Differential Repair

NOTE:
The transfer shaft should be removed for differential repair and bearing turning torque checking.

Remove Extension Seal:

Install New Seal Into Extension:

Differential Cover Bolts:

Remove Or Install Differential Cover:

NOTE: Use Mopar RTV sealant, or equivalent, when installing differential cover.

Remove Bearing Retainer Axle Seal:

Install Bearing Retainer Axle Seal:

Differential Bearing Retainer Bolts:

Remove Or Install Bearing Retainer:

Differential Bearing Retainer (Typical):

NOTE: Use Mopar RTV sealant, or equivalent, when installing differential bearing retainer.

Extension Bolts:

Remove Or Install Extension Housing:

Differential And Extension:

WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING.

Use Mopar Silicone Rubber Adhesive Sealant, or equivalent, when installing extension housing.

Remove Differential Bearing Cone (Extension Housing Side):

Position Bearing Cone Onto Differential:

Install Differential Bearing Cone:

Position Button And Collets Onto Differential And Bearing (Ring Gear Side):

Position Tool 5048 Over Button And Collets At Differential Bearing:

Remove Differential Bearing Cone:

To install the differential bearing cup and cone on the ring gear side, use Special Tool 5052, and Special Tool C-4171.

NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft.

Checking Side Gear End Play:

CAUTION: Side gear end play must be BETWEEN 0.001 to 0.013 inch.

Checking Side Gear End Play (Typical):

Differential Bearing Retainer:

Position Bearing Cup Remover Tool In Retainer:

Remove Bearing Cup:

Install Bearing Cup:

To remove the differential bearing cup from the extension housing adapter side, use Special Tool 6062A, Remover. To install the differential bearing cup on the extension housing/adapter side, use Special Tool 6536, Driver and Special Tool C-4171, Handle.

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of the following parts are replaced:
- Transaxle case
- Differential carrier
- Differential bearing retainer
- Extension housing
- Differential bearing cups and cones

Refer to Bearing Adjustment Procedure to determine proper shim thickness.