Jeep XJ. Manual — part 24
(1) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(2) Invert the differential case in the vise.
(3) Install new ring gear bolts and alternately
tighten to 95–122 N·m (70–90 ft. lbs.) torque (Fig.
66).
(4) Install differential in axle housing and verify
gear mesh and contact pattern.
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLY
(1) Remove the ring gear.
(2) Using a suitable roll pin punch, drive out the
roll pin holding pinion gear mate shaft in the differ-
ential case (Fig. 67).
(3) Remove the pinion gear mate shaft from the
differential case and the pinion mate gears.
(4) Rotate differential side gears and remove the
pinion mate gears and thrust washers (Fig. 68).
(5) Remove the differential side gears and thrust
washers.
ASSEMBLY
(1) Install the differential side gears and thrust
washers.
(2) Install the pinion mate gears and thrust wash-
ers.
Fig. 66 Ring Gear Bolt Installation
1 – TORQUE WRENCH
2 – RING GEAR BOLT
3 – RING GEAR
4 – CASE
Fig. 67 Mate Shaft Roll Pin Removal
1 – DRIFT
2 – LOCKPIN
3 – MATE SHAFT
Fig. 68 Pinion Mate Gear Removal
1 – THRUST WASHER
2 – SIDE GEAR
3 – PINION MATE GEAR
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TUBE, 181, AND 186 FBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
(3) Install the pinion gear mate shaft. Align the
roll pin holes in shaft and the differential case.
(4) Install the roll pin to hold the pinion mate
shaft in the differential case (Fig. 69).
(5) Install the ring gear.
(6) Lubricate
all
differential
components
with
hypoid gear lubricant.
FINAL ASSEMBLY
(1) Scrape the residual sealant from the housing
and cover mating surfaces. Clean the mating surfaces
with mineral spirits. Apply a bead of Mopar
t Silicone
Rubber Sealant, or equivalent, on the housing cover
(Fig. 70).
Install the housing cover within 5 minutes
after applying the sealant.
(2) Install the cover on the differential with the
attaching bolts. Install the identification tag. Tighten
the cover bolts to 41 N·m (30 ft. lbs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(3) Refill the differential housing with gear lubri-
cant. Refer to the Lubricant Specifications section of
this group for the gear lubricant requirements.
(4) Install the fill hole plug.
CLEANING AND INSPECTION
CARDAN U-JOINT
Clean all the U–joint yoke bores with cleaning sol-
vent and a wire brush. Ensure that all the rust and
foreign matter are removed from the bores.
Inspect the yokes for distortion, cracks and worn
bearing cap bores.
Replace the complete U–joint if any of the compo-
nents are defective.
AXLE COMPONENTS
Wash differential components with cleaning solvent
and dry with compressed air. Do not steam clean
the differential components.
Wash bearings with solvent and towel dry, or dry
with compressed air. DO NOT spin bearings with
compressed
air.
Cup
and
bearing
must
be
replaced as matched sets only.
Clean axle shaft tubes and oil channels in housing.
Inspect for;
• Smooth appearance with no broken/dented sur-
faces on the bearing rollers or the roller contact sur-
faces.
• Bearing cups must not be distorted or cracked.
• Machined surfaces should be smooth and with-
out any raised edges.
• Raised metal on shoulders of cup bores should
be removed with a hand stone.
Fig. 69 Mate Shaft Roll Pin Installation
1 – PUNCH
2 – PINION MATE SHAFT
3 – MATE SHAFT LOCKPIN
Fig. 70 Typical Housing Cover With Sealant
1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35mm (1/4”)
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 47
DISASSEMBLY AND ASSEMBLY (Continued)
• Wear and damage to pinion gear mate shaft,
pinion gears, side gears and thrust washers. Replace
as a matched set only.
• Ring and pinion gear for worn and chipped
teeth.
• Ring gear for damaged bolt threads. Replaced as
a matched set only.
• Pinion yoke for cracks, worn splines, pitted
areas, and a rough/corroded seal contact surface.
Repair or replace as necessary.
• Preload shims for damage and distortion. Install
new shims, if necessary.
ADJUSTMENTS
181 FBI PINION GEAR DEPTH
GENERAL INFORMATION
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
71). A plus (+) number, minus (–) number or zero (0)
is etched into the face of the pinion gear. This num-
ber is the amount (in thousandths of an inch) the
depth varies from the standard depth setting of a
pinion etched with a (0). The standard setting from
the center line of the ring gear to the back face of the
pinion is 92.08 mm (3.625 in.). The standard depth
provides the best gear tooth contact pattern. Refer to
Backlash and Contact Pattern Analysis paragraph in
this section for additional information.
Compensation
for
pinion
depth
variance
is
achieved with a select shim/oil baffle. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 72).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Depth Variance chart.
Note where Old and New Pinion Marking columns
intersect.
Intersecting
figure
represents
plus
or
minus the amount needed.
Note the etched number on the face of the pinion
gear 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 the
required thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 71 Pinion Gear ID Numbers
1 – PRODUCTION NUMBERS
2 – DRIVE PINION GEAR DEPTH VARIANCE
3 – GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 72 Shim Locations
1 – PINION GEAR DEPTH SHIM/OIL BAFFLE
2 – DIFFERENTIAL BEARING SHIM
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TUBE, 181, AND 186 FBI AXLE
XJ
CLEANING AND INSPECTION (Continued)
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the axle housing.
Take measurements with Pinion Gauge Set and Dial
Indicator C-3339 (Fig. 73).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6733, and rear pinion bearing onto Screw 6741
(Fig. 73).
(2) Insert assembled height gauge components,
rear bearing and screw into axle housing through
pinion bearing cups (Fig. 74).
(3) Install front pinion bearing and Cone-nut 6740
hand tight (Fig. 73).
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in axle housing side bearing cradles (Fig. 75).
Install differential bearing caps on Arbor Discs and
tighten 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 axle
being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position
in axle housing so dial probe and scooter block are
flush against the rearward surface of the pinion
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear 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
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. 73 Pinion Gear Depth Gauge Tools—Typical
1 – DIAL INDICATOR
2 – ARBOR
3 – PINION HEIGHT BLOCK
4 – CONE
5 – SCREW
6 – PINION BLOCK
7 – SCOOTER BLOCK
8 – ARBOR DISC
Fig. 74 Pinion Height Block—Typical
1 – PINION BLOCK
2 – PINION HEIGHT BLOCK
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 49
ADJUSTMENTS (Continued)
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