Differential Repair

PROCEDURE

Remove Extension Seal:

Install New Seal Into Extension:

NOTE: The transfer shaft should be removed for differential repair and bearing turning torque checking.

Differential Cover Bolts:

Remove Or Install Differential Cover:

Remove Bearing Retainer Axle Seal:

NOTE: Use MOPAR RTV sealant, or equivalent, when installing differential cover.

Install Bearing Retainer Axle Seal:

Differential Bearing Retainer Bolts:

Remove Or Install Bearing Retainer:

Differential Bearing Retainer (Typical):

Extension Bolts:

Remove Or Install Extension Housing:

NOTE: Use MOPAR RTV sealant, or equivalent, when installing differential bearing retainer.

Differential And Extension:

WARNING: Hold onto differential assembly to prevent it from rolling out of housing.

Use MOPAR Silicone Rubber Adhesive Sealant, or equivalent, when installing extension housing.

Remove Differential Bearing Cone (Extension Housing Side):

Position Bearing Cone Onto Differential:

Install Differential Bearing Cone:

Position Button And Collets Onto Differential And Bearing (Ring Gear Side):

Position Tool 5048 Over Button And Collets At Differential Bearing:

Remove Differential Bearing Cone:

Checking Side Gear End Play:

Checking Side Gear End Play (Typical):

Differential Bearing Retainer:

Position Bearing Cup Remover Tool In Retainer:

Remove Bearing Cup:

Install Bearing Cup:

To install the differential bearing cup and cone on the ring gear side, use Special Tool 5052, and Special Tool C-4171, or equivalents.

NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft.

CAUTION: Side gear end play must be Between 0.001 to 0.013 inch.

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of the following parts are replaced:
- Transaxle case
- Differential carrier
- Differential bearing retainer
- Extension housing
- Differential bearing cups and cones

Refer to Bearing Adjustment Procedure to determine proper shim thickness.

To remove the differential bearing cup from the extension housing/adapter side, use Special Tool 6062A, Remover. To install the differential bearing cup on the extension housing/adapter side, use Special Tool 6536, Driver and Special Tool C-4171, Handle, or equivalents.