Differential Case Assembly - M210 Front Axle: Notes

REMOVAL

Remove the differential cover.
Remove the left tie rod end from the knuckle and secure out of the way. Refer to: END, TIE ROD, REMOVAL AND INSTALLATION, LEFT .

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Cover Bolts
Remove the track bar. Refer to: TRACK BAR, FRONT, REMOVAL AND INSTALLATION .
Remove the axle shafts. Refer to: AXLE SHAFTS, DRIVE SHAFTS AND HALF SHAFTS - REMOVAL AND INSTALLATION .
If equipped with TRU-LOK, disconnect the axle locker wire harness connector.

Courtesy of CHRYSLER GROUP, LLC

1 - Axle Locker Wire Harness Connector
If equipped with TRU-LOK, remove the axle locker wire harness connector bolt and pull the connector away from the housing.
If equipped with TRU-LOK, disconnect the internal wire harness connector at the axle locker connector and remove the connector.
NOTE:
Note the reference letters stamped on the bearing caps and differential housing machined sealing surface.

Courtesy of CHRYSLER GROUP, LLC

1 - Internal Axle Locker Wire Harness

2 - Axle Locker Wire Harness Connector

If reference letters are not clearly visible, mark the bearing caps and differential housing so the caps can be reinstalled in their original positions.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Cap Bolts

2 - Reference Letters

3 - Axle Locker Coil Anti-rotation Bracket

Loosen the differential bearing cap bolts. If equipped, note the orientation of the axle locker actuator bracket when removing the bearing caps.
Position the special tool # W-129-B, (Differential Spreader) with the adapter kit special tool # 6987B, (Axle Spreader Adapter Kit) on the differential locating holes. Install the hold-down clamps and tighten the turnbuckle finger-tight.

Courtesy of CHRYSLER GROUP, LLC

1 - Hold Down Clamps

2 - Spreader

Install a pin from the special tool # C-3288-B, (Alignment Pins Set) at the left side of the differential housing. Attach the dial indicator with the SP-1917 or equivalent 90° dial indicator tip (special tool #C-3339A, (Dial Indicator Set)) to the pin. Load the SP-1917 or equivalent 90° dial indicator tip against the opposite side of the housing and zero the dial indicator.

Courtesy of CHRYSLER GROUP, LLC

1 - Spreader

2 - Dial Indicator And Mounting

3 - 90° Dial Indicator Tip

Spread the differential housing while measuring the distance with the dial indicator.
CAUTION:
Never spread housing over 0.50 mm (0.020 in). Failure to follow these instructions will damage the housing.
Remove the dial indicator.
Holding the differential case in position, remove the differential bearing caps.
Remove the differential case from the differential housing using a small pry bar or similar. Tag the differential bearing cups and shim locations.

Courtesy of CHRYSLER GROUP, LLC

1 - Pry Bar

2 - Differential Case

CLEANING:

Clean the housing cavity with flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning.

INSTALLATION

NOTE:

If new differential bearings or differential case are being installed, the differential side bearing washer requirements may change. To determine the proper shims selection. Refer to: ADJUSTMENTS - M210 FRONT AXLE, ADJUSTMENTS .

NOTE:

Non-locker rear differential case assembly shown for bearing clarity.

Install the differential case into the differential housing with bearing cups and preload shims while guiding the axle locker wire harness connector to the case opening, if equipped. Tap the differential case to ensure the bearings cups are fully seated in the differential housing.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Case

2 - Differential Housing

3 - Bearing Cups

Install the bearing caps with reference marks in their original locations. If equipped, install the axle locker coil anti rotation bracket on the locker side of the differential. Center the pin from the axle locker actuator in the slot in the axle locker actuator bracket.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Cap Bolts

2 - Reference Letters

3 - Axle Locker Coil Anti-rotation Bracket

Loosely install the differential bearing cap bolts.
Remove the differential housing spreader.
Tighten the bearing cap bolts in a criss-cross pattern to the proper torque specification.
If equipped with TRU-LOK, connect the internal wire harness connector at the axle locker connector and position the connector in the housing.

Courtesy of CHRYSLER GROUP, LLC

1 - Internal Axle Locker Wire Harness

2 - Axle Locker Wire Harness Connector

If equipped with TRU-LOK, install the axle locker wire harness connector bolt.

Courtesy of CHRYSLER GROUP, LLC

1 - Axle Locker Wire Harness Connector Bolt

2 - Axle Locker Wire Harness Connector

If equipped with TRU-LOK, connect the axle locker wire harness connector.
Install the axle shafts. Refer to: AXLE SHAFTS, DRIVE SHAFTS AND HALF SHAFTS - REMOVAL AND INSTALLATION .
Install the track bar. Refer to: TRACK BAR, FRONT, REMOVAL AND INSTALLATION .
Install the left tie rod end. Refer to: END, TIE ROD, REMOVAL AND INSTALLATION, LEFT .
Install the differential cover.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Cover
Remove the fill plug and fill the differential with the proper fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .