Jeep Wrangler TJ. Manual - part 226

(12) Remove pinion depth shim/oil slinger from

pinion shaft and record thickness.

INSTALLATION

NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If ring and pinion
gears are reused, the original pinion depth shim
can be used. Refer to Adjustments (Pinion Gear
Depth) to select the proper shim thickness if ring
and pinion gears are replaced.

(1) Apply Mopar Door Ease stick or equivalent

lubricant to outside surface of bearing cups.

(2) Install rear pinion bearing cup with Installer

D-146 and Handle C-4171 (Fig. 75).

(3) Install front pinion bearing cup with Installer

D-144 and Handle C-4171 (Fig. 76).

(4) Install pinion front bearing, oil slinger. Apply a

light coating of gear lubricant on the lip of pinion
seal.

(5) Install pinion seal with an appropriate installer

(Fig. 77).

(6) Install proper thickness depth shim on the pin-

ion gear.

Fig. 75 REAR PINION BEARING CUP

1 - INSTALLER
2 - HANDLE

Fig. 76 FRONT PINION BEARING CUP INSTALLER

1 - INSTALLER
2 - HANDLE

Fig. 77 PINION SEAL INSTALLER

1 - HANDLE
2 - INSTALLER

FRONT AXLE - 216FBI

3 - 81

PINION GEAR/RING GEAR (Continued)

(7) Install rear bearing and oil slinger, if equipped

on pinion gear with Installer W-262 (Fig. 78).

(8) Install pinion gear in housing.
(9) Install pinion preload shims (Fig. 79)

(10) Install yoke with Installer W-162-D and Yoke

Holder 6719A (Fig. 80).

(11) Install yoke washer and a new nut on the

pinion gear. Tighten the nut to specification (Fig. 81).

Fig. 78 REAR PINION BEARING

1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING

Fig. 79 PINION PRELOAD SHIMS

1 - PRELOAD SHIMS
2 - FRONT BEARING CUP
3 - SLINGER
4 - PINION YOKE
5 - WASHER
6 - PINION NUT
7 - PINION OIL SEAL
8 - FRONT PINION BEARING

Fig. 80 PINION YOKE INSTALLER

1 - INSTALLER
2 - YOKE HOLDER

Fig. 81 TIGHTENING PINION NUT

1 - PINION YOKE
2 - YOKE HOLDING
3 - DIFFERENTIAL HOUSING

3 - 82

FRONT AXLE - 216FBI

PINION GEAR/RING GEAR (Continued)

(12) Check bearing preload torque with an inch

pound torque wrench (Fig. 82). The torque to rotate
the pinion gear should be:

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

• New Bearings: 2.3 to 4.5 N·m (20 to 40 in. lbs.).

(13) Invert differential case in a vise and start two

ring gear bolts. This will provide case-to-ring gear
bolt hole alignment.

(14) Install new ring gear bolts and alternately

tighten to 136 N·m (100 ft. lbs.). (Fig. 83).

CAUTION: Never reuse the ring gear bolts. Failure
to heed caution may result in damage.

(15) Install differential in axle housing and verify

gear mesh and contact pattern. Refer to Adjustments
(Gear Contact Pattern).

Fig. 82 PINION ROTATION TORQUE

1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH

Fig. 83 RING GEAR INSTALLATION

1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE

FRONT AXLE - 216FBI

3 - 83

PINION GEAR/RING GEAR (Continued)

REAR AXLE - 194RBI

TABLE OF CONTENTS

page

REAR AXLE - 194RBI

DIAGNOSIS AND TESTING

. . . . . . . . . . . . . . . . 84

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 88

ADJUSTMENTS

. . . . . . . . . . . . . . . . . . . . . . . . 89

SPECIFICATIONS

REAR AXLE

. . . . . . . . . . . . . . . . . . . . . . . . . . 96

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . 97

AXLE SHAFTS

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 100

AXLE SHAFT SEALS

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 100

AXLE BEARINGS

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 101

PINION SEAL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 102

COLLAPSIBLE SPACER

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 103

DIFFERENTIAL COVER

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 105

DIFFERENTIAL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . 106

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . 106

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 107

DIFFERENTIAL - TRAC-LOK

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 108

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 108

DIAGNOSIS AND TESTING

. . . . . . . . . . . . . . . 108

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . 109

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . 110

DIFFERENTIAL CASE BEARINGS

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 113

PINION GEAR/RING GEAR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 115

REAR AXLE - 194RBI

DIAGNOSIS AND TESTING

GEAR NOISE

Axle gear noise can be caused by insufficient lubri-

cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.

Gear noise usually happens at a specific speed

range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by

driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:

• 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 cause
noise during straight-ahead driving when the gears

are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.

BEARING NOISE

The axle shaft, differential and pinion bearings can

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

Pinion bearings have a constant-pitch noise. This

noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.

Worn or damaged differential bearings usually pro-

duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.

Axle shaft bearings produce noise and vibration

when worn or damaged. The noise generally changes
when 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 noise

3 - 84

REAR AXLE - 194RBI

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