This procedure covers removal and replacement of the rear differential assembly on a 2012-2018 Jeep Wrangler with 3.6L V6 engine, including axle shaft removal, driveshaft disconnection, and differential mounting.

Warnings

Tools required

Parts

• Rear differential assembly (if replacing complete unit) × 1 — Use OEM specification or verified replacement
• Differential cover gasket or RTV sealant × 1 — Mopar RTV sealant recommended
• Axle shaft nuts (new, non-reusable) × 2 — Use OEM specification
• Differential cover bolts (if corroded) × 10 — M10 x 1.50

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 2 qt

Preparation

1. Park vehicle on level surface and place wheel chocks in front of front wheels
2. Loosen rear wheel lug nuts while vehicle is on ground
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 with paint or marker for proper alignment during reinstallation

Procedure

1. 1

   Drain differential fluid
   Remove the differential cover bolts in a crisscross pattern, starting with the top bolts. Leave two upper bolts partially threaded to prevent cover from falling. Carefully pry cover away from housing at bottom to drain fluid into pan. Once drained, remove remaining bolts and cover. Clean mating surfaces thoroughly with scraper and wire brush.
2. 2

   Remove axle shaft nuts
   Have an assistant apply brakes or use appropriate brake holding tool. Remove the stake marks from axle nuts using hammer and chisel. Using breaker bar and appropriate socket, remove both rear axle shaft nuts. Discard nuts as they are not reusable.
   ⚠Axle nuts are torqued to 207 lb-ft and may require significant force to loosen. Ensure socket is fully seated to prevent rounding.
3. 3

   Disconnect CV joints from differential
   Remove the CV joint bolts connecting the inner CV joint to the differential output flanges on both sides. There are typically 6 bolts per side. Support axle shafts with wire or bungee cords to prevent damage to CV boots. Do not allow axle shafts to hang freely.
   Torque spec

   CV Joint Bolts71 Nm (52 lb-ft)
4. 4

   Disconnect rear driveshaft
   Remove the four bolts securing the rear driveshaft to the differential pinion flange. Support driveshaft and push forward toward transfer case, securing it out of the way with wire or strap. Do not allow driveshaft to hang on slip joint.
   ℹ️Ensure alignment marks made during preparation are visible. Incorrect driveshaft alignment can cause vibration.
   Torque spec

   Driveshaft Bolts85 Nm (63 lb-ft)
5. 5

   Disconnect brake components and sensors
   Disconnect the rear wheel speed sensors from both sides by releasing connectors. Disconnect rear brake line or hose from differential housing if equipped with bracket. Note routing for reinstallation. Disconnect any vent hoses from differential.
6. 6

   Support differential assembly
   Position transmission jack or differential jack under the center of the differential housing. Raise jack until it just contacts differential and secure with safety chain or strap. Ensure jack is centered and stable before proceeding.
   ⚠️Differential assembly weighs 80-100 lbs and is awkward to handle. Ensure jack is properly positioned and secured before removing mounting bolts.
7. 7

   Remove differential mounting bolts
   Locate and remove all differential mounting bolts connecting the differential housing to the axle tubes or mounting brackets. On Wrangler JK models, there are typically front and rear mounting bolts. Remove bolts while supporting differential weight with jack.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Remove differential assembly
   Carefully lower the transmission jack while guiding the differential assembly down and out from the vehicle. Have an assistant help guide the assembly to prevent binding on axle tubes or suspension components. Once clear, remove from under vehicle and place on workbench.
9. 9

   Install replacement differential
   Clean all mounting surfaces on axle tubes and brackets. Position new or rebuilt differential on transmission jack and raise into position. Align differential with mounting points and axle tubes. Install mounting bolts finger-tight, then torque to specification in a crisscross pattern.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
10. 10

    Reconnect driveshaft
    Align driveshaft with pinion flange using reference marks made during disassembly. Install driveshaft bolts and torque to specification in a star pattern. Verify flange alignment is correct.
    Torque spec

    Driveshaft Bolts85 Nm (63 lb-ft)
11. 11

    Reconnect CV joints
    Position axle shafts and align CV joints with differential output flanges. Install new CV joint bolts and torque to specification in a crisscross pattern. Ensure CV boots are not twisted or damaged.
    Torque spec

    CV Joint Bolts71 Nm (52 lb-ft)
12. 12

    Install new axle nuts
    Install NEW axle shaft nuts (do not reuse old nuts). Have assistant apply brakes and torque axle nuts to specification. After torquing, use hammer and punch to stake the nut collar into the axle shaft groove at the staking point.
    ⚠Axle nuts must be staked after torquing to prevent loosening. Ensure stake mark is properly set in groove.
    Torque spec

    Axle Nut281 Nm (207 lb-ft)
13. 13

    Install differential cover and fill
    Clean differential cover and housing mating surfaces thoroughly. Apply continuous bead of RTV sealant to cover mating surface (approximately 3mm bead). Install cover and bolts, torquing in crisscross pattern to specification. Allow RTV to cure per manufacturer instructions (typically 1 hour) before filling. Fill differential with Mopar 75W-140 Synthetic Gear Lubricant to bottom of fill hole (approximately 2 quarts). Install fill plug.
    ℹ️Do not over-apply RTV sealant as excess can contaminate differential fluid. A 3mm bead is sufficient.
    Torque spec

    Differential Cover Bolts39 Nm (29 lb-ft)
14. 14

    Reconnect sensors and brake components
    Reconnect rear wheel speed sensors on both sides. Reconnect brake lines or hoses to differential housing brackets if applicable. Reconnect differential vent hose. Verify all connections are secure and properly routed.
15. 15

    Install wheels and lower vehicle
    Install rear wheels and hand-tighten lug nuts in star pattern. Lower vehicle until wheels just touch ground. Torque wheel lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Double-check all fasteners are torqued to specification, particularly axle nuts and driveshaft bolts
2. Verify axle nuts are properly staked and secure
3. Confirm differential fluid level is correct at fill plug
4. Ensure no tools or parts are left under vehicle

Verification

• Test drive vehicle at low speed and verify no unusual noises, vibrations, or leaks from differential
• Check for gear oil leaks around differential cover after test drive
• Verify proper operation of ABS system (no warning lights from wheel speed sensors)
• Re-check differential fluid level after test drive and top off if necessary
• After 50-100 miles, re-torque wheel lug nuts and inspect all differential connections for leaks

More procedures for this vehicle