Jeep Wrangler TJ Manual

Published on March 2017 | Categories: Documents | Downloads: 84 | Comments: 0 | Views: 751

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Content

Lubrication and Maintenance
Suspension
Differential and Driveline
Brakes
Clutch
Cooling System
Battery
Starting Systems
Charging System
Ignition System
Instrument Panel Systems
Instrument Panel Systems
Audio Systems
Horn Systems
Speed Control System
Turn Signal and Hazard Warning Systems
Wiper and Washer Systems
Lamps

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Introduction

Introduction

Lamps
Passive Restraint Systems
Electrically Heated System
Power Distribution System
Vehicle Theft/Security Systems
Chime/Buzzer Warning Systems
Wiring Diagrams
Engine
Exhaust System and Intake Manifold
Frame and Bumpers
Frame and Bumpers
Fuel System
Fuel System
Steering
Transmission and Transfer Case
Tires and Wheels
Body
Heating and Air Conditioning
Emission Control Systems
Emission Control Systems

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INTRODUCTION
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GENERAL INFORMATION

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POSITION

INTERPRETATION

CODE = DESCRIPTION

1

Country of Origin

1 = United States

2

Make

J = Jeep

3

Vehicle Type

4 = MPV

4

Gross Vehicle Weight Rating

E = 3001-4000 lbs.
F = 4001-5000 lbs.

5

Vehicle Line

Y = Wrangler 4X4

6

Series

1 = Sport
2 = SE
4 = Sahara

7

Body Style

9 = Open Body

8

Engine

P = 2.5L Unleaded-Gasoline
S = 4.0L Unleaded-Gasoline

9

Check Digit

10

Model Year

X = 1999

11

Assembly Plant

P = Toledo #2

12 thru 17

Vehicle Build Sequence

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9

INTRODUCTION
a
page

page

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1®¯d°U±²®¯³§´:µP¶@·¬³¹¸@¸@¸@¸@¸º¸@¸@¸@¸@¸@¸@¸@¸@¸º¸@¸@¸@¸@¸@¸@¸@¸»
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GENERAL INFORMATION

• ß>×1ÝÍ ß>×7Ï_Ñ_ê
Ë:•ØLÿ âJß>ØPÕGÍPÐbÕöÕGÌÍLÐ>ØPÔ@åXÛÝÍ<ßÖß>Ø<Ý

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VEHICLE
ËjÌ@ÍaÎDÍPÌIDENTIFICATION
Ï_Ð>Ñ_ÍnÒMÓJÍPÔÕGÏ_ÖÏ_Ð>×7ÕGÏØ<ÔÚNUMBER
ÙÜÛÝZÞ1Í<ß§à ÎÜÒ.ÙDáãâJÑ_×7ÕMÍäÏ_å

Ñ_ØPÐ>×7ÕGÍPÓØPÔKÕGÌÍæÑ_Ø.çZÍ<ßZçÏ_ÔÓJåcÌÏ_ÍPÑ_ÓÖÍPÔ@Ð>ÍæÔÍP×7ßaÕMÌÍæÑ_Í<ÖÕ
èÜé â1ÏÑ_Ñ_×7ß'êÇËjÌÍëÎÒMÙÚÐ>ØPÔÕG×7Ï_Ôå ìcí Ð>Ì@×1ß>×7Ð>ÕGÍPß>å~ÕMÌ×7ÕâJß>Ø.î3Ï_ÓJÍ
ÓJ×7ÕG×ãÐ>ØPÔÐ>Í<ß>ÔÏ_Ôï]ÕMÌ@ÍîdÍ<ÌÏ_Ð>Ñ_ÍPê¬ðDÍ<ÖÍPßÕMØ ÕMÌ@ÍÎÜÒ.ÙñÓJÍPÐbØPÓ é
Ï_ÔïÐ>Ì×7ß>ÕVÕGØÓJÍPÕGÍPßbÝÏÔ@ÍÕMÌÍÏ_ÓJÍ<ÔÕGÏÖÏ_Ð>×1ÕGÏ_ØPÔ§ØPÖD×hîdÍPÌÏ_Ð>Ñ_Í<ê
ËjÌ@ÍòÎDÍPÌÏ_Ð>Ñ_ÍóÒ.ÓJÍ<ÔÕMÏ_ÖÏÐ>×7ÕGÏ_ØPÔ
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• ø

ÕGÌÍPÖÕã×1Ô@ÓÚâJØ<åXåcÏ_Þ1Ñ_Í
Öß>×7ÛÓ ÕGÌÍ Ý×7ÔÛÖ×1Ð>ÕGÛß>Í<ßBÏ_å ß>Í ÛÏ_ß>ÍPÓ ÕGØ ÏÔ@Ð>ÑÛ@ÓJÍ ×
úDÌÍ<Ð VÏ_ïÇÏÕë×7ÕÕGÌÍÔÏ_ÔÕGÌãâJØPåcÏ_ÕMÏ_Ø<ÔãØPÖ¬ÕGÌÍjÎDÍPÌÏ_Ð>Ñ_ÍÒ.Ó1ÍPÔ é
ÕGÏÖÏ_Ð>×1ÕGÏ_ØPÔñÙÜÛÝÞ7ÍPß'ê~ËÌÍ Ð>ÌÍPÐ ÓJÏ_ïÇÏÕ Ï_åÛ@åXÍPÓ ÞcùNÕGÌÍ
Ý×7ÔÛÖ×1Ð>ÕGÛß>Í<ßZ×7ÔÓ§ïÊØ.î3ÍPß>Ô@ÝÍPÔÕÜ×7ïÊÍ<ÔÐ>Ï_ÍPåÕGØîdÍPß>Ï_Ö ùnÕGÌÍ
×7ÛÕGÌÍPÔÕGÏ_Ð>Ï_Õsù Ø<ÖaÕGÌÍæîdÍ<ÌÏ_Ð>Ñ_Í ×1Ô@ÓBØ<ÖÖÏ_Ð>Ï_×7Ñ[ÓJØ<Ð>ÛÝÍ<ÔÕM× é
ÕGÏØ<ÔêËjÌ@Í ÖØ<ß>ÝÛÑ_× ÕGØ Û@åXÍ ÕGÌÍ Ð>ÌÍPÐ ÓJÏ_ïÊÏ_ÕKÏ_å ÔØ<Õ
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POSITION

INTERPRETATION

CODE = DESCRIPTION

1

Country of Origin

1 = United States

2

Make

J = Jeep

3

Vehicle Type

4 = MPV

4

Gross Vehicle Weight Rating

E = 3001-4000 lbs.
F = 4001-5000 lbs.

5

Vehicle Line

Y = Wrangler 4X4

6

Series

1 = Sport
2 = SE
4 = Sahara

7

Body Style

9 = Open Body

8

Engine

P = 2.5L Gasoline
S = 4.0L Gasoline

9

Check Digit

10

Model Year

X = 1999

11

Assembly Plant

P = Toledo #2

12 thru 17

Vehicle Build Sequence

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µ¶

·r¸¹r¸º%»(¼¾½Y¹ ¿wÀrº(Á}»Âq½KÀr¹UÃÄ%ÅwÆwÇÈ`ÆwÉwÊwËwÌ

Fig. 1 Vehicle Safety Certification Label—Typical

VEHICLE
SAFETY CERTIFICATION LABEL
:<;>=@?3ACBDC=FEHGJIK=MLNOB=MPLQACIKACBGJLRACS@TUDCGJVJ=MDWYX1ACZ\[^]`_aACE
GJLRLQGJB?3=@bcLRSd=R;>=MPKNfe
?3PgN>EHDY=@P e
SMPhiS@PGJLRACS@Tj;k=M?3ACBDC=@[1l?3=
DCGJVm=@DBn=MPLQACIKAC=ME LQ?3GJL+LR?3=(;>=@?3ACBDY=oBSMT3IYSMPpqErLRSoGJDYDGJhihiDCACs
BGJVJDY=cX=Mbi=@PGJDqt"SMLQSMPvuw=@?3ACBDC='xkGmIY=MLNyxkLQGmTzbiGJPbiE{[ l?3=
DCGJVm=@DwGJDCE{SrDCACE{LQE{|
t"SMT3LQ?}GJT3bqN>=@GJP%S@I;k=M?3ACBDC=rpqGJT3~3IKGJBLQ~3P=@[
• PS@E{E uw=@?3ACBDC==@AYZ?3L
GmLQACT3Z W u
k_[ml?3=Z\PS@E{E

•
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u
=M?3ACBDC=rbi=@T3LQAYIYAYBnGmLQACSMT~3pqVJ=@P%W u/_n[
• l3N>hm= S@I8;>=M?3ACBDC=@[
• GJP%BS@bi=M[
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l?z=}DCGmVJ=@D(ACEDCS@BGJLR=@b$GJVmSR;>=}LQ?3=}bmSMS@P?3ACT3Z\=}S@TLR?z=
biPA ;k=MPsKE{ACbi=:sKhiACDCDCGJP`[

Fig. 2 Body Code Plate Location

BODY CODE PLATE
LOCATION
AND DECODING
:pq=MLQGJDVJS@bNBS@bi=hiDCGJLR=ACE5GJLQLRGJB?3=@brLQS+LQ?3=IKDCSMS@PhiGJT
~3T3bm=MPLR?3="bmPA ;k=MPEvEH=MGJLWKXACZ\[
H_n[/ACE{=@T3Z\GJZ\="LQ?3="E{TzGmhmE
GJLRLQGJB?3ACT3ZLR?z=BGJPhm=MLLQSLQ?3=¡IKDCSMS@PhiGJTLRS¡P=@GmbyLQ?3=
ACT3IKS@PpqGJLRACS@T3[3l?z=MP= GmPn="EH=;>=@TDCACT3=MEqSMIACT3IKS@PpqGJLRACS@TSMT
LQ?3=%VJSMbNBS@bi=%hiDCGJLR=@[8¢AYTz=ME£J8¤J8¥J8GJT3b"¦ GJP=%T3S@L~3EH=Mb
LQSbi=MIYAYTz=qEH=MPg;kACB=qACT3IYSMPpqGJLQACSMT3[RT3IKS@PpqGmLQACSMTdP=MGJbmE(IYPSMp
DC=MIYL5LQSvPACZ\?3LQEHLRGJPLQAYTzZ(%AYLQ?DCACT3=v§ACTLQ?3=vB=MT3LQ=@P(SMIwLR?z=
hiDCGJLQ= LQSrDCAYTz=j]GmLLR?3=rVJSMLQLQSMp¨SMI LR?z= hmDCGmLQ=rWKXAYZ[§H_n[
l?z=(DCGJE{LwBS@bi=+ACpqhiPACT3LQ=MbrSMToG5;>=@?3ACBDC=(BS@bi=+hiDCGJLR= ACDCD
VJ=dIKS@DCDYSR=@bcV{NfLQ?3=dACpqhmPAYTzLR=@bS@Pbc©
[?3=@TL%S
;>=@?3ACBDC=BS@bi='hiDCGJLR=@E}GmP='P=@ªm~zAYP=@bi(LQ?3='DCGmEHLGH;>GJACDYGJVJDC=
EHhiGJB=ME"SMTLQ?3=dIYAYPEHL%hiDCGmLQ=q%AYDCDVJ=dACpqhiPACT3LQ=MboACLR?LR?3=
DC=MLQLQ=MPEeklyWYIKSMP(BSMT3LQACT3~3=@b_n[
?z=MTGEH=MBSMTzbq;>=M?zAYBDC=rBS@bi=rhiDCGJLR=rACETz=MB=MEHE{GJPgN«LQ?3=
IKACPEHLwIYSM~3PEHhiGJB=MESMTo=@GJB?oPS$ACDCDTzSML
Vm=~3EH=MbrVJ=MBnGm~3EH=
SMI LQ?3=rhiDCGJLR=rSR;>=MPDCGJhi[

Fig. 3 Body Code Plate Decoding

M N
YZ\[Z\]^ _a`[+bdc] ef^hgH`
c[jilkmdndo*pqndrdsdtdu

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DISPLAY SYMBOLS
INTERNATIONAL VEHICLE CONTROL
AND
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GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 2

INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION
PARTS
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GENERAL INFORMATION
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 3

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3,000 Miles (5 000 km)
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27,000 Miles (43 000 km)
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6,000 Miles (10 000 km)
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30,000 Miles (48 000 km)
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9,000 Miles (14 000 km)
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33,000 Miles (53 000 km)
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12,000 Miles (19 000 km)
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36,000 Miles (58 000 km)
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15,000 Miles (24 000 km)
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18,000 Miles (29 000 km)
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21,000 Miles (34 000 km)
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24,000 Miles (38 000 km)
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39,000 Miles (62 000 km)
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42,000 Miles (67 000 km)
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45,000 Miles (72 000 km)
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48,000 Miles (77 000 km)
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51,000 Miles (82 000 km)
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54,000 Miles (86 000 km)
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57,000 Miles (91 000 km)
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60,000 Miles (96 000 km)
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63,000 Miles (101 000 km)
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66,000 Miles (106 000 km)
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69,000 Miles (110 000 km)
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72,000 Miles (115 000 km)
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75,000 Miles (120 000 km)
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78,000 Miles (125 000 km)
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81,000 Miles (134 000 km)
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84,000 Miles (134 000 km)
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87,000 Miles (139 000 km)
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90,000 Miles (144 000 km)
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93,000 Miles (149 000 km)
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96,000 Miles (154 000 km)
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99,000 Miles (158 000 km)
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102,000 Miles (163 000 km)
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105,000 Miles (168 000 km)
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108,000 Miles (173 000 km)
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111,000 Miles (178 000 km)
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JUMP STARTING, HOISTING AND TOWING
I2J6K6LNM
page

page

SERVICE PROCEDURES
EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . . 10
HOISTING RECOMMENDATIONS . . . . . . . . . . . 10
JUMP STARTING PROCEDURE . . . . . . . . . . . . . . 8

RECREATIONAL TOWING . . . . . . . . . . . . . . . . . 10
TOWING RECOMMENDATIONS . . . . . . . . . . . . . . 9
VEHICLE TOWING . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS.
DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.
DO NOT JUMP START WHEN BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. BATTERY CAN EXPLODE.
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL
ARCHING OF BATTERY CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW DISABLED VEHICLE’S
BATTERY TO EXCEED 16 VOLTS. PERSONAL
INJURY OR DAMAGE TO ELECTRICAL SYSTEM
CAN RESULT.

