Differential: Service and Repair

DIFFERENTIAL REPAIR

Refer to Figures 136 through 159 for differential repair procedures.

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

WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING.

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.

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.

Fig. 136:

Fig. 137:

Fig. 138:

Fig. 139:

Fig. 140:

Fig. 141:

Fig. 142:

Fig. 143:

Fig. 144:

Fig. 145:

Fig. 146:

Fig. 147:

Fig. 148:

Fig. 149:

Fig. 150:

Fig. 151:

Fig. 152:

Fig. 153:

Fig. 154:

Fig. 155:

Fig. 156:

Fig. 157:

Fig. 158:

Fig. 159:

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

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

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

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

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

DETERMINING SHIM THICKNESS

Fig. 159:

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.