Jeep XJ. Manual — part 18
(6) Apply a bead of Mopar
t Silicone Rubber Seal-
ant, or equivalent, to the housing cover (Fig. 3).
Install the housing cover within 5 minutes
after applying the sealant.
(7) Install the cover and any identification tag.
Tighten the cover bolts in a criss–cross pattern to 41
N·m (30 ft. lbs.) torque.
(8) Refill the differential with Mopar
t Hypoid
Gear Lubricant, or equivalent, to bottom of the fill
plug hole. Refer to the Lubricant Specifications in
this group for the quantity necessary.
(9) Install the fill hole plug and lower the vehicle.
Tighten fill plug to 34 N·m (25 ft. lbs.).
REMOVAL AND INSTALLATION
DRIVE AXLE ASSEMBLY
REMOVAL
(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the
axle.
(3) Secure axle to device.
(4) Remove the wheels and tires.
(5) Remove the brake rotors and calipers from the
axle. Refer to Group 5, Brakes, for proper procedures.
(6) Disconnect the wheel sensor wiring harness
from the vehicle wiring harness, if necessary.
(7) Disconnect the vent hose from the axle shaft
tube.
(8) Mark the propeller shaft and yoke for installa-
tion alignment reference.
(9) Remove propeller shaft.
(10) Disconnect stabilizer bar links at the axle.
(11) Disconnect shock absorbers from axle brack-
ets.
(12) Disconnect track bar.
(13) Disconnect the tie rod and drag link from the
steering knuckle. Refer to Group 2, Suspension, for
proper procedures.
(14) Disconnect the steering damper from the axle
bracket.
(15) Disconnect the upper and lower suspension
arms from the axle brackets.
(16) Lower the lifting device enough to remove the
axle. The coil springs will drop with the axle.
(17) Remove the coil springs from the axle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, ride height and
handling could be affected.
(1) Install the springs and retainer clips. Tighten
the retainer bolts to 21 N·m (16 ft. lbs.) torque.
(2) Support the axle on a suitable lifting device
and position axle under the vehicle.
(3) Raise the axle and align it with the spring
pads.
(4) Position the upper and lower suspension arms
in the axle brackets. Loosely install bolts and nuts to
hold suspension arms to the axle brackets.
(5) Connect the vent hose to the axle shaft tube.
(6) Connect the track bar to the axle bracket.
Loosely install the bolt to hold the track bar to the
axle bracket.
(7) Install the shock absorbers and tighten the
bolts to 23 N·m (17 ft. lbs.) torque.
(8) Install the stabilizer bar links to the axle
brackets. Tighten the nut to 95 N·m (70 ft. lbs.)
torque.
(9) Install the drag link and tie rod to the steering
knuckles. Refer to Group 2, Suspension, for proper
procedures.
(10) Install
the
steering
damper
to
the
axle
bracket and tighten the nut to 75 N·m (55 ft. lbs.)
torque.
(11) Install the brake rotors and calipers. Refer to
Group 5, Brakes, for the proper procedures.
(12) Connect the wheel speed sensor wiring har-
ness to the vehicle wiring harness, if necessary.
Fig. 3 Typical Housing Cover With Sealant
1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35mm (1/4”)
3 - 22
TUBE, 181, AND 186 FBI AXLE
XJ
SERVICE PROCEDURES (Continued)
(13) Align the previously made marks on the pro-
peller shaft and the yoke.
(14) Install the straps and bolts to hold the propel-
ler shaft to the yoke.
(15) Check and fill axle lubricant. Refer to the
Lubricant Specifications in this group for the quan-
tity necessary.
(16) Install the wheel and tire assemblies.
(17) Remove the lifting device from the axle and
lower the vehicle.
(18) Tighten the upper suspension arm nuts to 75
N·m (55 ft. lbs.) torque. Tighten the lower suspension
arm nuts to 115 N·m (85 ft. lbs.) torque.
(19) Tighten the track bar bolt at the axle bracket
to 100 N·m (74 ft. lbs.) torque.
(20) Check the front wheel alignment.
TUBE AXLE ASSEMBLY
REMOVAL
(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the
axle.
(3) Secure axle to device.
(4) Remove the wheels and tires.
(5) Remove the brake rotors and calipers from the
axle. Refer to Group 5, Brakes, for proper procedures.
(6) Disconnect the wheel sensor wiring harness
from the vehicle wiring harness, if necessary.
(7) Disconnect stabilizer bar links at the axle.
(8) Disconnect shock absorbers from axle brackets.
(9) Disconnect track bar.
(10) Disconnect the tie rod and drag link from the
steering knuckle. Refer to Group 2, Suspension, for
proper procedures.
(11) Disconnect the steering damper from the axle
bracket.
(12) Disconnect the upper and lower suspension
arms from the axle brackets.
(13) Lower the lifting device enough to remove the
axle. The coil springs will drop with the axle.
(14) Remove the coil springs from the axle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, ride height and
handling could be affected.
