Jeep Wrangler TJ. Manual — part 212
(18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 18).
(19) Push and hold differential case toward pinion
gear and zero the dial indicator (Fig. 21).
Fig. 18 DIFFERENTIAL SIDE PLAY MEASUREMENT
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 19 DIAL INDICATOR LOCATION
1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
4 - ZERO DIAL INDICATOR FACE
Fig. 20 READ DIAL INDICATOR
1 - READ DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
Fig. 21 ZERO DIAL INDICATOR
1 - ZERO DIAL INDICATOR FACE
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
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FRONT AXLE - 181FBI
3 - 25
FRONT AXLE - 181FBI (Continued)
(20) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 22).
(21) Subtract 0.05 mm (0.002 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness
shim required to achieve proper backlash.
(22) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
housing.
(23) Rotate dial indicator out of the way on pilot
stud.
(24) Remove differential case and dummy bearings
from the housing.
(25) Install the selected shims onto the differential
case hubs.
(26) Install side bearings and cups on differential
case.
(27) Install spreader W-129-B and adaters from
Adapter Set 6987, onto housing. Spread the housing
to receive differential case.
(28) Install differential case into the housing.
(29) Remove spreader from the housing.
(30) Install bearing caps and tighten bolts to 61
N·m (45 ft. lbs.).
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 23).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm - 0.20 mm (0.005
in. - 0.008 in.). If backlash is not within specifications
transfer the necessary amount of shim thickness
from one side of the housing to the other (Fig. 24).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform
Gear Contact Pattern procedure.
Fig. 22 DIFFERENTIAL CASE RING GEAR SIDE
1 - READ DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 23 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
Fig. 24 BACKLASH SHIM
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FRONT AXLE - 181FBI
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FRONT AXLE - 181FBI (Continued)
GEAR CONTACT PATTERN
The ring gear and pinion teeth contact patterns
will show if the pinion depth is correct in the hous-
ing. It will also show if the ring gear backlash has
been adjusted correctly. The backlash can be adjusted
within specifications to achieve desired tooth contact
patterns.
The TOP LAND of the gear tooth is the top surface
of the tooth. The PROFILE of the gear tooth is the
depth of the tooth. The TOE of the gear is the por-
tion of the tooth surface at the end towards the cen-
ter. The HEEL of the gear is the portion of the tooth
at the outer-end. The ROOT of the gear tooth is the
lowest portion of the tooth (Fig. 25).
NOTE: If the PROFILE across the tooth is the same
it is a 3 Axis cut gear. If the PROFILE across the
tooth is tapered it is a 2 Axis cut gear.
(1) Apply a thin coat of hydrated ferric oxide or equiva-
lent to the drive and coast side of the ring gear teeth.
(2) Wrap, twist and hold a shop towel around the pinion
yoke to increase the turning resistance of the pinion. This
will provide a more distinct contact pattern.
(3) With a boxed end wrench on the ring gear bolt,
rotate the differential case one complete revolution in
both directions while a load is being applied from
shop towel.
The areas on the ring gear teeth with the greatest
degree of contact against the pinion teeth will
squeeze the compound to the areas with the least
amount of contact. Note and compare patterns on the
ring gear teeth to Gear Tooth Contact Patterns chart
(Fig. 26) and (Fig. 27) and adjust pinion depth and
gear backlash as necessary.
Fig. 26 PATTERN INTERPRETATION (GEAR CUT 2 AXIS)
Fig. 25 GEAR DESCRIPTION
1 - TOP LAND
2 - PROFILE
3 - TOE
4 - HEEL
5 - ROOT
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FRONT AXLE - 181FBI
3 - 27
FRONT AXLE - 181FBI (Continued)
DIFFERENTIAL BEARING PRELOAD CHECK
The final check on the differential assembly before
installing the axles is torque to rotate pinion and dif-
ferential combined. This will verify the correct differ-
ential bearing preload.
Torque to rotate the differential and pinion should
be the torque to rotate the pinion plus 0.79-1.24 N·m
(7-11 in. lbs.).
Fig. 27 PATTERN INTERPRETATION (GEAR CUT 3 AXIS)
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FRONT AXLE - 181FBI
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FRONT AXLE - 181FBI (Continued)
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