REAR AXLE - 194RBI - Jeep VIN decoder · REAR AXLE - 194RBI TABLE OF CONTENTS page page ... rear...

REAR AXLE - 194RBI

TABLE OF CONTENTS

page page

REAR AXLE - 194RBIDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 76OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 76DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 76REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79ADJUSTMENTS

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 80SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 87SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 87

AXLE SHAFTSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91

AXLE SHAFT SEALSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91

AXLE BEARINGSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92

PINION SEALREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92

COLLAPSIBLE SPACERREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94

DIFFERENTIALDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 95OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 95REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 98ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 98

DIFFERENTIAL - TRAC-LOKDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 99OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 99DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 99DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 100ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

DIFFERENTIAL CASE BEARINGSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 104

PINION GEAR/RING GEARREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106

REAR AXLE - 194RBI

DESCRIPTIONThe Rear Beam-design Iron (RBI) axle housing has

an iron center casting (differential housing) with axleshaft tubes extending from either side. The tubes arepressed into and welded to the differential housing toform a one-piece axle housing. The housing has thecenterline of the pinion set below the centerline ofthe ring gear. The axles are semi-floating axle shafts,meaning that loads are supported by the axle shaftand bearings. The axle shafts are retained by C-clipsin the differential side gears.

OPERATIONThe axle receives power from the transmission/

transfer case through the rear propeller shaft. Therear propeller shaft is connected to the pinion gearwhich rotates the differential through the gear meshwith the ring gear bolted to the differential case. Theengine power is transmitted to the axle shaftsthrough the pinion mate and side gears. The sidegears are splined to the axle shafts.

DIAGNOSIS AND TESTING

GEAR NOISEAxle gear noise can be caused by insufficient lubri-

cant, incorrect backlash, incorrect pinion depth, toothcontact, worn/damaged gears, or the carrier housingnot having the proper offset and squareness.

Gear noise usually happens at a specific speedrange. The noise can also occur during a specific typeof driving condition. These conditions are accelera-tion, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid bydriving the vehicle at least 5 miles and then acceler-ate the vehicle to the speed range where the noise isthe greatest. Shift out-of-gear and coast through thepeak-noise range. If the noise stops or changesgreatly:

• Check for insufficient lubricant.• Incorrect ring gear backlash.• Gear damage.Differential side gears and pinions can be checked

by turning the vehicle. They usually do not causenoise during straight-ahead driving when the gearsare unloaded. The side gears are loaded during vehi-

3 - 76 REAR AXLE - 194RBI TJ

cle turns. A worn pinion shaft can also cause a snap-ping or a knocking noise.

BEARING NOISEThe axle shaft, differential and pinion bearings can

all produce noise when worn or damaged. Bearingnoise can be either a whining, or a growling sound.

Pinion bearings have a constant-pitch noise. Thisnoise changes only with vehicle speed. Pinion bearingnoise will be higher pitched because it rotates at afaster rate. Drive the vehicle and load the differen-tial. If bearing noise occurs, the rear pinion bearingis the source of the noise. If the bearing noise isheard during a coast, the front pinion bearing is thesource.

Worn or damaged differential bearings usually pro-duce a low pitch noise. Differential bearing noise issimilar to pinion bearing noise. The pitch of differen-tial bearing noise is also constant and varies onlywith vehicle speed.

Axle shaft bearings produce noise and vibrationwhen worn or damaged. The noise generally changeswhen the bearings are loaded. Road test the vehicle.Turn the vehicle sharply to the left and to the right.This will load the bearings and change the noiselevel. Where axle bearing damage is slight, the noiseis usually not noticeable at speeds above 30 mph.

LOW SPEED KNOCKLow speed knock is generally caused by a worn

U-joint or by worn side–gear thrust washers. A wornpinion shaft bore will also cause low speed knock.

VIBRATIONVibration at the rear of the vehicle is usually

caused by a:• Damaged drive shaft.

• Missing drive shaft balance weight(s).• Worn or out-of-balance wheels.• Loose wheel lug nuts.• Worn U-joint(s).• Loose/broken springs.• Damaged axle shaft bearing(s).• Loose pinion gear nut.• Excessive pinion yoke run out.• Bent axle shaft(s).Check for loose or damaged front-end components

or engine/transmission mounts. These componentscan contribute to what appears to be a rearend vibra-tion. Do not overlook engine accessories, bracketsand drive belts.

NOTE: All driveline components should be exam-ined before starting any repair.

DRIVELINE SNAPA snap or clunk noise when the vehicle is shifted

into gear (or the clutch engaged), can be caused by:• High engine idle speed.• Transmission shift operation.• Loose engine/transmission/transfer case mounts.• Worn U-joints.• Loose spring mounts.• Loose pinion gear nut and yoke.• Excessive ring gear backlash.• Excessive side gear to case clearance.The source of a snap or a clunk noise can be deter-

mined with the assistance of a helper. Raise the vehi-cle on a hoist with the wheels free to rotate. Instructthe helper to shift the transmission into gear. Listenfor the noise, a mechanics stethoscope is helpful inisolating the source of a noise.

DIAGNOSTIC CHART

Condition Possible Causes Correction

Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing. 2. Replace bearing.

Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.Correct as necessary.

2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.

TJ REAR AXLE - 194RBI 3 - 77

REAR AXLE - 194RBI (Continued)


Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft aftercorrecting tube mis-alignment.

2 Vehicle overloaded. 2. Replace broken shaft and avoidexcessive weight on vehicle.

3. Erratic clutch operation. 3. Replace broken shaft and avoidor correct erratic clutch operation.

4. Grabbing clutch. 4. Replace broken shaft and inspectand repair clutch as necessary.

Differential Cracked 1. Improper adjustment of thedifferential bearings.

1. Replace case and inspect gearsand bearings for further damage.Set differential bearing pre-loadproperly.

2. Excessive ring gear backlash. 2. Replace case and inspect gearsand bearings for further damage.Set ring gear backlash properly.

3. Vehicle overloaded. 3. Replace case and inspect gearsand bearings for further damage.Avoid excessive vehicle weight.

4. Erratic clutch operation. 4. Replace case and inspect gearsand bearings for further damage.Avoid erratic use of clutch.

Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Filldifferential with the correct fluid typeand quantity.

2. Improper grade of lubricant. 2. Replace scored gears. Filldifferential with the correct fluid typeand quantity.

3. Excessive spinning of onewheel/tire.

3. Replace scored gears. Inspect allgears, pinion bores, and shaft fordamage. Service as necessary.

Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correctlevel.

2. Worn axle shaft seals. 2. Replace seals.

3. Cracked differential housing. 3. Repair as necessary.

4. Worn pinion seal. 4. Replace seal.

5. Worn/scored yoke. 5. Replace yoke and seal.

6. Axle cover not properly sealed. 6. Remove, clean, and re-sealcover.

Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.

2. Improper grade of lubricant. 2. Fill differential with the correctfluid type and quantity.

3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.

4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.




Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine othergears and bearings for possibledamage.

2. Erratic clutch operation. 2. Replace gears and examine theremaining parts for damage. Avoiderratic clutch operation.

3. Ice-spotted pavement. 3. Replace gears and examineremaining parts for damage.

4. Improper adjustments. 4. Replace gears and examineremaining parts for damage. Ensurering gear backlash is correct.

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correctfluid type and quantity.

2. Improper ring gear and pinionadjustment.

2. Check ring gear and pinioncontact pattern. Adjust backlash orpinion depth.

3. Unmatched ring gear and pinion. 3. Replace gears with a matchedring gear and pinion.

4. Worn teeth on ring gear and/orpinion.

4. Replace ring gear and pinion.

5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.

6. Loose differential bearings. 6. Adjust differential bearingpre-load.

7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.Replace components as necessary.

8. Loose differential bearing capbolts.

8. Inspect differential componentsand replace as necessary. Ensurethat the bearing caps are torquedtot he proper specification.

9. Housing not machined properly. 9. Replace housing.

REMOVAL(1) Raise and support the vehicle.(2) Position a suitable lifting device under the

axle.(3) Secure axle to device.(4) Remove the wheels and tires.(5) Remove the brake drums from the axle. Refer

to Group 5, Brakes, for proper procedures.(6) Disconnect parking brake cables from brackets

and lever.(7) Remove wheel speed sensors, if necessary.

Refer to Group 5, Brakes, for proper procedures.(8) Disconnect the brake hose at the axle junction

block. Do not disconnect the brake hydraulic lines atthe wheel cylinders. Refer to Group 5, Brakes, forproper procedures.

(9) Disconnect the vent hose from the axle shafttube.

(10) Mark the propeller shaft and yokes for instal-lation alignment reference.

(11) Remove propeller shaft.(12) Disconnect stabilizer bar links.(13) Disconnect shock absorbers from axle.(14) Dis connect upper and lower control arms

from the axle brackets.(15) Separate the axle from the vehicle.

INSTALLATION

NOTE: The weight of the vehicle must be supportedby the springs before suspension arms and trackbar fasteners can be tightened. If the springs arenot at their normal ride position, vehicle ride heightand handling could be affected.



(1) Raise the axle with lifting device and align thespring centering bolts with the mating holes in theaxle spring perch.

(2) Install the upper and lower control arms in theaxle brackets. Install the mounting bolts but do nottighten at this time.

(3) Install shock absorbers and tighten nuts totorque specification.

(4) Install stabilizer bar links and tighten nuts totorque specification.

(5) Install the wheel speed sensors, if necessary.Refer to Group 5, Brakes, for proper procedures.

(6) Connect parking brake cable to brackets andlever.

(7) Install the brake drums. Refer to Group 5,Brakes, for proper procedures.

(8) Connect the brake hose to the axle junctionblock. Refer to Group 5, Brakes, for proper proce-dures.

(9) Install axle vent hose.(10) Align propeller shaft and pinion yoke refer-

ence marks. Install U-joint straps and bolts. Tightento 19 N·m (14 ft. lbs.).

(11) Install the wheels and tires.(12) Add gear lubricant, if necessary. Refer to

Lubricant Specifications in this section for lubricantrequirements.

(13) Remove lifting device from axle and lower thevehicle.

(14) Tighten upper and lower control arms nuts totorque specification.

ADJUSTMENTS

ADJUSTMENT

RING AND PINION GEARRing and pinion gears are supplied as matched

sets only. The identifying numbers for the ring andpinion gear are etched into the face of each gear (Fig.1). A plus (+) number, minus (–) number or zero (0) isetched into the face of the pinion gear. This numberis the amount (in thousandths of an inch) the depthvaries from the standard depth setting of a pinionetched with a (0). The standard depth provides thebest teeth contact pattern. Refer to Backlash andContact Pattern Analysis Paragraph in this sectionfor additional information.

Compensation for pinion depth variance isachieved with select shims. The shims are placedunder the inner pinion bearing cone (Fig. 2).

If a new gear set is being installed, note the depthvariance etched into both the original and replace-ment pinion gear. Add or subtract the thickness ofthe original depth shims to compensate for the differ-

ence in the depth variances. Refer to the Depth Vari-ance charts.

Note where Old and New Pinion Marking columnsintersect. Intersecting figure represents plus orminus amount needed.

Note the etched number on the face of the drivepinion gear (–1, –2, 0, +1, +2, etc.). The numbers rep-resent thousands of an inch deviation from the stan-dard. If the number is negative, add that value to therequired thickness of the depth shim(s). If the num-ber is positive, subtract that value from the thicknessof the depth shim(s). If the number is 0 no change isnecessary. Refer to the Pinion Gear Depth VarianceChart.

Fig. 1 PINION GEAR ID NUMBERS1 - PRODUCTION NUMBERS2 - DRIVE PINION GEAR DEPTH VARIANCE3 - GEAR MATCHING NUMBER

Fig. 2 ADJUSTMENT SHIM LOCATIONS1 - PINION GEAR DEPTH SHIM2 - DIFFERENTIAL SHIM-PINION GEAR SIDE3 - RING GEAR4 - DIFFERENTIAL SHIM-RING GEAR SIDE5 - COLLAPSIBLE SPACER



PINION GEAR DEPTH VARIANCE

Original PinionGear Depth

Variance

Replacement Pinion Gear Depth Variance

24 23 22 21 0 +1 +2 +3 +4

+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0

+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002 20.003

0 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002 20.003 20.004

21 +0.003 +0.002 +0.001 0 20.001 20.002 20.003 20.004 20.005

22 +0.002 +0.001 0 20.001 20.002 20.003 20.004 20.005 20.006

23 +0.001 0 20.001 20.002 20.003 20.004 20.005 20.006 20.007

24 0 20.001 20.002 20.003 20.004 20.005 20.006 20.007 20.008

PINION DEPTH MEASUREMENTMeasurements are taken with pinion cups and pin-

ion bearings installed in the housing. Take measure-ments with a Pinion Gauge Set, Pinion Block 6735,Arbor Discs 6732 and Dial Indicator C-3339 (Fig. 3).

(1) Assemble Pinion Height Block 6739, PinionBlock 6735 and rear pinion bearing onto Screw 6741(Fig. 3).

(2) Insert assembled height gauge components,rear bearing and screw into the housing through pin-ion bearing cups (Fig. 4).

(3) Install front pinion bearing and Cone 6740hand tight.

(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-tion in the housing side bearing cradles (Fig. 5).Install differential bearing caps on Arbor Discs andtighten cap bolts. Refer to the Torque Specificationsin this section.

Fig. 3 PINION GEAR DEPTH TOOLS1 - DIAL INDICATOR2 - ARBOR3 - PINION HEIGHT BLOCK4 - CONE5 - SCREW6 - PINION BLOCK7 - SCOOTER BLOCK8 - ARBOR DISC

Fig. 4 PINION HEIGHT BLOCK1 - PINION BLOCK2 - PINION HEIGHT BLOCK



NOTE: Arbor Discs 6732 have different step diame-ters to fit other axle sizes. Pick correct size step foraxle being serviced.