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CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will overheat and could fail.

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CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.

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CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle
charging system can result.

Fig. 1 Jumper Cable Clamp Connections

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CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.

Fig. 2 Tow Vehicles With Approved Equipment

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VEHICLE TOWING
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTOMATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
DO NOT ATTACH SLING-TYPE TOWING EQUIPMENT TO THE REAR OF A TJ.

Fig. 3 Towing With Tow Dollies

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RECREATIONAL
´&¸½A¸»¹/¼e¹/º¸eß~ÆÄTOWING
¸
»·làOµÄÃµÁ`½A¼»¹2¼2Æ¶"ÄÂÛ>»¼
À¸Å>Ã »¸·-È
EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.

á ¼
Õ¸â|¸¸
Û=¾9¸º¶"ÀÁ"¸
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æ¿ç4æ¿èPédæ¿êdë~ì ÛÃ»Û>¼
·1¸
·¼ÄÁ ÝVÈ
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.

HOISTING
í&îïAîðñ2òñ/óRECOMMENDATIONS
îô~õö îð÷ øPù=úö ûúüLï ò
ðlî
ýîðþ:îöÿ<î
ó"ÿü"î
ü"ï ñAö þ ðòÿî
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óî

ö ðò >î
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ñ/ò=ü*"ï ñPú,+|îî-9îó"ÿü"î/.10%"þ2 43!56 87<û#>ò
ðñdñ2ó î9<îó"ÿü"î/"ö
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ðî
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øòïmñ2ó îWïAðúýîWð=
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ø

Fig. 4 T-Hook Attachment

Fig. 6 Vehicle Lifting Locations
Fig. 5 Safety Chain Attachment

CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:

9

D¡8¢U£¤ ¥J¦#§¤ ¨8©N¦J©PªR«,¦U¤ ©8§¬D©8¦T©8¥U¬

®°¯¯

±Z²Z³9´^µ*¶`²b·Z³`¸d¶`²Z¹`ºd³g²Z±i»6¶`¼½¾¿n½ÀÁÂÃ

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sutv
wyxz-{|}:z~
s}:D

s!{zz't^x*tv:2zd'#tzt{~
s#' yz-!v:1{~

s'v:#1{T=z=' Tz*t!{~

NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.

zdzt*tz-g{'v:t!*!
tx#v:t~
zd1|zx{v:t~
s1't{P!|
=zt!*tv='~
'v:t
*z`'v=!z~

NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
T %
sTz'xz-'v:t}:z-x1{z<{

•
•

•

!#zd
xx~

s!*t2xz1=!{1'v:z*'t{v:'{P!{~
s{<t1=
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WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.

R1S

TVUHTVW9XZY[TG\ ][Y

^&_@`

SUSPENSION
Ä-ÅRÆdÇ ÈgÆ,ÇgÉ

page
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page
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ÕÖT×ÎTÑÙØÚTØ°Û%ÐÎTØ°Ì ×ÎÜÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒdÝ

ALIGNMENT
Ì*ÎàÐá

page

page

DESCRIPTION AND OPERATION
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
SUSPENSION AND STEERING SYSTEM . . . . . . . 3
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . 5

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DESCRIPTION AND OPERATION
WHEEL
ALIGNMENT
âãääåæ:åçè2éêäéëçéíìyîå ìTäïëãä`ð'îñ'ñ'äð'ëò=îï!ç*ëçîéçéèîó
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CAUTION: Never attempt to modify suspension or
steering components by heating or bending.

öç*åëçéè<ëãä9ëîòdîóëãäUô<ãääå%îúë ôgæ=ñ'ødò=ñ'î ìTçø=äïPò#îï
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ë

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NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rubber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the recommended maintenance schedule.

a&b$a cVd[cVeGfZg[c9h i[g
lmnop&qsrt quwvyxvzl{uwrmpxt quwv}|~oGG'9GGG

Fig. 1 Wheel Alignment Measurements

j4k

1

VHV9Z[G [

DIAGNOSIS AND TESTING
SUSPENSION AND STEERING SYSTEM
CONDITION
FRONT END NOISE

EXCESSIVE PLAY IN
STEERING

FRONT WHEELS SHIMMY

VEHICLE INSTABILITY

EXCESSIVE STEERING
EFFORT

VEHICLE PULLS TO ONE
SIDE

POSSIBLE CAUSES

CORRECTION

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or
suspension components.

2. Tighten or replace components as
necessary.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or
suspension components.

2. Tighten or replace components as
necessary.

3. Loose or worn steering gear.

3. Adjust or replace steering gear.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or
suspension components.

2. Tighten or replace components as
necessary.

3. Tires worn or out of balance.

3. Replace or balance tires.

4. Alignment.

4. Align vehicle to specifications.

5. Leaking steering dampener.

5. Replace steering dampener.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or
suspension components.

2. Tighten or replace components as
necessary.

3. Tire pressure.

3. Adjust tire pressure.

4. Alignment.

4. Align vehicle to specifications.

1. Loose or worn steering gear.

1. Adjust or replace steering gear.

2. Power steering fluid low.

2. Add fluid and repair leak.

3. Column coupler binding.

3. Replace coupler.

4. Tire pressure.

4. Adjust tire pressure.

5. Alignment.

5. Align vehicle to specifications.

1. Tire pressure.

1. Adjust tire pressure.

2. Alignment.

2. Align vehicle to specifications.

3. Loose or worn steering or
suspension components.

3. Tighten or replace components as
necessary.

4. Radial tire lead.

4. Rotate or replace tire as necessary.

5. Brake pull.

5. Repair brake as necessary.

6. Weak or broken spring.

6. Replace spring.

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132

SERVICE PROCEDURES
PRE-ALIGNMENT
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FKsK7ÍALIGNMENT
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NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3, Differential and Driveline for additional information.

å¥ê4á¸ëêGä@ì åì ê4í
NOTE: The wheel toe position adjustment is the
final adjustment. This adjustment must be performed with the engine running, if the vehicle is
equipped with power steering.

Fig. 3 Drag Link and Tie Rod Clamp

l
£¥¤¥¦l§_¨R©C¤«ª¥¦C¬©C¤¥C®¦¤¥£°¯©C±+²+³N´µ²+¶+·+¸+¹

'Y'/-(+ (

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V@BON];`:W/F_XYXL? Va$SZbdc6A>egDfhFP@BGHONFJ@BFEQH[\AEQHFONS?S]A>@iQHGMAEDAEDF FGHQHFNjkI6DACAlKMKMDDFNFNFJFJGMGHW3QH@^mnON]@BA_QHA>AEQHOJDS F
A>DF"opGH]`:PrqONGHAE@]@@8DOEKMS46sQRjtW/V u87:]S;rA>QRjtDA>FJSAEO_vw
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A>DFFJSjtQRSV FJW V
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
NOTE: Alignment specifications are in degrees.

Fig. 4 Steering Linkage

ADJUSTMENT

PREFERRED

RANGE

MAX RT/LT DIFFERENCE

CASTER

7°

6 1.0°

0.65°

CAMBER
(fixed angle)

− 0.25°

6 0.63°

1.0°

TOE-IN
(each front wheel)

0.15°

6 0.07°

0.05°

THRUST ANGLE 0° 6 0.25°

Z[\

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i)j
FRONT SUSPENSION

ºR»+¼+½J¾
page

page

DESCRIPTION AND OPERATION
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE PROCEDURES
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL AND INSTALLATION
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . . . . 8
HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 8

SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 7
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 8
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 8
WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 12

DESCRIPTION AND OPERATION

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Í8ú\ÏHÁ ÏRÍÇ>ÁJÄpÍÏiÖ:ÅEô\ÁNÖ:ÁJÆÇ>ðM¿LÀÁ ÚÍÄíËHÈÎÍÇEÇ>ÍÓpÀÁNÔ Ç>Å Í
Â6ÄpÍÖ:Á:ÄpÍËHÏ(ÚÄpÍÓpÑóÁJÇnÝMËHÇEÀÍÚÍÏHÏ(È8Ç>ÉÔ"ÍÆÔ"ËRÈ8ÅJÏHÍÇ>ÁJÔÝMËHÇ>À
ÍÚÉÈ8ÀËHÆÕ_ÍÇ Ç>ÀÁÍ8ú\ÏHÁÚÄpÍÓÑÁNÇEð

