Removal and Installation
DIFFERENTIAL REMOVAL1. Raise and support vehicle.
2. Remove the lubricant fill hole plug from the differential housing cover.
3. Remove the differential housing cover and allow fluid to drain
4. Clean the housing cavity with flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning.
5. Remove axle shafts.
6. Note the reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 36).
7. Loosen the differential bearing cap bolts.
8. Position Spreader W-129-B, utilizing some items from Adapter set 6987, with the tool dowel pins seated in the locating holes (Fig. 37). Install the holddown clamps and tighten the tool turnbuckle finger-tight.
9. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing (Fig. 38) and zero the indicator.
CAUTION: Do not spread over 0.38 mm (0.015 inch). If the housing is over-spread, it could be distorted or damaged.
10. Spread the housing enough to remove the differential case from the housing. Measure the distance with the dial indicator (Fig. 39).
11. Remove the dial indicator.
12. While holding the differential case in position, remove the differential bearing cap bolts and caps.
13. Remove the differential from the housing. Ensure that the differential bearing cups remain in position on the differential bearings (Fig. 40).
14. Remove bearing cups from the differential and tag them to indicate their location on the differential.
15. Remove differential case preload shims from the housing and tag them to indicate their location in the housing.
16. Remove spreader from housing.
INSTALLATION
NOTE: If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection.
1. Position Spreader W-129-B, utilizing some items from Adapter set 6987, with the tool dowel pins seated in the locating holes (Fig. 42). Install the holddown clamps and tighten the tool turnbuckle finger-tight.
2. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud, Load the indicator plunger against the opposite side of the housing and zero the indicator.
CAUTION: Do not spread over 0.38 mm (0.015 inch). If the housing is over-spread, it could be distorted or damaged.
3. Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator.
4. Remove the dial indicator.
5. Install differential case in the housing. Ensure that the differential bearing cups remain in position on the differential bearings and that the preload shims remain between the face of the bearing cup and the housing. Tap the differential case to ensure the bearings cups and shims are fully seated in the housing.
6. Install the bearing caps in their original locations (Fig. 43).
7. Loosely install differential bearing cap bolts.
8. Remove axle housing spreader.
9. Tighten the bearing cap bolts to 108 Nm (80 ft. lbs.).
10. Install the axle shafts.
11. Apply a 6.35mm (1/4 inch) bead of Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 44).
Install the housing cover within 5 minutes after applying the sealant.
12. Install the cover and any identification tag. Tighten the cover bolts in a crisscross pattern to 41 Nm (30 ft. lbs.).
13. Refill the differential with Mopar Hypoid Gear Lubricant or equivalent to bottom of the fill plug hole. Refer to Specifications.
14. Install the fill hole plug.
15. Remove support and lower the vehicle.