Jeep Wrangler TJ. Manual — part 236
Condition
Possible Causes
Correction
Gear Teeth Broke
1. Overloading.
1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation.
2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement.
3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments.
4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise
1. Insufficient lubricant.
1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion.
3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings.
5. Adjust pinion bearing pre-load.
6. Loose differential bearings.
6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear.
7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly.
9. Replace housing.
TJ
REAR AXLE - 216RBI
3 - 121
REAR AXLE - 216RBI (Continued)
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Position a suitable lifting device under the
axle.
(3) Secure axle to device.
(4) Remove brake components.
(5) Remove brake hose at the axle junction block.
(6) Remove vent hose from axle tube.
(7) If equipped with Locker differential disconnect
pressure hose from differential housing and locker
indicator connector (Fig. 1).
(8) Remove propeller shaft.
(9) Remove stabilizer bar links from axle.
(10) Remove shock absorbers from axle (Fig. 2).
(11) Remove track bar from axle (Fig. 3).
(12) Remove upper and lower suspension arms
from the axle brackets.
(13) Separate the axle from the vehicle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. Failure to
heed caution may result in damage.
(1) Raise axle with lifting device and align coil
springs.
(2) Position upper and lower suspension arms on
the axle brackets. Install nuts and bolts, do not
tighten bolts at this time.
(3) Install track bar and attachment bolts, do not
tighten bolts at this time.
(4) Install shock absorbers and tighten nuts to
torque specification.
(5) Install stabilizer bar links and tighten nuts to
torque specification.
(6) Install the wheel speed sensors, if necessary.
(7) Install brake components.
(8) Install brake hose to the axle junction block
and bleed brakes.
(9) Install axle vent hose.
(10) If equipped with Locker differential connect
pressure hose and Locker indicator swith.
(11) Install propeller shaft.
(12) Remove lifting device from axle and lower the
vehicle.
(13) Tighten upper and lower control arms nuts to
torque specification (Fig. 4).
(14) Tighten track bar bolts to torque specification.
Fig. 1 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 2 SHOCK ABSORBER
1 - AXLE BRACKET
2 - SHOCK
Fig. 3 REAR TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - REAR AXLE
3 - 122
REAR AXLE - 216RBI
TJ
REAR AXLE - 216RBI (Continued)
ADJUSTMENTS
RING AND PINION GEAR
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
5). A plus (+) number, minus (–) number or zero (0) is
etched into the face of the pinion gear. This number
is the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched with a (0). The standard depth provides the
best teeth contact pattern. Refer to Backlash and
Contact Pattern Analysis Paragraph in this section
for additional information.
Compensation
for
pinion
depth
variance
is
achieved with select shims. The shims are placed
under the inner pinion bearing on the pinion shaft.
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion gear. Add or subtract the thickness of
the original depth shims to compensate for the differ-
ence in the depth variances. Refer to the Depth Vari-
ance charts.
Note where Old and New Pinion Marking columns
intersect. The intersecting figure represents plus or
minus the amount needed.
Note the etched number on the face of the drive
pinion gear (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shim(s). If the num-
ber is positive, subtract that value from the thickness
of the depth shim(s). If the number is 0 no change is
necessary. Refer to the Pinion Gear Depth Variance
Chart.
Fig. 4 UPPER AND LOWER SUSPENSION ARMS
1 - UPPER SUSPENSION ARM
2 - REAR AXLE
3 - LOWER SUSPENSION ARM
Fig. 5 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEARS MATCHING NUMBER
TJ
REAR AXLE - 216RBI
3 - 123
REAR AXLE - 216RBI (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
2
4
2
3
2
2
2
1
0
+1
+2
+3
+4
+4
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
+3
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
+1
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
0
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
1
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
2
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
3
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
4
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
0.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion cups and pin-
ion bearings installed in housing. Take measure-
ments
with
Pinion
Gauge
Set
6730
and
Dial
Indicator C-3339 (Fig. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6734 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into axle housing through
pinion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone 6740
hand tight.
Fig. 6 PINION DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 7 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 124
REAR AXLE - 216RBI
TJ
REAR AXLE - 216RBI (Continued)
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