03. differential and driveline

DIFFERENTIAL & DRIVELINE

TABLE OF CONTENTS

page page

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1FRONT TUBE AXLE . . . . . . . . . . . . . . . . . . . . . . 15FRONT AXLE - 186FBI . . . . . . . . . . . . . . . . . . . . 16

REAR AXLE - 198RBI . . . . . . . . . . . . . . . . . . . . . 49REAR AXLE - 226RBA . . . . . . . . . . . . . . . . . . . . . 87

PROPELLER SHAFT

TABLE OF CONTENTS

page page

PROPELLER SHAFTDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 2STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 4

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 4SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PROPELLER SHAFT - FRONTREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PROPELLER SHAFT - FRONT 4.7LREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PROPELLER SHAFT - REARREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SINGLE CARDAN UNIVERSAL JOINTSDISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DOUBLE CARDAN UNIVERSAL JOINTSDISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 10ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PROPELLER SHAFT

DESCRIPTIONA propeller shaft (Fig. 1) is the shaft which con-

nects the transmission/transfer case to the axle dif-ferential. This is the link through which the enginepower is transmitted to the axle.

The propeller shaft is designed and built with theyoke lugs in line with each other which is called zerophasing. This design produces the smoothest runningcondition, an out-of-phase shaft can cause a vibra-tion.

Tubular propeller shafts are balanced by the man-ufacturer with weights spot welded to the tube.

Two styles of front propeller shafts are used on thisvehicle. The 4.7L engine propeller shaft uses a singlecardan U-joint at the axle end and a double cardanU-joint at the transfer case end. The rest uses a Con-stant Velocity (C/V) joint at both the axle and trans-fer case end of the propeller shaft. The C/V joint atthe axle end contracts and extends (plunges) as nec-

essary to accommodate the variations in length nec-essary due to suspension travel. The C/V joint at thetransfer case end of the propeller shaft is fixed. Thetwo C/V joints are connected by a hollow tube shaft.The shaft length is not adjustable and does varyaccording to application.

OPERATIONThe propeller shaft must operate through con-

stantly changing relative angles between the trans-mission and axle when going over various roadsurfaces. It must also be capable of changing lengthwhile transmitting torque. The axle rides suspendedby springs in a floating motion. This is accomplishedthrough universal joints, which permit the propellershaft to operate at different angles. The slip joints (oryokes) permit contraction or expansion.

Before undercoating a vehicle, the propellershaft and the U-joints should be covered to pre-vent an out-of-balance condition and drivelinevibration.

WJ DIFFERENTIAL & DRIVELINE 3 - 1

CAUTION: Use original equipment replacementparts for attaching the propeller shafts. The speci-fied torque must always be applied when tighteningthe fasteners.

DIAGNOSIS AND TESTING - PROPELLERSHAFT

VIBRATIONTires that are out-of-round, or wheels that are

unbalanced, will cause a low frequency vibration.(Refer to 22 - TIRES/WHEELS - DIAGNOSIS ANDTESTING)

Brake rotors that are unbalanced will cause aharsh, low frequency vibration. (Refer to 5 - BRAKES- DIAGNOSIS AND TESTING)

Driveline vibration can also result from loose ordamaged engine mounts.

Propeller shaft vibration increases as the vehiclespeed is increased. A vibration that occurs within aspecific speed range is not usually caused by a pro-peller shaft being unbalanced. Defective universaljoints, or an incorrect propeller shaft angle, are usu-ally the cause of such a vibration.

Fig. 1 Propeller Shafts - Except 4.7L1 - REAR AXLE 6 - PINION FLANGE2 - STRAP 7 - FRONT AXLE3 - BOLT 8 - BOLT4 - SLIP YOKE 9 - FRONT PROPELLER SHAFT5 - REAR PROPELLER SHAFT 10 - TRANSFER CASE

3 - 2 PROPELLER SHAFT WJ

PROPELLER SHAFT (Continued)

DRIVELINE VIBRATION

Drive Condition Possible Cause Correction

Propeller Shaft Noise 1) Undercoating or other foreign materialon shaft.

1) Clean exterior of shaft and wash withsolvent.

2) Loose U-joint clamp screws. 2) Install new clamps and screws andtighten to proper torque.

3) Loose or bent U-joint yoke or excessiverunout.

3) Install new yoke.

4) Incorrect driveline angularity. 4) Measure and correct driveline angles.

5) Rear spring center bolt not in seat. 5) Loosen spring u-bolts and seat centerbolt.

6) Worn U-joint bearings. 6) Install new U-joint.

7) Propeller shaft damaged or out ofbalance.

7) Installl new propeller shaft.

8) Broken rear spring. 8) Install new rear spring.

9) Excessive runout or unbalancedcondition.

9) Re-index propeller shaft, test, andevaluate.

10) Excessive drive pinion gear shaftrunout.

10) Re-index propeller shaft and evaluate.

11) Excessive axle yoke deflection. 11) Inspect and replace yoke if necessary.

12) Excessive transfer case runout. 12) Inspect and repair as necessary.

Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws andtighten to proper torque.

2) Lack of lubrication. 2) Replace U-joints as necessary.

BALANCE

NOTE: Removing and re-indexing the propellershaft 180° relative to the yoke may eliminate somevibrations.

If propeller shaft is suspected of being unbalanced,it can be verified with the following procedure:

(1) Raise the vehicle.(2) Clean all the foreign material from the propel-

ler shaft and the universal joints.(3) Inspect the propeller shaft for missing balance

weights, broken welds, and bent areas. If the pro-peller shaft is bent, it must be replaced.

(4) Inspect the universal joints to ensure that theyare not worn, are properly installed, and are cor-rectly aligned with the shaft.

(5) Check the universal joint clamp screws torque.(6) Remove the wheels and tires. Install the wheel

lug nuts to retain the brake drums or rotors.(7) Mark and number the shaft six inches from the

yoke end at four positions 90° apart.(8) Run and accelerate the vehicle until vibration

occurs. Note the intensity and speed the vibrationoccurred. Stop the engine.

(9) Install a screw clamp at position 1 (Fig. 2).

(10) Start the engine and re-check for vibration. Ifthere is little or no change in vibration, move the

Fig. 2 Clamp Screw At Position 11 - CLAMP2 - SCREWDRIVER

WJ PROPELLER SHAFT 3 - 3


clamp to one of the other three positions. Repeat thevibration test.

(11) If there is no difference in vibration at theother positions, the source of the vibration may notbe propeller shaft.

(12) If the vibration decreased, install a secondclamp (Fig. 3) and repeat the test.

(13) If the additional clamp causes an additionalvibration, separate the clamps (1/4 inch above andbelow the mark). Repeat the vibration test (Fig. 4).

(14) Increase distance between the clamp screwsand repeat the test until the amount of vibration isat the lowest level. Bend the slack end of the clampsso the screws will not loosen.

(15) If the vibration remains unacceptable, applythe same steps to the front end of the propeller shaft.

(16) Install the wheel and tires. Lower the vehicle.

RUNOUT(1) Remove dirt, rust, paint, and undercoating

from the propeller shaft surface where the dial indi-cator will contact the shaft.

(2) The dial indicator must be installed perpendic-ular to the shaft surface.

(3) Measure runout at the center and ends of theshaft sufficiently far away from weld areas to ensurethat the effects of the weld process will not enter intothe measurements.

(4) Refer to Runout Specifications chart.(5) If the propeller shaft runout is out of specifica-

tion, remove the propeller shaft, index the shaft 180°,and re-install the propeller shaft. Measure shaftrunout again.

(6) If the propeller shaft runout is now withinspecifications, mark the shaft and yokes for properorientation.

(7) If the propeller shaft runout is not within spec-ifications, verify that the runout of the transmission/transfer case and axle are within specifications.Correct as necessary and re-measure propeller shaftrunout.

(8) Replace the propeller shaft if the runout stillexceeds the limits.

RUNOUT SPECIFICATIONS

Front of Shaft 0.020 in. (0.50 mm)

Center of Shaft 0.025 in. (0.63 mm)

Rear of Shaft 0.020 in. (0.50 mm)

note:Measure front/rear runout approximately 3 inches(76 mm) from the weld seam at each end of theshaft tube for tube lengths over 30 inches. Fortube lengths under 30 inches, the maximumallowed runout is 0.020 in. (0.50 mm) for the fulllength of the tube.

STANDARD PROCEDURES - PROPELLERSHAFT ANGLE

The procedure applies to both the front propellershafts and the rear propeller shaft. To obtain thefront (output) angle on the C/V front propeller shaft,the inclinometer is placed on the machined ring ofthe pinion flange. To obtain the propeller shaft anglemeasurement on the C/V front propeller shaft, theinclinometer is placed on the propeller shaft tube.

(1) Raise and support the vehicle at the axles aslevel as possible. Allow the wheels and propellershaft to turn.

(2) Remove any external bearing snap rings fromuniversal joint if equipped, so the inclinometer basewill sits flat.

Fig. 3 Two Clamp Screws At The Same Position

Fig. 4 Clamp Screws Separated1 - 1⁄2 INCH



(3) Rotate the shaft until transmission/transfercase output yoke bearing cap is facing downward, ifnecessary.

Always make measurements from front torear.

(4) Place Inclinometer on yoke bearing cap, or thepinion flange ring, (A) parallel to the shaft (Fig. 5).Center bubble in sight glass and record measure-ment.

This measurement will give you the transmis-sion or Output Yoke Angle (A).

(5) Rotate propeller shaft 90 degrees and placeInclinometer on yoke bearing cap, or propeller shafttube on C/V propeller shaft, parallel to the shaft (Fig.6). Center bubble in sight glass and record measure-ment. This measurement can also be taken at therear end of the shaft.

This measurement will give you the propellershaft angle (C).

(6) Subtract smaller figure from larger (C minusA) to obtain transmission output operating angle.

(7) Rotate propeller shaft 90 degrees and placeInclinometer on pinion yoke bearing cap parallel tothe shaft (Fig. 7). Center bubble in sight glass andrecord measurement.

This measurement will give you the pinionshaft or input yoke angle (B).

(8) Subtract smaller figure from larger (C minusB) to obtain axle Input Operating Angle.

Refer to rules given below and the example in (Fig.8) for additional information.

• Good cancellation of U-joint operating angles(within 1°).

• Operating angles less than 3°.• Operating angles less than 10° for double cardan

U-joint.• At least 1/2 of one degree continuous operating

(propeller shaft) angle.

Fig. 5 Front (Output) Angle Measurement (A)1 - SLIP YOKE BEARING CAP2 - INCLINOMETER

Fig. 6 Propeller Shaft Angle Measurement (C)1 - SHAFT YOKE BEARING CAP2 - INCLINOMETER

Fig. 7 Rear (Input) Angle Measurement (B)1 - PINION YOKE BEARING CAP2 - INCLINOMETER



SPECIFICATIONS

PROPELLER SHAFT

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Front Shaft - CompanionFlange Bolts

32 24—

Rear Shaft - Yoke Nuts 19 14 —

Fig. 8 Universal Joint Angle Example1 - 4.9° Angle (C)2 - 3.2° Angle (B)3 - Input Yoke

4 - 3.0° Angle (A)5 - Output Yoke


SPECIFICATIONS (Continued)

SPECIAL TOOLS

SPECIAL TOOLS

PROPELLER SHAFT - FRONT

REMOVAL

NOTE: Different length propeller shafts are used fordifferent drivetrain applications. Ensure that thecorrect propeller shaft is used.

(1) Place vehicle on floor or drive-on hoist with fullweight of vehicle on suspension.

(2) Shift the transmission and transfer case, if nec-essary, into the Neutral position.

(3) Measure the distance from the face of the C/Vjoint cup to the end of the C/V joint boot (Fig. 9).

(4) The correct length is 142.7 mm (5.61 in.).

NOTE: If the measurement is not correct, the wrongshaft may have been installed or a mating compo-nent (front axle or transfer case) may be installedincorrectly. Investigate and correct as necessary.

(5) Mark a line across the companion flange at thetransfer case and C/V joint at the rear of the frontpropeller shaft for installation reference.

(6) Mark a line across the C/V joints and the pin-ion companion flanges for installation reference.

(7) Remove bolts from the front C/V joint to thepinion companion flange.

(8) Remove bolts from the rear C/V joint to thetransfer case companion flange.

(9) Push the propeller shaft forward to clear trans-fer case companion flange and remove the shaft.

INSTALLATION

NOTE: Different length propeller shafts are used fordifferent drivetrain applications. Ensure that thecorrect propeller shaft is used.

(1) Install the shaft between companion flanges.(2) The shaft should rotate freely in the pinion

flange.(3) Align marks on the companion flanges with the

marks on the C/V joints.(4) Install bolts to the front C/V joint and tighten

bolts to 32 N·m (24 ft. lbs.).(5) Install the bolts to the rear C/V joint and

tighten bolts to 32 N·m (24 ft. lbs.).(6) Verify propeller shaft length.(7) Lower vehicle.

PROPELLER SHAFT - FRONT4.7L

REMOVAL(1) Raise and support vehicle.(2) Remove crossmember/skid plate as necessary to

gain access to the propeller shaft.(3) Shift transmission and transfer case, if neces-

sary into Neutral.(4) Mark a line across the yoke at the transfer

case, link yoke and propeller shaft yoke at the rear ofthe front propeller shaft for installation reference(Fig. 10).

(5) Mark a line across the propeller shaft yoke andpinion shaft yoke for installation reference.

(6) Remove the U-joint strap bolts at the pinionshaft yoke (Fig. 11).

(7) Remove bolts holding rear universal joint tothe transfer case yoke.

(8) Separate the rear universal joint from thetransfer case yoke.

Inclinometer 7663

Fig. 9 Measurement1 - C/V JOINT CUP2 - C/V BOOT END3 - MEASUREMENT


(9) Push rear of propeller shaft upward to cleartransfer case yoke.

(10) Separate front universal joint from front axle.(11) Separate propeller shaft from vehicle.

INSTALLATION(1) Position front propeller shaft under vehicle

with rear universal joint over the transfer case yoke.(2) Place front universal joint into the axle pinion

yoke.

(3) Align mark on the rear link yoke and universaljoint to the mark on the transfer case yoke.

(4) Loosely install bolts to hold universal joint totransfer case yoke.

(5) Align mark on front universal joint to the markon the axle pinion yoke.

(6) Tighten the U-joint strap/clamp bolts at theaxle yoke to 19 N·m (14 ft. lbs.).

(7) Tighten the universal joint to transfer casebolts to 27 N·m (20 ft. lbs.).

(8) Lower the vehicle.

PROPELLER SHAFT - REAR

REMOVAL(1) Raise and support vehicle on safety stands.(2) Shift the transmission and transfer case if nec-

essary, to their neutral positions.(3) Mark a line across the axle pinion yoke and the

propeller shaft yoke for installation reference.(4) Remove the bolts holding the universal joint

clamps to the pinion yoke.(5) Slide the slip yoke off of the transmission, or

transfer case, output shaft and remove the propellershaft (Fig. 12).

Fig. 10 Reference Marks on Yokes1 - REFERENCE MARKS

Fig. 11 Front Propeller Shaft - 4.7L1 - FRONT AXLE2 - BOOT3 - PROPELLER SHAFT4 - DOUBLE CARDAN U-JOINT5 - TRANSFER CASE6 - BOOT7 - SLINGER8 - CLAMP9 - YOKE

Fig. 12 Rear Propeller Shaft1 - SLIDING YOKE2 - PROPELLER SHAFT3 - PINION YOKE4 - CLAMP/STRAP5 - BOLT6 - OUTPUT SHAFT


PROPELLER SHAFT - FRONT 4.7L (Continued)

INSTALLATION(1) Slide the slip yoke on the transmission, or

transfer case, output shaft.(2) Align the installation reference marks made on

the propeller shaft and pinion yoke.(3) Position universal joint into pinion yoke.(4) Install the universal joint clamp and clamp

bolts to the pinion yoke. Tighten bolts to 19 N·m (14ft. lbs.).

(5) Lower the vehicle.

SINGLE CARDAN UNIVERSALJOINTS

DISASSEMBLYIndividual components of cardan universal joints

are not serviceable. If worn or leaking, they must bereplaced as an assembly.

(1) Remove the propeller shaft.(2) Using a soft drift, tap the outside of the bear-

ing cap assembly to loosen snap ring.(3) Remove snap rings from both sides of yoke

(Fig. 13).

(4) Set the yoke in an arbor press or vise with asocket whose inside diameter is large enough toreceive the bearing cap positioned beneath the yoke.

(5) Position the yoke with the grease fitting, ifequipped, pointing up.

(6) Place a socket with an outside diametersmaller than the upper bearing cap on the upperbearing cap and press the cap through the yoke torelease the lower bearing cap (Fig. 14).

(7) If the bearing cap will not pull out of the yokeby hand after pressing, tap the yoke ear near thebearing cap to dislodge the cap.

(8) To remove the opposite bearing cap, turn theyoke over and straighten the cross in the open hole.Then, carefully press the end of the cross until theremaining bearing cap can be removed (Fig. 15).

CAUTION: If the cross or bearing cap are notstraight during installation, the bearing cap willscore the walls of the yoke bore and damage canoccur.

ASSEMBLY(1) Apply extreme pressure (EP) N.L.G.I. Grade 1

or 2 grease to inside of yoke bores to aid in installa-tion.

(2) Position the cross in the yoke with its lube fit-ting, if equipped, pointing up (Fig. 16).

(3) Place a bearing cap over the trunnion andalign the cap with the yoke bore (Fig. 17). Keep theneedle bearings upright in the bearing assembly. Aneedle bearing lying at the bottom of the cap willprevent proper assembly.

(4) Press the bearing cap into the yoke boreenough to install a snap ring.

(5) Install a snap ring.

Fig. 13 Remove Snap Ring1 - SNAP RING

Fig. 14 Press Out Bearing1 - PRESS2 - SOCKET


PROPELLER SHAFT - REAR (Continued)

(6) Repeat Step 3 and Step 4to install the oppositebearing cap. If the joint is stiff or binding, strike theyoke with a soft hammer to seat the needle bearings.

(7) Add grease to lube fitting, if equipped.(8) Install the propeller shaft.

DOUBLE CARDAN UNIVERSALJOINTS

DISASSEMBLYIndividual components of cardan universal joints

are not serviceable. If worn or leaking, they must bereplaced as an assembly.

(1) Remove the propeller shaft.(2) Using a soft drift, tap the outside of the bear-

ing cap assembly to loosen snap ring.(3) Remove all the bearing cap snap rings (Fig.

18).(4) Set the joint in an arbor press or vise with a

socket whose inside diameter is large enough toreceive the bearing cap positioned beneath the linkyoke.

(5) Place a socket with an outside diametersmaller than the upper bearing cap on the upperbearing cap and partially press one bearing cap fromthe outboard side of the link yoke enough to graspthe bearing cap with vise jaws (Fig. 19). Be sure toremove grease fittings that interfere with removal.

