DRIVE, Final: Assembly: Assembly

Fig 1: Thrust Washer Installation

Courtesy of CHRYSLER LLC

1 - THRUST WASHER

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.

1. Install side gear thrust washer (1) to differential case.
   Fig 2: Side Gear Installation

   Courtesy of CHRYSLER LLC

   1 - DIFFERENTIAL SIDE GEAR

2. Install side gear (1) to differential case.
   Fig 3: Pinion Gear And Washer Installation

   Courtesy of CHRYSLER LLC

   1 - PINION GEAR

   2 - TABBED WASHER

   3 - LOCATING TAB

   4 - NOTCH

3. Install both pinion gears (1) and washers (2) to case, while orientating washer tabs to notch in case.
   Fig 4: Pinion Shaft Installation

   Courtesy of CHRYSLER LLC

   1 - PINION SHAFT

4. Install pinion shaft (1).
   Fig 5: Side Gear Installation

   Courtesy of CHRYSLER LLC

   1 - DIFFERENTIAL SIDE GEAR

5. Install side gear (1) to case.
   Fig 6: Side Gear Thrust Washer

   Courtesy of CHRYSLER LLC

   1 - SIDE GEAR THRUST WASHER

6. Install side gear thrust washer (1) to case.
   Fig 7: Differential Support Installation

   Courtesy of CHRYSLER LLC

   1 - DIFFERENTIAL SUPPORT

   2 - DIFFERENTIAL CASE

7. Install differential support (1) into position, while aligning through-holes.
   Fig 8: Ring Gear Installation

   Courtesy of CHRYSLER LLC

   1 - DIFFERENTIAL CASE

   2 - RING GEAR

8. Install differential ring gear (2) to case (1).
   Fig 9: Ring Gear-to-Case Bolts

   Courtesy of CHRYSLER LLC

   1 - DIFFERENTIAL CASE

   2 - PINION SHAFT RETAINER

   3 - RING GEAR

   4 - RING GEAR-TO-CASE BOLT

   NOTE: New bolts must be used.
9. Install ring gear-to-case bolts, with pinion shaft retainers, and tighten bolts (4) to 95 N.m (70 ft. lbs.).
10. Check differential side gear turning torque using Differential Bearing Torque Tool C- 4995-1. Turning torque should be no more than 10 to 20 in-lbs (drag). If drag exceeds 20 in-lbs decrease shim size, if the drag is less than 10 in-lbs (drag) increase shim size.
    Fig 10: Install Differential Pinion Side Bearing

    Courtesy of CHRYSLER LLC
11. Using Installer 6888 (1) and a press (2), install differential bearing (3) to pinion side of the differential housing.
    Fig 11: Install Ring Gear Side Bearing

    Courtesy of CHRYSLER LLC
12. Using Installer C-4213 (2) and a press (1), install differential bearing (3) to ring gear side of the differential.
    Fig 12: Install Large Side Pinion Bearing

    Courtesy of CHRYSLER LLC
13. Using Installer MD998911 (1) and a press, install the large pinion bearing to the pinion shaft.
    Fig 13: Install Small Side Pinion Bearing

    Courtesy of CHRYSLER LLC
14. Using Installer 9723 (1) and a press, install the small pinion bearing to the pinion shaft.