Jeep Wrangler TJ. Manual — part 224
(4) Remove axle shafts.
(5) Remove pressure hose from actuator assembly
(Fig. 47).
(6) Note the reference letters stamped on the bear-
ing caps and housing machined sealing surface (Fig.
48).
(7) Loosen differential bearing cap bolts.
(8) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes (Fig. 49). Install
hold-down clamps and tighten the turnbuckle finger-
tight.
(9) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud (Fig. 50). Load indicator plunger against
the opposite side of the housing and zero the indica-
tor.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). Failure to heed caution may result in
damage.
Fig. 47 PRESSURE HOSE
1 - PRESSURE HOSE
2 - BEARING CAP
3 - PRESSURE HOSE CLAMP
Fig. 48 BEARING CAP REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
Fig. 49 SPREADER LOCATION
1 - DIFFERENTIAL CASE
2 - ADAPTER
3 - HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 50 DIAL INDICATOR LOCATION
1 - DIAL INDICATOR
2 - PILOT STUD
TJ
FRONT AXLE - 216FBI
3 - 73
DIFFERENTIAL - TRU-LOK (Continued)
(10) Spread housing while measuring the distance
with the dial indicator (Fig. 51).
(11) Remove dial indicator.
(12) Remove differential bearing cap bolts and ring
gear side bearing cap.
(13) Remove differential from housing with pinion
gear side bearing cap (Fig. 52) and tag differential
bearing cups and preload shims to indicate location.
CAUTION: Do not bend actuator mounting tabs,
during differential removal. Failure to heed caution
may result in damage.
(14) Remove spreader from housing.
(15) Remove indicator switch (Fig. 53) from differ-
ential housing.
(16) Clean the housing cavity with flushing oil,
light engine oil or lint free cloth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
Fig. 51 SPREAD DIFFERENTIAL CASE
1 - DIAL INDICATOR
2 - SPREADER
Fig. 52 DIFFERENTIAL
1 - DIFFERENTIAL
2 - BEARING CAP
Fig. 53 LOCKER INDICATOR SWITCH
1 - DIFFERENTIAL CASE
2 - SWITCH
3 - 74
FRONT AXLE - 216FBI
TJ
DIFFERENTIAL - TRU-LOK (Continued)
DISASSEMBLY
(1) Install Plug C-293-3 into the differential axle
shaft hole.
(2) Remove differential case bearings with Puller
6444, Puller Rods 6444-3 and Puller Flange 6444-1.
Position puller (Fig. 54) on the differential.
(3) Position Puller Jaws 6444-7 (Fig. 55) around
the case bearing and puller flange.
(4) Position Puller Collar 6444-8 (Fig. 56) around
the puller jaws.
Fig. 55 PULLER AND JAWS
1 - PULLER
2 - ROD
3 - PLUG
4 - JAW
Fig. 56 PULLER AND COLLAR
1 - PULLER
2 - ROD
3 - PLUG
4 - COLLAR
Fig. 54 PULLER AND FLANGE
1 - PULLER
2 - ROD
3 - PLUG
4 - FLANGE
TJ
FRONT AXLE - 216FBI
3 - 75
DIFFERENTIAL - TRU-LOK (Continued)
(5) Tighten the puller nut and remove differential
case bearing.
(6) Remove actuator (Fig. 57).
ASSEMBLY
(1) Verify pressure plate tabs (Fig. 58) are seated
on the dog clutch slots.
(2) Place actuator on the pressure plate and case
bearing on the case (Fig. 59).
(3) Install differential case bearings with Installer
D-156 and Handle C-4171.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Install indicator switch into the housing.
(2) Position Spreader W-129-B and adapters from
Adapter set 6987, with the tool dowel pins seated in
the locating holes (Fig. 60). Install hold-down clamps
and tighten the tool turnbuckle finger-tight.
(3) Install 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 and zero indicator.
(4) Spread housing while measuring the distance
with the dial indicator.
CAUTION: Never spread over 0.38 mm (0.015 in).
Failure to heed caution may result in damage.
(5) Remove dial indicator.
(6) Install differential case with pinion gear side
bearing cap and differential preload shims in the
Fig. 57 LOCKING ACTUATOR
1 - ACTUATOR
2 - PRESSURE PLATE
Fig. 58 PRESSURE PLATE
1 - PLATE
2 - PLATE TABS
Fig. 59 ACTUATOR AND CASE BEARING
1 - CASE BEARING
2 - ACTUATOR
3 - 76
FRONT AXLE - 216FBI
TJ
DIFFERENTIAL - TRU-LOK (Continued)
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