(5) Assemble Dial Indicator C-3339 into ScooterBlock D-115-2 and secure set screw.

(6) Position Scooter Block/Dial Indicator flush onthe pinion height block. Hold scooter block and zerothe dial indicator.

(7) Slowly slide the scooter block across the pinionheight block over to the arbor (Fig. 6). Move thescooter block till the dial indicator probe crests thearbor, then record the highest reading.

(8) Select a shim equal to the dial indicator read-ing plus the drive pinion gear depth variance numberetched in the face of the pinion gear (Fig. 1) usingthe opposite sign on the variance number. For exam-ple, if the depth variance is –2, add +0.002 in. to thedial indicator reading.

(9) Remove the pinion depth gauge componentsfrom the housing

DIFFERENTIAL BEARING PRELOADDifferential side bearing preload and gear backlash

is achieved by selective shims inserted between thebearing cup and the housing. The proper shim thick-ness can be determined using slip-fit Dummy Bear-ings D-348 in place of the differential side bearingsand a Dial Indicator C-3339. Before proceeding withthe differential bearing preload and gear backlashmeasurements, measure the pinion gear depth andprepare the pinion gear for installation. Establishingproper pinion gear depth is essential to establishinggear backlash and tooth contact patterns. After theoverall shim thickness to take up differential sideplay is measured, the pinion gear is installed and the

gear backlash shim thickness is measured. The over-all shim thickness is the total of the dial indicatorreading, starting point shim thickness and the pre-load specification added together. The gear backlashmeasurement determines the thickness of the shimused on the ring gear side of the differential case.Subtract the gear backlash shim thickness from thetotal overall shim thickness and select that amountfor the pinion gear side of the differential (Fig. 7).

PRELOAD SHIM SELECTION

NOTE: It is difficult to salvage the differential sidebearings during the removal procedure. Installreplacement bearings if necessary.

Fig. 5 GAUGE TOOLS IN HOUSING1 - ARBOR DISC2 - PINION BLOCK3 - ARBOR4 - PINION HEIGHT BLOCK

Fig. 6 PINION GEAR DEPTH MEASUREMENT1 - ARBOR2 - SCOOTER BLOCK3 - DIAL INDICATOR

Fig. 7 SHIM LOCATIONS1 - PINION GEAR DEPTH SHIM2 - DIFFERENTIAL SHIM-PINION GEAR SIDE3 - RING GEAR4 - DIFFERENTIAL SHIM-RING GEAR SIDE5 - COLLAPSIBLE SPACER



(1) Remove side bearings from differential case.(2) Install ring gear, if necessary, on differential

case and tighten bolts to specification.(3) Install Dummy Bearings D-348 on differential

case.(4) Install differential case in the housing.(5) Insert Dummy Shims 8107 ( 3.0 mm / 0.118 in.)

starting point shims between the dummy bearingand the housing (Fig. 8).

(6) Install bearing caps in their correct positionsand snug the bolts.

(7) Using a dead-blow hammer to seat the differ-ential dummy bearings to each side of the housing(Fig. 9) and (Fig. 10).

(8) Thread Pilot Stud C-3288-B into rear cover bolthole below ring gear (Fig. 11).

(9) Attach Dial Indicator C-3339 to the pilot studand position indicator plunger on a flat surface of thering gear bolt head (Fig. 11).

(10) Push differential case to the pinion gear sideof the housing (Fig. 12) and zero dial indicator.

(11) Push differential case to the ring gear sideand record dial indicator reading (Fig. 13).

(12) Add the dial indicator reading to the startingpoint shim thickness to determine total shim thick-ness to achieve zero differential end play.

(13) Add 0.008 in. (0.2 mm) to the zero end playtotal. This new total represents the thickness ofshims to compress or preload the new bearings whenthe differential is installed.

(14) Rotate dial indicator out of the way.(15) Remove differential case, dummy bearings

and starting point shims from the housing.(16) Install pinion gear in the housing. Install the

yoke and establish the correct pinion rotating torque.(17) Install differential case and dummy bearings

in the housing (without shims) and tighten retainingcap bolts.

(18) Position the dial indicator plunger on a flatsurface between the ring gear bolt heads (Fig. 11).

(19) Push and hold differential case toward piniongear.

(20) Zero dial indicator face to pointer.(21) Push and hold differential case to ring gear

side of the housing and record dial indicator reading.

Fig. 8 DUMMY SHIM LOCATION1 - DUMMY SHIM2 - DIFFERENTIAL HOUSING3 - DIFFERENTIAL CASE4 - DUMMY BEARING

Fig. 9 SEAT DUMMY BEARING PINION GEAR SIDE1 - MALLET2 - DIFFERENTIAL HOUSING3 - DIFFERENTIAL CASE

Fig. 10 SEAT DUMMY BEARING RING GEAR SIDE1 - DIFFERENTIAL HOUSING2 - MALLET3 - DIFFERENTIAL CASE



(22) Subtract 0.002 in. (0.05 mm) from the dialindicator reading to compensate for backlash betweenring and pinion gears. This total is the thickness ofshim required to achieve proper backlash.

(23) Subtract the backlash shim thickness fromthe total preload shim thickness. The remainder isthe shim thickness required on the pinion side of thehousing.

(24) Rotate dial indicator out of the way on pilotstud.

(25) Remove differential case and dummy bearingsfrom the housing.

(26) Install new side bearing cones and cups ondifferential case.

(27) Install spreader W-129-B and some compo-nents of Adapter Set 6987 on differential housing andspread axle opening enough to receive differentialcase.

(28) Place side bearing shims into the housingagainst the differential bearing bore.

(29) Install differential case in the housing.(30) Rotate the differential case several times to

seat the side bearings.(31) Position the indicator plunger against a ring

gear tooth (Fig. 14).

Fig. 11 DIFFERENTIAL SIDE PLAY MEASUREMENT1 - DIFFERENTIAL CASE2 - DIFFERENTIAL HOUSING3 - PILOT STUD4 - DIAL INDICATOR

Fig. 12 ZERO DIAL INDICATOR1 - DIFFERENTIAL CASE TO PINION GEAR SIDE2 - PILOT STUD3 - DIAL INDICATOR EXTENSION4 - ZERO DIAL INDICATOR FACE

Fig. 13 RECORD DIAL INDICATOR READING1 - READ DIAL INDICATOR2 - DIFFERENTIAL CASE TO RING GEAR SIDE3 - DIFFERENTIAL HOUSING

Fig. 14 RING GEAR BACKLASH1 - DIAL INDICATOR



(32) Push and hold ring gear upward while notallowing the pinion gear to rotate.

