Absolutely, I’d be happy to walk you through the process of overhauling the gear set on a Chrysler Daytona. Click to explore details and download the manual……
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This is a detailed job that requires careful attention to precision, so let’s dive right in, step by step.
### tools and Materials Needed
Before we start, let’s talk about the tools and materials you’ll need. Having everything ready will make the process smoother and more efficient.
1. **Basic hand Tools:**
– **Socket Set:** A metric socket set is essential, usually ranging from 8mm to 19mm for most fasteners on the Daytona.
– **Wrenches:** Combination wrenches, especially in the same metric sizes, are useful for tight spaces.
– **Screwdrivers:** Both flathead and Phillips screwdrivers in various sizes will be necessary for removing various screws and clips.
2. **Specialized Tools:**
– **Torque Wrench:** This is crucial for ensuring that all fasteners are tightened to the manufacturer’s specifications, which is imperative for the longevity and reliability of the gear set.
– **Dial Indicator:** A dial indicator is necessary for measuring backlash and ensuring proper gear alignment, which is critical in a gear set overhaul.
– **Bearing Puller:** This tool will help you remove bearings from the axle or differential housing without damaging them.
– **Gear Oil Pump:** To refill the differential with new oil after the overhaul, a gear oil pump can make this task much easier.
– **Seal Installer:** This tool helps in installing new seals without damaging them, ensuring a proper fit.
3. **Cleaning Supplies:**
– **Parts Cleaner:** This will be used to clean the differential housing and gears thoroughly.
– **Rags and Brushes:** For scrubbing and wiping down parts.
– **Solvent:** A degreaser or brake cleaner will help in removing old oil and grime.
4. **Replacement Parts:**
– **Gaskets and Seals:** New gaskets and seals should be obtained to prevent leaks once the differential is reassembled.
– **Bearings:** If any bearings show signs of wear, it’s best to replace them during the overhaul.
– **Gear Set:** Depending on the condition of your current gear set, you may want to replace it with a new one or a performance upgrade.
### Preparation Steps
1. **Safety First:** Start by ensuring you’re wearing appropriate safety gear, including gloves and goggles. A clean work area is also essential to keep track of small parts and fasteners.
2. **Lift the Vehicle:** Use a hydraulic floor jack to lift the rear of the Chrysler Daytona and secure it with jack stands. This is critical as you’ll be working underneath the vehicle. Ensure the vehicle is on a flat surface for stability.
3. **Remove the Wheels:** using a lug wrench, loosen the lug nuts on the rear wheels and remove them. This will give you access to the brake assemblies and the differential.
### Disassembly of the Differential
4. **Remove the Brake Assemblies:** Start by removing the brake calipers and hang them securely out of the way using zip ties or wire. Then, remove the brake rotors if necessary.
5. **Drain the Differential Fluid:** Place a drain pan underneath the differential and remove the drain plug. Allow all the old fluid to fully drain out. It’s a good idea to inspect the fluid for metal shavings or debris, which could indicate wear or damage.
6. **Remove the Differential Cover:** using a socket wrench, remove the bolts that secure the differential cover. Carefully pry the cover off with a flathead screwdriver if it’s stuck due to old gasket material. Be cautious of any remaining fluid that may spill out.
7. **Remove the Ring Gear and Pinion:** To access the gear set, you’ll need to remove the ring gear. This typically involves unbolting it from the differential case. Once removed, you can proceed to take out the pinion gear. Use your dial indicator to measure backlash before removal as a reference for reassembly.
8. **Take Out the Carrier:** Remove the carrier assembly by unbolting it from the housing. This may require a bearing puller to gently extract the bearings without damaging them.
### Inspection and Cleaning
9. **Inspect Components:** Carefully inspect the ring and pinion gears for wear, chipping, or scoring. Check the bearings for signs of pitting or roughness. If any components are damaged, they should be replaced.
10. **Clean All Parts:** Use the parts cleaner to thoroughly clean the differential housing, gear set,
and any other components. Remove all old gasket material and debris to ensure a proper seal during reassembly.
### Reassembly of the Differential
11. **Install New Bearings:** If you replaced any bearings, now is the time to install them. Use the bearing installer to press them into place gently.
12. **Install the pinion Gear:** Position the pinion gear in the differential housing, ensuring it is aligned correctly. Use your torque wrench to tighten any bolts to the specified torque settings from the manufacturer’s manual.
13. **Install the Ring Gear:** Attach the ring gear to the carrier and ensure it is secured tightly. Again, use your torque wrench for the proper tightness.
14. **Adjust Backlash:** using the dial indicator, check the backlash between the ring and pinion gears. Adjust if necessary by modifying the shim thickness until you reach the manufacturer’s specifications.
15. **Reinstall the Carrier Assembly:** Place the carrier assembly back into the differential housing and secure it with the appropriate bolts.
16. **Install the Differential Cover:** Before reattaching the cover, make sure to apply a fresh bead of gasket maker or a new gasket. Secure the cover with the bolts, tightening them in a crisscross pattern to ensure even pressure.
### Final Steps
17. **Refill Differential with Gear Oil:** using the gear oil pump, refill the differential with the appropriate gear oil specified for your Chrysler Daytona. Ensure you fill it to the correct level, usually until it starts to seep out of the fill hole.
18. **Reattach the Brake Components:** Reinstall the brake rotors and calipers in the reverse order of removal. Make sure to tighten all bolts to the manufacturer’s specifications.
19. **Reattach the Wheels:** Place the wheels back on the hubs and hand-tighten the lug nuts. Lower the vehicle back to the ground and then use the lug wrench to fully tighten the lug nuts in a crisscross pattern.
20. **Test Drive:** Finally, take the vehicle for a test drive to ensure everything is functioning correctly. Listen for any unusual noises which may indicate a problem.
### Conclusion
Overhauling the gear set on a Chrysler Daytona is a detailed and time-consuming process, but with the right tools, attention to detail, and care during reassembly, you can achieve a successful overhaul. Always consult the vehicle’s service manual for specific torque specifications and procedures to ensure you’re following the manufacturer’s guidelines. And remember, if you ever feel unsure, don’t hesitate to consult a professional mechanic. Happy wrenching!
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