Fig. 15 Press Out Remaining Bearing1 - CROSS2 - BEARING CAP

Fig. 16 Cross In Yoke1 - CROSS2 - YOKE

Fig. 17 Install Bearing On Trunnion1 - BEARING CAP2 - TRUNNION


SINGLE CARDAN UNIVERSAL JOINTS (Continued)

(6) Grasp the protruding bearing by vise jaws. Tapthe link yoke with a mallet and drift to dislodge thebearing cap from the yoke (Fig. 20).

(7) Flip assembly and repeat Step 4, Step 5, andStep 6 to remove the opposite bearing cap. This willthen allow removal of the cross centering kit assem-bly and spring (Fig. 21).

(8) Press the remaining bearing caps out the otherend of the link yoke as described above to completethe disassembly.

ASSEMBLYDuring assembly, ensure that the alignment

marks on the link yoke and propeller shaftyoke are aligned.

(1) Apply extreme pressure (EP) N.L.G.I. Grade 1or 2 grease to inside of yoke bores to aid in installa-tion.

(2) Fit a cross into the propeller shaft yoke (Fig.22).

Fig. 18 Remove Snap Rings

Fig. 19 Press Out Bearing

Fig. 20 Remove Bearing From Yoke

Fig. 21 Remove Centering


DOUBLE CARDAN UNIVERSAL JOINTS (Continued)

(3) Place a bearing cap over the trunnion andalign the cap with the yoke bore (Fig. 23). Keep theneedle bearings upright in the bearing assembly. Aneedle bearing lying at the bottom of the cap willprevent proper assembly.

(4) Press the bearing cap into the yoke boreenough to install a snap ring (Fig. 24).

(5) Install a snap ring.

(6) Flip the propeller shaft yoke and install thebearing cap onto the opposite trunnion. Install asnap ring (Fig. 25).

(7) Fit the link yoke on the remaining two trun-nions and press both bearing caps into place (Fig.26).

(8) Install snap rings.

Fig. 22 Install Cross In Yoke

Fig. 23 Install Bearing Cap

Fig. 24 Press In Bearing Cap




(9) Install the centering kit assembly inside thelink yoke making sure the spring is properly posi-tioned (Fig. 27).

(10) Place two bearing caps on opposite trunnionsof the remaining cross. Fit the open trunnions intothe link yoke bores and the bearing caps into thecentering kit (Fig. 28).

(11) Press the remaining two bearing caps intoplace and install snap rings (Fig. 29).

(12) Tap the snap rings to allow them to seat intothe grooves (Fig. 30).

Fig. 26 Install Link Yoke

Fig. 27 Install Centering Kit

Fig. 28 Install Remaining Cross




(13) Check for proper assembly. Flex the jointbeyond center, it should snap over-center in bothdirections when correctly assembled (Fig. 31).

(14) Install the propeller shaft.

Fig. 30 Seat Snap Rings In GrooveFig. 31 Check Assembly



FRONT TUBE AXLE

TABLE OF CONTENTS

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FRONT TUBE AXLEREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

FRONT TUBE AXLE

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 rotors (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/ROTORS - REMOVAL)and calipers from the axle. (Refer to 5 - BRAKES/HY-DRAULIC/MECHANICAL/DISC BRAKE CALIPERS- REMOVAL)

(6) Disconnect the wheel sensor wiring harnessfrom the vehicle wiring harness, if necessary.

(7) Disconnect stabilizer bar links at the axle.(8) Disconnect shock absorbers from axle brackets.(9) Disconnect track bar.(10) Disconnect the tie rod and drag link from the

steering knuckle.(11) Disconnect the steering damper from the axle

bracket.(12) Disconnect the upper and lower suspension

arms from the axle brackets.(13) Lower the lifting device enough to remove the

axle. The coil springs will drop with the axle.(14) Remove the coil springs from the axle.

INSTALLATION

CAUTION: The weight of the vehicle must be sup-ported by the springs before suspension arms andtrack bar fasteners can be tightened. If the springsare not at their normal ride position, ride height andhandling could be affected.

(1) Install the springs and retainer clips. Tightenthe retainer bolts to 21 N·m (16 ft. lbs.) torque.

(2) Support the axle on a suitable lifting deviceand position axle under the vehicle.

(3) Raise the axle and align it with the springpads.

(4) Position the upper and lower suspension armsin the axle brackets. Loosely install bolts and nuts tohold suspension arms to the axle brackets.

(5) Connect the track bar to the axle bracket.Loosely install the bolt to hold the track bar to theaxle bracket.

(6) Install the shock absorbers and tighten thebolts to 23 N·m (17 ft. lbs.) torque.

(7) Install the stabilizer bar links to the axlebrackets. Tighten the nut to 95 N·m (70 ft. lbs.)torque.

(8) Install the drag link and tie rod to the steeringknuckles.

(9) Install the steering damper to the axle bracketand tighten the nut to 75 N·m (55 ft. lbs.) torque.

(10) Install the brake rotors (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL)and calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS -REMOVAL)

(11) Connect the wheel speed sensor wiring har-ness to the vehicle wiring harness, if necessary.

(12) Install the wheel and tire assemblies.(13) Remove the lifting device from the axle and

lower the vehicle.(14) Tighten the upper suspension arm nuts to 75

N·m (55 ft. lbs.) torque. Tighten the lower suspensionarm nuts to 115 N·m (85 ft. lbs.) torque.

(15) Tighten the track bar bolt at the axle bracketto 100 N·m (74 ft. lbs.) torque.

(16) Check the front wheel alignment.

WJ FRONT TUBE AXLE 3 - 15

FRONT AXLE - 186FBI

TABLE OF CONTENTS

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FRONT AXLE - 186FBIDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 17

FRONT AXLE - 186FBI . . . . . . . . . . . . . . . . . . . 17REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 22SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 30SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 30

AXLE SHAFTSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33

AXLE SHAFT SEALSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

AXLE - C/V JOINTREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

AXLE - U-JOINTREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 36PINION SEAL

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 36

COLLAPSIBLE SPACERREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38

DIFFERENTIALREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 40ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DIFFERENTIAL CASE BEARINGSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43

PINION GEAR/RING GEARREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 45

FRONT AXLE - 186FBI

DESCRIPTIONThe 186 Front Beam-design Iron (FBI) axle con-

sists of a cast iron differential housing with axleshaft tubes extending from either side. The tubes arepressed into the differential housing and welded.

The integral type housing, hypoid gear design hasthe centerline of the pinion set below the centerlineof the ring gear.

The axle has a fitting for a vent hose used torelieve internal pressure caused by lubricant vapor-ization and internal expansion.

The axles are equipped with semi–floating axleshafts, meaning that loads are supported by the hubbearings. The axle shafts are retained by nuts at thehub bearings. The hub bearings are bolted to thesteering knuckle at the outboard end of the axle tubeyoke. The hub bearings are serviced as an assembly.

For vehicles with ABS brakes, the ABS wheelspeed sensors are attached to the knuckle assem-blies. The tone rings for the ABS system are pressedonto the axle shaft. Do not damage ABS tonewheel or the sensor when removing axle shafts.

The stamped steel cover provides a means forinspection and servicing the differential.

The 186 FBI axle has the assembly part numberand gear ratio listed on a tag. The tag is attached tothe housing cover by a cover bolt. Build date identi-fication codes are stamped on the cover side of theaxle shaft tube.

The differential case is a one–piece design. The dif-ferential pinion mate shaft is retained with a rollpin. Differential bearing preload and ring gear back-lash is adjusted by the use of shims (select thick-ness). The shims are located between the differentialbearing cups and axle housing. Pinion bearing pre-load is set and maintained by the use of a collapsiblespacer.

Axles equipped with a Vari-Loky differential areoptional. A Vari-Loky differential has a one-piece dif-ferential case which contains the gerotor pumpassembly and the clutch mechinism. The Vari-Lokyunit is serviced only as an assembly.

OPERATIONThe axle receives power from the transfer case

through the front propeller shaft. The front propellershaft is connected to the pinion gear which rotatesthe differential through the gear mesh with the ringgear bolted to the differential case. The engine poweris transmitted to the axle shafts through the pinion

3 - 16 FRONT AXLE - 186FBI WJ

mate and side gears. The side gears are splined tothe axle shafts.

STANDARD DIFFERENTIALDuring 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. 1).

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.2). 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.

VARI-LOKY DIFFERENTIALIn a standard differential if one wheel spins, the

opposite wheel will generate only as much torque asthe spinning wheel.

A gerotor pump and clutch pack are used to pro-vide the torque transfer capability. One axle shaft issplined to the gerotor pump and one of the differen-tial side gears, which provides the input to the pump.As a wheel begins to lose traction, the speed differ-ential is transmitted from one side of the differentialto the other through the side gears. The motion of

one side gear relative to the other turns the innerrotor of the pump. Since the outer rotor of the pumpis grounded to the differential case, the inner andouter rotors are now moving relative to each otherand therefore creates pressure in the pump. The tun-ing of the front and rear axle orifices and valvesinside the gerotor pump is unique and each systemincludes a torque-limiting pressure relief valve toprotect the clutch pack, which also facilitates vehiclecontrol under extreme side-to-side traction varia-tions. The resulting pressure is applied to the clutchpack and the transfer of torque is completed.

Under conditions in which opposite wheels are onsurfaces with widely different friction characteristics,Vari-loky delivers far more torque to the wheel onthe higher traction surface than do conventionalTrac-loky systems. Because conventional Trac-lokydifferentials are initially pre-loaded to assure torquetransfer, normal driving (where inner and outerwheel speeds differ during cornering, etc.) producestorque transfer during even slight side-to-side speedvariations. Since these devices rely on friction fromthis preload to transfer torque, normal use tends tocause wear that reduces the ability of the differentialto transfer torque over time. By design, the Vari-lokysystem is less subject to wear, remaining more con-sistent over time in its ability to transfer torque. Thecoupling assembly is serviced as a unit. From a ser-vice standpoint the coupling also benefits from usingthe same lubricant supply as the ring and piniongears.

DIAGNOSIS AND TESTING - AXLE

GEAR NOISEAxle gear noise can be caused by insufficient lubri-

cant, incorrect backlash, tooth contact, worn/damaged

Fig. 1 Differential Operation-Straight Ahead Driving1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT100% OF CASE SPEED2 - PINION GEAR3 - SIDE GEAR4 - PINION GEARS ROTATE WITH CASE

Fig. 2 Differential Operation-On Turns1 - PINION GEARS ROTATE ON PINION SHAFT

WJ FRONT AXLE - 186FBI 3 - 17

FRONT AXLE - 186FBI (Continued)

gears, or the carrier housing not having the properoffset 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-cle turns. A worn pinion mate shaft can also cause asnapping 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 rear-endvibration. Do not overlook engine accessories, brack-ets and drive belts.

All driveline components should be examinedbefore starting any repair.

(Refer to 22 - TIRES/WHEELS - DIAGNOSIS ANDTESTING)

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.

3. End-play in pinion bearings. 3. Refer to pinion pre-loadinformation and correct asnecessary.

4. Excessive gear backlashbetween the ring gear and pinion.

4. Check adjustment of the ringgear and pinion backlash. Correctas necessary.

5. Improper adjustment of piniongear bearings.

5. Adjust the pinion bearingspre-load.

6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.

7. Scuffed gear tooth contactsurfaces.

7. Inspect and replace asnecessary.

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.

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.



VARI-LOKY(1) Park the vehicle on a level surface or raise

vehicle on hoist so that the vehicle is level.(2) Remove the axle fill plug.(3) Verify that the axle fluid level is correct. The

fluid level is correct if the fluid is level with the bot-tom of the fill hole.

(4) Shift the transfer case into the 4WD full-timeposition.

(5) Drive the vehicle in a tight circle for 2 minutesat 5mph to fully prime the pump.

(6) Block the tires opposite the axle to be tested toprevent the vehicle from moving.

(7) Shift the transfer case into the 4WD Low posi-tion and the transmission into the Park position.

(8) Raise both the wheels of the axle to be testedoff of the ground.

(9) Rotate the left wheel by hand at a minimum ofone revolution per second while an assistant rotatesthe right wheel in the opposite direction.

(10) The left wheel should spin freely at first andthen increase in resistance within 5 revolutions untilthe wheels cannot be continuously rotated in oppositedirections.

(11) The Vari-loky differential has engaged prop-erly if the wheels cannot be rotated in opposite direc-tions for a moment. After the wheels stop rotating fora moment, the fluid pressure will drop in the differ-ential and the wheels begin to rotate once again.

(12) If the system does not operate properly,replace the Vari-loky differential.

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 rotors (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/ROTORS - REMOVAL)and calipers (Refer to 5 - BRAKES/HYDRAULIC/ME-CHANICAL/DISC BRAKE CALIPERS - REMOVAL)from the axle.

(6) Disconnect the wheel sensor wiring harnessfrom the vehicle wiring harness, if necessary.

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

(8) Mark the propeller shaft and yoke, or pinionflange, for installation alignment reference.

(9) Remove propeller shaft.(10) Disconnect stabilizer bar links at the axle.(11) Disconnect shock absorbers from axle brack-

ets.(12) Disconnect track bar.(13) Disconnect the tie rod and drag link from the

steering knuckle.

(14) Disconnect the steering damper from the axlebracket.

(15) Disconnect the upper and lower suspensionarms from the axle brackets.

(16) Lower the lifting device enough to remove theaxle. The coil springs will drop with the axle.

(17) Remove the coil springs from the axle.

INSTALLATION

CAUTION: The weight of the vehicle must be sup-ported by the springs before suspension arms andtrack bar fasteners can be tightened. If the springsare not at their normal ride position, ride height andhandling could be affected.

(1) Install the springs and retainer clips. Tightenthe retainer bolts to 21 N·m (16 ft. lbs.) torque.

(2) Support the axle on a suitable lifting deviceand position axle under the vehicle.

(3) Raise the axle and align it with the springpads.

(4) Position the upper and lower suspension armsin the axle brackets. Loosely install bolts and nuts tohold suspension arms to the axle brackets.

(5) Connect the vent hose to the axle shaft tube.(6) Connect the track bar to the axle bracket.

Loosely install the bolt to hold the track bar to theaxle bracket.

(7) Install the shock absorbers and tighten thebolts to 23 N·m (17 ft. lbs.) torque.

(8) Install the stabilizer bar links to the axlebrackets. Tighten the nut to 95 N·m (70 ft. lbs.)torque.

(9) Install the drag link and tie rod to the steeringknuckles.

(10) Install the steering damper to the axlebracket and tighten the nut to 75 N·m (55 ft. lbs.)torque.

(11) Install the brake rotors (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLA-TION) and calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERS - INSTALLATION)

(12) Connect the wheel speed sensor wiring har-ness to the vehicle wiring harness, if necessary.

(13) Align the previously made marks on the pro-peller shaft and the yoke, or pinion flange.

(14) Install the bolts to hold the propeller shaft tothe pinion flange, if equipped.

(15) Install the straps and bolts to hold the propel-ler shaft to the yoke, if equipped.

(16) Check and fill axle lubricant. Refer to theLubricant Specifications in this group for the quan-tity necessary.

(17) Install the wheel and tire assemblies.



(18) Remove the lifting device from the axle andlower the vehicle.

(19) Tighten the upper suspension arm nuts to 75N·m (55 ft. lbs.) torque. Tighten the lower suspensionarm nuts to 115 N·m (85 ft. lbs.) torque.

(20) Tighten the track bar bolt at the axle bracketto 100 N·m (74 ft. lbs.) torque.

(21) Check the front wheel alignment.

ADJUSTMENTSRing 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.3). 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 setting from the cen-ter line of the ring gear to the back face of the pinionis 92.1 mm (3.625 in.). The standard depth providesthe best gear tooth contact pattern. Refer to Back-lash and Contact Pattern Analysis paragraph in thissection for additional information.

Compensation for pinion depth variance isachieved with a select shim/oil baffle. The shims areplaced between the rear pinion bearing and the pin-ion gear head (Fig. 4).

If a new gear set is being installed, note the depthvariance etched into both the original and replace-ment pinion. Add or subtract this number from thethickness of the original depth shim/oil slinger tocompensate for the difference in the depth variances.Refer to the Pinion Gear Depth Variance chart.

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

Note the etched number on the face of the piniongear head (–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 shims. If the numberis positive, subtract that value from the thickness ofthe depth shim. If the number is 0 no change is nec-essary.

PINION GEAR DEPTH VARIANCE

Original PinionGear Depth

Variance

Replacement Pinion Gear Depth Variance

−4 −3 −2 −1 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 −0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003

Fig. 3 Pinion Gear ID Numbers1 - PRODUCTION NUMBERS2 - PINION GEAR DEPTH VARIANCE3 - GEAR MATCHING NUMBER

Fig. 4 Adjustment Shims Locations1 - PINION GEAR DEPTH SHIM/OIL BAFFLE2 - DIFFERENTIAL BEARING SHIM3 - RING GEAR4 - DIFFERENTIAL BEARING SHIM5 - COLLAPSIBLE SPACER




Variance


−4 −3 −2 −1 0 +1 +2 +3 +4

0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004

−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005

−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006

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

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

PINION DEPTH MEASUREMENTMeasurements are taken with pinion bearing cups

and pinion bearings installed in the housing. Takemeasurements with Pinion Gauge Set and Dial Indi-cator C-3339 (Fig. 5).

(1) Assemble Pinion Height Block 6739, PinionBlock 6733 and rear pinion bearing onto Screw 6741(Fig. 5).

(2) Insert assembled height gauge components,rear bearing and screw into the housing through pin-ion bearing cups (Fig. 6).

(3) Install front pinion bearing and Cone-nut 6740hand tight (Fig. 5).

(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-tion, in the housing side bearing cradles (Fig. 7).Install differential bearing caps on Arbor Discs andtighten cap bolts to 41 N·m (30 ft. lbs.).

NOTE: Arbor Discs 6732 has different step diame-ters to fit other axles. Choose proper step for axlebeing serviced.

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

(6) Place Scooter Block/Dial Indicator in positionin axle housing so dial probe and scooter block areflush against the rearward surface of the pinionheight block (Fig. 5). Hold scooter block in place andzero the dial indicator face to the pointer. Tightendial indicator face lock screw.

(7) With scooter block still in position against thepinion height block, slowly slide the dial indicatorprobe over the edge of the pinion height block.

