Complete rebuild of the rear differential assembly including disassembly, bearing and seal replacement, gear pattern setup, and reassembly with new components.

Warnings

Tools required

Parts

• Master differential rebuild kit (bearings, seals, shims) × 1 — Use OEM specification for Dana 44 rear
• Ring and pinion gear set × 1 — Match existing gear ratio or desired ratio
• Pinion crush sleeve × 1 — Use OEM specification
• Pinion nut × 1 — Use OEM specification
• Axle shaft seals × 2 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Mopar RTV or equivalent
• Drain plug washer × 1 — Use OEM specification
• Gear marking compound × 1 — Use OEM specification
• Shop towels × 1 — Generic

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen rear wheel lug nuts before raising vehicle
3. Raise rear of vehicle and support securely on jack stands at frame rails
4. Remove both rear wheels
5. Place drain pan under differential
6. Mark driveshaft and pinion flange orientation for reassembly alignment
7. Photograph or mark axle shaft and CV joint positions for reference
8. Ensure work area is clean and well-lit for precision work

Procedure

1. 1

   Drain differential and remove cover
   Remove drain plug with new washer and drain gear oil completely into drain pan. Remove all differential cover bolts in crisscross pattern. Carefully pry cover off using gasket scraper, taking care not to damage sealing surface. Clean cover and housing mating surfaces thoroughly with gasket scraper and brake cleaner.
   Torque spec

   Drain Plug47 Nm (35 lb-ft)

   Cover Bolts39 Nm (29 lb-ft)
2. 2

   Remove axle shafts and driveshaft
   Unbolt CV joint bolts at differential flange on both sides. Support axle shafts and carefully pull outward to disengage from carrier. Remove driveshaft bolts at pinion flange and support driveshaft, then lower and remove from vehicle. Keep all hardware organized.
   Torque spec

   CV Joint Bolts71 Nm (52 lb-ft)

   Driveshaft Bolts85 Nm (63 lb-ft)
3. 3

   Mark and measure existing setup
   Before disassembly, measure and record pinion bearing preload using inch-pound torque wrench (should be 15-25 in-lbs rotating torque for used bearings). Measure and record ring gear backlash at 4 points around the gear using dial indicator (should be 0.005-0.008 inches). Mark carrier caps for orientation. These measurements verify if existing setup was correct and provide baseline.
4. 4

   Remove carrier assembly
   Remove carrier bearing cap bolts. Carefully pry carrier assembly with ring gear out of housing. If tight, use case spreader tool to spread housing slightly (maximum 0.020 inches). Remove carrier and set aside. Remove carrier bearing shims and keep with their respective sides, marking left and right.
   ⚠Do not over-spread differential housing beyond 0.020 inches or permanent distortion will occur.
5. 5

   Remove pinion assembly
   Hold pinion flange with holding tool and remove pinion nut. Use puller to remove pinion flange. Carefully tap pinion out from front of housing using soft mallet. Catch pinion as it comes free to prevent dropping. Remove pinion seal, front and rear pinion bearings, crush sleeve, and shims. Keep all shims organized and measure thickness for reference.
   ℹ️Pinion nut and crush sleeve must be replaced and cannot be reused.
6. 6

   Remove old bearings and races
   Using hydraulic press and bearing separator, press carrier bearings off carrier. Remove ring gear bolts and separate ring gear from carrier if replacing gears. Use bearing race driver and hammer to remove all bearing races from housing and pinion. Clean all bearing surfaces thoroughly with brake cleaner and inspect for damage or wear.
7. 7

   Install new pinion races and determine pinion depth
   Press new pinion bearing races into housing using bearing race driver, ensuring they seat fully. Install pinion depth setting gauge tools per manufacturer instructions. Measure pinion depth and select appropriate shim pack. New ring and pinion sets have pinion depth variance numbers etched on them - use these to calculate correct shim thickness. This is critical for proper gear contact pattern.
   ⚠Pinion depth setting is the most critical measurement in differential rebuild. Incorrect depth will cause noise and premature gear failure.
8. 8

