Assembly

ASSEMBLY

NOTE: The differential is serviced as an assembly. Differential service is limited to bearing cups and cones. Any other differential component failure must be remedied by differential assembly and transfer shaft replacement.

Fig. 185 Thrust Washer Installation:

1) Install side gear thrust washer to differential case (Fig. 185).

Fig. 186 Side Gear Installation:

2) Install side gear to differential case (Fig. 186).

Fig. 187 Pinion Gear and Washer Installation:

3) Install both pinion gears and washers to case, while orientating washer tabs to notch in case (Fig. 187).

Fig. 188 Pinion Shaft Installation:

4) Install pinion shaft (Fig. 188).

Fig. 189 Side Gear Installation:

5) Install side gear to case (Fig. 189).

Fig. 190 Side Gear Thrust Washer:

6) Install side gear thrust washer to case (Fig. 190).

Fig. 191 Diff Support Installation:

7) Install differential support into position, while aligning through-holes (Fig. 191).

Fig. 192 Ring Gear Installation:

8) Install differential ring gear to case (Fig. 192).

Fig. 193 Ring Gear-to-Case Bolts:

9) Install ring gear-to-case bolts, with pinion shaft retainers (Fig. 193), and torque bolts to 95 Nm (70 ft. lbs.).

Fig. 194 Position Bearing Cone Onto Differential-Typical:

10) Using Miller Special Tool L-4410, and C-4171, install differential bearing to differential (extension housing side) (Fig. 194).
11) Using Miller Special Tool 5052 and C-4171, install differential bearing to differential (bearing retainer side).

Fig. 195 Differential Bearing Retainer:

12) Using Miller Special Tool 6061 and C-4171, install differential bearing race to bearing retainer (Fig. 195).
13) Using Miller Special Tool L-4520 and C-4171, install differential bearing to extension housing.

NOTE: Use Mopar Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case.

Fig. 196 Differential Bearing Retainer:

Fig. 197 Differential Retainer Bolts:

14) Install differential assembly into transaxle case. Install differential bearing retainer (Fig. 196) and torque retainer-to-case bolts (Fig. 197) to 28 Nm (21 ft. lbs.).
15) Apply a bead of Mopar Silicone Rubber Adhesive Sealant to extension housing/adapter plate and install into position. Install and torque bolts to 28 Nm (21 ft. lbs.).
16) Measure and adjust differential bearing preload.

Fig. 198 Install Differential Cover:

17) Apply a bead of Mopar Silicone Rubber Adhesive Sealant to differential cover and install to case (Fig. 198).

Fig. 199 Differential Cover Bolts:

18) Install and torque cover-to-case bolts to 19 Nm (165 inch lbs.) (Fig. 199).