Disassembly and Assembly - Standard
REMOVAL1. Raise and support the vehicle.
2. Remove fill hole plug from the differential housing cover.
3. Remove differential housing cover and drain lubricant 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 axle shafts.
6. Note the orientation of the installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 28).
7. Remove the differential bearing caps.
8. Position Spreader W-129-B with the tool dowel pins seated in the locating holes (Fig. 29).
9. Install the hold down clamps and tighten the tool turnbuckle finger-tight.
10. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach dial indicator to housing pilot stud. Load the indicator plunger against the opposite side of the housing (Fig. 29) and zero the indicator.
11. Spread the housing enough to remove the case from the housing. Measure the distance with the dial indicator (Fig. 29).
CAUTION: Never spread the housing over 0.50 mm (0.020 inch). If housing is over-spread, it could be distorted or damaged.
12. Remove the dial indicator.
13. Pry the differential case loose from the housing. To prevent damage, pivot on housing with the end of the pry bar against spreader (Fig. 30).
14. Remove the case from housing. Tag bearing cups to indicate their location.
DISASSEMBLY
1. Remove roll-pin holding mate shaft in housing.
2. Remove pinion gear mate shaft (Fig. 31).
3. Rotate the differential side gears and remove the pinion mate gears and thrust washers (Fig. 32).
4. Remove the differential side gears and thrust washers.
ASSEMBLY
1. Install the differential side gears and thrust washers.
2. Install the pinion mate gears and thrust washers.
3. Install the pinion gear mate shaft.
4. Align the hole in the pinion gear mate shaft with the hole in the differential case.
5. Install and seat the pinion mate shaft roll-pin in the differential case and mate shaft with a punch and hammer (Fig. 33). Peen the edge of the roll-pin hole in the differential case slightly in two places, 180° apart.
6. Lubricate all differential components with hypoid gear lubricant.
INSTALLATION
NOTE: If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to Adjustments (Differential Bearing Preload and Gear Backlash) procedures to determine proper shim selection.
1. Position Spreader W-129-B with the tool dowel pins seated in the locating holes. Install the hold down clamps and tighten the tool turnbuckle finger tight.
2. Install a Pilot Stud C-3288-B at the left side of the differential housing and attach dial indicator to the pilot stud. Load the indicator plunger against the opposite side of the housing and zero the dial indicator.
3. Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator.
CAUTION: Never spread the housing over 0.50 mm (0.020 inch). If housing is over-spread, it could be distorted or damaged.
4. Remove the dial indicator.
5. Install differential into the housing. Tap the differential case with a rawhide/rubber hammer to ensure the bearings are seated in housing (Fig. 34).
6. Remove the spreader.
7. Install bearing caps in their original locations (Fig. 35) and tighten bearing cap bolts in a crisscross pattern to 108 Nm (80 ft. lbs.).
8. Install axle shafts.
9. Install the hub bearings.
10. Apply a bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 36).
CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
11. Install the cover and tighten bolts in a crisscross pattern to 47 Nm (35 ft. lbs.).
12. Fill the differential with Mopar Hypoid Gear Lubricant or equivalent to bottom of the fill plug hole.
13. Install fill hole plug and tighten to 34 Nm (25 ft. lbs.).
14. Remove support and lower vehicle.