Rear Axle - 198RII: Differential: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If replacement differential side bearings or differential case are being installed, it is necessary to measure and adjust Differential Side Bearing Preload and Gear Backlash. Refer to ADJUSTMENT - SIDE BEARING PRELOAD AND RING GEAR BACKLASH to determine proper snap ring selection.

Fig 1: Removing/Installing Differential

Courtesy of DAIMLERCHRYSLER CORP.

Install differential assembly (1) into axle housing.

Fig 2: Removing/Installing Side Bearing Cups
Courtesy of DAIMLERCHRYSLER CORP.
Install differential side bearing cups (2).

Fig 3: Tool 9522 In Use
Courtesy of DAIMLERCHRYSLER CORP.
Use Tool 9522 (1) to aid in seating side bearing cups (2).

Fig 4: Measuring Carrier Spread
Courtesy of DAIMLERCHRYSLER CORP.
Set up Dial Indicator Set C-3339-A to measure housing spread as shown Fig 4:
- Clamp SP-5426 (1)
- Post SP-5425-B (2)
- Metric Dial Indicator 9524 (3)
Fig 5: Expanding/Contracting W-129-B Spreader
Courtesy of DAIMLERCHRYSLER CORP.
Expand spreader W-129-B (1) to spread axle housing no more than 0.30 mm (0.012 in.).
NOTE: The differential side bearing snap rings are select-fit, and control ring gear backlash and differential side bearing preload. It is necessary to return snap rings to their original position. If replacement differential side bearings or differential case are being installed, refer to ADJUSTMENT - SIDE BEARING PRELOAD AND RING GEAR BACKLASH to determine proper snap ring selection.

Fig 6: Snap Ring Removal/Installation
Courtesy of DAIMLERCHRYSLER CORP.
Using suitable snap ring pliers (2), install differential side bearing snap rings (1).

Fig 7: Expanding/Contracting W-129-B Spreader
Courtesy of DAIMLERCHRYSLER CORP.
Back off W-129-B spreader (1) to relax tension on housing.

Fig 8: Axle Seal Installation
Courtesy of DAIMLERCHRYSLER CORP.
Install axle seals (1) using Tool 9223 (2).

Fig 9: Spreader Adapters 9226
Courtesy of DAIMLERCHRYSLER CORP.
Remove spreader W-129-B and adapter plates 9226 (1).

Fig 10: 198 Sealant Application
Courtesy of DAIMLERCHRYSLER CORP.
Apply 4mm (0.157 in.) bead (2) of Mopar® Axle RTV to axle housing cover (1) as shown in Fig 10.

Fig 11: Axle Housing Cover and Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Install cover to axle housing. Install and torque cover-to-housing bolts to 30 N.m (22 ft. lbs.) + 90°.