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ÀÅJÓpÑiÍÚÈ8ÅJÄpÚÁJÄpÈ
• Ù ÅJËHÏ+È8ÊÄpËHÆÕtÈ
• Û ÊÊÁJÄCÍÆÔÏHÅEÝMÁJÄCÈBÉÈBÊÁNÆÈBËHÅNÆrÍÄpÖ:È
• Ü ÇEÍÚËHÏRËHÞ-ÁNÄÚÍÄ
Ù ÄpÍÓpÑiÚÍÄ
• ¿Y
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ßdà áâã ä$åà æTçnèéNênëáéNà åáì<¿¢ÀÁíÏHËHÆÑNÒ ÓpÅJËHÏ"È8ÉÈ8ÊÁJÆÈBËHÅJÆ
ÍÏHÏRÅEÝMÈCÁJÍÓpÀîÝMÀÁNÁJÏ(Ç>Å:ÍÔÍÊÇ$ÇEÅ:ÔËHÂRÂ6ÁJÄpÁNÆÇ$ÄpÅJÍÔ"ÈBÉÄÂ6ÍÓpÁJÈ
ÝMËHÇ>ÀÅJÉÇ3ÕkÄpÁJÍÇ>Ï ïÍÂ6ÂRÁJÓpÇ>ËHÆÕÇEÀÁÅNÊÊÅNÈBËHÇ>ÁCÝÀÁJÁNÏRðñÀÁNÁJÏHÈ CAUTION: Components attached with a nut and
ÍÄpÁÍÇ>ÇEÍÓpÀÁNÔZÇEÅUÍÀÉÚ8Ò ÚÁJÍÄpËHÆÕtÈÝMÀËHÓpÀòÚÅJÏHÇ>ÈÇ>ÅÇ>ÀÁ cotter pin must be torqued to specification. Then if
ÑóÆÉÓpÑóÏHÁJÈ8ð¿¢ÀÁiÀÉÚBÒ ÚÁJÍÄpËHÆÕrËHÈÆÅJÇ:ÈBÁNÄô\ËHÓpÁNÍÚÏHÁÍÆÔËHÈ the slot in the nut does not line up with the cotter
ÄpÁNÊÏHÍÓpÁNÔõÍÈöÍ÷ÉÆËRÇ>ð Ù Ç>ÁJÁJÄpËHÆÕøÑóÆÉÓpÑóÏHÁJÈöÊË ô\ÅNÇÐÅJÆ pin hole, tighten nut until it is aligned. Never loosen
ÄpÁNÊÏHÍÓpÁNÍÚÏHÁÐÚÍÏHÏMùNÅNËHÆÇEÈòÍÇ>Ç>ÍÓpÀÁJÔöÇEÅÐÇ>ÀÁÐÍ8ú\ÏHÁÐÇ>ÉÚÁ the nut to align the cotter pin hole.
ï\ÅNÑóÁJÈBð
çnûåüâUýCþ'éJåÿþ'ëÿtéNì¢¿¢ÀÁÈ8ÀÅJÓpÑZÍÚÈBÅJÄÚÁNÄpÈÔÍÖMÊÁJÆ CAUTION: Suspension components with rubber/
ùNÅNÉÆÓpÁ"ÍÆÔÄÁJÚÅJÉÆÔÖ:ÅJÇ>ËHÅJÆÅJÂ Ç>ÀÁMô ÁJÀËHÓpÏHÁÅEô\ÁNÄ3ô ÍÄËR× urethane
(except stabilizer bar) should be
ÅJÉÈ_ÄpÅJÍÔÓpÅJÆÔËHÇEËHÅNÆÈBð¿¢ÀÁTÇ>ÅNÊÅNÂ<ÇEÀÁTÈBÀÅNÓpÑÍÚÈBÅNÄpÚÁNÄpÈ tightened bushings
with
the
vehicle
at normal ride height. It is
ÍÄpÁ
ÚÅNÏHÇEÁNÔÃÇ>Å ÍZÂRÄpÍÖMÁ ÚÄpÍÓpÑóÁJÇ>ð ¿¢ÀÁ
ÚÅJÇ>Ç>ÅJÖ ÅNÂ"Ç>ÀÁ important to have the springs
supporting the weight
È8ÀÅJÓpÑóÈMÍÄpÁÚÅNÏHÇEÁNÔÇ>ÅÍÍ8ú\ÏHÁÚÄÍÓpÑóÁNÇEð
of
the
vehicle
when
the
fasteners
are torqued. If
ä$åàµæ/çênÿà á éNì¿LÀÁ:ÓpÅNËHÏ(È8ÊÄpËHÆÕkÈCÓpÅNÆÇ>ÄpÅJÏYÄpËHÔÁ ÉÍÏRËHÇ ï springs are not at their normal ride position,
ÍÆÔ Ö:ÍËHÆÇ>ÍËHÆ ÊÄpÅNÊÁNÄÄpËHÔÁ
ÀÁJËHÕtÀÇEð¥¿¢ÀÁ
ÓpÅNËRÏÈ8ÊÄpËHÆÕtÈ ride comfort could be affected and prematurevehicle
bushÖ:ÅNÉÆÇ$ÉÊ"ËHÆiÇ>ÀÁ¥ÝMÀÁNÁJÏHÀÅJÉÈBÁNð ÎÄpÉÚÚÁJÄ3ÔÅNÉÕkÀÆÉÇ$ËRÈ8ÅJ× ing wear may occur.
ÏHÍÇEÅNÄ ËRÈ<ÏHÅJÓpÍÇEÁNÔÚÁJÇ ÝMÁNÁJÆÇ>ÀÁÇ>ÅJÊÅNÂYÇEÀÁÈBÊÄpËHÆÕîÍÆÔÇ>ÀÁ
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å Tëÿ^çèéJêëáéNà åáìn¿LÀÁTÈBÉÈ8ÊÁJÆÈBËHÅJÆ
ÍÄpÖ:ÈCÉÈ8Á:ÚÉÈBÀËRÆÕkÈCÇ>Å:ËHÈBÅNÏRÍÇ>Á:ÄpÅJÍÔ"ÆÅNËRÈ8ÁJð¿¢ÀÁ:ÈBÉÈ8ÊÁNÆ× DIAGNOSIS AND TESTING
È8ËRÅNÆÍÄpÖ:ÈÍÄpÁ"ÚÅJÏHÇ>ÁJÔrÇ>Å"ÇEÀÁ"ÂRÄpÍÖ:Á"ÍÆÔÍ8ú\ÏHÁ"Ç>ÀÄpÅNÉÕkÀ
Ç>ÀÁ:ÄpÉÚÚÁNÄlÚÉÈ8ÀËHÆÕkÈ8ð¿¢ÀÁ:ÏHÅgÝÁJÄlÈ8ÉÈ8ÊÁJÆÈBËHÅJÆÍÄÖ:ÈÓpÍÆ SHOCK
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FRONT SUSPENSION

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üýþ

SERVICE PROCEDURES
LUBRICATION
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REMOVAL AND INSTALLATION
SHOCK ABSORBER

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½-¾¹ÀÉXÉ=¹(ÂÊ3½-ÀÆ½-¾Â!»(À#ÇL¾P¹(¿ÇÄK¿#¹Ë!»(ºÉ=Ã=Â!½-º¹ ¿½&Ã,Ë!Ë!¹(Ê>Ê
¾» ÌK¹&µKÍ Ä$ÇLÎ¶·Î
µ6Ï>·¸¹(º5»z¼F¹½-¾¹Ì$»zÐ¹(Â)¿À½-ÊÃ=¿#Æ;Ñ,»(Ì$½-ÊÈ6Â!» º¤½-¾¹Ã>ÒFÌ$¹
Ñ,Â!Ã,Ë!Ó#¹ ½Ã,¿ÆÂ!¹(º»/¼F¹&½/¾#¹0Ê>¾» Ë!ÓYÃ,Ñ=Ê>»(Â!Ñ,¹(Â¨Î
Ô6ÕFÖ×L³´#´(³#×Ô ±)Õ
µ¶¨·Ø»(Ê>ÄK½-Ä$»(¿½-¾¹Ì$»/Ð5¹(ÂÂ!¹ ½/Ã,Ä$¿¹ ÂÃ,¿Æ&ÇÂ!»(ºº¹ ½c» ¿½/¾#¹
ÀÉ=ÉX¹(ÂÊ>½/À#ÆXÎÙz¿Ê>¹(Â!½½-¾¹Ê>¾»(Ë!Ó{Ã,Ñ,Ê3» Â!Ñ=¹ Â½-¾Â!»(ÀÇ¾G½-¾¹
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µ6Ï>·Ùz¿Ê>½-Ã=Ì$Ì½-¾¹;Ì$»zÐ5¹ Â0Ñ,»(Ì$½-Ê9Ã,¿ÆW¿#À½/Ê>ÎÚcÄ$ÇL¾½-¹(¿¿À½-Ê
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µ6á>·Ùz¿Ê>½-Ã=Ì$Ìc½-¾¹&ÀÉ=ÉX¹(ÂÇLÂ!» ºº¹(½Ã=¿ÆÂ!¹ ½/Ã,Ä$¿¹ Â» ¿V½-¾¹
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COIL SPRING

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µ¶¨·¸Ã,Ä$Ê3¹DÃ=¿#ÆäÊ>ÀÉXÉX» Â!½N½/¾¹8¼F¹ ¾Ä$Ë!Ì$¹(ÎØ»(Ê>ÄK½-Ä$»(¿åÃ
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æÆXÂ!Ã,ÀÌ$Ä$Ë ç Ã,Ë!ÓYÀ#¿ÆX¹(Â½-¾¹&Ã3ÒÌ$¹0½-»&Ê3À#ÉXÉX» Â!½ÄK½-Î

µ6Ï>·ØÃ=Fig.
Ä$¿½»(1ÂCoil
Ê>Ë!Â!Ä$Spring
Ñ=¹¡Ã=Ì$Ä$ÇL¿#&ºShock
¹(¿½ºAbsorber
Ã,Â!Ó#ÊV»(¿G½-¾¹ËÃ=º
Ã,Æ-ç À#Ê3½-¹(Â!Ê5Ã,¿ÆÃ>ÒFÌ$¹&Ñ=Â!Ã,Ë!Ó¹(½ÈK»(ÂÄ$¿Ê3½-Ã,ÌKÌ$Ã,½-ÄK» ¿Â!¹(È6¹ Â!¹(¿Ë¹(Î
µ6á>·è9Ã=Â!ÓÃ,¿Æ¡ÆXÄ$Ê>Ë!»(¿¿#¹(Ë!½½-¾¹OÈ6Â!» ¿½ÉXÂ!» ÉX¹(Ì$Ì$¹ ÂÊ>¾Ã=ÈK½
È6Â!» ºÞ½-¾¹&Ã>ÒFÌ$¹(Î
µ6é>·¸¹(º»/¼F¹½/¾#¹{Ì$»zÐ¹(ÂÊ>ÀÊ>ÉX¹(¿Ê>Ä$»(¿8Ã,Â!º©¿À½-Á9Ë!Ã=º
Ã,¿ÆË!Ã=ºAÑ,»(Ì$½È6Â!» ºÞ½-¾¹&Ã>ÒFÌ$¹(Î
µ6ß>·êÄ$Ê>Ë!»(¿¿#¹(Ë!½9½/¾¹ÅÊ3½-Ã,Ñ=Ä$Ì$Ä$ëe¹(ÂOÑ,Ã,ÂOÌKÄ$¿ÓÊÃ,¿ÆxÊ3¾» Ë!Ó
Ã,Ñ,Ê3»(ÂÑ=¹ Â!Ê5È6Â!» ºÞ½-¾¹&Ã3ÒÌ$¹(Î
µ6ì>·êÄ$Ê>Ë!»(¿¿#¹(Ë!½9½/¾#¹W½-Â!Ã=ËÓÑ,Ã,ÂOÈ6Â!» ºí½/¾#¹WÈ6ÂÃ=º¹ÅÂ!Ã,ÄKÌ
Ñ,Â!Ã,Ë!Ó#¹ ½/Î
µ6ã>·êÄ$Ê>Ë!»(¿¿#¹(Ë!½½-¾¹Æ=Â!Ã,Ç9Ì$Ä$¿ÓÈ6Â!» º¤½-¾¹ÉXÄ$½/ºÃ,¿OÃ=Â!ºÎ
µ6Û>·î»zÐ5¹ Â½-¾¹Ã3ÒÌK¹À¿½-Ä$Ì ½-¾¹Ê>ÉXÂ!Ä$¿ÇÄ$Ê)ÈKÂ!¹(¹È6Â!» º£½-¾¹
ÀÉXÉ=¹(Âº»(À¿#½Ã=¿#ÆOÂ!¹ º»z¼¹0½-¾¹&Ê>ÉXÂ!Ä$¿ÇLÎ
NOTE: Left coil spring has a retainer and bolt
which must be removed from the axle pad.

µ6ï>·¸¹(º»/¼F¹¡½-¾¹5çe»(À¿#Ë!¹¡Ñ,ÀºÉX¹ ÂYÄKÈ¿#¹(Ë!¹ Ê3Ê>Ã=ÂæGÈ6Â!»(º
½-¾¹&ÀÉXÉX¹ ÂÊ>ÉXÂ!Ä$¿Çº»(À#¿½/Î
Ô6ÕFÖ×L³´#´(³#×Ô ±)Õ
µ¶¨·Ø»(Ê3Ä$½-Ä$»(¿½/¾#¹0Ë»(Ä$ÌcÊ3É=Â!Ä$¿Ç»(¿½/¾¹&Ã>ÒFÌ$¹&ÉXÃ,ÆXÎ

NOTE: Install retainer and bolt on the left spring
and tighten to 22 N·m (16 ft. lbs.).

6µ Ï>·Ùz¿Ê>½-Ã=Ì$Ìc½-¾¹ç » À¿Ë!¹&Ñ,ÀºÉX¹ ÂÎ
µ6á>·¸Ã,Ä$Ê3¹x½-¾¹Ã3ÒÌ$¹xÄ$¿½-»xÉX» Ê3Ä$½-ÄK» ¿ðÀ¿½-Ä$Ì0½/¾¹Ê3É=Â!ÄK¿#Ç
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TORQUE CHART

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øùúø

ûü ûý
þÿ û ÿ

SPECIAL TOOLS
FRONT SUSPENSION

Bolt, Special 7604

Remover/Installer Suspension Bushing 7932

Remover C-4150A

Nut, Long 7603

Ä}Å

Æ_ÇwÆRÈÉ(ÊwÆË ÌwÊ

Í`ÎÏÐ

REAR SUSPENSION

page
DESCRIPTION AND OPERATION
REAR SUSPENSION . . . . . . . .
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS . . . . . . . . .
REMOVAL AND INSTALLATION
COIL SPRING . . . . . . . . . . . . . .
LOWER SUSPENSION ARM . . .

. . . . . . . . . . . . . 13
. . . . . . . . . . . . . 13
. . . . . . . . . . . . . 14
. . . . . . . . . . . . . 14

DESCRIPTION AND OPERATION
REAR
SUSPENSION
"! #"%$""&('*)! "$,+- "./0)!(12" +

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page
SHOCK ABSORBER . . . . . .
STABILIZER BAR . . . . . . . .
TRACK BAR . . . . . . . . . . . .
UPPER SUSPENSION ARM
SPECIFICATIONS
TORQUE CHART . . . . . . . .

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14
15
16
15

. . . . . . . . . . . . . . . . 16

CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. This
will maintain vehicle ride comfort and prevent premature bushing wear.