(33) Zero dial indicator face to pointer.(34) Push and hold ring gear downward while not

allowing the pinion gear to rotate. Dial indicatorreading should be between 0.12 mm (0.005 in.) and0.20 mm (0.008 in.). If backlash is not within specifi-cations transfer the necessary amount of shim thick-ness from one side of the differential housing to theother (Fig. 15).

(35) Verify differential case and ring gear runoutby measuring ring to pinion gear backlash at eightlocations around the ring gear. Readings should notvary more than 0.05 mm (0.002 in.). If readings varymore than specified, the ring gear or the differentialcase is defective.

After the proper backlash is achieved, perform theGear Contact Pattern Analysis procedure.

GEAR CONTACT PATTERNThe ring gear and pinion teeth contact patterns

will show if the pinion depth is correct in the hous-ing. It will also show if the ring gear backlash hasbeen adjusted correctly. The backlash can be adjustedwithin specifications to achieve desired tooth contactpatterns.

(1) Apply a thin coat of hydrated ferric oxide orequivalent to the drive and coast side of the ring gearteeth.

(2) Wrap, twist, and hold a shop towel around thepinion yoke to increase the turning resistance of thepinion. This will provide a more distinct contact pat-tern.

(3) With a boxed end wrench on a ring gear bolt,rotate the differential case one complete revolution inboth directions while a load is being applied fromshop towel.

The areas on the ring gear teeth with the greatestdegree of contact against the pinion teeth willsqueeze the compound to the areas with the leastamount of contact. Note and compare patterns on thering gear teeth to Gear Tooth Contact Patterns chart(Fig. 16) and adjust pinion depth and gear backlashas necessary.

Fig. 15 BACKLASH SHIM ADJUSTMENT



Fig. 16 GEAR TOOTH CONTACT PATTERNS



DIFFERENTIAL BEARING PRELOAD CHECKThe final check on the differential assembly before

installing the axles is torque to rotate pinion and dif-ferential combined. This will verify the correct differ-ential bearing preload.

Torque to rotate the differential and pinion shouldbe the torque to rotate the pinion plus 0.79-1.24 N·m(7-11 in. lbs.).

SPECIFICATIONSAXLE SPECIFICATIONS

DESCRIPTION SPECIFICATION

Axle Ratio 3.07, 3.73, 4.11, 4.56

Differential Bearing Preload 0.2 mm (0.008 in.)

Differential Side Gear Clearance 0.0-0.15 mm (0.0-0.006 in.)

Ring Gear Diameter 194 mm (7.6 in.)

Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)

Pinion Bearing Preload - Original Bearings 1-2 N·m (10-20 in. lbs.)

Pinion Bearing Preload - New Bearings 2-4 N·m (20-35 in. lbs.)

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Differential Cover Bolts 41 30 -

Bearing Cap Bolts 77 57 -

Ring Gear Bolts 136 100 -

Pinion Nut Min / Max 271-475 200-350 -

Pinion Mate Shaft Screw 16.25 12 -

SPECIAL TOOLS

PULLER C-293-PA

ADAPTER C-293-39

ADAPTER C-293-40

ADAPTER PLUG SP-3289



PULLER C-452

WRENCH C-3281

WRENCH SPANNER 6958

INSTALLER SCREW 8112

CUP 8109

HANDLE C-4171

INSTALLER D-130

INSTALLER D-146

REMOVER C-4345

REMOVER D-149



INSTALLER W-262

INSTALLER 6436

INSTALLER 6437

Pinion Depth 6774

Trac-lok Tools 6960

Holder Fixture 6965

Puller 7794-A

Shim Dummy 8107

Spreader W-129-B



AXLE SHAFTS

REMOVAL(1) Place transmission is in neutral.(2) Raise and support vehicle.(3) Remove wheel and tire assembly.(4) Remove brake drum.(5) Remove differential housing cover and drain

fluid.

(6) Rotate differential case to access pinion mategear shaft lock screw. Remove lock screw and shaftfrom differential case (Fig. 17).

(7) Push axle shaft inward and remove axle C-cliplock (Fig. 18).

(8) Remove axle shaft.

CAUTION: Use care to prevent shaft splines fromdamaging axle bearing and wheel speed sensor onvehicles if equipped.

(9) Inspect roller bearing contact surface on axleshaft for signs of brinelling, galling and pitting. Ifany of these conditions exist, the axle shaft/bearingmust be replaced.

Adapter Kit 6987

Pilot Studs C-3288-B

Bearing Remover 6310

Hub Puller 6790

Dial Indicator C-3339

Fig. 17 MATE SHAFT LOCK SCREW1 - LOCK SCREW2 - PINION GEAR MATE SHAFT

Fig. 18 AXLE SHAFT C-CLIP1 - C-CLIP LOCK2 - AXLE SHAFT3 - SIDE GEAR



INSTALLATION(1) Lubricate bearing bore and seal lip with gear

lubricant. Insert axle shaft through seal, bearing,and engage it into side gear splines.

CAUTION: Use care to prevent shaft splines fromdamaging axle shaft seal and wheel speed sensoron vehicles if equipped.

(2) Install C-clip lock on the axle shaft, then pushaxle outward to seat C-clip lock in side gear.

(3) Insert pinion mate shaft into differential caseand through thrust washers and pinion gears.

(4) Align hole in shaft with hole in the differentialcase and install lock screw with Loctitet on thethreads. Tighten lock screw to 19 N·m (14 ft. lbs.).

(5) Install cover and add fluid to the bottom of thefill plug hole.

(6) Install brake drum.(7) Install wheel and tire.(8) Lower vehicle.

AXLE SHAFT SEALS

REMOVAL(1) Remove the axle shaft.(2) Remove axle shaft seal from the end of the axle

shaft tube with a small pry bar.(3) Inspect the axle shaft tube bore for roughness

and burrs and remove as necessary.

INSTALLATION(1) Wipe the axle shaft tube bore clean.(2) Install new axle shaft seal with Installer 6437

and Handle C-4171 (Fig. 19).(3) Install the axle shaft.

AXLE BEARINGS

REMOVAL(1) Remove the axle shaft.(2) Remove axle shaft seal from the end of the axle

shaft tube with a small pry bar.(3) Remove axle shaft bearing from the axle tube

with Bearing Removal Tool Set 6310 and AdapterFoot 6310-5 (Fig. 20).

(4) Inspect the axle shaft tube bore for roughnessand burrs and remove as necessary.

Fig. 19 AXLE SHAFT SEAL1 - INSTALLER2 - SEAL3 - AXLE SHAFT TUBE4 - HANDLE

Fig. 20 AXLE SHAFT BEARING TOOLS1 - AXLE SHAFT TUBE2 - NUT3 - GUIDE PLATE4 - GUIDE5 - THREADED ROD6 - ADAPTER7 - FOOT


AXLE SHAFTS (Continued)

INSTALLATION(1) Wipe the axle shaft tube bore clean.(2) Install axle shaft bearing with Installer 6436

and Handle C-4171.

NOTE: Part number on the bearing must be againstthe installer.

