Jeep Wrangler TJ. Manual — part 240
(5) Using Spanner Wrench 6958 to hold the pinion
yoke, remove the pinion nut and washer.
(6) Remove pinion yoke with Remover C-452 and
Flange Wrench C-3281 (Fig. 33).
(7) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer 8681
(Fig. 34).
(2) Install yoke on pinion gear with Installer
W-162–D, Cup 8109 and Spanner Wrench 6958 (Fig.
35).
(3) Install pinion washer and a new nut on the
pinion gear and tighten the nut until there is zero
bearing end-play.
(4) Hold pinion yoke with Spanner Wrench 6958
(Fig. 36) and tighten pinion nut to 217 to 271N·m
(160 to 200 ft. lbs.).
(5) Install propeller shaft.
(6) Install brake drums/calipers.
Fig. 33 PINION YOKE REMOVER
1 - FLANGE WRENCH
2 - PINION YOKE
3 - REMOVER
Fig. 34 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 35 YOKE SPANNER WRENCH
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 36 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
TJ
REAR AXLE - 216RBI
3 - 137
PINION SEAL (Continued)
DIFFERENTIAL COVER
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove drain plug.
(3) If equipped with Tru-Lok, disconnect indicator
switch harness and remove connector from differen-
tial cover (Fig. 37).
(4) Remove cover bolts.
(5) Remove cover and drain lubricant.
INSTALLATION
(1) Apply a 6.35mm (1/4 in.) bead of Mopar Sili-
cone Rubber Sealant or equivalent to the housing
cover (Fig. 38).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.
(2) Install cover, identification tag and indicator
switch connector if equipped with Tru-Lok (Fig. 39).
Tighten cover bolts in a criss-cross pattern to 41 N·m
(30 ft. lbs.).
(3) Connect indicator switch harness if equipped
with Tru-Lok.
(4) Fill differential to specifications.
(5) Install fill plug and tighten to 34 N·m (25 ft.
lbs.).
Fig. 37 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 38 HOUSING COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKESS
Fig. 39 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
3 - 138
REAR AXLE - 216RBI
TJ
DIFFERENTIAL
REMOVAL
(1) Remove differential housing cover and drain
fluid.
(2) Remove axle shafts.
(3) Note the reference letters stamped on the bear-
ing caps and housing machined sealing surface (Fig.
40).
(4) Loosen the differential bearing cap bolts.
(5) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes (Fig. 41). Install
hold-down clamps and tighten the turnbuckle finger-
tight.
(6) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing (Fig. 42) and zero the
indicator.
Fig. 40 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 41 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 42 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
TJ
REAR AXLE - 216RBI
3 - 139
(7) Spread housing while measuring the distance
with the dial indicator (Fig. 43).
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). Failure to heed caution may result in
damage.
(8) Remove dial indicator.
(9) Hold differential case in position and remove
differential bearing caps.
(10) Remove differential from housing and tag dif-
ferential bearing cups to indicate location (Fig. 44).
(11) Remove spreader from housing.
(12) Clean housing cavity with flushing oil, light
engine oil or lint free cloth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
DISASSEMBLY
(1) Remove pinion shaft lock roll pin with a ham-
mer and punch.
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove dif-
ferential pinions and thrust washers (Fig. 45).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion gears and thrust
washers.
(3) Install pinion mate shaft.
(4) Align hole in the pinion mate shaft with the
hole in the differential case and install pinion mate
shaft roll pin. Stake (peen) metal of case over pin in
two places 180 degrees apart.
(5) Lubricate
all
differential
components
with
hypoid gear lubricant.
Fig. 43 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
Fig. 44 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
Fig. 45 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
3 - 140
REAR AXLE - 216RBI
TJ
DIFFERENTIAL (Continued)
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