(8) Slide the dial indicator probe across the gapbetween the pinion height block and the arbor barwith the scooter block against the pinion height block(Fig. 8). When the dial probe contacts the arbor bar,

Fig. 5 Pinion Gear Depth Tools1 - DIAL INDICATOR - C-33392 - ARBOR - D-115-33 - PINION HEIGHT BLOCK - 67394 - CONE - 67405 - SCREW -67416 - PINION BLOCK -67337 - SCOOTER BLOCK - D-115-28 - ARBOR DISC v- 6732

Fig. 6 Pinion Height Block1 - PINION BLOCK - 67332 - PINION HEIGHT BLOCK - 6739



the dial pointer will turn clockwise. Continue movingthe dial probe to the crest of the arbor bar and recordthe highest reading. If the dial indicator can notachieve the zero reading, the rear bearing cup or thepinion depth gauge set is not installed correctly.

(9) Select a shim/oil baffle equal to the dial indica-tor reading plus the pinion depth variance numberetched in the face of the pinion (Fig. 3). For example,if the depth variance is –2, add +0.002 in. to the dialindicator reading.

DIFFERENTIALDifferential side bearing preload and gear backlash

is achieved by selective shims positioned behind thedifferential side bearing cones. The proper shimthickness can be determined using slip-fit DummyBearings D-348 in place of the differential side bear-ings and a Dial Indicator C-3339. Before proceedingwith the differential bearing preload and gear back-lash measurements, measure the pinion gear depthand prepare the pinion 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 is installed, and thegear backlash shim thickness is measured. The over-all shim thickness is the total of the dial indicatorreading and the preload specification added together.The gear backlash measurement determines thethickness of the shim used on the ring gear side ofthe differential case. Subtract the gear backlash shimthickness from the total overall shim thickness andselect that amount for the pinion gear side of the dif-ferential (Fig. 9). Differential shim measurementsare performed with spreader W-129-B removed.

SHIM SELECTION

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

(1) Remove differential side bearings from differ-ential case.

Fig. 7 Tools In Housing1 - ARBOR DISC - 67322 - PINION BLOCK - 67333 - ARBOR - D-115-34 - PINION HEIGHT BLOCK - 6739

Fig. 8 Pinion Gear Depth Measurement1 - ARBOR - D-115-32 - SCOOTER BLOCK - D-115-23 - DIAL INDICATOR - C-3339

Fig. 9 Adjustment Shims Locations1 - PINION GEAR DEPTH SHIM/OIL BAFFLE2 - DIFFERENTIAL BEARING SHIM3 - RING GEAR4 - DIFFERENTIAL BEARING SHIM5 - COLLAPSIBLE SPACER



(2) Install ring gear on differential case andtighten bolts to specification.

(3) Install dummy side bearings D-348 on differen-tial case.

(4) Install differential case in the housing.

CAUTION: When installing a Vari-Lok Y differential,the oil feed tube must be pointed to the bottom ofthe housing. If differential is forced in with the oilfeed towards the top, the anti-rotation tabs will bedamaged.

(5) Record the thickness of Dummy Shims 8107.Insert the shims between the dummy bearings andthe differential housing (Fig. 10).

(6) Install the marked bearing caps in their correctpositions. Install and snug the bolts (Fig. 11).

(7) Using a dead-blow hammer, seat the differen-tial dummy bearings to each side of the axle housing(Fig. 12) and (Fig. 13).

(8) Thread Pilot Stud C-3288-B into rear cover bolthole below ring gear (Fig. 14).

(9) Attach a dial indicator C-3339 to Pilot Stud.Position the dial indicator plunger on a flat surfacebetween the ring gear bolt heads (Fig. 14).

(10) Push and hold differential case to pinion gearside of the housing and zero dial indicator (Fig. 15).

(11) Push and hold differential case to ring gearside of the housing and record dial indicator reading(Fig. 16).

(12) Add 0.006 in. (0.152 mm) to the zero end playtotal. This new total represents the thickness ofshims to compress or preload the new bearings whenthe differential is installed.

Fig. 10 Dummy Shim Location1 - DUMMY SHIM - 81072 - AXLE HOUSING3 - DIFFERENTIAL CASE4 - DUMMY BEARINGS - D-348

Fig. 11 Bearing Cap Bolts1 - BEARING CAP2 - DIFFERENTIAL HOUSING3 - DIFFERENTIAL CASE

Fig. 12 Seat Dummy Side Bearing1 - HAMMER2 - DIFFERENTIAL HOUSING3 - DIFFERENTIAL CASE



(13) Rotate dial indicator out of the way on thepilot stud.

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

(15) Install the pinion gear in the housing. Installthe pinion yoke and establish the correct pinionrotating torque.

(16) Install differential case and Dummy BearingsD-348 in the housing.

(17) Install a single dummy Sshim in the ring gearside. Install bearing caps and tighten bolts snug.

Fig. 13 Seat Dummy Side Bearing1 - DIFFERENTIAL HOUSING2 - HAMMER3 - DIFFERENTIAL CASE

Fig. 14 Differential Side Play1 - DIFFERENTIAL CASE2 - DIFFERENTIAL HOUSING3 - PILOT STUD - C-3288-B4 - DIAL INDICATOR - C-3339

Fig. 15 Zero Dial Indicator1 - DIFFERENTIAL CASE TO PINION GEAR SIDE2 - PILOT STUD - C-3288-B3 - INDICATOR EXTENSION4 - DIAL INDICATOR FACE

Fig. 16 Dial Indicator1 - READ DIAL INDICATOR2 - DIFFERENTIAL CASE TO RING GEAR SIDE3 - DIFFERENTIAL HOUSING



(18) Seat ring gear side dummy bearing (Fig. 13).(19) Position the dial indicator plunger on a flat

surface between the ring gear bolt heads (Fig. 14).(20) Push and hold differential case toward pinion

gear and zero dial indicator (Fig. 17).

(21) Push and hold differential case to ring gearside of the housing and record dial indicator reading(Fig. 18). Add dummy shim thickness to this reading.This will be the total shim thickness to achieve zerobacklash.

(22) Subtract 0.003 in. (0.076 mm) from the dialindicator reading to compensate for backlash betweenring and pinion gears. This total is the thicknessshim 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 theaxle housing.

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


(26) Install side bearings and cups on differentialcase.

(27) Install spreader W-129-B, utilizing some itemsfrom Adapter Set 6987, on the housing and spreadaxle opening enough to receive differential case.

(28) Place the bearing preload shims in the axlehousing, against the axle tubes.

(29) Install differential case into the housing.

CAUTION: When installing a Vari-Lok Y differential,the oil feed tube must be pointed to the bottom ofthe housing. If differential is forced in with the oilfeed towards the top, the anti-rotation tabs will bedamaged.

(30) Remove spreader from the housing.(31) Rotate the differential case several times to

seat the side bearings.(32) Position the indicator plunger against a ring

gear tooth (Fig. 19).

Fig. 17 Zero Dial Indicator1 - ZERO DIAL INDICATOR FACE2 - DIFFERENTIAL CASE TO PINION GEAR SIDE3 - PINION GEAR4 - DIFFERENTIAL HOUSING5 - DIFFERENTIAL CASE

Fig. 18 Dial Indicator Reading1 - DIAL INDICATOR2 - DIFFERENTIAL CASE TO RING GEAR SIDE3 - PINION GEAR4 - DIFFERENTIAL HOUSING5 - DIFFERENTIAL CASE

Fig. 19 Ring Gear1 - DIAL INDICATOR



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

(34) Zero dial indicator face to pointer.(35) 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 housing to the other (Fig.20).

(36) 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, performGear 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 will squee-gee the compound to the areas with the least amountof contact. Note and compare patterns on the ringgear teeth to Gear Tooth Contact Patterns chart (Fig.21)and adjust pinion depth and gear backlash as nec-essary.

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.).

Fig. 20 Backlash Shim



Fig. 21 Gear Tooth Contact Patterns



SPECIFICATIONS

FRONT AXLE - 186FBI

AXLE SPECIFICATIONS

DESCRIPTION SPECIFICATION

Axle Ratio 3.07, 3.55, 3.73, 4.10

Differential Side Gear Clearance 0.13-0.20 mm (0.005-0.008 in.)

Differential Bearing Preload 0.152 mm (0.006 in.)

Ring Gear Diameter 186 mm (7.33 in.)

Ring Gear Backlash 0.13-0.20 mm (0.005-0.008 in.)

Pinion Gear Std. Depth 92.08 mm (3.625 in.)

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

Pinion Bearing Preload - New Bearings 1.7-3.4 N·m (15-30 in. lbs.)



Fill Hole Plug 34 25 —

Differential Cover Bolts 41 30 —

Bearing Cap Bolts 61 45 —

Ring Gear Bolts 108 80 —

Axle Nut 237 175 —

Hub Bearing Bolts 102 75 —

Lower Ball Stud Nut 108 80 —

Upper Ball Stud Nut 101 75 —

SPECIAL TOOLS

AXLE

Puller C-293-PA

Adapter Plug SP-3289

Adapter 8352

Puller C-452


Wrench Flange C-3281

Dial Indicator C-3339

Installer C-3716-A

Handle C-4171

Installer D-146

Remover D-149

Installer W-162-D

Cup 8109

Installer Discs 8110

Turnbuckle 6797


SPECIAL TOOLS (Continued)

Pinion Depth Set 6774

Shims Dummy 8107

Pinion Block 6733

Puller 794-A

Installer Clamp C-4975-A

Spanner Wrench 6958

Installer 8108

Spreader W-129-B

Adapter Kit 6987

Pilot Stud C-3288-B

Remover C-4345



AXLE SHAFTS

REMOVALIf the axle shaft and hub bearing are being

removed in order to service another component, theaxle shaft and hub bearing can be removed as anassembly.

(1) Raise and support the vehicle.(2) Remove the wheel and tire assembly.(3) Remove brake caliper (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/DISC BRAKE CALI-PERS - REMOVAL) , rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL)and ABS wheel speed sensor. (Refer to 5 - BRAKES/ELECTRICAL/FRONT WHEEL SPEED SENSOR -REMOVAL)

(4) Remove the cotter pin, nut retainer and axlehub nut.

(5) Remove the hub bearing bolts (Fig. 22).(6) Remove hub bearing and axle shaft assembly

(Fig. 23). Avoid damaging the axle shaft oil sealsin the axle housing.

(7) Remove the brake rotor shield from the hubbearing or knuckle.

INSTALLATION(1) Thoroughly clean the axle shaft and apply a

thin film of Mopart Wheel Bearing Grease or equiv-alent to the shaft splines, seal contact surface andhub bore.

(2) Install the brake rotor shield to the knuckle.(3) Install the hub bearing and axle shaft assem-

bly or axle shaft into the housing and differential

side gears. Avoid damaging the axle shaft oil seals inthe axle housing.

(4) Install the hub bearing, if necessary.(5) Install hub to knuckle bolts and tighten to 102

N·m (75 ft. lbs.).(6) Install hub washer and nut if necessary.

Tighten axle nut to 237 N·m (175 ft. lbs.). Install thenut retainer and a new cotter pin.

(7) Install ABS wheel speed sensor. (Refer to 5 -BRAKES/ELECTRICAL/FRONT WHEEL SPEEDSENSOR - INSTALLATION)

Installer D-130

Installer W-262

Fig. 22 Hub Bearing Bolts1 - AXLE SHAFT2 - AXLE3 - KNUCKLE4 - HUB BEARING

Fig. 23 Hub Bearing and Axle Assembly1 - AXLE2 - KNUCKLE3 - HUB BEARING4 - AXLE SHAFT



(8) Install brake rotor and caliper. (Refer to 5 -BRAKES/HYDRAULIC/MECHANICAL/ROTORS -INSTALLATION)

(9) Install the wheel and tire assembly.(10) Remove support and lower the vehicle.

AXLE SHAFT SEALS

REMOVAL(1) Raise and support vehicle.(2) Remove differential assembly.(3) Remove the inner axle shaft seals with a pry bay.

INSTALLATION(1) Remove any sealer remaining from original seals.(2) Remove sealer from axle tube to housing junc-

tion, if necessary.(3) Install oil seals with Discs 8110 and Turn-

buckle 6797 (Fig. 24). Tighten tool until disc bottomsin housing.

(4) Install differential assembly and fill with fluid.(5) Remove support and lower vehicle.

AXLE - C/V JOINT

REMOVALThe only service procedure to be performed

on the axle C/V joint, is the replacement of the

joint seal boot. If any failure of internal axle shaftcomponents is diagnosed during a vehicle road test,the axle shaft must be replaced as an assembly.

(1) Remove axle shaft.(2) Remove large boot clamp retaining C/V joint

sealing boot, to C/V joint housing and discard.(3) Remove small clamp that retains outer C/V

joint sealing boot to axle shaft and discard (Fig. 25).(4) Remove sealing boot from outer C/V joint hous-

ing and slide it down and off the axle shaft.

(5) Thoroughly clean and inspect axle C/V jointassembly and axle shaft for any signs of excessivewear. If any parts show signs of excessive wear,the axle shaft assembly will require replace-ment. Component parts of these axle shaftassemblies are not serviceable.

INSTALLATIONThe only service procedure to be performed

on the axle C/V joint, is the replacement of thejoint seal boot. If any failure of internal axle shaftcomponents is diagnosed during a vehicle road test,the axle shaft must be replaced as an assembly.

(1) Slide new sealing boot large clamp over axleshaft and onto C/V joint.

(2) Slide the axle C/V joint sealing boot onto theaxle shaft.

(3) Distribute 1/2 the amount of grease provided inseal boot service package (DO NOT USE ANYOTHER TYPE OF GREASE) into axle C/V jointassembly housing. Put the remaining amount intothe sealing boot.

(4) Install axle C/V joint boot small clamp evenlyon sealing boot.

Fig. 24 Axle Seal Tools1 - TURNBUCKLE - 67972 - DISCS - 8110

Fig. 25 Outer C/V Joint Seal Boot Clamps1 - AXLE C/V JOINT HOUSING2 - LARGE CLAMP3 - AXLE SHAFT4 - SMALL CLAMP5 - SEALING BOOT


AXLE SHAFTS (Continued)

(5) Position axle C/V joint boot into retaininggroove in axle C/V joint housing. Then, install largeretaining clamp evenly on sealing boot.

(6) Clamp small sealing boot clamp onto axle shaftusing Clamp Installer C-4975A. Place clamp tool overbridge of clamp (Fig. 26).

(7) Tighten nut on the tool until jaws on tool areclosed completely together, face to face (Fig. 27).

CAUTION: Seal must not be dimpled, stretched orout of shape in any way. If seal is NOT shaped cor-rectly, equalize pressure in seal and shape it byhand.

(8) Place the clamp tool over bridge of clamp (Fig.28).

(9) Tighten nut on the tool until jaws on tool areclosed completely together, face to face.

AXLE - U-JOINT

REMOVALSingle cardan U-joint components are not service-

able. If defective they must be replaced as a unit.

CAUTION: Clamp only the narrow forged portion ofthe yoke in the vise. To avoid distorting the yoke,do not over tighten the vise jaws.

(1) Remove axle shaft.(2) Remove the bearing cap retaining snap rings

(Fig. 29).

NOTE: Saturate the bearing caps with penetratingoil prior to removal.

(3) Locate a socket with an inside diameter islarger than the bearing cap. Place the socket (receiv-er) against the yoke and around the perimeter of thebearing cap to be removed.

(4) Locate a socket with an outside diameter issmaller than the bearing cap. Place the socket (driv-er) against the opposite bearing cap.

(5) Position the yoke with the sockets in a vise(Fig. 30).

(6) Tighten the vise jaws to force the bearing capinto the larger socket (receiver).

(7) Release the vise jaws. Remove the sockets andbearing cap that was partially forced out of the yoke.

Fig. 26 Crimping Tool1 - CLAMP TOOL2 - AXLE SHAFT3 - CLAMP4 - SEALING BOOT

Fig. 27 Crimping Clamp1 - CLAMP2 - JAWS3 - AXLE SHAFT4 - SEALING BOOT

Fig. 28 Large Boot Clamp1 - CLAMP TOOL2 - SEALING BOOT3 - OUTER C/V JOINT4 - BOOT CLAMP


AXLE - C/V JOINT (Continued)

(8) Repeat the above procedure for the remainingbearing cap and remove spider from the propellershaft yoke.

INSTALLATION(1) Pack the bearing caps 1/3 full of wheel bearing

lubricant. Apply extreme pressure (EP), lithium-baselubricant to aid in installation.

(2) Position the spider in the yoke. Insert the sealsand bearings. Tap the bearing caps into the yokebores far enough to hold the spider in position.

(3) Place the socket (driver) against one bearingcap. Position the yoke with the socket in a vise.

(4) Tighten the vise to force the bearing caps intothe yoke. Force the caps enough to install the retain-ing clips.

(5) Install the bearing cap retaining clips.(6) Install axle shaft.

PINION SEAL

REMOVAL(1) Raise and support the vehicle.(2) Remove wheel and tire assemblies.(3) Remove brake rotors and calipers, refer to

Group 5 Brakes for procedures.(4) Mark propeller shaft and pinion companion

flange for installation reference.(5) Remove the propeller shaft from the pinion

companion flange.(6) Rotate the pinion gear a minimum of ten times

and verify the pinion rotates smoothly.(7) Record torque necessary to rotate the pinion

gear with a inch pound dial-type torque wrench.(8) Using a short piece of pipe and Spanner

Wrench 6958 to hold the pinion companion flangeand remove the pinion nut and washer.

(9) Remove pinion companion flange with RemoverC-452 and Flange Wrench C-3281.

(10) Remove pinion seal with Remover 7794-A anda slide hammer (Fig. 31).

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

lip of pinion seal. Install seal with Installer 8108 andHandle C-4171 (Fig. 32).

(2) Install pinion companion flange on the piniongear with Installer W-162-D, Cup 8109 and Wrench6958.

CAUTION: Do not exceed the minimum tighteningtorque 216 N·m (160 ft. lbs.) when installing the pin-ion companion flange retaining nut at this point.Damage to collapsible spacer or bearings mayresult.

Fig. 29 Axle Shaft Outer U—Joint1 - SHAFT YOKE2 - BEARING CAP3 - SNAP RINGS4 - BEARING CAP5 - SPINDLE YOKE6 - BEARING7 - BEARING CAP8 - SNAP RINGS9 - BEARING CAP

Fig. 30 Yoke Bearing Cap1 - LARGE-DIAMETER SOCKET WRENCH2 - VISE3 - SMALL-DIAMETER SOCKET WRENCH


AXLE - U-JOINT (Continued)

(3) Install the pinion washer and a new nut on thepinion gear. Tighten the nut only enough toremove the shaft end play.

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.

(4) Rotate pinion a minimum of ten time and ver-ify pinion rotates smoothly. Rotate the pinion shaftwith an inch pound torque wrench. Rotating torqueshould be equal to the reading recorded duringremoval plus 0.56 N·m (5 in. lbs.) (Fig. 33).

(5) If the rotating torque is low, use SpannerWrench 6958 to hold the pinion companion flange(Fig. 34), and tighten the pinion shaft nut in 6.8 N·m

(5 ft. lbs.) increments until proper rotating torque isachieved.

CAUTION: If the maximum tightening torque isreached prior to reaching the required rotatingtorque, the collapsible spacer may have been dam-aged. Replace the collapsible spacer.

(6) Install propeller shaft with installation refer-ence marks aligned.

(7) Fill differential with gear lubricant.(8) Install brake rotors (Refer to 5 - BRAKES/HY-

DRAULIC/MECHANICAL/ROTORS - INSTALLA-TION) and calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERS - INSTALLATION)

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

COLLAPSIBLE SPACER

REMOVAL(1) Raise and support the vehicle.(2) Remove wheel and tire assemblies.(3) Remove brake rotors and calipers. Refer to

Brakes for procedures.(4) Mark the propeller shaft and pinion companion

flange for installation reference.

Fig. 31 Pinion Seal1 - REMOVER - 7794-A2 - SLIDE HAMMER3 - PINION SEAL

Fig. 32 Pinion Seal1 - HANDLE - C-41712 - INSTALLER - 8108

Fig. 33 Pinion Rotation Torque - Typical1 - PINION YOKE2 -TORQUE WRENCH


PINION SEAL (Continued)

(5) Remove propeller shaft from the pinion com-panion flange.

(6) Rotate pinion gear a minimum of ten times andverify pinion rotates smoothly.

(7) Record pinion gear rotating torque with atorque wrench for installation reference.

(8) Remove pinion nut and washer. Using a shortpiece of pipe and Spanner Wrench 6958 to hold thepinion companion flange.

(9) Remove pinion companion flange with RemoverC-452 and Flange Wrench C-3281.

(10) Remove pinion shaft seal with Remover7794-A and slide hammer (Fig. 35).

(11) Remove front pinion bearing using a pair ofpick tools to pull the bearing straight off pinionshaft. If the bearing becomes bound on the pinionshaft, lightly tap the end of the pinion gear with arawhide or rubber mallet.

(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

lip of pinion seal. Install seal with Installer 8108 andHandle C-4171 (Fig. 36).

(4) Install pinion companion flange with InstallerW-162-D, Cup 8109 and Flange Holder 6958.

(5) Install pinion washer and a new nut on thepinion gear. Tighten the nut to 216 N·m (160 ft. lbs.)minimum. Do not overtighten. Maximum torque is678 N·m (500 ft. lbs.).

CAUTION: Never loosen pinion gear nut to decreasepinion gear bearing rotating torque and neverexceed specified preload torque. If preload torqueis exceeded a new collapsible spacer must beinstalled.

(6) Using Flange Wrench 6958, a length of 1 in.pipe and a torque wrench set at 678 N·m (500 ft. lbs.)crush collapsible spacer until bearing end play istaken up (Fig. 37).

(7) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.)increments until the required rotating torque isachieved. Measure the rotating torque frequently toavoid over crushing the collapsible spacer.

Fig. 34 Pinion Shaft Nut1 - PINION FLANGE2 - FRONT AXLE3 - SPANNER WRENCH - 6958

Fig. 35 Pinion Seal Puller1 - REMOVER2 - SLIDE HAMMER3 - PINION SEAL

Fig. 36 Pinion Seal Installer1 - HANDLE2 - INSTALLER


COLLAPSIBLE SPACER (Continued)

(8) Rotate pinion gear a minimum of ten times andverify pinion rotates smoothly. Check rotating torquewith an inch pound torque wrench. The rotatingtorque should be the amount recorded duringremoval plus:

• Original Bearings: 0.56 N·m (5 in. lbs.).• New Bearings: 1.7 to 3.4 N·m (15 to 35 in. lbs.).(9) Install propeller shaft with reference marks

aligned.(10) Install brake rotors and calipers. Refer to

Brakes for proper procedures.(11) Add gear lubricant if necessary. Refer to

Lubricant Specifications for lubricant requirements.(12) Install wheel and tire assemblies.(13) Lower vehicle.

DIFFERENTIAL

REMOVAL(1) Raise and support the vehicle.(2) Remove lubricant fill hole plug from the differ-

ential housing cover.(3) Remove differential housing cover and drain

the lubricant from the housing.

(4) Clean the housing cavity with a flushing oil,light engine oil or lint free cloth. Do not use water,steam, kerosene or gasoline for cleaning.

(5) Remove hub bearings and axle shafts.(6) Note the installation reference letters stamped

on the bearing caps and housing machined sealingsurface (Fig. 38).

(7) Loosen the differential bearing cap bolts.(8) Position Spreader W-129-B, utilizing some

items from Adapter Kit 6987, with the tool dowelpins seated in the locating holes (Fig. 39). Install theholddown clamps and tighten the tool turnbuckle fin-ger-tight.

(9) Install a Pilot Stud C-3288-B at the left side ofthe differential housing. Attach Dial Indicator C-3339to stud. Load the lever adapter against the oppositeside of the housing (Fig. 40) and zero the indicator.

(10) Spread housing enough to remove the differ-ential case from the housing. Measure the distancewith the dial indicator (Fig. 41).

CAUTION: Do not spread over 0.50 mm (0.020 in). Ifthe housing is over-spread, it could be distorted ordamaged.

(11) Remove the dial indicator.(12) Hold differential case in position and remove

differential bearing cap bolts and caps.(13) Remove differential from the housing and tag

differential bearing cups to ensure location (Fig. 42).(14) Remove differential case preload shims from

the axle housing.(15) Remove spreader from housing. Tag differen-

tial bearing preload shims to ensure correct location.

Fig. 37 Companion Flange1 - COMPANION FLNAGE2 - DIFFERENTIAL HOUSING3 - SPANNER WRENCH

Fig. 38 Bearing Cap Identification1 - REFERENCE LETTERS2 - REFERENCE LETTERS



DISASSEMBLY(1) Remove the ring gear.(2) Drive out the roll pin holding pinion gear mate

shaft with a punch (Fig. 43).

Fig. 39 Differential Housing And Spreader1 - DIFFERENTIAL HOUSING2 - DOWEL3 - SAFETY HOLD DOWN4 - SPREADER5 - TURNBUCKLE

Fig. 40 Dial Indicator Location1 - CLAMP2 - DIAL INDICATOR3 - LEVER ADAPTER4 - SPREADER5 - PILOT STUD

Fig. 41 Spread Housing1 - DIAL INDICATOR2 - SPREADER

Fig. 42 Differential Case Removal1 - DIFFERNTIAL HOUSING2 - DIFFERENTIAL CASE3 - BEARING CUPS


DIFFERENTIAL (Continued)

(3) Remove pinion gear mate shaft from the differ-ential case and the pinion mate gears.

(4) Rotate differential side gears and remove thepinion mate gears and thrust washers (Fig. 44).

(5) Remove differential side gears and thrustwashers.

ASSEMBLY(1) Install differential side gears and thrust wash-

ers.(2) Install pinion mate gears and thrust washers.(3) Install pinion gear mate shaft. Align the roll

pin holes in shaft and the differential case.(4) Install the roll pin in the differential case (Fig.

45).(5) Install the ring gear.(6) Lubricate all differential components with

hypoid gear lubricant.

INSTALLATION

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

Fig. 43 Mate Shaft Roll Pin1 - DRIFT2 - LOCKPIN3 - MATE SHAFT

Fig. 44 Pinion Mate Gear1 - THRUST WASHER2 - SIDE GEAR3 - PINION MATE GEAR

Fig. 45 Mate Shaft Roll Pin1 - PUNCH2 - PINION MATE SHAFT3 - MATE SHAFT LOCKPIN



(1) Position Spreader W-129-B, utilizing someitems from Adapter Kit 6987 with the tool dowel pinsseated in the locating holes (Fig. 46). Install the hold-down clamps and tighten the tool turnbuckle finger-tight.

(2) 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 and zero the indicator.

CAUTION: Do not spread over 0.50 mm (0.020 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 and that the preloadshims remain between the face of the bearing cupand housing. Tap the differential case to ensure thebearings cups and shims are fully seated in the hous-ing.

NOTE: When installing a Vari-lok Y differential theoil feed tube must be pointed to the bottom of thehousing. If differential is installed with the oil feedtube pointed toward the top, the anti-rotation tabswill be damaged.

(6) Install the bearing caps at their original loca-tions (Fig. 47).

(7) Loosely install differential bearing cap bolts.(8) Remove axle housing spreader.(9) Tighten the bearing cap bolts to 61 N·m (45 ft.

lbs.).(10) Install the hub bearings and axle shafts.(11) Apply a bead 6.35mm (1/4 inch) of Mopar Sil-

icone Rubber Sealant or equivalent to the housingcover (Fig. 48).

Install the housing cover within 5 minutesafter applying the sealant.

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

(13) Fill differential with Mopar Hypoid GearLubricant or equivalent to bottom of the fill plughole. Refer to Lubricant Specifications for quantityand type.

(14) Tighten fill plug to 34 N·m (25 ft. lbs.).(15) Remove support and lower the vehicle.

DIFFERENTIAL CASEBEARINGS

REMOVAL(1) Remove differential case from axle housing.

Fig. 46 Spreader Location1 - DIFFERENTIAL HOUSING2 - DOWEL3 - SAFETY HOLD DOWN4 - SPREADER5 - TURNBUCKLE

Fig. 47 Bearing Cap Reference1 - REFERENCE LETTERS2 - REFERENCE LETTERS



(2) Remove bearings from the differential casewith Puller/Press C-293-PA, Adapters 8352 and PlugSP-3289 (Fig. 49).

INSTALLATION

NOTE: If replacement differential side bearings ordifferential case are being installed, differential sidebearing shim requirements may change. Refer toAdjustments (Differential Bearing Preload and GearBacklash) to determine the proper shim selection.

CAUTION: Be sure that the Vari-lok Y plenum is fullyseated against the differential case prior to install-ing the ring gear side differential bearing.

(1) Install differential side bearings with InstallerC-3716-A and Handle C-4171 (Fig. 50).

(2) Install differential in axle housing.

Fig. 48 Differential Cover1 - COVER2 - SEALANT3 - SEALANT BEAD

Fig. 49 Differential Bearings1 - ADAPTERS - 83522 - BEARING3 - DIFFERENTIAL4 - PLUG - SP-32895 - PULLER - C-293-PA


DIFFERENTIAL CASE BEARINGS (Continued)

PINION GEAR/RING GEAR

REMOVAL

NOTE: The ring gear and pinion are serviced as amatched set. Nevar replace one gear without replac-ing the other.

(1) Raise and support vehicle(2) Mark pinion companion flange and propeller

shaft for installation alignment.(3) Remove propeller shaft from pinion companion

flange and tie propeller shaft to underbody.(4) Remove differential from axle housing.(5) Place differential case in a vise with soft metal

jaw (Fig. 51).(6) Remove bolts holding ring gear to differential

case.

NOTE: On Veri-Lok differential the side bearing andoil feed plenum must be removed before removingthe ring gear bolts.

(7) Driver ring gear off the differential case with arawhide hammer (Fig. 51).

(8) Using Spanner Wrench 6958 to hold pinioncompanion flange, and a short length of 1 in. pipe,remove the pinion nut and washer (Fig. 52).

(9) Remove the pinion companion flange from pin-ion shaft with Remover C-452 and Flange WrenchC-3281.

(10) Remove the pinion gear and collapsible spacerfrom housing (Fig. 53).

Fig. 50 Differential Side Bearing1 - INSTALLER - C-3716-A2 - HANDLE - C-4171

Fig. 51 Ring Gear1 - CASE2 - RING GEAR3 - RAWHIDE HAMMER

Fig. 52 Pinion Nut1 - PINION FLANGE2 - FRONT AXLE3 - SPANNER WRENCH - 6958


PINION GEAR/RING GEAR (Continued)

(11) Remove front pinion bearing cup, bearing, oilslinger and pinion seal with Remover C-4345 andHandle C-4171 (Fig. 54).

(12) Remove rear pinion bearing cup from axlehousing (Fig. 55) with Remover D-149 and HandleC-4171.

(13) Remove collapsible preload spacer from piniongear (Fig. 56).

(14) Remove rear pinion bearing from the pinionwith Puller/Press C-293-PA and Adapters C-293-39(Fig. 57). Remove oil slinger/pinion depth shim fromthe pinion shaft and record thickness.

INSTALLATION

NOTE: Pinion depth shims are placed between therear pinion bearing cone and the pinion head toachieve proper ring and pinion gear mesh. If ringand pinion gears are reused, the pinion oil slinger/depth shim should not require replacement. Referto Adujstments (Pinion Gear Depth) to select theproper thickness shim before installing pinion gear.

(1) Apply Mopar Door Ease or equivalent lubricantto outside surface of rear pinion bearing cup. Installbearing cup with Installer D-146 and Handle C-4171(Fig. 58). Verify cup is seated.

(2) Apply Mopar Door Ease, or equivalent lubri-cant to outside surface of front pinion bearing cup.Install bearing cup with Installer D-130 and HandleC-4171 (Fig. 59). Verify cup is seated.

(3) Install front pinion bearing, and oil slinger ifequipped.

Fig. 53 Pinion Gear1 - RAWHIDE HAMMER

Fig. 54 Front Pinion Bearing Cup1 - REMOVER - D-1032 - HANDLE - C-4171

Fig. 55 Rear Pinion Bearing Cup1 - DRIVER - C-43072 - HANDLE - C-4171



Fig. 56 Collapsible1 - COLLAPSIBLE SPACER2 - SHOULDER3 - PINION GEAR4 - OIL SLINGER5 - REAR BEARING

Fig. 57 Rear Pinion Bearing1 - PULLER - C-293-PA2 - VISE3 - ADAPTERS - C-293-424 - PINION GEAR SHAFT

Fig. 58 Rear Pinion Bearing Cup1 - INSTALLER2 - HANDLE

Fig. 59 Front Pinion Bearing Cup1 - INSTALLER2 - HANDLE



(4) Apply a light coating of gear lubricant on thelip of pinion seal and intall seal with Installer 8108and Handle C-4171 (Fig. 60).

(5) Install rear pinion bearing and oil slinger/depthshim onto the pinion shaft with Installer W-262 anda press (Fig. 61).

(6) Install a new collapsible spacer on pinion shaftand install the pinion into the axle housing (Fig. 62).

(7) Install pinion companion flange, with InstallerW-162-B, Cup 8109 and Spanner Wrench 6958.

(8) Install pinion washer and a new nut onto thepinion gear and tighten the nut to 216 N·m (160 ft.lbs.). Do not over–tighten.

CAUTION: Never loosen pinion gear nut to decreasepinion gear bearing rotating torque and neverexceed specified preload torque. If preload torqueis exceeded a new collapsible spacer must beinstalled.

(9) Use Flange Wrench 6958, a length of 1 in. pipeand a torque wrench set at 678 N·m (500 ft. lbs.) andcrush collapsible spacer until bearing end play istaken up (Fig. 63).

(10) Slowly tighten the nut in 6.8 N·m (5 ft. lb.)increments until the required rotating torque isachieved. Measure the rotating torque frequently toavoid over crushing the collapsible spacer (Fig. 64).

(11) Rotate the pinion a minimum of ten times.Verify pinion rotates smoothly and check rotatingtorque with an inch pound torque wrench (Fig. 64).Pinion gear rotating torque is:

• Original Bearings: 1 to 2.25 N·m (10 to 20 in.lbs.).

• New Bearings: 1.7 to 3.4 N·m (15 to 30 in. lbs.).

Fig. 60 Pinion Seal1 - HANDLE - C-41712 - INSTALLER - 8108

Fig. 61 Rear Pinion Bearing1 - INSTALLER2 - OIL SLINGER3 - DRIVE PINION GEAR4 - PINION REAR BEARING5 - PRESS

Fig. 62 Collapsible Preload Spacer1 - COLLAPSIBLE SPACER2 - SHOULDER3 - PINION GEAR4 - OIL SLINGER5 - REAR BEARING



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

(13) Invert the differential case in the vise.(14) Install new ring gear bolts and alternately

tighten to 108 N·m (80 ft. lbs.) (Fig. 65).

CAUTION: Do not reuse the bolts that held the ringgear to the differential case. The bolts can fracturecausing extensive damage.

NOTE: If equipped with Veri-Lok differential installoil feed plenum and side bearing.

(15) Install differential in housing and verify dif-ferential bearing preload, gear mesh and contact pat-tern. Refer to Adjustment for procedure.

(16) Install differential cover and fill with gearlubricant.

(17) Install propeller shaft with reference marksaligned.

(18) Remove supports and lower vehicle.

Fig. 63 Pinion Nut1 - PINION FLANGE2 - FRONT AXLE3 - SPANNER WRENCH - 6958

Fig. 64 Pinion Rotating Torque-Typical1 - TORQUE WRENCH2 - PINION YOKE

Fig. 65 Ring Gear Bolts1 - TORQUE WRENCH2 - RING GEAR BOLTS3 - RING GEAR4 - DIFFERENTIAL CASE



REAR AXLE - 198RBI

TABLE OF CONTENTS

page page

REAR AXLE - 198RBIDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 50

AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 55ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 55SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 64SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 64

AXLE SHAFTSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 67

AXLE BEARINGS/SEALSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 67

PINION SEALREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 70

COLLAPSIBLE SPACERREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 72

DIFFERENTIALREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 75ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 75

DIFFERENTIAL - TRAC-LOCDIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 77

TRAC-LOKY. . . . . . . . . . . . . . . . . . . . . . . . . . . 77DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 77ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

DIFFERENTIAL CASE BEARINGSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 81

PINION GEAR/RING GEARREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 84

REAR AXLE - 198RBI

DESCRIPTIONThe 198 Rear Beam-design Iron (RBI) axle housing

has an iron center casting (differential housing) withaxle shaft tubes extending from either side. Thetubes are pressed into and welded to the differentialhousing to form a one-piece axle housing.

The integral type, hypoid gear design, housing hasthe centerline of the pinion set below the centerlineof the ring gear.

The axle has a vent hose to relieve internal pres-sure caused by lubricant vaporization and internalexpansion.

The axles are equipped with semi-floating axleshafts, meaning that loads are supported by the axleshaft and bearings. The axle shafts are retained bybearing retainer plates on the axles which are boltedto flanges at the outboard end of the axle tubes.

The cover provides a means for servicing the differ-ential without removing the axle.

For vehicles equipped with ABS brakes, the axleshave a tone ring pressed onto the axle shaft. Usecare when removing axle shafts to ensure that thetone wheel or the wheel speed sensor are not dam-aged.

The axle has the assembly part number and gearratio listed on a tag. The tag is attached to the dif-

ferential housing by a cover bolt. Build date identifi-cation codes are stamped on the cover side of an axleshaft tube.

The differential case is a one-piece design. The dif-ferential pinion mate shaft is retained with athreaded pin. Differential bearing preload and ringgear backlash is adjusted by the use of selectivespacer shims. Pinion bearing preload is set andmaintained by the use of a collapsible spacer (Fig. 1).

Axles equipped with a Trac-Loky differential areoptional. A Trac-Lok differential has a one-piece dif-ferential case, and the same internal components asa standard differential, plus two clutch disc packs.

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.


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 side

WJ REAR AXLE - 198RBI 3 - 49

gears. As a result, the pinion gears revolve with thepinion mate shaft but do not rotate around it (Fig. 2).

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.3). 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 shaft

attached to the outside wheel to rotate at a fasterspeed.

TRAC-LOKY DIFFERENTIALThe Trac-loky clutches are engaged by two concur-

rent forces. The first being the preload force exertedthrough Belleville spring washers within the clutchpacks. The second is the separating forces generatedby the side gears as torque is applied through thering gear (Fig. 4).

The Trac-loky design provides the differentialaction needed for turning corners and for drivingstraight ahead during periods of unequal traction.When one wheel looses traction, the clutch packstransfer additional torque to the wheel having themost traction. Trac-loky differentials resist wheelspin on bumpy roads and provide more pulling powerwhen one wheel looses traction. Pulling power is pro-vided continuously until both wheels loose traction. Ifboth wheels slip due to unequal traction, Trac-lokyoperation is normal. In extreme cases of differencesof traction, the wheel with the least traction mayspin.



cant, incorrect backlash, tooth contact, worn/damagedgears, or the carrier housing not having the properoffset and squareness.


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 is

Fig. 1 Shim Locations1 - PINION GEAR DEPTH SHIM2 - DIFFERENTIAL BEARING SHIM3 - RING GEAR4 - DIFFERENTIAL BEARING SHIM5 - COLLAPSIBLE SPACER

Fig. 2 Differential Operation - Straight Ahead Driving1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT100% OF CASE SPEED2 - PINION GEAR3 - SIDE GEAR4 - PINION GEARS ROTATE WITH CASE

Fig. 3 Differential Operation - On Turns1 - PINION GEARS ROTATE ON PINION SHAFT

3 - 50 REAR AXLE - 198RBI WJ

REAR AXLE - 198RBI (Continued)

the greatest. Shift out-of-gear and coast through thepeak-noise range. If the noise stops or changesgreatly:





Pinion bearings have a constant-pitch noise. Thisnoise changes only with vehicle speed. Pinion bearing

noise 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.




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


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.




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.

Fig. 4 Trac-lok Y Limited Slip Differential1 - CASE2 - RING GEAR3 - DRIVE PINION4 - PINION GEAR5 - MATE SHAFT6 - CLUTCH PACK7 - SIDE GEAR8 - CLUTCH PACK



• 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






































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

secure axle.(3) Remove the wheels and tires.(4) Remove brake rotors (Refer to 5 - BRAKES/HY-

DRAULIC/MECHANICAL/ROTORS - REMOVAL)and calipers (Refer to 5 - BRAKES/HYDRAULIC/ME-CHANICAL/DISC BRAKE CALIPERS - REMOVAL)from the axle.

(5) Disconnect parking brake cables from bracketsand lever.

(6) Remove wheel speed sensors. (Refer to 5 -BRAKES/ELECTRICAL/REAR WHEEL SPEEDSENSOR - REMOVAL)

(7) Disconnect the brake hose at the axle junctionblock. Do not disconnect the brake hydraulic lines atthe calipers.


(9) Mark propeller shaft and yokes for installationreference.

(10) Remove propeller shaft. (Refer to 3 - DIFFER-ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-PELLER SHAFT - REMOVAL)

(11) Disconnect stabilizer bar links.(12) Remove nut holding upper suspension arm to

the rear axle ball joint.(13) Using Remover 8278, separate the rear axle

ball joint from the upper suspension arm (Fig. 5).(14) Disconnect shock absorbers from axle.(15) Disconnect track bar.

(16) Disconnect lower suspension arms from theaxle brackets.

(17) Separate the axle from the vehicle.

Fig. 5 Rear Ball Joint1 - REMOVER - 82782 - UPPER SUSPENSION ARM3 - BALL JOINT STUD



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 coilsprings.

(2) Position the lower suspension arms on the axlebrackets. Install nuts and bolts, do not tighten boltsat this time.

(3) Install the upper suspension arm to the rearaxle ball joint.

(4) Install nut to hold the upper suspension arm tothe rear axle ball joint. Torque the nut to 122 N·m(90 ft.lbs.) (Fig. 6).

(5) Install track bar and attachment bolts, do nottighten bolts at this time.

(6) Install shock absorbers and tighten nuts to 60N·m (44 ft. lbs.).

(7) Install stabilizer bar links and tighten nuts to36 N·m (27 ft. lbs.).

(8) Install wheel speed sensors. (Refer to 5 -BRAKES/ELECTRICAL/REAR WHEEL SPEEDSENSOR - INSTALLATION)

(9) Connect parking brake cable to brackets andlever.

(10) Install brake rotors (Refer to 5 - BRAKES/HY-DRAULIC/MECHANICAL/ROTORS - INSTALLA-TION) and calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERS - INSTALLATION)

(11) Connect the brake hose to the axle junctionblock.

(12) Install axle vent hose.(13) Align propeller shaft and pinion yoke refer-

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

(14) Install the wheels and tires.(15) Add gear lubricant, if necessary.(16) Remove support and lower the vehicle.(17) Tighten lower suspension arm bolts to 177

N·m (130 ft. lbs.).(18) Tighten track bar bolts to 100 N·m (74 ft.

lbs.).

ADJUSTMENTS

PINION GEAR DEPTHRing 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.7). 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 setting from the cen-ter line of the ring gear to the back face of the pinionis 96.850 mm (3.813 in.). The standard depth pro-vides the best gear tooth contact pattern. Refer toBacklash and Contact Pattern Analysis paragraph inthis section for additional information.

Fig. 6 Rear Suspention1 - UPPER SUSPENSION ARM2 - REAR AXLE BALL JOINT3 - REAR AXLE

Fig. 7 Pinion Gear ID Numbers1 - PRODUCTION NUMBERS2 - PINION GEAR DEPTH VARIANCE3 - GEAR MATCHING NUMBER)



Compensation for pinion depth variance isachieved with a select shim/oil baffle. The shims areplaced between the rear pinion bearing and the pin-ion gear head (Fig. 8).






Variance


−4 −3 −2 −1 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 −0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003

0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004

−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005

−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006

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

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


and pinion bearings installed in the housing. Takemeasurements with Pinion Gauge Set and Dial Indi-cator C-3339 (Fig. 9).




(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-tion in the housing side bearing cradles (Fig. 11).Install differential bearing caps on Arbor Discs andtighten cap bolts to 41 N·m (30 ft. lbs.).

NOTE: Arbor Discs 6732 has different step diame-ters to fit other axles. Choose proper step for axlebeing serviced.

Fig. 8 Adjustment Shim Locations1 - PINION GEAR DEPTH SHIM/OIL BAFFLE2 - DIFFERENTIAL BEARING SHIM3 - RING GEAR4 - DIFFERENTIAL BEARING SHIM5 - COLLAPSIBLE SPACER




(6) Place Scooter Block/Dial Indicator in positionin the housing so dial probe and scooter block are

flush against the rearward surface of the pinionheight block (Fig. 9). Hold scooter block in place andzero the dial indicator face to the pointer. Tightendial indicator face lock screw.


(8) Slide the dial indicator probe across the gapbetween the pinion height block and the arbor barwith the scooter block against the pinion height block(Fig. 12). When the dial probe contacts the arbor bar,the dial pointer will turn clockwise. Bring dialpointer back to zero against the arbor bar, do notturn dial face. Continue moving the dial probe to thecrest of the arbor bar and record the highest reading.If the dial indicator can not achieve the zero reading,the rear bearing cup or the pinion depth gauge set isnot installed correctly.


DIFFERENTIALDifferential side bearing preload and gear backlash

is achieved by selective shims positioned behind thedifferential side bearing cones. The proper shimthickness can be determined using slip-fit DummyBearings D-348 in place of the differential side bear-ings and a Dial Indicator C-3339. Before proceedingwith the differential bearing preload and gear back-lash measurements, measure the pinion gear depthand prepare the pinion for installation. Establishing

Fig. 9 Pinion Gear Depth Gauge Tools1 - DIAL INDICATOR - C-33392 - ARBOR - D-115-33 - PINION HEIGHT BLOCK - 67394 - CONE - 67405 - SCREW - 67416 - PINION BLOCK - 67357 - SCOOTER BLOCK - D-115-28 - ARBOR DISC - 6732


Fig. 11 Gauge Tools In Housing1 - ARBOR DISC - 67322 - PINION BLOCK - 67353 - ARBOR - D-115-34 - PINION HEIGHT BLOCK - 6739



proper 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 is installed, and thegear backlash shim thickness is measured. The over-all shim thickness is the total of the dial indicatorreading and the preload specification added together.The gear backlash measurement determines thethickness of the shim used on the ring gear side ofthe differential case. Subtract the gear backlash shimthickness from the total overall shim thickness andselect that amount for the pinion gear side of the dif-ferential (Fig. 13). Differential shim measurementsare performed with the spreader W-129-B removed.

PRELOAD SHIM SELECTION




(3) Install Dummy Bearings D-348 on differentialcase.

(4) Install differential case in the housing.(5) Record the thickness of Dummy Shims 8107.

Insert the shims between the dummy bearings andthe differential housing (Fig. 14).

Fig. 12 Pinion Gear Depth Measurement1 - ARBOR - 67322 - SCOOTER BLOCK - D-115-23 - DIAL INDICATOR - C-3339


Fig. 14 SHIM POINT1 - DUMMY SHIM - 81072 - AXLE HOUSING3 - DIFFERENTIAL CASE4 - DUMMY BEARINGS - D-348



(6) Install the marked bearing caps in their correctpositions. Install and snug the bolts (Fig. 15).

(7) Using a dead-blow type hammer seat the differ-ential dummy bearings to each side of the housing(Fig. 16) and (Fig. 17).


(9) Attach a Dial Indicator C-3339 to pilot stud.Position the dial indicator plunger on a flat surfacebetween the ring gear bolt heads (Fig. 18).


Fig. 15 Tighten Bolts Holding1 - BEARING CAP2 - AXLE HOUSING3 - DIFFERENTIAL CASE

Fig. 16 Seat Dummy Side Bearing1 - MALLET2 - AXLE HOUSING3 - DIFFERENTIAL CASE

Fig. 17 Seat Dummy Side Bearing1 - AXLE HOUSING2 - MALLET3 - DIFFERENTIAL CASE

Fig. 18 Differential Side play Measurement1 - DIFFERENTIAL CASE2 - AXLE HOUSING3 - SPECIAL TOOL - C-3288-B4 - SPECIAL TOOL - C-3339




(12) Add 0.152 mm (0.006 in.) to the zero end playtotal. This new total represents the thickness ofshims to compress, or preload the new bearings whenthe differential is installed.



(15) Install the pinion gear in axle housing. Installthe pinion yoke and establish the correct pinionrotating torque.

(16) Install differential case and Dummy BearingsD-348 in the housing.

(17) Install a single dummy shim in the ring gearside. Install bearing caps and tighten bolts snug.


surface between the ring gear bolt heads. (Fig. 18).(20) Push and hold differential case toward pinion

gear and zero dial indicator (Fig. 21).

(21) Push and hold differential case to ring gearside of the housing and record dial indicator reading(Fig. 22). Add dummy shim thickness to this reading.This will be the total shim thickness to achieve zerobacklash.

(22) Subtract 0.076 mm (0.003 in.) from the dialindicator reading to compensate for backlash betweenring and pinion gears. This total is the thicknessshim 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.




Fig. 19 Zero Dial Indicator1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE2 - SPECIAL TOOL - C-3288-B3 - SPECIAL TOOL - C-33394 - ZERO DIAL INDICATOR FACE

Fig. 20 Differential Case and Dial Indicator1 - READ DIAL INDICATOR2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE3 - AXLE HOUSING

Fig. 21 Zero Dial Indicator1 - ZERO DIAL INDICATOR FACE2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE3 - PINION GEAR4 - AXLE HOUSING5 - DIFFERENTIAL CASE



(27) Install spreader W-129-B utilizing some itemsfrom Adapter Set 6987, on the housing and spreadaxle opening enough to receive differential case.

CAUTION: Do not spread over 0.38 mm (0.015 in.). Ifhousing is over-spread, it could be distorted ordamaged.

(28) Place the bearing preload shims in the hous-ing, against the axle tubes.

(29) Install differential case into the housing.(30) Remove spreader from the housing.(31) Rotate the differential case several times to


gear tooth (Fig. 23).(33) Push and hold ring gear upward while not

allowing the pinion gear to rotate.(34) Zero dial indicator face to pointer.(35) Push and hold ring gear downward while not

allowing the pinion gear to rotate. Dial indicatorreading should be between 0.12-0.20 mm (0.005-0.008in.). If backlash is not within specifications transferthe necessary amount of shim thickness from oneside of the axle housing to the other (Fig. 24).


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


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.


(2) Wrap, twist and hold a shop towel around thepinion yoke to increase the turning resistance of the

Fig. 22 Differential To Ring Gear Side1 - READ DIAL INDICATOR2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE3 - PINION GEAR4 - AXLE HOUSING5 - DIFFERENTIAL CASE

Fig. 23 Ring Gear Backlash Measurement1 - DIAL INDICATOR




pinion. This will provide a more distinct contact pat-tern.


The areas on the ring gear teeth with the greatestdegree of contact against the pinion teeth will squee-gee the compound to the areas with the least amountof contact. Note and compare patterns on the ringgear teeth to Gear Tooth Contact Patterns chart (Fig.25) and adjust pinion depth and gear backlash asnecessary.






Fig. 25 Gear Tooth Contact Patterns



SPECIFICATIONS

REAR AXLE - 198RBI

AXLE SPECIFICATIONS


Axle Ratio 3.07, 3.55, 3.73, 4.10




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



Pinion Bearing Preload - New Bearings 1.7-3.4 N·m (15-30 in. lbs.)





Ring Gear Bolts 129-142 95-105 —

Pinion Nut 271-474 200-350 —

Pinion Mate Shaft Screw 16.25 12 —

Axle Bearing Retainer PlateNuts

61 45—

SPECIAL TOOLS

AXLE

Puller C-293-PA

Adapter 8352

Adapter C-293-40

Adapter Plug SP-3289


Puller C-452

Wrench C-3281

Installer C-3972-A

Spanner Wrench 6958

Installer Screw 8112

Cup 8109

Handle C-4171

Installer C-3716-A

Installer D-130

Installer D-146



Remover C-4345

Remover D-149

Installer W-262

Pinion Depth 6774

Trac-lok Tools 6960

Fixture Holding 6965

Shims Dummy 8107

Spreader W-129-B

Adapter Kit 6987

Pilot Studs C-3288-B



AXLE SHAFTS

REMOVAL(1) Place transmission in neutral.(2) Raise and support vehicle.(3) Remove wheel and tire assembly.(4) Remove brake caliper (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/DISC BRAKE CALI-PERS - REMOVAL) and rotor. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL)

(5) Remove nuts holding axle retainer plate to axletube from the rear of the axle flange.

(6) Pull axle shaft from the axle with Slide Ham-mer 7420 and Adapter 6790. Mount the adapter tothe axle with lug nuts.

NOTE: It is normal that the axle bearing race isloose in the axle tube.

INSTALLATION(1) Insall axle into the axle tube with the flat area

of the retainer plate upward.(2) Insert retaining plate studs into the brake

backing plate and axle tube flange.(3) Install retainer nuts and tighten nuts to 61

N·m (45 ft. lbs.).(4) Install the brake caliper (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/DISC BRAKE CALI-PERS - INSTALLATION) and rotor. (Refer to 5 -BRAKES/HYDRAULIC/MECHANICAL/ROTORS -INSTALLATION)

(5) Install wheel and tire.(6) Check and fill the differential with gear lubri-

cant.(7) Lower vehicle.

AXLE BEARINGS/SEALS

REMOVAL(1) Remove axle shaft from vehicle.


(2) Drill a shallow hole into soft steel axle bearingretaining ring with a 3/8 in. drill bit (Fig. 26). Use adrill depth stop to avoid marking the axle.

(3) With a cold chisel cut the retaining ring acrossdrilled hole. (Fig. 27)

(4) Slide retaining ring from axle shaft.(5) Remove axle bearing from the shaft with, a

press and Splitter 1130 placed between the seal andbearing (Fig. 28).

(6) Remove seal from axle.(7) Remove retaining plate from axle shaft.

INSTALLATION(1) Verify axle shaft retaining plate is flat with a

straight edge.

NOTE: If the plate is warped or the studs are loosein the plate replace the retaining plate.

(2) Install retaining plate on the axle shaft (Fig.29).

(3) Apply a coat of multi-purpose grease on sealingsurface of axle seal.

(4) Install seal on the axle shaft with cavity awayfrom retaining plate (Fig. 29).

Hub Puller 6790


Splitter Bearing 1130

Installer Gear/Bearing 7913-A



(5) Lubricate bearing with Mopart Wheel BearingGrease or equivalent. Wipe excess grease from thebearing.

(6) Install bearing on the axle shaft with Installer7913 and a press (Fig. 30).

(7) Press soft metal retaining ring onto axle shaftwith Installer 7913 and a press (Fig. 31).

(8) Install axle in vehicle.

Fig. 26 Drill Retaining Ring1 - DRILL BIT2 - AXLE3 - RETAINING PLATE4 - RETAINING RING

Fig. 27 Retaining Ring1 - AXLE2 - COLD CHISEL3 - VISE4 - RETAINING RING

Fig. 28 Axle Bearing And Seal1 - AXLE2 - PRESS PLATES3 - BLOCKS4 - SPLITTER - 1130

Fig. 29 Axle Bearing And Seal Components1 - RETAINING RING2 - SEAL3 - AXLE4 - RETAINING PLATE5 - AXLE BEARING


AXLE BEARINGS/SEALS (Continued)

PINION SEAL

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

DRAULIC/MECHANICAL/ROTORS - REMOVAL)and calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS -REMOVAL)

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

(5) Remove propeller shaft from the yoke.(6) Rotate the pinion gear a minimum of ten times

and verify pinion rotates smoothly.(7) Record rotating torque of the pinion gear with

an inch pound dial-type torque wrench, for installa-tion reference.

(8) Hold the pinion yoke with Spanner Wrench6958 and remove the pinion nut and washer (Fig.32).

(9) Remove pinion yoke with Remover C-452 andWrench C-3281 (Fig. 33).

Fig. 30 Bearing On Axle1 - PRESS RAM2 - INSTALLER - 79133 - AXLE BEARING4 - SEAL5 - RETAINING PLATE6 - AXLE

Fig. 31 Bearing Retaining Ring On Axle1 - PRESS2 - AXLE3 - AXLE BEARING4 - INSTALLER - 79135 - RETAINING RING

Fig. 32 Pinion Yoke Holder1 - PIPE2 - PINION YOKE3 - WRENCH - 69584 - LOWER CONTROL ARM



(10) Remove pinion gear seal with Remover7794-A and slide hammer (Fig. 34).


lip of pinion seal and install seal with InstallerC-3972-A and Handle C-4171 (Fig. 35).

