Disassembly and Assembly - Standard

DIFFERENTIAL

REMOVAL
1. Raise and support vehicle.
2. Remove fill hole plug from the differential housing cover.
3. Remove differential housing cover and drain from the housing.
4. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning.
5. Remove the axle shafts.

NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.





6. Mark the differential housing and bearing caps for installation reference (Fig. 25).
7. Remove bearing threaded adjuster locks from each bearing cap.
8. Loosen bearing cap bolts, them loosen the threaded adjusters with Wrench C-4164.
9. Hold the differential case while removing bearing caps and adjusters.
10. Remove the differential case.

NOTE: Tag bearing cups and threaded adjusters location, for installation reference.

DISASSEMBLY





1. Remove pinion shaft lock screw (Fig. 26).
2. Remove pinion shaft.





3. Rotate differential side gears and remove differential pinions and thrust washers (Fig. 27).
4. Remove differential side gears and thrust washers.

ASSEMBLY
1. Install differential side gears and thrust washers.
2. Install differential pinion and thrust washers.
3. Install the pinion shaft.
4. Align the hole in the pinion shaft with the hole in the differential case and install the pinion shaft lock screw.
5. Lubricate all differential components with hypoid gear lubricant.

INSTALLATION
1. Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups and threaded adjusters. A dab of grease can be used to keep the adjusters in position. Carefully position the assembled differential case in the housing.





2. Install differential bearing caps in their original locations (Fig. 28).
3. Install bearing cap bolts and tighten the upper bolts to 14 Nm (10 ft. lbs.). Tighten the lower bolts finger-tight until the bolt head is seated.
4. Perform the differential bearing preload and adjustment procedure.
5. Tighten bearing cap bolts in a cries-cross pattern to 95 Nm (70 ft. lbs.).
6. Install adjuster locks on the bearing caps.
7. Install axle shafts.





8. Apply a bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 29).

CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.

9. Install cover and tighten bolts in a cries-cross pattern to 41 Nm (30 ft. lbs.).
10. Fill differential with gear lubricant to bottom of the fill plug hole.
11. Install the fill hole plug.
12. Install wheel and tire assemblies.
13. Remove support and lower vehicle.
14. Trac-lok differential equipped vehicles should be road tested by making 10 to 12 slow figure-eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint.