Jeep Wrangler TJ. Manual — part 219
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Position a lift under the axle and secure to the
axle.
(3) Remove brake components.
(4) Remove vent hose from axle shaft tube.
(5) Remove propeller shaft.
(6) Remove stabilizer bar links at the axle (Fig. 1).
(7) Remove shock absorbers from axle brackets
(Fig. 2).
(8) Remove track bar from axle bracket (Fig. 3).
(9) Remove tie rod and drag link from steering
knuckle.
(10) Remove steering damper from axle bracket.
(11) Remove upper and lower suspension arms
from axle brackets.
(12) Lower lift enough to remove the axle. The coil
springs will drop with the axle.
(13) Remove coil springs from the axle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. Failure to
heed caution may result in damage.
(1) Install
springs
and
retainers
and
tighten
retainer bolts to 21 N·m (16 ft. lbs.).
(2) Position axle under vehicle and align it with
the spring pads.
Fig. 1 STABILIZER BAR
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
Fig. 2 COIL SPRING AND SHOCK ABSORBER
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
Fig. 3 TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
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FRONT AXLE - 216FBI
3 - 53
FRONT AXLE - 216FBI (Continued)
(3) Install upper and lower suspension arms in the
axle brackets and loosely install bolts and nuts (Fig.
4).
(4) Connect the vent hose to the axle shaft tube.
(5) Install track bar to the axle bracket and loosely
install bolt (Fig. 5).
(6) Install shock absorbers and tighten the bolts
(Fig. 6) to torque specification.
(7) Install stabilizer bar links to the axle brackets
and tighten nuts (Fig. 7) to torque specification.
(8) Install drag link and tie rod and tighten nut to
torque specification
(9) Install steering damper to the axle bracket and
tighten nut to torque specification.
(10) Install brake components.
(11) Install propeller shaft.
(12) Remove lift from the axle and lower vehicle.
(13) Tighten upper and lower control arm nuts to
torque specification.
(14) Tighten track bar bolt at the axle bracket to
torque specification.
(15) Check the front wheel alignment.
Fig. 4 UPPER AND LOWER SUSPENSION ARMS
1 - UPPER SUSPENSION ARM
2 - FRONT AXLE
3 - LOWER SUSPENSION ARM
Fig. 5 TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
Fig. 6 COIL SPRING AND SHOCK ABSORBER
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
Fig. 7 STABILIZER BAR
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
3 - 54
FRONT AXLE - 216FBI
TJ
FRONT AXLE - 216FBI (Continued)
ADJUSTMENTS
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.
8). 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 gear tooth contact pattern. Refer to Backlash
and Contact Pattern in this section for additional
information.
Compensation
for
pinion
depth
variance
is
achieved with a select shim/oil slinger. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 9).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Depth Variance chart.
Note where Old and New Pinion Marking columns
intersect.
Intersecting
figure
represents
plus
or
minus the amount needed.
Note the etched number on the face of the pinion
gear head (–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 shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 8 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 9 PINION PRELOAD SHIMS
1 - PRELOAD SHIMS
2 - FRONT BEARING CUP
3 - SLINGER
4 - PINION YOKE
5 - WASHER
6 - PINION NUT
7 - PINION OIL SEAL
8 - FRONT PINION BEARING
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FRONT AXLE - 216FBI
3 - 55
FRONT AXLE - 216FBI (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 AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 10).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6734 and rear pinion bearing onto Screw 6741
(Fig. 10).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 11).
(3) Install front pinion bearing and Cone-nut 6740
hand tight.
Fig. 10 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 11 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 56
FRONT AXLE - 216FBI
TJ
FRONT AXLE - 216FBI (Continued)
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