Delorean DMC - Page 159

Manual Transmission
F:06:03
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UNIT REASSEMBLY
Before reassembly is performed, the differential
carrier bearing preload must be adjusted.
1. Clean the half-case mating surfaces.
2. Insert the differential assembly in the right-
hand half-casing.
3. Install left-hand case and torque tighten the
bolts in the correct sequence. (Fig. 13)
4. Lubricate the threads on the ring nut and install
in the case until it contacts the bearing race
using Tool J28866.
5. T/ghten the ring nut until all play is removed
from the bearings.
6. Attach a piece of string to the differential
housing and wrap around the housing several
times.
7. Pull the string using a spring scale to measure
the bearing preload. (Fig. 16) The reading is
taken when there is a constant rotating
movement of the differential.
8. Tighten differential nut until the proper reading
is obtained.
New Bearings: 10-30 NM (3-7 ft. lb.)
Used Bearings: Differential should turn free
without any play in the bearings.
9. Install adjusting nut lock plate and tighten bolt.
10. Remove left-hand case and differential
assembly.
11. Insert the 3mm thick washer, the reverse gear
and the 5mm thick washer into the half-case.
Fit the reverse shaft in the case, washer, gear
and washer. (Fig. 17)
NOTE: Reverse gear must be installed with the
shift fork flange facing the rear cover end of
the transmission and the 3mm washer placed
between the flange and the case.
12. Insert the secondary shaft assembly into the
right-hand half-case.
NOTE: When installing the secondary shaft,
align the notch in the double roller bearing with
the pin in the case.
13. Insert the primary shaft assembly into right-
hand half-case, taking care that the flange of
the clutch shaft tube seal is in the inner
groove of the case. (Fig. 18)
14. Install the differential assembly into the right-
hand half-case.
15. Coat the half-casing joint faces with specified
sealer in accordance with its labelled
precautions. Assemble the case-halves.
NOTE: Use specified sealer, in accordance
with its labelled precautions, on No. 1 bolt.
16. Torque tighten the half-case bolts in the proper
sequence as shown. (Fig. 19)
17. Install the double taper roller bearing retaining
plate and torque bolts. (Fig. 20)
18. Install the 5th speed gear, conical washer and
nut onto the secondary shaft.
NOTE: Install the conical washer with the cone
side towards the nut.
19. Fit the bearing washer and needle bearing race
onto the primary shaft.
20. Fit the synchro spring into the lower groove of
the 5th speed sliding gear to the hub.
21. Install the 5th speed gear assembly, needle
roller half-bearings and shift fork onto the
primary shaft.
22. Install the 5th speed synchro ring and dog onto
the primary shaft.
23. Install the conical washer and nut on the
primary shaft.
NOTE: Install the conical washer with the cone
side towards the nut.