Removal and Installation
REMOVAL1. Raise and support vehicle.
2. Remove the lubricant fill hole plug from the differential housing cover.
3. Remove the differential housing cover and allow fluid to drain.
4. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning.
5. Remove hub bearings and axle shafts.
6. Note the installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 36).
7. Loosen the differential bearing cap bolts.
8. Position Spreader W-129-B, utilizing some items from Adapter Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 37). Install the hold down clamps and tighten the tool turnbuckle finger-tight.
9. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to guide pin. Load the lever adapter against the opposite side of the housing (Fig. 38) and zero the indicator.
CAUTION: Do not spread over 0.50 mm (0.020 inch). If the housing is over-spread it could be distorted or damaged.
10. Spread the housing enough to remove the differential case from the housing. Measure the distance with the dial indicator (Fig. 39).
11. Remove the dial indicator.
12. Hold the differential case in position while removing the differential bearing cap bolts and caps.
13. Remove the differential and differential preload shims from the housing. Ensure that the differential bearing cups remain in position on the differential bearings (Fig. 40).
14. Tag the differential bearing cups, and preload shims to indicate their original location.
15. Remove spreader from housing.
INSTALLATION
NOTE: If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection.
1. Position Spreader W-129-B, utilizing some items from Adapter Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 44). Install the hold down clamps and tighten the tool turnbuckle finger-tight.
2. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the lever adapter against the opposite side of the housing (Fig. 45) and zero the indicator.
CAUTION: Do not spread over 0.50 mm (0.020 inch). If the housing is over-spread, it could be distorted or damaged.
3. Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator.
4. Remove the dial indicator.
5. Install differential case, and the differential preload shims in the housing. Ensure that the differential bearing cups remain in position on the differential bearings. Tap the differential case to ensure the bearings cups are fully seated in the housing.
6. Install the bearing caps at their original locations (Fig. 46).
7. Loosely install differential bearing cap bolts.
8. Remove axle housing spreader.
9. Tighten the bearing cap bolts to 61 Nm (45 ft. lbs.).
10. Install the hub bearings and axle shafts.
11. Apply a 6.35 mm (1/4 inch) bead of leopard Silicone Rubber Sealant or equivalent to the housing cover (Fig. 47). Install the housing cover within 5 minutes after applying the sealant.
12. Install the cover and any identification tag. Tighten the cover bolts in a cries-cross pattern to 41 Nm (30 ft. lbs.).
13. Refill the differential with Mopar Hypoid Gear Lubricant or equivalent to bottom of the fill plug hole. Refer to Lubricant Specifications for the correct quantity necessary.
14. Install the fill hole plug and lower the vehicle. Tighten fill plug to 34 Nm (25 ft. lbs.).
15. Remove support and lower vehicle.