Differental Disassembly

DISASSEMBLY
1. Remove the ring gear.





2. Using a suitable roll pin punch, drive out the roll pin holding pinion gear mate shaft in the differential case.
3. Remove the pinion gear mate shaft from the differential case and the pinion mate gears.





4. Rotate differential side gears and remove the pinion mate gears and thrust washers.
5. Remove the differential side gears and thrust washers.

ASSEMBLY
1. Install the differential side gears and thrust washers.
2. Install the pinion mate gears and thrust washers.
3. Install the pinion gear mate shaft. Align the roll pin holes in shaft and the differential case.





4. Install the roll pin to hold the pinion mate shaft in the differential case.
5. Install the ring gear.
6. Lubricate all differential components with hypoid gear lubricant.





FINAL ASSEMBLY
1. Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating surfaces with mineral spirits. Apply a bead of Mopar (R) Silicone Rubber Sealant, or equivalent, on the housing cover.

NOTE: Install the housing cover within 5 minutes after applying the sealant.

2. Install the cover on the differential with the attaching bolts. Install the identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque.

CAUTION: Overfilling the differential can result in lubricant foaming and overheating.

3. Refill the differential housing with gear lubricant.
4. Install the fill hole plug.