Still trying to resolve this issue and not having any luck. Anyone else have any input.

 

I'm sorry. I got a bit side track. Here is the list of the tools.
DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER
Diff. Bear. On Retainer Side 5048, 5048-4 Collets, L-4539-2 Button 5052, C-4171
Diff. Bear. On Ext. Hous. Side 5048, 5048-3 Collets, L-4539-2 Button L-4410, C-4171
Diff. Race. On Retainer Side 6062-A 6061, C-4171
Diff. Race. On Ext. Hous. Side L-4518 L-4520, C-4171
Extension Housing Seal 7794-A, C-637 Slide Hammer L-4520, C-4171
Bearing Retainer Seal 794-A, C-637 Slide Hammer L-4520, C-4171

CHECKING SIDE GEAR END PLAY
Check side gear end play whenever the differential is removed for service

Checking Side Gear End Play (Extension Housing Side)

NOTE: Side gear end play must be BETWEEN 0.001 to 0.013 inch

Checking Side Gear End Play (Bearing Retainer Side)

ASSEMBLY
NOTE: Use MoparŽ Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case.

Using Miller Special Tool L-4410, and C-4171, install differential bearing to differential (extension housing side) Position Bearing Cone Onto Differential
Using Miller Special Tool 5052 and C-4171, install differential bearing to differential (bearing retainer side)
Using Miller Special Tool 6061 and C-4171, install differential bearing race to bearing retainer Differential Bearing Retainer
Using Miller Special Tool L - 4520 and C-4171, install differential bearing to extension housing.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
NOTE: Perform all differential bearing preload measurements with the transfer shaft and gear removed.

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING EXISTING SHIM
Position the transaxle assembly vertically on the support stand, differential bearing retainer side up.
Install Tool L-4436A into the differential and onto the pinion mate shaft Tool L-4436 and Torque Wrench
Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated.
Using Tool L-4436A and an inch-pound torque wrench, check the turning torque of the differential Checking Differential Bearings Turning Torque The turning torque should be between 5 and 18 inch-pounds.
If the turning torque is within specifications, remove tools. Setup is complete.
If turning torque is not within specifications proceed with the following steps.
Remove differential bearing retainer from the transaxle case.
Remove the bearing cup from the differential bearing retainer using Tool 6062A.
Remove the existing shim from under the cup.
Measure the existing shim.
If the turning torque was too high when measured, install a.05 mm (.002 inch) thinner shim. If the turning torque is was too low, install a.05 mm (.002 inch) thicker shim. Repeat until 5 to 18 inch-pounds turning torque is obtained. Oil Baffle is not required to be installed when making shim selection.
Install the proper shim under the bearing cup. Make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and cup.
Install the differential bearing retainer using Tool 5052 and C-4171. Seal the retainer to the housing with MOPARŽ Adhesive Sealant and torque bolts to 28 Nˇm (250 in. lbs.)
Using Tool L-4436A and an inch-pound torque wrench, recheck the turning torque of the differential Checking Differential Bearings Turning Torque The turning torque should be between 5 and 18 inch-pounds.
Shim thickness need be determined only if any of the following parts are replaced:

Transaxle case
Differential carrier
Differential bearing retainer
Extension housing
Differential bearing cups and cones

 

I think I may have the same problem on my 98 GCaravan. I just replaced the tranny with a recently remaned unit out of a wrecked 98 T&C. Everything is running fine and then I notice a grinding noise when it is in gear. I pulled the front tires and calipers to make sure the noise was not from there. So when I put it in gear I can hear a grinding noise from the rear of the tranny where the axles go in, and it only grinds as long as axels are spinning. In park and nuetral no grinding as long as axel does'nt spin. So it sounds like maybe the same problem, what do you all think?

 

differential roll pin failed, diff pin is rubbing case, cover. you need to remove diff cover to determine if I am right or full if it. (about 2hr job w.o hoist 35-40 min with hoist)

 

what is the process to replace the differential roll pin?

 

remove transmission, remove differential, check for damage, replace any damaged/worn parts.

 

Well dang thats not what I wanted to hear, I just put this tranny in. That really sucks, but what do ya do.

 

Does anyone have any pics. or links w/pics so I can see the roll pin. I think I located it on my old tranny. I pulled the diff cover and see 4 spider gears with a pin about 1/2 inch in diameter in the center, is this it? How easy is it to replace said roll pin? Any special tools needed?

 

you drive out the roll pin holding in the diff pin. I think 3/16" pin punch will do the trick. not something you can easily do in the car and if the roll pin is damaged, you'll find the spider gears, diff pin and differential housing damaged too.

Really not something you want to try and short cut. however before even condeming this as being the problem you really need to verify that is the problem. Obviously I cannot hear, see, feel what you are so it's best guess on my behalf based on my knowledge, skills and abilities.

 

So to verify if this is the problem I need to pull diff cover and inspect pin and gears? Will I need to pull tranny to get diff cover off?