Rear Axle - 210RII: 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

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Install differential assembly (1) into axle housing. Note: If difficulty installing differential is encountered due to interference with spreader and plates, remove axle housing from spreader, plates from housing, and install differential. Return assembly to the spreader.

Fig 2: Removing/Installing Side Bearing Cups
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Install differential side bearing cups (2). Use tool 9522 (1) to aid in differential alignment.

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

Fig 4: Measuring Carrier Spread
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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
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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, differential case, or axle housing 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
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Using suitable snap ring pliers (2), install differential side bearing snap rings (1).

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

Fig 8: Spreader Adapters 9226
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Remove axle assembly from spreader. Remove plates (1).

Fig 9: 210 Sealant Application
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Apply 4mm (0.157 in.) bead (2) of Mopar® Axle RTV to axle housing cover (1) as shown in Fig 9.

Fig 10: 210 Axle Housing Cover and Bolts
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Install cover (2) to axle housing. Install and torque cover-to-housing bolts (1) to 30 N.m (22 ft. lbs.) + 90°.

Fig 11: Axle Seal Installation
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Install axle seals (1) using Tool 9223 (2).