Jeep XJ. Manual — part 21
(8) Install a Guide Pin C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to guide pin. Load the lever adapter against the
opposite side of the housing (Fig. 30) and zero the
indicator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(9) Spread the housing enough to remove the dif-
ferential case from the housing. Measure the dis-
tance with the dial indicator (Fig. 31).
(10) Remove the dial indicator.
(11) While holding the differential case in position,
remove the differential bearing cap bolts and caps.
(12) Remove the differential, and the differential
preload shims for the 181FBI axles, from the hous-
ing. Ensure that the differential bearing cups remain
in position on the differential bearings (Fig. 32).
(13) Mark or tag the differential bearing cups, and
the differential preload shims for the 181FBI axles,
to indicate which side of the differential they were
removed from.
(14) Remove spreader from housing.
Fig. 29 Install Axle Housing Spreader
1 – AXLE HOUSING
2 – DOWEL
3 – SAFETY HOLD DOWN
4 – SPECIAL TOOL
W-129–B
5 – TURNBUCKLE
Fig. 30 Install Dial Indicator
1 – SPECIAL TOOL
C-3339
2 – DIAL INDICATOR
3 – LEVER ADAPTER
4 – SPECIAL TOOL
W-129–B
5 – SPECIAL TOOL
C-3288–B
Fig. 31 Spread Axle Housing
1 – SPECIAL TOOL
C-3339
2 – SPECIAL TOOL
W-129–B
3 - 34
TUBE, 181, AND 186 FBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
If replacement differential bearings or differential
case are being installed, differential side bearing
shim requirements may change. Refer to the Differ-
ential Bearing Preload and Gear Backlash proce-
dures in this section to determine the proper shim
selection.
(1) Position
Spreader
W-129-B,
utilizing
some
items from Adapter Kit 6987, with the tool dowel
pins seated in the locating holes (Fig. 33). Install the
holddown clamps and tighten the tool turnbuckle fin-
ger–tight.
(2) Install a Guide Pin C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to guide pin. Load the lever adapter against the
opposite side of the housing (Fig. 30) and zero the
indicator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator (Fig. 31).
(4) Remove the dial indicator.
(5) Install differential case, and the differential
preload shims for the 181FBI axles, in the housing.
Ensure that the differential bearing cups remain in
position on the differential bearings. Tap the differ-
ential case to ensure the bearings cups are fully
seated in the housing.
(6) Install the bearing caps at their original loca-
tions (Fig. 34).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten the bearing cap bolts to 61 N·m (45 ft.
lbs.) torque.
(10) Install the hub bearings and axle shafts.
Fig. 32 Differential Case Removal
1 – AXLE HOUSING
2 – DIFFERENTIAL CASE
3 – BEARING CUPS
Fig. 33 Install Axle Housing Spreader
1 – AXLE HOUSING
2 – DOWEL
3 – SAFETY HOLD DOWN
4 – SPECIAL TOOL
W-129–B
5 – TURNBUCKLE
Fig. 34 Differential Bearing Cap Reference Letters
1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 35
REMOVAL AND INSTALLATION (Continued)
DIFFERENTIAL SIDE BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove the bearings from the differential case
with
Puller/Press
C-293-PA,
C-293-39
Adapter
Blocks, and Plug SP-3289 (Fig. 35).
INSTALLATION
If replacement differential side bearings or differ-
ential case are being installed, differential side bear-
ing shim requirements may change. Refer to the
Differential Bearing Preload and Gear Backlash pro-
cedures in this section to determine the proper shim
selection.
(1) Install differential side bearing shims onto dif-
ferential case hubs, for 186FBI axles.
(2) Using Installer C-3716-A and Handle C-4171,
install differential side bearings (Fig. 36).
(3) Install differential in axle housing.
AXLE SHAFT OIL SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove differential assembly.
(3) Remove the inner axle shaft seals with a pry
bay.
INSTALLATION
(1) Remove any sealer remaining from original
seals.
(2) Remove sealer from axle tube to housing junc-
tion, if necessary.
(3) Install oil seals with Discs 8110 and Turn-
buckle 6797 (Fig. 37). Tighten tool until disc bottoms
in housing.
(4) Install differential assembly.
181 FBI PINION
The ring gear and pinion are serviced as a matched
set. Do not replace the pinion without replacing the
ring gear.
REMOVAL
(1) Remove differential assembly from axle hous-
ing.
(2) Mark pinion yoke and propeller shaft for
installation alignment.
(3) Disconnect propeller shaft from pinion yoke.
Using suitable wire, tie propeller shaft to underbody.
Fig. 35 Differential Bearing Removal
1 – SPECIAL TOOL C–293–39
2 – BEARING
3 – DIFFERENTIAL
4 – SPECIAL TOOL SP–3289
5 – SPECIAL TOOL C–293–PA
Fig. 36 Differential Side Bearing Installation
1 – SPECIAL TOOL C-3716–A
2 – SPECIAL TOOL C-4171
3 - 36
TUBE, 181, AND 186 FBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
(4) Using Holder 6958 to hold yoke, remove the
pinion nut and washer.
(5) Using Remover C-452 and Holder C-3281,
remove the pinion yoke from pinion shaft (Fig. 38).
(6) Remove the pinion gear and preload shims
from housing (Fig. 39). Catch the pinion with your
hand to prevent it from falling and being damaged.
(7) Remove the front pinion bearing cup, bearing,
oil slinger, if equipped, and pinion seal with Remover
D-147 and Handle C–4171 (Fig. 40).
Fig. 37 Axle Seal Installation
1 – TURNBUCKLE 6797
2 – DISCS 8110
Fig. 38 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 39 Remove Pinion Gear
1 – RAWHIDE HAMMER
Fig. 40 Front Bearing Cup Removal
1 – REMOVER
2 – HANDLE
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 37
REMOVAL AND INSTALLATION (Continued)
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