Differential Carrier Assembly

1. Apply multipurpose grease to lip of oil seal, then using installer bar tool No. C-4171 and oil seal installer tool No. MB991115, or equivalents, press seal into gear carrier.
2. Using installer handle tool No. C-4171 and bearing installer tool Nos. MB990932 and MB990935, or equivalents, press drive pinion rear and front bearing outer races into gear carrier.
3. Adjust drive pinion height as follows:
a. Install a pinion height gauge set tool Nos. MB990835 and MB990836, or equivalent, and drive pinion front and rear bearing inner races on gear carrier as shown.
NOTE:
Apply a thin coat of multipurpose grease to mating surface on washer of tool.

Fig.39 Drive Pinion Height Adjustment:

b. Tighten handle of special tool until standard value of drive pinion turning torque is obtained. On Colt Vista, specification is 6-9 inch lbs. and on Talon, refer to the chart below.

Fig.40 Talon Drive Pinion Turning Torque Specifications (with oil seal installed):

c. Measure drive pinion turning torque (without oil seal).
d. Position special tool No. MB990835, or equivalent, in side bearing seat of gear carrier as shown. Select a drive pinion rear shim of a thickness which corresponds to the gap between special tools.
CAUTION:
Clean side bearing seat thoroughly. When positioning special tool, ensure cutout sections of tool are in position shown, and that special tool is in close contact with side bearing seat. When selecting drive pinion rear shims, keep number of drive shims to a minimum.

Fig.41 Selecting Drive Pinion Adjustment Shims:

e. Fit selected drive pinion rear shims to drive pinion, then using bearing installer tool No. MB990728, or equivalent, press rear bearing inner race onto drive pinion as shown.

Fig.42 Drive Pinion Inner Race Installation:

4. Adjust drive pinion preload as follows:
a. Fit drive pinion front shims between drive pinion spacer and drive pinion front bearing inner race.
b. Torque companion flange nut to 116-159 ft. lbs. using end yoke holder tool No. MB990767, or equivalent. Do not install oil seal.
c. Using a torque wrench, measure drive opinion turning torque as shown

Fig.43 Drive Pinion Turning Torque Check:

d. Compare measurement. On Colt Vista, specification is 6-9 inch lbs., and on Talon, refer to the chart. If turning torque is not within specification, adjust by replacing drive pinion front shims or drive pinion spacer.
NOTE:
If a number of shims will be required to bring preload within specified value, reduce the number of shims by replacing the spacer.

Fig.40 Talon Drive Pinion Turning Torque Specifications (with oil seal installed):

e. Remove companion flange and drive pinion, then drive oil seal into gear carrier front lip. Apply a thin coat of multipurpose grease to the oil seal lip.
f. Apply a thin coat of multipurpose grease to companion flange washer contacting surface prior to installing drive pinion.
g. Install drive pinion assembly and companion flange with mating marks aligned, and torque companion flange self-locking nut to 116-159 ft. lbs.
h. Measure drive pinion turning torque, and compare with specified value. On Colt Vista, specification is 6-9 inch lbs., and on Talon, refer to the chart. If turning torque is not within specified value, ensure companion flange self-locking nut is tightened within specification and oil seal is correctly installed.

Fig.44 Drive Pinion Turning Torque Specifications (w/oil seal installed):

5. On models except Laser and Talon, adjust differential gear backlash as follows:
a. Assemble side gears, side gear spacers, pinion gears and opinion washers into differential case.
b. Temporarily install pinion shaft. Do not drive in lockpin at this time.
c. While locking side gear with wedge measure differential gear backlash with dial indicator as shown. Measurement should be made for both gears individually.

Fig.45 Differential Gear Backlash Check:

d. Gear backlash should not exceed 0.008 inch (0.2 mm). If side gear exceeds limit, adjust by installing thicker side gear spacers.
e. After adjustment, ensure differential gear rotates smoothly.
f. If backlash cannot be adjusted, replace side gear and pinion gear as a set.
g. Align pinion shaft lockpin hole with differential case lockpin hole, and drive in lockpin.
h. Stake lockpin with punch at two points as shown.

Fig.46 Lockpin Installation:

6. On all models, clean drive gear attaching bolts, then using a M10 X 1.25 tap, remove adhesive adhering to threaded holes of drive gear. Clean remaining material out of drive gear using compressed air.
7. Apply multipurpose adhesive MOPAR Loctite No. 271 or equivalent to threaded holes of drive gear.
8. Install drive gear onto differential case with mating marks aligned. Torque drive gear attaching bolts in a diagonal sequence to 58-65 ft. lbs.
9. Using bearing installer tool No. MB990728, or equivalent, press side bearing inner races to differential case.
10. Adjust final drive gear backlash as follows:
a. Install side bearing spacers, which are thinner than those removed, to side bearing outer races and then mount differential case assembly into gear carrier.
NOTE:
Use side bearing spacers with the same thickness for both drive pinion and drive gear sides.

b. Push differential case to one side of the gear carrier and measure clearance between gear carrier and side bearing as shown.

Fig.47 Gear Carrier & Side Bearing Clearance Check:

c. Measure thickness of side bearing spacers on one side, then select two pairs of spacers which correspond to that thickness plus one half of clearance plus 0.002 inch. Install one pair each to drive pinion side and drive gear side.

Fig.48 Side Bearing Spacers Selection:

d. Install side bearing spacers and differential case assembly to gear carrier as shown.

Fig.49 Side Bearing Spacers & Differential Case Assembly Installation:

e. Tap side bearing spacers with a brass bar to fit them to side bearing outer race.
f. Align mating marks on gear carrier and bearing cap, then tighten bearing cap.
g. With drive pinion locked in place, measure final drive gear backlash with a dial indicator mounted on drive gear as shown.

Fig.29 Final Drive Gear Backlash Measurement:

h. Measure at four or more points around the circumference of the drive gear, backlash should be within 0.004-0.006 inch (.11-.16 mm).
i. Change side bearing spacers as shown, and then adjust final drive gear backlash between drive gear and drive pinion.
NOTE:
When increasing number of side bearing spacers, use the same number of each, and as few as possible.

Fig.50 Side Bearing Spacers Change:

j. Check drive gear and drive pinion for proper tooth contact, refer to "Pre-Disassemble Inspection" for adjustment procedure.
k. Measure drive gear runout at shoulder on reverse side of drive gear. If drive gear runout exceeds 0.002 inch, reinstall by changing phase of drive gear and differential case, and measure.

Fig.30 Drive Gear Runout Measurement:

11. On Colt Vista and Talon models, apply a semi-drying sealant to installation surface of differential cover and vent plug, torque cover bolts to 22-30 ft. lbs.