DIAGNOSIS AND TESTING
SHOCK
0j(DIAGNOSIS
"h 9@ ""d("¡¢A£7 ¤¥¡¦ §-¡ §¢(

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¢(@¡³´f¦¢ ¡¢ "¡¢(¡2-©¡©- " ¨Z§-¢d¡@(±±¢(ª;§¨Z@"x¦@²
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"¡±¢ c£ ,ª¤2x¢ ªkª2®A(§©¡¦"x¡ºFªk@9¦²
"%(¤2± ¢(9¡³»¢ ±"g¡d¢ ¢(¡¡¼¨O"£]-T¨W £]9¦¢ ¡¢
(ª"@"(¡A¢a½b¡9³
0¡¾©¢ j"d("¡¢A£7 ¤¯@¦¢A¡¦ §-¡ §¢(¤2¨:§¢
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9¢ 9³t´f¦"¡\(ª"9(O"¡ E¢(±"-§ "¢-ª9¦¢k¡¦(
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"!$#&%('&) *'

REMOVAL AND INSTALLATION
SHOCK ABSORBER

ÑÒÓÔÕbÖ×
ØYÙqÚkÛÜÝ"ÞßhÜàákÞâã-ãä åæcæ9çßè_ß(çÝ"éê"ßhÜ-àá%æ9çßhÜë_ê"ß ì
Ø7íÚkÛß îAäaè_ßhæ9çßhâãã-ß åEîAä âàæ9Ý"àï\ðä ê"æ@ÞAØñIÝ"ïxìnÙ*Úì
Ø7òÚkÛß îAäaè_ß%æ@çß%êä@óAß(å\àâægÜàáð-ä(ê"ægô7åä(îõæ@çß;Üë_ê"ß
ðåÜéöß(æ9ìFÛß î2ä@è_ßhæ9çßhÞçä(éö;Üð-Þä åðß(å*ì

+-,

Ø7ò
Ú ä ààß éæ0æ9çß¥Þæ9Ü-ðÝ"ê"Ý Dß å°ðÜå°ê"Ý"àöjÞ Üàá¶Þçä(éö
ÜðÞä åYð-ß(åÞ2æ9ädæ@çßdÜëbêßdðåÜéöjß æ9ìä(ààß éYææ@çßdæ@åÜéö:ðÜå
æ9ädæ9çßhô7åYÜ-î2ßhåÜÝ"êðåÜéöjß æ9ì
Ø7ÿÚkÛß î2ä@è_ßhæ9çßhÞâã-ãä åYæ@ÞAÜàákê"äaóAß(åEæ9çßè_ß(çÝ"éê"ß ì
Ø Ú2üÝï/çæ9ß àWæ9çßÞæ9ÜðÝê"Ý Dß åhðÜådê"Ý"àöjÞ rÞçä éöZÜ-ðÞä åð

ß åÞAÜàákæ9åÜéö;ðÜ-å,æ@ähÞãß éYÝôÝß(ákæ@ä(å -âß ì
LOWER SUSPENSION ARM

ÑÒÓÔÕbÖ×
ØYÙqÚkÛÜÝ"ÞßhÜàákÞâãã-ä åæcæ9çßè_ß(çÝ"éê"ß ì
Ø7íÚkÛß î2ä@è_ßAæ9çßAê"ä@óAß åÞâÞã-ß àÞÝ"ä àkÜåî¯àâæÜàá\ðä(êæ
Üæcæ@çßhÜëbêßhðåÜéöjß æcØ7ñtÝ"ïxìFíÚì
Ø7òÚkÛß î2ä@è_ß¹æ9çßXàâæZÜ-àáÀðä ê"æZÜæZæ@çß¹ô7åÜî2ß¹åÜÝ"ê
î2ä âàæØ7ñtÝ"ïxìbòÚnÜàáhåß(î2äaè_ß}æ9çß}êä@óAß(å]ÞâÞã-ß àÞÝä(à`Üåî2ì

Fig. 1 Shock Absorber

÷7ø_ùtúxÖf×× ÖúF÷ Ôø
ØYÙqÚkûaàÞæ9Ü-ê"êæ9çß`Þçä éöÜð-Þä åðß(ågä àæ9çß`âããß(ågô7åÜî2ß
åÜÝ"êÜàákÝàÞæ9Ü-ê"êî2ä âàæ9Ý"àï\ðä ê"æ@Þì
Ø7íÚ2üÝï/çæ9ß à:æ@çßdâããß(åEðä ê"æ9ÞAæ@ähòRÙAýþ îØ7íòô7æ9ìFê"ðÞì ÚYì
Ø7òÚkûaàÞæ9Ü-ê"êê"ä@óAß å,ðä ê"æcÜàákàâæcô7Ý"àï/ß å,æ@Ý"ïxçæ@ì
Ø7ÿÚkÛß îAäaè_ßhæ9çßhÞâããä åYæ@ÞAÜàákê"äaóAß(åEæ9çßè_ß(çÝ"éê"ß ì
Ø Ú2üÝï/çæ9ß à:æ@çßdê"ä@óAß å,àâæcæ9ä;Ù `ýþ îiØ ÿôæ@ìKêðÞì ÚYì

Fig. 2 Upper & Lower Suspension Arms

÷7ø_ùtúxÖf×× ÖúF÷ Ôø

COIL SPRING

ÑÒÓÔÕbÖ×
ØYÙqÚkÛÜÝ"Þß«Ü-àá Þâããä(åæ¯æ@çß¥è_ß(çÝ"éê"ß ìtä ÞÝæ9Ý"ä à Ü
ç báåÜâê"Ý"é
(Üéö;âàáß å,æ9çßhÜëbê"ßdæ9ähÞâããä(åæcÝæ9ì
Ø7í
Ú nÝ"Þéä ààß éææ@çßÞæ9Üð-Ý"ê"Ý Dß å%ðÜå%êÝ"àöjÞ;Ü-àá¸Þçä(éö
ÜðÞä(åð-ß(åÞAô7åä(îiæ9çßhÜë_ê"ßhð-åÜéöjß æ9Þì
Ø7ò
Ú nÝ"Þéä ààß éææ@çßZæ9åÜéö0ðÜå%ô7åä(î æ9çßZô7åYÜ-î2ßåÜÝ"ê
ðåÜéöß(æ9ì
Ø7ÿ
Ú täaóAß(åcæ9çß,Üëbêß,âàæ@Ý"êIæ9çß,ÞãåÝ"àï2Ý"Þô7åß ß,ô7åä(îÀæ9çß
âã-ãß å,î2ä âàæcÞß(Ü-æcÜàákåß(î2äaè_ßhæ9çßhÞã-åÝ"àïxì
÷7ø_ùtúxÖf×× ÖúF÷ Ôø
NOTE: Springs can be install with either end up.

ØYÙqÚ
tä ÞÝæ9Ý"ä à\æ9çß}éä Ý"êtÞãåÝ"àïAä à\æ9çß}Üë_ê"ß}ãÜádÝ"Þä ê"Üæ@ä(å*ì
Ø7íÚkÛÜÝ"Þß¸æ9çß~Üëbê"ß¸Ý"àæ9ä¸ãä(ÞÝ"æ9Ýä(àâàæ9Ý"êdæ@çß¸Þã-åÝ"àï
Þß Üæ@ÞAä(àæ9çßhâãã-ß å,ÝÞä ê"Üæ9ä å*ì

Fig. 3 Upper & Lower Suspension Arms

YØ ÙqÚ
tä ÞÝ"æ9Ý"ä àWæ9çßê"ä@óAß åhÞâÞã-ß àÞÝ"ä àWÜåî Ý"àWæ@çßÜë_ê"ß
ðåÜéöß(æcÜàákô7åÜî2ßhåÜ-Ý"êîAä âàæ9ì
Ø7íÚkûaàÞæ9Ü-ê"êAæ9çßZî2ä(âàæ9Ý"àïOð-ä(ê"æ@Þ:Üàáô7Ý"àï/ß å%æ@Ý"ï/çæ@ß(à
æ9çßhàâæ9Þì

¤|¥

¦"§¦$¨&©(ª¦&« ¬ª

®l¯°

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UPPER SUSPENSION ARM
d&eBf-g&hjilk
.DZm0
13FM?2;FG>H
?@>AA65C:n:=<>2L8"2(<>MNI25O
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Fig. 5 Stabilizer Bar Link

Fig. 4 Parking Brake Cable/Bracket And Wiring
Bracket
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Fig. 6 Stabilizer Bar
"ikBk5iBb g-
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NOTE: Ensure the bar is centered with equal spacing on both sides and is positioned above the differential housing (Fig. 6).
.o0RQ&MTSU<>:=25G:=<>2pC2(:=FMG>2(CVc65I:E?:=6pP

]n^ 4 .P`aT:EO

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STABILIZER BAR
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VWYX[Z]\^_`^acbedfacgYhL^_O_O^hidfZcakjmlnOoOpQq/oOrOsOtOu

TU
SPECIFICATIONS

TRACK BAR
Ë&ÌBÍ-Î&ÏjÐlÑ
ÒDÓmÔ
Õ3Ö×ØÙ;ÖÚ>Û
ØÜ>ÝÝÞ5ßànà=á>ÙLâ"Ù(á>×ãäÙ5å
ÒæÔ
Õ3Ù5ç7Þ9â"ÙvàEá>ÙvèÞ5äà;ÖÚ>Û¢Ú>Ü>àXéßÞ5ç{à=á>ÙvéßÖçRÙßÖ×ä
èßÖãêBÙ(ànÒë×ìåbíÔDå
ÒîÔ
Õ3Ù5ç7Þ9â"Ùà=á>ÙèÞ(äTàLéTßÞ5çàEá>ÙÖï"äÙèßÖãêsÙ5àLÒTë×ìåíÔ
ÖÚ>Û
ßÙ5çRÞEâ"Ù;à=á>Ù;àEßÖãêvèÖßå

Fig. 7 Rear Track Bar
ðñ"òóÐÑBÑ5ÐBóbð Î-ñ
ÒDÓmÔ
ô9Ú>Øà=Öääà=á>Ù[à=ßÖãêqèÖß
×Úà=á>Ù[ÖïjäTÙõèßÖãDêBÙ(àÖÚ>Û
×Ú>ØàEÖää&à=á>Ù;èÞ(äànäÞ5Þ5ØÙ5ä ö å
ÒæÔ
ô9Ú>Øà=Öäälà=á>ÙWàEßÖãê[èÖßX×Úà=á>ÙWéßÖçRÙWßÖ×TäèßÖãêsÙ5à
ÖÚ>Û
äTÞ(Þ5ØÙ5ä ö[×Ú>Øà=Öää&àEáBÙèÞ(äTà´ÖÚBÛÚ>ÜBàEå

NOTE: It may be necessary to pry the axle assembly over to install the track bar.
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DIFFERENTIAL AND DRIVELINE
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PROPELLER SHAFTS

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page
GENERAL INFORMATION
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT JOINT ANGLE . . . . . . . .
PROPELLER SHAFT JOINTS . . . . . . . . . . . . .
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . .
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION . . . . . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT ANGLE MEASUREMENT

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

2
3
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1
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... 4
... 3

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... 6

GENERAL INFORMATION
PROPELLER
SHAFTS
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page
REMOVAL AND INSTALLATION
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . 8
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . 8
DISASSEMBLY AND ASSEMBLY
DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . . 10
SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . . 9
CLEANING AND INSPECTION
SINGLE AND DOUBLE CARDAN JOINT . . . . . . . 13
ADJUSTMENTS
AXLE PINION ANGLE ADJUSTMENT . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 14

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CAUTION: Use original equipment replacement
parts for attaching the propeller shafts. The specified torque must always be applied when tightening
the fasteners.

PROPELLER
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Fig. 1 Propeller Shafts

Fig. 2 Single Cardan U-Joint

PROPELLER
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Fig. 3 Double Cardan U-Joint

Fig. 4 Maximum Angles And Engine Speed

PRECAUTIONS
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CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.

Fig. 5 Reference Marks on Yokes

DIAGNOSIS AND TESTING
VIBRATION
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Drive Condition
Propeller Shaft Noise

Universal Joint Noise

Possible Cause

Correction

1) Undercoating or other foreign
material on shaft.

1) Clean exterior of shaft and wash
with solvent.

2) Loose U-joint clamp screws.

2) Install new clamps and screws
and tighten to proper torque.

3) Loose or bent U-joint yoke or
excessive runout.

3) Install new yoke.

4) Incorrect driveline angularity.

4) Measure and correct driveline
angles.

5) Rear spring center bolt not in
seat.

5) Loosen spring u-bolts and seat
center bolt.

6) Worn U-joint bearings.

6) Install new U-joint.

7) Propeller shaft damaged or out
of balance.

7) Installl new propeller shaft.

8) Broken rear spring.

8) Install new rear spring.

9) Excessive runout or unbalanced
condition.

9) Re-index propeller shaft 180°,
test, and evaluate.

10) Excessive drive pinion gear
shaft runout.

10) Re-index propeller shaft 180°
and evaluate.

11) Excessive axle yoke deflection.

11) Inspect and replace yoke if
necessary.

12) Excessive transfer case runout.

12) Inspect and repair as necessary.

1) Loose U-joint clamp screws.

1) Install new clamps and screws
and tighten to proper torque.