(1) Install the springs and retainer clips. Tighten
the retainer bolts to 21 N·m (16 ft. lbs.) torque.
(2) Support the axle on a suitable lifting device
and position axle under the vehicle.
(3) Raise the axle and align it with the spring
pads.
(4) Position the upper and lower suspension arms
in the axle brackets. Loosely install bolts and nuts to
hold suspension arms to the axle brackets.
(5) Connect the track bar to the axle bracket.
Loosely install the bolt to hold the track bar to the
axle bracket.
(6) Install the shock absorbers and tighten the
bolts to 23 N·m (17 ft. lbs.) torque.
(7) Install the stabilizer bar links to the axle
brackets. Tighten the nut to 95 N·m (70 ft. lbs.)
torque.
(8) Install the drag link and tie rod to the steering
knuckles. Refer to Group 2, Suspension, for proper
procedures.
(9) Install the steering damper to the axle bracket
and tighten the nut to 75 N·m (55 ft. lbs.) torque.
(10) Install the brake rotors and calipers. Refer to
Group 5, Brakes, for the proper procedures.
(11) Connect the wheel speed sensor wiring har-
ness to the vehicle wiring harness, if necessary.
(12) Install the wheel and tire assemblies.
(13) Remove the lifting device from the axle and
lower the vehicle.
(14) Tighten the upper suspension arm nuts to 75
N·m (55 ft. lbs.) torque. Tighten the lower suspension
arm nuts to 115 N·m (85 ft. lbs.) torque.
(15) Tighten the track bar bolt at the axle bracket
to 100 N·m (74 ft. lbs.) torque.
(16) Check the front wheel alignment.
AXLE SHAFT—CARDAN U-JOINT
Single cardan U–joint components are not service-
able. If defective, they must be replaced as a unit. If
the bearings, seals, spider, or bearing caps are dam-
aged or worn, replace the complete U–joint.
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Also, to avoid distorting the
yoke, do not over tighten the vise jaws.
(1) Remove axle shaft.
(2) Remove the bearing cap retaining snap rings
(Fig. 4).
It can be helpful to saturate the bearing caps
with penetrating oil prior to removal.
(3) Locate a socket where the inside diameter is
larger in diameter than the bearing cap. Place the
socket (receiver) against the yoke and around the
perimeter of the bearing cap to be removed.
(4) Locate a socket where the outside diameter is
smaller in diameter than the bearing cap. Place the
socket (driver) against the opposite bearing cap.
(5) Position the yoke with the sockets in a vise
(Fig. 5).
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 23
REMOVAL AND INSTALLATION (Continued)
(6) Compress the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(8) Repeat the above procedure for the remaining
bearing cap.
(9) Remove the remaining bearing cap, bearings,
seals and spider from the propeller shaft yoke.
INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium–base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket wrench in a
vise.
(4) Compress the vise to force the bearing caps
into the yoke. Force the caps enough to install the
retaining clips.
(5) Install the bearing cap retaining clips.
(6) Install axle shaft.
181 FBI PINION SHAFT SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pinion yoke (Fig. 6).
(10) Use a suitable pry tool or a slide hammer
mounted screw to remove the pinion shaft seal.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-3972-A
and Handle C-4171 (Fig. 7).
(2) Install yoke on the pinion gear with Installer
W-162–D, Cup 8109, and Holder 6958 (Fig. 8).
Fig. 4 Axle Shaft Outer U–Joint
1 – SHAFT YOKE
2 – BEARING CAP
3 – SNAP RINGS
4 – BEARING CAP
5 – SPINDLE YOKE
6 – BEARING
7 – BEARING CAP
8 – SNAP RINGS
9 – BEARING CAP
Fig. 5 Yoke Bearing Cap Removal
1 – LARGE-DIAMETER SOCKET WRENCH
2 – VISE
3 – SMALL-DIAMETER SOCKET WRENCH
3 - 24
TUBE, 181, AND 186 FBI AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to the pinion bearings may
result.
(3) Install the pinion washer and a new nut on the
pinion gear. Tighten the nut only enough to
remove the shaft end play.
(4) Tighten pinion nut to 217 N·m (160 ft. lbs.).
(5) Rotate the pinion shaft using a (in. lbs.) torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal, plus an additional 0.56
N·m (5 in. lbs.) (Fig. 9).
(6) If the rotating torque is low, use Holder 6958 to
hold the pinion yoke, and tighten the pinion shaft
nut in 6.8 N·m (5 ft. lbs.) increments until proper
rotating torque is achieved.
(7) Align the installation reference marks on the
propeller shaft and yoke, and install the propeller
shaft.
(8) Check and fill the gear lubricant. Refer to the
Lubricant Specifications for gear lubricant require-
ments.
(9) Install the brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(10) Install wheel and tire assemblies.
(11) Lower the vehicle.
Fig. 6 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 7 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 8 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
Fig. 9 Check Pinion Rotation Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
XJ
TUBE, 181, AND 186 FBI AXLE
3 - 25
REMOVAL AND INSTALLATION (Continued)
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