Jeep Wrangler TJ. Manual — part 234
INSTALLATION
(1) Install differential side bearings with Installer
C-3716-A with Handle C-4171 (Fig. 61).
(2) Install differential in the housing.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced in a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft metal
jaw.
(3) Remove ring gear bolts from the differential
case.
(4) Drive ring gear off the differential case with a
dead-blow hammer (Fig. 62).
(5) Hold pinion yoke with Wrench 6958 and
remove pinion yoke nut and washer.
(6) Remove pinion yoke from pinion shaft with
Remover C-452 and Wrench C-3281 (Fig. 63).
Fig. 61 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 62 RING GEAR
1 - CASE
2 - RING GEAR
3 - DEAD-BLOW HAMMER
Fig. 63 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - PULLER
TJ
REAR AXLE - 194RBI
3 - 113
DIFFERENTIAL CASE BEARINGS (Continued)
(7) Remove pinion gear from housing with a dead-
blow hammer (Fig. 64).
(8) Remove pinion shaft seal with a pry tool or a
slide hammer mounted screw.
(9) Remove oil slinger, if equipped, and front pin-
ion bearing.
(10) Remove
front
pinion
bearing
cup
with
Remover C-4345 and Handle C-4171 (Fig. 65).
(11) Remove rear bearing cup from housing (Fig.
66) with Remover D-149 and Handle C-4171.
(12) Remove collapsible preload spacer (Fig. 67).
Fig. 64 REMOVE PINION GEAR
1 - DEAD-BLOW HAMMER
Fig. 65 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 66 REAR PINION BEARING CUP
1 - DRIVER
2 - HANDLE
Fig. 67 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - SHIM
5 - REAR BEARING
3 - 114
REAR AXLE - 194RBI
TJ
PINION GEAR/RING GEAR (Continued)
(13) Remove rear bearing from the pinion shaft
with Puller/Press C-293-PA and Adapters C-293-40
(Fig. 68).
(14) Remove depth shims from the pinion shaft
and record the shims thickness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of bearing cups.
(2) Install pinion rear bearing cup with Installer
D-146 and Driver Handle C-4171 (Fig. 69) and verify
cup is seated.
(3) Install pinion front bearing cup with Installer
D-130 and Handle C-4171 (Fig. 70) and verify cup is
seated.
(4) Install pinion front bearing and shim.
Fig. 68 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
Fig. 69 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 70 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
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REAR AXLE - 194RBI
3 - 115
PINION GEAR/RING GEAR (Continued)
(5) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 71).
(6) Install depth shim on the pinion gear.
(7) Install rear bearing and shim on the pinion
gear with Installer W-262 and a press (Fig. 72).
(8) Install a new collapsible preload spacer on pin-
ion shaft and install pinion gear in the housing (Fig.
73).
(9) Install yoke with Installer Screw 8112, Cup
8109 and Wrench 6958 (Fig. 74).
Fig. 71 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 72 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - DRIVE PINION GEAR
4 - REAR PINION BEARING
Fig. 73 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - SHIM
5 - REAR BEARING
Fig. 74 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
3 - 116
REAR AXLE - 194RBI
TJ
PINION GEAR/RING GEAR (Continued)
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