2) Lack of lubrication.

2) Lubricate U-joint and evaluate.
Replace as necessary.

UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
vibrations.
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Fig. 7 Two Clamp Screws At The Same Position
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Front of Shaft

0.020 in. (0.50 mm)

Center of Shaft

0.025 in. (0.63 mm)

Rear of Shaft

0.020 in. (0.50 mm)

Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.

ëìí

îïððñòñ!óô#ï õ&öõ'ó,î®î*òï ÷&ñöï ó,ñ

øù

SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION
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Fig. 10 Propeller Shaft Angle Measurement (C)

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Fig. 11 Rear (Input) Angle Measurement (B)

Fig. 12 Universal Joint Angle Example

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REMOVAL AND INSTALLATION
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;\F=f¥(ArUOE`SBIE`UOStpqj +@BADI4E_CYE`PQG[N¦yVQWDG[efNu[@BWDE`C§G[E_E`UOS
GFTWDSq]T@+w4SE`@¨<Y mq© e;%<FZEdaªWu[CFa =E`@BP%«JMOS+a

REAR PROPELLER SHAFT
1(24365(798:
;%<,=?c9UOADZ\EE`UOSE`PQG[IOCFefACFCYAD@+IG[IOKsEdPQG[IOCFZ\S+P¨VQG[CYS¯ADIOE`@
mqS+MOE`PQGJWDa
;\bF=?>6@BADCYEGJI4KLCFMONN@+PQERTS+UOADVQWDSn@+IXCYG[Z\S+E^]_CYE`G[IOKCFa
;\oF=?c9VQPQADuJSG[WDADrIOefS+IOE(efG[PQw4CHG[E(E`UOSNADIOAD@BICYU4GJZE(G[IOK
G[E6S+GJVQU_S+IOK¨@BZEdUOSnNPQ@BNJSBWDWDSBP|CYU4GJZEdaO¥U4SBCFS~efG[PQw4C|ADWDW
u[SMOCYS+KLZ@BPAI4CYE`G[WWDG[E`A@+IP%SBZ\S+PQSBIOVQS+a
;\F=?SBef@dRTSE`UOSpqj @BADIOE CFEdP%GJN{u[@BWDE`CGJE E`UOSNADIOAD@+I
CYU4GJZE]T@+w4S+a
;\F=?}Pk]?@+NS+I VQWDG[efNUO@BWDKADIOr|E`UOSKMOCFE(u[@B@+E(E`@NJPQ@BNS+WDj
WDSBPCYUOG[Z\E]T@BwxS;\}ADra<FF=%a
;\F=?c9WADKJSEdUOSCFWDADN]9@BwxS@BZZ_@BZ_E`UOSE`PQGJI4CYefADCFCYAD@BIl¦
E`PQGJI4CYZSBPVQG[CYS@+MOE`NMOECYUOG[Z\EG[IOK_PQS+ef@RTS EdU4SNPQ@+NSBWDWDSBP
CYU4GJZEH;\}Ara<FF=%a

Fig. 15 Dust Boot Clamp

!#"

$&%')(+*#,&-.,&/1032
/145,&-6-6,7582
(1/:9<;&=6>6?A@B>6C6D6E6F

Æ\ïFÈ?ýÍBØfÓdõTÍÐYÕO×[ÑÿÖQËDÕOßÐsÚ\ÖQÓ+Ø
Æ\â}ËDßÝÇ È%Ý

éJÓ+Î`ÏÐYËDÌÍ+ÐsÓBÚÒ9ÓBÔxÍ

Fig. 16 Rear Propeller Shaft

¿\ÀTÁ}ÂÃÄ4ÄBÃ4Â¿ Å6À
Æ%Ç,È?É9ÊËDÌJÍ"Î`ÏOÍÐYÊDËDÑÒ9ÓBÔxÍ"Ó+ÕÎ`ÏOÍÎdÖ%×JÕ4ÐYØfËDÐYÐFËDÓBÕlÙyÎ`ÖQ×[ÕOÐYÚÍBÖ
×Û [ÐYÍtÓBÜOÎ`ÑÜOÎ_ÐYÏO×[ÚÎdÝÞqÊDËDßÕàÎ`ÏOÍËDÕOÐFÎ`×JÊDÊD×[ÎdËDÓ+ÕàÖQÍBÚ\Í+ÖQÍBÕ Û Í
Øf×[ÖQÔxÐH×[Î(Î`ÏOÍ×FáTÊDÍÒ9ÓBÔxÍ×[ÕOÌËDÕOÐFÎd×[ÊDÊ
ÎdÏOÍ6ÑÖQÓBÑJÍBÊDÊDÍBÖgÐFÏO×[Ú\Î
Æ\â}ËDßÝÇFãFÈ%Ý
Æ\äFÈfå(ËßÏOÎ`ÍBÕÎ`ÏOÍtæqç è+ÓBËDÕ4Î_ÐYÎ`ÖQ×[ÑÙ Û ÊD×[ØfÑé[ÓBÊDÎ`Ð§×[Î_Î`ÏOÍ
×FáTÊDÍqÒTÓ+Ô4ÍÎ`Ó¨ÇYê ëqì ØÆ%ÇFíÚÎdÝªÊé[ÐFÝ ÈÎ`ÓBÖ%îJÜOÍ+Ý
Æ\ïFÈ?ðÖQËDØfÑ Û Ê×[ØfÑñÎdÓÏOÓ+ÊÌñÌÜOÐFÎéJÓ+ÓBÎÎ`ÓzÑJÖQÓBÑJÍBÊDÊDÍBÖ
ÐFÏO×[Ú\ÎÒTÓ+Ô4ÍÆ\â}ËDßÝÇFòFÈ%Ý
Æ\íFÈ?ó}Óô|Í+Ö"Î`ÏOÍqõTÍ+ÏOË Û ÊDÍBÝ

Fig. 18 Remove Snap Ring

Æ\íFÈ?É9ÍBÎ"ÎdÏOÍ|ÒTÓBÔxÍ?ËDÕv×[Õv×[ÖQé[ÓBÖnÑÖQÍ+ÐYÐ~ÓBÖ6õTËDÐFÍfô|ËDÎ`Ïv×
ÐYÓ Û ÔxÍBÎXô|ÏOÓ+ÐYÍËDÕOÐYËDÌÍÌËD×[ØfÍBÎ`ÍBÖËDÐzÊD×JÖQßÍÿÍ+ÕOÓBÜOßÏ Î`Ó
ÖQÍ Û ÍBË õTÍÎ`ÏOÍéJÍ+×[ÖQËDÕOß Û ×JÑ?ÑÓ+ÐYËDÎ`ËÓ+ÕOÍ+ÌLé[ÍBÕ4ÍB×[ÎdÏXÎ`ÏOÍqÒTÓ+Ô4Í+Ý
Æ F

È }ÓBÐYËDÎ`ËDÓBÕàÎ`ÏOÍ¯ÒTÓBÔxÍ¯ô|ËDÎdÏÎdÏOÍtßÖQÍ+×[ÐYÍtÚ\ËDÎdÎ`ËDÕOßü~ËDÚ
ÍBî[ÜOËDÑÑJÍBÌüªÑÓBËDÕOÎ`ËDÕOßÜOÑÝ
Æ\ãF
È }Ê× Û Í × ÐYÓ Û ÔxÍBÎñô"ËDÎdÏ ×[Õ ÓBÜ4ÎdÐFËÌJÍ ÌËD×[ØfÍBÎ`ÍBÖ
ÐYØ|×JÊDÊDÍBÖ¯Î`ÏO×[ÕÿÎ`ÏOÍ§Ü4ÑÑÍ+Öé[ÍB×[ÖQËDÕOß Û ×[ÑzÓBÕÎ`ÏOÍ§ÜOÑJÑÍBÖ
é[ÍB×[ÖQËDÕOß Û ×JÑ×[ÕOÌÑÖQÍBÐFÐÎdÏOÍ Û ×[ÑvÎ`ÏOÖQÓ+ÜOßÏ§ÎdÏ4ÍnÒ9ÓBÔxÍ¨ÎdÓ
ÖQÍBÊDÍ+×JÐFÍÎdÏ4ÍÊÓdô|ÍBÖé[ÍB×[ÖQËDÕOß Û ×[ÑLÆâiËDßÝgÇYêFÈ%Ý

Fig. 17 Crimping Dust Boot Clamp

DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT
ö(¿ Á}ÃiÁ}Á÷xø~ùiÄ`ú
û ÕOÌJË õ9ËÌJÜO×[Ê Û Ó+ØfÑÓBÕ4ÍBÕOÎ`Ð¯Ó+Ú Û ×JÖ%Ì×[ÕÜ4ÕOË õTÍBÖ%ÐY×[ÊèÓBËDÕOÎ`Ð
×[ÖQÍÕOÓBÎgÐYÍBÖ\õTË Û ÍB×[é[ÊDÍBÝ û Ú
ô"ÓBÖQÕ¨ÓBÖÊDÍB×[ÔxËÕ4ßüªÎ`ÏOÍdÒ_ØfÜ4ÐYÎé[Í
ÖQÍ+ÑÊD× Û Í+Ì?×JÐ|×[ÕX×JÐFÐYÍ+Øfé[Ê ÒlÝ
Æ%Ç,È?ýÍBØ|ÓõTÍÎ`ÏOÍÑÖQÓ+ÑÍBÊDÊDÍBÖÐYÏ4×JÚÎdÝ
Æ\äFÈ?æqÐFËDÕOß?×¨ÐFÓBÚ\Î6ÌÖQËDÚ\Î`ü(Î`×[ÑXÎdÏ4ÍÓBÜOÎ`ÐFËÌJÍÓBÚgÎ`ÏOÍé[ÍB×[Öþç
ËDÕOß Û ×[ÑL×[ÐFÐYÍ+ØféJÊ Ò_Î`ÓnÊDÓ+ÓBÐFÍBÕXÐYÕO×[Ñ?ÖQËDÕOßÝ

Fig. 19 Press Out Bearing

º»¼½

¾¿\ÀÀÁÂÁÃÄ¿ ÅÆÅÃ¾.¾Â¿ ÇÁÆ¿ ÃÁ

ÈÉ

Ê_ËÌÍ&ÌÌÎÏ|ÐbÑtÒÓÍ&Ô1ÊÓÍ&ÌÌÎÏ)Ð&ÑtÒ3ÕÖ&×6Ø6ÙAÚBØ6Û6Ü6Ý6Þ
GHJIKML6NPORQTSUQWVUXZY\[R]_^ZVU`8abY
c\cd[ReAN`gfRc\c6eAfRNeWLNhORQijeWkQ
SJiORVU[RlmVUL
NPQAXn`XZQWoJopY\[R]rqNPVU`mNhORQsiteWkQuQAVgXn[vQWVUXnNhORQ
SUQWVUXZY\[R]_^ZVU`wNhe+lY\opc\eAl]xQ+NhORQ+^ZVU`y
GzJI8{e|XZQA}8eM~tQ|NPORQeW``eAopY\NhQ|SUQWVUXZY\[R]u^ZVU`qNhfRXZ[mNhORQ
ijeAkQeM~tQWXVU[RlnoJNPXZVUY\]xOvNPQA[)NPOvQ^ZXZeAopoTY\[)NhORQ1eW`QA[)OReWc\QAy
{7ORQW[Rq#^ZVUXZQWL
fRc\c i`XZQWoJoNhORQwQA[RlueWLNhORQw^ZXeWopo_fR[RNhY\cNhORQ
XZQA}8VgY\[RY\[R]_SUQWVUXZY\[R]_^ZVU`w^Vg[SUQ+XZQW}8eP~jQWlGY\]xyUJIy

CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.

