Rear Differential

Complete removal and installation of the rear differential assembly on a 2008 Dodge Viper, including driveshaft disconnection, axle shaft removal, and differential mounting bolt removal.

Warnings

Tools required

Parts

• Rear differential gasket or RTV sealant × 1 — Use OEM specification
• Crush washer for differential fill plug × 1 — Use OEM specification
• Crush washer for differential drain plug × 1 — Use OEM specification

Fluids

• 75W-90 synthetic gear oil — 2.75 qt

Preparation

1. Park vehicle on a level surface and engage parking brake.
2. Chock the front wheels securely.
3. Raise the rear of the vehicle using a floor jack and support on jack stands under the frame rails.
4. Remove both rear wheels to improve access.
5. Allow differential to cool if vehicle was recently driven.

Procedure

1. 1

   Drain differential fluid
   Place a drain pan under the rear differential. Locate the drain plug on the bottom of the differential housing. Using the appropriate socket, remove the drain plug and allow the gear oil to drain completely into the pan. Inspect the drained fluid for metal particles or abnormal debris. Once drained, reinstall the drain plug finger-tight to prevent contamination during removal.
2. 2

   Mark driveshaft orientation
   Before disconnecting the driveshaft, use marking paint or a punch to mark the relationship between the driveshaft flange and the differential pinion flange. This ensures the driveshaft is reinstalled in the same orientation to maintain balance.
3. 3

   Disconnect driveshaft from differential
   Remove the 4 bolts securing the driveshaft flange to the rear differential pinion flange. Support the driveshaft and carefully lower it away from the differential. Use a bungee cord or wire to secure the driveshaft to the exhaust or chassis to prevent it from hanging on the transmission output shaft.
4. 4

   Disconnect rear axle shafts
   On each side, locate the bolts securing the axle shaft flange to the differential stub shaft flange. Remove the 6 bolts on each side. Carefully pull the axle shafts away from the differential just enough to disengage them from the stub shafts. Support the axle shafts with wire or bungee cords to prevent them from hanging on the wheel bearings. Do not allow the axle shafts to hang freely as this can damage the CV joints.
5. 5

   Disconnect brake lines and ABS sensors
   If brake lines or ABS sensor wiring is routed through or clipped to the differential mounting brackets, carefully disconnect or unclip them to provide clearance. Note the routing for reinstallation. For brake lines, use a flare nut wrench to avoid rounding off fittings if disconnection is necessary. If lines can remain connected with adequate slack, leave them attached.
6. 6

   Support differential with transmission jack
   Position a transmission jack or differential jack under the center of the differential housing. Raise the jack until it makes contact and securely supports the weight of the differential. Use a block of wood or rubber pad between the jack and differential to prevent damage to the housing.
7. 7

   Remove differential mounting bolts
   Locate the differential mounting bolts that secure the differential to the rear subframe or crossmember. There are typically 4 main mounting bolts. Remove these bolts while supporting the differential with the transmission jack. Keep track of any washers, bushings, or spacers on the mounting bolts as their positions are critical for proper alignment.
8. 8

   Remove rear differential assembly
   With all mounting bolts removed and the differential supported on the jack, carefully lower the differential assembly. Guide it forward and downward, ensuring the pinion shaft clears the driveshaft tunnel and that no brake lines, ABS wiring, or other components are still attached. The assembly is heavy and awkward; use caution and consider a second person for assistance. Once clear of the vehicle, roll the jack away from the work area.
9. 9

   Inspect mounting points and bushings
   With the differential removed, inspect all mounting bushings, brackets, and hardware for wear, cracking, or damage. Inspect the differential mounting points on the subframe for cracks or damage. Replace any worn bushings or damaged hardware before reinstallation. Clean the mounting surfaces with a wire brush if necessary.
10. 10

    Position replacement or serviced differential
    If installing a replacement differential, ensure it is the correct unit for the vehicle and matches the gear ratio of the original. Place the differential assembly on the transmission jack with the pinion shaft oriented toward the front of the vehicle. Raise the jack and carefully guide the differential into position, aligning the mounting holes with the subframe brackets. Ensure all studs, bushings, and spacers are properly seated.
11. 11

    Install differential mounting bolts
    Install the 4 main differential mounting bolts along with any washers, bushings, or spacers in their original positions. Start all bolts by hand to ensure proper thread engagement and alignment. Tighten the mounting bolts in a cross pattern to draw the differential evenly into position. Final torque specifications should be applied per manufacturer specifications.
12. 12

    Reconnect rear axle shafts
    Align the rear axle shaft flanges with the differential stub shaft flanges on each side. Install the 6 bolts on each side, ensuring the flanges are fully seated before tightening. Tighten the bolts in a star pattern to ensure even clamping force. Torque to manufacturer specifications.
13. 13

    Reconnect driveshaft
    Align the driveshaft flange with the differential pinion flange using the alignment marks made during disassembly. Install the 4 flange bolts and tighten them in a cross pattern. Torque to manufacturer specifications. Verify that the driveshaft rotates freely without binding or interference.
14. 14

    Reconnect brake lines and ABS sensors
    Reconnect any brake lines or ABS sensor wiring that was disconnected during removal. Ensure all clips and routing are returned to their original positions. If brake lines were disconnected, the brake system will require bleeding after reassembly.
15. 15

    Fill differential with gear oil
    Remove the differential fill plug located on the side or rear of the differential housing. Using a gear oil pump or funnel with hose, add the manufacturer-specified quantity of OEM-specified gear oil through the fill hole. Fill until oil begins to drip from the fill hole, indicating proper level. Install a new crush washer on the fill plug and reinstall the plug, tightening to manufacturer specifications. Also install a new crush washer on the drain plug if not already done, and torque the drain plug to specifications.

Reassembly

1. Reinstall rear wheels and torque lug nuts to manufacturer specifications in a star pattern.
2. Lower the vehicle to the ground.
3. If brake lines were disconnected, bleed the brake system thoroughly and verify proper brake pedal feel.
4. Perform a final inspection of all fasteners, ensuring nothing was missed during reassembly.
5. Wipe down the differential housing and check for any signs of fluid leakage from the fill or drain plugs.

Verification

• Start the vehicle and allow it to idle. Listen for any abnormal noises from the differential area.
• With the vehicle on the ground, shift through gears (if manual) or move the shifter through positions (if automatic) to verify driveline engagement.
• Test drive the vehicle in a safe area at low speed, listening for abnormal noises, vibrations, or handling issues.
• After test drive, raise the vehicle and inspect the differential for any signs of gear oil leakage around the fill plug, drain plug, pinion seal, and axle shaft seals.
• Check the differential fluid level after test drive to ensure it remains at the proper level.
• Verify that all fasteners remain tight and that there is no excessive play in the driveshaft or axle shaft connections.

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