Differential Case: Service and Repair

1. Raise and support rear of vehicle and remove propeller shaft.
2. On Dakota trucks with four wheel drive, disconnect front CV driveshaft from axle shaft flange.

Fig. 1 Exploded View Of Rear Drive Axle.:

Fig. 2 Exploded View Of Drive Axle Dakota Front Drive Axle Assembly:

3. On all models, remove cover and gasket and drain lubricant.

Fig. 3 Differential pinion shaft removal:

4. Rotate differential to gain access to differential pinion shaft lock screw, and remove lock screw and pinion shaft.

Fig. 4 Axle shaft ``C'' lock removal:

5. Push axle shafts toward center of housing, and remove axle shaft "C" locks and the axle shafts.

Fig. 5 Ring gear runout check:

6. Check ring gear runout and ring gear and pinion backlash with suitable dial indicator to aid assembly. If original ring gear and pinion are reused, backlash should be adjusted to measured value in order to maintain established gear tooth contact pattern.
7. On models equipped with anti-lock brakes, remove anti-lock brake sensor retaining bracket, then the sensor.

Fig. 6 Marking side bearing caps:

8. On all models, mark position of differential side bearing caps to aid assembly remove side bearing adjuster locks, then loosen but do not remove side bearing cap bolts.

Fig. 7 Typical side bearing adjustment:

9. Using tool No. C-4164 or equivalent, insert through each axle tube and loosen side bearing adjusters.
10. Support differential assembly, remove side bearing caps, then differential assembly. Use caution to avoid damaging RWAL brake exciter ring and ring gear.
11. Place side bearing outer races with respective bearing caps to ensure proper assembly.

Fig. 8 Measuring pinion rotating torque (bearing preload):

12. Measure pinion rotating torque (bearing preload) with suitable torque wrench. If preload is not within specifications, or if endplay is present, pinion must be removed.
13. Hold companion flange with suitable tool and remove pinion nut and washer.

Fig. 9 Typical companion flange removal:

14. Using tool Nos. C-452, C3281 and C-748 or equivalents, remove companion flange then pry pinion seal from housing.
15. Temporarily install rear cover using 2 bolts, then drive pinion from bearings taking care not to damage threaded end of pinion shaft. Pinion removal will cause excessive impact loading of front pinion bearing assembly. If pinion removal is necessary, front bearing must be replaced.
16. Press rear bearing from pinion using suitable spacers, then remove depth adjusting shim, if equipped.
17. Remove pinion bearing races using suitable pullers or brass drift and hammer, and retain pinion depth adjusting shims located under rear bearing race, if equipped.
18. Inspect components, refer to Transmission and Drivetrain/Differential/Service and Repair, keeping components in order, and replace as needed. Components that are reused must be installed in original position.