Fig. 21 Install Cross In Yoke

Fig. 20 Press Out Remaining Bearing
7vP
GBI8``gc iQPjNhXZQW}8Q_`XQWopoJfRXZQ_GdgIy y #yKPy6XZVUlQ)
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Y\NP
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VU^ZQV¡SUQWVUXZY\[R]¢^Vg`£eP~jQAX¤NPORQNPXfR[R[RY\eW[¥VU[Rl
VUc\Y
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[RQAQWlc\Q|SUQWVUXZY\[R]rowfR`XZY\]xOvN1Y\[¤NhORQ|SUQAVgXZY\[R]uVUoJopQA}8Sgc i§y
[RQAQWlc\Q¨SgQAVUXZY\[R]©c ijY\[R]ªVUNNhORQ¨SgeANhNPeA}«eWL8NPOvQu^ZVU`)abY
c\c
`XZQP~jQA[RN`XZeA`QWX&VUopoJQW}8SUc iry
G¬JIXZQWoJoNPORQ®SUQAVgXZY\[R]¯^ZVU`3Y\[RNPe®NhORQ°iteWkQ®SgeAXZQ
QW[veWfR]rO|Nhe+Y\[RopNhVUc
cdVsop[vVg`XZY\[R]xy
G±JIKM[RoJNhVgc\c6Vop[RVU`XZY\[R]xy

Fig. 22 Install Bearing On Trunnion

DOUBLE CARDAN JOINT
¶6· #v1h

G²JI³dQW`gQWVUNb´jNhQW`) |VU[Rl¨´tNPQA`¨¬|NhesY
[vopNhVgc\cNhORQseW``geW

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lgfRVUc+^ZeA}8`eW[vQW[RNho¨eAL1^ZVgXZlgVU[¸fv[RY ~jQWXZoJVUcdµeWY\[RNho

oJY
NhQSUQWVUXZY\[R]+^ZVU`yKMLNhORQµeWY\[RN#Y\oopNhY
L
LeWXSUY\[RlY\[R]xqoJNPXZY\kQ

VUXZQT[ReWNopQWX~jY\^ZQWVUSUc\QWyKPLabeWXZ[neWXc\QWVUkvY\[R]rqNhORQMi|}8fvopNSUQ

NhORQ#ijeWkQ#aY\NhOV+opeWL
N7ORVU}8}8QWXNheoJQWVUN7NhORQb[RQWQAlc\QbSgQAVUX

XZQA`c\Vg^ZQAlVgoVU[VgoJopQA}8SUc i§y

Y\[R]xoJy
GHJI8ll]xXZQAVUopQ+Nhe1c\fRSUQ+LY\NhNPY\[R]rqY\LQWUfRY\``QAly
GzJIKM[RoJNhVgc\c6NhORQ+`XZeA`QAc
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GBI³dQW}8eP~jQ+NhORQ+`XZeA`QWc\c\QWX&opORVUL
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GJI¹oJY\[R]VnoJeWLNlXZY\LNhq6NhVU`NPOvQ_eWfRNhoJY
lgQ_eWLNhORQ_SUQWVUX<
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"!#!#$&%

$('

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%

2
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798:<;=:<:<><?A@CBEDF;=GH7F;=:<:<><?I@=BEDKJML=N-O-PQRO-S-T-U-V
ßàJáâdãWäåMæjã©çgè\è1éhêRãìëUãWçUíZî\ïRðmñZçgòôópïRçUò.íZî\ïRðróß
õî\ðxö
÷ àJáö

ß
JáíZçUóJò_éhêRãbòíZåAéPíÿRþî\ïRðTëUãWçUíZî\ïRðTë æjî\óJãúAçJûóJöçUò
åWüãûî\éhê|çsäçgè\è\ãWéçUïRþþíZî
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ëUãWçUíZî\ïRð_ñZçUò
íZåWäéPêRã

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÷ pá<ö

Fig. 23 Remove Snap Rings
ßøJáùtãWééhêRãúåWî\ïRébî
ïªçUïªçUíZëgåAí1òíZãWóJó_åWíætî
óJã8ûî\éhêªç
óJåWñZüãWéûêRåAópãýî\ïRópî\þãýþî\çUä8ãWéhãWíôî\ó.è\çgíZðrã°ãAïRåWÿRðrê

éhå

íZãAñZãWî æjãnéhêRãnëUãWçUíZî\ïRð)ñZçUòòåWóJî\éPî\åAïRãWþëUãWïvãWçUéPêìéhêRãnè\î\ïRü
åAüãWö
ßJáè
çUñZã«ç

ópåAñZüãWé¢ûbî\éPê

çUï

åWÿvéPóJî\þã«þî\çUä8ãWéhãWí

óJä8çgè\è\ãWí¨éhêRçUïýéPêRãìÿvòòãAíuëUãWçUíZî\ïRð¤ñZçUò.åWïýéhêRãìÿRògòãWí

Fig. 25 Remove Bearing From Yoke
ßJáõè
î\òuçUópóJãWä8ëUè
çUïRþuíZãWògãWçUé8ùtéPãAòuøùtéPãAòçUïRþ
ùtéPãAò
éhå1íZãWä8åPæjã1éhêRã1åWòògåWóJî
éhã1ëUãWçUíZî\ïRðñZçUòö#êRî\óûbî
è\è
éhêRãWï|çUè\è\åMûíZãAä8åMæjçUè6å7éhêRã1ñZíZåAópóñZãWïRéhãWíZî\ïRð_üvî\éçUóJópãAä
ëUè

çUïRþópògíZî\ïRð_ßõî\ðrö

÷
pá<ö

ëUãWçUíZî\ïRð+ñZçUòçUïRþ_òçUíZéPî\çUè\è òíZãAópóåWïvã8ëUãAçgíZî\ïRð+ñZçUò
íZåWä
éhêRãnåWÿvéPëUåWçUíZþóJî
þgãnåéhêRãnè\î\ïRü åAüvãnãAïRåAÿRðxêìéhånðxíZçUópò
éhêRãëUãWçUíZî\ïRðwñZçUò_ûbî
éhêsæjî\ópã#úçJûó1ßõî\ðxö

÷ øJáö
dãóJÿRíZãéhå

íZãAä8åMæjã+ðríZãWçUópã
î
éhéhî
ïvðxóéhêRçUéî
ïvéPãAí ãWíãûbî\éPêíZãWä8åPæjçUè\ö

Fig. 26 Remove Centering Kit
ßJáíZãWóJóéhêRãíZãAä8çUî
ïvî
ïvð+ëUãWçUíZî\ïRð+ñZçUòóåWÿvé#éhêRãåAéhêRãWí
ãWïvþ)åéhêRãè\î\ïRü
éhêRã+þî\ópçUóJópãWäëgè ö

Fig. 24 Press Out Bearing

åAüvãçUó1þãWóJñZíZî\ëUãWþ|çgëUåMætãéPåñZåAä8òè\ãWéhã

ÐÑ¦Ò#Ó

Ô

ÕÖ&Ö#×#Ø

×(Ù

Ú*Õ Û
ÜÛtÙ0Ô1Ô

Ø

Õ Ý
×#Ü&Õ Ù0×

Þdß

à9áâ<ã=â<â<ä<åAæCçEèFã=éHàFã=â<â<ä<åIæ=çEèKêMë=ì-í-îïRí-ð-ñ-ò-ó
WYX*X[Z\^]Y_a`
bdcfehgjifkmlnnoqprts u&vCo#ifncfehoxwzyfl{w|wzyfoxlsRgRk{ifpo#ifw
pl{eh}Yn~iKwzyfosgji*}u
u

~{}*ol{ifYeh~{Yo#ssRoqenyflaw

ÄY a·{Å²§ ®¯ «Æµ §
·{ ©± Ç² ©
® ¯ ©
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§ ®¯ «9´ ® «¬¡ÈªÉM¡
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Fig. 29 Press In Bearing Cap
Ë´Y ® xa·{Ã# © #
A·{§ ° ©± Â§ ¯ ¨
®"¯ §q·{
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a
¡ ¤ ¯ a§|§
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© # © ® 1 ¯{¯®"©¯
¯ §q ®¯ «9´ ® «¸¡ÈºÌM¡

Fig. 27 Install Cross In Yoke
ºY"§µ m§»²§ ® ¯ «¼µM§q
¾a·{maM ¯{¯{®©¯
§ ¯ ¨
©a½
§ ® « ¯
a·{Hµ §q¿ ® ·I·{ ©± ^
² ©
^´ ® «¸¡ªÀM¡ Á¦|·{
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¯ ¨#A²§ ® ¯ «¬{# ® «¸· ®¯

#
¨

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q
²

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Ã
«

§

{
·
¶

² © ©
¯
® ¯
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© ° a·µ §I¿ ®

# ½ ¯ 0# © #=§² ¬¡

Fig. 30 Press In Bearing Cap
¹´ ® ·{Í ®¯{±
·{Í § ® ¯{®¯ I
«
Î¿ ©
¯ ³
© ±
©¯
·
²§ ®¯ «Âµ §#
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q
« ¡
¯{®©¯ A§ ¯ ¨¾#MI² © aÏ
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ºtRM¡
À¤ ¯ §q- ¯ § ®"¯ «¸¡

Fig. 28 Install Bearing Cap

W
3B>Y= X=¢¡*£¤¥¦ §¨¥©ª«¬

#
V$ ;G G

! #"$&%(') *%

Fig. 33 Install Remaining Cross

Fig. 31 Install Link Yoke

ôõö÷ùø{úûüqýýHûþ{ÿ

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Fig. 34 Press In Bearing Cap

CLEANING AND INSPECTION
SINGLE
*+ .K AND DOUBLE
H CARDAN
(NV WJOINT

/ X0Y
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102332
Install
* 4. /Centering
5 Kit ! 4#

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SPECIFICATIONS
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181 FBI AXLE

"!#$&%
page
GENERAL INFORMATION
181 FBI AXLE . . . . . . . . . . . . . . . .
LUBRICANT SPECIFICATIONS . . .
DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL . . . . .
DIAGNOSIS AND TESTING
BEARING NOISE . . . . . . . . . . . . .
DRIVELINE SNAP . . . . . . . . . . . .
FRONT AXLES . . . . . . . . . . . . . . .
GEAR NOISE . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . .
LOW SPEED KNOCK . . . . . . . . . .
VIBRATION . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . .
REMOVAL AND INSTALLATION
AXLE BUSHING REPLACEMENT .
AXLE SHAFT OIL SEAL . . . . . . . .
AXLE SHAFT—CARDAN U-JOINT
COLLAPSIBLE SPACER . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . .
DIFFERENTIAL SIDE BEARINGS .

. . . . . . . . . . . 15
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GENERAL INFORMATION
181
FBI,/.0AXLE
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page
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . .
HUB BEARING AND AXLE SHAFT . . . . . .
PINION GEAR . . . . . . . . . . . . . . . . . . . . .
PINION SHAFT SEAL . . . . . . . . . . . . . . . .
RING GEAR . . . . . . . . . . . . . . . . . . . . . . .
STEERING KNUCKLE AND BALL STUDS .
DISASSEMBLY AND ASSEMBLY
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . .
STANDARD DIFFERENTIAL . . . . . . . . . .
CLEANING AND INSPECTION
AXLE COMPONENTS . . . . . . . . . . . . . . . .
CARDAN U-JOINT . . . . . . . . . . . . . . . . . .
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH . . . . . . . . . . . . . . . . .
GEAR CONTACT PATTERN ANALYSIS . . .
PINION GEAR DEPTH . . . . . . . . . . . . . . .
SPECIFICATIONS
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . .
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . .

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Fig. 7 Pinion Seal Installation

MX [
jenac]uku }xv_dvjacbedmikjeikvEjld]gh+wyika{bjenac]ukukdh
»²ZYggÀÁUtTm~´¿Y½g¸¦]jT~¶WvEudh+¸gg´XMPiklRzU´[Zz

Fig. 8 Pinion Yoke Installation
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bearings may result.

Fig. 6 Pinion Yoke Removal

ZX Y½[
µnd] nteikac]fgukdmh}¾a{vEvu¨vh«]£nuikdbe]g<<dh
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jenac]ukuacbed+mijTivEjwy]gnbedEh]gje6]Âjedw¡jetea vj%acbed
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COLLAPSIBLE SPACER

Fig. 9 Check Pinion Rotation Torque
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been damaged. Replace the collapsible spacer.

