Differential

DIFFERENTIAL

REMOVAL
1. Remove filler plug from the differential cover.
2. Remove differential cover and drain the lubricant.
3. Clean 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.

4. Remove axle shafts.
5. Remove RWAL/ABS sensor from housing.

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





6. Mark differential housing and bearing caps (3) for installation reference.
7. Remove bearing threaded adjuster lock from each bearing cap.
8. Loosen differential bearing cap bolts.





9. Loosen differential bearing adjusters through the axle tubes (1) with Wrench C-4164 (3).
10. Hold differential case while removing bearing caps and adjusters.

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

11. Remove differential case.

DISASSEMBLY





1. Rotate one pinion gear (2) with thrust washer (3) to the differential window (1) and remove gear and thrust washer.





2. Rotate remaining pinion gear (3) with thrust washer (2) to the differential window (1) and remove gear and washer.





3. Remove differential side gears (1) (2) and thrust washers.

ASSEMBLY

NOTE: If same gears and thrust washers are being used, install them into their original locations.

1. Lubricate all differential components with axle lubricant.





2. Install differential side gears (2) and thrust washers through differential window (1).






3. Install first pinion gear (3) with thrust washer into differential window (1) and side gears (2). Rotate pinion gear into the case.
4. Install remaining pinion gear and thrust washer. Rotate gears to align hole in the pinion gears with hole in the differential case.





5. Slide pinion shaft (4) into the case and through the pinion gears (3) to align the gears.

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 differential assembly into the housing.





3. Install differential bearing caps (4) in their original locations.
4. Install bearing cap bolts and tighten the upper bolts to 14 Nm (10 ft. lbs.). Tighten lower bolts finger-tight until the bolt head is seated. Then 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.

5. Install axle shafts.





6. Apply a bead of orange Mopar Axle RTV Sealant (1) or equivalent to the cover (2).

CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instruction will result in a leak.

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

NOTE: Trac-lok(tm) 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.