Front Axle - 186FIA: Differential: Assembly

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: PINION MATE GEAR

Courtesy of DAIMLERCHRYSLER CORP.

1 - THRUST WASHER

2 - SIDE GEAR

3 - PINION MATE GEAR

Install differential side gears (2) and thrust washers. See Fig 1.
Install pinion mate gears (3) and thrust washers (1).

Install pinion gear mate shaft.

Fig 2: PINION MATE SHAFT ROLL-PIN

Courtesy of DAIMLERCHRYSLER CORP.

1 - PUNCH

2 - PINION MATE SHAFT

3 - MATE SHAFT LOCK PIN

Align hole in the pinion gear mate shaft (2) with the hole in the differential case. See Fig 2.
Install the roll-pin (3) in the differential case with a hammer and punch (1). Peen the edge of the roll-pin hole in the differential case in two places 180° apart.
Lubricate all differential components with hypoid gear lubricant.
Install ring gear.