(3) Install new axle shaft seal with Installer 6437and Handle C-4171 (Fig. 21).

(4) Install the axle shaft.

PINION SEAL

REMOVAL(1) Raise and support the vehicle.(2) Remove wheel and tire assemblies.(3) Remove the brake drums (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL/DRUM -REMOVAL).

(4) Mark propeller shaft and pinion yoke forinstallation reference.

(5) Remove the propeller shaft from the yoke.(6) Rotate the pinion gear three or four times.(7) Recored torque necessary to rotate the pinion

gear with an inch pound dial-type torque wrench.(8) Hold the yoke with Wrench 6958 and remove

the pinion nut and washer.

(9) Remove pinion yoke with Remover C-452 andWrench C-3281 (Fig. 22).

(10) Remove pinion seal with a pry tool or slidehammer mounted screw.

INSTALLATION(1) Apply a light coating of gear lubricant on the

lip of pinion seal and install seal with an appropriateinstaller (Fig. 23).

Fig. 21 AXLE SHAFT SEAL INSTALLER1 - INSTALLER2 - SEAL3 - AXLE SHAFT TUBE4 - HANDLE

Fig. 22 PINION YOKE REMOVER1 - WRENCH2 - YOKE3 - REMOVER

Fig. 23 PINION SEAL INSTALLER1 - HANDLE2 - INSTALLER


AXLE BEARINGS (Continued)

(2) Install yoke on the pinion gear with Screw8112, Cup 8109 and Spanner Wrench 6958 (Fig. 24).

CAUTION: Do not exceed the minimum tighteningtorque 271 N·m (200 ft. lbs.) when installing the pin-ion yoke at this point. Damage to the collapsiblespacer or bearings may result.

(3) Install yoke washer and new nut on the piniongear and tighten nut until there is zero bearing end-play.

(4) Tighten the nut to 271 N·m (200 ft. lbs.).

CAUTION: Never loosen pinion gear nut to decreasepinion gear bearing rotating torque and neverexceed specified preload torque. If preload torqueor rotating torque is exceeded a new collapsiblespacer must be installed.

(5) Rotate the pinion shaft using an inch poundtorque wrench. Rotating torque should be equal tothe reading recorded during removal plus an addi-tional 0.56 N·m (5 in. lbs.) (Fig. 25).

(6) If the rotating torque is low, use Wrench 6958to hold the pinion yoke (Fig. 26), and tighten the pin-ion shaft nut in 6.8 N·m (5 ft. lbs.) increments untilthe proper rotating torque is achieved.

CAUTION: If the maximum tightening torque 475N·m (350 ft. lbs.) is reached prior to reaching therequired rotating torque, the collapsible spacer mayhave been damaged. Replace the collapsiblespacer.Fig. 24 PINION YOKE INSTALLER

1 - INSTALLER2 - PINION YOKE3 - SPANNER WRENCH

Fig. 25 PINION ROTATING TORQUE1 - TORQUE WRENCH2 - PINION YOKE

Fig. 26 YOKE HOLDER1 - PINION YOKE2 - SPANNER WRENCH3 - PIPE


PINION SEAL (Continued)

(7) Install the propeller shaft with the referencemarks alinged.

(8) Add gear lubricant to the differential housing,if necessary.

(9) Install the brake drums, refer to Group 5Brakes for procedures.

(10) Install wheel and tire assemblies.(11) Lower the vehicle.

COLLAPSIBLE SPACER

REMOVAL(1) Raise and support the vehicle.(2) Remove wheel and tire assemblies.(3) Remove rear brake drums.(4) Mark propeller shaft and pinion yoke for

installation reference.(5) Remove propeller shaft from the yoke.(6) Rotate pinion gear three or four times.(7) Record torque necessary to rotate the pinion

gear with an inch pound dial-type torque wrench.(8) Hold pinion yoke with Spanner Wrench 6958

and remove pinion nut and washer.(9) Remove pinion yoke with Remover C-452 and

Flange Wrench C-3281 (Fig. 27).

(10) Remove pinion shaft seal with a pry tool or aslide hammer mounted screw.

(11) Remove front pinion bearing using a pair ofpick tools to pull the bearing straight off the piniongear shaft.

NOTE: If bearing becomes bound on pinion shaft,lightly tap the pinion shaft with a rawhide/rubberhammer.

(12) Remove the collapsible spacer.

INSTALLATION(1) Install a new collapsible preload spacer on pin-

ion shaft.(2) Install pinion front bearing.(3) Apply a light coating of gear lubricant on the


(4) Install yoke with Screw 8112, Cup 8109 andSpanner Wrench 6958 (Fig. 29).

(5) Install yoke washer and new nut on the piniongear. Tighten the nut to 271 N·m (200 ft. lbs.).

Fig. 27 PINION YOKE REMOVER1 - WRENCH2 - YOKE3 - REMOVER


Fig. 29 PINION YOKE INSTALLER1 - INSTALLER2 - PINION YOKE3 - SPANNER WRENCH


PINION SEAL (Continued)


(6) Using yoke with Spanner Wrench 6958 and atorque wrench set at 475 N·m (350 ft. lbs.), (Fig. 30)slowly tighten the nut in 6.8 N·m (5 ft. lbs.) incre-ments until the rotating torque is achieved. Measurethe rotating torque frequently to avoid over crushingthe collapsible spacer (Fig. 31).

NOTE: If more than 475 N·m (350 ft. lbs.) torque isrequired to crush the collapsible spacer, the spaceris defective and must be replaced.

(7) Check rotating torque with an inch poundtorque wrench (Fig. 31). The rotating torque of thepinion gear should be, the reading recorded duringremoval plus an additional 0.56 N·m (5 in. lbs.).

(8) Install propeller shaft with reference marksaligned.

(9) Install rear brake drums.(10) Add gear lubricant, if necessary.(11) Install wheel and tire assemblies.(12) Remove supports and lower vehicle.

DIFFERENTIAL

DESCRIPTIONThe differential case is a one-piece design. The dif-

ferential pinion mate shaft is retained with a lockscrew. Differential bearing preload and ring gearbacklash is adjusted by the use of selective shims.Pinion bearing preload is set and maintained by theuse of a collapsible spacer. The cover provides ameans for servicing the differential without removingthe axle. The axle has a vent hose to relieve internalpressure caused by lubricant vaporization and inter-nal expansion.

OPERATIONDuring straight-ahead driving, the differential pin-

ion gears do not rotate on the pinion mate shaft. Thisoccurs because input torque applied to the gears isdivided and distributed equally between the two sidegears. As a result, the pinion gears revolve with thepinion mate shaft but do not rotate around it (Fig.32).

Fig. 30 YOKE HOLDER1 - PINION YOKE2 - SPANNER WRENCH3 - PIPE



COLLAPSIBLE SPACER (Continued)

When turning corners, the outside wheel musttravel a greater distance than the inside wheel tocomplete a turn. The difference must be compensatedfor to prevent the tires from scuffing and skiddingthrough turns. To accomplish this, the differentialallows the axle shafts to turn at unequal speeds (Fig.33). In this instance, the input torque applied to thepinion gears is not divided equally. The pinion gearsnow rotate around the pinion mate shaft in oppositedirections. This allows the side gear and axle shaftattached to the outside wheel to rotate at a fasterspeed.

