Final Drive: Assembly: Differential

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Removing/Installing Ring Gear Bolt

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1 - RING GEAR BOLTS

NOTE: Use Mopar® Silicone Rubber Adhesive Sealant or equivalent, on retainer and extension housing/adapter plate to seal to transaxle case.

Position differential case to ring gear. Install ring gear-to-differential case bolts (1) and draw ring gear into position. Torque bolts to 95 N.m (70 ft. lbs.). See Fig 1.

Fig 2: Identifying Side Gear Washer
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1 - SIDE GEAR THRUST WASHER
Install side gear thrust washers (1). See Fig 2.

Fig 3: Removing/Installing Side Gear
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1 - SIDE GEAR
Install differential side gears (1). See Fig 3.

Fig 4: Identifying Pinion Gear and Washer
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1 - WASHER

2 - PINION GEAR
Install pinion gears (2) and thrust washers (1) 180° apart. See Fig 4.

Fig 5: Identifying Pinion Washer Anti-Rotate Tab
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1 - ANTI-ROTATE TAB

2 - POCKET
Rotate pinion gears into position, ensuring the anti-rotate tabs (1) are located into the differential case (2). See Fig 5.

Fig 6: Removing/Installing Pinion Shaft
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1 - PINION SHAFT
Install pinion shaft (1). See Fig 6.

Fig 7: Identifying Pinion Shaft Retainer
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1 - PINION SHAFT RETAINER
Install pinion shaft retainer (1). See Fig 7.

Fig 8: Removing/Installing Retainer/Ring Gear Bolt
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1 - PINION SHAFT RETAINER
Install pinion shaft retainer/ring (1) gear-to-differential case bolts and torque to 95 N.m (70 ft. lbs.). See Fig 8.

Fig 9: Positioning Bearing Cone Onto Differential (Typical)
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1 - DIFFERENTIAL ASSEMBLY

2 - DIFFERENTIAL BEARING
Position differential side bearing cone (2) onto differential. See Fig 9.

Fig 10: Installing Side Bearing - Ring Gear Side
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1 - HANDLE C-4171

2 - INSTALLER 5052
Using Installer 5052 (2) and Handle C-4171 (1), install differential bearing to differential (ring gear side). See Fig 10.

Fig 11: Installing Side Bearing - Extension Housing Side
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1 - HANDLE C-4171

2 - BEARING INSTALLER L-4410
Using Bearing Installer L-4410 (2) and Handle C-4171 (1), install differential bearing to differential (ring gear side). See Fig 11.

Fig 12: View Of Differential Bearing Retainer
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1 - DIFFERENTIAL BEARING CUP

2 - DIFFERENTIAL BEARING RETAINER
Using Installer 6061 and Handle C-4171, install differential bearing race to bearing retainer (2). See Fig 12.

Fig 13: Identifying Differential Retainer Bolts
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1 - DIFFERENTIAL RETAINER BOLTS
Using Installer L-4520 and Handle C-4171, install differential bearing cup to extension housing.
Measure and adjust differential bearing preload. See ADJUSTMENTS .
Install differential assembly to case. Install extension housing/adapter plate and bearing retainer.
Install bearing retainer with a bead of Mopar® Silicone Rubber Adhesive Sealant and torque bolts (1) to 28 N.m (250 in. lbs.). See Fig 13.

Fig 14: Locating Differential Cover Sealant Application Areas
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1 - DIFFERENTIAL ASSEMBLY

2 - DIFFERENTIAL COVER
Install extension housing/adapter plate with a bead of Mopar® Silicone Rubber Adhesive Sealant and torque bolts to 28 N.m (250 in. lbs.).
Install differential cover (2) with a bead of Mopar® Silicone Rubber Adhesive Sealant and torque bolts to 28 N.m (250 in. lbs.). See Fig 14.