Differential Removal
DIFFERENTIAL ASSEMBLY1. Block brake pedal in the up position using suitable wooden block.
2. Raise and support rear of vehicle, then remove rear axles. Refer to "Axle Shaft, Replace" for procedure.
3. If not done previously, loosen axle housing cover bolts and allow lubricant to drain, then remove bolts and cover.
4. Remove propeller shaft. Refer to "Propeller Shaft, Replace" in the "Chrysler Rear Wheel Drive Chapter" for procedure.
5. Using suitable cleaning solvent, clean inside axle housing and differential case.
6. Using a suitable pry bar or screwdriver positioned between left side of axle housing and differential case flange, check for differential side play by attempting to move differential with a prying motion. No side play should be present. If side play is evident and is the result of the bearing cones becoming loose from the differential case hubs, the case must be replaced. If side play is the result of any other cause, adjust side play using threaded adjuster so next step can be performed.
7. Mount suitable dial indicator on axle housing with stylus against left side of ring gear. Rotate differential case while observing dial indicator. Mark ring gear and differential case at point of maximum runout for later use. If runout exceeds 0.005 inch, the case may be damaged. Refer to Differential Case Disassembly for further service.
8. Using suitable tool, mark bearing caps and axle housing to be used as reference marks during reassembly.
9. Remove adjuster locks from each cap, then loosen, but do not remove bearing cap bolts.
Fig. 1 Hex adjuster tool installation:
10. Insert tool C-4164, through axle tube on each side and loosen hex adjuster.
11. While holding differential assembly in place with one hand, remove bearing cap bolts, then very carefully remove bearing caps, adjusters and differential assembly. Differential bearing cups must remain with their respective bearing cones. On 8 1/4inch axles, the threaded adjusters must also be kept with their respective bearings. On 7 1/4 and 9 1/4 inch axles, the threaded adjusters will remain in the axle housing.
12. Mount differential assembly in vise equipped with soft jaws.
DRIVE PINION
1. Using suitable inch lbs. torque wrench, measure pinion bearing preload and record. Remove drive pinion nut, washer and flange.
2. Using suitable screwdriver and hammer, remove front oil seal.
3. Using suitable hammer, drive pinion shaft rearward to remove drive pinion and front bearing cone. After drive pinion removal, both bearings and cones will be damaged and must be replaced. Discard collapsible spacer.
4. Using C-4306 remover and C-4171 handle, remove bearing cups from axle housing. On 8 1/4 inch axles, a shim will be located behind rear bearing cup. Measure and record shim thickness and discard.
5. Using suitable bearing puller, remove rear pinion bearing. On 7 1/4, 9 1/4 and some 8 1/4 inch axles, remove shim from drive pinion stem. Measure and record shim thickness.