Differential

Fig. 8:

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

REMOVAL
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 rear axle from the vehicle.

CAUTION: 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.

CAUTION: 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.

Fig. 9:

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.

Fig. 10:

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

Fig. 11:

7. Install differential carrier spreader (Special Tool W-129-13). The use of adapters (Kent-Moore J-24385-20) will be required when using spreader.

Fig. 12:

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.

Fig. 13:

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.

INSTALLATION

Fig. 14:

1. Install differential carrier spreader (Special Tool W-129-13). The use of adapters (Kent-Moore J-243815-20) will be required when using spreader.

Fig. 15:

2. Install dial indicator onto case.
3. Hand tighten spreader, then zero dial indicator.

CAUTION: Do not spread differential carrier more than 0.10 inch. If the carrier is spread more than 0.010 inch case distortion or cracking may occur.

4. Tighten spreader with wrench. Spread carrier 0.10 inch.

Fig. 16:

5. With the case spread 0.010 inches, remove the dial indicator and then install differential into the differential carrier.
6. Remove spreader from carrier.

Fig. 17:

7. Note the markings stamped on the bearing caps so that the caps can be installed in the same position as they were removed. Install bearing cap bolts.

Fig. 18:

8. Install output shafts into carrier. Install output shaft snap rings.
9. Install rear axle cover plate.

CAUTION: 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.

CAUTION: 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.

10. Install the rear axle into the vehicle.
11. Add one four ounce container of Mopar(R) Limited Slip Additive (MS-5630), then fill the rear axle with Mopar(R) Synthetic Gear & Axle Lubricant 75W140 (MS-8985).
12. Lower vehicle to ground.