Jeep Wrangler TJ. Manual — part 228
(3) Install shock absorbers and tighten nuts to
torque specification.
(4) Install stabilizer bar links and tighten nuts to
torque specification.
(5) Install brake components.
(6) Install axle vent hose.
(7) Install propeller shaft (Fig. 5).
(8) Tighten upper and lower control arms nuts to
torque specification.
ADJUSTMENTS
RING AND PINION GEAR
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
6). A plus (+) number, minus (–) number or zero (0) is
etched into the face of 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 with a (0). The standard depth provides the
best teeth contact pattern. Refer to Backlash and
Contact Pattern Analysis Paragraph in this section
for additional information.
Compensation
for
pinion
depth
variance
is
achieved with select shims. The shims are placed
under the inner pinion bearing cone (Fig. 7).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion gear. Add or subtract the thickness of
the original depth shims to compensate for the differ-
ence in the depth variances. Refer to the Depth Vari-
ance charts.
Note where Old and New Pinion Marking columns
intersect.
Intersecting
figure
represents
plus
or
minus amount needed.
Note the etched number on the face of the drive
pinion gear (–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 shim(s). If the num-
ber is positive, subtract that value from the thickness
of the depth shim(s). If the number is 0 no change is
necessary. Refer to the Pinion Gear Depth Variance
Chart.
Fig. 5 REAR PROPELLER SHAFT
1 - CLAMP
2 - YOKE
3 - PROPELLER SHAFT
4 - AXLE YOKE
5 - CLAMP
6 - OUTPUT SHAFT
7 - BOOT
Fig. 6 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 7 ADJUSTMENT SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL SHIM-PINION GEAR SIDE
3 - RING GEAR
4 - DIFFERENTIAL SHIM-RING GEAR SIDE
5 - COLLAPSIBLE SPACER
TJ
REAR AXLE - 194RBI
3 - 89
REAR AXLE - 194RBI (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
Measurements are taken with pinion cups and pin-
ion bearings installed in the housing. Take measure-
ments with a Pinion Gauge Set, Pinion Block 6735,
Arbor Discs 6732 and Dial Indicator C-3339 (Fig. 8).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6735 and rear pinion bearing onto Screw 6741
(Fig. 8).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 9).
(3) Install front pinion bearing and Cone 6740
hand tight.
Fig. 8 PINION GEAR DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 9 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 90
REAR AXLE - 194RBI
TJ
REAR AXLE - 194RBI (Continued)
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 10).
Install differential bearing caps on Arbor Discs and
tighten cap bolts. Refer to the Torque Specifications
in this section.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size 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. 11). Move the
scooter block till the dial indicator probe crests the
arbor, then record the highest reading.
(8) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
etched in the face of the pinion gear (Fig. 6) using
the opposite sign on the variance number. For exam-
ple, if the depth variance is –2, add +0.002 in. to the
dial indicator reading.
(9) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD
Differential side bearing preload and gear backlash
is achieved by selective shims inserted between the
bearing cup and the housing. The proper shim thick-
ness can be determined using slip-fit Dummy Bear-
ings D-348 in place of the differential side bearings
and a Dial Indicator C-3339. Before proceeding with
the differential bearing preload and gear backlash
measurements, measure the pinion gear depth and
prepare the pinion gear 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 gear is installed and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading, starting point shim thickness and the pre-
load 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 differential (Fig. 12).
Fig. 10 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 11 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 12 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL SHIM-PINION GEAR SIDE
3 - RING GEAR
4 - DIFFERENTIAL SHIM-RING GEAR SIDE
5 - COLLAPSIBLE SPACER
TJ
REAR AXLE - 194RBI
3 - 91
REAR AXLE - 194RBI (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 side bearings from differential case.
(2) Install ring gear, if necessary, on differential
case and tighten bolts to specification.
(3) Install Dummy Bearings D-348 on differential
case.
(4) Install differential case in the housing.
(5) Insert Dummy Shims 8107 ( 3.0 mm / 0.118 in.)
starting point shims between the dummy bearing
and the housing (Fig. 13).
(6) Install bearing caps in their correct positions
and snug the bolts.
(7) Using a dead-blow hammer to seat the differ-
ential dummy bearings to each side of the housing
(Fig. 14) and (Fig. 15).
Fig. 13 DUMMY SHIM LOCATION
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARING
Fig. 14 SEAT DUMMY BEARING PINION GEAR SIDE
1 - MALLET
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 15 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - MALLET
3 - DIFFERENTIAL CASE
3 - 92
REAR AXLE - 194RBI
TJ
REAR AXLE - 194RBI (Continued)
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