Rear Axle - 210RII: Differential: Assembly

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.

Fig 1: Install Side Gears With 9631

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Lubricate all differential components with hypoid gear lubricant.
Install differential side gears (2) and thrust washers to Tools 9631 (1) as shown in Fig 1.

Fig 2: Remove/Install Pinion Gear and Washer
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Install differential pinion gears (1) and thrust washers into position across from each other.

Fig 3: Rotate Differential Gears With 9631
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Rotate pinion gears into place using Tool 9631 and line up gear centers with pinion shaft bore.

Fig 4: Roll Pin Installation
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Using a brass hammer, drive pinion shaft (3) into differential case (1), making sure to line up roll pin bores.
Using suitable punch (2), drive new roll pin into position.

Fig 5: Measure Rotating Torque
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Measure differential gear rotating torque as shown in Fig 5. Differential gear rotating torque should be 5-30 N.m (44-266 in. lbs.) Rotating torque is adjusted using select side gear thrust washers. Refer to the following chart.

Available Side Gear Thrust Washer Thicknesses

1.25 mm (0.049 in.)

1.30 mm (0.051 in.)

1.35 mm (0.053 in.)

1.40 mm (0.055 in.)

1.45 mm (0.057 in.)

1.50 mm (0.059 in.)

1.55 mm (0.061 in.)

1.60 mm (0.063 in.)

1.65 mm (0.065 in.)

Fig 6: Differential Mounted on Tool 9630

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Remove differential case from Tool 9630 (2).

Fig 7: Ring Gear Bolts
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Install ring gear to case. Lightly tap ring gear into position to facilitate starting of bolts.
Install new ring gear-to-case bolts and torque to 85 N.m (63 ft. lbs.).

Fig 8: Differential Side Bearing Installation
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Using Tool 9523 (2) and Handle C-4171 (1), press new differential side bearings (3) onto differential case.