Chrysler Colt/Vista 1990-1993 Repair Information

Differential

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Differential carrier removal/installation

4WD Vista
  1. Raise and support the rear of the vehicle with jackstand placed under the frame.
  2.  
  3. Drain the differential fluid.
  4.  
  5. Remove the intermediate shafts.
  6.  
  7. Matchmark and disconnect the driveshaft.
  8.  
  9. Take the weight off of the differential with a floor jack.
  10.  
  11. Remove the bolt that connects the differential front support bracket and the crossmember.
  12.  
  13. Remove the bolts connecting the differential rear support and the differential carrier.
  14.  
  15. Lower the carrier and remove it from under the vehicle. Service as required.
  16.  
  17. Position the differential and connect it to the supports. Connect the driveshaft and intermediate shafts. Torque the rear support to carrier bolts to 95 ft. lbs.; the front support to crossmember bolt to 101 ft. lbs.
  18.  

OVERHAUL



Disassembly

See Figures 2 through 9



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Fig. Fig. 2: Differential disassembly



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Fig. Fig. 3: Prying case out of carrier



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Fig. Fig. 4: Side bearing removal



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Fig. Fig. 5: ring gear removal

  1. Remove the differential cover and vent plug.
  2.  
  3. Remove the bearing caps.
  4.  



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Fig. Fig. 6: Lock pin removal



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Fig. Fig. 7: Flange nut removal



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Fig. Fig. 8: Pinion removal



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Fig. Fig. 9: Pinion inner bearing removal

  1. Carefully lift out the differential case assembly. Take care to avoid dropping the side bearing spacers and outer races. Keep the races separate and identified.
  2.  
  3. Using a bearing puller, remove the side bearings.
  4.  
  5. If the ring gear is to be re-used, matchmark it with the case and remove it. If the gear is being re-used, remove the bolts in a crisscross sequence.
  6.  
  7. On conventional units, drive out the lock pin and remove the pinion gears, washers, side gears and spacers.
  8.  
  9. Remove the differential case assembly.
  10.  
  11. Hold the companion flange and remove the companion flange locknut. Discard the locknut.
  12.  
  13. Remove the washer.
  14.  
  15. Matchmark the drive pinion and companion flange, and, using a forcing tool, separate the pinion from the flange, along with the spacer and shims.
  16.  
  17. Using a puler, remove the pinion rear bearing.
  18.  
  19. Remove the pinion rear shim.
  20.  
  21. Remove the pinion.
  22.  
  23. Pry out the pinion seal and remove the bearing. Drive out the bearing race.
  24.  
  25. Drive out the halfshaft seals.
  26.  

Assembly

See 10 through 29

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Fig. Fig. 10: Differential assembly

  1. Drive a new pinion seal into place. Oil the seal lips with chassis lube.
  2.  



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Fig. Fig. 11: Front and rear bearing race installation

  1. Drive a new pinion bearing race into place and install the bearing.
  2.  
  3. Install special tools MB990836 in the carrier along with the bearings and races. Tighten the tools until a turning torque of 8-10 inch lbs. is obtained with new, unoiled bearings, or 3-4 inch lbs. with used or new/oiled bearings is obtained. Remove the tools.
  4.  



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Fig. Fig. 12: Pinion height adjusting tools



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Fig. Fig. 13: Checking rotational force

  1. Position special tool MB990392 in the side bearing seat of the carrier, and select a drive pinion rear shim of a thickness that corresponds to the gap between the tools. Keep the shims to a minimum needed to fill the gap. Remove the tools.
  2.  



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Fig. Fig. 14: Positioning side bearing adjusting tool



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Fig. Fig. 15: Pinion shim and rear bearing tool



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Fig. Fig. 16: Adjusting drive pinion preload



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Fig. Fig. 17: Checking rotational force

  1. Install the shims and press-fit the drive pinion rear bearing inner race.
  2.  
  3. Install the drive pinion front shims between the drive pinion spacer and the drive pinion front bearing.
  4.  
  5. Using tool MB990850, tighten the companion flange to 137 ft. lbs. Measure the turning torque. It should be equal to that recorded in Step 18. If not, add or delete shims, or change spacers.
  6.  
  7. Remove the companion flange and pinion. If the seal lip was damaged, replace the seal.
  8.  



