Assembly

ASSEMBLY




Figure 1 Thrust Washer Installation


1 - THRUST WASHER


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.

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




Figure 2 Side Gear Installation


1 - DIFFERENTIAL SIDE GEAR

2. Install side gear to differential case (Figure 2).




Figure 3 Pinion Gear and Washer Installation






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




Figure 4 Pinion Shaft Installation


1 - PINION SHAFT

4. Install pinion shaft (Figure 4).




Figure 5 Side Gear Installation


1 - DIFFERENTIAL SIDE GEAR

5. Install side gear to case (Figure 5).




Figure 6 Side Gear Thrust Washer


1 - SIDE GEAR THRUST WASHER

6. Install side gear thrust washer to case (Figure 6).




Figure 7 Diff Support Installation






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




Figure 8 Ring Gear Installation






8. Install differential ring gear to case (Figure 8).




Figure 9 Ring Gear-to-Case Bolts






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




Figure 10 Position Bearing Cone Onto Differential-Typical






10. Using Miller Special Tool L-4410, and C-4171, install differential bearing to differential (extension housing side) (Figure 10).




Figure 11 Differential Bearing Retainer






11. Using Miller Special Tool 5052 and C-4171, install differential bearing to differential (bearing retainer side).
12. Using Miller Special Tool 6061 and C-4171, install differential bearing race to bearing retainer (Figure 11).




Figure 12 Differential Bearing Retainer






13. Using Miller Special Tool L-4520 and C-4171, install differential bearing to extension housing.

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

14. Install differential assembly into transaxle case. Install differential bearing retainer (Figure 12).




Figure 13 Differential Retainer Bolts


1 - DIFFERENTIAL RETAINER BOLTS

15. Torque retainer-to-case bolts (Figure 13) to 28 Nm (21 ft. lbs.).




Figure 14 Install Differential Cover






16. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant to extension housing/adapter plate and install into position. Install and torque bolts to 28 Nm (21 ft. lbs.).
17. Measure and adjust differential bearing preload.
18. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant to differential cover and install to case (Figure 14).




Figure 15 Differential Cover Bolts






19. Install and torque cover-to-case bolts to 19 Nm (165 in. lbs.) (Figure 15).