Rear Driveline Module: Disassembly

WARNING: This page is about a different car, the 2004 Chrysler Pacifica. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Differential is only to be serviced as an assembly, and no disassembly is required.

Loosen input flange nut and washer using Tool 6958 and a breaker bar (Fig 1 ).

Fig 1: Loosening Input Flange Nut And Washer
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Remove input flange nut (Fig 2 ).

Fig 2: Removing Input Flange Nut
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Remove input flange and washer (Fig 3 ) (Fig 4 ).

Fig 3: Removing Input Flange And Washer
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Fig 4: Removing Input Flange
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Remove input flange seal from overrunning clutch housing using suitable screwdriver (Fig 5 ).

Fig 5: Removing Input Flange Seal From Overrunning Clutch Housing
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Remove four overrunning clutch housing-to-differential assembly bolts and remove housing (Fig 6 ) (Fig 7 ).

Fig 6: Removing Overrunning Clutch Housing Bolts
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Fig 7: Removing Overrunning Clutch Housing
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Remove front bearing snap ring (Fig 14 ).
Remove front bearing (Fig 14 ).
Remove o-ring and washer from overrunning clutch assembly (Fig 8 ) (Fig 9 ).

Fig 8: Removing Input Flange O-Ring Seal
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Fig 9: Removing Input Flange Washer
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Remove overrunning clutch assembly from viscous coupler (Fig 10 ).

Fig 10: Removing Overrunning Clutch Assembly From Viscous Coupler
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Remove viscous coupler from differential pinion shaft (Fig 11 ).

Fig 11: Removing Viscous Coupler From Differential Pinion Shaft
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Remove shim (select) from differential pinion gear (Fig 12 ). Verify shim thickness when removed and be sure to use shim of same thickness.

Fig 12: Removing Shim (Select) From Differential Pinion Gear
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Remove overrunning clutch housing large o-ring from differential assembly (Fig 14 ).
Remove output flange seals (Fig 13 ).

Fig 13: Removing Axle Seal
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Fig 14: Identifying Drive Line Module Components
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