Jeep Wrangler TJ. Manual — part 243
(2) Remove differential case bearings with Puller
6444, Puller Rods 6444-3 and Puller Flange 6444-1.
Position puller (Fig. 70) on the differential.
Fig. 67 SPREAD DIFFERENTIAL CASE
1 - DIAL INDICATOR
2 - SPREADER
Fig. 68 DIFFERENTIAL
1 - DIFFERENTIAL
2 - BEARING CAP
Fig. 69 INDICATOR SWITCH
1 - DIFFERENTIAL CASE
2 - SWITCH
Fig. 70 PULLER AND FLANGE
1 - PULLER
2 - ROD
3 - PLUG
4 - FLANGE
TJ
REAR AXLE - 216RBI
3 - 149
DIFFERENTIAL - TRU-LOK (Continued)
(3) Position Puller Jaws 6444-7 (Fig. 71) around
the case bearing and puller flange.
(4) Position Puller Collar 6444-8 (Fig. 72) around
the puller jaws.
(5) Tighten the puller nut and remove differential
case bearing.
(6) Remove locking actuator (Fig. 73).
Fig. 71 PULLER AND JAWS
1 - PULLER
2 - ROD
3 - PLUG
4 - JAW
Fig. 72 PULLER AND COLLAR
1 - PULLER
2 - ROD
3 - PLUG
4 - COLLAR
Fig. 73 ACTUATOR
1 - ACTUATOR
2 - PRESSURE PLATE
3 - 150
REAR AXLE - 216RBI
TJ
DIFFERENTIAL - TRU-LOK (Continued)
ASSEMBLY
(1) Verify pressure plate tabs are seated (Fig. 74)
in the dog clutch slots.
(2) Place actuator on the pressure plate and case
bearing on the case (Fig. 75).
(3) Install differential case bearings with Installer
D-156 and Handle C-4171.
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) Install indicator switch into the housing.
(2) Position Spreader W-129-B and adapters from
Adapter set 6987, with the tool dowel pins seated in
the locating holes (Fig. 76). Install hold-down clamps
and tighten the tool turnbuckle finger-tight.
(3) 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 indicator.
(4) 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.
Fig. 74 PRESSURE PLATE
1 - PLATE
2 - PLATE TABS
Fig. 75 ACTUATOR AND CASE BEARING
1 - CASE BEARING
2 - ACTUATOR
Fig. 76 SPREADER LOCATION
1 - DIFFERENTIAL CASE
2 - ADAPTER
3 - HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
TJ
REAR AXLE - 216RBI
3 - 151
DIFFERENTIAL - TRU-LOK (Continued)
(5) Remove dial indicator.
(6) Install differential case with pinion gear side
bearing cap and differential preload shims in the
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. 77).
(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. 78).
DIFFERENTIAL - TRU-LOK
PUMP
REMOVAL
(1) Disconnect pumps and axle harness connectors
(Fig. 79).
Fig. 77 BEARING CAP REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
Fig. 78 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 79 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
3 - 152
REAR AXLE - 216RBI
TJ
DIFFERENTIAL - TRU-LOK (Continued)
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