Fig. 10 Tightening Pinion Shaft Nut—Typical

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Fig. 11 Pinion Yoke Removal

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Fig. 13 Collapsible Preload Spacer

Fig. 14 Pinion Seal Installation
Ì èÎ LÔÒÚÐ ÞÞí3Ø"åNÓMâ]ÑÚÛ
LÔÒÚÐÞÞÓ"Ù¡ýò¶Í/îàò=éUû;Ö×FóÿÍú öé
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Ì î
Î Læ¨ÚÛÓOØ"Ù$ÑïÑÔÐÞ× ÑÔÑØ"Ô{ã ÓÐÙ$ÑÔïÒÐÙ$ÓOãÓ"ÑÔï+ÖÒÓ"ÕVé
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Ò/ÐÙ|í ß
Fig. 12 Remove Pinion Gear
É ÊÄÅ*Å"ÄÉ ÂdÊ
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NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
Ì ð
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•

Fig. 15 Pinion Yoke Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded, a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
ijlk mnlo6pq rsct7uwvscxy*u$z {}|}~}j}pys$z&*uzucpv
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o6pzucu$pn¥pox¦vu§zs$}o6pq¨s$z}u§on¥}vo6uª©u$y

Fig. 17 Check Pinion Gear Rotation Torque—Typical

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HUB
BEARING AND AXLE SHAFT
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Fig. 16 Tightening Pinion Nut

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Fig. 18 Hub, Knuckle and Axle Shaft

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Fig. 20 Hub Bearing and Axle Assembly

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Fig. 19 Hub Bearing Bolts

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¼'½ÀÀ(ÁÃÎÏê)Î)¾Äê »Àº+ÁË<ÒFÓÀ(ÌÀ(Á@½0ÆíaÁÆ¾Å[×+îFï¾¼ÅqÀ(Î¼ÃÆ(Îî
ÌÆÁxÅqÁ Æ(ÅqÀÁxÅqÁ Æ(ÄÀ(¿;¾ÁÀ(¼Ò

STEERING
KNUCKLE AND BALL STUDS
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¾¼ÀÆ(ÌCÔLÆ(Æ»{ÕaÃ½sÖ+×+Ø;Ù+Ò

57698%:

AXLE
BUSHING REPLACEMENT
ÓÀ(ÌÀ(Á½0Æ í§ÁÆ(¾Å}×+îhï¾¼ÅqÀ(Î)¼'ÃÆ(Î)îhÌÆÁ½ÍÀ Å;ÁÆ(ÅqÀÁºÑ»À
Ç+¾¼'Í)ÃÎ)Ï?Å;ÁÆ(ÄÀ¿q¾ÁÀ¼'Ò

ÚÛ{Ü.Ý§ÚÞ)ß[à{ß)áâ{ãähÞ
å æZç

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å × çXè Ã¼ÄÆ(ÎÎ)À(Ä½[½ÍÀ:½0ÃÀéÁÆ¿ÆÁ~¿qÁ º;Ïl»ÃÎêëÌÁÆËì½ÍÀ
¼½0ÀÀ(ÁÃÎÏê)Î)¾Äê »Àº+ÁË<ÒFÓÀÌÀ(Á@½0ÆíaÁÆ¾Å[×+îFï¾¼ÅqÀ(Î)¼'ÃÆ(Îî
ÌÆÁxÅ;ÁÆ(ÅqÀÁxÅ;ÁÆ(ÄÀ¿q¾ÁÀ(¼Ò
åðç ÓÀ(Ë"ÆÂ.Àl½0Í)ÀñÄÆ½0½À(Á^ÅqÃÎ¼:ÌÁÆ(Ëò½0ÍÀl¾ÅqÅ;À(Á8º+Î¿
»ÆÈxÀ(ÁxÇ+º+»»{¼½0¾¿;¼'Ò
åóç ÓÀ(Ë"ÆÂ.À½ÍÀ¾ÅqÅ;À(Áxº+Î¿X»ÆÈxÀ(Á@Ç;º+»»{¼½0¾¿XÎ¾)½0¼Ò
åôç ï½0ÁÃê À½ÍÀ$¼'½À(ÀÁÃÎÏXê Î¾Äê »À@ÈxÃ½0Í}ºnÇ+Áº+¼'¼Íº+Ë<é
Ë<ÀÁ?½Æn»Æ(Æ(¼À(Îmê Î¾Äê »ÀnÌÁÆ(Ëõ½ÍÀnÇ+º;»»j¼½¾¿q¼ÒÓÀ(Ë<Æ0Â.À
ê Î¾Äê »ÀÌÁÆ(ËöÇ+º;»»{¼½¾¿q¼ å÷ ÃÏÒF× æZç Ò

DIFFERENTIAL
à{ß)ájâ{ãä§Þ
å æZç
å × ç

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¿qÃÌÌÀ(ÁÀÎ½0Ãº+»{ÍÆ¾¼ÃÎ)Ï?ÄÆ0Â.ÀÁIÒ
åðç ÓÀ(Ë<Æ0Â.À
½ÍÀA¿qÃÌÌÀÁÀ(Î½Ãº+» ÍÆ¾¼ÃÎ)ÏõÄÆÂÀ(Áöº+Î¿
º+»»Æ0È
Ì»¾Ã¿[½Æ¿qÁº+ÃÎÒ
åóç ÓÀ(Ë<Æ0Â.ÀÍ¾Ç?Ç;Àº+ÁÃÎÏ¼"º+Î¿Xº'Ñ»À¼Íº+Ì½¼'Ò
åôç Æ½0À½0Í)À$ÃÎ¼½0º+»»º;½ÃÆ(Î}ÁÀÌÀÁÀ(ÎÄÀ»À(½½0ÀÁ¼¼½º;Ë<Å;À(¿
Æ(Îñ½ÍÀ~Ç+Àº;ÁÃÎÏ^Äº+Åq¼nº+Î¿JÍ)Æ(¾¼ÃÎÏ8Ë"º;ÄÍ)ÃÎ)À(¿m¼'À(º+»ÃÎÏ
¼'¾)ÁÌº+ÄÀ å÷ ÃÏoÒF× óç Ò
å Ö ç
Æ(Æ(¼À(Î½ÍÀ¿qÃÌÌÀÁÀ(Î½Ãº+»{Ç+À(º+ÁÃÎÏÄº+Å[Ç+Æ(»½¼'Ò
å çXý Æ(¼'Ã½ÃÆ(Î¯ï.Å;ÁÀ(º+¿qÀÁ
æ ×+Ù ;¹îJ¾½0Ã»Ã ÃÎÏõ¼'ÆË<À
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ÅqÃÎ¼j¼'Àº;½À(¿$ÃÎ ½0ÍÀx»Æ(Äº+½0ÃÎÏÍÆ(»À¼ å÷ ÃÏÒC× ô'ç Ò Î¼'½º+»»1½ÍÀ
ÍÆ»¿;¿qÆÈxÎ Ä»º;Ë"Åq¼jº+Î¿$½ÃÏÍ½À(Î?½0ÍÀ@½0ÆÆ(»L½¾ÁÎÇ+¾Äê »ÀxÌÃÎé
ÏÀÁ +½0ÃÏÍ)½0Ò
å Ø ç
Î¼½º;»»Fº$ía¾Ã¿;À ý ÃÎ
é ð ×+Ø;Ø+é¹8º;½§½ÍÀ"»ÀÌ½§¼'Ã¿;À<ÆÌ
½ÍÀ¿qÃÌÌÀÁÀ(Î)½0Ãº+»ÍÆ¾¼'ÃÎÏoÒ ½0½º+ÄÍ è Ãº;» Î¿qÃÄº+½Æ(Á
é ð+ð;ð Ù
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ÃÎ¿qÃÄº+½Æ(ÁIÒ

CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
å Ù ç ïÅqÁÀ(º+¿}½ÍÀ ÍÆ¾¼'ÃÎÏnÀÎÆ(¾ÏoÍ^½0Æ ÁÀË<ÆÂÀ ½0ÍÀ ¿;ÃÌé
ÌÀÁÀ(Î½Ãº+»?Äº+¼ÀlÌÁÆË
½ÍÀJÍÆ(¾¼ÃÎÏÒ Àº+¼'¾ÁÀJ½0ÍÀJ¿qÃ¼'é
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å æ ç ÓÀ(Ë<Æ0Â.À½ÍÀ¿qÃº;»ÃÎ)¿qÃÄº+½0ÆÁIÒ
å æ(æZç 9ÍÃ»À"ÍÆ»¿qÃÎÏ½0ÍÀx¿qÃÌÌÀ(ÁÀÎ½Ãº+»1Äº+¼'ÀxÃÎXÅ;Æ(¼Ã½ÃÆ(Îî
ÁÀË<ÆÂ.À½ÍÀ¿qÃÌÌÀ(ÁÀÎ½0Ãº+»{Ç+À(º+ÁÃÎÏÄº+Å[Ç+Æ»½¼"º+Î¿XÄº+Åq¼'Ò
å æ × ç ÓÀ(Ë<Æ0Â.À
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ÅqÆ¼'Ã½ÃÆÎ7ÆÎ½0ÍÀ¿qÃÌÌÀ(ÁÀÎ½Ãº;»{Ç+Àº;Á ÃÎ)Ï¼ å÷ ÃÏoÒF×+Ø ç Ò
å æðç º+ÁêmÆ(Á ½º;Ï9½ÍÀ7¿;ÃÌÌÀÁÀ(Î½Ãº;»Ç+À(º+ÁÃÎÏ9Ä¾)Åq¼[½Æ
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Æ(Ì~½0ÍÀ ¿qÃÌÌÀ(ÁÀÎ½Ãº+»}½ÍÀ &ÈxÀ(ÁÀ
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å æóç ÓÀ(Ë<Æ0Â.À¼'Å;ÁÀ(º+¿qÀÁxÌÁÆË
Í)Æ(¾¼ÃÎÏÒ

Fig. 21 Steering Knuckle Removal/Installation

Ü{øøLß)àJù;ä§Þ)ÞúûFÜ{üJà{ß)øLÞ(äÝ§ß)áß)Û.û

å æZçXý Æ(¼Ã½ÃÆ(Îm½Æ(Æ»¼?º+¼ ¼'ÍÆ0È"Îm½ÆnÁÀË<ÆÂ.À[º;Î)¿^ÃÎ)¼'½º;»»
Ç+º+»»¼'½¾¿ å÷ ÃÏoÒF×+× ç Ò
Þ(â{þ8ß)àJùqähÞ)ÞúûFÜ{ülàß)øLÞ(äÝ§ß)áß)Û.û
å æZçXý (
Æ ¼Ã½ÃÆ(Îm½Æ(Æ»¼?º+¼ ¼'ÍÆ0È"Îm½ÆnÁÀË<ÆÂ.À[º;Î)¿^ÃÎ)¼'½º;»»
Ç+º+»»¼'½¾¿ å÷ ÃÏoÒF× ð'ç Ò
ÚÛ{Ü.Ý§ÚÞ)ß[ÿÛ.úLûoähÞ)Þ(ä)ûFÿ âjÛ
å æZçXý (
Æ ¼Ã½ÃÆ(ÎX½ÍÀx¼'½À(ÀÁÃÎÏê Î¾Äê »À"ÆÎX½0Í)À"Ç+º+»»1¼½0¾)¿q¼'Ò
å × ç
Î
¼ ½º;»»Vº+Î¿ ½ÃÏÍ½À(În½ÍÀ<Ç;Æ½½0ÆË
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ý ÁÀ»Æ(º+¿&º;Î)¿&íaÀ(º+Ál¹º+Äê)»º+¼Í
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Å;ÁÆ(ÄÀé
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\7]_^%` a"bc(c%d%e"d*f"g,b h4i7hjf1a2a"e"b k4d%i(b f1d
o=p?qArs9t=u2t=vGwIx$vGy?z"t=u/u/tLzMx$rGvO{Q|=}/~/VW~////

Fig. 22 Upper Ball Stud Remove/Install

Fig. 23 Lower Ball Stud Remove/Install

lnm

ãä
ó=ô?õAö÷9ø=ù2ø=úGûIü$úGý?þ"ø=ù/ù/øLþMü$öGúOÿ

å"æ$ç%ç%è(é"è*ê"ë,æ ì/íì0ê1å2å"é"æ î4è%í%æ ê1è

Fig. 24 Bearing Cap Identification

Fig. 26 Install Dial Indicator

WFig.
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VHousing

¢¡¤Spreader
£¥$¦§*¥¨©VªM
ªM«$ª¬n%VA_¯®°±¡_²³´´µV¦%²³¦
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Housing

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£¥¥¨ÐVAxle
¥£µ¨¼´Ñ
7$µ¦$¦_´µ¸
Ò´¥Ó´µ£¥¥¨¼»?Ô¶£µÓ´¥Óµ¸G²·$´Ò´¥Ð%¦
¥%¸·$º,¨¼»Õ±Q»

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CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.

