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Old 03-08-2009, 09:19 PM   #7
Geo Metro Lover
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Join Date: May 2005
Location: Eastern Washington State, Washington
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Re: 94 Metro 5 Speed Manual Transmission Rebuild - PART 2 - Assembly

. . . . . . . . . . . . . . . . . . . . . . Assembling the Differential . . . . . . . . . . . . . . . . . . . . . .

The Gear & Bearing Puller was used again to push the two Ball Bearings onto the

A couple of side grasping rods comes with the set and I used them to grasp the side flange
of the Differential when the Ball Bearings were pulled on.

The large washers and different short Bolts and Flair Nuts which I purchased to
push things on with - now are very handy!

A drop of the oil was put on the inside of the L - Bearing where it slides down the shaft before pressing.
Everything went well. No worries....

The Plastic Speedometer Gear was placed on the right side with the flat side away from the Differential
and the R - Ball Bearing was pressed on as above.

Notice the 3/8 Threaded Rods screwed into the Gear Puller grasper nuts to lengthen the reach -
Thank God I had them !

Again - no worries.

At this point, I put the Large Differential Gear on, noted which side had bolt marks and placed the bolts.

The nuts require tightening with a torque wrench which is a tool all backyard auto mechanics
must have on hand...bought mine a long time ago !

A setting of 60 ft lbs was used.

I opened my Large Vise (a very good investment!) enough to allow the Differential to set
inside the jaws without touching the gears.

The Differential cannot turn due to the sides hitting the Vise Jaws allowing one to
easily tighten the eight bolts.

As each bolt was torqued, I put a dot on it with a "Sharpie" silver marking pen
so I would not miss one.
If any of these come loose when the Transmission is in use - That's all she wrote...

The Differential is assembled now.

Time, I think, to start the assembly process of putting all this stuff back into the case...

More to come.....


Last edited by DOCTORBILL; 03-08-2009 at 10:57 PM.
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