Jeep XJ. Manual — part 23
(6) Remove the pinion and collapsible spacer from
housing (Fig. 52). Catch the pinion with your hand to
prevent it from falling and being damaged.
(7) Remove the front pinion bearing cup, bearing,
oil slinger, if equipped, and pinion seal with Remover
C-4345 and Handle C–4171 (Fig. 53).
(8) Remove the rear pinion bearing cup from axle
housing (Fig. 54). Use Remover D-149 and Handle
C–4171.
(9) Remove the collapsible preload spacer from
pinion gear (Fig. 55).
Fig. 52 Remove Pinion
1 – RAWHIDE HAMMER
Fig. 53 Front Bearing Cup Removal
1 – REMOVER
2 – HANDLE
Fig. 54 Rear Bearing Cup Removal
1 – DRIVER
2 – HANDLE
Fig. 55 Collapsible Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION
4 – PINION DEPTH SHIM
5 – REAR BEARING
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TUBE, 181, AND 186 FBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
(10) Remove the rear pinion bearing from the pin-
ion
with
Puller/Press
C–293-PA
and
Adapters
C–293–39 (Fig. 56).
Place 4 adapter blocks so they do not damage
the bearing cage.
(11) Remove the depth shim/oil slinger from the
pinion shaft. Record the thickness of the depth shim/
oil slinger.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If the factory installed ring gear and pinion
are reused, the pinion depth shim/oil slinger should
not require replacement. Refer to Pinion Gear Depth
to select the proper thickness shim/oil slinger
before installing pinion.
(1) Apply Mopar
t Door Ease, or equivalent, stick
lubricant to outside surface of rear pinion bearing
cup. Install the bearing cup with Installer D-146 and
Driver Handle C–4171 (Fig. 57). Verify cup is cor-
rectly seated.
(2) Apply Mopar
t Door Ease, or equivalent, stick
lubricant to outside surface of front pinion bearing
cup. Install the bearing cup with Installer D-130 and
Handle C–4171 (Fig. 58).
(3) Install front pinion bearing, and oil slinger, if
equipped.
(4) 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. 59).
(5) Install the rear pinion bearing and the pinion
depth shim/oil slinger onto the pinion with Installer
W-262 and a shop press (Fig. 60).
Fig. 56 Inner Bearing Removal
1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT
Fig. 57 Rear Pinion Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 58 Pinion Outer Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 43
REMOVAL AND INSTALLATION (Continued)
(6) Install a new collapsible preload spacer on pin-
ion shaft and install pinion in housing (Fig. 61).
(7) Install yoke with Installer W-162-B, Cup 8109,
and Holder 6958 (Fig. 62).
(8) Install the pinion washer and a new nut onto
the pinion. Tighten the nut to 216 N·m (160 ft. lbs.)
minimum. Do not over–tighten. Maximum torque
is 352 N·m (260 ft. lbs.).
CAUTION: Never loosen the pinion nut to decrease
pinion bearing rotating torque and never exceed
specified
preload
torque.
If
preload
torque
is
exceeded
a
new
collapsible
spacer
must
be
installed. The torque sequence will then have to be
repeated.
(9) Using Holder 6958 and torque wrench (set at
352 N·m (260 ft. lbs.)), crush collapsible spacer until
Fig. 59 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 60 Rear Pinion Bearing Installation
1 – PRESS
2 – INSTALLATION TOOL
3 – PINION DEPTH SHIM/OIL BAFFLE
4 – DRIVE PINION
5 – DRIVE PINION SHAFT REAR BEARING
Fig. 61 Collapsible Preload Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING
Fig. 62 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
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TUBE, 181, AND 186 FBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
bearing end play is taken up (Fig. 63). If more than
353 N·m (260 ft. lbs.) is needed to begin to collapse
the spacer, the spacer is defective and must be
replaced.
(10) Slowly tighten the nut in 6.8 N·m (5 ft. lb.)
increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over
crushing the collapsible spacer (Fig. 64).
(11) Check bearing rotating torque with an inch
pound torque wrench (Fig. 64). The torque necessary
to rotate the pinion should be:
• Original Bearings — 1 to 2 N·m (10 to 20 in.
lbs.).
• New Bearings — 1.5 to 4 N·m (15 to 35 in. lbs.).
(12) Install differential assembly.
RING GEAR
NOTE: The ring gear and pinion are serviced as a
matched set. Do not replace the ring gear without
replacing the pinion.
REMOVAL
(1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with
soft metal jaw protectors. (Fig. 65)
(3) Remove bolts holding ring gear to differential
case.
(4) Using a soft hammer, drive ring gear from dif-
ferential case (Fig. 65).
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
Fig. 63 Tightening Pinion Nut—Typical
1 – PINION FLANGE
2 – FRONT AXLE
3 – TOOL 6958
Fig. 64 Check Pinion Rotation Torque
1 – in. lbs. TORQUE WRENCH
2 – PINION YOKE
Fig. 65 Ring Gear Removal
1 – CASE
2 – RING GEAR
3 – RAWHIDE HAMMER
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 45
REMOVAL AND INSTALLATION (Continued)
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