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HOMESERVICE MANUALSDODGE AND RAM2000INTREPID R/TREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSOVERHAUL - 42LE AUTOMATIC TRANSMISSIONTRANSAXLE REASSEMBLYDIFFERENTIAL ASSEMBLY & TRANSFER SHAFTDIFFERENTIAL ASSEMBLY WITH NEW BEARINGS & COMPONENTS
2000 Dodge and Ram Intrepid R/T

Differential Assembly With NEW Bearings & Components

2000 Dodge and Ram Intrepid R/TSECTION Differential Assembly With NEW Bearings & Components
  1. Apply sealant on back of differential vent baffle plate as indicated. See Figure .
  2. Install differential vent baffle plate on transaxle case. See Figure . Install and tighten differential vent baffle plate bolts to specification. See TORQUE SPECIFICATIONS  .
    CAUTION: Inner and outer bearing adjusters must be replaced if differential bearings are replaced.
  3. Install NEW "O" ring on inner bearing adjuster. Lubricate threads on inner bearing adjuster and lip of oil seal with gear oil.
  4. Using Socket (6502-B), screw inner bearing adjuster into transaxle case until surface of inner bearing adjuster is flush with surface of differential side of transaxle case. Inner bearing adjuster must be at same position as when differential bearing rotating torque was checked.
  5. Install differential assembly in transaxle case. Ensure ring gear backlash is present between ring gear and transfer shaft. Apply sealant on differential cover-to-transaxle case contact areas. Install differential cover. Install and tighten differential cover bolts to specification. See TORQUE SPECIFICATIONS  .
  6. Install Seal Protector (6591) on short stub shaft. Lubricate seal protector with gear oil. Install NEW "O" ring on outer bearing adjuster. Lubricate threads on outer bearing adjuster and lip of oil seal with gear oil.
  7. Using Socket (6503), screw outer bearing adjuster into differential cover. Using torque wrench and socket, tighten outer bearing adjuster until same torque reading obtained in step  7 of DIFFERENTIAL BEARING ROTATING TORQUE under COMPONENT DISASSEMBLY & REASSEMBLY is obtained.
  8. Rotate differential assembly back and forth several times to ensure bearings are seated. Retighten outer bearing adjuster until proper torque reading is obtained. Repeat this procedure until correct torque reading is maintained on outer bearing adjuster.
    9. NOTE: When checking ring gear backlash it will be necessary to use torque reading obtained in step  7 of DIFFERENTIAL BEARING ROTATING TORQUE under COMPONENT DISASSEMBLY & REASSEMBLY using NEW bearings and races.
  9. Remove inspection plug from inspection hole on top of transaxle case. Install dial indicator with stem of dial indicator against one tooth on ring gear. See Figure .
  10. Hold transfer shaft. Rotate differential assembly back and forth. Note ring gear backlash on dial indicator. Ring gear backlash should be .006-.009" (.15-.23 mm).
  11. If excessive ring gear backlash is present, using Socket (6503), loosen outer bearing adjuster. Using Socket (6502-B), slightly rotate inner bearing adjuster so it moves away from ring gear.
  12. Using torque wrench and socket, tighten outer bearing adjuster until same torque reading obtained in step  7 of DIFFERENTIAL BEARING ROTATING TORQUE under COMPONENT DISASSEMBLY & REASSEMBLY is obtained. Recheck ring gear backlash.
  13. If ring gear backlash is less than specified, using Socket (6503), slightly loosen outer bearing adjuster. Slightly rotate inner bearing adjuster so it moves toward ring gear.
  14. Using torque wrench and socket, tighten outer bearing adjuster until same torque reading obtained in step  7 of DIFFERENTIAL BEARING ROTATING TORQUE under COMPONENT DISASSEMBLY & REASSEMBLY is obtained. Recheck ring gear backlash.
  15. Once correct ring gear backlash is obtained, check ring gear backlash at 4 different areas on ring gear at 90 degrees apart. Ring gear backlash should be consistent and within specification.
  16. Install bearing adjuster lock bracket on inner bearing adjuster. Install and tighten bearing adjuster lock bracket bolt to specification. See TORQUE SPECIFICATIONS  .
  17. Install lock bracket on outer bearing adjuster. Install and tighten lock bracket bolt to specification. Use wooden block to tap NEW inspection plug into inspection hole on top of transaxle case.
NOTE: When installing differential assembly with all original components, inner and outer bearing adjusters must initially be placed at original location as during disassembly to maintain proper bearing preload.
RENDER: 1.0x

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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.