(2) Install yoke on pinion gear with Screw 8112,Cup 8109 and Spanner Wrench 6958 (Fig. 36).

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 a new nut on the pin-ion gear and tighten the nut until there is zero bear-ing end-play.

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


(5) Rotate the pinion gear a minimum of ten timesand verify pinion rotates smoothly. Rotate pinionshaft an inch pound torque wrench. Rotating torqueshould be equal to recorded reading plus an addi-tional 0.56 N·m (5 in. lbs.) (Fig. 37).

(6) If the rotating torque is low, use SpannerWrench 6958 to hold the pinion yoke (Fig. 38), and

Fig. 33 Pinion Yoke1 - SPECIAL TOOL C-32812 - YOKE3 - SPECIAL TOOL C-452


Fig. 35 Pinion Seal1 - SPECIAL TOOL C-41712 - SPECIAL TOOL C-3972–A

Fig. 36 Pinion Yoke1 - PINION YOKE2 - AXLE HOUSING



tighten the pinion nut in 6.8 N·m (5 ft. lbs.) incre-ments until the proper rotating torque is achieved.

CAUTION: If the maximum tightening torque isreached prior to reaching required rotating torque,the collapsible spacer may have been damaged.Replace the collapsible spacer.

(7) Install the propeller shaft with reference marksaligned.

(8) Add gear lubricant to the differential if neces-sary.



COLLAPSIBLE SPACER

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

BRAKES/HYDRAULIC/MECHANICAL/ROTORS -REMOVAL) and calipers. (Refer to 5 - BRAKES/HY-DRAULIC/MECHANICAL/DISC BRAKE CALIPERS- REMOVAL)

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


(6) Record rotate torque of the pinion gear, with aninch pound torque wrench for installation reference.

(7) Hold pinion yoke with Spanner Wrench 6958and remove pinion nut and washer (Fig. 39).

(8) Remove the pinion yoke with Remover C-452and Wrench C-3281 (Fig. 40).

(9) Remove pinion shaft seal with Remover 7794-Aand slide hammer (Fig. 41).

Fig. 37 Pinion Rotation Torque1 - PINION YOKE2 -TORQUE WRENCH

Fig. 38 Pinion Shaft Nut1 - SPANNER WRENCH - 69582 - PIPE3 - TORQUE WRENCH

Fig. 39 Pinion Yoke1 - PIPE2 - PINION YOKE3 - SPANNER WRENCH - 69584 - LOWER CONTROL ARM



(10) Remove front pinion bearing using a pair ofpick tools to pull the bearing off the pinion gearshaft. If the pinion gear becomes bound on the pinionshaft, lightly tap the end of the shaft with a rawhide/rubber mallet.


INSTALLATION(1) Install a new collapsible spacer on pinion

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

lip of pinion seal and install seal with InstallerC-3972-A and Handle C-4171 (Fig. 42).

(4) Install yoke with Screw 8112, Cup 8109 andSpanner Wrench 6958 (Fig. 43).

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


(6) Using yoke with Spanner Wrench 6958 and atorque wrench set at 474 N·m (350 ft. lbs.), (Fig. 44)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. 45).

Fig. 40 Pinion Yoke Puller1 - WRENCH - C-32812 - YOKE3 - PULLER - C-452

Fig. 41 Pinion Seal Remover1 - REMOVER - 7794-A2 - SLIDE HAMMER3 - PINION SEAL

Fig. 42 Pinion Seal Installer1 - HANDLE - C-41712 - INSTALLER - C-3972-A

Fig. 43 Pinion Yoke1 - PINION YOKE2 - DIFFERENTIAL HOUSING



NOTE: If more than 474 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. 45). 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 marksalign.

(9) Install rear brake rotors (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLA-TION) and calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERS - INSTALLATION)

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

DIFFERENTIAL

REMOVAL(1) Raise and support vehicle.(2) Remove the lubricant fill hole plug from the

differential housing cover.(3) Remove the differential housing cover and

allow fluid to drain.(4) Clean the housing cavity with flushing oil, light

engine oil or lint free cloth. Do not use water,steam, kerosene or gasoline for cleaning.

(5) Remove axle shafts.(6) Note the reference letters stamped on the bear-

ing caps and housing machined sealing surface (Fig.46).


items from Adapter set 6987, with the tool dowel pinsseated in the locating holes (Fig. 47). Install the hold-down clamps and tighten the tool turnbuckle finger-tight.

(9) 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 the

Fig. 44 Pinion Nut1 - SPANNER WRENCH - 69582 - PIPE3 - TORQUE WRENCH

Fig. 45 Pinion Gear Rotating Torque1 - PINION YOKE2 - TORQUE WRENCH




opposite side of the housing (Fig. 48) and zero theindicator.

CAUTION: Do not spread over 0.38 mm (0.015 in). Ifthe housing is over–spread, it could be distorted ordamaged.

(10) Spread the housing enough to remove the dif-ferential case from the housing. Measure the dis-tance with the dial indicator (Fig. 49).

(11) Remove the dial indicator.(12) While holding the differential case in position,

remove the differential bearing cap bolts and caps.(13) Remove the differential from the housing.

Ensure that the differential bearing cups remain inposition on the differential bearings (Fig. 50).

(14) Remove bearing cups from the differential andtag them to indicate their location on the differential.

(15) Remove differential case preload shims fromthe housing and tag them to indicate their location inthe housing.

(16) Remove spreader from housing.

Fig. 47 Spreader Location1 - DIFFERENTIAL HOUSING2 - ADAPTER3 - SAFETY HOLD DOWN4 - SPREADER5 - TURNBUCKLE


Fig. 49 Spread Differential Housing1 - DIAL INDICATOR2 - SPREADER



DISASSEMBLY(1) Remove pinion mate shaft lock screw (Fig. 51).

(2) Remove pinion mate shaft.(3) Rotate differential side gears and remove the

differential pinion gears and thrust washers (Fig.52).

(4) Remove the differential side gears and thrustwashers.

ASSEMBLY(1) Install the differential side gears and thrust

washers.(2) Install the differential pinion gears and thrust

washers.(3) Install the pinion mate shaft.

(4) Align the hole in the pinion mate shaft withthe hole in the differential case and install the pinionmate shaft lock screw.

(5) Lubricate all differential components withhypoid gear lubricant.

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, utilizing some itemsfrom Adapter set 6987, with the tool dowel pins seatedin the locating holes (Fig. 53). Install the holddownclamps and tighten the tool turnbuckle finger-tight.




Fig. 50 Differential1 - DIFFERENTIAL HOUSING2 - DIFFERENTIAL CASE3 - BEARING CUPS

Fig. 51 Pinion Mate Shaft Lock Screw1 - LOCK SCREW2 - PINION MATE SHAFT





that the differential bearing cups remain in positionon the differential bearings and that the preloadshims remain between the face of the bearing cupand the housing. Tap the differential case to ensurethe bearings cups and shims are fully seated in thehousing.


(6) Install the bearing caps in their original loca-tions (Fig. 54).


lbs.).(10) Install the axle shafts.(11) Apply a 6.35mm (1/4 in.) bead of Mopart Sil-




(13) Refill the differential with Mopart HypoidGear Lubricant or equivalent to bottom of the fillplug hole. Refer to Lubricant Specifications for cor-rect quantity and type.

(14) Install fill hole plug.(15) Remove support and lower the vehicle.

Fig. 53 Spreader Location1 - DIFFERENTIAL HOUSING2 - ADAPTER KIT COMPONENTS - 69873 - SAFETY HOLD DOWN4 - SPREADER - W-129-B5 - TURNBUCKLE


Fig. 55 Differential Cover - Typical1 - COVER2 - SEALANT3 - SEALANT BEAD



DIFFERENTIAL - TRAC-LOC

DIAGNOSIS AND TESTING - TRAC-LOKYThe most common problem is a chatter noise when

turning corners. Before removing a Trac-loky unitfor repair, drain, flush and refill the axle with thespecified lubricant. A container of Mopar Trac-lokyLubricant (friction modifier) should be added afterrepair service 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.

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. 56).

(6) If rotating torque is less than 22 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 Holding Fixture 6965 in a vise

and position the differential case on the Holding Fix-ture (Fig. 57).

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

(3) Remove the pinion gear mate shaft lock screw(Fig. 58).

(4) Remove pinion gear mate shaft with a drift andhammer (Fig. 59).

(5) Install and lubricate Step Plate C-6960-3 (Fig.60).

(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-6960-1 (Fig. 61) to preventadapter from turning.

Fig. 56 Trac-lok Y Test -Typical1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE2 - TORQUE WRENCH

Fig. 57 Differential Case Holding Fixture1 - FIXTURE - 69652 - VISE3 - DIFFERENTIAL


(8) Install Forcing Screw C-6960-4 and tightenscrew to 122 N·m (90 ft. lbs.) maximum to compressBelleville springs in clutch packs (Fig. 62).

(9) With a feeler gauge remove thrust washersfrom behind the pinion gears (Fig. 63).

(10) Insert Turning Bar C-6960-2 into the pinionmate shaft hole in the case (Fig. 64).

(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 and

Threaded Adapter.

Fig. 58 Mate Shaft Lock Screw1 - LOCK SCREW2 - PINION GEAR MATE SHAFT

Fig. 59 Mate Shaft1 - PINION MATE SHAFT2 - SIDE GEAR3 - DRIFT4 - PINION MATE GEAR

Fig. 60 Step Plate1 - LOWER SIDE GEAR2 - DIFFERENTIAL CASE3 - STEP PLATE - C-6960-3

Fig. 61 Threaded Adapter Disc1 - SOCKET2 - SLOT IN ADAPTER3 - SCREWDRIVER4 - STEP PLATE - C-6960-35 - FORCING SCREW - C-6960-46 - THREADED ADAPTER DISC - C-6960-1


DIFFERENTIAL - TRAC-LOC (Continued)

(15) Remove top side gear, clutch pack retainerand clutch pack. Keep plates in correct order duringremoval (Fig. 65).

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

ASSEMBLYClean all components in cleaning solvent. Dry com-

ponents with compressed air. Inspect clutch packplates for wear, scoring or damage. Replace bothclutch packs if any one component in either pack isdamaged. Inspect side gears and pinions. Replaceany gear that is worn, cracked, chipped or damaged.Inspect differential case and pinion shaft. Replace ifworn or damaged.

Fig. 62 Compress Belleville Spring1 - TORQUE WRENCH2 - TOOL ASSEMBLED3 - DIFFERENTIAL CASE

Fig. 63 Pinion Gear Thrust Washer1 - THRUST WASHER2 - FEELER GAUGE

Fig. 64 Pinion Gear1 - PINION GEARS2 - TURNING BAR - C-6960-2

Fig. 65 Side Gear & Clutch Pack1 - DIFFERENTIAL CASE2 - RETAINER3 - SIDE GEAR AND CLUTCH DISC PACK



Lubricate each component with gear lubricantbefore assembly.

(1) Assemble the clutch discs into packs andsecure disc packs with retaining clips (Fig. 66).

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.

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

(3) Install clutch pack and side gear in the ringgear side of the differential case (Fig. 67). Be sureclutch pack retaining clips remain in positionand are seated in the case pockets.

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

(5) Install lubricated Step Plate C-6960-3 in lowerside gear (Fig. 68).

(6) Install the upper side gear and clutch disc pack(Fig. 68).

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

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

(9) Place pinion gears in position in side gears andverify that the pinion mate shaft hole is aligned.

(10) Rotate case with Turning Bar C-6960-2 untilthe pinion mate shaft holes in pinion gears align

with holes in case. It may be necessary to slightlytighten the forcing screw in order to install the pin-ion gears.

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

(12) Lubricate and install thrust washers behindpinion gears and align washers with a small screw

Fig. 66 Clutch Disc Pack1 - CLUTCH PACK2 - RETAINER3 - SIDE GEAR4 - RETAINER

Fig. 67 Clutch Pack and Side Gear1 - DIFFERENTIAL CASE2 - SIDE GEAR AND CLUTCH PACK

Fig. 68 Clutch Pack and Upper Side Gear1 - SIDE GEAR AND CLUTCH PACK2 - DIFFERENTIAL CASE3 - STEP PLATE - C-6960-3



driver. Insert mate shaft into each pinion gear to ver-ify alignment.

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

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

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



REMOVAL(1) Raise and support vehicle.(2) Remove differential case from axle housing.(3) Remove bearings from the differential case

with Puller/Press C-293-PA, Adapter 8352 and PlugSP-3289 (Fig. 69).

INSTALLATION

NOTE: If differential side bearings or differentialcase are replaced, differential side bearing shimrequirements may change. Refer to Adjustments(Differential Bearing Preload and Gear Backlash) forprocedures.

(1) Install differential side bearings with InstallerC-3716-A and Handle C-4171 (Fig. 70).

(2) Install differential in axle housing.(3) Remove support and lower vehicle.


REMOVAL

NOTE: The ring and pinion gears are serviced as amatched set. Never replace one gear without theother gear.

(1) Raise and support vehicle.(2) Mark pinion yoke and propeller shaft for

installation reference.(3) Disconnect propeller shaft from pinion yoke

and tie shaft to underbody.(4) Remove differential from the housing.

Fig. 69 Differential Bearing1 - ADAPTERS - 83522 - BEARING3 - DIFFERENTIAL4 - PLUG - SP-32895 - PULLER - C-293-PA

Fig. 70 Differential Side Bearing1 - INSTALLER - C-3716-A2 - HANDLE - C-4171



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

(6) Remove bolts holding ring gear to differentialcase.

(7) Drive ring gear from differential case with arawhide hammer (Fig. 71).

(8) Hold the pinion yoke with Spanner Wrench6958 and remove the pinion yoke nut and washer(Fig. 72).

(9) Remove pinion yoke from pinion shaft withRemover C-452 and Wrench C-3281 (Fig. 73).

(10) Remove pinion gear from housing (Fig. 74).Fig. 71 Ring Gear

1 - CASE2 - RING GEAR3 - RAWHIDE HAMMER

Fig. 72 Pinion Yoke Holder1 - PIPE2 - PINION YOKE3 - SPANNER WRENCH - 69584 - LOWER CONTROL ARM

Fig. 73 Pinion Yoke1 - WRENCH - C-32812 - YOKE3 - REMOVER - C-452





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

(13) Remove front pinion bearing cup withRemover C-4345 and Handle C-4171 (Fig. 76).

(14) Remove rear bearing cup from housing (Fig.77) with Remover D-149 and Handle C-4171.

(15) Remove collapsible preload spacer (Fig. 78).


Fig. 76 Front Bearing Cup1 - REMOVER - C-43452 - HANDLE - C-4171

Fig. 77 Rear Bearing Cup1 - REMOVER - D-1492 - HANDLE - C-4171

Fig. 78 Collapsible Spacer1 - COLLAPSIBLE SPACER2 - SHOULDER3 - PINION GEAR4 - OIL SLINGER5 - REAR BEARING



(16) Remove rear bearing from the pinion withPuller/Press C-293-PA and Adapters C-293-40 (Fig.79).

(17) Remove depth shims from the pinion gearshaft and record shim 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 Mopart Door Ease or equivalent lubri-cant to outside surface of bearing cup.

(2) Install pinion rear bearing cup with InstallerD-146 and Driver Handle C-4171 (Fig. 80) and verifycup is seated.


(4) Install pinion front bearing cup with InstallerD-130 and Handle C-4171 (Fig. 81) and verify cup isseated.

(5) Install pinion front bearing and oil slinger, ifequipped.

(6) Apply a light coating of gear lubricant on thelip of pinion seal. Install seal with Installer C-3972-Aand Handle C-4171 (Fig. 82).

(7) Install depth shim on the pinion gear.(8) Install rear bearing and slinger if equipped, on

the pinion gear with Installer W-262 and a press(Fig. 83).

Fig. 79 Rear Bearing1 - PULLER - C-293-PA2 - VISE3 - ADAPTERS - C-293-404 - PINION GEAR SHAFT





(9) Install a new collapsible preload spacer on pin-ion shaft and install pinion gear in the housing (Fig.84).

(10) Install yoke with Installer C-3718 and Span-ner Wrench 6958 (Fig. 85).

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



Fig. 82 Pinion Seal Installer1 - SPECIAL TOOL C-41712 - SPECIAL TOOL C-3972–A

Fig. 83 Rear Pinion Bearing1 - PRESS2 - INSTALLATION TOOL3 - DRIVE PINION GEAR4 - DRIVE PINION GEAR SHAFT REAR BEARING


Fig. 85 Pinion Yoke Installation1 - PINION YOKE2 - AXLE HOUSING



(13) Using Spanner Wrench 6958 and a torquewrench set at 474 N·m (350 ft. lbs.), (Fig. 86) 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. 87).


(14) Check bearing rotating torque with a inchpound torque wrench (Fig. 87). The pinion gear rotat-ing torque should be:


• New Bearings: 1.7 to 3.4 N·m (15 to 30 in. lbs.).(15) Invert the differential case and start two ring

gear bolts. This will provide case-to-ring gear bolthole alignment.


tighten to 136 N·m (100 ft. lbs.) (Fig. 88).


(18) Install differential in housing and verify dif-ferential bearing preload, gear mesh and contact pat-tern. Refer to Ajustments for procedure.


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



Fig. 87 Pinion Gear Rotating Torque1 - PINION YOKE2 -TORQUE WRENCH

Fig. 88 Ring Gear1 - TORQUE WRENCH2 - RING GEAR BOLT3 - RING GEAR4 - CASE



REAR AXLE - 226RBA

TABLE OF CONTENTS

page page

REAR AXLE - 226RBADESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 87OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 89

AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 93ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 93SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 102SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 102

AXLE SHAFTSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 105

AXLE BEARINGS/SEALSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 105

PINION SEALREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 108

COLLAPSIBLE SPACERREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 109

DIFFERENTIALREMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 113ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 113

DIFFERENTIAL - TRAC-LOKDIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 114

TRAC-LOKY . . . . . . . . . . . . . . . . . . . . . . . . . . 114DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 115ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

DIFFERENTIAL CASE BEARINGSREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 119

PINION GEAR/RING GEARREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 122

REAR AXLE - 226RBA

DESCRIPTIONThe 226 Rear Beam-design Aluminum (RBA) axle

housing has an aluminum center casting (differentialhousing) with axle shaft tubes extending from eitherside. The tubes are pressed into the differential hous-ing to form a one-piece axle housing.

The integral type housing, hypoid gear design hasthe center-line of the pinion set below the center-lineof the ring gear.

The axle has a vent hose to relieve internal pres-sure caused by lubricant vaporization and internalexpansion.