REMOVAL(1) Remove fill hole plug from the differential

housing cover.(2) Remove differential housing cover and drain

fluid.(3) Remove axle shafts.

(4) Note the reference letters stamped on the bear-ing caps and housing machined sealing surface (Fig.34).

(5) Loosen the differential bearing cap bolts.(6) Position Spreader W-129-B with Adapter Kit

6987B on differential locating holes (Fig. 35). Installholddown clamps and tighten the turnbuckle finger-tight.

Fig. 32 STRAIGHT AHEAD DRIVING1 - WHEELS ROTATE AT CASE SPEED2 - PINION GEAR3 - SIDE GEAR4 - PINION GEARS ROTATE WITH CASE

Fig. 33 DIFFERENTIAL ON TURNS1 - PINION GEARS ROTATE ON PINION SHAFT

Fig. 34 BEARING CAP REFERENCE1 - REFERENCE LETTERS2 - REFERENCE LETTERS

Fig. 35 SPREADER LOCATION1 - DIFFERENTIAL HOUSING2 - DOWEL3 - SAFETY HOLD DOWN4 - SPREADER5 - TURNBUCKLE


DIFFERENTIAL (Continued)

(7) Install a Pilot Stud C-3288-B at the left side ofthe differential housing. Attach Dial Indicator C-3339to pilot stud. Load the indicator plunger against theopposite side of the housing (Fig. 36) and zero theindicator.

CAUTION: Never spread the housing over 0.38 mm(0.015 in). If housing is over-spread, it could dis-torted and damaged the housing.

(8) Spread housing enough to remove the differen-tial case from the housing. Measure the distancewith the dial indicator (Fig. 37).

(9) Remove the dial indicator.(10) While holding the differential case in position,

remove the differential bearing cap bolts and caps.(11) Remove differential from the housing and tag

differential bearing cups to indicate location (Fig. 38).(12) Remove spreader from housing.(13) Clean the housing cavity with flushing oil,

light engine oil or lint free cloth.

NOTE: Do not use water, steam, kerosene or gaso-line for cleaning.

Fig. 36 DIAL INDICATOR LOCATION1 - CLAMP2 - DIAL INDICATOR3 - LEVER ADAPTER4 - SPREADER5 - PILOT STUD

Fig. 37 SPREAD DIFFERENTIAL HOUSING1 - DIAL INDICATOR2 - SPREADER

Fig. 38 DIFFERENTIAL CASE REMOVAL1 - DIFFERENTIAL HOUSING2 - DIFFERENTIAL CASE3 - BEARING CUPS



DISASSEMBLY(1) Remove pinion shaft.(2) Rotate differential side gears and remove the

differential pinions and thrust washers (Fig. 39).

(3) Remove the differential side gears and thrustwashers.

ASSEMBLY(1) Lubricate all differential components with

hypoid gear lubricant.(2) Install the differential side gears and thrust

washers.(3) Install the differential pinion gears and thrust

washers.(4) Install the pinion mate shaft.(5) Align the hole in the pinion mate shaft with

the hole in the differential case and install the pinionmate shaft lock screw finger tight.

INSTALLATION

NOTE: If replacement differential bearings or differ-ential case are being installed, differential sidebearing shim requirements may change. ReferAdjustments (Differential Bearing Preload and GearBacklash) to determine the proper shim selection.

(1) Position Spreader W-129-B and adapters fromAdapter set 6987, with the tool dowel pins seated in

the locating holes (Fig. 40). Install holddown clampsand tighten the tool turnbuckle finger-tight.

(2) Install Pilot Stud C-3288-B at the left side ofthe differential housing. Attach Dial Indicator C-3339to pilot stud. Load the indicator plunger against theopposite side of the housing and zero the indicator.

CAUTION: Never spread over 0.38 mm (0.015 in). Ifthe housing is over–spread, it could be distorted ordamaged.

(3) Spread the housing enough to install the casein the housing. Measure the distance with the dialindicator.

(4) Remove the dial indicator.(5) Install differential case in the housing. Ensure

that the differential bearing cups remain in positionon the differential bearings. Tap the differential caseto ensure the bearings cups are seated in the hous-ing.

(6) Install bearing caps in their original locations(Fig. 41).

(7) Loosely install differential bearing cap bolts.(8) Remove axle housing spreader.(9) Tighten the bearing cap bolts to 77 N·m (57 ft.

lbs.).(10) Install the axle shafts.

Fig. 39 DIFFERENTIAL GEARS1 - THRUST WASHER2 - SIDE GEAR3 - DIFFERENTIAL PINION

Fig. 40 SPREADER LOCATION1 - DIFFERENTIAL HOUSING2 - DOWEL3 - SAFETY HOLD DOWN4 - SPREADER5 - TURNBUCKLE



(11) Apply a 6.35mm (1/4 in.) bead of red MoparSilicone Rubber Sealant or equivalent to the housingcover (Fig. 42).

CAUTION: If housing cover is not installed within 3to 5 minutes, the cover must be cleaned and newRTV applied or adhesion quality will be compro-mised.

(12) Install the cover and any identification tag.Tighten the cover bolts in a criss-cross pattern to 41N·m (30 ft. lbs.).

(13) Refill the differential with Mopar HypoidGear Lubricant or equivalent to bottom of the fillplug hole.

(14) Install the fill hole plug.

DIFFERENTIAL - TRAC-LOK

DESCRIPTIONThe Trac-Lokt differential has a one-piece differen-

tial case, and similar internal components as a stan-dard differential, plus two clutch disc packs.Differential bearing preload and ring gear backlashare adjusted with shims located between the differ-ential case bearing cups and housing. Pinion bearingpreload is set and maintained by the use of a collaps-ible spacer.

OPERATIONThis differentials clutches are engaged by two con-

current forces. The first being the preload forceexerted through Belleville spring washers within theclutch packs. The second is the separating forces gen-erated by the side gears as torque is applied throughthe ring gear (Fig. 43).

This design provides the differential action neededfor turning corners and for driving straight aheadduring periods of unequal traction. When one wheellooses traction, the clutch packs transfer additionaltorque to the wheel having the most traction. Thisdifferential resist wheel spin on bumpy roads andprovide more pulling power when one wheel loosestraction. Pulling power is provided continuously untilboth wheels loose traction. If both wheels slip due tounequal traction, Trac-lokt operation is normal. Inextreme cases of differences of traction, the wheelwith the least traction may spin.

DIAGNOSIS AND TESTINGThe most common problem is a chatter noise when

turning corners. Before removing the unit for repair,drain, flush and refill the axle with the specifiedlubricant. A container of Mopar Trac-lokt Lubricant(friction modifier) should be added after repair ser-vice or during a lubricant change.

