For 1990-2009 cars

#### Special Tools

J 45185 Bore Gage Set

1. Remove the input shaft thrust bearing (540).
2. Remove the front sun gear assembly (544).
3. Remove the rear sun gear thrust bearing (538).
4. Remove the rear sun gear thrust bearing race (537).
5. Remove the rear internal gear (536).
6. Remove the rear internal gear thrust bearing (535).
7. Remove the front carrier thrust bearing race (543).
8. Remove the front carrier assembly (542).
9. Remove the rear internal gear flange retaining ring (548) from the rear internal gear (536).
10. Remove the rear internal gear flange (547) from the rear internal gear.
11. Remove the other rear internal gear flange retaining ring (548).
12. Clean the rear internal gear and air dry.
13. Inspect the rear internal teeth for the following:

• | Chips

• | Cracks

• | Excessive wear

• | Metal debris embeded in teeth

14. Replace the rear internal gear if any of the above conditions are found.
15. Install a rear internal gear flange retaining ring (548).
16. Install the rear internal gear flange (547) in the rear internal gear (536).
17. Install the other rear internal gear flange retaining ring (548).
18. If the rear sun gear bushing is not within specifications or any of the above conditions are found, replace the rear sun gear.
19. Clean the front carrier assembly (542) and air dry. Ensure to remove all solvent in the pinion gears.
20. Inspect the front carrier assembly pinion teeth for the following conditions:

• | Chips

• | Cracks

• | Excessive wear

• | Metal debris embeded in teeth

21. Inspect for missing washers on both sides of the pinion gears.
22. Inspect the front carrier bushing for scoring or excessive wear.
23. Using J 45185 and a micrometer measure the front carrier bushing inner diameter (A). Measure in three locations and take the average.

Specification
Front carrier bushing: 30.056-30.132 mm (1.183-1.186 in)

24. If the front carrier bushing is not within specifications or any of the above conditions are found, replace the front carrier assembly.
25. Clean the front sun gear (544) and air dry.
26. Inspect the front sun gear teeth for the following conditions:

• | Chips

• | Cracks

• | Excessive wear

• | Metal debris embeded in teeth

27. Inspect the rear sun gear teeth for the following:

• | Chips

• | Cracks

• | Excessive wear

• | Metal debris embeded in teeth

28. Inspect the front sun gear shaft for excessive wear or scoring at the front carrier assembly bushing area.
29. Using J 45185 and a micrometer measure the bushing inner diameter (A). Measure in three locations and take the average.

Specification
Front sun gear bushing: 22.200-22.276 mm (0.874-0.877 in)

30. If the front sun gear bushings are not within specifications or any of the above conditions are found, replace the front sun gear.
31. Inspect the bushing for scoring or excessive wear.
32. Using J 45185 and a micrometer measure the rear sun gear bushing inner diameter (A). Measure in three locations and take the average.

Specification
Rear sun gear bushing: 22.200-22.276 mm (0.874-0.877 in)