Differential Electric Locker

DIFFERENTIAL ELECTRIC LOCKER

REMOVAL
1. Remove differential housing cover and drain lubricant from the housing.
2. Remove hub bearings and axle shafts.





3. Cut sensor wire tie strap (4) from adjuster lock.
4. Remove sensor target magnet (1) from bearing cap.





5. Remove adjuster lock bolts (3) and adjuster locks (2).





6. Remove electric locker connector (1) retainer (2) bolt from differential housing.





7. Remove retainer (1) and connector (2) from differential housing.
8. Remove retainer (1) from connector (2) and remove o-ring (3) from connector.
9. Mark bearing caps left and right for installation reference.
10. Loosen bearing cap bolts and loosen adjusters with Wrench 8883.
11. Remove bearing cap bolts and bearing caps.
12. Slid electric locker connector through differential housing.
13. Remove differential case and bearing cups from the housing.
14. Tag bearing cups left and right for installation reference.

DISASSEMBLY

NOTE: Internal differential components are serviced with the case.

1. Bend antirotation tabs outward.





2. Install Plug 9611(1) into coil side of the case.
3. Remove differential case bearing (2) with Puller C293PA (3) and Adapters 9613 (4).





4. Remove coil (1) mounting bolts (2).
5. Remove coil (1) with harness.

ASSEMBLY

NOTE: Internal differential components are serviced with the case.





1. Position locker coil on differential case (1) mounting location (2).





2. Clean coil bolts and apply Mopar Lock & Seal adhesive to the threads.
3. Install coil (1) and bolts (2).





4. Install differential case bearing (1) with Handle C4171 (2) and Installer 9612 (3).

INSTALLATION
1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth.
2. Lubricate differential case bearing.
3. Install differential case with bearings cups into the housing.
4. Slide electric locker connector through differential housing.
5. Install O-ring on electric locker connector.





6. Install electric locker connector (1) with retainer (2) in differential housing.
7. Install connector retainer and bolt.





8. Install bearing caps (2) and tighten bearing cap bolts finger-tight.

NOTE: Do not torque bearing cap and bolts at this time.

9. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
10. Holding the differential case toward the pinion gear, turn bearing adjusters with Wrench 8883 until they make contact with the differential bearings/cups.
11. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
12. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
13. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
14. Rotate the pinion several times to seat the differential bearings.
15. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.
16. Tighten pinion gear side adjuster until it just makes contact with the bearing cup.
17. Tighten pinion gear side adjuster an additional:
^ New Bearings: 6 Adjuster Holes
^ Original Bearings: 4 Adjuster Holes





18. Tighten bearing cap bolts (4) to 85 Nm (63 ft. lbs.).
19. Install adjuster locks (2) and tighten bolts (3) to 25 Nm (18 ft. lbs.).





20. Install sensor target magnet (1) on bearing cap.
21. Energize locker and verify dog clutch is engaged.
22. Set sensor air gap (2) to 5.05 mm ± 0.25 mm (0.20 in. ± 0.01 inch).
23. Tighten sensor target magnet bolt (3) to 7 Nm (62 inch lbs.).
24. Install sensor wire tie strap (4) to adjuster lock and deenergize coil.
25. Measure ring gear backlash and check gear tooth contact pattern.
26. Install axle shafts and hub bearings.
27. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.).
28. Fill differential with lubricant.
29. Install fill plug and tighten to 32 Nm (24 ft. lbs.).