Final Drive: Assembly

NOTE: The differential is serviced as an assembly. Differential service is limited to bearing cups and cones. Any other differential component failure must be remedied by differential assembly and transfer shaft replacement.

Install side gear thrust washer to differential case (Fig 1).

Fig 1: Installing Thrust Washer
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Install side gear to differential case (Fig 2).

Fig 2: Installing Side Gear To Differential Case
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Install both pinion gears and washers to case, while orientating washer tabs to notch in case (Fig 3).

Fig 3: Installing Pinion Gear
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Install pinion shaft (Fig 4).

Fig 4: Installing Pinion Shaft
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Install side gear to case (Fig 5).

Fig 5: Installing Side Gear To Case
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Install side gear thrust washer to case (Fig 6).

Fig 6: Installing Side Gear Thrust Washer
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Install differential support into position, while aligning through-holes (Fig 7).

Fig 7: Installing Differential Support Into Position
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Install differential ring gear to case (Fig 8).

Fig 8: Identifying Ring Gear
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Install ring gear-to-case bolts, with pinion shaft retainers (Fig 9), and torque bolts to 95 N.m (70 ft. lbs.).

Fig 9: Identifying Ring Gear-To-Case Bolts
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Using Miller Special Tool L-4410, and C-4171, install differential bearing to differential (extension housing side) (Fig 10).

Fig 10: Positioning Bearing Cone Onto Differential - Typical
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Using Miller Special Tool 5052 and C-4171, install differential bearing to differential (bearing retainer side).
Using Miller Special Tool 6061 and C-4171, install differential bearing race to bearing retainer (Fig 11).

Fig 11: Identifying Differential Bearing Retainer
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Using Miller Special Tool L-4520 and C-4171, install differential bearing to extension housing.
NOTE: Use Mopar® Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case.
Install differential assembly into transaxle case. Install differential bearing retainer (Fig 12)and torque retainer-to-case bolts (Fig 13)to 28 N.m (21 ft. lbs.).

Fig 12: Installing Differential Bearing Retainer
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Fig 13: Identifying Differential Retainer Bolts
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Apply a bead of Mopar® Silicone Rubber Adhesive Sealant to extension housing/adapter plate and install into position. Install and torque bolts to 28 N.m (21 ft. lbs.).
Measure and adjust differential bearing preload. (Refer to ADJUSTMENTS )
Apply a bead of Mopar® Silicone Rubber Adhesive Sealant to differential cover and install to case (Fig 14).

Fig 14: Installing Differential Cover
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Install and torque cover-to-case bolts to 19 N.m (165 in. lbs.) (Fig 15).

Fig 15: Tightening Differential Cover Bolts
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