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Section 33 (Front Axle - C205F): Differential: Installation

WARNING: This page is about a different car, the 2004 Dodge Dakota and 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: If replacement differential bearings or differential case are replaced, Refer to adjustments fore Differential Bearing Preload and Gear Backlash procedures.
  1. Install Spreader W-129-B and Adapter Plates 8142-A and tighten spreader turnbuckle finger-tight.
  2. Install a Pilot Stud L-4438 to the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator.
  3. Spread housing to 0.34 mm (0.013 in).
    CAUTION: Never spread over 0.34 mm (0.013 in). If the housing is over-spread, it could be distorted or damaged.
  4. Remove the dial indicator.
  5. Install differential case in the housing. Ensure differential bearing cups remain in position on the bearings and differential preload shims are seated in the housing. Tap differential case to ensure bearings cups are seated in the housing.
  6. Install bearing caps to their original locations and loosely install cap bolts.
  7. Remove housing spreader.
  8. Tighten the bearing cap bolts to 61 N.m (45 ft. lbs.).
  9. Install the axle shafts and half shafts.
  10. Apply a bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover.
    CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
  11. Install cover and tighten bolts in a criss-cross pattern to 41 N.m (30 ft. lbs.).
  12. Fill the differential housing with the correct lubricant.
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