Final Drive: Disassembly

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The transfer shaft should be removed for differential repair and bearing turning torque checking.

Remove the differential cover and bolts. See Fig 1. See Fig 2.

Fig 1: Differential Cover Bolts
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1 - DIFFERENTIAL COVER BOLTS

2 - DIFFERENTIAL COVER

Fig 2: Removing/Installing Differential Cover
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1 - DIFFERENTIAL ASSEMBLY

2 - DIFFERENTIAL COVER
Remove the differential bearing retainer and bolts. See Fig 3. See Fig 4.

Fig 3: Differential Retainer Bolts
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1 - DIFFERENTIAL RETAINER BOLTS

Fig 4: Remove Bearing Retainer
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1 - DIFFERENTIAL BEARING RETAINER

2 - TOOL L-4435
Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING.
Remove differential assembly.

Set up dial indicator set C-3339 and tool C-4996 as shown in Fig 5 to measure side gear end play. See Fig 6.Side gear end play must be within 0.001-0.013 in.

Fig 5: Checking Side Gear End Play (Extension Housing Side)

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1 - SPECIAL TOOL C-4996 (NOTE POSITION)

2 - DIAL INDICATOR SET

3 - DIFFERENTIAL ASSEMBLY

4 - SIDE GEAR

Fig 6: Checking Side Gear End Play (Ring Gear Side)

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1 - SPECIAL TOOL C-4996 (NOTE POSITION)

2 - DIAL INDICATOR SET

3 - DIFFERENTIAL ASSEMBLY

Remove differential side bearing cone from ring gear side of differential. Install button L-4539-2, and Collets 5048-2. See Fig 7.

Fig 7: Button L-4539-2 and Collets 5048-4

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1 - COLLETS 5048-4

2 - BUTTON L-4539-2

3 - BEARING CONE

Install 5048 as shown, remove and discard bearing cone. See Fig 8.

Fig 8: Side Bearing Removal Using Tool 5048 (Ring Gear Side)

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1 - TOOL 5048

2 - COLLETS 5048-4

3 - SLEEVE 5048

Remove differential side bearing cone from outboard end (opposite ring gear) of differential. Install Button L-4539-2 as shown. See Fig 9.

Fig 9: Install Button L-4539-2
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1 - BUTTON L-4539-2

Install 5048 as shown. See Fig 10. Remove and discard bearing cone.

Fig 10: Side Bearing Removal Using Tool 5048

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1 - TOOL 5048

2 - COLLET 5048-3

2 - SLEEVE 5048

Remove pinion shaft retainer plate bolts. See Fig 11.

Fig 11: Remove/Install Retainer/Ring Gear Bolt
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1 - PINION SHAFT RETAINER
Remove pinion shaft retainer. See Fig 12.

Fig 12: Pinion Shaft Retainer
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1 - PINION SHAFT RETAINER
Remove pinion shaft from differential case. See Fig 13.

Fig 13: Pinion Shaft Removal/Installation
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1 - PINION SHAFT
Rotate pinion gears about case and remove (w/washer). See Fig 14.

Fig 14: Pinion Gear and Washer
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1 - WASHER

2 - PINION GEAR
Remove differential side gears. See Fig 15.

Fig 15: Side Gear Removal/Installation
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1 - SIDE GEAR
Remove side gear thrust washers. See Fig 16.

Fig 16: Side Gear Washer
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1 - SIDE GEAR THRUST WASHER
Remove remaining differential ring gear-to-case bolts. See Fig 17.

Fig 17: Ring Gear Bolt Removal/Installation
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1 - RING GEAR BOLTS
Using a soft-faced hammer, remove ring gear from case. See Fig 18.

Fig 18: Ring Gear Removal
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1 - SOFT-FACED HAMMER

2 - RING GEAR
Using Miller Special Tool L-4518, remove the differential bearing race from the extension housing/adapter plate.
Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer. See Fig 19. See Fig 20.

Fig 19: Position Bearing Cup Remover Tool In Retainer

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1 - SPECIAL TOOL 6062A

2 - DIFFERENTIAL BEARING RETAINER

Fig 20: Remove Bearing Cup

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1 - SPECIAL TOOL 6062A

2 - DIFFERENTIAL BEARING RETAINER

DIFFERENTIAL SERVICE TOOLS

COMPONENT	REMOVER	INSTALLER
Diff. Bear. On Retainer Side	5048, 5048-4 Collets, L-4539-2 Button	5052, C-4171
Diff. Bear. On Ext. Hous. Side	5048, 5048-3 Collets, L-4539-2 Button	L-4410, C-4171
Diff. Race. On Retainer Side	6062-A	6061, C-4171
Diff. Race. On Ext. Hous. Side	L-4518	L-4520, C-4171
Extension Housing Seal	7794-A, C-637 Slide Hammer	L-4520, C-4171
Bearing Retainer Seal	794-A, C-637 Slide Hammer	L-4520, C-4171