For 1990-2009 cars only
- Inspect the input carrier assembly (640) for the following conditions:
- Inspect the input thrust washers (639, 641) for wear. Inspect the washers for bent or damaged tangs.
- Use a feeler gage in order to measure the pinion end play. End play should measure 0.24-0.69 mm (0.009-0.027 in).
- Inspect the input shaft thrust washer (636) for damage.
- Inspect the input internal gear (637) for the following conditions:
- Inspect the input sun gear (642) for the following conditions:
- Insert the input sun gear (642) into the case.
- Use TRANSJEL™ or equivalent in order to affix the two thrust washers (639, 641) onto the input carrier assembly (640).
- Install the input carrier (640) into the case. Use a slight twisting motion in order to engage the pinions into the sun gear.
- Install the input internal gear (637) into the case. Use a slight twisting motion in order to engage the input carrier pinions.
- Insert the thrust washer (636) for the input shaft into the case.
| • | Pinion damage |
| • | Carrier wear |
| • | Spline damage |
Important: If the pinion end play is outside of these dimensions, replace the input carrier (640).
| • | Damaged splines |
| • | Blocked or missing lube holes |
| • | Damaged gear teeth |
| • | Worn bushing |
| • | Worn gear teeth |
| • | Damaged splines |
| • | A worn thrust surface |
Important: Before installing the sun gear, confirm that the machined grooved side is facing down.
