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HOMESERVICE MANUALSDODGE AND RAM1999CARAVAN BASE, 2.4 BREPAIR AND DIAGNOSISTRANSMISSIONAUTOMATIC TRANSOVERHAUL - 31THCOMPONENT DISASSEMBLY & REASSEMBLYDIFFERENTIAL ASSEMBLYDISASSEMBLY
1999 Dodge and Ram Caravan Base, 2.4 B

Differential Assembly: Disassembly

1999 Dodge and Ram Caravan Base, 2.4 BSECTION Disassembly
  1. Remove side bearings from carrier (if necessary). Remove bolts and ring gear. Side gear end play should be checked before disassembling side gears to determine if different thickness side gear thrust washer is required.
  2. Install Shaft (C-4996) in side gear. Install dial indicator. See Fig 1 . Move side gear upward and zero dial indicator. Move side gear downward and note side gear end play.
  3. Side gear end play should be .001-.013" (.03-.33 mm). Repeat procedure on remaining side gear. If side gear end play is not within specification, 4 different thickness side gear thrust washers are available.
  4. Using a hammer and punch, remove roll pin from carrier. See Fig 2 . Remove pinion gear shaft. Rotate pinion gears and remove pinion gears and pinion gear thrust washers. Remove side gears and side gear thrust washers.
Fig 1: Checking Side Gear End Play
G92H12606Courtesy of CHRYSLER CORP.
RENDER: 1.0x

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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.