Jeep Wrangler TJ. Manual — part 216
(4) Rotate differential side gears and remove pin-
ion mate gears and thrust washers (Fig. 54).
(5) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft. Align roll pin
holes in shaft and the differential case.
(4) Install pinion mate shaft roll pin in the differ-
ential case (Fig. 55).
(5) Install the ring gear.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Position Spreader W-129-B and Adapter Kit
6987, with the tool dowel pins seated in the locating
holes (Fig. 56). Install holddown clamps and tighten
turnbuckle finger-tight.
Fig. 54 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 55 MATE SHAFT ROLL PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
Fig. 56 SPREADER LOCATION
1 - AXLE HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
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FRONT AXLE - 181FBI
3 - 41
DIFFERENTIAL (Continued)
(2) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the lever adapter against the
opposite side of the housing (Fig. 57) and zero indi-
cator.
(3) Spread housing while measuring the distance
with the dial indicator (Fig. 58).
CAUTION: Do not spread over 0.50 mm (0.020 in).
Failure to heed caution may result in damage.
(4) Remove dial indicator.
(5) Install differential case in the housing. Tap dif-
ferential case to seat bearings cups in the housing.
(6) Install bearing caps at their original locations
(Fig. 59).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten bearing cap bolts to 61 N·m (45 ft.
lbs.).
(10) Install hub bearings and axle shafts.
(11) Install differential cover.
Fig. 57 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 58 SPREAD DIFFERENTIAL HOUSING
1 - INDICATOR
2 - SPREADER
Fig. 59 BEARING CAP IDENTIFICATION
1 - INSTALLATION REFERENCE LETTERS
2 - INSTALLATION REFERENCE LETTERS
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FRONT AXLE - 181FBI
TJ
DIFFERENTIAL (Continued)
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove bearings from the differential case
with Puller/Press C-293-PA, C-293-39 Adapter and
Plug SP-3289 (Fig. 60).
INSTALLATION
NOTE: If replacement differential side bearings or
differential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Install differential side bearing shims onto dif-
ferential case hubs.
(2) Install differential side bearings with Installer
C-3716-A and Handle C-4171 (Fig. 61).
Fig. 60 DIFFERENTIAL BEARING
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
Fig. 61 DIFFERENTIAL CASE BEARING
1 - INSTALLER
2 - HANDLE
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FRONT AXLE - 181FBI
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PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without replac-
ing the other matched gear.
(1) Remove differential from axle housing.
(2) Secure differential case in a vise with soft
metal jaw (Fig. 62).
(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 yoke with Spanner Wrench 6958 and
remove the pinion nut and washer (Fig. 63).
(6) Remove pinion yoke with Remover C-452 and
Flange Wrench C-3281 (Fig. 64).
Fig. 62 RING GEAR
1 - DIFFERENTAIL CASE
2 - RING GEAR
3 - HAMMER
Fig. 63 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 64 PINION YOKE
1 - FLANGE WRENCH
2 - PINION YOKE
3 - REMOVER
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FRONT AXLE - 181FBI
TJ
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