Jeep Wrangler TJ. Manual — part 211
(8) Install drag link and tie rod and tighten nut to
torque specification
(9) Install steering damper to the axle bracket and
tighten nut to torque specification.
(10) Install brake components.
(11) Install propeller shaft.
(12) Remove lift from the axle and lower vehicle.
(13) Tighten upper and lower control arm nuts to
torque specification.
(14) Tighten track bar bolt at the axle bracket to
torque specification.
(15) Check the front wheel alignment.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched/marked onto each gear (Fig.
8). A plus (+) number, minus (–) number or zero (0) is
etched/marked on the pinion gear. This number is
the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched/marked with a (0). The standard setting from
the center line of the ring gear to the back face of the
pinion is 92.08 mm (3.625 in.). The standard depth
provides the best gear tooth contact pattern.
Compensation
for
pinion
depth
variance
is
achieved with a select shim/oil slinger. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 9).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Pinion Gear Depth Variance chart.
Note where Old and New Pinion Marking columns
intersect.
Intersecting
figure
represents
plus
or
minus the amount needed.
Note the etched number on the face of the pinion
gear head (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 8 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 9 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
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FRONT AXLE - 181FBI
3 - 21
FRONT AXLE - 181FBI (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
2
4
2
3
2
2
2
1
0
+1
+2
+3
+4
+4
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
+3
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
+1
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
0
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
1
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
2
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
3
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
4
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
0.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 10).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6733 and rear pinion bearing onto Screw 6741
(Fig. 10).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 11).
(3) Install front pinion bearing and Cone-nut 6740
hand tight.
Fig. 10 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 11 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 22
FRONT AXLE - 181FBI
TJ
FRONT AXLE - 181FBI (Continued)
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in axle housing side bearing cradles (Fig. 12).
Install differential bearing caps on arbor discs and
tighten cap bolts to 41 N·m (30 ft. lbs.).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(7) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 13). Move the
scooter block till the dial indicator probe crests the
arbor and record the highest reading.
(8) Select a shim/oil baffle equal to the dial indica-
tor reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 8). For example,
if the depth variance is –2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL SIDE BEARING PRELOAD AND
GEAR BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims positioned behind the
differential side bearing cones. The proper shim
thickness can be determined using slip-fit Dummy
Bearings D-348 in place of the differential side bear-
ings and a Dial Indicator C-3339. Before proceeding
with the differential bearing preload and gear back-
lash measurements, measure the pinion gear depth
and prepare the pinion for installation. Establishing
proper pinion gear depth is essential to establishing
gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential side
play is measured, the pinion is installed, and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 14). Differential shim measurements
are performed with spreader W-129-B removed.
Fig. 12 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 13 PINION DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 14 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
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FRONT AXLE - 181FBI
3 - 23
FRONT AXLE - 181FBI (Continued)
PRELOAD SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove differential side bearings from differ-
ential case.
(2) Remove factory installed shims from differen-
tial case.
(3) Install ring gear on differential case and
tighten bolts to specification.
(4) Install dummy side bearings D-348 on differen-
tial case.
(5) Install differential case in the housing.
(6) Install marked bearing caps in their correct
positions. Install and snug the bolts (Fig. 15).
(7) With a dead-blow hammer, seat the differential
dummy bearings to each side of the housing (Fig. 16)
and (Fig. 17).
(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 18).
(9) Attach the Dial Indicator C-3339 to pilot stud.
Position the dial indicator plunger on a flat surface
between the ring gear bolt heads (Fig. 18).
(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 19).
(11) Push and hold differential case to ring gear
side of the housing and record the dial indicator
reading (Fig. 20).
(12) Add 0.008 in. (0.2 mm) to the zero end play
total. This new total represents the thickness of
shims to compress or preload the new bearings when
the differential is installed.
(13) Rotate dial indicator out of the way on the
pilot stud.
(14) Remove differential case and dummy bearings
from the housing.
(15) Install the pinion gear in the housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(16) Install differential case and dummy bearings
D-348 in the housing (without shims), install bearing
caps and tighten bolts snug.
(17) Seat ring gear side dummy bearing (Fig. 17).
Fig. 15 BEARING CAP BOLTS
1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 16 SEAT DUMMY BEARINGS PINION SIDE
1 - MALLET
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 17 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - MALLET
3 - DIFFERENTIAL CASE
3 - 24
FRONT AXLE - 181FBI
TJ
FRONT AXLE - 181FBI (Continued)
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