Jeep Cherokee (XJ): Differential side bearings. Axle shaft oil seal. 181 FBI pinion

Differential side bearings

REMOVAL

(1) Remove differential case from axle housing.

(2) Remove the bearings from the differential case with Puller/Press C-293-PA, C-293-39 Adapter Blocks, and Plug SP-3289 (Fig. 35).

Fig. 35 Differential Bearing Removal

1 - SPECIAL TOOL C-293-39
2 - BEARING
3 - DIFFERENTIAL
4 - SPECIAL TOOL SP-3289
5 - SPECIAL TOOL C-293-PA

INSTALLATION

If replacement differential side bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to the Differential Bearing Preload and Gear Backlash procedures in this section to determine the proper shim selection.

(1) Install differential side bearing shims onto differential case hubs, for 186FBI axles.

(2) Using Installer C-3716-A and Handle C-4171, install differential side bearings (Fig. 36).

(3) Install differential in axle housing.

Fig. 36 Differential Side Bearing Installation

1 - SPECIAL TOOL C-3716-A
2 - SPECIAL TOOL C-4171

Axle shaft oil seal

REMOVAL

(1) Raise and support vehicle.

(2) Remove differential assembly.

(3) Remove the inner axle shaft seals with a pry bay.

INSTALLATION

(1) Remove any sealer remaining from original seals.

(2) Remove sealer from axle tube to housing junction, if necessary.

(3) Install oil seals with Discs 8110 and Turnbuckle 6797 (Fig. 37). Tighten tool until disc bottoms in housing.

(4) Install differential assembly.

181 FBI pinion

The ring gear and pinion are serviced as a matched set. Do not replace the pinion without replacing the ring gear.

REMOVAL

(1) Remove differential assembly from axle housing.

(2) Mark pinion yoke and propeller shaft for installation alignment.

(3) Disconnect propeller shaft from pinion yoke.

Using suitable wire, tie propeller shaft to underbody.

Fig. 37 Axle Seal Installation

1 - TURNBUCKLE 6797
2 - DISCS 8110

(4) Using Holder 6958 to hold yoke, remove the pinion nut and washer.

(5) Using Remover C-452 and Holder C-3281, remove the pinion yoke from pinion shaft (Fig. 38).

Fig. 38 Pinion Yoke Removal

1 - SPECIAL TOOL C-3281
2 - YOKE
3 - SPECIAL TOOL C-452

(6) Remove the pinion gear and preload shims from housing (Fig. 39). Catch the pinion with your hand to prevent it from falling and being damaged.

Fig. 39 Remove Pinion Gear

1 - RAWHIDE HAMMER

(7) Remove the front pinion bearing cup, bearing, oil slinger, if equipped, and pinion seal with Remover D-147 and Handle C-4171 (Fig. 40).

Fig. 40 Front Bearing Cup Removal

1 - REMOVER
2 - HANDLE

(8) Remove the rear pinion bearing cup and oil slinger from the axle housing (Fig. 41). Use Remover D-149 and Handle C-4171. Record the thickness of the oil slinger for future reference.

Fig. 41 Rear Bearing Cup Removal

1 - DRIVER
2 - HANDLE

(9) Remove the rear pinion bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-39 (Fig. 42).

Place 4 adapter blocks so they do not damage the bearing cage.

(10) Remove the pinion depth shim/oil baffle from the pinion shaft. Record the thickness of the depth shim/oil baffle.

INSTALLATION

NOTE: A pinion depth shim/oil baffle is placed between the rear pinion bearing cone and pinion gear. If the factory installed ring and pinion gears are reused, the pinion depth shim/oil baffle should not require replacement. Refer to Pinion Gear Depth to select the proper thickness shim before installing pinion gear.

(1) Install a new oil slinger of the same thickness as the original into the rear pinion bearing bore of the axle housing.

(2) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of rear pinion bearing cup. Install the bearing cup with Installer D-146 and Handle C-4171 (Fig. 43). Verify cup is correctly seated.

Fig. 42 Rear Bearing Removal

1 - SPECIAL TOOL C-293-PA
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT

Fig. 43 Rear Pinion Bearing Cup Installation

1 - INSTALLER
2 - HANDLE

(3) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of front pinion bearing cup. Install the bearing cup with Installer D-144 and Handle C-4171 (Fig. 44).

Fig. 44 Pinion Outer Bearing Cup Installation

1 - INSTALLER
2 - HANDLE

(4) Install front pinion bearing, and oil slinger, if equipped.

(5) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972-A and Handle C-4171 (Fig. 45).

Fig. 45 Pinion Seal Installation

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3972-A

(6) Install the rear pinion bearing and pinion depth shim/oil baffle onto the pinion gear with Installer W-262 and a shop press (Fig. 46).

Fig. 46 Rear Pinion Bearing Installation

1 - PRESS
2 - INSTALLATION TOOL
3 - PINION DEPTH SHIM/OIL BAFFLE
4 - DRIVE PINION
5 - DRIVE PINION SHAFT REAR BEARING

(7) Install pinion bearing preload shims onto the pinion gear (Fig. 47).

(8) Install pinion gear in housing.

(9) Install yoke with Installer W-162-B, Cup 8109, and Holder 6958 (Fig. 48).

Fig. 47 Pinion Preload Shims-Typical

1 - PINION PRELOAD SHIMS
2 - FRONT BEARING CUP
3 - SLINGER
4 - PINION YOKE
5 - WASHER
6 - PINION NUT
7 - PINION OIL SEAL
8 - FRONT BEARING CONE

Fig. 48 Pinion Yoke Installation

1 - PINION YOKE
2 - AXLE HOUSING

(10) Install the pinion washer and a new nut on the pinion gear. Tighten the nut to 217 N·m (160 ft.

lbs.).

CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload rotating torque.

(11) Check bearing preload torque with an inch pound torque wrench (Fig. 49). The torque necessary to rotate the pinion gear should be:

•  Original Bearings-1 to 2 N·m (10 to 20 in. lbs.).
•  New Bearings-1.5 to 4 N·m (15 to 35 in. lbs.).

(12) If rotating torque is above the desired amount, remove the pinion yoke and increase the preload shim pack thickness. Increasing the shim pack thickness 0.025 mm (0.001 in.) will decrease the rotating torque approximately 0.9 N·m (8 in. lbs.).

(13) Tighten pinion shaft nut in 6.8 N·m (5 ft. lbs.) increments until the maximum tightening or desired rotating torque is reached. Maximum tightening torque is 271 N·m (200 ft.lbs.).

(14) If the maximum tightening torque is reached prior to achieving the desired rotating torque, remove the pinion yoke and decrease the thickness of the preload shim pack. Decreasing the shim pack thickness 0.025 mm (0.001 in.) will increase the rotating torque approximately 0.9 N·m (8 in. lbs.).

Fig. 49 Check Pinion Gear Rotating Torque

1 - in. lbs. TORQUE WRENCH
2 - PINION YOKE

(15) Install differential assembly.