Jeep XJ. Manual — part 664
SPECIFICATIONS
REAR AXLE
AXLE SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Axle Ratio
3.07, 3.55, 3.73
Differential Bearing Preload
0.2 mm (0.008 in.)
Differential Side Gear Clearance
0.0-0.15 mm (0.0-0.006 in.)
Ring Gear Diameter
194 mm (7.638 in.)
Ring Gear Backlash
0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth
96.85 mm (3.813 in.)
Pinion Bearing Preload - Original Bearings
1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings
1.7-3.4 N·m (15-30 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Differential Cover Bolts
41
30
Bearing Cap Bolts
77
57
Ring Gear Bolts - 3/8 in.
108
80
Ring Gear Bolts - 7/16 in.
136
100
Pinion Nut
271-474
200-350
Pinion Mate Shaft Screw
16.25
12
3s - 22
REAR AXLE - 194RBI
XJ
REAR AXLE - 194RBI (Continued)
2001 JEEP CHEROKEE
REAR AXLE - 8 1/4
TABLE OF CONTENTS
page
page
REAR AXLE - 8 1/4
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 29
REAR AXLE - 8 1/4
ADJUSTMENTS
Ring gears and pinions are supplied as matched
sets only. The identifying numbers for the ring gear
and pinion are etched into the face of each gear (Fig.
1). A plus (+) number, minus (–) number or zero (0) is
etched into the face of the pinion. This number 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 depth provides the best gear
tooth contact pattern. Refer to Backlash and Contact
Pattern Analysis paragraph in this section for addi-
tional information.
Compensation
for
pinion
depth
variance
is
achieved with select shims. The shims are placed
behind the rear pinion bearing (Fig. 2).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract the thickness of the
original depth shims 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. 1 Pinion Gear ID Numbers
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 2 Adjustment Shim Locations
1 - DIFFERENTIAL HOUSING
2 - COLLAPSIBLE SPACER
3 - REAR PINION BEARING
4 - PINION DEPTH SHIM
5 - PINION GEAR
6 - BEARING CUP
XJ
REAR AXLE - 8 1/4
3s - 23
2001 JEEP CHEROKEE
PINION GEAR DEPTH VARIANCE
Original
Pinion
Gear
Depth
Variance
Replacement Pinion Gear Depth Variance
2
4
2
3
2
2
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
2
0.001
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
+1
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
0
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
1
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
2
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
3
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
4
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
0.008
PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339.
(1) Assemble Pinion Height Block 6739, Pinion
Block 8540 and rear pinion bearing onto Screw 6741
(Fig. 3).
(2) Insert assembled height gauge components,
rear bearing, and screw into the housing through
pinion bearing cups (Fig. 4).
(3) Install front pinion bearing and Cone-Nut 6740
hand tight (Fig. 3).
(4) Place Arbor Disc 8541 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 5).
Install differential bearing caps on Arbor Discs and
tighten cap bolts to 41 N·m (30 ft. lbs.).
NOTE: Arbor Discs 8541 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
height block (Fig. 3). Hold scooter block in place and
zero the dial indicator. Tighten dial indicator face
lock screw.
(7) Slowly slide the dial indicator probe over the
edge of the pinion height block.
Fig. 3 Pinion Depth Gauge Tools
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOOK
8 - ARBOR DISC
3s - 24
REAR AXLE - 8 1/4
XJ
REAR AXLE - 8 1/4 (Continued)
2001 JEEP CHEROKEE
(8) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 6). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Continue moving
the dial probe to the crest of the arbor bar and record
the highest reading. If the dial indicator can not
achieve the zero reading, the rear bearing cup or the
pinion depth gauge set is not installed correctly.
(9) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
etched in the face of the pinion (Fig. 1). For example,
if the depth variance is –2, add +0.002 in. to the dial
indicator reading.
BEARING PRELOAD AND GEAR BACKLASH
The following must be considered when adjusting
bearing preload and gear backlash:
• The maximum ring gear backlash variation is
0.003 inch (0.076 mm).
• Mark the gears so the same teeth are meshed
during all backlash measurements.
• Maintain the torque while adjusting the bearing
preload and ring gear backlash.
• Excessive adjuster torque will introduce a high
bearing load and cause premature bearing failure.
Insufficient adjuster torque can result in excessive
differential case free-play and ring gear noise.
• Insufficient adjuster torque will not support the
ring gear correctly and can cause excessive differen-
tial case free-play and ring gear noise.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
• Maintain the gear teeth engaged (meshed) as
marked.
• The bearings must be seated by rapidly rotating
the pinion gear a half turn back and forth.
• Do this five to ten times each time the threaded
adjusters are adjusted.
(1) Use Wrench C-4164 to adjust each threaded
adjuster inward until the differential bearing free-
play is eliminated (Fig. 7). Allow some ring gear
backlash (approximately 0.01 inch/0.25 mm) between
the ring and pinion gear. Seat the bearing cups with
the procedure described above.
Fig. 4 Pinion Height Block
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
Fig. 5 Gauge Tools In Housing
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 6 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
XJ
REAR AXLE - 8 1/4
3s - 25
REAR AXLE - 8 1/4 (Continued)
2001 JEEP CHEROKEE
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