Removal and Installation
REMOVAL1. Raise and support the vehicle.
2. Remove lubricant fill hole plug from the differential housing cover.
3. Remove differential cover and drain lubricant.
4. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Never use water, steam, kerosene or gasoline for cleaning.
5. Remove hub bearings and axle shafts.
6. Note installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 37).
7. Loosen the differential bearing cap bolts.
8. Position Spreader W-129-B with Adapter Kit 6987B on differential locating holes (Fig. 38). Install hold down clamps and tighten the tool turnbuckle finger-tight.
9. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to stud. Load the lever adapter against the opposite side of the housing (Fig. 39) and zero the indicator.
10. Spread housing enough to remove the differential case from the housing. Measure the distance with the dial indicator (Fig. 40).
CAUTION: Never spread the housing over 0.38 mm (0.015 in.). If housing is over-spread, it could distorted and damaged the housing.
11. Remove the dial indicator.
12. Hold differential case in position and remove differential bearing cap bolts and caps.
13. Remove differential from the housing and tag differential bearing cups to ensure location (Fig. 41).
14. Remove differential case preload shims from the axle housing.
15. Remove spreader from housing. Tag differential bearing preload shims to ensure correct location.
INSTALLATION
NOTE: If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection.
1. Position Spreader W-129-B with Adapter Kit 6987B on differential locating holes. Install hold down clamps and tighten the tool turnbuckle finger-tight.
2. Install a Pilot Stud C-3288-B at 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 the housing enough to install the case in the housing. Measure the distance with the dial indicator.
CAUTION: Never spread the housing over 0.38 mm (0.015 in.). If housing is over-spread, it could distorted and damaged the housing.
4. Remove the dial indicator.
5. Install differential case in the housing (Fig. 45). Make sure the differential bearing cups remain on the bearings and the preload shims remain between the face of the bearing cup and housing. Tap the differential case to ensure the bearings cups and shims are fully seated in the housing.
CAUTION: On a Vari-Lok differential the oil feed tube must be pointed at the bottom of the housing (Fig. 46). If differential is installed with the oil feed tube pointed at the top, the anti-rotation tabs will be damaged.
6. Install the bearing caps at their original locations (Fig. 47).
7. Loosely install differential bearing cap bolts.
8. Remove axle housing spreader.
9. Tighten the bearing cap bolts to 61 Nm (45 ft. lbs.).
10. Install the hub bearings and axle shafts.
11. Apply a bead 6.35 mm (1/4 in.) of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 48).
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.
12. Install differential cover and tighten cover bolts in a criss-cross pattern to 41 Nm (30 ft. lbs.).
13. Fill differential with gear lubricant to bottom of the fill plug hole.
14. Tighten fill plug to 34 Nm (25 ft. lbs.).
15. Remove support and lower the vehicle.