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Drive, Final: Disassembly: Disassembly

WARNING: This page is about a different car, the 2013 Dodge Avenger and 2013 Chrysler 200. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Differential Cover Bolts
GC0115795Courtesy of CHRYSLER GROUP, LLC
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
NOTE:

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

  1. Remove the differential cover and bolts (1).
    Fig 2: Differential Retainer Bolts
    GC0115796Courtesy of CHRYSLER GROUP, LLC
    1 - DIFFERENTIAL RETAINER BOLTS
  2. Remove the differential bearing retainer bolts (1).
    Fig 3: Remove Bearing Retainer
    GC0115797Courtesy of CHRYSLER GROUP, LLC
    1 - DIFFERENTIAL BEARING RETAINER
    2 - BEARING PULLER L-4435
  3. Remove the differential bearing retainer (1) using Bearing Puller (special tool #L-4435, Remover) (2).
    Fig 4: Checking Side Gear End Play (Extension Housing Side)
    GC0115798Courtesy of CHRYSLER GROUP, LLC
    1 - ADAPTOR C-4996 (NOTE POSITION)
    2 - DIAL INDICATOR SET
    3 - DIFFERENTIAL ASSEMBLY
    4 - SIDE GEAR
  4. 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.

  5. Remove differential assembly.
  6. Set up Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (2) and Adapter (special tool #C-4996, Adapter, Plug) (1) to measure side gear end play (Extension Housing Side). Side gear end play must be within 0.001-0.013 in. 
    Fig 5: Checking Side Gear End Play (Ring Gear Side)
    GC0115799Courtesy of CHRYSLER GROUP, LLC
    1 - ADAPTOR C-4996 (NOTE POSITION)
    2 - DIAL INDICATOR SET
    3 - DIFFERENTIAL ASSEMBLY
  7. Set up Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (2) and Adaptor (special tool #C-4996, Adapter, Plug) (1) to measure side gear end play (Ring Gear Side).Side gear end play must be within 0.001-0.013 in. 
    Fig 6: Identifying Button & Collets
    GC0115800Courtesy of CHRYSLER GROUP, LLC
    1 - COLLETS 5048-4
    2 - BUTTON L-4539-2
    3 - BEARING CONE
  8. Remove differential side bearing cone (3) from ring gear side of differential. Install Thrust Button (special tool #L-4539-2, Pad, Thrust) (2), and Collets (special tool #5048-4, Set, Collet Half) (1).
    Fig 7: Removing Side Bearing Using Tool (Ring Gear Side)
    GC0115801Courtesy of CHRYSLER GROUP, LLC
    1 - PULLER SET 5048
    2 - COLLETS 5048-4
     
  9. Install Puller Set (special tool #5048, Puller, Bearing) (1), Collets (special tool #5048-4, Set, Collet Half) (2) and sleeve. Remove and discard bearing cone.
    Fig 8: Installing Button
    GC0115802Courtesy of CHRYSLER GROUP, LLC
    1 - BUTTON L-4539-2
  10. Remove differential side bearing cone from outboard end (opposite ring gear) of differential. Install Thrust Button (special tool #L-4539-2, Pad, Thrust) (1).
    Fig 9: Removing Side Bearing Using Tool
    GC0115803Courtesy of CHRYSLER GROUP, LLC
    1 - PULLER SET 5048
    2 - COLLET 5048-3
     
  11. Install Puller Set (special tool #5048, Puller, Bearing) (1), (2) Collets (special tool #5048-3, Set, Collet Half) and sleeve. Remove and discard bearing cone.
    Fig 10: Removing/Installing Retainer/Ring Gear Bolt
    GC0115804Courtesy of CHRYSLER GROUP, LLC
    1 - PINION SHAFT RETAINER
  12. Remove pinion shaft retainer plate bolts (1).
    Fig 11: Identifying Pinion Shaft Retainer
    GC0115805Courtesy of CHRYSLER GROUP, LLC
    1 - PINION SHAFT RETAINER
  13. Remove pinion shaft retainer (1).
    Fig 12: Pinion Shaft Removal/Installation
    GC0115806Courtesy of CHRYSLER GROUP, LLC
    1 - PINION SHAFT
  14. Remove pinion shaft (1) from differential case.
    Fig 13: Identifying Pinion Gear & Washer
    GC0115807Courtesy of CHRYSLER GROUP, LLC
    1 - WASHER
    2 - PINION GEAR
  15. Rotate pinion gears (2) about case and remove (w/washer) (1).
    Fig 14: Removing/Installing Side Gear
    GC0115808Courtesy of CHRYSLER GROUP, LLC
    1 - SIDE GEAR
  16. Remove differential side gears (1).
    Fig 15: Identifying Side Gear Washer
    GC0115809Courtesy of CHRYSLER GROUP, LLC
    1 - SIDE GEAR THRUST WASHER
  17. Remove side gear thrust washers (1).
    Fig 16: Removing/Installing Ring Gear Bolt
    GC0115810Courtesy of CHRYSLER GROUP, LLC
    1 - RING GEAR BOLTS
  18. Remove remaining differential ring gear-to-case bolts (1).
    Fig 17: Ring Gear Removal
    GC0115811Courtesy of CHRYSLER GROUP, LLC
    1 - SOFT-FACED HAMMER
    2 - RING GEAR
  19. Using a soft-faced hammer (1), remove ring gear (2) from case.
    Fig 18: Position Bearing Cup Remover Tool In Retainer
    GC0115812Courtesy of CHRYSLER GROUP, LLC
    1 - JAW SET 6062A
    2 - DIFFERENTIAL BEARING RETAINER
  20. Using Remover (special tool #6062A, Puller, Bearing Cup), remove the differential bearing race from the extension housing/adapter plate.
    Fig 19: Remove Bearing Cup
    GC0115813Courtesy of CHRYSLER GROUP, LLC
    1 - JAW SET 6062A
    2 - DIFFERENTIAL BEARING RETAINER
  21. Using Remover (special tool #6062A, Puller, Bearing Cup), remove the differential bearing race from the bearing retainer.
DIFFERENTIAL SERVICE TOOLS

COMPONENT REMOVER INSTALLER
Differential Bearing On Retainer Side 5048, 5048-4 Collets, L-4539-2 Button 5052, C-4171
Differential Bearing On Extension Housing Side 5048, 5048-3 Collets, L-4539-2 Button L-4410, C-4171
Differrential Race On Retainer Side 6062A 6061, C-4171
Differential Race On Extension Housing 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
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