Jeep XJ. Manual — part 38
Adapter Kit—6987
Guide Pin—C-3288-B
Bearing Remover Tool Set—6310
Hub Puller—6790
Dial Indicator—C-3339
3 - 102
194 RBI AXLE
XJ
SPECIAL TOOLS (Continued)
8 1/4 REAR AXLE
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
8 1/4 AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 105
TRAC-LOK
DIFFERENTIAL . . . . . . . . . . . . . . . 105
DIAGNOSIS AND TESTING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 106
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . 109
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . 109
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . 109
TRAC–LOK
DIFFERENTIAL NOISE . . . . . . . . . 109
TEST . . . . . . . . . . . . . . . . . . . . . . 110
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . 110
REMOVAL AND INSTALLATION
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
AXLE SEAL AND BEARING . . . . . . . . . . . . . . . . 112
PINION SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . 114
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . 115
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 117
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 120
TRAC-LOK
DIFFERENTIAL . . . . . . . . . . . . . . . 121
CLEANING AND INSPECTION
8 1/4 AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
TRAC-LOK
. . . . . . . . . . . . . . . . . . . . . . . . . . . 125
ADJUSTMENTS
8 1/4 AXLE PINION GEAR DEPTH . . . . . . . . . . . 126
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . 127
SPECIFICATIONS
SPECIAL TOOLS
8 1/4 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
DESCRIPTION AND OPERATION
8 1/4 AXLE
DESCRIPTION
The 8 1/4 inch axle housings consist of a cast iron
center section with axle tubes extending from either
side. The tubes are pressed into and welded to the
differential housing to form a one-piece axle housing
(Fig. 1).
The axles have a vent hose to relieve internal pres-
sure caused by lubricant vaporization and internal
expansion.
The axles are equipped with semi-floating axle
shafts, meaning vehicle loads are supported by the
axle shaft and bearings. The axle shafts are retained
by C-locks in the differential side gears.
The removable, stamped steel cover provides a
means for inspection and service without removing
the complete axle from the vehicle.
The 8 1/4 axle have a date tag and a gear ratio tag.
The tags are attached to the differential housing by a
cover bolt.
The differential case is a one-piece design. The dif-
ferential pinion mate shaft is retained with a
threaded pin. Differential bearing preload and ring
gear backlash are set and maintained by threaded
adjusters at the outside of the differential housing.
Pinion bearing preload is set and maintained by the
use of a collapsible spacer.
Axles equipped with a Trac-Lok
y differential are
optional. A Trac-Lok differential has a one-piece dif-
ferential case, and the same internal components as
a standard differential, plus two clutch disc packs.
AXLE IDENTIFICATION
The axle differential cover can be used for identifi-
cation of the axle (Fig. 2). A tag is also attached to
the cover.
OPERATION
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
through the pinion mate and side gears. The side
gears are splined to the axle shafts.
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8 1/4 REAR AXLE
3 - 103
LUBRICANT
DESCRIPTION
Multi-purpose, hypoid gear lubricant should be
used for rear axles with a standard differential. The
lubricant should have a MIL-L-2105C and API GL 5
quality specifications.
Trac-Lok differentials require the addition of 4 oz.
of friction modifier to the axle lubricant after service.
The 8 1/4 axle lubricant capacity is 2.08 L (4.4 pts.)
total, including the friction modifier, if necessary.
CAUTION: If the rear axle is submerged in water,
the lubricant must be replaced immediately. Avoid
the possibility of premature axle failure resulting
from water contamination of the lubricant.
Fig. 1 8 1/4 Axle
Fig. 2 Differential Cover 8 1/4 Inch Axle
1 – DIFFERENTIAL COVER
2 – IDENTIFICATION TAG
3 – PUSH-IN FILL PLUG
4 – DATE TAG
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8 1/4 REAR AXLE
XJ
DESCRIPTION AND OPERATION (Continued)
STANDARD DIFFERENTIAL
DESCRIPTION
The differential gear system divides the torque
between the axle shafts. It allows the axle shafts to
rotate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.
OPERATION
In operation, power flow occurs as follows:
• The pinion gear rotates the ring gear
• The ring gear (bolted to the differential case)
rotates the case
• The differential pinion gears (mounted on the
pinion mate shaft in the case) rotate the side gears
• The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 3).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
4). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
TRAC-LOK
Y DIFFERENTIAL
DESCRIPTION
In a standard differential, if one wheel spins, the
opposite wheel will generate only as much torque as
the spinning wheel.
In the Trac-lok
y differential, part of the ring gear
torque is transmitted through clutch packs which
contain multiple discs. The clutches will have radial
grooves on the plates, and concentric grooves on the
discs or bonded fiber material that is smooth in
appearance.
OPERATION
In operation, the Trac-lok
y clutches are engaged
by two concurrent forces. The first being the preload
force
exerted
through
Belleville
spring
washers
within the clutch packs. The second is the separating
forces generated by the side gears as torque is
applied through the ring gear (Fig. 5).
Fig. 3 Differential Operation—Straight Ahead Driving
1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 – PINION GEAR
3 – SIDE GEAR
4 – PINION GEARS ROTATE WITH CASE
Fig. 4 Differential Operation—On Turns
1 – PINION GEARS ROTATE ON PINION SHAFT
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8 1/4 REAR AXLE
3 - 105
DESCRIPTION AND OPERATION (Continued)
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