Torque Converter & Final Drive Section

Using Drift (398437700), install torque converter oil seal into torque converter section. Install differential assembly into case. DO NOT damage differential side retainer contact surfaces. Install NEW "C" clips onto axle shafts. Insert axle shafts into differential case and tap into place. Measure shaft end play. End play should be approximately .012-.020" (.30-.50 mm). If no play is felt, ensure shaft is fully installed. If shaft is installed correctly and no play is felt or play exceeds specification, replace axle shaft.
Wrap axle shaft splined portion with tape. Install oil seals and taper roller bearing outer races to differential side retainers. See Figure . Coat threads with oil and install retainers into torque converter section. Using Wrench (499787000), thread retainers inward until light contact is felt. Ensure right side retainer is threaded slightly deeper than left side retainer.

CAUTION: When installing drive pinion shaft, DO NOT force pinion against housing bore or damage may occur.

Install drive pinion shaft to oil pump housing with shim(s) selected during DRIVE PINION SHAFT reassembly. Install 4 drive pinion collar bolts and tighten to 28-32 ft. lbs. (38-44 N.m).

CAUTION: After tightening bolts, thoroughly remove all excess liquid gasket from oil pump housing and torque converter section.

Clean oil pump housing and torque converter section mating surfaces. Use Liquid Gasket (Three-Bond 1215), and install oil pump housing to torque converter section. Tighten bolts to 28-32 ft. lbs. (38-44 N.m).
Using Holder (498937100) and (Wrench (499787700), rotate drive pinion several times to set drive pinion bearings. See Figure . Tighten left side retainer until contact is felt when rotating drive pinion shaft. Loosen right side retainer. Tighten left side retainer and loosen right side retainer until drive pinion shaft can no longer be turned. This is "zero" state.
After "zero" state is established, loosen left side retainer 3 notches and secure with locking tab. Loosen right side retainer and retighten until it stops. Repeat loosening and tightening procedure of right side retainer several times. Then, tighten right side retainer 1 3/4 notches further and secure with locking tab. This sets preload.

NOTE: Turning retainer by one notch changes backlash about .002" (.05 mm).

Using Wrench (499787700), turn drive pinion shaft several rotations. Using a dial indicator, measure backlash. See Figure . Backlash should be .005-.007" (.13-.18 mm). After confirming backlash is correct, inspect tooth contact.
Remove pump housing and apply Red lead to 3 or 4 tooth surfaces of ring gear. Reinstall pump housing. Rotate drive pinion shaft forward and reverse several times. Remove oil pump housing and check tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.
Adjust drive pinion shaft shim or backlash as necessary. When tooth contact is correct, mark differential side retainer positions and loosen. Install "O" rings and retighten differential side retainers to marked positions. Tighten lock tab bolts to 17-20 ft. lbs. (23-27 N.m). Install NEW seal pipe to torque converter section.
Install 2 NEW oil seals to drive pinion shaft oil seal retainer with Installer (499247300). Install NEW "O" ring to oil seal retainer with petroleum jelly. Install NEW "O" ring to oil pump housing bore. Install oil seal retainer and tighten bolts to 53-71 INCH lbs. (6-8 N.m).
Apply petroleum jelly to grooves on oil pump cover and ensure 4 NEW seal rings are installed. See Figure and Figure . The 2 innermost seal rings are larger in diameter than the outer 2 seal rings. Install rubber seal onto torque converter section mating surface. Set section aside and DO NOT lose rubber seal.