DIFFERENTIAL
REMOVAL
1. Remove differential fill plug.
2. Remove differential cover and drain lubricant.
3. Remove pinion mate shaft (1) lock screw (2) from differential case.
4. Remove pinion mate shaft (1) from differential case (2).
5. Push axle shaft inward and remove axle shaft C-lock (1) from the axle shaft (2). Slide axle shafts (2) out of differential side gears (3).
6. Mark (1) (2) differential housing and bearing caps (3) for installation reference.
7. Remove bearing adjuster lock bolt (3) from bearing caps.
8. Loosen differential bearing cap bolts (2).
9. Loosen differential bearing adjusters through the axle tubes (1) with Adjuster C-4164 (3).
10. Hold differential case while removing bearing caps and adjusters.
11. Remove differential case and tag differential bearing cups and adjusters to indicate location.
12. Clean housing cavity with flushing oil, light engine oil or a lint free cloth.
DISASSEMBLY
1. Rotate one pinion gear (2) with thrust washer (3) to the differential window (1) and remove gear and thrust washer.
2. Rotate remaining pinion gear (3) with thrust washer (2) to the differential window (1) and remove gear and washer.
3. Remove differential side gears (1) (2) and thrust washers.
ASSEMBLY
NOTE: If same gears and thrust washers are being used, install them into their original locations.
1. Lubricate all differential components with axle lubricant.
2. Install differential side gears (2) and thrust washers through differential window (1).
3. Install first pinion gear (3) with thrust washer into differential window (1) and side gears (2). Rotate pinion gear into the case.
4. Install remaining pinion gear (2) and thrust washer (3). Rotate gears to align hole in the pinion gears with hole in the differential case.
5. Slide pinion shaft (1) into the case and through the pinion gears (3) to align the gears.
INSTALLATION
1. Apply a coat of hypoid gear lubricant to differential bearings, bearing cups and threaded adjusters.
NOTE: Grease can be used to keep the adjusters in position.
2. Install differential assembly into the housing.
3. Install differential bearing caps in their original locations.
4. Install bearing cap bolts (2) and tighten upper bolts to 14 N·m (10 ft. lbs.). Tighten lower bolts finger-tight until bolt head is seated.
5. Perform differential bearing preload adjustment procedure with Wrench C-4164 (3).
6. Tighten bearing cap bolts in a criss-cross pattern to 95 N·m (70 ft. lbs.) .
7. Install adjuster locks on bearing caps and tighten to 10 N·m (90 in. lbs.).
8. Install axle shaft (1) in axle tube (2) and engage into side gear splines.
9. Lubricate bearing bore and seal lip with gear lubricant.
10. Install C-lock (1) in axle shaft end, then push axle shaft outward to seat C-lock in side gear.
11. Install pinion mate shaft (1) into differential case (2) and through thrust washers and differential pinions.
12. Align hole in mate shaft (1) with hole in the differential case. Apply Mopar Lock & Seal Adhesive or Loctite® to lock screw (2) threads. Install lock screw and tighten to 11 N·m (8 ft. lbs.).
13. Install differential cover.