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Fig. Fig. 18: Pinion seal installation

  1. Coat the pinion and flange, and related parts with gear oil. Align the matchmarks and install the parts. Install a new nut and torque it to 137 ft. lbs. Check that the turning torque is still with specifications. If not, you'll have to find the cause and start over again.
  2.  



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Fig. Fig. 19: Installing the pinion



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Fig. Fig. 20: Measuring final preload

  1. Assemble the side gears, spacers, washers and pinion gears in the case. Temporarily install the pinion shaft. Adjust the differential gear backlash as follows:
    1. Lock the side gear with a wedge and measure the gear backlash with a dial indicator. Backlash should be 0-0.003 in. (0-0.76mm). The service limit is 0.008 in. (0.2mm).
    2.  
    3. If backlash exceeds the limit, install thicker side gear spacers.
    4.  
    5. Remeasure backlash. Adjust with shims until the backlash is correct. If backlash cannot be brought within specifications, replace the side gear and pinon gear as a set.
    6.  

  2.  



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Fig. Fig. 21: Side gear installation



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Fig. Fig. 22: Checking side gear backlash

  1. With the pinion completely assembled, install the lockpin and stake it at two points.
  2.  



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Fig. Fig. 23: Lock pin installation

  1. If you are installing a new ring gear, clean the threaded holes with a 1.25 tap and blow out the threads with compressed air. Coat the threaded holes with MOPAR adhesive 4318031 or equivalent.
  2.  



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Fig. Fig. 24: Cleaning ring gear threads

  1. Align the matchmarks and attach the ring gear using new bolts. Torque the bolts to 58-65 ft. lbs. (80-90 Nm) in a crisscross sequence.
  2.  
  3. Drive the side bearing races into place.
  4.  
  5. To adjust the ring gear backlash:
    1. Install the side bearing spacers and mount the case assembly in the carrier. The spacers should be the same thicknesses on each side.
    2.  
    3. Push the case to one side and measure the gap between the carrier and the side bearing.
    4.  
    5. Measure the thickness of the side bearing spacers on one side. Select 2 pairs of spacers which match that thickness, plus 1 / 2 the clearance, plus 0.05mm. Install one pair to each drive pinion side. Install the assembled spacers and case in the carrier.
    6.  
    7. Tap the side bearing spacers with a brass hammer to make sure that they are seated on the bearing.
    8.  
    9. Align the matchmarks on the gear carrier and bearing cap, and tighten the cap bolts to 25-29 ft. lbs.
    10.  
    11. Lock the drive pinion and measure the ring gear backlash with a dial indicator. Take the measurement at a minimum of 4 points around the gear. Backlash should be 0.004-0.006 in. (0.11-0.16mm). If it is not correct, change the side bearing spacers. If you are increasing the number of spacers, use the same number for each side, using as few as possible.
    12.  
    13. Check the ring gear tooth contact pattern as shown in the accompanying illustration. Adjust as necessary.
    14.  
    15. Measure the ring gear runout at the shoulder on the reverse side of the gear. Runout limit is 0.002 in. (0.05mm). If runout is excessive, remove the ring gear from the case and reposition it.
    16.  

  6.  
  7. If everything is assembled satisfactorily, install the cover and vent plug.
  8.  



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Fig. Fig. 25: Pressing in side bearing inner race



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Fig. Fig. 26: Selecting side bearing spacers



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Fig. Fig. 27: Measuring the ring gear backlash



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Fig. Fig. 28: Changing the side bearing spacers



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Fig. Fig. 29: Measuring ring gear runout

 
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