2005 CHRYSLER CARAVAN Service Manual

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Page 1681 of 2339

CHRYSLER CARAVAN 2005 Service Manual OPERATION The differential assembly is driven by the transfer shaft by way of the differential ring gear. The ring gear drives the differential case, and the case drives the driveshafts through the di

Page 1682 of 2339

CHRYSLER CARAVAN 2005 Service Manual (5) Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bear- ing cone on the bearing retainer side (Fig. 173) (Fig. 174) (Fig. 175). (6) Using Miller Special

Page 1683 of 2339

CHRYSLER CARAVAN 2005 Service Manual (8) Remove ring gear-to-differential case bolts and floating pinion shaft retainers (Fig. 178). (9) Separate ring gear from differential case (Fig. 179).(10) Separate differential cover from case usin

Page 1684 of 2339

CHRYSLER CARAVAN 2005 Service Manual (12) Remove side gear thrust washer (Fig. 182). (13) Remove side gear (Fig. 183).(14) Remove pinion shaft (Fig. 184). (15) Remove pinion gears and tabbed washers (Fig. 185). Fig. 182 Side Gear Thrust

Page 1685 of 2339

CHRYSLER CARAVAN 2005 Service Manual (16) Remove differential side gear (Fig. 186). (17) Remove side gear thrust washer (Fig. 187). (18) Inspect all components for excessive wear. ASSEMBLY NOTE: The differential is serviced as an assembl

Page 1686 of 2339

CHRYSLER CARAVAN 2005 Service Manual (3) Install both pinion gears and washers to case, while orientating washer tabs to notch in case (Fig. 190). (4) Install pinion shaft (Fig. 191).(5) Install side gear to case (Fig. 192). (6) Install

Page 1687 of 2339

CHRYSLER CARAVAN 2005 Service Manual (7) Install differential support into position, while aligning through-holes (Fig. 194). (8) Install differential ring gear to case (Fig. 195).(9) Install ring gear-to-case bolts, with pinion shaft re

Page 1688 of 2339

CHRYSLER CARAVAN 2005 Service Manual (11) Using Miller Special Tool 5052 and C-4171, install differential bearing to differential (bearing retainer side). (12) Using Miller Special Tool 6061 and C-4171, install differential bearing race
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