DIFFERENTIAL OVERHAUL PROCEDURE
Automotif Engine What follows is a little overhaul procedure I did months ago of a Chrysler 8.25" differential to show the steps common in any differential overhau
Patien :
1998 Jeep Cherokee 4.0L I6 with a 8.25" Chrysler open
style differential
Symptom/Complaint:
This unit had a little incident where the pinion nut became loose while driving in the highway, loosing it and causing the driveshaft to drop. The unit was towed to the shop and a new pinion nut was installed. The internals were not checked and a test drive showed the differential did suffer from a bat mesh pattern due to the whine sound from it.
The Cherokee was used for a week by the customer and brought back for a full differential overhaul after the real damage was assessed. This is what I found.
As you can see, the pinion did a number on the carrier unit even though no major damage to the pinion or ring themselves was noted. I then proceeded to check the existing mesh pattern to see where it was for reference and here is the result:
Definitely not the optimum or the typical after a little over 190k miles.
Unit Removal:
So..... removing the unit internals begin:
As you can see, this unit is different from the 8.8 Ford unit because the carrier uses adjustable rings on each side instead of shims to adjust backlash.
Carrier Damage Assesment:
The following pictures shows the damage the pinion inflicted to the carrier
housing. To my surprise, the pinion did not show any signs of damage, nicks or
cracks.
Carrier Housing Damage Repair/Fix:
Since a thorough inspection did not show any major problems, it was decided to deburr the indentation marks to prevent any metal filings/material to fall into the mesh or bearings and reuse it.
Parts Ordered:
Initially I made the mistake of identifying the differential as a Dana 35 unit w/out looking at a specific clause regarding Jeep Cherokee rear differentials and the following kits were ordered w/out having the vehicle at the shop:
Tools and Equipment Used:
Aside the classic wrenches, sockets, torque wrenches (in Ft-lbs and In-lbs), the Pinion Depth Setting Gage. I have the Central Tools 6470 unit.
Definitely not the optimum or the typical after a little over 190k miles.
Unit Removal:
So..... removing the unit internals begin:
As you can see, this unit is different from the 8.8 Ford unit because the carrier uses adjustable rings on each side instead of shims to adjust backlash.
Carrier Damage Assesment:
The following pictures shows the damage the pinion inflicted to the carrier housing. To my surprise, the pinion did not show any signs of damage, nicks or cracks.
The following pictures shows the damage the pinion inflicted to the carrier housing. To my surprise, the pinion did not show any signs of damage, nicks or cracks.
Carrier Housing Damage Repair/Fix:
Since a thorough inspection did not show any major problems, it was decided to deburr the indentation marks to prevent any metal filings/material to fall into the mesh or bearings and reuse it.
Parts Ordered:
Initially I made the mistake of identifying the differential as a Dana 35 unit w/out looking at a specific clause regarding Jeep Cherokee rear differentials and the following kits were ordered w/out having the vehicle at the shop:
Tools and Equipment Used:
Aside the classic wrenches, sockets, torque wrenches (in Ft-lbs and In-lbs), the Pinion Depth Setting Gage. I have the Central Tools 6470 unit.
Aside the classic wrenches, sockets, torque wrenches (in Ft-lbs and In-lbs), the Pinion Depth Setting Gage. I have the Central Tools 6470 unit.
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