Clean the outside surface of the transaxle. Place the shifter in neutral position. Remove detent cover screw (item 3), detent cover (item 4), detent springs (item 5), and detent balls (item 6). Use a magnet to remove detent balls. Remove neutral switch (item 7) if present. Remove shifter boot (item 8). Remove all upper housing screws using a T30 Torx wrench. Lift upper housing (item 1) straight up to remove. Remove the shifter assembly (item 9). Clean and inspect for defects. Replace the shifter assembly if there is wear or damage. Page 1 of 7 4360 Teardown 11/19/2003
Remove idler shaft assembly from the lower housing. Caution: Care should be taken to keep the parts in proper sequence. Placement of spacers and washers is critical. Disassemble the idler shaft assembly. Lubricate the shaft with sae 30 oil and reassemble the idler shaft assembly. Note: Maintain a clearance of.013"/.025" between the shim washer (item 12) and the housing. Change washer if necessary to achieve the proper clearance. Remove the intermediate and drive shaft assemblies by lifting on the ends of both shafts. Remove the flange bearing (item 14), washer (item 15), and spacer (item 16) from the chain side of the drive shaft (item 20). Hold the intermediate shaft (item 35) assembly while removing the remainder of the drive shaft assembly from the intermediate shaft assembly. Page 2 of 7 4360 Teardown 11/19/2003
Remove the remaining parts from the drive shaft (item 20). Caution: Care should be taken to keep the parts in proper sequence. Placement of spacers and washers is critical. Lubricate the shaft with SAE 30 oil and reassemble the drive shaft assembly. Disassemble the intermediate shaft assembly starting at the end opposite the clutch collar (item 33). Caution: Care should be taken to keep the parts in proper sequence. Placement of spacers and washers is critical. Remove the parts one at a time stopping at the retaining ring (item 37) near the center of the shaft. Remove the parts from the other end stopping at the clutch collar (item 33). Remove the clutch keys (item 34) and collar (item 33) by pulling the collar off of the end of the shaft. This should also pull the keys under the retaining ring and allow them to be removed. Inspect the tips of the clutch keys (item 34) and drive lug areas of the gears for wear. Lubricate the shaft and drive lug areas with SAE 30 oil and reassemble the intermediate shaft assembly. The clutch keys and collar must slide freely after assembly. Caution: Install the gears with the drive lug areas facing the clutch collar. Reassemble the drive shaft assembly to the intermediate shaft assembly. Page 3 of 7 4360 Teardown 11/19/2003
Remove the axles and differential assembly in one piece by grasping each axle firmly then pushing toward the center and lifting. Disassemble the differential assembly. Caution: Placement of spacers and washers is critical. Reassemble the differential assembly. Remove the input shaft assembly by first removing the retaining ring (item 59) below input pinion gear (item 60). Push the input shaft out from the inside. Remove the bearings (item 64) from the upper housing. Care should be taken not to damage the bore of the housing. Reassemble the bearings in the housing with the flat lettered ends facing outboard. They should be installed with a maximum recess of.030". Fill the gap between the bearings with Unirex N3 grease. Install the input shaft through the housing and reassemble the pinion gear (item 60). Install the retaining ring (item 59) below the pinion gear. Maintain a maximum shaft float of.005" by changing shim washers if necessary (item 65). Page 4 of 7 4360 Teardown 11/19/2003
Remove the brake assembly by first removing the two brake bolts (items 78) using a 1/2" socket. Disassemble the remaining parts. Caution: Placement of spacers and washers is critical. Clean and inspect the parts. Place the drive assembly into the lower. Caution: Care should be taken to be sure that the anti-rotation tabs on the flange bearings are placed into the notches of the lower housing. Reassemble the brake assembly. Install the brake assembly onto the lower housing (item 67). The brake bolts (items 78) should be tightened to 160/200 inch pounds torque. Install the entire differential assembly by holding each axle and applying inward pressure while placing it into the lower housing. After installation the axles must rotate freely. Note: If the differential will not rotate freely, one of the axle miter gears must be rotated to the right or left one tooth. Repeat the process until free rotation is achieved. Check the clearance between the thrust washer outside the miter gear and the housing. The clearance should be.007"/.015". Change washers if necessary to achieve the proper clearance. Page 5 of 7 4360 Teardown 11/19/2003
Apply anti-seize lubricant to the top of the detent plate and shaft of shifter assembly (item 9). Install the shifter assembly (item 9) into the lower housing (item 67) while making sure that the pins on the shifter fit into the groove of the clutch collar (item 33). Apply sealant to the lower housing making sure not at apply any to shaft or bearing surfaces. Note: Use Loctite Superflex silicone 5699 or the equivalent. Page 6 of 7 4360 Teardown 11/19/2003
Install the upper housing (item 1). Install the housing screws (item 2). Tighten to 140/160 inch pounds torque. Install the shifter boot (item 8) over the shifter assembly. Install detent balls (item 6), detent springs (item 5), detent cover (item 4), and detent cover screw (item 3). Tighten detent cover screw to 30/40 inch pounds torque. Install neutral switch (item 7), if present, into the upper housing (item 1). Tighten to 240/300 inch pounds torque. After the unit is reassembled it is necessary to check the brake clearance. It should be.019"/.024" between the brake disc and the outside friction puck while the brake lever contacts the brake jaw. Page 7 of 7 4360 Teardown 11/19/2003