Jeep Wrangler TJ. Manual — part 225
housing. Tap differential case to seat bearings cups
in the housing.
CAUTION: Ensure indicator switch plunger head is
positioned under the actuator. Failure to heed cau-
tion may result in damage.
(7) Install ring gear side bearing cap with refer-
ence marks aligned (Fig. 61).
(8) Loosely install differential bearing cap bolts.
(9) Remove axle housing spreader.
(10) Tighten bearing cap bolts to 108 N·m (80 ft.
lbs.).
(11) With a 1/4 inch drill bit check the clearance
between the actuator and actuator pressure plate at
the top and the bottom.
CAUTION: If clearance is not correct, indicator
switch plunger may be on top of the actuator or
actuator mounting tabs may be bent. Failure to
heed caution may result in damage.
(12) Install pressure hose on the actuator assem-
bly.
(13) Install axle shafts.
(14) Install differential cover, identification tag
and indicator switch connector (Fig. 62).
DIFFERENTIAL - TRU-LOK
PUMP
REMOVAL
(1) Disconnect pumps and axle harness connectors
(Fig. 63).
(2) Remove pressure hoses from the front and rear
pumps.
(3) Remove pump mounting bracket bolts (Fig. 64).
(4) Remove pumps and bracket assembly from the
vehicle.
(5) Remove pump connectors from the mounting
bracket.
Fig. 60 SPREADER LOCATION
1 - DIFFERENTIAL CASE
2 - ADAPTER
3 - HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 61 BEARING CAP REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
Fig. 62 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
TJ
FRONT AXLE - 216FBI
3 - 77
DIFFERENTIAL - TRU-LOK (Continued)
(6) Remove pump mounting screws (Fig. 65) from
the bracket and remove pump/pumps.
INSTALLATION
(1) Align pump with screw holes in pump bracket.
(2) Install and tighten pump mounting screws
(Fig. 66).
(3) Install pump bracket assembly on the cross-
member/skid plate and install pump bracket mount-
ing bolts (Fig. 67).
(4) Tighten pump bracket bolts to 14 N·m (125 in.
lbs.).
Fig. 63 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
Fig. 64 PUMP BRACKET
1 - PUMP BRACKET
2 - CROSSMEMBER/SKID PLATE
Fig. 65 PUMP SCREWS
1 - REAR PUMP SCREWS
2 - FRONT PUMP SCREWS
Fig. 66 PUMP SCREWS
1 - REAR PUMP SCREWS
2 - FRONT PUMP SCREWS
Fig. 67 PUMP BRACKET
1 - PUMP BRACKET
2 - CROSSMEMBER/SKID PLATE
3 - 78
FRONT AXLE - 216FBI
TJ
DIFFERENTIAL - TRU-LOK PUMP (Continued)
(5) Connector pump and axle harness connectors
(Fig. 68).
(6) Install pressure hoses on the pumps.
(7) Verify pump operation.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Remove differential from housing.
(2) Secure differential case in a vise with soft
metal jaw.
(3) Remove ring gear bolts from the differential
case.
(4) Drive ring gear off the differential case with a
dead-blow hammer (Fig. 69).
(5) Hold yoke with Holder 6719A and remove pin-
ion nut and washer.
(6) Remove pinion yoke from the pinion shaft with
Puller C-452 and Flange Wrench C-3281 (Fig. 70).
Fig. 68 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
Fig. 69 RING GEAR REMOVAL
1 - CASE
2 - RING GEAR
3- HAMMER
Fig. 70 PINION YOKE REMOVAL
1 - FLANGER WRENCH
2 - YOKE
3 - PULLER
TJ
FRONT AXLE - 216FBI
3 - 79
DIFFERENTIAL - TRU-LOK PUMP (Continued)
(7) Remove pinion gear and preload shims from
housing (Fig. 71).
(8) Remove pinion seal with a pry bar or slide
hammer mounted screw.
(9) Remove front pinion bearing cup with Remover
D-147 and Handle C-4171 (Fig. 72).
(10) Remove rear bearing cup (Fig. 73) with
Remover D-148 and Handle C-4171.
(11) Remove
rear
pinion
bearing
with
Puller
C-293-PA and Adapters C-293-39 (Fig. 74).
Fig. 71 REMOVE PINION GEAR
1 - DEAD-BLOW HAMMER
Fig. 72 FRONT BEARING CUP REMOVAL
1 - REMOVER
2 - HANDLE
Fig. 73 REAR BEARING CUP REMOVAL
1 - DRIVER
2 - HANDLE
Fig. 74 REAR BEARING REMOVAL
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
3 - 80
FRONT AXLE - 216FBI
TJ
PINION GEAR/RING GEAR (Continued)
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