Jeep XJ. Manual — part 33
(7) Use a suitable pry tool or a slide hammer
mounted screw to remove the pinion shaft seal.
(8) Remove oil slinger, if equipped, and front pin-
ion bearing.
(9) Remove the front pinion bearing cup with
Remover C-4345 and Handle C–4171 (Fig. 36).
(10) Remove the rear bearing cup from housing
(Fig. 37). Use Remover D-149 and Handle C–4171.
(11) Remove the collapsible preload spacer (Fig.
38).
(12) Remove the rear bearing from the pinion with
Puller/Press C-293-PA and Adapters C-293-40 (Fig.
39).
Place 4 adapter blocks so they do not damage
the bearing cage.
Fig. 34 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 35 Remove Pinion Gear
1 – RAWHIDE HAMMER
Fig. 36 Front Bearing Cup Removal
1 – REMOVER
2 – HANDLE
Fig. 37 Rear Bearing Cup Removal
1 – DRIVER
2 – HANDLE
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194 RBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
(13) Remove the depth shims from the pinion gear
shaft. Record the thickness of the depth shims.
INSTALLATION
(1) Apply Mopar
t Door Ease, or equivalent, stick
lubricant to outside surface of bearing cup.
(2) Install
the
pinion
rear
bearing
cup
with
Installer D-146 and Driver Handle C–4171 (Fig. 40).
Ensure cup is correctly seated.
(3) Apply Mopar
t Door Ease, or equivalent, stick
lubricant to outside surface of bearing cup.
(4) Install the pinion front bearing cup with
Installer D–130 and Handle C–4171 (Fig. 41).
(5) Install pinion front bearing, and oil slinger, if
equipped.
(6) 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. 42).
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin-
ion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
bearing.
(7) Place the proper thickness depth shim on the
pinion gear.
Fig. 38 Collapsible Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING
Fig. 39 Rear Bearing Removal
1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT
Fig. 40 Pinion Rear Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
XJ
194 RBI AXLE
3 - 83
REMOVAL AND INSTALLATION (Continued)
(8) Install
the
rear
bearing
and
slinger,
if
equipped, on the pinion gear with Installer W-262
(Fig. 43).
(9) Install a new collapsible preload spacer on pin-
ion shaft and install pinion gear in housing (Fig. 44).
(10) Install pinion gear in housing.
(11) Install yoke with Installer Screw 8112, Cup
8109, and holder 6958 (Fig. 45).
(12) Install the yoke washer and a new nut on the
pinion gear and tighten the pinion nut until there is
zero bearing end-play.
(13) 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.
Fig. 41 Pinion Front Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 42 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 43 Shaft Rear Bearing Installation
1 – PRESS
2 – INSTALLATION TOOL
3 – DRIVE PINION GEAR
4 – DRIVE PINION GEAR SHAFT REAR BEARING
Fig. 44 Collapsible Preload Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING
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194 RBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
(14) Using yoke holder 6958 and a torque wrench
set at 474 N·m (350 ft. lbs.), crush collapsible spacer
until bearing end play is taken up (Fig. 46).
NOTE: If the spacer requires more than 474 N·m
(350 ft. lbs.) torque to crush, the collapsible spacer
is defective and must be replaced.
(15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.)
increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over
crushing the collapsible spacer (Fig. 47).
(16) Check bearing rotating torque with a (in. lbs.)
torque wrench (Fig. 47). The torque necessary to
rotate the pinion gear 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.).
(17) Install differential in housing.
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. 48).
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.
Fig. 45 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
Fig. 46 Tightening Pinion Nut–Typical
1 – SPECIAL TOOL 6958
2 – 1 in. PIPE
3 – 3/4 DRIVE TORQUE WRENCH
Fig. 47 Check Pinion Gear Rotating Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
XJ
194 RBI AXLE
3 - 85
REMOVAL AND INSTALLATION (Continued)
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