Capri L4-1597cc 1.6L DOHC (1992)
gears.
5. On all models, coat differential side gears and thrust washers with transaxle fluid.
6. Install differential side gear thrust washers to side gears, then the side gears into gear case.
7. Coat differential pinion gear thrust washers with transaxle fluid, then install thrust washers to pinion gears and pinion gear assemblies to gear case.
Install differential pinion gears to gear case so they are parallel to each other.
8. After installing thrust washers on pinion gears, turn gears back on side gear and install them into gear case.
NOTE: Pinion gears and pinion shaft hole must be aligned on both sides of gear case. If gears and gear case shaft hole do not line up, remove
pinion gears and install into case.
Pinion Shaft Installation
9. Install pinion shaft into gear case.
10. Install roll pin through gear case and into the pinion shaft using suitable drift and hammer. Sink pin until it is approximately 1/6 inch below gear
case surface.
11. Stake gear case to prevent pin from coming out, then install ring gear to gear case with depression on gear toward gear case.
12. Align threaded holes in gear with holes in case, then install and hand-tighten ring gear bolts.
13. Torque bolts to 51-61 ft lbs in two stages. Mark first bolt tightened and work in clockwise direction until all bolts have been properly tightened.
14. Check and adjust side gear and pinion gear backlash as follows:
a. Install both axle shafts into differential assembly.
b. Support axle shafts on V-blocks.
c. Measure backlash of both pinion gears. Correct backlash measurement is less than 0.004 inch.
d. If backlash is more than specified, adjust by selecting thrust washer from Side Gear Thrust Washer Thickness Selection Chart.
e. Thrust washer should be same thickness at each side gear.