After changing the lubricant, drive the vehicle andmake 10 to 12 slow, figure-eight turns. This maneu-ver will pump lubricant through the clutches. Thiswill correct the condition in most instances. If thechatter persists, clutch damage could have occurred.

Fig. 41 BEARING CAP REFERENCE1 - REFERENCE LETTERS2 - REFERENCE LETTERS

Fig. 42 DIFFERENTIAL COVER1 - SEALANT SURFACE2 - SEALANT3 - SEALANT THICKNESS



DIFFERENTIAL TESTThe differential can be tested without removing the

differential case by measuring rotating torque. Makesure brakes are not dragging during this measure-ment.

(1) Place blocks in front and rear of both frontwheels.

(2) Raise one rear wheel until it is completely offthe ground.

(3) Engine off, transmission in neutral, and park-ing brake off.

(4) Remove wheel and bolt Special Tool 6790 orequivalent tool to studs.

(5) Use torque wrench on special tool to rotatewheel and read rotating torque (Fig. 44).

(6) If rotating torque is less than 41 N·m (30 ft.lbs.) or more than 271 N·m (200 ft. lbs.) on eitherwheel the unit should be serviced.

DISASSEMBLY(1) Clamp side gear Fixture 6965 in a vise and set

differential case on the fixture (Fig. 45).

(2) Remove ring gear if the ring gear is to bereplaced. The Trac-lokt differential can be servicedwith the ring gear installed.

(3) Remove pinion gear mate shaft lock screw (Fig.46).

(4) Remove pinion gear mate shaft with a drift andhammer.

Fig. 43 TRAC-LOK LIMITED SLIP DIFFERENTIAL1 - CASE2 - RING GEAR3 - DRIVE PINION4 - PINION GEAR5 - MATE SHAFT6 - CLUTCH PACK7 - SIDE GEAR8 - CLUTCH PACK

Fig. 44 ROTATING TORQUE TEST1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE2 - TORQUE WRENCH

Fig. 45 DIFFERENTIAL CASE FIXTURE1 - HOLDING FIXTURE2 - VISE3 - DIFFERENTIAL


DIFFERENTIAL - TRAC-LOK (Continued)

(5) Install and lubricate Step Plate C-6960-3 (Fig.47).

(6) Assemble Threaded Adapter C-6960-1 into topside gear. Thread Forcing Screw C-6960-4 intoadapter until it becomes centered in adapter plate.

(7) Position a small screw driver in slot ofThreaded Adapter Disc C-6960-3 (Fig. 48) to preventadapter from turning.

(8) Install Forcing Screw C-6960-4 and tightenscrew to 122 N·m (90 ft. lbs.) maximum to compressBelleville springs in clutch packs (Fig. 49).

Fig. 46 MATE SHAFT LOCK SCREW1 - LOCK SCREW2 - PINION GEAR MATE SHAFT

Fig. 47 Step Plate1 - LOWER SIDE GEAR2 - DIFFERENTIAL CASE3 - STEP PLATE

Fig. 48 THREAD ADAPTER DISC1 - SOCKET2 - SLOT IN ADAPTER3 - SCREWDRIVER4 - STEP PLATE5 - THREADED ROD6 - ADAPTER DISC

Fig. 49 COMPRESS BELLEVILLE SPRING1 - TORQUE WRENCH2 - FORCING SCREW3 - DIFFERENTIAL CASE



(9) With a feeler gauge remove thrust washersfrom behind the pinion gears (Fig. 50).

(10) Insert Turning Bar C-6960-2 into the pinionmate shaft hole in the case (Fig. 51).

(11) Loosen the Forcing Screw in small incrementsuntil the clutch pack tension is relieved and the dif-ferential case can be turned using Turning Bar.

(12) Rotate differential case until the pinion gearscan be removed.

(13) Remove pinion gears from differential case.

(14) Remove Forcing Screw, Step Plate andThreaded Adapter.

(15) Remove top side gear, clutch pack retainerand clutch pack. Keep plates in order during removal(Fig. 52).

(16) Remove differential case from the HoldingFixture. Remove side gear, clutch pack retainer andclutch pack. Keep plates in order during removal.

ASSEMBLY

NOTE: New Plates and discs with fiber coating (nogrooves or lines) must be presoaked in FrictionModifier before assembly. Soak plates and discs fora minimum of 20 minutes.

(1) Lubricate components with gear lubricant.(2) Assemble clutch discs into packs and secure

disc packs with retaining clips (Fig. 53).

NOTE: Dished plate is position with the convex sideagainst the side gear.

(3) Position assembled clutch disc packs on theside gear hubs.

(4) Install clutch pack and side gear in the ringgear side of the differential case (Fig. 54).Verifyclutch pack retaining clips are in position andseated in the case pockets.

(5) Position the differential case on the HoldingFixture 6965.

Fig. 50 PINION GEAR THRUST WASHER1 - THRUST WASHER2 - FEELER GAUGE

Fig. 51 PINION GEARS1 - PINION GEARS2 - TURNING BAR

Fig. 52 SIDE GEARS AND CLUTCH DISCS1 - DIFFERENTIAL CASE2 - RETAINER3 - SIDE GEAR AND CLUTCH DISC PACK



(6) Install lubricated Step Plate C-6960-3 in lowerside gear (Fig. 55).

(7) Install the upper side gear and clutch disc pack(Fig. 55).

(8) Hold assembly in position. Insert ThreadedAdapter C-6960-1 into top side gear.

(9) Install Forcing Screw C-6960-4 and tightenscrew to slightly compress clutch disc.

(10) Place pinion gears in position in side gearsand verify that the pinion mate shaft hole is aligned.

(11) Rotate case with Turning Bar C-6960-2 untilthe pinion mate shaft holes in pinion gears alignwith holes in case. It may be necessary to slightlytighten the forcing screw in order to install the pin-ion gears.

(12) Tighten forcing screw to 122 N·m (90 ft. lbs.)maximum to compress the Belleville springs.

(13) Lubricate and install thrust washers behindpinion gears and align washers with a small screwdriver. Insert mate shaft into each pinion gear to ver-ify alignment.

(14) Remove Forcing Screw, Step Plate andThreaded Adapter.

(15) Install pinion gear mate shaft and align holesin shaft and case.

(16) Install pinion mate shaft lock screw fingertight to hold shaft during differential installation.

(17) Lubricate all differential components withhypoid gear lubricant.

Fig. 53 CLUTCH PACK1 - DISCS2 - DISHED PLATE3 - RETAINER4 - SIDE GEAR5 - RETAINER6 - PLATES

Fig. 54 CLUTCH PACK AND LOWER SIDE GEAR1 - DIFFERENTIAL CASE2 - SIDE GEAR AND CLUTCH PACK

Fig. 55 CLUTCH PACK AND UPPER SIDE GEAR1 - SIDE GEAR AND CLUTCH PACK2 - DIFFERENTIAL CASE3 - STEP PLATE



DIFFERENTIAL CASEBEARINGS

REMOVAL(1) Remove differential from the housing.(2) Remove bearings from the differential case

with Puller/Press C-293-PA , C-293-39 Blocks andPlug SP-3289 (Fig. 56).

