Jeep XJ. Manual — part 42
(2) Ensure cup is correctly seated.
(3) Apply Mopar
t Door Ease, or equivalent, stick
lubricant to outside surface of bearing cup.
(4) Install the pinion front bearing cup (Fig. 31)
with Installer D–130 and Handle C–4171.
(5) Install pinion front bearing, and oil slinger, if
equipped.
(6) Apply a light coating of gear lubricant on the
lip
of
pinion
seal.
Install
seal
with
Installer
C-4076–B and Handle C-4735-1 (Fig. 32).
Fig. 26 Front Bearing Cup Removal
1 – REMOVER
2 – HANDLE
Fig. 27 Rear Bearing Cup Removal
1 – DRIVER
2 – HANDLE
Fig. 28 Collapsible Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION
4 – PINION DEPTH SHIM
5 – REAR BEARING
Fig. 29 Rear Bearing Removal
1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT
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8 1/4 REAR AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion head to
achieve proper ring and pinion gear mesh. If the
factory installed ring gear and pinion are reused,
the pinion depth shim should not require replace-
ment. If required, refer to Pinion Gear Depth to
select the proper thickness shim before installing
rear pinion bearing.
(7) Place the proper thickness depth shim on the
pinion.
(8) Install
the
rear
bearing
and
slinger,
if
equipped, on the pinion (Fig. 33) with Installer 6448.
(9) Install a new collapsible preload spacer on pin-
ion shaft and install pinion in housing (Fig. 34).
(10) Install pinion in housing.
(11) Install yoke with Installer C-3718 and Yoke
Holder 6719.
(12) Install the yoke washer and a new nut on the
pinion and tighten the pinion nut until there is zero
Fig. 30 Pinion Rear Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 31 Pinion Front Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 32 Pinion Seal Installation
1 – SPECIAL TOOL C-4735
2 – DIFFERENTIAL HOUSING
3 – SPECIAL TOOL C-4076-A
Fig. 33 Shaft Rear Bearing Installation
1 – PRESS
2 – INSTALLATION TOOL
3 – DRIVE PINION
4 – DRIVE PINION SHAFT REAR BEARING
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8 1/4 REAR AXLE
3 - 119
REMOVAL AND INSTALLATION (Continued)
bearing end-play. It will not be possible at this point
to achieve zero bearing end-play if a new collapsible
spacer was installed.
(13) Tighten the nut to 285 N·m (210 ft. lbs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
(14) Using Yoke Holder 6719, crush collapsible
spacer until bearing end play is taken up.
(15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.)
increments until the desired rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer (Fig. 35).
(16) Check bearing rotating torque with an inch
pound torque wrench (Fig. 35). The torque necessary
to rotate the pinion gear should be:
• Original Bearings — 1 to 2 N·m (10 to 20 in. lbs.).
• New Bearings — 1 to 5 N·m (10 to 30 in. lbs.).
(17) Install propeller shaft.
(18) Install differential in housing.
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLY
(1) Remove pinion mate shaft lock screw (Fig. 36).
(2) Remove pinion mate shaft.
(3) Rotate the differential side gears and remove the
differential pinion gears and thrust washers (Fig. 37).
(4) Remove the differential side gears and thrust
washers.
Fig. 34 Collapsible Preload Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION
4 – PINION DEPTH SHIM
5 – REAR BEARING
Fig. 35 Check Pinion Rotating Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
Fig. 36 Pinion Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION MATE SHAFT
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8 1/4 REAR AXLE
XJ
REMOVAL AND INSTALLATION (Continued)
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.
TRAC-LOK
Y DIFFERENTIAL
The Trac–lok
y differential components are illus-
trated in (Fig. 38). Refer to this illustration during
repair service.
DISASSEMBLY
(1) Clamp Side Gear Holding Tool 8138 in a vise.
(2) Position the differential case on Side Gear
Holding Tool 8138 (Fig. 39).
(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.
Fig. 37 Pinion Mate Gear Removal
1 – THRUST WASHER
2 – SIDE GEAR
3 – PINION MATE GEAR
Fig. 38 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
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8 1/4 REAR AXLE
3 - 121
DISASSEMBLY AND ASSEMBLY (Continued)
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