Jeep XJ. Manual — part 34
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLY
(1) Remove pinion mate shaft lock screw (Fig. 49).
(2) Remove pinion mate shaft.
(3) Rotate the differential side gears and remove
the differential pinion gears and thrust washers (Fig.
50).
(4) Remove the differential side gears and thrust
washers.
ASSEMBLY
(1) Install the differential side gears and thrust
washers.
(2) Install the differential pinion gears and thrust
washers.
(3) Install the pinion mate shaft.
(4) Align the hole in the pinion mate shaft with
the hole in the differential case and install the pinion
mate shaft lock screw.
(5) Lubricate
all
differential
components
with
hypoid gear lubricant.
Fig. 48 Typical Housing Cover With Sealant
1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35mm (1/4”)
Fig. 49 Pinion Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION MATE SHAFT
Fig. 50 Pinion Mate Gear Removal
1 – THRUST WASHER
2 – SIDE GEAR
3 – PINION MATE GEAR
3 - 86
194 RBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
TRAC-LOK
Y DIFFERENTIAL
The Trac–lok
y differential components are illus-
trated in (Fig. 51). Refer to this illustration during
repair service.
DISASSEMBLY
(1) Clamp Side Gear Holding Tool 6965 in a vise.
(2) Position the differential case on Side Gear
Holding Tool 6965 (Fig. 52).
(3) Remove ring gear, if necessary. Ring gear
removal is necessary only if the ring gear is to be
replaced. The Trac-lok
y differential can be serviced
with the ring gear installed.
(4) Remove the pinion gear mate shaft lock screw
(Fig. 53).
(5) Remove the pinion gear mate shaft. If neces-
sary, use a drift and hammer (Fig. 54).
(6) Install and lubricate Step Plate C-6960-3 (Fig.
55).
Fig. 51 Trac–lok
Y
Differential Components
1 – THRUST WASHER
2 – PINION
3 – SHAFT LOCK SCREW
4 – PINION MATE SHAFT
5 – SIDE GEAR
6 – RETAINER
7 – DISC
8 – CLUTCH PACK
9 – DIFFERENTIAL CASE
10 – RETAINER
Fig. 52 Differential Case Holding Tool
1 – SPECIAL TOOL 6965
2 – VISE
3 – DIFFERENTIAL
XJ
194 RBI AXLE
3 - 87
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Assemble Threaded Adapter C-6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
(8) Position
a
small
screw
driver
in
slot
of
Threaded Adapter C-6960-1 (Fig. 56) to prevent
adapter from turning.
(9) Tighten forcing screw tool 122 N·m (90 ft. lbs.)
maximum to compress Belleville springs in clutch
packs (Fig. 57).
Fig. 53 Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION GEAR MATE SHAFT
Fig. 54 Mate Shaft Removal
1 – PINION MATE SHAFT
2 – SIDE GEAR
3 – DRIFT
4 – PINION MATE GEAR
Fig. 55 Step Plate Tool Installation
1 – LOWER SIDE GEAR
2 – DIFFERENTIAL CASE
3 – SPECIAL TOOL C-6960–3
Fig. 56 Threaded Adapter Installation
1 – SOCKET
2 – SLOT IN ADAPTER
3 – SCREWDRIVER
4 – DISC C-6960–3
5 – THREADED ROD C-6960–4
6 – THREADED ADAPTER DISC C–6960–1
3 - 88
194 RBI AXLE
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(10) Using
an
appropriate
size
feeler
gauge,
remove thrust washers from behind the pinion gears
(Fig. 58).
(11) Insert Turning Bar C-6960-2 in case (Fig. 59).
(12) Loosen the Forcing Screw C-6960-4 in small
increments until the clutch pack tension is relieved
and the differential case can be turned using Turning
Bar C-6960-2.
(13) Rotate differential case until the pinion gears
can be removed.
(14) Remove pinion gears from differential case.
(15) Remove Forcing Screw C-6960-4, Step Plate
C-6960-3, and Threaded Adapter C-6960-1.
(16) Remove top side gear, clutch pack retainer,
and clutch pack. Keep plates in correct order during
removal (Fig. 60).
Fig. 57 Tighten Belleville Spring Compressor Tool
1 – TORQUE WRENCH
2 – TOOL ASSEMBLED
3 – DIFFERENTIAL CASE
Fig. 58 Remove Pinion Gear Thrust Washer
1 – THRUST WASHER
2 – FEELER GAUGE
Fig. 59 Pinion Gear Removal
1 – PINION GEARS
2 – TOOL
Fig. 60 Side Gear & Clutch Disc Removal
1 – DIFFERENTIAL CASE
2 – RETAINER
3 – SIDE GEAR AND CLUTCH DISC PACK
XJ
194 RBI AXLE
3 - 89
DISASSEMBLY AND ASSEMBLY (Continued)
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