The axles are equipped with semi–floating axleshafts, meaning that vehicle load is supported by theaxle shaft and bearings. The axle shafts are retainedby bearing retainer plates on the axles which arebolted to flanges at the outboard end of the axletubes.

The cover provides a means for servicing the differ-ential without removing the axle.

For vehicles equipped with ABS brakes, the axleshave a tone ring pressed onto the axle shaft. Usecare when removing axle shafts to ensure that thetone wheel or the wheel speed sensor are not dam-aged.

The 226 RBA axle has the assembly part numberand gear ratio listed on a tag. The tag is attached tothe differential housing by a cover bolt. Build dateidentification codes are stamped on the cover side ofan axle shaft tube.

The differential case is a one-piece design. The dif-ferential pinion mate shaft is retained with athreaded pin. Differential bearing preload and ringgear backlash is adjusted by the use of selectivespacer shims. Pinion bearing preload is set andmaintained by the use of a collapsible spacer (Fig. 1).

Axles equipped with a Trac-Loky differential areoptional. A Trac-Lok differential has a one-piece dif-ferential case, and the same internal components asa standard differential, plus two clutch disc packs.

Axles equipped with a Vari-Loky differential areoptional. A Vari-Loky differential has a one-piece dif-ferential case which contains the gerotor pumpassembly and the clutch mechinism. The Vari-Lokyunit is serviced only as an assembly.

OPERATIONThe axle receives power from the transfer case

through the front propeller shaft. The front propellershaft is connected to the pinion gear which rotatesthe differential through the gear mesh with the ringgear bolted to the differential case. The engine poweris transmitted to the axle shafts through the pinion

WJ REAR AXLE - 226RBA 3 - 87

mate and side gears. The side gears are splined tothe axle shafts.


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. 2).

When turning corners, the outside wheel musttravel a greater distance than the inside wheel to

complete 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.3). 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.

TRAC-LOKY DIFFERENTIALThe Trac-loky clutches are engaged by two concur-

rent forces. The first being the preload force exertedthrough Belleville spring washers within the clutchpacks. The second is the separating forces generatedby the side gears as torque is applied through thering gear (Fig. 4).

The Trac-loky design provides the differentialaction needed for turning corners and for drivingstraight ahead during periods of unequal traction.When one wheel looses traction, the clutch packstransfer additional torque to the wheel having themost traction. Trac-loky differentials resist wheelspin on bumpy roads and provide more pulling powerwhen one wheel looses traction. Pulling power is pro-vided continuously until both wheels loose traction. Ifboth wheels slip due to unequal traction, Trac-lokyoperation is normal. In extreme cases of differencesof traction, the wheel with the least traction mayspin.

VARI-LOKY DIFFERENTIALIn a standard differential, if one wheel spins, the

opposite wheel will generate only as much torque asthe spinning wheel.

A gerotor pump and clutch pack are used to pro-vide the torque transfer capability. One axle shaft is

Fig. 1 Shim Locations1 - PINION GEAR DEPTH SHIM2 - DIFFERENTIAL BEARING SHIM3 - RING GEAR4 - DIFFERENTIAL BEARING SHIM5 - COLLAPSIBLE SPACER

Fig. 2 Differential Operation-Straight Ahead Driving1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT100% OF CASE SPEED2 - PINION GEAR3 - SIDE GEAR4 - PINION GEARS ROTATE WITH CASE

Fig. 3 Differential Operation-On Turns1 - PINION GEARS ROTATE ON PINION SHAFT

3 - 88 REAR AXLE - 226RBA WJ

REAR AXLE - 226RBA (Continued)

splined to the gerotor pump and one of the differen-tial side gears, which provides the input to the pump.As a wheel begins to lose traction, the speed differ-ential is transmitted from one side of the differentialto the other through the side gears. The motion ofone side gear relative to the other turns the innerrotor of the pump. Since the outer rotor of the pumpis grounded to the differential case, the inner andouter rotors are now moving relative to each otherand therefore creates pressure in the pump. The tun-ing of the front and rear axle orifices and valvesinside the gerotor pump is unique and each systemincludes a torque-limiting pressure relief valve toprotect the clutch pack, which also facilitates vehiclecontrol under extreme side-to-side traction varia-tions. The resulting pressure is applied to the clutchpack and the transfer of torque is completed.

Under conditions in which opposite wheels are onsurfaces with widely different friction characteristics,

Vari-loky delivers far more torque to the wheel onthe higher traction surface than do conventionalTrac-loky systems. Because conventional Trac-lokydifferentials are initially pre-loaded to assure torquetransfer, normal driving (where inner and outerwheel speeds differ during cornering, etc.) producestorque transfer during even slight side-to-side speedvariations. Since these devices rely on friction fromthis preload to transfer torque, normal use tends tocause wear that reduces the ability of the differentialto transfer torque over time. By design, the Vari-lokysystem is less subject to wear, remaining more con-sistent over time in its ability to transfer torque. Thecoupling assembly is serviced as a unit. From a ser-vice standpoint the coupling also benefits from usingthe same lubricant supply as the ring and piniongears.



cant, incorrect backlash, tooth contact, worn/damagedgears, or the carrier housing not having the properoffset and squareness.


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:





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 is

Fig. 4 Power-lok Y Limited Slip Differential1 - CASE2 - RING GEAR3 - DRIVE PINION4 - PINION GEAR5 - MATE SHAFT6 - CLUTCH PACK7 - SIDE GEAR8 - CLUTCH PACK



heard during a coast, the front pinion bearing is thesource.




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


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.




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

































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

secure axle.(3) Remove the wheels and tires.(4) Remove brake rotors (Refer to 5 - BRAKES/HY-

DRAULIC/MECHANICAL/ROTORS - REMOVAL)and calipers (Refer to 5 - BRAKES/HYDRAULIC/ME-CHANICAL/DISC BRAKE CALIPERS - REMOVAL)from the axle.

(5) Disconnect parking brake cables from bracketsand lever.

(6) Remove wheel speed sensors. (Refer to 5 -BRAKES/ELECTRICAL/REAR WHEEL SPEEDSENSOR - REMOVAL)

(7) Disconnect the brake hose at the axle junctionblock. Do not disconnect the brake hydraulic lines atthe calipers.


(9) Mark propeller shaft and yokes for installationreference.

(10) Remove propeller shaft. (Refer to 3 - DIFFER-ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-PELLER SHAFT - REMOVAL)

(11) Disconnect stabilizer bar links.(12) Remove nut holding upper suspension arm to

the rear axle ball joint.(13) Using Remover 8278, separate the rear axle

ball joint from the upper suspension arm (Fig. 5).(14) Disconnect shock absorbers from axle.(15) Disconnect track bar.(16) Disconnect lower suspension arms from the

axle brackets.(17) 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 coilsprings.

(2) Position the lower suspension arms on the axlebrackets. Install nuts and bolts, do not tighten boltsat this time.

(3) Install the upper suspension arm to the rearaxle ball joint.

(4) Install nut to hold the upper suspension arm tothe rear axle ball joint. Torque the nut to 122 N·m(90 ft.lbs.) (Fig. 6).

(5) Install track bar and attachment bolts, do nottighten bolts at this time.

(6) Install shock absorbers and tighten nuts to 60N·m (44 ft. lbs.).

(7) Install stabilizer bar links and tighten nuts to36 N·m (27 ft. lbs.).

(8) Install wheel speed sensors. (Refer to 5 -BRAKES/ELECTRICAL/REAR WHEEL SPEEDSENSOR - INSTALLATION)

(9) Connect parking brake cable to brackets andlever.


(11) Connect the brake hose to the axle junctionblock.

(12) Install axle vent hose.(13) Align propeller shaft and pinion yoke refer-

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

(14) Install the wheels and tires.(15) Add gear lubricant, if necessary.(16) Remove support and lower the vehicle.(17) Tighten lower suspension arm bolts to 177

N·m (130 ft. lbs.).(18) Tighten track bar bolts to 100 N·m (74 ft.

lbs.).

ADJUSTMENTSRing 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.7). 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 setting from the cen-ter line of the ring gear to the back face of the pinionis 109.52 mm (4.312 in.). The standard depth pro-vides the best gear tooth contact pattern. Refer toBacklash and Contact Pattern in this section foradditional information.

Compensation for pinion depth variance isachieved with a select shim/oil baffle. The shims are

Fig. 5 Rear Ball Joint1 - REMOVER - 82782 - UPPER SUSPENSION ARM3 - BALL JOINT STUD

Fig. 6 Rear Suspention1 - UPPER SUSPENSION ARM2 - REAR AXLE BALL JOINT3 - REAR AXLE



placed between the rear pinion bearing and the pin-ion gear head (Fig. 8).






Variance


−4 −3 −2 −1 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 −0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003

0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004

−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005

−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006

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

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

Fig. 7 Pinion Gear ID Numbers1 - PRODUCTION NUMBERS2 - DRIVE PINION GEAR DEPTH VARIANCE3 - GEAR MATCHING NUMBER (SAME AS RING GEARNUMBER)





and pinion bearings installed in the housing. Takemeasurements with Pinion Gauge Set and Dial Indi-cator (Fig. 9).




(4) Place Arbor Disc 6927A on Arbor D-115-3 inposition in the housing side bearing cradles (Fig. 11).Install differential bearing caps on arbor discs andtighten cap bolts to 85 N·m (63 ft. lbs.).

NOTE: Arbor Discs 6927A has different step diame-ters to fit other axles. Choose proper step for axlebeing serviced.


(6) Place Scooter Block/Dial Indicator in positionin axle housing so dial probe and scooter block areflush against the rearward surface of the pinionheight block (Fig. 9). Hold scooter block in place andzero the dial indicator face to the pointer. Tightendial indicator face lock screw.


(8) Slide the dial indicator probe across the gapbetween the pinion height block and the arbor barwith the scooter block against the pinion height block(Fig. 12). When the dial probe contacts the arbor bar,

Fig. 9 Pinion Gear Depth Gauge Tools1 - DIAL INDICATOR - C-33392 - ARBOR - D-115-33 - PINION HEIGHT BLOCK - 67394 - CONE - 67405 - SCREW - 67416 - PINION BLOCK - 81447 - SCOOTER BLOCK - D-115-28 - ARBOR DISC - 6927-A


Fig. 11 Gauge Tools In Housing1 - ARBOR DISC - 6927-A2 - PINION BLOCK - 81443 - ARBOR - D-115-34 - PINION HEIGHT BLOCK - 6739



the dial pointer will turn clockwise. Bring dialpointer back to zero against the arbor bar, do notturn dial face. Continue moving the dial probe to thecrest of the arbor bar and record the highest reading.If the dial indicator can not achieve the zero reading,the rear bearing cup or the pinion depth gauge set isnot installed correctly.


DIFFERENTIAL BEARING PRELOAD & GEARBACKLASH

Differential side bearing preload and gear backlashis achieved by selective shims positioned behind thedifferential side bearing cones. The proper shimthickness can be determined using slip-fit DummyBearings 6929-A in place of the differential side bear-ings and a Dial Indicator C-3339. Before proceedingwith the differential bearing preload and gear back-lash measurements, measure the pinion gear depthand prepare the pinion 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 is installed, and thegear backlash shim thickness is measured. The over-all shim thickness is the total of the dial indicatorreading and the preload specification added together.The gear backlash measurement determines thethickness of the shim used on the ring gear side ofthe differential case. Subtract the gear backlash shimthickness from the total overall shim thickness and

select that amount for the pinion gear side of the dif-ferential (Fig. 13). Differential shim measurementsare performed with the spreader W-129-B removed.

SHIM SELECTION




(3) Install Dummy Bearings 6929-A on differentialcase.

(4) Install differential case in the housing.(5) Record the thickness of Dummy Shims 8107,

then insert the shims between the dummy bearingsand the differential housing (Fig. 14).

(6) Install the bearing caps in the correct positionsand snug the bolts (Fig. 15).

(7) Using a dead-blow type hammer, seat the dif-ferential dummy bearings to each side of the housing(Fig. 16) and (Fig. 17).


(9) Attach the Dial Indicator C-3339 to pilot studand position the indicator plunger on the flat surfacebetween the ring gear bolts (Fig. 18).


Fig. 12 Pinion Gear Depth Measurement1 - ARBOR - D-115-32 - SCOOTER BLOCK - D-115-23 - DIAL INDICATOR - C-3339





(12) Add 0.0254 mm (0.001 in.) to the zero endplay total. This new total represents the thickness ofshims to compress, or preload the new bearings whenthe differential is installed.



(15) Install the pinion gear in the housing. Installthe pinion yoke and establish the correct pinionrotating torque.

(16) Install differential case and Dummy Bearings6929-A in the housing.

(17) Install a single dummy shim in the ring gearside. Install bearing caps and tighten bolts snug.


surface between the ring gear bolt heads. (Fig. 18).

Fig. 14 Dummy Shim Point1 - DUMMY SHIM - 81072 - HOUSING3 - DIFFERENTIAL CASE4 - DUMMY BEARINGS - 6929-A

Fig. 15 Tighten Bearing Cap Bolts1 - BEARING CAP2 - HOUSING3 - DIFFERENTIAL CASE

Fig. 16 Seat Dummy Bearing1 - HAMMER2 - HOUSING3 - DIFFERENTIAL CASE

Fig. 17 Seat Dummy Bearing1 - HOUSING2 - HAMMER3 - DIFFERENTIAL CASE



(20) Push and hold differential case toward piniongear and zero dial indicator (Fig. 21).

(21) Push and hold differential case to ring gearside of the housing and record dial indicator reading(Fig. 22). Add Dummy Shim thickness to this read-

ing. This will be the total shim thickness to achievezero backlash.

(22) Subtract 0.152 mm (0.006 in.) from the dialindicator reading to compensate for backlash betweenring and pinion gears. This total is the thicknessshim 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.


Fig. 18 Differential Side play Measurement1 - DIFFERENTIAL CASE2 - HOUSING3 - PILOT STUD- C-3288-B4 - DIAL INDICATOR- C-3339

Fig. 19 Differential Case Pinion Gear Side1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE2 - PILOT STUD - C-3288-B3 - DIAL INDICATOR - C-33394 - ZERO DIAL INDICATOR FACE

Fig. 20 Differential Case Ring Gear Side1 - READ DIAL INDICATOR2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE3 - HOUSING

Fig. 21 Zero Dial Indicator1 - ZERO DIAL INDICATOR FACE2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE3 - PINION GEAR4 - HOUSING5 - DIFFERENTIAL CASE





(27) Install spreader W-129-B, utilizing some itemsfrom Adapter Set 6987, on the housing and spreadaxle opening enough to receive differential case.

(28) Place the bearing preload shims in the hous-ing against the axle tubes.

(29) Install differential case into the housing.(30) Remove spreader from housing.(31) Rotate the differential case several times to


gear tooth (Fig. 23).(33) Push and hold ring gear upward while not

allowing the pinion gear to rotate.(34) Zero dial indicator face to pointer.(35) Push and hold ring gear downward while not

allowing the pinion gear to rotate. Dial indicatorreading should be between 0.076 mm (0.003 in.) and0.15 mm (0.006 in.). If backlash is not within specifi-cations transfer the necessary amount of shim thick-ness from one side of the housing to the other (Fig.24).


After the proper backlash is achieved, performGear Contact Pattern procedure.


will show if the pinion depth is correct in the axlehousing. It will also show if the ring gear backlashhas been adjusted correctly. The backlash can beadjusted within specifications to achieve desiredtooth contact patterns.


(2) Wrap, twist and hold a shop towel around thepinion yoke to increase the turning resistance of the

Fig. 22 Differential Case Ring Gear Side1 - READ DIAL INDICATOR2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE3 - PINION GEAR4 - HOUSING5 - DIFFERENTIAL CASE

Fig. 23 Ring Gear Backlash Measurement1 - DIAL INDICATOR




pinion. This will provide a more distinct contact pat-tern.


The areas on the ring gear teeth with the greatestdegree of contact against the pinion teeth will squee-gee the compound to the areas with the least amountof contact. Note and compare patterns on the ringgear teeth to Gear Tooth Contact Patterns chart (Fig.

25) and adjust pinion depth and gear backlash asnecessary.






Fig. 25 Gear Contact Patterns



SPECIFICATIONS

REAR AXLE - 226RBA

AXLE SPECIFICATIONS


Axle Ratio 3.55, 3.73




Ring Gear Backlash 0.076.-0.15 mm (0.003-0.006 in.)



Pinion Bearing Preload - New Bearings 2.8-4 N·m (25-35 in. lbs.)





Ring Gear Bolts 136 100 —

Pinion Nut 298-380 220-280 —

Pinion Mate Shaft Screw 17.6 13 —

Axle Bearing Retainer PlateNuts

61 45—

SPECIAL TOOLS

AXLE

Puller Set C-293-PA

Adapter 8353

Adapter 8353

Adapter Plug C-293-3


Remover C-452

Wrench Flange C-3281

Installer C-3718

Handle C-4171

Remover C-4307

Installer C-4308

Installer C-4340

Pilot Studs C-3288-B


Trac-lok Tool C-4487



Installer C-3972-A

Installer D-129

Remover D-103

Spreader

Installer 6448

Adapter 6790

Pinion Depth Set 6955

Bearing Dummy Set 6956

Gauge Block 8144

Shims Dummy 8107



AXLE SHAFTS

REMOVAL(1) Place transmission in neutral.(2) Raise and support vehicle.(3) Remove wheel and tire assembly.

(4) Remove brake caliper (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALI-PERS - REMOVAL) and rotor. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL)

(5) Remove nuts holding axle retainer plate to axletube from the rear of the axle flange.

(6) Pull axle shaft from the axle with Slide Ham-mer 7420 and Adapter 6790. Mount the adapter tothe axle with lug nuts.


INSTALLATION(1) Insall axle into the axle tube with the flat area

of the retainer plate upward.(2) Insert retaining plate studs into the brake

backing plate and axle tube flange.(3) Install retainer nuts and tighten nuts to 61

N·m (45 ft. lbs.).(4) Install the brake caliper (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/DISC BRAKE CALI-PERS - INSTALLATION) and rotor. (Refer to 5 -BRAKES/HYDRAULIC/MECHANICAL/ROTORS -INSTALLATION)

(5) Install wheel and tire.(6) Check and fill the differential with gear lubri-

cant.(7) Lower vehicle.

AXLE BEARINGS/SEALS

REMOVAL(1) Remove axle shaft from vehicle.


(2) Drill a shallow hole into soft steel axle bearingretaining ring with a 3/8 in. drill bit (Fig. 26). Use adrill depth stop to avoid marking the axle.

(3) With a cold chisel cut the retaining ring acrossdrilled hole. (Fig. 27)

(4) Slide retaining ring from axle shaft.(5) Remove axle bearing from the shaft with, a

press and Splitter 1130 placed between the seal andbearing (Fig. 28).

