Jeep Wrangler TJ. Manual — part 223
PINION SEAL
REMOVAL
(1) Mark the propeller shaft and pinion yoke for
installation reference.
(2) Remove propeller shaft from the yoke.
(3) Rotate pinion gear three or four times and ver-
ify it rotates smoothly.
(4) Remove pinion yoke nut and washer with
Remover C-452 and Flange Wrench C-3281 (Fig. 37).
(5) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 38).
(2) Install yoke on the pinion gear with Installer
W-162-D and Spanner Wrench 6958 (Fig. 39).
(3) Install a new nut on the pinion gear and
tighten the nut to 217-271 N·m (160-200 in. lbs.)
(Fig. 40).
(4) Installation
propeller
shaft
with
reference
marks aligned.
(5) Check and add gear lubricant to axle if neces-
sary.
Fig. 36 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 37 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - PULLER
Fig. 38 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
TJ
FRONT AXLE - 216FBI
3 - 69
SINGLE CARDAN UNIVERSAL JOINT (Continued)
DIFFERENTIAL COVER
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove drain plug.
(3) Disconnect
indicator
switch
harness
and
remove connector from differential cover (Fig. 41).
(4) Remove cover bolts.
(5) 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. 42).
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, identification tag and indicator
switch connector (Fig. 43). Tighten cover bolts in a
criss-cross pattern to 41 N·m (30 ft. lbs.).
(3) Connect indicator switch harness.
(4) Fill differential to specifications.
(5) Install fill plug and tighten to 34 N·m (25 ft.
lbs.).
Fig. 39 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 40 PINION SHAFT NUT
1 - PINION FLANGE
2 - HOLDING TOOL
3 - DIFFERENTIAL HOUSING
Fig. 41 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
3 - 70
FRONT AXLE - 216FBI
TJ
PINION SEAL (Continued)
DIFFERENTIAL - TRU-LOK
DESCRIPTION
The differential is a locking differential, that pro-
vides a positive mechanical connection between the
right and left axle when engauged. The differential
uses a dog clutch to connection the right and left
axle.
OPERATION
The Tru-lok differential is activated by the axle
lock switch located on the dash panel. When the
switch is activated, an air pump with a built-in pres-
sure regulator sends 5 PSI of air pressure to a accua-
tor diaphragm in the differential housing. The
diaphragm then engages a dog clutch and a position
switch. The dog clutch has one gear attached to the
differential case and another gear attached to a dif-
ferential side gear. When the dog clutch is engaged
the right and left wheels turn at the same speed. The
position switch lights a lamp on the dash to indicate
the system has been engaged. The differential works
as standard differential when not engaged.
NOTE: The differential is serviced as an assembly,
the diaphragm and indicator switch are serviced
separately. The differential case must be removed
to service the diaphragm actuator and indicator
switch.
DIAGNOSIS AND TESTING
UNLOCKED
(1) Block tires opposite the axle to be tested to pre-
vent the vehicle from rolling.
(2) Place transfer case in 4WD Low and automan-
tic transmission in Park (1st gear if manual trans-
mission).
(3) Raise both wheels of the axle to be tested off
the ground.
(4) Turn ignition to the ON position and dash
switch to the OFF position.
(5) Rotate one tire by hand. The other tire should
spin in the opposite direction.
NOTE: If wheel cannot be rotated the differential
must be repaired/replaced.
Fig. 42 HOUSING COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKESS
Fig. 43 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
TJ
FRONT AXLE - 216FBI
3 - 71
DIFFERENTIAL COVER (Continued)
LOCKED
(1) Block tires opposite the axle to be tested to pre-
vent the vehicle from rolling.
(2) Place transfer case in 4WD Low and automan-
tic transmission in Park (1st gear if manual trans-
mission).
(3) Raise both wheels of the axle to be tested off
the ground.
(4) Turn ignition to the ON position and dash
switch to the ON position.
(5) Try to rotate one tire by hand. You should not
be able to rotate the tire.
NOTE: If wheel does rotate verify locker pump oper-
ation. If the pump is operating properly the differen-
tial must be repaired/replaced.
TRU-LOK INDICATOR SWITCH
(1) Turn ignition switch off.
(2) Disconnect indicator switch harness (Fig. 44)
from the differential housing.
(3) Measure electrical continuity across the switch
terminals. Circuit should be closed (zero resistance).
NOTE: If circuit is not closed remove differential
and replace locker indicator switch.
TRU-LOK PUMPS
(1) Connect a pressure gauge to the front pump.
(2) Place transfer case in 4WD Low and automatic
transmission in Park (1st gear if manual transmis-
sion).
(3) Turn ignition to the ON position and push the
dash switch twice to activate the front pump.
NOTE: If pump is not running, verify pump has (Fig.
45) 12 volts and a ground.
(4) With the pump running the pressure gauge
should show 5 psi..
NOTE: If pump does not produce 5 psi. replace the
pump.
REMOVAL
(1) Remove drain plug from the differential hous-
ing.
(2) Disconnect
indicator
switch
harness
and
remove connector from differential cover (Fig. 46).
(3) Remove differential housing cover.
Fig. 44 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 45 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
Fig. 46 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
3 - 72
FRONT AXLE - 216FBI
TJ
DIFFERENTIAL - TRU-LOK (Continued)
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