Front Axle - 186FIA: Differential: Installation

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: VARI-LOK

Courtesy of DAIMLERCHRYSLER CORP.

1 - ANTI-ROTATION TAB

2 - OIL FEED TUBE

NOTE: If differential bearings or differential case are replaced, Refer to adjustments fore Differential Bearing Preload and Gear Backlash procedures.

Position Spreader W-129-B on differential location holes and install safety holddown clamps. Tighten spreader turnbuckle finger-tight.
Install Pilot Stud C-3288-B to the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load indicator plunger against the opposite side of the housing and zero the indicator.
Spread housing while measuring the distance with the dial indicator.
CAUTION: Never spread the differential housing over 0.34 mm (0.013 in). Failure to follow these instructions will damage the housing.
Remove dial indicator.
Install differential case in the housing. Tap differential case to seat bearings cups and preload shims in housing.
CAUTION: On a Vari-lok(R) differential the oil feed tube (2) must be pointed at the bottom of the housing. Failure to follow these instructions will damage the anti-rotation tabs (1). See Fig 1.

Install bearing caps and loosely install bolts.

Fig 2: DIFFERENTIAL SPREADER

Courtesy of DAIMLERCHRYSLER CORP.

1 - DIFFERENTIAL HOUSING

2 - SAFETY CLAMPS

3 - SPREADER

4 - TURNBUCKLE

Loosen turnbuckle (4) remove safety clamp (2) and remove spreader (3). See Fig 2.
Tighten bearing cap bolts in a crisscross pattern to 54-68 N.m (39-50 ft. lbs.).
Install right axle shaft.
Install differential housing cover.