Jeep Wrangler TJ. Manual — part 217
(7) Remove pinion and collapsible spacer from the
housing (Fig. 65).
(8) Remove front pinion bearing cup, bearing, oil
slinger and pinion seal with Remover C-4345 and
Handle C-4171 (Fig. 66).
(9) Remove rear pinion bearing cup from the hous-
ing (Fig. 67) with Remover D-149 and Handle
C-4171.
(10) Remove collapsible spacer from pinion shaft
(Fig. 68).
Fig. 65 PINION GEAR
1 - DEAD-BLOW HAMMER
Fig. 66 FRONT BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 67 REAR BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 68 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
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FRONT AXLE - 181FBI
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PINION GEAR/RING GEAR (Continued)
(11) Remove rear pinion bearing with Puller/Press
C-293-PA and Adapters C-293-39 (Fig. 69).
(12) Remove pinion depth shim/oil slinger from the
pinion shaft and record thickness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Apply Mopar
t Door Ease or equivalent lubri-
cant to outside surface of the pinion bearing cups.
Install rear bearing cup with Installer D-146 and
Driver Handle C-4171 (Fig. 70) and verify cup is
seated.
(2) Install front bearing cup with Installer D-130
and Handle C-4171 (Fig. 71) and verify cup is seated.
Fig. 69 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 70 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 71 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
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FRONT AXLE - 181FBI
TJ
PINION GEAR/RING GEAR (Continued)
(3) Install front pinion bearing, and oil slinger.
(4) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 72).
(5) Install rear pinion depth shim/oil slinger and
bearing on the pinion shaft with Installer W-262 and
a press (Fig. 73).
(6) Install new collapsible spacer on pinion shaft
and install pinion into the housing (Fig. 74).
(7) Install yoke with Installer W-162-B, Cup 8109
and Spanner Wrench 6958 (Fig. 75).
(8) Install pinion washer and a new nut onto the
pinion. Tighten the nut to 216 N·m (160 ft. lbs.).
Fig. 72 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 73 REAR PINION BEARING
1 - PRESS
2 - INSTALLATER
3 - PINION DEPTH SHIM/OIL SLINGER
4 - DRIVE PINION
5 - REAR PINION BEARING
Fig. 74 COLLAPSIBLE PRELOAD SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 75 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
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PINION GEAR/RING GEAR (Continued)
CAUTION: Never loosen the pinion nut to decrease
pinion bearing rotating torque and never exceed
specified preload torque. Failure to heed caution
may result in damage.
(9) Using
Spanner
Wrench
6958
and
torque
wrench set at 678 N·m (500 ft. lbs.) (Fig. 76). Slowly
tighten the nut in 6.8 N·m (5 ft. lb.) increments until
the rotating torque is achieved. Measure rotating
torque frequently to avoid over crushing the collaps-
ible spacer (Fig. 77).
CAUTION: If more than 678 N·m (500 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced. Failure to
heed caution may result in damage.
(10) Check bearing rotating torque with an inch
pound torque wrench (Fig. 77). The torque necessary
to rotate the pinion should be:
• Original Bearings: 1.13 to 2.26 N·m (10 to 20 in.
lbs.).
• New Bearings: 1.7 to 3.4 N·m (15 to 30 in. lbs.).
(11) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(12) Invert the differential case in the vise and
install new ring gear bolts and alternately tighten to
108 N·m (80 ft. lbs.) (Fig. 78).
CAUTION: Never reuse ring gear bolts. Failure to
heed caution may result in damage.
(13) Install differential and verify differential bear-
ing preload, gear mesh and contact pattern.
Fig. 76 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 77 PINION ROTATION TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 78 RING GEAR BOLT
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
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FRONT AXLE - 181FBI
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PINION GEAR/RING GEAR (Continued)
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