For 1990-2009 cars

Table 1: | Differential Thrust Washer Gage Installation
Table 2: | Torque Sequence
Table 3: | Differential Thrust Washer Selection

### Differential Thrust Washer Gage Installation

Callout | Component Name
--- | ---
1 | Front Differential Carrier Assembly Tip Install the differential assembly and the pinion gear assembly together to avoid interference with the gears during installation.
2 | Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly Tip Install the differential assembly and the pinion gear assembly together to avoid interference with the gears during installation.
3 | Front Differential Drive Pinion Gear Bearing Cup Tip After placing the bearing cup on the gear, place DT 47800-2 which is part of DT-47800 selection gage kit , onto the bearing cup.

#### Special Tools

DT-47800 Thrust Washer Selection Gage Kit

For equivalent regional tools, refer to Special Tools.

4 | Front Differential Carrier Bearing Cup Tip After placing the bearing cup on the gear, place DT 47800-1 which is part of DT-47800 selection gage kit , onto the bearing cup.

#### Special Tools

DT-47800 Thrust Washer Selection Gage Kit

For equivalent regional tools, refer to Special Tools.

5 | Torque Converter Housing Outer Seal
6 | Torque Converter and Support and A/Trans Fluid Pump Housing Assembly Tip Install 2 DT 47800-6 which is part of DT-47800 selection gage kit , into a case threaded hole at approximately 180 degrees apart. Tip Some alignment of DT 47800-1 and 2 which is part of DT-47800 selection gage kit , may be required while lowering the TC housing onto the case.

Install DT 47800-3 which is part of DT-47800 selection gage kit , spacer over DT 47800-6.

#### Special Tools

DT-47800 Thrust Washer Selection Gage Kit

For equivalent regional tools, refer to Special Tools.

### Torque Sequence

Callout | Component Name
--- | ---
1 | Spacer Bolt M8 x 127 (Qty: 8) Caution: Refer to Fastener Caution in the Preface section.

#### Procedure

1. Install the remaining spacers evenly at every other bolt hole.
2. Remove the DT 47800-6 which is part of DT-47800 selection gage kit , guide pins and install spacer bolts in all bolt holes at spacer locations.
3. Tighten the bolts in sequence to:

Tighten
30 N·m (22 lb ft)

#### Special Tools

DT-47800 Thrust Washer Selection Gage Kit

For equivalent regional tools, refer to Special Tools.

2 | Front Differential Carrier Assembly Caution: If the bearings are not properly seated into the bearing cups, the washer selection will be inaccurate and the bearing pre-load will be set too low. Low bearing pre-load will cause premature failure of the front differential drive pinion gear.

Rotate the differential assembly 10 revolutions to allow the bearings to seat into the cups.

Tip
Differential rotating tool DT-47793 differential rotating tool can be used to rotate the differential from the case side.

#### Special Tools

DT-47793 Differential Rotating Tool

For equivalent regional tools, refer to Special Tools.

### Differential Thrust Washer Selection

Callout | Component Name
--- | ---
Caution: Improper thrust washer selection can cause insufficient taper bearing pre-load which will cause premature failure of the front differential drive pinion gear.
1 | Front Differential Bearing Washer Tip Place DT 47800-7 in the gap in DT 47800-2 which are both part of DT-47800 selection gage kit , to determine the proper thrust washer. Choose the correct thrust washer. Refer to Taper Bearing Preload Selective Specifications.

Tip

• | Continue trying different sizes of DT 47800-7 which is part of DT-47800 selection gage kit , until the gage will no longer fit into the gap. The correct thrust washer size is equal to the largest blade gage that fits into the gap.

• | Match the size of the correct DT 47800-7 blade which is part of DT-47800 selection gage kit , to the color code in the thrust washer specification chart. The washer color coding is on the outside diameter of the washer.

• | The gap in DT 47800-2 which are both part of DT-47800 selection gage kit may not be even. Hold the top of the gage and rotate the bottom of the gage to even out the gap. Take two gap measurements 180 degrees apart. Average the two measurements and select the thrust washer that is closest to the average.

• | The washer color coding is on the outside diameter of the washer.

#### Special Tools

DT-47800 Thrust Washer Selection Gage Kit

For equivalent regional tools, refer to Special Tools.

2 | Front Differential Drive Pinion Gear Bearing Thrust Washer

#### Procedure

Place DT 47800-7 in the gap in DT 47800-1 which are both part of DT-47800 selection gage kit , to determine the proper thrust washer. Choose the correct thrust washer. Refer to Taper Bearing Preload Selective Specifications.

Tip

• | Continue trying different sizes of DT 47800-7 which is part of DT-47800 selection gage kit , until the gage will no longer fit into the gap. The correct thrust washer size is equal to the largest gage that fits into the gage.

• | Match the size of the correct DT 47800-7 blade which is part of DT-47800 selection gage kit to the color code in the thrust washer selection chart.

• | The gap in DT 47800-1 which is part of DT-47800 selection gage kit may not be even. Hold the top of the gage and rotate the bottom of the gage to even out the gap. Take two gap measurements 180 degrees apart. Average the two measurements and select the thrust washer that is closest to the average.

• | The washer color coding is on the outside diameter of the washer.

#### Special Tools

DT-47800 Thrust Washer Selection Gage Kit

For equivalent regional tools, refer to Special Tools.

3 | Torque Converter and Support and A/Trans Fluid Pump Housing Assembly

#### Procedure

1. Remove DT 47800-3 which are both part of DT-47800 selection gage kit , bolts and spacers.
2. Remove the torque converter housing.
3. Remove DT 47800-1 and DT 47800-2 which are both part of DT-47800 selection gage kit .
4. Remove the torque converter housing seal.
5. Remove the pinion gear and differential bearing cups.
6. Install the bearing cups and thrust washers into the torque converter housing per the replacement procedures. Refer to Front Differential Carrier Bearing Cup and Washer Replacement - Torque Converter Housing Side and Front Differential Drive Pinion Gear Bearing Cup and Lubricant Dam Replacement.

Tip
DT 47800-1 and DT 47800-2 which are both part of DT-47800 selection gage kit , may stick in the torque converter housing. Be careful not to drop the gages.

#### Special Tools

DT-47800 Thrust Washer Selection Gage Kit

For equivalent regional tools, refer to Special Tools.