Differential - Standard
DIFFERENTIALREMOVAL
1. Raise and support vehicle.
2. Remove fill hole plug from the differential housing cover.
3. Remove differential housing cover and drain fluid.
4. Clean the housing cavity with flushing oil, light engine oil or lint free cloth.
NOTE: Do not use water, steam, kerosene or gasoline for cleaning.
5. Remove axle shafts.
6. Note the 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 with Adapter Kit 6987B on differential locating holes (Fig. 37). Install holddown clamps and tighten the 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 pilot stud. Load the indicator plunger against the opposite side of the housing (Fig. 38) and zero the indicator.
CAUTION: Never spread the housing over 0.38 mm (0.015 in.). If housing is over-spread, it could distorted and damaged the housing.
10. Spread 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. While holding the differential case in position, remove the differential bearing cap bolts and caps.
13. Remove differential from the housing and tag differential bearing cups to indicate location (Fig. 40).
14. Remove spreader from housing.
DISASSEMBLY
1. Remove pinion shaft lock roll pin with a hammer and punch.
2. Remove pinion shaft.
3. Rotate differential side gears and remove the differential pinions and thrust washers (Fig. 41).
4. Remove the differential side gears and thrust washers.
ASSEMBLY
1. Install the differential side gears and thrust washers.
2. Install the differential pinion gears and thrust washers.
3. Install the pinion mate shaft.
4. Align the hole in the pinion mate shaft with the hole in the differential case and install the pinion mate shaft roll pin.
5. 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 Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection.
1. Position Spreader W-129-B and adapters from Adapter set 6987, with the tool dowel pins seated in the locating holes (Fig. 42). Install holddown clamps and tighten the tool turnbuckle finger-tight.
2. Install Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator.
CAUTION: Never spread over 0.38 mm (0.015 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 seated in the housing.
6. Install bearing caps in their original locations (Fig. 43).
7. Loosely install differential bearing cap bolts.
8. Remove axle housing spreader.
9. Tighten the bearing cap bolts to 77 Nm (57 ft. lbs.).
10. Install the axle shafts.
11. Apply a 6.35mm (1/4 in.) bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 44).
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. Refill the differential with Mopar Hypoid Gear Lubricant or equivalent to bottom of the fill plug hole.
14. Install the fill hole plug.
15. Install wheel and tire assemblies.
16. Remove support and lower the vehicle.