Jeep XJ. Manual — part 16
(10) Place two bearing caps on opposite trunnions
of the remaining cross. Fit the open trunnions into
the link yoke bores and the bearing caps into the
centering kit (Fig. 33).
(11) Press the remaining two bearing caps into
place and install snap rings (Fig. 34).
(12) Tap the snap rings to allow them to seat into
the grooves (Fig. 35).
(13) Check for proper assembly. Flex the joint
beyond center, it should snap over-center in both
directions when correctly assembled (Fig. 36).
(14) Install the propeller shaft.
CLEANING AND INSPECTION
PROPELLER SHAFT
(1) Clean all universal joint bores with cleaning
solvent and a wire brush.
(2) Inspect the yokes for distortion, cracks, and
worn bearing cap bores.
Fig. 33 Install Remaining Cross
Fig. 34 Press In Bearing Cap
Fig. 35 Seat Snap Rings In Groove
Fig. 36 Check Assembly
3 - 14
PROPELLER SHAFTS
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
ADJUSTMENTS
REAR AXLE PINION INPUT ANGLE
Adjust the rear axle pinion input angle on vehicles
equipped with leaf springs with tapered shims (Fig.
37). Install tapered shims between the springs and
axle pad to correct the angle. Refer to Group 2, Sus-
pension, for additional information.
FRONT AXLE PINION INPUT ANGLE
Adjust the front axle pinion input angle at the
lower suspension arms with shims (Fig. 38). Adding
shims will decrease the pinion shaft angle but will
also increase the caster angle. The pinion shaft angle
has priority over the caster angle. Refer to Group 2,
Suspension, for additional information.
SPECIFICATIONS
PROPELLER SHAFTS AND U–JOINTS
DESCRIPTION
TORQUE
Bolts, Transfer Case Yoke . . . . . 27 N·m (20 ft. lbs.)
Bolts, Axle Yoke . . . . . . . . . . . . . 19 N·m (14 ft. lbs.)
Bolts, Axle Yoke . . . . . . . . . . . . . 19 N·m (14 ft. lbs.)
SPECIAL TOOLS
PROPELLER SHAFT
Fig. 37 Pinion Angle Adjustment at Leaf Springs
1 – WEDGE
Fig. 38 Front Axle Angle Adjustment
1 – SHIM
2 – SUSPENSION ARM
Inclinometer—7663
Boot Clamp Installer—C-4975-A
XJ
PROPELLER SHAFTS
3 - 15
TUBE, 181, AND 186 FBI AXLE
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 19
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 21
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . . 21
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL AND INSTALLATION
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . 22
TUBE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 23
AXLE SHAFT—CARDAN U-JOINT . . . . . . . . . . . . 23
FBI PINION SHAFT SEAL . . . . . . . . . . . . . . . 24
FBI PINION SHAFT SEAL . . . . . . . . . . . . . . . 26
COLLAPSIBLE SPACER. . . . . . . . . . . . . . . . . . . . 27
HUB BEARING AND AXLE SHAFT . . . . . . . . . . . . 30
STEERING KNUCKLE AND BALL STUDS. . . . . . . 31
AXLE BUSHING REPLACEMENT . . . . . . . . . . . . . 33
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . . 36
AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . 36
181 FBI PINION . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FBI PINION . . . . . . . . . . . . . . . . . . . . . . . . . . 41
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . . 46
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 47
CLEANING AND INSPECTION
ADJUSTMENTS
FBI PINION GEAR DEPTH. . . . . . . . . . . . . . . 48
FBI PINION GEAR DEPTH. . . . . . . . . . . . . . . 50
FBI DIFFERENTIAL BEARING PRELOAD
AND GEAR BACKLASH . . . . . . . . . . . . . . . . . . 52
FBI DIFFERENTIAL BEARING PRELOAD
AND GEAR BACKLASH . . . . . . . . . . . . . . . . . . 56
GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 59
SPECIFICATIONS
SPECIAL TOOLS
and 186 FBI AXLE . . . . . . . . . . . . . . . . . . . . . 61
DESCRIPTION AND OPERATION
181 FBI AXLE
DESCRIPTION
The 181 Front Beam-design Iron (FBI) axle con-
sists of a cast iron differential housing with axle
shaft tubes extending from either side. The tubes are
pressed into the differential housing and welded.
The integral type housing, hypoid gear design has
the centerline of the pinion set above the centerline
of the ring gear.
The axle has a fitting for a vent hose used to
relieve internal pressure caused by lubricant vapor-
ization and internal expansion.
The axles are equipped with semi–floating axle
shafts, meaning that loads are supported by the hub
bearings. The axle shafts are retained by nuts at the
hub bearings. The hub bearings are bolted to the
steering knuckle at the outboard end of the axle tube
yoke. The hub bearings are serviced as an assembly.
For vehicles with ABS brakes, the ABS wheel
speed sensors are attached to the knuckle assem-
blies. The tone rings for the ABS system are pressed
onto the axle shaft. Do not damage ABS tone
wheel or the sensor when removing axle shafts.
The stamped steel cover provides a means for
inspection and servicing the differential.
The 181 FBI axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
the housing cover by a cover bolt. Build date identi-
fication codes are stamped on the cover side of the
axle shaft tube.
The differential case is a one–piece design. The dif-
ferential pinion mate shaft is retained with a roll
pin. Differential bearing preload and ring gear back-
lash is adjusted by the use of shims (select thick-
ness). The shims are located between the differential
bearing cones and case. Pinion bearing preload is set
and maintained by the use of shims (select thick-
ness).
3 - 16
TUBE, 181, AND 186 FBI AXLE
XJ
OPERATION
The axle receives power from the transfer case
through the front propeller shaft. The front 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.
186 FBI AXLE
DESCRIPTION
The 186 Front Beam-design Iron (FBI) axle con-
sists of a cast iron differential housing with axle
shaft tubes extending from either side. The tubes are
pressed into the differential housing and welded.
The integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline
of the ring gear.
The axle has a fitting for a vent hose used to
relieve internal pressure caused by lubricant vapor-
ization and internal expansion.
The axles are equipped with semi–floating axle
shafts, meaning that loads are supported by the hub
bearings. The axle shafts are retained by nuts at the
hub bearings. The hub bearings are bolted to the
steering knuckle at the outboard end of the axle tube
yoke. The hub bearings are serviced as an assembly.
For vehicles with ABS brakes, the ABS wheel
speed sensors are attached to the knuckle assem-
blies. The tone rings for the ABS system are pressed
onto the axle shaft. Do not damage ABS tone
wheel or the sensor when removing axle shafts.
The stamped steel cover provides a means for
inspection and servicing the differential.
The 186 FBI axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
the housing cover by a cover bolt. Build date identi-
fication codes are stamped on the cover side of the
axle shaft tube.
The differential case is a one–piece design. The dif-
ferential pinion mate shaft is retained with a roll
pin. Differential bearing preload and ring gear back-
lash is adjusted by the use of shims (select thick-
ness). The shims are located between the differential
bearing cones and case. Pinion bearing preload is set
and maintained by the use of a collapsible spacer.
OPERATION
The axle receives power from the transfer case
through the front propeller shaft. The front 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.
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.
The 181 FBI axle lubricant capacity is 1.2 L (2.5
pts.). The 186 FBI axle lubricant capacity is 1.18 L
(2.5 pts.).
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 17
DESCRIPTION AND OPERATION (Continued)
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