Front Differential Removal

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Rowdy Yates

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Spider gears are fubar. Any help/tips on getting the diff out would be very appreciated. Getting the axles out seems pretty straight forward. Thanks.
BTW, 2002 3.7L.
 

Bushmonster73

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Front Diff Replace

REMOVAL
1.
Remove axle from the vehicle.

2.
Remove differential housing cover DIFFERENTIAL COVER.





Click to enlarge

DIFFERENTIAL COVER





1 - COVER




2 - VENT TUBE



3.
Push right axle shaft out of side gear RIGHT SHAFT IN SIDE GEARand remove the shaft.





Click to enlarge

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.





Click to enlarge

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.





Click to enlarge

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.





Click to enlarge

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.





Click to enlarge

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.
 

TwoBobsKJ

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That's way too complicated :waytogo:

The bolts that hold the diff to the brackets on both sides are pretty obvious - however the front bolts are blocked by the lower control arms. If Jeep had just designed it so the bolt was turned the other direction it would be simple to remove the nut and slide the bolt out. But NOOOOOOO....!

What you'll need to do for those particular bolts is cut the bolt head off and remove it. Obviously you'll need to replace it with a Grade 8 or better but the other bolts can be reused. You'll need to remove the front shocks/springs and spindles, the CV axles, and disconnect the tie rod ends and sway bar links so you have plenty of room to work. The diff breather tube - which connects under the battery tray - will need to be removed so you can drop the diff out. The tube's connector is just pressed on to one of the shock bolts which need to come out anyway; you'll see the connector when you remove the battery tray to get to the shock bolts.

Here's what your Jeep will look like when the front suspension and diff is removed. TomMudd and I did a diff swap last November. It's really not hard - beforehand just look at all that you'll need to remove and DON'T follow the Factory Service Manual! It has you removing the lower control arms just to save one bolt.
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Bob
 

tommudd

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Wow , yes way easier than what Bushmonster posted up, his way would take all day long.
I found out a long time ago that the factory manual is way off base
pull the front springs etc out, then CVs , loosen and cut the two front mounting bolts and remove the rest of the brackets and done
 

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