Jeep Wrangler TJ. Manual — part 210
Condition
Possible Causes
Correction
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.
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.
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FRONT AXLE - 181FBI
3 - 17
FRONT AXLE - 181FBI (Continued)
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.
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.
3 - 18
FRONT AXLE - 181FBI
TJ
FRONT AXLE - 181FBI (Continued)
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Position a lift under the axle and secure to the
axle.
(3) Remove brake components.
(4) Remove vent hose from axle shaft tube.
(5) Remove propeller shaft.
(6) Remove stabilizer bar links at the axle (Fig. 1).
(7) Remove shock absorbers from axle brackets
(Fig. 2).
(8) Remove track bar from axle bracket (Fig. 3).
(9) Remove tie rod and drag link from steering
knuckle.
(10) Remove steering damper from axle bracket.
(11) Remove upper and lower suspension arms
from axle brackets.
(12) Lower lift enough to remove the axle. The coil
springs will drop with the axle.
(13) Remove 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. Failure to
heed caution may result in damage.
(1) Install
springs
and
retainers
and
tighten
retainer bolts to 21 N·m (16 ft. lbs.).
(2) Position axle under vehicle and align it with
the spring pads.
Fig. 1 STABILIZER BAR
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
Fig. 2 COIL SPRING & SHOCK ABSORBER
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
Fig. 3 TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
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FRONT AXLE - 181FBI
3 - 19
FRONT AXLE - 181FBI (Continued)
(3) Install upper and lower suspension arms in the
axle brackets and loosely install bolts and nuts (Fig.
4).
(4) Connect the vent hose to the axle shaft tube.
(5) Install track bar to the axle bracket and loosely
install bolt (Fig. 5).
(6) Install shock absorbers and tighten the bolts
(Fig. 6) to torque specification.
(7) Install stabilizer bar links to the axle brackets
and tighten nuts (Fig. 7) to torque specification.
Fig. 4 UPPER & LOWER SUSPENSION ARMS
1 - UPPER SUSPENSION ARM
2 - FRONT AXLE
3 - LOWER SUSPENSION ARM
Fig. 5 TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
Fig. 6 COIL SPRING & SHOCK ABSORBER
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
Fig. 7 STABILIZER BAR
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
3 - 20
FRONT AXLE - 181FBI
TJ
FRONT AXLE - 181FBI (Continued)
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