Jeep XJ. Manual — part 30
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, 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 mate shaft can also cause a
snapping 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
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U–joint or by worn side–gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration 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 components
can contribute to what appears to be a rear–end
vibration. Do not overlook engine accessories, brack-
ets and drive belts.
All driveline components should be examined
before starting any repair.
Refer to Group 22, Wheels and Tires, for additional
vibration information.
DRIVELINE SNAP
A 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. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
TRAC–LOK
Y DIFFERENTIAL NOISE
The most common problem is a chatter noise when
turning corners. Before removing a Trac-lok
y unit
for repair, drain, flush and refill the axle with the
specified lubricant. Refer to Lubricant change in this
Group.
A container of Mopar
t Trac-loky Lubricant (fric-
tion modifier) should be added after repair service or
during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. This
will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
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194 RBI AXLE
XJ
DIAGNOSIS AND TESTING (Continued)
TRAC–LOK
Y TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOK
Y
DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE
SUPPORTED.
A
TRAC–LOK
Y
AXLE
CAN
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON-
TACT WITH A SURFACE TO CAUSE THE VEHICLE
TO MOVE.
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 to
studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 5).
(6) If rotating torque is less than 22 N·m (30 ft.
lbs.) or more than 271 N·m (200 ft. lbs.) on either
wheel the unit should be serviced.
SERVICE PROCEDURES
LUBRICANT CHANGE
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.
(3) Remove the 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 the original sealant from the housing
and cover surfaces.
(6) Apply a bead of Mopar
t Silicone Rubber Seal-
ant, or equivalent, to the housing cover (Fig. 6).
Install the housing cover within 5 minutes
after applying the sealant.
(7) Install the cover and any identification tag.
Tighten the cover bolts to 41 N·m (30 ft. lbs.) torque.
(8) For Trac–lok
y differentials, a quantity of
Mopar
t Trac–loky lubricant (friction modifier), or
equivalent, must be added after repair service or a
lubricant change. Refer to the Lubricant Specifica-
tions section of this group for the quantity necessary.
(9) Fill differential with Mopar
t Hypoid Gear
Lubricant, or equivalent, to bottom of the fill plug
hole. Refer to the Lubricant Specifications section of
this group for the quantity necessary.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(10) Install the fill hole plug and lower the vehicle.
(11) Trac–lok
y
differential
equipped
vehicles
should be road tested by making 10 to 12 slow figure-
eight turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
ter noise complaint.
Fig. 5 Trac-lok
Y
Test —Typical
1 – SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 – TORQUE WRENCH
Fig. 6 Apply Sealant
1 – SEALANT
2 – AXLE HOUSING COVER
XJ
194 RBI AXLE
3 - 71
DIAGNOSIS AND TESTING (Continued)
REMOVAL AND INSTALLATION
REAR 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 drums from the axle. Refer
to Group 5, Brakes, for proper procedures.
(6) Disconnect parking brake cables from brackets
and lever.
(7) Remove wheel speed sensors, if necessary.
Refer to Group 5, Brakes, for proper procedures.
(8) Disconnect the brake hose at the axle junction
block. Do not disconnect the brake hydraulic lines at
the wheel cylinders. Refer to Group 5, Brakes, for
proper procedures.
(9) Disconnect the vent hose from the axle shaft
tube.
(10) Mark the propeller shaft and yokes for instal-
lation alignment reference.
(11) Remove propeller shaft.
(12) Disconnect stabilizer bar links.
(13) Disconnect shock absorbers from axle.
(14) Remove the U-bolts which hold the axle to the
spring brackets.
(15) Separate the axle from the vehicle.
INSTALLATION
NOTE: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, vehicle ride
height and handling could be affected.
(1) Raise the axle with lifting device and align the
spring centering bolts with the mating holes in the
axle spring perch.
(2) Install the U-bolts which hold the axle to the
spring brackets. Tighten nuts to 70 N·m (52 ft. lbs.).
(3) Install shock absorbers and tighten nuts to 60
N·m (44 ft. lbs.) torque.
(4) Install stabilizer bar links and tighten nuts to
74 N·m (55 ft. lbs.) torque.
(5) Install the wheel speed sensors, if necessary.
Refer to Group 5, Brakes, for proper procedures.
(6) Connect parking brake cable to brackets and
lever.
(7) Install the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(8) Connect the brake hose to the axle junction
block. Refer to Group 5, Brakes, for proper proce-
dures.
(9) Install axle vent hose.
(10) Align propeller shaft and pinion yoke refer-
ence marks. Install U-joint straps and bolts. Tighten
to 19 N·m (14 ft. lbs.) torque.
(11) Install the wheels and tires.
(12) Add gear lubricant, if necessary. Refer to
Lubricant Specifications in this section for lubricant
requirements.
(13) Remove lifting device from axle and lower the
vehicle.
PINION SHAFT SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(4) Mark the propeller shaft and pinion yoke for
installation alignment reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pinion yoke (Fig. 7).
Fig. 7 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
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194 RBI AXLE
XJ
(10) Use a suitable pry tool or slide hammer
mounted screw to remove the pinion gear seal.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-3972-A
and Handle C-4171 (Fig. 8).
(2) Install yoke on the pinion gear with Screw
8112, Cup 8109, and Holder 6958 (Fig. 9).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.
(3) Install the yoke washer and a new nut on the
pinion gear and tighten the pinion nut until there is
zero bearing end-play.
(4) Tighten the nut to 271 N·m (200 ft. lbs.).
CAUTION: Never
loosen
pinion
gear
nut
to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
(5) Rotate the pinion shaft using a (in. lbs.) torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal plus an additional 0.56
N·m (5 in. lbs.) (Fig. 10).
(6) If the rotating torque is low, use Holder 6958 to
hold the pinion yoke (Fig. 11), and tighten the pinion
shaft nut in 6.8 N·m (5 ft. lbs.) increments until the
proper rotating torque is achieved.
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
(7) Align the installation reference marks on the
propeller shaft and yoke and install the propeller
shaft.
(8) Add gear lubricant to the differential housing,
if necessary. Refer to the Lubricant Specifications for
gear lubricant requirements.
(9) Install the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(10) Install wheel and tire assemblies.
Fig. 8 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 9 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
Fig. 10 Check Pinion Rotation Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
XJ
194 RBI AXLE
3 - 73
REMOVAL AND INSTALLATION (Continued)
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