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Front Axle - C200FE: Differential-ELSD: Installation

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Differential Assembly
GC0028518Courtesy of DAIMLERCHRYSLER CORP.
  1. Bolt spreader Adapters 9669 to the differential housing.
  2. Install Spreader W-129-B on adapters and spread case 3 mm (0.011 in.).
  3. Slide differential assembly (1) into the right of the housing. Then slide ELSD pump (2) and differential into housing.
    Fig 2: Left Snap Ring
    GC0028517Courtesy of DAIMLERCHRYSLER CORP.
  4. Install differential bearing cups into their original locations.
  5. Install axle tube side differential housing (1) snap ring (2).
    Fig 3: Select Snap-Rings
    GC0028448Courtesy of DAIMLERCHRYSLER CORP.
  6. Install snap ring (1) into differential housing (2).
  7. Install differential housing seal with Installer 9505 and Handle C-4171.
    Fig 4: Bearing Cap Bolts
    GC0028516Courtesy of DAIMLERCHRYSLER CORP.
  8. Install differential bearing cap (2) between ELSD anti rotation tabs. Install bearing cap bolts (1) finger tight. Remove spreader then tighten bearing cap bolts to 135 N.m (100 ft. lbs.).
    Fig 5: Solenoid Connector
    GC0028514Courtesy of DAIMLERCHRYSLER CORP.
  9. Install solenoid valve connector (1) to ELSD solenoid valve (2).
    Fig 6: Axle Tube
    GC0028451Courtesy of DAIMLERCHRYSLER CORP.
  10. Lube new o-ring and install on axle tube (1).
  11. Align axle tube (1) with differential housing flange (3) and push tube into place.
    CAUTION: The tube must be perfectly aligned to the housing to prevent damage to the o-ring. Failure to follow these instructions will result in a leak.
    Fig 7: Axle Tube Bolts
    GC0028450Courtesy of DAIMLERCHRYSLER CORP.
  12. Install three axle tube (1) mounting bolts (2) and tighten to 56 N.m (41 ft. lbs.).
  13. Apply a 6.35 mm (1/4 in.) bead of Mopar® Gear Sealant RTV Silicone Rubber Adhesive MS-GF44D or equivalent to the differential case.
    CAUTION: If housing cover is not installed within 3 to 5 minutes, the differential case must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak.
  14. Install cover and tighten cover bolts in a crisscross pattern to 56 N.m (41 ft. lbs.).
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