Drive, Final: Assembly: Assembly

WARNING: This page is about a different car, the 2016 Dodge Journey and 2015 Dodge Journey. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Thrust Washer

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1 - THRUST WASHER

NOTE:

The differential is serviced as an assembly. Differential service is limited to bearing cups and cones. Any other differential component failure must be remedied by differential assembly and transfer shaft replacement.

Install the side gear thrust washer (1) in the differential case.

Fig 2: Identifying Differential Side Gear
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1 - DIFFERENTIAL SIDE GEAR

Install the side gear (1) in the differential case.

Fig 3: Identifying Pinion Gear, Tab, Notch & Washer

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1 - PINION GEAR

2 - TABBED WASHER

3 - LOCATING TAB

4 - NOTCH

Install both pinion gears (1) and washers (2) in the differential case, while orientating the washer tabs to the notch in case.

Fig 4: Identifying Pinion Shaft
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1 - PINION SHAFT
Install the pinion shaft (1).

Fig 5: Removing/Installing Side Gear
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1 - DIFFERENTIAL SIDE GEAR
Install the differential side gear (1) in the case.

Fig 6: Identifying Side Gear Thrust Washer
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1 - SIDE GEAR THRUST WASHER
Install the side gear thrust washer (1) in the case.

Fig 7: Identifying Differential Support And Case
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1 - DIFFERENTIAL SUPPORT

2 - DIFFERENTIAL CASE
Install the differential support (1) into position, while aligning the through-holes.

Fig 8: Identifying Differential Case And Ring Gear
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1 - DIFFERENTIAL CASE

2 - RING GEAR

Install the differential ring gear (2) in the case (1).

Fig 9: Identifying Differential Case, Pinion Shaft Retainer, Ring Gear, And Ring Gear-To-Case Bolts

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1 - DIFFERENTIAL CASE

2 - PINION SHAFT RETAINER

3 - RING GEAR

4 - RING GEAR-TO-CASE BOLT

NOTE:

New bolts must be used.

Install the ring gear-to-case bolts, with the pinion shaft retainers, and tighten the bolts (4) to 95 N.m (70 ft. lbs.).
Check the differential side gear turning torque using the (special tool #C-4995A, Tool, Differential Bearing Torque). Turning torque should be no more than 10 to 20 in-lbs (drag). If drag exceeds 20 in-lbs decrease shim size, if the drag is less than 10 in-lbs (drag) increase shim size.

Fig 10: Installing Differential Pinion Side Bearing
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Using (special tool #6888, Installer, Seal) (1) and a press (2), install the differential bearing (3) to the pinion side of the differential housing.

Fig 11: Installing Ring Gear Side Bearing
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Using (special tool #C-4213, Installer, Bearing) (2) and a press (1), install the differential bearing (3) to the ring gear side of the differential.

Fig 12: Installing Large Side Pinion Bearing
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Using (special tool #C-4340, Installer, Bearing) (1) and a press, install the large pinion bearing to the pinion shaft.

Fig 13: Installing Small Side Pinion Bearing
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Using Installer (special tool #9723, Installer, Bearing) (1) and a press, install the small pinion bearing to the pinion shaft.