Disassembly

NOTE: The Viper uses a Dana (model 44) axle. The rebuild procedure is similar to the procedures used to repair most Dana axles.

1. Raise vehicle on hoist.
2. Remove fill plug located on side of the differential carrier. Install a fluid transfer pump into fill plug hole. Remove (draw out) the fluid from the axle. Allow the axle to drain completely.
3. Remove the differential from the vehicle.

CAUTIONS:
^ The drive shaft and axle shaft strap bolts incorporate a Loctite patch for retention on initial installation. These screws must be replaced with new pieces or cleaned and Loctite thread locker reapplied whenever they are removed.

^ Replace both drive shaft and axle shaft universal joint straps whenever they are removed. The straps slightly deform when torqued in place. Reuse of the straps may result in reduced clamp load on the universal joint cap.

4. Remove rear cover plate.





5. Remove output shaft snap rings. Then pull out output shafts from carrier.

CAUTION: Tag snap rings as they are being removed. This will ensure that they are reinstalled in the same position that they were in when they were removed.





6. Remove bearing cap bolts. Note the markings stamped on the bearing caps so that the cap; can be installed in the same position they were removed.





7. Install differential carrier spreader (Special Tool W-129-B, or equivalent). The use of adapters (Special Tool D-242-1, or equivalent) will be required when using spreader.





8. Install dial indicator onto case.
9. Hand tighten spreader, then zero dial indicator.

CAUTION: Do not spread differential carrier more than 0.010 inch. If the carrier is spread more than 0.010 inch case distortion or cracking may occur.

10. Tighten spreader with wrench. Spread carrier 0.010 inch.





11. With the case spread 0.010 inches, remove the dial indicator and then pry differential case out of the differential carrier.
12. Remove spreader from carrier.





13. Remove yoke nut from pinion shaft.





14. Remove yoke from pinion shaft using a two jawed puller.
15. Remove pinion from the differential carrier.
16. Remove pinion seal, thrust washer and outer pinion bearing cone.

CAUTION: Use care not to nick sealing surface on carrier.





17. Remove outer pinion cup with special tool D-103, extension C- 4291 and handle C-4171, or equivalents.
18. Remove inner pinion bearing cup with special tool C-4307 and handle C-4171, or equivalents. Use the same technique used to remove the outer pinion bearing.





19. Remove output shaft bearings and seals.
20. Remove collapsible spacer from pinion shaft. Discard original collapsible spacer. Always use a new collapsible spacer when reassembling.





21. Remove inner pinion bearing cone using special tool C-293 PA and adapters C-293-42, or equivalents. The pinion depth shim is located between the pinion head and inner bearing cone.





22. Remove both bearings from the differential case. Use special tools C-293-PA, C-293-48 and adapter plug C-293-3, or equivalents.
23. At this point the axle has been completely disassembled. Clean and inspect all parts for wear or damage. Replace all suspect parts. Never reuse the original collapsible spacer regardless of its condition.
24. After inspecting and/or replacing all necessary parts, begin the reassembly process by setting the pinion depth.