Jeep Wrangler TJ. Manual — part 241
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 indicator plunger against the
opposite side of the housing and zero the indicator.
(3) Spread housing while measuring the distance
with the dial indicator.
CAUTION: Never spread over 0.38 mm (0.015 in).
Failure to heed caution may result in damage.
(4) Remove dial indicator.
(5) Install differential case in the housing. Tap dif-
ferential case to seat bearings cups in the housing.
(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 108 N·m (80 ft.
lbs.).
(10) Install axle shafts.
(11) Install cover and identification tag.
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.
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 - 216RBI
3 - 141
DIFFERENTIAL (Continued)
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 the
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.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 49).
(6) If rotating torque is less than 41 N·m (56 ft.
lbs.) or more than 271 N·m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp side gear Fixture 6965 in a vise and set
differential case on the fixture (Fig. 50).
NOTE: The Trac-lok
T
differential can be serviced
with the ring gear installed unless the gear hangs
over the pinion shaft, then it must be removed.
(2) Remove pinion gear mate shaft roll pin with a
hammer and punch.
(3) Remove pinion gear mate shaft with a drift and
hammer.
(4) Lubricate and install disc without threaded
hole from Trac-lok
t Tool C-4487 into lower side gear
(Fig. 51).
(5) Lubricate and install disc with threaded hole
from Trac-lok
t Tool C-4487 into upper side gear.
Thread forcing screw from tool into threaded disc
until it becomes centered in lower disc.
(6) Position a small screw driver in slot of the
threaded disc (Fig. 52) to prevent adapter from turn-
ing.
(7) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress Belleville springs in clutch
packs (Fig. 53).
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
Fig. 49 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 142
REAR AXLE - 216RBI
TJ
DIFFERENTIAL -TRAC-LOK (Continued)
Fig. 50 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 51 TRAC-LOK DISC
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
Fig. 52 TRAC-LOK TOOLS ASSEMBLY
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - STEP PLATE
5 - THREADED ROD
6 - DISC
Fig. 53 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
TJ
REAR AXLE - 216RBI
3 - 143
DIFFERENTIAL -TRAC-LOK (Continued)
(8) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 54).
(9) Insert turning bar from tool into the pinion
mate shaft hole in the case (Fig. 55).
(10) Loosen forcing screw in small increments
until clutch pack tension is relieved and the differen-
tial case can be turned using turning bar.
(11) Rotate differential case until the pinion gears
can be removed.
(12) Remove pinion gears from differential case.
(13) Remove
Forcing
Screw,
Step
Plate
and
Threaded Adapter.
(14) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in order during removal
(Fig. 56).
(15) Remove differential case from the Holding
Fixture. Remove side gear, clutch pack retainer and
clutch pack. Keep plates in order during removal.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Lubricate components with gear lubricant.
(2) Assemble clutch discs into packs and secure
disc packs with retaining clips (Fig. 57).
NOTE: Dished plate is position with the convex side
against the side gear.
(3) Position assembled clutch disc packs on the
side gear hubs.
(4) Install clutch pack and side gear in the ring
gear side of the differential case, with retaining clips
seated in the case pockets (Fig. 58).
(5) Position the differential case on the Holding
Fixture 6965.
Fig. 54 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 55 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 56 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
3 - 144
REAR AXLE - 216RBI
TJ
DIFFERENTIAL -TRAC-LOK (Continued)
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