Jeep XJ. Manual — part 29
LUBRICANT
DESCRIPTION
A multi-purpose, hypoid gear lubricant which con-
forms to the following specifications should be used.
Mopar
t Hypoid Gear Lubricant conforms to all of
these specifications.
• The lubricant should have MIL–L–2105C and
API GL 5 quality specifications.
• Lubricant is a thermally stable SAE 80W–90
gear lubricant.
• Lubricant for axles intended for heavy-duty or
trailer tow use is SAE 75W–140 SYNTHETIC gear
lubricant.
Trac-lok differentials require the addition of 3.5 oz.
of friction modifier to the axle lubricant. The 194 RBI
axle lubricant capacity is 1.66L (3.50 pts.) total,
including the friction modifier if necessary.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
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. 2).
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.
3). 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.
Fig. 1 Shim Locations
1 – PINION GEAR DEPTH SHIM
2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 – RING GEAR
4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 – COLLAPSIBLE SPACER
Fig. 2 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
3 - 66
194 RBI AXLE
XJ
DESCRIPTION AND OPERATION (Continued)
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. 4).
The Trac-lok
y design provides the differential
action needed for turning corners and for driving
straight ahead during periods of unequal traction.
When one wheel looses traction, the clutch packs
transfer additional torque to the wheel having the
most traction. Trac-lok
y differentials resist wheel
spin on bumpy roads and provide more pulling power
when one wheel looses traction. Pulling power is pro-
vided continuously until both wheels loose traction. If
both wheels slip due to unequal traction, Trac-lok
y
operation is normal. In extreme cases of differences
of traction, the wheel with the least traction may
spin.
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Axle bearing problem conditions are usually caused
by:
• Insufficient or incorrect lubricant.
• Foreign matter/water contamination.
• Incorrect bearing preload torque adjustment.
• Incorrect backlash.
Axle gear problem conditions are usually the result
of:
• Insufficient lubrication.
• Incorrect or contaminated lubricant.
• Overloading (excessive engine torque) or exceed-
ing vehicle weight capacity.
• Incorrect clearance or backlash adjustment.
Axle component breakage is most often the result
of:
• Severe overloading.
• Insufficient lubricant.
• Incorrect lubricant.
• Improperly tightened components.
• Differential housing bores not square to each
other.
Fig. 3 Differential Operation—On Turns
1 – PINION GEARS ROTATE ON PINION SHAFT
Fig. 4 Trac-lok
Y
Limited Slip Differential Operation
1 – CASE
2 – RING GEAR
3 – DRIVE PINION
4 – PINION GEAR
5 – MATE SHAFT
6 – CLUTCH PACK
7 – SIDE GEAR
8 – CLUTCH PACK
XJ
194 RBI AXLE
3 - 67
DESCRIPTION AND OPERATION (Continued)
DIAGNOSTIC CHART
Condition
Possible Causes
Correction
Wheel Noise
1. Wheel loose.
1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing.
2. Replace bearing.
Axle Shaft Noise
1. Misaligned axle tube.
1. Inspect axle tube alignment. Correct as
necessary.
2. Bent or sprung axle shaft.
2. Inspect and correct as necessary.
3. End-play in pinion bearings.
3. Refer to pinion pre-load information and
correct as necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring gear and
pinion backlash. Correct as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings pre-load.
6. Loose pinion yoke nut.
6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as necessary.
Axle Shaft Broke
1. Misaligned axle tube.
1. Replace the broken shaft after correcting
tube mis-alignment.
2 Vehicle overloaded.
2. Replace broken shaft and avoid excessive
weight on vehicle.
3. Erratic clutch operation.
3. Replace broken shaft and avoid or correct
erratic clutch operation.
4. Grabbing clutch.
4. Replace broken shaft and inspect and
repair clutch as necessary.
Differential Cracked
1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears and
bearings for further damage. Set differential
bearing pre-load properly.
2. Excessive ring gear backlash.
2. Replace case and inspect gears and
bearings for further damage. Set ring gear
backlash properly.
3. Vehicle overloaded.
3. Replace case and inspect gears and
bearings for further damage. Avoid excessive
vehicle weight.
4. Erratic clutch operation.
4. Replace case and inspect gears and
bearings for further damage. Avoid erratic use
of clutch.
Differential Gears Scored
1. Insufficient lubrication.
1. Replace scored gears. Fill differential with
the correct fluid type and quantity.
2. Improper grade of lubricant.
2. Replace scored gears. Fill differential with
the correct fluid type and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all gears,
pinion bores, and shaft for damage. Service
as necessary.
3 - 68
194 RBI AXLE
XJ
DIAGNOSIS AND TESTING (Continued)
Condition
Possible Causes
Correction
Loss Of Lubricant
1. Lubricant level too high.
1. Drain lubricant to the correct level.
2. Worn axle shaft seals.
2. Replace seals.
3. Cracked differential housing.
3. Repair as necessary.
4. Worn pinion seal.
4. Replace seal.
5. Worn/scored yoke.
5. Replace yoke and seal.
6. Axle cover not properly sealed.
6. Remove, clean, and re-seal cover.
Axle Overheating
1. Lubricant level low.
1. Fill differential to correct level.
2. Improper grade of lubricant.
2. Fill differential with the correct fluid type
and quantity.
3. Bearing pre-loads too high.
3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash.
4. Re-adjust ring gear backlash.
Gear Teeth Broke
1. Overloading.
1. Replace gears. Examine other gears and
bearings for possible damage.
2. Erratic clutch operation.
2. Replace gears and examine the remaining
parts for damage. Avoid erratic clutch
operation.
3. Ice-spotted pavement.
3. Replace gears and examine remaining
parts for damage.
4. Improper adjustments.
4. Replace gears and examine remaining
parts for damage. Ensure ring gear backlash
is correct.
Axle Noise
1. Insufficient lubricant.
1. Fill differential with the correct fluid type
and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion contact pattern.
3. Unmatched ring gear and pinion.
3. Replace gears with a matched ring gear
and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings.
5. Adjust pinion bearing pre-load.
6. Loose differential bearings.
6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear.
7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components and replace
as necessary. Ensure that the bearing caps
are torqued tot he proper specification.
9. Housing not machined properly.
9. Replace housing.
XJ
194 RBI AXLE
3 - 69
DIAGNOSIS AND TESTING (Continued)
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