Assembly

ASSEMBLY

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.

Fig. 229 Thrust Washer Installation:

1. Install side gear thrust washer to differential case (Fig. 229).

Fig. 230 Side Gear Installation:

2. Install side gear to differential case (Fig. 230).

Fig. 231 Pinion Gear and Washer Installation:

3. Install both pinion gears and washers to case, while orientating washer tabs to notch in case (Fig. 231).

Fig. 232 Pinion Shaft Installation:

4. Install pinion shaft (Fig. 232).

Fig. 233 Side Gear Installation:

5. Install side gear to case (Fig. 233).

Fig. 234 Side Gear Thrust Washer:

6. Install side gear thrust washer to case (Fig. 234).

Fig. 235 Diff Support Installation:

7. Install differential support into position, while aligning through-holes (Fig. 235).

Fig. 236 Ring Gear Installation:

8. Install differential ring gear to case (Fig. 236).

Fig. 237 Ring Gear-to-Case Bolts:

9. Install ring gear-to-case bolts, with pinion shaft retainers (Fig. 237), and torque bolts to 95 Nm (70 ft. lbs.).

Fig. 237 Ring Gear-to-Case Bolts - Typical:

10. Using Miller Special Tool L-4410, and C-4171, install differential bearing to differential (extension housing side) (Fig. 238).
11. Using Miller Special Tool 5052 and C-4171, install differential bearing to differential (bearing retainer side).

Fig. 239 Differential Bearing Retainer:

12. Using Miller Special Tool 6061 and C-4171, install differential bearing race to bearing retainer (Fig. 239).
13. Using Miller Special Tool L-4520 and C-4171, install differential bearing to extension housing.

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

Fig. 240 Differential Bearing Retainer:

Fig. 241 Differential Retainer Bolts:

14. Install differential assembly into transaxle case. Install differential bearing retainer (Fig. 240) and torque retainer-to-case bolts (Fig. 241) to 28 Nm (21 ft. lbs.).
15. Apply a bead of Mopar Silicone Rubber Adhesive Sealant to extension housing/adapter plate and install into position. Install and torque bolts to 28 Nm (21 ft. lbs.).
16. Measure and adjust differential bearing preload.

Fig. 242 Install Differential Cover:

17. Apply a bead of Mopar Silicone Rubber Adhesive Sealant to differential cover and install to case (Fig. 242).

Fig. 243 Differential Cover Bolts:

18. Install and torque cover-to-case bolts to 19 Nm (165 inch lbs.) (Fig. 243).