Jeep Wrangler TJ. Manual — part 232
DIFFERENTIAL COVER
REMOVAL
(1) With vehicle in neutral, position vehicle on hoist.
(2) Remove drain plug.
(3) Remove cover bolts.
(4) Remove cover and drain lubricant.
INSTALLATION
(1) Apply a 6.35mm (1/4 in.) bead of Mopar Sili-
cone Rubber Sealant or equivalent to the housing
cover (Fig. 39).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.
(2) Install cover and identification tag. Tighten
cover bolts in a criss-cross pattern to 41 N·m (30 ft.
lbs.).
(3) Fill differential to specifications.
(4) Install fill plug and tighten to 34 N·m (25 ft.
lbs.).
DIFFERENTIAL
REMOVAL
(1) Remove differential fill plug.
(2) Remove differential cover and drain fluid.
(3) Remove axle shafts.
(4) Note reference letters stamped on the bearing
caps and housing machined sealing surface (Fig. 40).
(5) Loosen differential bearing cap bolts.
(6) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes (Fig. 41). Install
hold-down clamps and tighten the turnbuckle finger-
tight.
Fig. 39 HOUSING COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKESS
Fig. 40 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 41 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
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REAR AXLE - 194RBI
3 - 105
(7) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339 to
pilot stud. Load indicator plunger against the opposite
side of the housing (Fig. 42) and zero the indicator.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). Failure to heed caution may result in
damage.
(8) Spread housing while measuring the distance
with the dial indicator (Fig. 43).
(9) Remove dial indicator.
(10) While holding differential case in position,
remove differential bearing caps.
(11) Remove differential from housing and tag dif-
ferential bearing cups to indicate location (Fig. 44).
(12) Remove spreader from housing.
(13) Clean the housing cavity with flushing oil,
light engine oil or lint free cloth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
DISASSEMBLY
(1) Remove pinion shaft.
(2) Rotate differential side gears and remove dif-
ferential pinions and thrust washers (Fig. 45).
(3) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Lubricate
all
differential
components
with
hypoid gear lubricant.
(2) Install differential side gears and thrust wash-
ers.
(3) Install differential pinion gears and thrust
washers.
(4) Install the pinion mate shaft.
(5) Align hole in the pinion mate shaft with the
hole in the differential case and install pinion mate
shaft lock screw finger tight.
Fig. 42 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 43 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
Fig. 44 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
3 - 106
REAR AXLE - 194RBI
TJ
DIFFERENTIAL (Continued)
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Position Spreader W-129-B and adapters from
Adapter set 6987, with the tool dowel pins seated in
the locating holes (Fig. 46). Install hold-down clamps
and tighten turnbuckle finger-tight.
(2) Install Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.
CAUTION: Never spread over 0.38 mm (0.015 in).
Failure to heed caution may result in damage.
(3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator.
(4) Remove the dial indicator.
(5) Install differential case in the housing. Ensure
that the differential bearing cups remain in position
on the differential bearings. Tap the differential case
to ensure the bearings cups are seated in the hous-
ing.
(6) Install bearing caps in their original locations
(Fig. 47).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten bearing cap bolts to 77 N·m (57 ft.
lbs.).
(10) Install axle shafts.
(11) Install cover and identification tag.
Fig. 45 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
Fig. 46 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 47 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
TJ
REAR AXLE - 194RBI
3 - 107
DIFFERENTIAL (Continued)
DIFFERENTIAL - TRAC-LOK
DESCRIPTION
The Trac-Lok
t differential has a one-piece differen-
tial case, and similar internal components as a stan-
dard
differential,
plus
two
clutch
disc
packs.
Differential bearing preload and ring gear backlash
are adjusted with shims located between the differ-
ential case bearing cups and housing. Pinion bearing
preload is set and maintained by the use of a collaps-
ible spacer.
OPERATION
This differentials clutches are engaged by two con-
current forces. The first being the preload force
exerted through Belleville spring washers within the
clutch packs. The second is the separating forces gen-
erated by the side gears as torque is applied through
the ring gear (Fig. 48).
This design provides the differential action needed
for turning corners and for driving straight ahead
during periods of unequal traction. When one wheel
looses traction, the clutch packs transfer additional
torque to the wheel having the most traction. This
differential resist wheel spin on bumpy roads and
provide more pulling power when one wheel looses
traction. Pulling power is provided continuously until
both wheels loose traction. If both wheels slip due to
unequal traction, Trac-lok
t operation is normal. In
extreme cases of differences of traction, the wheel
with the least traction may spin.
DIAGNOSIS AND TESTING
The most common problem is a chatter noise when
turning corners. Before removing the unit for repair,
drain, flush and refill the axle with the specified
lubricant. A container of Mopar Trac-lok
t Lubricant
(friction modifier) should be added after repair ser-
vice or during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. This
will correct the condition in most instances. If chatter
persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
Fig. 48 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
3 - 108
REAR AXLE - 194RBI
TJ
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