Jeep Wrangler TJ. Manual — part 237
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8).
Install differential bearing caps on Arbor Discs and
tighten cap bolts to 41 N·m (30 ft. lbs.).
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) Place Scooter Block/Dial Indicator in position
in axle housing so dial probe and scooter block are
flush against the rearward surface of the pinion
height block. Hold scooter block in place and zero the
dial indicator face to the pointer. Tighten dial indica-
tor face lock screw.
(7) Slowly slide the Scooter Block/Dial Indicator
across the pinion height block over to the arbor bar
(Fig. 9). Move the Scooter Block/Dial Indicator to the
crest of the arbor bar and record the highest reading.
(8) Select a shim equal to the thickest dial indica-
tor reading plus or minus the drive pinion gear depth
variance number etched in the face of the pinion gear
(Fig. 5).
(9) Remove the pinion depth gauge components
from the axle housing.
PRELOAD SHIM SELECTION
Differential side bearing preload and gear backlash
is achieved by selective shims inserted between the
bearing cups and the housing. The proper shim
thickness can be determined using slip-fit dummy
bearings D-345 in place of the differential side bear-
ings and a dial indicator C-3339. Before proceeding
with the differential bearing preload and gear back-
lash measurements, measure the pinion gear depth
and prepare the pinion gear for installation. Estab-
lishing proper pinion gear depth is essential to estab-
lishing gear backlash and tooth contact patterns.
After the overall shim thickness to take up differen-
tial side play is measured, the pinion gear is
installed, and the gear backlash shim thickness is
measured. The overall shim thickness is the total of
the dial indicator reading and the preload specifica-
tion 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. 10).
Fig. 8 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 9 PINION DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 10 ADJUSTMENT SHIM LOCATIONS
1 - PINION DEPTH SHIM
2 - DIFFERENTIAL BEARING PRELOAD SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING PRELOAD SHIM
TJ
REAR AXLE - 216RBI
3 - 125
REAR AXLE - 216RBI (Continued)
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove differential side bearings from differ-
ential case.
(2) Remove factory installed shims from differen-
tial case.
(3) Install ring gear on differential case and
tighten bolts to specification.
(4) Install dummy side bearings D-345 on differen-
tial case.
(5) Install differential case in axle housing (Fig.
11).
(6) Install the marked bearing caps in their correct
positions. Install and snug the bolts (Fig. 12).
(7) Using a dead-blow hammer seat the differen-
tial dummy bearings to each side of the housing (Fig.
13) and (Fig. 14).
Fig. 11 DIFFERENTIAL DUMMY BEARINGS
1 - DUMMY BEARINGS
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 12 BEARING CAP BOLTS
1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 13 SEAT DUMMY BEARING PINION SIDE
1 - MALLET
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 14 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - MALLET
3 - DIFFERENTIAL CASE
3 - 126
REAR AXLE - 216RBI
TJ
REAR AXLE - 216RBI (Continued)
(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 15).
(9) Attach a dial indicator C-3339 to Pilot Stud
C-3288-B. Position the dial indicator plunger on a
flat surface between the ring gear bolt heads (Fig.
15).
(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 16).
(11) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 17).
(12) Add dial indicator reading to the starting
point shim thickness. This is the total shim thickness
to achieve zero differential end play.
(13) Add 0.254 mm (0.010 in.) to the zero end play
total. This new total represents the thickness of
shims to compress, or preload the new bearings when
the differential is installed.
(14) Rotate dial indicator out of the way on pilot
stud.
(15) Remove differential case and dummy bearings
from the housing.
(16) Install pinion gear in the housing. Install the
pinion yoke and establish the correct pinion rotating
torque.
(17) Install differential case and dummy bearings
D-345 in the housing (without shims), install bearing
caps and tighten bolts snug.
(18) Seat ring gear side dummy bearing (Fig. 14).
(19) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads. (Fig. 15).
(20) Push and hold differential case toward the
pinion gear and zero dial indicator (Fig. 18).
(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 19).
(22) 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.
(23) 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.
Fig. 15 DIFFERENTIAL SIDE PLAY MEASUREMENT
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 16 ZERO DIAL INDICATOR
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PILOT STUD
4 - EXTENSION
Fig. 17 RECORD DIAL INDICATOR READING
1 - READ DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
TJ
REAR AXLE - 216RBI
3 - 127
REAR AXLE - 216RBI (Continued)
(24) Rotate dial indicator out of the way on pilot
stud.
(25) Remove differential case and dummy bearings
from the housing.
(26) Install side bearing shims on differential case
hubs.
(27) Install new side bearing cones and cups on
differential case.
(28) Install spreader W-129-B on the housing and
spread axle opening enough to receive differential
case.
(29) Install differential case in the housing.
(30) Install differential bearing caps loosely.
(31) Remove spreader from the housing.
(32) Tighten bearing caps bolts to 108 N·m (80 ft.
lbs.).
(33) Rotate the differential case several times to
seat the side bearings.
(34) Position the indicator plunger against a ring
gear tooth (Fig. 20).
(35) Push and hold ring gear upward while not
allowing the pinion gear to rotate and zero dial indi-
cator.
(36) 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. 21).
(37) 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 Analysis procedure.
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
Fig. 18 ZERO DIAL INDICATOR
1 - DIAL INDICATOR FACE
2 - DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 19 RECORD DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 20 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
3 - 128
REAR AXLE - 216RBI
TJ
REAR AXLE - 216RBI (Continued)
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