(6) Remove seal from axle.(7) Remove retaining plate from axle shaft.

INSTALLATION(1) Verify axle shaft retaining plate is flat with a

straight edge.

Wrench Spanner 6958

Fixture Holding 6963-A

Remover 7794-A

Splitter Bearing 1130

Installer Gear/Bearing 7913-A



NOTE: If the plate is warped or the studs are loosein the plate replace the retaining plate.

(2) Install retaining plate on the axle shaft (Fig.29).

(3) Apply a coat of multi-purpose grease on sealingsurface of axle seal.

(4) Install seal on the axle shaft with cavity awayfrom retaining plate (Fig. 29).

Fig. 26 Drill Retaining Ring1 - DRILL BIT2 - AXLE3 - RETAINING PLATE4 - RETAINING RING

Fig. 27 Retaining Ring1 - AXLE2 - COLD CHISEL3 - VISE4 - RETAINING RING

Fig. 28 Axle Bearing And Seal1 - AXLE2 - PRESS PLATES3 - BLOCKS4 - SPLITTER - 1130

Fig. 29 Axle Bearing And Seal Components1 - RETAINING RING2 - SEAL3 - AXLE4 - RETAINING PLATE5 - AXLE BEARING



(5) Lubricate bearing with Mopart Wheel BearingGrease or equivalent. Wipe excess grease from thebearing.

(6) Install bearing on the axle shaft with Installer7913 and a press (Fig. 30).

(7) Press soft metal retaining ring onto axle shaftwith Installer 7913 and a press (Fig. 31).

(8) Install axle in vehicle.

PINION SEAL



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

(5) Remove the propeller shaft from the yoke.(6) Rotate pinion gear three or four times and ver-

ify that pinion rotates smoothly.(7) Record torque necessary to rotate the pinion

gear with a inch pound dial-type torque wrench.

(8) Using a short piece of pipe and SpannerWrench 6958 to hold the pinion yoke and remove thepinion nut and washer (Fig. 32).

(9) Remove pinion companion flange with RemoverC-452 and Flange Wrench C-3281. (Fig. 33)


Fig. 30 Bearing On Axle1 - PRESS RAM2 - INSTALLER - 79133 - AXLE BEARING4 - SEAL5 - RETAINING PLATE6 - AXLE

Fig. 31 Bearing Retaining Ring On Axle1 - PRESS2 - AXLE3 - AXLE BEARING4 - INSTALLER - 79135 - RETAINING RING





lip of pinion seal. Install seal with Installer D-163and Handle C-4171 (Fig. 35).

(2) Install yoke on the pinion gear with InstallerC-3718 and Spanner Wrench 6958 (Fig. 36).

(3) Install a new nut on the pinion gear. Tightenthe nut only enough to remove the shaft endplay.

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

(4) Rotate the pinion a minimum of ten times. Ver-ify that the pinion rotates smoothly. Rotate the pin-ion shaft using an inch pound torque wrench.Rotating torque should be equal to the readingrecorded during removal, plus 0.56 N·m (5 in. lbs.)(Fig. 37).

(5) If rotating torque is low, use Wrench 6958 tohold the pinion yoke (Fig. 38) and tighten the pinionshaft nut in 6.8 N·m (5 ft. lbs.) increments untilrotating torque is achieved.

CAUTION: If the maximum tightening torque isreached prior to reaching the required rotatingtorque, the collapsible spacer may have been dam-aged. Replace the collapsible spacer.

(6) Align the installation reference marks on thepropeller shaft and pinion companion flange andinstall the propeller shaft.

Fig. 33 Pinion Yoke Remover1 - SPECIAL TOOL C-32812 - YOKE3 - SPECIAL TOOL C-452



Fig. 36 Pinion Yoke Installer1 - INSTALLER - C-37182 - PINION YOKE3 - AXLE HOUSING4 - SPANNER WRENCH - 6958



(7) Fill differential with gear lubricant.(8) Install the brake rotors (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/ROTORS - INSTALLA-TION) and calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERS - INSTALLATION)


COLLAPSIBLE SPACER



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


(6) Record rotate torque of the pinion gear, with aninch pound torque wrench for installation reference.

(7) Hold pinion yoke with Spanner Wrench 6958and remove pinion nut and washer (Fig. 39).

(8) Remove the pinion yoke with Remover C-452and Wrench C-3281 (Fig. 40).

(9) Remove pinion shaft seal with Remover 7794-Aand slide hammer (Fig. 41).

(10) Remove front pinion bearing using a pair ofpick tools to pull the bearing off the pinion gearshaft. If the pinion gear becomes bound on the pinionshaft, lightly tap the end of the shaft with a rawhide/rubber mallet.


INSTALLATION(1) Install a new collapsible spacer on pinion

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

lip of pinion seal and install seal with Installer D-163and Handle C-4171 (Fig. 42).

Fig. 37 Pinion Rotating Torque1 - PINION YOKE2 -TORQUE WRENCH

Fig. 38 Pinion Shaft Nut1 - SPANNER WRENCH - 69582 - PIPE3 - TORQUE WRENCH

Fig. 39 Pinion Yoke1 - PIPE2 - PINION YOKE3 - SPANNER WRENCH - 69584 - LOWER CONTROL ARM



(4) Install yoke with Installer C-3718 and SpannerWrench 6958 (Fig. 43).

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


(6) Using yoke with Spanner Wrench 6958 and atorque wrench set at 474 N·m (350 ft. lbs.), (Fig. 44)slowly tighten the nut in 6.8 N·m (5 ft. lbs.) incre-ments until the rotating torque is achieved. Measure

the rotating torque frequently to avoid over crushingthe collapsible spacer (Fig. 45).


(7) Check rotating torque with an inch poundtorque wrench (Fig. 45). 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 marksalign.

(9) Install rear brake rotors (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLA-TION) and calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERS - INSTALLATION)

Fig. 40 Pinion Yoke Puller1 - WRENCH - C-32812 - YOKE3 - PULLER - C-452


Fig. 42 Pinion Seal Installer1 - HANDLE - C-41712 - INSTALLER - D-163




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

DIFFERENTIAL

REMOVAL(1) Raise and support vehicle.(2) Remove the lubricant fill hole plug from the

differential housing cover.(3) Remove the differential housing cover and

allow fluid to drain.(4) Clean the housing cavity with flushing oil, light

engine oil or lint free cloth. Do not use water,steam, kerosene or gasoline for cleaning.

(5) Remove axle shafts.(6) Note the reference letters stamped on the bear-

ing caps and housing machined sealing surface (Fig.46).


items from Adapter set 6987, with the tool dowel pinsseated in the locating holes (Fig. 47). Install the hold-down clamps and tighten the tool turnbuckle finger-tight.

(9) 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. 48) and zero theindicator.


Fig. 44 Pinion Nut1 - WRENCH - 69582 - PIPE3 - TORQUE WRENCH

Fig. 45 Pinion Gear Rotating Torque1 - PINION YOKE2 - TORQUE WRENCH




(10) Spread the housing enough to remove the dif-ferential case from the housing. Measure the dis-tance with the dial indicator (Fig. 49).

(11) Remove the dial indicator.

(12) While holding the differential case in position,remove the differential bearing cap bolts and caps.

(13) Remove the differential from the housing.Ensure that the differential bearing cups remain inposition on the differential bearings (Fig. 50).

(14) Remove bearing cups from the differential andtag them to indicate their location on the differential.

Fig. 47 Spreader Location1 - DIFFERENTIAL HOUSING2 - ADAPTER3 - SAFETY HOLD DOWN4 - SPREADER5 - TURNBUCKLE


Fig. 49 Spread Differential Housing1 - DIAL INDICATOR2 - SPREADER

Fig. 50 Differential1 - DIFFERENTIAL HOUSING2 - DIFFERENTIAL CASE3 - BEARING CUPS



(15) Remove differential case preload shims fromthe housing and tag them to indicate their location inthe housing.

(16) Remove spreader from housing.

DISASSEMBLY(1) Remove pinion mate shaft lock screw (Fig. 51).

(2) Remove pinion mate shaft.(3) Rotate differential side gears and remove the

differential pinion gears and thrust washers (Fig.52).

(4) Remove the differential side gears and thrustwashers.

ASSEMBLY(1) Install the differential side gears and thrust

washers.(2) Install the differential pinion gears and thrust

washers.(3) Install the pinion mate shaft.(4) Align the hole in the pinion mate shaft with

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


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, utilizing someitems from Adapter set 6987, with the tool dowel pins

seated in the locating holes (Fig. 53). Install the hold-down clamps and tighten the tool turnbuckle finger-tight.





that the differential bearing cups remain in positionon the differential bearings and that the preloadshims remain between the face of the bearing cupand the housing. Tap the differential case to ensurethe bearings cups and shims are fully seated in thehousing.


Fig. 51 Pinion Mate Shaft Lock Screw1 - LOCK SCREW2 - PINION MATE SHAFT




(6) Install the bearing caps in their original loca-tions (Fig. 54).


lbs.).

(10) Install the axle shafts.(11) Apply a 6.35mm (1/4 in.) bead of Mopart Sil-




(13) Refill the differential with Mopart HypoidGear Lubricant or equivalent to bottom of the fillplug hole. Refer to Lubricant Specifications for cor-rect quantity and type.

(14) Install fill hole plug.(15) Remove support and lower the vehicle.

DIFFERENTIAL - TRAC-LOK

DIAGNOSIS AND TESTING - TRAC-LOKYThe most common problem is a chatter noise when

turning corners. Before removing a Trac-loky unitfor repair, drain, flush and refill the axle with thespecified lubricant. A container of Mopar Trac-lokyLubricant (friction modifier) should be added afterrepair service 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. This

Fig. 53 Spreader Location1 - DIFFERENTIAL HOUSING2 - ADAPTER KIT COMPONENTS - 69873 - SAFETY HOLD DOWN4 - SPREADER - W-129-B5 - TURNBUCKLE


Fig. 55 Differential Cover - Typical1 - COVER2 - SEALANT3 - SEALANT BEAD



will correct the condition in most instances. If thechatter persists, clutch damage could have occurred.

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. 56).

(6) If rotating torque is less than 22 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 Holding Fixture 6965 in a vise

and position the differential case on the Holding Fix-ture (Fig. 57).

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

(3) Remove the pinion gear mate shaft lock screw(Fig. 58).

Fig. 56 Trac-lok Y Test -Typical1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE2 - TORQUE WRENCH

Fig. 57 Differential Case Holding Fixture1 - FIXTURE - 69652 - VISE3 - DIFFERENTIAL

Fig. 58 Mate Shaft Lock Screw1 - LOCK SCREW2 - PINION GEAR MATE SHAFT


DIFFERENTIAL - TRAC-LOK (Continued)

(4) Remove pinion gear mate shaft with a drift andhammer (Fig. 59).

(5) Install and lubricate Step Plate C-6960-3 (Fig.60).

(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-6960-1 (Fig. 61) 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. 62).

(9) With a feeler gauge remove thrust washersfrom behind the pinion gears (Fig. 63).

Fig. 59 Mate Shaft1 - PINION MATE SHAFT2 - SIDE GEAR3 - DRIFT4 - PINION MATE GEAR

Fig. 60 Step Plate1 - LOWER SIDE GEAR2 - DIFFERENTIAL CASE3 - STEP PLATE - C-6960-3

Fig. 61 Threaded Adapter Disc1 - SOCKET2 - SLOT IN ADAPTER3 - SCREWDRIVER4 - STEP PLATE - C-6960-35 - FORCING SCREW - C-6960-46 - THREADED ADAPTER DISC - C-6960-1

Fig. 62 Compress Belleville Spring1 - TORQUE WRENCH2 - TOOL ASSEMBLED3 - DIFFERENTIAL CASE



(10) Insert Turning Bar C-6960-2 into the pinionmate shaft hole in the case (Fig. 64).

(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.


(15) Remove top side gear, clutch pack retainerand clutch pack. Keep plates in correct order duringremoval (Fig. 65).

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

ASSEMBLYClean all components in cleaning solvent. Dry com-

ponents with compressed air. Inspect clutch packplates for wear, scoring or damage. Replace bothclutch packs if any one component in either pack isdamaged. Inspect side gears and pinions. Replaceany gear that is worn, cracked, chipped or damaged.Inspect differential case and pinion shaft. Replace ifworn or damaged.

Lubricate each component with gear lubricantbefore assembly.

(1) Assemble the clutch discs into packs andsecure disc packs with retaining clips (Fig. 66).

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.

Fig. 63 Pinion Gear Thrust Washer1 - THRUST WASHER2 - FEELER GAUGE

Fig. 64 Pinion Gear1 - PINION GEARS2 - TURNING BAR - C-6960-2

Fig. 65 Side Gear & Clutch Pack1 - DIFFERENTIAL CASE2 - RETAINER3 - SIDE GEAR AND CLUTCH DISC PACK



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

(3) Install clutch pack and side gear in the ringgear side of the differential case (Fig. 67). Be sureclutch pack retaining clips remain in positionand are seated in the case pockets.

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

(5) Install lubricated Step Plate C-6960-3 in lowerside gear (Fig. 68).

(6) Install the upper side gear and clutch disc pack(Fig. 68).

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

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

(9) Place pinion gears in position in side gears andverify that the pinion mate shaft hole is aligned.

(10) 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.

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

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

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


Fig. 66 Clutch Disc Pack1 - CLUTCH PACK2 - RETAINER3 - SIDE GEAR4 - RETAINER

Fig. 67 Clutch Pack and Side Gear1 - DIFFERENTIAL CASE2 - SIDE GEAR AND CLUTCH PACK

Fig. 68 Clutch Pack and Upper Side Gear1 - SIDE GEAR AND CLUTCH PACK2 - DIFFERENTIAL CASE3 - STEP PLATE - C-6960-3




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

with Puller/Press C-293-PA, Adapters 8353 and PlugC-293-3 (Fig. 69).

INSTALLATIONIf differential side bearings or differential case are

replaced, differential side bearing shim requirementsmay change. Refer to Adjustments (Differential Bear-ing Preload and Gear Backlash) for procedures.

CAUTION: Ensure Vari-lok Y plenum is fully seatedagainst the differential case prior to installing thering gear side differential bearing.

(1) Install differential side bearings with InstallerC-4340 and Handle C-4171 (Fig. 70).

(2) Install differential case in axle housing.(3) Remove support and lower vehicle.


REMOVAL

NOTE: The ring and pinion gears are serviced as amatched set. Never replace one gear without theother gear.

(1) Raise and support vehicle.(2) Mark pinion yoke and propeller shaft for

installation reference.(3) Disconnect propeller shaft from pinion yoke

and tie shaft to underbody.(4) Remove differential from axle housing.(5) Place differential case in a vise with soft metal

jaw.(6) Remove bolts holding ring gear to differential

case.(7) Drive ring gear from differential case with a

rawhide hammer (Fig. 71).(8) Hold the pinion yoke with Spanner Wrench

6958 and remove the pinion yoke nut and washer(Fig. 72).

(9) Remove pinion yoke from pinion shaft withRemover C-452 and Wrench C-3281 (Fig. 73).

(10) Remove pinion gear from housing (Fig. 74).

Fig. 69 Differential Bearing Removal1 - ADAPTERS - 83532 - BEARING3 - DIFFERENTIAL4 - PLUG - C-293-35 - PULLER - C-293-PA

Fig. 70 Install Differential Side Bearings1 - HANDLE - C-41712 - DIFFERENTIAL3 - BEARING4 - INSTALLER - C-4340



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

Fig. 71 Ring Gear1 - DIFFERENTIAL CASE2 - RING GEAR3 - RAWHIDE HAMMER


Fig. 73 Pinion Yoke Remover1 - SPECIAL TOOL C-32812 - YOKE3 - SPECIAL TOOL C-452




(13) Remove the front pinion bearing cup withRemover D-103 and Handle C-4171 (Fig. 76).

(14) Remove rear bearing cup from housing (Fig.77) with Remover C-4307 and Handle C-4171.

(15) Remove collapsible preload spacer (Fig. 78).(16) Remove rear bearing from the pinion with

Puller/Press C-293-PA and Adapters C-293-42 (Fig.79). (17) Remove depth shims from the pinion gear

shaft and record shim thickness.


Fig. 76 Front Pinion Bearing Cup1 - REMOVER - D-1032 - HANDLE - C-4171

Fig. 77 Rear Pinion Bearing Cup1 - DRIVER - C-43072 - HANDLE - C-4171

Fig. 78 Collapsible Spacer1 - COLLAPSIBLE SPACER2 - SHOULDER3 - PINION GEAR4 - OIL SLINGER5 - REAR BEARING



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.


(2) Install pinion rear bearing cup with InstallerC-4308 and Driver Handle C-4171 (Fig. 80) and ver-ify cup is seated.


(4) Install pinion front bearing cup with InstallerD-129 and Handle C-4171 (Fig. 81) and verify cup isseated.

(5) Install pinion front bearing and oil slinger, ifequipped.

(6) Apply a light coating of gear lubricant on thelip of pinion seal. Install seal with Installer D-163and Handle C-4171 (Fig. 82).

Fig. 79 Rear Pinion Bearing Puller1 - PULLER - C-293-PA2 - VISE3 - ADAPTERS - C-293-424 - PINION GEAR SHAFT





(7) Install depth shim on the pinion gear.(8) Install rear bearing and slinger if equipped, on

the pinion gear with Installer 6448 and a press (Fig.83).

(9) Install a new collapsible preload spacer on pin-ion shaft and install pinion gear in the housing (Fig.84).

(10) Install yoke with Installer C-3718 and Span-ner Wrench 6958 (Fig. 85).

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



Fig. 83 Rear Pinion Bearing1 - PRESS2 - INSTALLATION TOOL3 - DRIVE PINION GEAR4 - DRIVE PINION GEAR SHAFT REAR BEARING






(13) Using Spanner Wrench 6958 and a torquewrench set at 380 N·m (280 ft. lbs.), (Fig. 86) 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. 87).


(14) Check bearing rotating torque with a inchpound torque wrench (Fig. 87). The pinion gear rotat-ing torque should be:


• New Bearings: 2.8 to 4 N·m (25 to 35 in. lbs.).(15) Invert the differential case and start two ring

gear bolts. This will provide case-to-ring gear bolthole alignment.


tighten to 95-122 N·m (70-90 ft. lbs.) (Fig. 88).


NOTE: If equipped with Veri-Lok differential installoil feed plenum and side bearing. (18) Install differential in housing.


Fig. 87 Pinion Gear Rotating Torque1 - PINION YOKE2 -TORQUE WRENCH

Fig. 88 Ring Gear1 - TORQUE WRENCH2 - RING GEAR BOLT3 - RING GEAR4 - CASE




(19) Verify differential bearing preload, gear meshand contact pattern. Refer to Ajustments for proce-dure.


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




03. differential and driveline

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