Differential Case Assembly - M220 Rear Axle: Notes

REMOVAL 

1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
2. Remove the differential drain plug and drain the fluid.
3. Remove the differential cover. Refer to: DIFFERENTIAL COVER - M220, REMOVAL AND INSTALLATION .
4. Remove the axle shafts. Refer to: AXLE SHAFTS, DRIVE SHAFTS AND HALF SHAFTS - REMOVAL AND INSTALLATION .
5. If equipped with TRU-LOK, disconnect the axle locker wire harness connector.

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   1 - Axle Locker Wire Harness Connector Bolt

   2 - Axle Locker Wire Harness Connector

6. If equipped with TRU-LOK, remove the axle locker wire harness connector bolt and pull the connector away from the housing.
7. 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.

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   1 - Internal Axle Locker Wire Harness

   2 - Axle Locker Wire Harness Connector

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

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   1 - Differential Cap Bolts

   2 - Reference Letters

   3 - Axle Locker Coil Anti-rotation Bracket

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

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    1 - Spreader

    2 - Dial Indicator And Mounting

    3 - 90° Dial Indicator Tip

11. Install the special tool # C-3288-B, (Alignment Pins Set) on the left side of the differential housing. Attach the special tool # C-3339A, (Dial Indicator Set) with the SP-1917 equivalent 90° dial indicator tip to the pin. Load the SP-1917 or equivalent 90° dial indicator tip against the opposite side of the differential housing and zero the dial indicator.
12. Spread differential housing while measuring the distance with the dial indicator.
    NOTE:

    Never spread the differential housing over 0.50 mm (0.020 in.). Failure to follow these instructions will damage the housing. 

13. Remove the dial indicator.
14. Holding the differential case in position, remove the differential bearing cap bolts.

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    1 - Differential Bearing Cap Bolts

    2 - Differential Bearing Cap Bolts

15. Remove the axle locker coil anti-rotation bracket from the bearing cap, remove both bearing caps.

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    1 - Differential Bearing Cap Bolts

    2 - Differential Bearing Cap

    3 - Axle Locker Coil Anti-rotation Bracket

16. Remove the differential case from the differential housing and tag the differential bearing cup and shim locations.
    NOTE:

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

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    1 - Differential Case

    2 - Differential Housing

    3 - Differential Bearing Cup and Spacer

CLEANING: 

• Clean the differential housing cavity with flushing oil, light engine oil or lint free cloth.
  NOTE:

  Do not use water, steam, kerosene or gasoline for cleaning.

INSTALLATION 

1. 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.
   NOTE:

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

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   1 - Differential Case

   2 - Differential Housing

   3 - Bearing Cups

2. 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.

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   1 - Differential Bearing Cap Bolts

   2 - Differential Bearing Cap

   3 - Axle Locker Coil Anti-rotation Bracket

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

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   1 - Internal Axle Locker Wire Harness

   2 - Axle Locker Wire Harness Connector

7. 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

8. If equipped with TRU-LOK, connect the axle locker wire harness connector.
9. Install the axle shafts. Refer to: AXLE SHAFTS, DRIVE SHAFTS AND HALF SHAFTS - REMOVAL AND INSTALLATION .
10. Install the axle locker switch. Refer to: AXLE LOCKER SWITCHES - REMOVAL AND INSTALLATION .
11. Install the differential cover. Refer to: DIFFERENTIAL COVER - M220, REMOVAL AND INSTALLATION .
12. Fill the differential with the specified fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
13. Remove the support and lower the vehicle.