Differential

DIFFERENTIAL

REMOVAL
1. 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-129-13, utilizing some items from Adapter Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 37). Install the holddown 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 in.). 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 differential from the housing. Ensure that the differential bearing cups remain in position on the differential bearings (Fig. 40).
14. Remove spreader from housing.

DISASSEMBLY
1. Remove the ring gear.





2. Drive out the roll pin holding pinion gear mate shaft with a punch (Fig. 41).
3. Remove pinion gear mate shaft from the differential case and pinion mate gears.





4. Rotate differential side gears and remove pinion mate gears and thrust washers (Fig. 42).
5. Remove differential side gears and thrust washers.

ASSEMBLY
1. Install differential side gears and thrust washers.
2. Install pinion mate gears and thrust washers.
3. Install pinion gear mate shaft. Align the roll pin holes in shaft and the differential case.





4. Install the roll pin to hold the pinion mate shaft in the differential case (Fig. 43).
5. Install the ring gear.
6. Lubricate all differential components with hypoid gear lubricant.

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-129-13, utilizing some items from Adapter Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 44). Install the holddown 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 in.). 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 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 in.) bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 47).

CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.

12. Install the cover and any identification tag. Tighten the cover bolts in a criss-cross pattern to 41 Nm (30 ft. lbs.).
13. Fill the differential with Mopar Hypoid Gear Lubricant or equivalent to bottom of the fill plug hole. Refer to Lubricant Specifications for correct quantity and type.
14. Install fill hole plug and tighten to 34 Nm (25 ft. lbs.).
15. Remove support and lower vehicle.