Disassembly and Assembly - Standard

DIFFERENTIAL

REMOVAL
1. Raise and support vehicle.
2. Remove filler plug from the differential cover.
3. Remove differential cover and drain the lubricant.
4. Clean the housing cavity with flushing oil, light engine oil or a lint free cloth.

NOTE: Do not use steam, kerosene or gasoline to clean the housing.

5. Remove the axle shafts.
6. Remove RWAL/ABS sensor from housing.

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





7. Mark differential housing and bearing caps for installation reference (Fig. 28).
8. Remove bearing threaded adjuster lock from each bearing cap.
9. Loosen differential bearing cap bolts.





10. Loosen differential bearing adjusters through the axle tubes with Wrench C-4164 (Fig. 29).
11. Hold the differential case while removing bearing caps and adjusters.
12. Remove the differential case.

NOTE: Tag the differential bearing cups and threaded adjusters to indicate their location.

DISASSEMBLY





1. Remove pinion shaft lock screw (Fig. 30).
2. Remove pinion shaft.





3. Rotate differential side gears and remove differential pinions and thrust washers (Fig. 31).
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.
2. Install the differential assembly into the housing.





3. Install the differential bearing caps in their original locations (Fig. 32).
4. 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.
5. Perform the differential bearing preload and adjustment procedure.

NOTE: Be sure that all bearing cap bolts are tightened to their final torque of 136 Nm (100 ft. lbs.) before proceeding.

6. Install axle shafts.





7. Apply a 1/4 in. bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 33).

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.

8. Install the cover and any identification tag and tighten cover bolts to 41 Nm (30 ft. lbs.).
9. Fill differential with lubricant to bottom of the fill plug hole.
10. Install the fill hole plug and lower the vehicle.
11. 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.