2004 Chrysler Pacifica FWDFACTORY OEM SERVICE PROCEDURE

Rear Driveline Module: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Install axle seals using tools C4171 and 8493 (Fig 1 ).
    Fig 1: Installing Axle Seals Using Tools
    G03571293Courtesy of DAIMLERCHRYSLER CORP.
  2. Install large overrunning clutch housing o-ring to differential assembly (Fig 2 ). Lube o-ring with ATF.
    Fig 2: Installing Overrunning Clutch Housing O-Ring To Differential Assembly
    G03571294Courtesy of DAIMLERCHRYSLER CORP.
  3. Install shim to differential pinion shaft (Fig 3 ). Be sure to use shim of same thickness as removed.
    Fig 3: Installing Shim To Differential Pinion Shaft
    G03571295Courtesy of DAIMLERCHRYSLER CORP.
  4. Install viscous coupler to differential pinion shaft (Fig 4 ).
    Fig 4: Installing Viscous Coupler To Differential Pinion Shaft
    G03571296Courtesy of DAIMLERCHRYSLER CORP.
  5. Install overrunning clutch assembly to viscous coupler (Fig 5 ).
    Fig 5: Installing Overrunning Clutch Assembly
    G03571297Courtesy of DAIMLERCHRYSLER CORP.
  6. Install washer to overrunning clutch (Fig 6 ).
    Fig 6: Installing Bottoming Washer To Overrunning Clutch
    G03571298Courtesy of DAIMLERCHRYSLER CORP.
  7. Install o-ring to overrunning clutch (Fig 7 ) (Fig 8 ).
    Fig 7: Installing O-Ring To Overrunning Clutch
    G03571299Courtesy of DAIMLERCHRYSLER CORP.
  8. Align overrunning clutch ground tab to 3 o'clock position (Fig 9 ).
    Fig 8: Installing Proper O-Ring And Washer
    G03571300Courtesy of DAIMLERCHRYSLER CORP.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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