Jeep Wrangler TJ. Manual — part 235
(10) Install yoke washer and a new nut on the
pinion gear and tighten the pinion nut until there is
zero bearing end-play.
(11) Tighten the nut to 271 N·m (200 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. Failure to heed
caution may result in damage.
(12) Using Spanner Wrench 6958 and a torque
wrench set at 475 N·m (350 ft. lbs.), (Fig. 75) slowly
tighten the nut in 6.8 N·m (5 ft. lbs.) increments
until the rotating torque is achieved. Measure the
rotating torque frequently to avoid over crushing the
collapsible spacer (Fig. 76).
CAUTION: If more than 475 N·m (350 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced. Failure to
heed caution may result in damage.
(13) Check bearing rotating torque with a inch
pound torque wrench (Fig. 76). The pinion gear rotat-
ing torque should be:
• Original Bearings: 1 to 2 N·m (10 to 20 in. lbs.).
• New Bearings: 2 to 4 N·m (20 to 35 in. lbs.).
(14) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(15) Invert the differential case in the vise.
(16) Install new ring gear bolts and alternately
tighten to 136 N·m (100 ft. lbs.) (Fig. 77).
CAUTION: Do not reuse ring gear bolts, the bolts
can fracture causing extensive damage. Failure to
heed caution may result in damage.
(17) Install differential in axle housing and verify
gear mesh and contact pattern. Refer to Adjustments
(Gear Contact Pattern) for procedure.
Fig. 75 PINION YOKE WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 76 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 77 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
TJ
REAR AXLE - 194RBI
3 - 117
PINION GEAR/RING GEAR (Continued)
REAR AXLE - 216RBI
TABLE OF CONTENTS
page
page
REAR AXLE - 216RBI
. . . . . . . . . . . . . . . 118
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
. . . . . . . . . . . . . . . . . . . . . . . . 122
. . . . . . . . . . . . . . . . . . . . . . . 123
. . . . . . . . . . . . . . . . . . . . . . . . . 131
. . . . . . . . . . . . . . . . . . . . . . . 131
AXLE SHAFTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
. . . . . . . . . . . . . . . . . . . . . . . . 134
AXLE BEARINGS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
. . . . . . . . . . . . . . . . . . . . . . . . 136
PINION SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
. . . . . . . . . . . . . . . . . . . . . . . . 137
DIFFERENTIAL COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
. . . . . . . . . . . . . . . . . . . . . . . . 138
DIFFERENTIAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
. . . . . . . . . . . . . . . . . . . . . . . . 140
. . . . . . . . . . . . . . . . . . . . . . . . . . . 140
. . . . . . . . . . . . . . . . . . . . . . . . 141
DIFFERENTIAL -TRAC-LOK
. . . . . . . . . . . . . . . . . . . . . . . . 141
. . . . . . . . . . . . . . . . . . . . . . . . . . 141
. . . . . . . . . . . . . . . 142
. . . . . . . . . . . . . . . . . . . . . . . . 142
. . . . . . . . . . . . . . . . . . . . . . . . . . . 144
DIFFERENTIAL - TRU-LOK
. . . . . . . . . . . . . . . . . . . . . . . . 146
. . . . . . . . . . . . . . . . . . . . . . . . . . 146
. . . . . . . . . . . . . . . 146
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
. . . . . . . . . . . . . . . . . . . . . . . . 148
. . . . . . . . . . . . . . . . . . . . . . . . . . . 151
. . . . . . . . . . . . . . . . . . . . . . . . 151
DIFFERENTIAL - TRU-LOK PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
. . . . . . . . . . . . . . . . . . . . . . . . 153
DIFFERENTIAL CASE BEARINGS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
. . . . . . . . . . . . . . . . . . . . . . . . 154
PINION GEAR/RING GEAR/TONE RING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
. . . . . . . . . . . . . . . . . . . . . . . . 157
REAR AXLE - 216RBI
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
• Check for insufficient lubricant.
• Incorrect ring gear backlash.
• Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.
3 - 118
REAR AXLE - 216RBI
TJ
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
• Damaged drive shaft.
• Missing drive shaft balance weight(s).
• Worn or out-of-balance wheels.
• Loose wheel lug nuts.
• Worn U-joint(s).
• Loose/broken springs.
• Damaged axle shaft bearing(s).
• Loose pinion gear nut.
• Excessive pinion yoke run out.
• Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
• High engine idle speed.
• Transmission shift operation.
• Loose engine/transmission/transfer case mounts.
• Worn U-joints.
• Loose spring mounts.
• Loose pinion gear nut and yoke.
• Excessive ring gear backlash.
• Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
DIAGNOSTIC CHART
Condition
Possible Causes
Correction
Wheel Noise
1. Wheel loose.
1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing.
2. Replace bearing.
Axle Shaft Noise
1. Misaligned axle tube.
1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft.
2. Inspect and correct as necessary.
Axle Shaft Broke
1. Misaligned axle tube.
1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded.
2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation.
3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch.
4. Replace broken shaft and inspect
and repair clutch as necessary.
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REAR AXLE - 216RBI
3 - 119
REAR AXLE - 216RBI (Continued)
Condition
Possible Causes
Correction
Differential Cracked
1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash.
2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded.
3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation.
4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored
1. Insufficient lubrication.
1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant.
2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant
1. Lubricant level too high.
1. Drain lubricant to the correct
level.
2. Worn axle shaft seals.
2. Replace seals.
3. Cracked differential housing.
3. Repair as necessary.
4. Worn pinion seal.
4. Replace seal.
5. Worn/scored yoke.
5. Replace yoke and seal.
6. Axle cover not properly sealed.
6. Remove, clean, and re-seal
cover.
Axle Overheating
1. Lubricant level low.
1. Fill differential to correct level.
2. Improper grade of lubricant.
2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high.
3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash.
4. Re-adjust ring gear backlash.
3 - 120
REAR AXLE - 216RBI
TJ
REAR AXLE - 216RBI (Continued)
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