   Assemble and install pinion
   Install selected pinion depth shim on pinion. Press rear pinion bearing onto pinion shaft using hydraulic press and bearing installer. Install pinion into housing with front bearing, new crush sleeve, and pinion seal. Install pinion flange and new pinion nut. Gradually tighten pinion nut while checking rotating torque with inch-pound torque wrench. Target preload is 20-30 in-lbs for new bearings. Stop when correct preload is achieved - you cannot back off and retighten.
   ⚠️Crush sleeve is one-time use. If you overtighten, you must replace crush sleeve and start over. Monitor preload constantly during tightening.
9. 9

   Install ring gear on carrier
   If installing new ring gear, clean carrier and ring gear mating surfaces. Heat ring gear to approximately 200°F to ease installation. Install ring gear on carrier and install new ring gear bolts with thread locker. Torque ring gear bolts in star pattern to specification per ring gear manufacturer instructions (typically 70-90 ft-lbs for Dana 44).
10. 10

    Install carrier bearings and determine shim thickness
    Press new carrier bearings onto carrier using hydraulic press and bearing installer. Install carrier into housing without shims initially. Measure gap between bearing and housing on both sides using feeler gauges. Add 0.010 inches to each side measurement to determine starting shim pack thickness for bearing preload. Install calculated shims.
11. 11

    Install carrier assembly and set backlash
    Install carrier with shims into housing, using case spreader if necessary (maximum 0.020 inches spread). Install carrier caps in correct orientation. Hand tighten cap bolts. Mount dial indicator to measure backlash at ring gear. Adjust shim thickness side-to-side to achieve 0.005-0.008 inches backlash. Moving shims from one side to other changes backlash without affecting preload. Torque carrier cap bolts to specification (typically 45-55 ft-lbs).
12. 12

    Check and verify gear contact pattern
    Apply gear marking compound to 4-6 teeth on ring gear. Rotate pinion in both directions under light resistance to create wear pattern. Examine pattern - it should be centered on tooth face for both drive and coast sides. Adjust pinion depth (by changing pinion shims) to move pattern up or down on tooth, and adjust backlash (by moving carrier shims) to move pattern in or out. Repeat until pattern is correct.
    ℹ️Correct gear pattern is essential for quiet operation and long gear life. Pattern should be centered and oval-shaped, not at toe or heel of tooth.
13. 13

    Install axle seals
    Clean axle seal bores in housing thoroughly. Using seal driver, install new axle seals on both sides of differential. Ensure seals are seated fully and evenly. Coat seal lips with small amount of gear oil.
14. 14

    Reinstall differential cover
    Clean differential cover and housing mating surfaces thoroughly. Apply continuous bead of RTV sealant approximately 1/8 inch wide to cover flange. Install cover and all cover bolts finger tight. Torque bolts in crisscross pattern to specification. Allow RTV to cure per manufacturer recommendation (typically 1 hour before filling, 24 hours before operation).
    ℹ️Do not overtighten cover bolts as this can distort cover and cause leaks.
    Torque spec

    Cover Bolts39 Nm (29 lb-ft)
15. 15

    Reinstall driveshaft and axle shafts
    Align driveshaft to pinion flange using reference marks made during disassembly. Install driveshaft bolts and torque to specification. Install both axle shafts into carrier, ensuring splines engage properly. Align CV joints to flanges and install CV bolts, torquing to specification.
    Torque spec

    Driveshaft Bolts85 Nm (63 lb-ft)

    CV Joint Bolts71 Nm (52 lb-ft)
16. 16

    Fill differential with gear oil
    Remove fill plug. Fill differential with Mopar 75W-140 Synthetic Gear Lubricant until oil reaches bottom of fill hole (approximately 2.0-2.5 quarts). Install fill plug with torque specification. Wipe any spilled oil from housing exterior.
    Torque spec

    Fill Plug47 Nm (35 lb-ft)

Reassembly

1. Install rear wheels and hand tighten lug nuts
2. Lower vehicle to ground
3. Torque wheel lug nuts to specification in star pattern
4. Double-check all fasteners for proper torque
5. Verify no leaks at differential cover and pinion seal
6. Clean all tools and work area

Verification

• Start vehicle and verify no abnormal noises from differential
• Test drive vehicle in empty parking lot, checking for smooth operation in forward and reverse
• Listen for whine, growl, or clicking noises which indicate incorrect gear setup
• Drive 50-100 miles and recheck differential oil level and inspect for leaks
• After 500 miles, drain and refill differential oil to remove any break-in debris
• Monitor differential for leaks and noise during first 1000 miles of operation

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