Jeep XJ. Manual — part 45

Fig. 59 Gear Tooth Contact Patterns

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8 1/4 REAR AXLE

XJ

ADJUSTMENTS (Continued)

(7) If clearance is 0.012 inch (0.305 mm) or

greater, both side gears must be replaced (matched
set) and the clearance measurements repeated.

(8) If clearance (above) continues to be 0.012 inch

(0.305 mm) or greater, the case must be replaced.

SPECIFICATIONS

8 1/4 INCH AXLE

Axle Type . . . . . . . . . . . . . . . Semi-floating, hypoid
Lubricant . . . . . . . . . . . . . . . . . . . . . . SAE 80W-90
Lube Capacity . . . . . . . . . . . . . . . . 2.08 L (4.4 pts.)
Trac-Lok Additive . . . . . . . . . . . . . . . 118 ml (4 oz.)
Axle Ratio . . . . . . . . . . . . . . . . . . . . 3.07, 3.55,.4.10
Differential
Case Clearance . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Case Flange Runout . . . . . . . . 0.076 mm (0.003 in.)
Ring Gear
Diameter . . . . . . . . . . . . . . . . . . 20.95 cm (8.25 in.)
Backlash . . . . . . . . . 0.12-0.20 mm (0.005-0.008 in.)
Runout . . . . . . . . . . . . . . . . . . 0.127 mm (0.005 in.)
Pinion Bearing
Preload-Used Bearings . . . . 1-2 N·m (10-20 in.lbs.)
Preload-New Bearings . . . . . 1-5 N·m (10-30 in.lbs.)

8 1/4 INCH AXLE

DESCRIPTION

TORQUE

Diff. Cover Bolt . . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bearing Cap Bolt . . . . . . . . . . 136 N·m (100 ft. lbs.)
Pinion Nut–Minimum . . . . . . 285 N·m (210 ft. lbs.)
Ring Gear Bolt . . . . . . . . . . . . . 95 N·m (70 ft. lbs.)
Backing Plate Bolt . . . . . . . . . 614 N·m (45 ft. lbs.)
RWAL/ABS Sensor Bolt . . . . . . 24 N·m (18. ft. lbs.)

SPECIAL TOOLS

8 1/4 AXLES

Fig. 60 Side Gear Clearance Measurement

1 – FEELER GAUGE BLADES
2 – SIDE GEAR

Fig. 61 Side Gear Calculations

Puller, Hub—6790

Remover, Bearing—6310

Installer—C-4198

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8 1/4 REAR AXLE

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ADJUSTMENTS (Continued)

Handle—C-4171

Installer—C-4076-B

Handle—C-4735-1

Holder—6719

Puller—C-452

Installer—C-3718

Adjustment Rod—C-4164

Puller/Press—C-293–PA

Adapters—C-293-48

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8 1/4 REAR AXLE

XJ

SPECIAL TOOLS (Continued)

Plug—SP-3289

Adapters—C-293-47

Installer—C-4340

Holder—8138

Installer—C-4345

Remover—C-4307

Installer—C-4308

Installer—D-130

Installer—6448

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8 1/4 REAR AXLE

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SPECIAL TOOLS (Continued)