INSTALLATION(1) Install differential side bearings with Installer

C-3716-A with Handle C-4171 (Fig. 57).(2) Install differential in the housing.

PINION GEAR/RING GEAR

REMOVAL

NOTE: The ring and pinion gears are serviced in amatched set. Never replace one gear without replac-ing the other gear.

(1) Remove differential from axle housing.

(2) Place differential case in a vise with soft metaljaw.

(3) Remove ring gear bolts from the differentialcase.

(4) Drive ring gear from the differential case witha dead-blow hammer (Fig. 58).

(5) Hold pinion yoke with Wrench 6958 andremove pinion yoke nut and washer.

Fig. 56 BEARING REMOVAL1 - ADAPTERS2 - BEARING3 - DIFFERENTIAL4 - PLUG5 - PULLER

Fig. 57 DIFFERENTIAL CASE BEARINGS1 - HANDLE C-41712 - DIFFERENTIAL3 - BEARING4 - TOOL C-3716–A

Fig. 58 RING GEAR1 - CASE2 - RING GEAR3 - DEAD-BLOW HAMMER


(6) Remove pinion yoke from pinion shaft withRemover C-452 and Wrench C-3281 (Fig. 59).

(7) Remove the pinion gear from housing with adead-blow hammer (Fig. 60).

(8) Remove pinion shaft seal with a pry tool or aslide hammer mounted screw.

(9) Remove oil slinger, if equipped, and front pin-ion bearing.

(10) Remove front pinion bearing cup withRemover C-4345 and Handle C-4171 (Fig. 61).

(11) Remove rear bearing cup from housing (Fig.62) with Remover D-149 and Handle C-4171.

(12) Remove collapsible preload spacer (Fig. 63).(13) Remove rear bearing from the pinion shaft

with Puller/Press C-293-PA and Adapters C-293-40(Fig. 64).

Fig. 59 PINION YOKE REMOVER1 - WRENCH2 - YOKE3 - PULLER

Fig. 60 REMOVE PINION GEAR1 - DEAD-BLOW HAMMER

Fig. 61 FRONT PINION BEARING CUP1 - REMOVER2 - HANDLE

Fig. 62 REAR PINION BEARING CUP1 - DRIVER2 - HANDLE


PINION GEAR/RING GEAR (Continued)

(14) Remove depth shims from the pinion shaftand record the shims thickness.

INSTALLATION

NOTE: A pinion depth shim/oil slinger is placedbetween the rear pinion bearing cone and the pin-ion head to achieve proper ring gear and pinionmesh. If ring gear and pinion are reused, the piniondepth shim/oil slinger should not require replace-ment. Refer to Adjustment (Pinion Gear Depth) toselect the proper thickness shim/oil slinger if ringand pinion gears are replaced.

(1) Apply Mopar Door Ease or equivalent lubricantto outside surface of bearing cups.

(2) Install pinion rear bearing cup with InstallerD-146 and Driver Handle C-4171 (Fig. 65) and verifycup is seated.

(3) Install pinion front bearing cup with InstallerD-130 and Handle C-4171 (Fig. 66) and verify cup isseated.

(4) Install pinion front bearing and shim.(5) Apply a light coating of gear lubricant on the


Fig. 63 COLLAPSIBLE SPACER1 - COLLAPSIBLE SPACER2 - SHOULDER3 - PINION GEAR4 - SHIM5 - REAR BEARING

Fig. 64 REAR PINION BEARING1 - PULLER2 - VISE3 - ADAPTERS4 - DRIVE PINION GEAR SHAFT

Fig. 65 REAR PINION BEARING CUP1 - INSTALLER2 - HANDLE



(6) Install depth shim on the pinion gear.(7) Install rear bearing and shim on the pinion

gear with Installer W-262 and a press (Fig. 68).(8) Install a new collapsible preload spacer on pin-

ion shaft and install pinion gear in the housing (Fig.69).

Fig. 66 FRONT PINION BEARING CUP1 - INSTALLER2 - HANDLE


Fig. 68 REAR PINION BEARING1 - PRESS2 - INSTALLER3 - DRIVE PINION GEAR4 - REAR PINION BEARING

Fig. 69 COLLAPSIBLE SPACER1 - COLLAPSIBLE SPACER2 - SHOULDER3 - PINION GEAR4 - SHIM5 - REAR BEARING



(9) Install yoke with Installer Screw 8112, Cup8109 and Wrench 6958 (Fig. 70).

(10) Install yoke washer and a new nut on thepinion gear and tighten the pinion nut until there iszero bearing end-play.

(11) Tighten the nut to 271 N·m (200 ft. lbs.).


(12) Using Spanner Wrench 6958 and a torquewrench set at 475 N·m (350 ft. lbs.), (Fig. 71) slowlytighten the nut in 6.8 N·m (5 ft. lbs.) incrementsuntil the rotating torque is achieved. Measure therotating torque frequently to avoid over crushing thecollapsible spacer (Fig. 72).

NOTE: If more than 475 N·m (350 ft. lbs.) torque isrequired to crush the collapsible spacer, the spaceris defective and must be replaced.

(13) Check bearing rotating torque with a inchpound torque wrench (Fig. 72). The pinion gear rotat-ing torque should be:

• Original Bearings: 1 to 2 N·m (10 to 20 in. lbs.).• New Bearings: 2 to 4 N·m (20 to 35 in. lbs.).

Fig. 70 PINION YOKE INSTALLER1 - INSTALLER2 - PINION YOKE3 - SPANNER WRENCH

Fig. 71 PION YOKE WRENCH1 - PINION YOKE2 - SPANNER WRENCH3 - PIPE




(14) Invert the differential case and start two ringgear bolts. This will provide case-to-ring gear bolthole alignment.

(15) Invert the differential case in the vise.(16) Install new ring gear bolts and alternately

tighten to 136 N·m (100 ft. lbs.) (Fig. 73).

CAUTION: Do not reuse ring gear bolts, the boltscan fracture causing extensive damage.

(17) Install differential in axle housing and verifygear mesh and contact pattern. Refer to Ajustment(Gear Contact Pattern) for procedure.

(18) Install differential cover and fill with gearlubricant.

(19) Install the propeller shaft with the referencemarks aligned.

(20) Remove supports and lower vehicle.

Fig. 73 RING GEAR BOLTS1 - TORQUE WRENCH2 - RING GEAR BOLT3 - RING GEAR4 - CASE



Date post:	09-May-2018
Category:	Documents
Upload:	vandiep
View:	215 times
Download:	1 times

REAR AXLE - 194RBI - Jeep VIN decoder · REAR AXLE - 194RBI TABLE OF CONTENTS page page ... rear...

Documents