Jeep Wrangler TJ. Manual — part 233
(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 (30 ft.
lbs.) or more than 271 N·m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp Holding Fixture 6965 in vise and set
differential case on fixture (Fig. 50).
(2) Remove pinion gear mate shaft lock screw.
(3) Remove pinion gear mate shaft.
(4) Lubricate and install disc without threaded
hole from Trac-Lok
t Tool Kit 6960 into lower side
gear (Fig. 51).
(5) Install disc with threaded hole in the upper
side gear. Thread forcing screw from Trac-Lok
t Tool
Kit 6960 through the upper disc until it comes in
contact with lower disc.
Fig. 49 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 50 DIFFERENTIAL CASE FIXTURE
1 - FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 51 DISC PLATE
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
TJ
REAR AXLE - 194RBI
3 - 109
DIFFERENTIAL - TRAC-LOK (Continued)
(6) Insert a screw driver in slot of upper disc (Fig.
52) to prevent disc from turning.
(7) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress Belleville springs in clutch
packs (Fig. 53).
(8) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 54).
(9) Insert turning bar from tool kit 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 rotated with turning bar.
(11) Rotate differential case until pinion gears can
be removed.
(12) Remove pinion gears from differential case.
(13) Remove forcing screw and discs.
(14) Remove top side gear, clutch pack retainers
and clutch pack (Fig. 56).
NOTE: Keep plates in order during removal.
(15) Remove differential case from the fixture.
(16) Remove side gear, clutch pack retainer and
clutch pack.
NOTE: 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.
Fig. 52 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - LOWER DISC
5 - FORCING SCREW
6 - UPPER DISC
Fig. 53 TIGHTEN FORCING SCREW
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 54 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
3 - 110
REAR AXLE - 194RBI
TJ
DIFFERENTIAL - TRAC-LOK (Continued)
(1) Assemble clutch discs into packs and secure
disc packs with retaining clips (Fig. 57).
(2) Install assembled clutch disc packs on side
gear hubs.
(3) Install clutch pack and lower side gear in dif-
ferential case (Fig. 58).
NOTE: Verify clutch pack retaining clips are in posi-
tion and seated in case pockets.
Fig. 55 TURNING BAR
1 - PINION GEARS
2 - TURNING BAR
Fig. 56 SIDE GEAR & CLUTCH DISC
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 57 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 58 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
TJ
REAR AXLE - 194RBI
3 - 111
DIFFERENTIAL - TRAC-LOK (Continued)
(4) Lubricated and install disc without the hole
from Trac-Lok
t Tool Kit 6960 into lower side gear.
(5) Install upper side gear and clutch disc pack
(Fig. 59).
NOTE: Verify clutch pack retaining clips are in posi-
tion and seated in case pockets.
(6) Lubricate and install disc with threaded hole
into top side gear.
(7) Thread forcing screw from tool kit through the
top disc and until screw slightly compress clutch disc.
(8) Place pinion gears in position in side gears and
verify pinion mate shaft hole is aligned.
(9) Rotate case with turning bar until pinion mate
shaft holes in pinion gears align with holes in case.
NOTE: It may be necessary to slightly tighten the
forcing screw in order to install the pinion gears.
(10) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress the Belleville springs.
(11) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(12) Remove forcing screw and discs.
(13) Install pinion gear mate shaft and align holes
in shaft and case.
(14) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(15) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential from housing.
(2) Remove bearings from differential case with
Puller/Press C-293-PA , Adapters C-293-39 and Plug
SP-3289 (Fig. 60).
Fig. 59 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 60 BEARING REMOVAL
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
3 - 112
REAR AXLE - 194RBI
TJ
DIFFERENTIAL - TRAC-LOK (Continued)
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