Front Diff Replace
REMOVAL
1.
Remove axle from the vehicle.
2.
Remove differential housing cover DIFFERENTIAL COVER.
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DIFFERENTIAL COVER
1 - COVER
2 - VENT TUBE
3.
Push right axle shaft out of side gear RIGHT SHAFT IN SIDE GEARand remove the shaft.
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RIGHT SHAFT IN SIDE GEAR
1 - AXLE SHAFT
2 - SCREWDRIVER
3 - SIDE GEAR
4.
Mark differential bearing caps for installation reference.
5.
Loosen the bearing cap bolts.
6.
Position Spreader W-129-B onto the differential locating holes and install the safety holddown clamps DIFFERENTIAL SPREADER. Tighten the tool turnbuckle finger-tight.
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DIFFERENTIAL SPREADER
1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
7.
Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load indicator plunger against the opposite side of the housing and zero the indicator.
8.
Spread the housing to remove the differential case from the housing. Measure the distance with the dial indicator SPREAD DIFFERENTIAL CASE.
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SPREAD DIFFERENTIAL CASE
1 - PILOT STUD
2 - DIAL INDICATOR
3 - SPREADER
Caution:
Never spread the differential housing over 0.34 mm (0.013 in). If housing is over-spread, it could be distorted or damaged.
9.
Remove the dial indicator.
10.
Holding the differential case in position, and remove bearing cap bolts and caps.
11.
Remove the differential from the housing DIFFERENTIAL CASE. Ensure differential bearing cups and shims remain in position on the differential bearings.
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DIFFERENTIAL CASE
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - DIFFERENTIAL BEARINGS
12.
Tag differential bearing cups and shims to indicate their location.
13.
Remove spreader from housing.
INSTALLATION
Important:
If differential bearings or differential case are replaced, Refer to adjustments fore Differential Bearing Preload and Gear Backlash procedures.
1.
Position Spreader W-129-B on differential location holes and install safety holddown clamps. Tighten the tool turnbuckle finger-tight.
2.
Install Pilot Stud C-3288-B to 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.
3.
Spread the housing to install the differential case and preload shims in the housing. Measure the distance with the dial indicator.
Caution:
Never spread the differential housing over 0.34 mm (0.013 in). If housing is over-spread, it could be distorted or damaged.
4.
Remove the dial indicator.
5.
Install differential case in the housing. Ensure differential bearing cups remain on the bearings and preload shims are seated in the housing. Tap differential case to ensure bearings cups are seated in the housing.
6.
Install bearing caps to their original locations and loosely install cap bolts.
7.
Remove differential housing spreader DIFFERENTIAL SPREADER.
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DIFFERENTIAL SPREADER
1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
8.
Tighten the bearing cap bolts in a criss-cross pattern to 54-68 N·m (39-50 ft. lbs.).
9.
Install the right axle shaft.
10.
Apply a 6.38mm (1/4 in.) bead of red Mopar Silicone Sealer or equivalent to the housing cover.
Caution:
If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
1.
Install differential housing cover and tighten bolts in a criss-cross pattern to 19-26 N·m (14-19 ft. lbs.).
2.
Install axle assembly in vehicle.
3.
Fill differential with lubricant and install fill plug.