Section 10 --- Chassis Information
Cayman 2005
340
DRIVE AXLE & DRIVE SHAFT
Drive Axle:
The chassis drive axle is a single reduction axle,
with a gear ratio of 4.88:1. The differential gears
consist of a hypoid pinion and ring gear set and
bevel differential gears. The differential carrier can
be removed from the axle housing as a unit in
order to perform repairs.
All power from the engine to the rear tires is
transferred through the rear axle. For this reason, it
is important that maintenance be performed on the
axle as required to avoid premature wear of the
gears and bearings in the axle.
Drive Axle Lubricant:
The rear axle is filled at the factory with synthetic gear oil meeting MIL-L-2105D specifications. Change
interval every 250,000 miles, or 36 months, whichever occurs first. If petroleum based lubricant is used, the
change interval will be at 100,000 miles or yearly, whichever occurs first.
During lubricant change, fine metal particles will be observed clinging to the magnetic fill and drain
plugs of the axle. These particles are normal wear particles from the axle components, but will cause
faster than normal wear of the axle components if allowed to circulate through the lubricant. It is rec-
ommended that the magnetic plugs be tested, if not replaced, at each lubricant change. These plugs should
have sufficient magnetic strength to pick up a 1.5 pound weight of low carbon steel. Never replace a mag-
netic plug with a non-magnetic "pipe plug" as they will not keep the lubricant clear of metal particles or
seal properly.
The level of lubricant in the rear axle should be checked every 30,000 miles or annually, whichever
comes first. This will ensure adequate lubricant in the axle for proper operation.
Proper Drive Axle Lubricant Level:
Regular inspection of the drive axle lube levels is an essential maintenance procedure.
• Clean the area around the fill plug, which is located approximately halfway up the axle
housing bowl.
• Remove the fill plug and observe the lubricant level.
• The lubricant should be level with bottom of the hole.
• Important: The lube level close enough to the hole to be seen or touched is not sufficient.
The lube must be level with the hole.
• Correct the level as necessary.
• Re-install the fill plug and tighten to 35 ft. lbs.
NOTE:
When checking the lube level also check the housing breathers. Clean the breathers
if dirty or replace them if damaged.
090416
Ring and Pinion Gears
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