Jeep Wrangler TJ. Manual — part 208
INSTALLATION
(1) Align installation reference marks at the pinion
yoke, transfer case flange and propeller shaft.
(2) Install U-joint strap and tighten bolts to 19
N·m (14 ft. lbs.).
(3) Install transfer case flange bolts (Fig. 15) and
tighten to 115 N·m (85 ft. lbs.).
SINGLE CARDAN UNIVERSAL
JOINTS
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable, they must be replaced as
an assembly.
(1) Tap the outside of the bearing cap assembly
with a drift to loosen the snap rings.
(2) Remove snap rings from both sides of yoke
(Fig. 16).
(3) Position a socket with a inside diameter large
enough to receive the bearing cap beneath the yoke
on the press.
(4) Position
yoke
with
the
grease
fitting
if
equipped, pointing up.
(5) Place another socket with an outside diameter
smaller than bearing cap on the upper bearing cap
and press the lower cap through the yoke (Fig. 17).
(6) Pull bearing cap of the yoke.
NOTE: If bearing cap will not come out, tap the
yoke ear near the bearing cap to dislodge the cap.
Fig. 15 TRANSFER CASE FLANGE BOLTS
1 - REAR PROPELLER SHAFT
2 - TRANSFER CASE FLANGE
Fig. 16 YOKE SNAP RING
1 - SNAP RING
Fig. 17 PRESS OUT BEARING CAP
1 - PRESS
2 - SOCKET
TJ
PROPELLER SHAFT
3 - 9
PROPELLER SHAFT - REAR RUBICON (Continued)
(7) Turn yoke over and straighten the cross in the
open hole. Then carefully press the end of the cross
until the other bearing cap can be removed (Fig. 18).
ASSEMBLY
CAUTION: Keep cross and bearing cap straight dur-
ing installation. Failure to heed caution may result
in damage.
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to inside of yoke bores.
(2) Position cross in the yoke with lube fitting if
equipped, pointing up (Fig. 19).
(3) Place a bearing cap over the trunnion and
align cap with yoke bore (Fig. 20).
(4) Press bearing cap into the yoke bore enough to
clear snap ring groove.
(5) Install a snap ring.
(6) Repeat Step 3 and Step 4 to install the other
bearing cap.
NOTE: If joint is stiff or binding, strike the yoke with
a soft hammer to seat the needle bearings.
(7) Add grease to lube fitting, if equipped.
Fig. 18 PRESS OUT BEARING CAP
1 - CROSS
2 - BEARING CAP
Fig. 19 U-JOINT CROSS
1 - CROSS
2 - YOKE
Fig. 20 BEARING AND CROSS
1 - BEARING CAP
2 - TRUNNION
3 - 10
PROPELLER SHAFT
TJ
SINGLE CARDAN UNIVERSAL JOINTS (Continued)
DOUBLE CARDAN UNIVERSAL
JOINTS
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable they must be replaced as
an assembly.
(1) Mark propeller shaft yoke and link yoke for
assembly reference.
(2) Tap the outside of the bearing cap assembly
with drift to loosen snap rings.
(3) Remove all bearing cap snap rings (Fig. 21).
(4) Remove any grease fittings if equipped.
(5) Position a socket on the press with an inside
diameter large enough to receive the bearing cap
under the link yoke.
(6) Place another socket with an outside diameter
smaller than the bearing cap on the upper bearing
cap.
(7) Press one bearing cap from the outboard side of
the link yoke enough to grasp the cap with vise jaws
(Fig. 22).
(8) Grasp protruding bearing cap with vise jaws
and tap link yoke with a mallet and drift to remove
bearing cap (Fig. 23).
Fig. 21 SNAP RINGS
Fig. 22 PRESS OUT BEARING
Fig. 23 REMOVE BEARING FROM YOKE
TJ
PROPELLER SHAFT
3 - 11
(9) Flip assembly and repeat Step 5, Step 6, Step 7
and Step 8 to remove the opposite bearing cap.
(10) Remove cross centering kit assembly and
spring (Fig. 24).
(11) Press remaining bearing caps out the other
end of the link yoke, as described above to complete
the disassembly.
ASSEMBLY
CAUTION: Alignment marks on link yoke and pro-
peller shaft yoke must be aligned during assem-
bled. Keep needle bearings upright in the bearing
cap. Failure to heed caution may result in damage.
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to inside of yoke bores.
(2) Fit a cross into propeller shaft yoke (Fig. 25).
(3) Place a bearing cap over the trunnion and
align cap with the yoke bore (Fig. 26).
(4) Press bearing cap into the yoke bore enough to
clear snap ring groove (Fig. 27).
(5) Install a snap ring.
Fig. 24 CENTERING KIT
Fig. 25 INSTALL CROSS IN YOKE
Fig. 26 INSTALL BEARING CAP
Fig. 27 PRESS BEARING CAP
3 - 12
PROPELLER SHAFT
TJ
DOUBLE CARDAN UNIVERSAL JOINTS (Continued)
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