Differential Overhaul

Fig. 10 Sure-Grip differential assembly:

Both standard and Sure-Grip limited slip differential assemblies are used with Chrysler built rear axles. Ring gear and side bearing service procedures are identical for both type differential assemblies. However, due to critical tolerances required for proper operation, the Sure-Grip differential, should not be disassembled for service. If the differential assembly on these models requires service, the complete assembly should be replaced.

Fig. 11 Differential case side bearing removal:

Fig. 12 Ring gear installation:

Fig. 13 Differential case side bearing installation:

STANDARD DIFFERENTIAL
Do not remove ring gear from differential case unless gear or case is to be replaced, or ring gear runout measured during disassembly exceeds 0.005 inch.
1. Support case assembly, then remove and discard ring gear bolts. Ring gear bolts have lefthand threads.
2. Tap ring gear from case using brass drift and hammer. Do not pry gear from case.
3. Rotate one side gear and remove differential pinions and thrust washers, noting position for assembly.
4. Remove side gears and thrust washers, noting installation position.
5. Inspect components as outlined in "Cleaning and Inspection," and replace as needed.
6. If side bearings are to be replaced, remove bearings using suitable puller. If bearings are loose on case, both case and side bearings must be replaced. Coat components with specified lubricant prior to assembly. Components that are reused should be installed in original position to ensure proper operation.
7. Install side gears and thrust washers in respective sides of case.
8. Install thrust washers on differential pinions, using grease to adhere washers.
9. Position pinion assemblies 180° apart in case, in mesh with side gears, then roll pinions into case until they align with pinion shaft bores.
10. Insert pinion shaft and temporarily secure with lock bolt.
11. Relieve sharp edge of chamfer on inside diameter of ring gear with hard Arkansas stone, then ensure that ring gear and case mounting surfaces are clean and free from burrs.
12. Fabricate 3 pilot studs from old ring gear bolts and install studs evenly spaced around ring gear.
13. Evenly heat ring gear using oven, sun lamp or hot fluid. Do not allow temperature of gear to exceed 300°F. Do not heat gear with torch.
14. Mount ring gear on case and install new ring gear bolts.
15. Support case, then evenly torque bolts to 70 ft. lbs. in crossing pattern.
16. Install side bearings on case using suitable driver. Support case on pilot when installing second bearing to prevent damage to bearing already installed.