFFERENTIAL
CARRIER
RINGGEA R
2. Instal l th e rin g gea r b y tightenin g th e bolt s i n a criss -
cros s pattern , i n severa l steps . I f th e bolt s ar e
difficul t t o tighten , mak e sur e tha t th e rin g gea r i s
goin g o n t o th e differentia l carrie r correctly .
ProCarManuals.com
Page 1111 of 1771

9. Clea n an d pain t th e rin g gea r teet h lightl y an d even -
l y wit h Prussia n Blu e (o n bot h side s o f eac h tooth) .
10 . Appl y lubrican t t o th e tapere d rolle r bearings , instal l
th e differentia l carrie r int o th e differentia l case , the n
instal l th e differentia l cas e cover .
11 . Instal l th e bolt s an d tighte n in a crisscros s pattern ,
i n severa l steps .
10 x 1.2 5 mm47 N- m (4. 8 kgf-m , 3 5 Ibf-ft )
DIFFERENTIA L CAS E
COVE R
DIFFERENTIA L
CARRIER
DIFFERENTIA L
CAS E
12. Instal l th e specia l too l a s shown . Rotat e th e rin g gea r
on e ful l tur n i n bot h direction s whil e applyin g
resistanc e t o th e driv e pinion .
PRELOA D INSPECTIO N
TOO L
07HAJ-PK40201
DRIV E PINIO N
CORREC T TOOT H CONTAC T
13. Remov e th e differentia l cas e cover , an d chec k th e
toot h contac t patter n (hee l an d toe) . Adjus t th e rin g
gea r toot h contac t a s neede d (se e pag e 15-26 ).
14 . Afte r adjustin g th e rin g gea r toot h contact , remov e
th e driv e pinion , the n instal l a ne w pinio n space r an d
thrus t washer s o n th e driv e pinion .
THRUS T WASHER SPINIO
N SPACE R
Replace .
DRIV E PINIO N
DIFFERENTIA L
CAS E
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Page 1115 of 1771
32. Instal l th e differentia l cas e cover .
NOTE: Torqu e th e bolt s i n a crisscros s pattern , i n
severa l steps .
DIFFERENTIA L
CAS E COVE R10 x 1.2 5 m m47 N- m (4. 8 kgf-m , 3 5 Ibf-ft )
33. Instal l th e oi l sea l usin g th e specia l tool s a s shown .
DRIVER07749-001000 0
DRIVER ATTACHMEN T07947-6110501 o r
07947-611050 0
OIL SEA L
Replace .
PILOT,
28 x 30 m m07JAD-PH80400
34. Instal l th e O-rin g an d th e oi l cooler .
OIL COOLE R
O-RIN G
Replace .
8 x 1.2 5 mm27 N- m (2. 8 kgf-m , 2 0 Ibf-ft )
6 x 1. 0 m m12 N- m (1. 2 kgf-m ,8.7 Ibf-ft )
35. Stak e th e locknu t ta b int o th e groove .
1.0 m m (0.04 in)
3.5 m m (0.1 4 in)
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