Jeep Wrangler TJ. Manual — part 245
(12) Remove and record pinion depth shims from
the pinion gear shaft.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing and pinion gear head to achieve
proper ring and pinion gear mesh. If the ring and
pinion gears are reused, the original pinion depth
shim can be used. Refer to Adjustments (Pinion
Gear Depth) to select the proper shim thickness.
(1) Install pinion depth shim in rear pinion bear-
ing cup bore.
(2) Apply Mopar Door Ease or equivalent lubricant
to the outside surface of pinion bearing cups. Install
rear bearing cup with Installer D-145 and Handle
C-4171 (Fig. 94) and verify cup is seated.
(3) Install front bearing cup with Installer D-144
and Handle C-4171 (Fig. 95) and verify cup is seated.
(4) Install front pinion bearing and oil slinger, if
equipped.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer 8681
(Fig. 96).
Fig. 94 REAR BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 95 FRONT BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 96 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
TJ
REAR AXLE - 216RBI
3 - 157
PINION GEAR/RING GEAR/TONE RING (Continued)
(6) Install pinion depth shim on the pinion shaft.
Install rear pinion bearing on the pinion gear with
Installer W-262 and a press (Fig. 97).
(7) Install pinion gear into the housing.
(8) Install yoke with Installer W-162-B, Cup 8109
and Spanner Wrench 6958 (Fig. 98).
(9) Install pinion washer and a new nut hold pin-
ion yoke Spanner Wrench 6958 (Fig. 99) and tighten
nut to 217-271 N·m (160-200 ft. lbs.).
Fig. 97 REAR PINION BEARING
1 - INSTALLER
2 - SHIM
3 - DRIVE PINION GEAR
4 - REAR PINION BEARING
5 - PRESS
Fig. 98 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 99 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
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REAR AXLE - 216RBI
TJ
PINION GEAR/RING GEAR/TONE RING (Continued)
(10) Check bearing preload torque with an inch
pound torque wrench (Fig. 100). The torque neces-
sary to rotate the pinion gear should be:
• Original Bearings: 1 to 2.26 N·m (10 to 20 in.
lbs.).
• New Bearings: 2.26 to 4.52 N·m (20 to 40 in.
lbs.).
(11) If
rotating
torque
is
above
the
desired
amount, remove the pinion yoke and increase the
preload shim pack thickness. Increasing the shim
pack thickness 0.025 mm (0.001 in.) will decrease the
rotating torque approximately 0.9 N·m (8 in. lbs.).
(12) If the maximum tightening torque is reached
prior to achieving the desired rotating torque, remove
the pinion yoke and decrease the thickness of the
preload shim pack. Decreasing the shim pack thick-
ness 0.025 mm (0.001 in.) will increase the rotating
torque approximately 0.9 N·m (8 in. lbs.).
(13) Invert differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
CAUTION: Never reuse ring gear bolts, the bolts
can fracture causing extensive damage. Failure to
heed caution may result in damage.
(14) Invert differential case in the vise.
(15) Install new ring gear bolts and alternately
tighten to 108 N·m (100 ft. lbs.) (Fig. 101).
(16) Install differential in axle housing and verify
gear mesh and contact pattern. Refer to Adjustment
(Gear Contact Pattern).
Fig. 100 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 101 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
TJ
REAR AXLE - 216RBI
3 - 159
PINION GEAR/RING GEAR/TONE RING (Continued)
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