We've all likely swapped rear...
We've all likely swapped rear ends without thinking much about what it takes to build a differential that can handle the abuse of a powerful Mopar engine. This month we'll discuss a critical part of your car's drivetrain, the rear differential, and show you how to build and install your 8 3/4 rear end the right way.
As automotive enthusiasts, we often talk about the different methods of making engine power, as much of our interest lies under the hood of our Mopars. The pros and cons of automatic versus manual transmissions are also a subject of our conversations, as are the various ways to get our cars to run quicker elapsed times, or make more power on the dyno. When it comes to the rear differential in our Mopars, however, most of us are aware that gear ratio selection is an important factor determining how a car will perform, but aside from that we have very little understanding of how the differential actually works.
Installing the components...
Installing the components necessary to build a rear differential requires special tools and expertise. We've done it before, but this time decided to rely on Randy's Ring and Pinion to build a stout 8 3/4 centersection using all new parts. (Somewhere a high school is missing a cafeteria tray.)
Since most of our Mopars came with the Chrysler 8 3/4 rear end, we seldom have any major problems with this area of the car. In fact, even a factory 8 3/4 can handle substantial engine power without fatigue, and we've seen high-mileage rear ends handle modified big-blocks without much trouble. So, barring a catastrophic failure of the rear end, we generally just tend to forget about how many parts are in the rear differential and the various ways they can wear out, negatively affecting the performance of our vehicles. Worn ring and pinion gears will whine, and more serious problems will cause vibrations, excess drag, and even rear end lockup.
Our Road Runner is basically...
Our Road Runner is basically a street car that will see occasional track time on the weekends. With a four-speed and warmed over 383, we chose an Auburn Sure Grip and 3.55 ratio gears for our 8 3/4.
Swapping the rear end for another used one is an option, and most of us have swapped the centersection of our 8 3/4 to gain more optimal gearing as well. But as even the most recently produced factory 8 3/4 rear ends are 30 or more years old, the centersection you find to install in your car may be just as worn as the one you removed. Thankfully, most 8 3/4 differentials can be rebuilt, and many new parts are available. Since we needed a solid rear for our '71 Road Runner, we contacted Randy's Ring and Pinion to check out our options for the 8 3/4 in our car.
Randy's Ring and Pinion stocks...
Randy's Ring and Pinion stocks all the parts necessary to build an 8 3/4 centersection, and even has new aluminum housings for extreme applications. We chose a factory 742 case that they have thoroughly inspected and cleaned for our street car.
Like most Mopar enthusiasts, we like to perform much of the work on our cars ourselves. One area that we tend to leave to the experts, however, is the rear differential, and specifically the Sure Grip unit and ring and pinion gears of the car. It's not that the differential is beyond our technical expertise so much as this type of work requires specialty tools and must be done correctly so that the rear end has minimal drag and the appropriate amount of gear noise for the application. For these reasons, we decided to let the pros at Randy's Ring and Pinion build our 8 3/4 centersection, and we followed along to show you how it's done the right way.
After cleaning all the new...
After cleaning all the new parts, a first step prior to assembly is to make sure the back of the ring gear is flat and free of machining burrs that can happen when the bolt holes are drilled and tapped.
When choosing a rear differential, the first determination that must be made is the intention of the car. For all-out drag cars with slicks that don't see street duty, a spool (solid) rear axle makes the most sense. The spool is lighter and locks the rear axles together, ensuring both tires spin at equal rpm at all times. At the other end of the spectrum, if you're just replacing the rear in your '74 Dart four-door with a Slant-Six, an inexpensive open style unit will work just fine. For the majority of us, however, a limited-slip type differential is the best choice for our street cars, or even cars that see a blend of street and strip duty. Chrysler called their limited-slip differentials Sure Grip and they were used extensively in muscle cars, trucks, and even station wagons.

Ring gear bolts are fine thread,...

Ring gear bolts are fine thread, and thread locker is used to ensure they stay put. The bolts can be run down with an air tool, then torqued to spec with a torque wrench.

Having all the proper tools...

Having all the proper tools makes any job easier, especially when it comes to precision pieces like the rear differential.

Randy's Ring and Pinion has...

Randy's Ring and Pinion has all the tools to do the job properly, ensuring our new parts weren't damaged during assembly.

The 742 and 489 case centersection...

The 742 and 489 case centersection housings have a larger pinion bearing than the 741 case, making either a good choice for a performance build. We chose a 742 case for our Road Runner. The main difference between the 742 and the 489 case is the pinion bearing size is larger in the 489, and the 489 also uses a crush-sleeve to set preload.

With the pinion bearing pressed...

With the pinion bearing pressed in place, the pinion gear can be placed in the housing and the seal is installed.

Using a little sealer around...

Using a little sealer around the outside of the seal will prevent any gear lube from leaking past the seal through imperfections in the case.