Jeep Wrangler TJ. Manual — part 229
(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 16).
(9) Attach Dial Indicator C-3339 to the pilot stud
and position indicator plunger on a flat surface of the
ring gear bolt head (Fig. 16).
(10) Push differential case to the pinion gear side
of the housing (Fig. 17) and zero dial indicator.
(11) Push differential case to the ring gear side
and record dial indicator reading (Fig. 18).
(12) Add the dial indicator reading to the starting
point shim thickness to determine total shim thick-
ness to achieve zero differential end play.
(13) Add 0.008 in. (0.2 mm) 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.
(15) Remove differential case, dummy bearings
and starting point shims from the housing.
(16) Install pinion gear in the housing. Install the
yoke and establish the correct pinion rotating torque.
(17) Install differential case and dummy bearings
in the housing (without shims) and tighten retaining
cap bolts.
(18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 16).
(19) Push and hold differential case toward pinion
gear.
(20) Zero dial indicator face to pointer.
(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading.
(22) Subtract 0.002 in. (0.05 mm) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness of
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.
(24) Rotate dial indicator out of the way on pilot
stud.
(25) Remove differential case and dummy bearings
from the housing.
Fig. 16 DIFFERENTIAL SIDE PLAY MEASUREMENT
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 17 ZERO DIAL INDICATOR
1 - DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR EXTENSION
4 - ZERO DIAL INDICATOR FACE
Fig. 18 RECORD DIAL INDICATOR READING
1 - READ DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
TJ
REAR AXLE - 194RBI
3 - 93
REAR AXLE - 194RBI (Continued)
(26) Install new side bearing cones and cups on
differential case.
(27) Install spreader W-129-B and some compo-
nents of Adapter Set 6987 on differential housing and
spread axle opening enough to receive differential
case.
(28) Place side bearing shims into the housing
against the differential bearing bore.
(29) Install differential case in the housing.
(30) Rotate the differential case several times to
seat the side bearings.
(31) Position the indicator plunger against a ring
gear tooth (Fig. 19).
(32) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(33) Zero dial indicator face to pointer.
(34) 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 differential housing to the other
(Fig. 20).
(35) 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 the
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
at the outer-end. The ROOT of the gear tooth is the
lowest portion of the tooth (Fig. 21).
NOTE: If the PROFILE across the tooth is the same
it is a 3 Axis cut gear. If the PROFILE across the
tooth is tapered it is a 2 Axis cut gear.
Fig. 19 RING GEAR BACKLASH
1 - DIAL INDICATOR
Fig. 20 BACKLASH SHIM ADJUSTMENT
Fig. 21 GEAR DESCRIPTION
1 - TOP LAND
2 - PROFILE
3 - TOE
4 - HEEL
5 - ROOT
3 - 94
REAR AXLE - 194RBI
TJ
REAR AXLE - 194RBI (Continued)
(1) Apply a thin coat of hydrated ferric oxide or
equivalent to the drive and coast side of the ring gear
teeth.
(2) Wrap, twist, and hold a shop towel around the
pinion yoke to increase the turning resistance of the
pinion. This will provide a more distinct contact pat-
tern.
(3) With a boxed end wrench on a ring gear bolt,
rotate the differential case one complete revolution in
both directions while a load is being applied from
shop towel.
The areas on the ring gear teeth with the greatest
degree of contact against the pinion teeth will
squeeze the compound to the areas with the least
amount of contact. Note and compare patterns on the
ring gear teeth to Gear Tooth Contact Patterns
charts (Fig. 22) and (Fig. 23) and adjust pinion depth
and gear backlash as necessary.
DIFFERENTIAL BEARING PRELOAD CHECK
The final check on the differential assembly before
installing the axles is torque to rotate pinion and dif-
ferential combined. This will verify the correct differ-
ential bearing preload.
Torque to rotate the differential and pinion should
be the torque to rotate the pinion plus 0.79-1.24 N·m
(7-11 in. lbs.).
Fig. 22 PATTERN INTERPRETATION (GEAR CUT 2 AXIS)
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REAR AXLE - 194RBI
3 - 95
REAR AXLE - 194RBI (Continued)
SPECIFICATIONS
REAR AXLE
AXLE SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Axle Ratio
3.07, 3.73, 4.10, 4.56
Ring Gear Backlash
0.12-0.20 mm (0.005-0.008 in.)
Pinion Bearing Preload - Original Bearings
1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings
2-4 N·m (20-35 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Differential Cover Bolts
41
30
-
Bearing Cap Bolts
77
57
-
Ring Gear Bolts
136
100
-
Pinion Nut Min / Max
271-475
200-350
-
Pinion Mate Shaft Screw
16.25
12
-
Fig. 23 PATTERN INTERPRETATION (GEAR CUT 3 AXIS)
3 - 96
REAR AXLE - 194RBI
TJ
REAR AXLE - 194RBI (Continued)
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