Differential

DIFFERENTIAL

REMOVAL
1. Remove differential housing cover and drain fluid.
2. Remove axle shafts.
3. Loosen bearing cap bolts.

NOTE: Differential bearing cap reference numbers are stamped on caps and machined flat on the housing. If reference numbers cannot be found, make new marks for later reference.





4. Install Adapter Plates 8142-A (1) onto the housing.
5. Install Spreader W-129-B (2) onto the adapter plates (1) and tighten the turnbuckle finger-tight.





6. Install a Pilot Stud L-4438 at the left side of the differential housing. Attach Dial Indicator C-3339 (1) to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator.
7. Spread the housing to remove the differential case from the housing. Measure the distance with the dial indicator.

CAUTION: Never spread housing over 0.50 mm (0.020 inch). Failure to follow these instructions will damaged the housing.

8. Remove dial indicator.
9. While holding the differential case in position, remove bearing cap bolts and caps.





10. Remove differential (2) from the housing (1). Ensure differential bearing cups (3) and shims remain in position on the differential bearings.
11. Tag differential bearing cups and shims to indicate their location.
12. Remove spreader from housing.

DISASSEMBLY
1. Remove ring gear.
2. Remove roll-pin holding mate shaft in housing.
3. Remove pinion gear mate shaft.





4. Rotate differential side gears (2) and remove pinion gears (3) and thrust washers (1).
5. Remove differential side gears and thrust washers.

ASSEMBLY

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

1. Lubricate differential components with hypoid gear lubricant.
2. Install side gears and thrust washers into the differential case.
3. Rotate pinion mate gears and thrust washers into the differential case.





4. Install pinion gear mate shaft (2).
5. Align hole in pinion gear mate shaft with hole in the differential case.
6. Install roll-pin (3) in the differential case with a punch (1) and hammer. Peen edge of roll-pin hole in differential case in two places 180° apart.
7. Install ring gear.

INSTALLATION

NOTE: If replacement differential bearings or differential case are replaced, Refer to adjustments for Differential Bearing Preload and Gear Backlash procedures.





1. Install Spreader W-129-B (2) with the Adapter Plates 8142-A (1) and install the safety holddown clamps. Tighten the tool turnbuckle finger-tight.
2. Install a Pilot Stud L-4438 at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load indicator plunger against the opposite side of the housing and zero the indicator.
3. Spread housing and measure the distance with the dial indicator.

CAUTION: Never spread housing over 0.50 mm (0.020 inch). Failure to follow these instruction will damage the housing.

4. Remove dial indicator.
5. Install differential case in the housing. Ensure differential bearing coos remain in position on the bearings and the differential preload shims are seated in the housing. Tap differential case to ensure bearings cups are seated in the housing.
6. Install bearing caps to their original locations and loosely install cap bolts.
7. Remove housing spreader.
8. Tighten the bearing cap bolts to 61 Nm (45 ft. lbs.).
9. Install axle shafts.
10. Apply a bead of orange Mopar Axle RTV sealant or equivalent to the housing cover.

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 cause a leak.

11. Install cover and tighten bolts in a criss-cross pattern to 22 Nm (15 ft. lbs.).
12. Fill differential with lubricant.