ï7ð9ñ%ò

k{+

p-Y++ppI kajxpp +Y j

)x ~¡£¢. ~¤¥pf¥h¢.~ §¦¨©ª«¬ ª®¯°

Fig. 28 Differential Case Removal

Fig. 30 Differential Bearing Cap Reference Letters

Fig. 29 Install Axle Housing Spreader

DIFFERENTIAL SIDE BEARINGS

"!$#&%')(+*-,.,/"012435*.6879168:;),/01#"!<6;='7-)>4#"?4:;*-24@BA
/C; "!$#&%')35>4)D8"6801*-24@E:$,/01#"!<35>4)(+*-,/,."01243F*-6879168:;
*
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7
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1
9
Y
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R
6824([HK7-?4@]\'HKN/P8C8^8O_/`K*.@EAZPa A
W
b/c'dKeBf"eZb c
g ,01V+7-6891"!h243h(i*-,/,/01"2435*-6i7j:;*-(+[D8"6801*-24@E:k#"0l(i*.,.,/0N
"23F*-687 9168:;m6i01mD8*.2@l*.2:n35687.7-(+Ro(i*.,.,/"012435*-6i7p:n*-(+mD86i0N
*-24@q:;>4*-!r01s8?4*-01"!h243F:t!$6nuv91>6i2@B"Ak ",."0w3F#x35>4
y *-,/,."012435*.687 W "6801*-24@lHI017-#"68(6824(_z{"680 W 6891XY7-68:n>|Vi01#"N
91(+?401:$*.2|35>4*-:$:n9135*.#2|3F#)(i"35"01!h*-24)35>4)V+01#V+0}:;>4*-!
:;"7-"9135*-#"24A

Fig. 31 Differential Bearing Removal

g 24:;356i7-7(+*-,/,."01243F*-687:n*-(+)D8"6801*-24@k:;>4*-!h:$#"2435#~(i*.,.N

,/01"2435*-6879168:n)>4?4D8:;A
/C;S:;*-24@ g 24:;3F687-7-"0L N/P8a;iN Q6824(6i2(+7-L N/a;anR
*-24:n35687-7(+*-,/,."01243F*-687:;*-(+)Di6801*.2@B:$/`K*-@BAZP8C;A
/P; g 24:;356i7-7(i*.,.,/"0"2435*-6i7 *.2|6;='7-)>4#"?:n*-24@BA

!#"%$'&)(*#+*#,.-0/
,.1%2*#++*324/
&.,6587#9:;=<>:?@AB

Fig. 32 Differential Side Bearing Installation

Fig. 33 Axle Seal Installation

AXLE SHAFT OIL SEAL
±²³´µ¶·
¸¹ º» 8
¼ ½-¾n¿)¼8À4Á¾nÂ4ÃiÃ+Ä"Å1ÆpÇ¿"È4½-É1Ê-¿"Ë
¸/Ì;º» "
¿ Í$Ä&Ç'¿)Á+½-Î.Î/¿"Å1¿À4Æ5½.¼8Ê¼8¾;¾n¿ÍhÏiÊ ÐÑË
¸/Ò;º» "
¿ Í$Ä&Ç'¿[ÆFÈ¿Ó½-À4À4¿Å]¼nÔÊ-¿Ó¾;È4¼8Î/Æh¾n¿"¼8Ê-¾}Õ$½-ÆFÈÖ¼×ÃiÅØÐ
Ï8¼;ÐEË
Ù/Ú'ÛKÜB¶f··"¶ÜZÙ ´Ú
¸¹ º» ¿"Í$Ä&Ç'¿Ý¼8ÀÑÐÞ¾n¿¼8Ê.¿ÅßÅ¿"Íh¼8½-À4½-À4àáÎ/Å1Ä"ÍUÄ"Å½.àE½.À¼iÊ
¾;¿"¼8Ê-¾nË
¸/Ì;º» ¿"Í$Ä&Ç'¿~¾n¿¼iÊ-¿Å$Î/Å1Ä"Ív¼;Ô'Ê-¿~ÆFÂ4Ï8¿~ÆFÄ~È4Ä"Â4¾;½-À4à{âÂ4À4É1ã
Æ5½-Ä"À4äZ½-ÎÀ4¿É1¿"¾;¾n¼8ÅØÐÑË
¸/Ò;ºå&À4¾;Æ5¼iÊ-ÊÓÄ"½-ÊÓ¾n¿¼8Ê.¾æÕ$½-Æ5Èç{½-¾nÉ¾éèa¹"¹;êÝ¼iÀÁìëZÂ4Å1Àã
Ï8Â4É1íYÊ-¿hî8ï8ðiïl¸/ñK½-àBËKÒ8ÒnºËië½-àBÈÆF¿À[Æ5Ä"Ä"ÊZÂ4ÀÆF½-ÊZÁ+½-¾nÉÏ8ÄÆFÆ5Ä"Íh¾
½-ÀòÈÄ"Â4¾;½-À4àBË
¸/ó;ºå&À4¾;Æ5¼iÊ-ÊÁi½.Î.Î/¿"Å¿"À4Æ5½-¼iÊ ¼i¾;¾n¿ÍhÏ8Ê ÐÑË

Fig. 34 Ring Gear Removal

Ù/Ú'ÛKÜB¶f··"¶ÜZÙ ´Ú

RING
GEAR
ëÈ¿}Å½.Ààm¼8À4Á~Ã+½-À4½-Ä"ÀkàB¿¼8Å1¾S¼iÅ1¿¾;¿"ÅØÇ½.É1¿½-Àk¼)Íh¼8ÆFÉ1È¿"Á
¾;¿"Æ5Ëç{Ä|ÀÄ"ÆmÅ1¿"ÃiÊ.¼8É1¿ÓÆFÈ¿|Å1½-À4ààB¿"¼8Å}Õ}½.Æ5È4ÄÂ4ÆmÅ1¿"Ã+Ê-¼8É1½-À4à
Æ5È4¿)Ã+½-À4½-Ä"À|àB¿¼iÅ Ë

CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.

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Fig. 37 Pinion Yoke Removal

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Fig. 35 Ring Gear Bolt Installation

PINION
CDFEHGJI
GEAR
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Fig. 38 Remove Pinion Gear

Fig. 36 Pinion Yoke Holder—Typical

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Fig. 39 Front Bearing Cup Removal

Fig. 41 Collapsible Spacer

NOTE: The pinion depth shims can be very thin.
Verify that all shims have been removed before proceeding.

Fig. 42 Inner Bearing Removal
,.-0/
13254 42 16, 78-

Fig. 40 Rear Bearing Cup Removal

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NOTE: Pinion depth shims are placed between the
rear pinion bearing cup and axle housing to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pinion depth shim should not require replacement.
Refer to Pinion Gear Depth to select the proper
thickness shim before installing pinion gear.

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Fig. 45 Pinion Seal Installation

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Fig. 43 Rear Pinion Bearing Cup Installation

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Fig. 46 Rear Pinion Bearing Installation

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Fig. 44 Pinion Outer Bearing Cup Installation

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Fig. 47 Collapsible Preload Spacer

Fig. 49 Tightening Pinion Nut

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Fig. 48 Pinion Yoke Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
ôõö÷røùú@û üý8þhÿ

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Fig. 50 Check Pinion Gear Rotation Torque

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DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
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Fig. 52 Pinion Mate Gear Removal

Fig. 51 Mate Shaft Roll Pin Removal
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Fig. 53 Mate Shaft Roll Pin Installation
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ADJUSTMENTS
PINION GEAR DEPTH

Fig. 54 Typical Housing Cover With Sealant
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

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ÇÑ9ÏÕÖ-×Ï Ì<ÇÈ;Õ'Î+Õ×Ï+ÛÊ*Ö-Ï+Î ÛQÕ'×Ï+ÍÇÈ;ÇÎ ÈbÉ)ÏÊ*ÐvÙ;Ú^×;ÇÑ&ÈÒÔ9ê
Ü*ÏÐ<ÇÑVÕ'×;ÏcÊÔ&ÎÒÈÕRÞÇÈãÕ'×Î ÒÑ"Ê*ÈÌÕ'×;ÑVÎÛ9Ê*ÈãÇÈ;Ö-×]á
Õ'×;Ï
Ì8Ï Í8Õ×gë7ÊÐÇÏ Ñ:ÛÐ-Î ÔìÕ×Ï(ÑÕ'Ê*ÈÌ8Ê*Ð-ÌíÌ8Ï Í8Õ×|ÑÏÕÕÇÈ;É ÎÛ%Ê
Í8ÇÈÇÎ È{Ï Õ'Ö-×;ÏÌ[î&ÇÕ×{ÊVÞéáÙÚ^×ÏYÑÕÊÈ;Ì8Ê*Ð-Ì:Ñ"ÏÕÕÇÈÉHÛÐ-Î Ô
Õ×ÏÝÖ-ÏÈ;Õ'Ï ÐÓÇÈÏÝÎ Û3Õ'×;ÏÝÐ-ÇÈ;É&É)ÏÊ*Ð\ÕÎÝÕ'×;ÏÝÜÊ*Ö-ï+ÛÊ*Ö-ÏÝÎÛ3Õ×Ï
Í8ÇÈÇÎ È ÇÑyð*ñ*Ù é*òcÔ9ÔÞó*Ù ô*ñà:ÇÈÙ áÙ3Ú^×Ï<ÑÕÊÈÌÊ*Ð-Ì`Ì8ÏÍÕ'×
Í8Ð-Î'ëXÇÌ8Ï ÑÝÕ×Ï&Ü*ÏÑÕ^É>ÏÊ*Ð5Õ'Î ÎÕ×
Ö-ÎÈ;Õ'Ê*Ö-ÕQÍ8Ê*Õ'ÕÏÐ-È;ÙtÆ Ï ÛÏÐ5ÕÎ
õ Ê*Ö-ïPÓÊ*Ñ×HÊ*ÈÌyö Î ÈÕÊÖ-Õ^÷3Ê*ÕÕ'Ï Ð-È=â5ÈÊ*Ó ØXÑÇÑ=Í8Ê*Ð-Ê*É)Ð-Ê*Í8×<ÇÈ
Õ×ÇÑ&Ñ"ÏÖÕ'ÇÎÈVÛÎ Ð?Ê*Ì8ÌÇÕÇÎÈÊ*ÓFÇÈÛÎÐ-Ô9Ê*ÕÇÎÈÙ

AXLE
8

-* B968;!1$&
_ *![COMPONENTS

Fig. 55 Pinion Gear ID Numbers

Ä
ÅmÄÆ
ÇÈAÉzÉÊËÊÍÌÎcÈ Ï¾Ð
ÏµÌÇ¶ÇËÈ Ñ¾ÊÐzÈ ÌÊ
ÔÕÖ×\ØÙÚÛÜ\ÙØ²Ý$ÞßàáÍâvàãäåæ
/1032547638:9<;>=@?A038CB0)DE4?A8:?A038CF6347=@GIH;7DJ?A;>8:KJ6L?A9
;>KJG:?A6MH63FON?A=@GP9<63QA6)KJ=9<G:?A259SRUTVG:6W9SG:?A259X;7DJ6W4QA;>KJ63F
Y 63G:?A8:FZ=[G:6\DJ63;>D4?A8:?A038 Y 6);>DJ?A8:]
K$^:4`_bac?A]dRfe>gShiR

ÒlÓ
_¯<h j 8:9<=[;7QAQBDJ038r=4?A8:?A038 Y 63;>DJ?A8:]k;>8:F/10)8:63tb8:^:=g>>®>
G:;>8:FZ=@?A]uG:=_ao?A]dRe><h$R
_®<hZoQb;>KJ6cwlD Y 0)Dm}m?A9<Kmg>>¯7{038wUD Y 03D}mt$)Se>t¯{?b8k40)9S?At
=[?b0)8q?b8q;<§pQA6 G:03^r9S?A8:]¹9S?AF6 Y 63;>DJ?A8:]¹KJDJ;>FQA6)9_bac?A]dRUe>°ShiR
j 8:9<=@;>QAQF?ABB6)DJ638:=[?A;>Q Y 63;>DJ?A8:]KJ;>49
0)8
wUD Y 03Dk}?b9<KJ9
;>8:F
=[?b]uG:=[638KJ;>4 Y 03QA=[9{=@0\®µ Uº 2¨_¯>B=[RQ Y 9SR hiR
NOTE: Arbor Discs 6732 has different step diameters to fit other axles. Choose proper step for axle
being serviced.

Fig. 56 Shim Locations

j B1;k8:6MNP]d63;>Dl9S6)=m?A9 Y 6)?A8:]?A8:9S=[;>QAQb6)Fno8:03=[65=[G:65F7634=[G
Hp;>DJ?A;>8:KJ6 63=[KJG:6)FW?A8:=[0 Y 0)=@Gq=@Gr6s0)DJ?A]d?A8:;>Q;>8:FWDJ6)4QA;>KJ63t
256)8:=4?A8:?A038q]u63;>DvRowUFFx03DZ9<^ Y =@DJ;>KJ==[G:6=@G:?AKJyz8:6)9S9`03B
=[G:603D$?b]u?A8:;7QoF6)4=[G
9SG:?A259U=[0KJ0)254638r9S;>=[6B03D=[G:6F7?bBbB63Dit
638rKJ6{?A8Z=[G:6F6347=@G{Hp;>DJ?A;78rKJ639<Ro|16)B6)DU=@0=[G:6{}634=[G5~1;>DJ?bt
;>8:KJ6\KJG:;>DJ=[R
0)=@6NG:63DJ6QbF;>8:F 6@Nc?A8:?A038k;7DJyz?A8:]kKJ0)Qb^r258:9
?A8:=[63DJ9<63KJ=[R j 8r=@6)DJ9S6)KJ=@?A8:]B?A]u^:DJ6DJ634D$639<638:=[9"4QA^:9"03D
25?A8:^:9{=[G:6\;>2503^:8r=8:636)F63F7R
0)=@6=[G:663=[KJG:63FX8:^:2 Y 6)D0)8=[G:6B;>KJ603B=@Gr6F7DJ? H6
4?A8:?A0)8
]d63;>D_bo<n>>np>nSnr>n63=[KJR h$RuTGr68:^:2 Y 6)DJ9UDJ6)4t
DJ6)9S638r==@Gr03^:9<;>8:F903B;>8?A8:KJGF76MH?b;>=[?A038BDJ032=[G:69S=[;>8:t
F;>DJFR j Bo=@Gr68:^:2 Y 6)Dm?A98:6)]d;>=@? H63n:;>FF\=[G:;>=pH;>Qb^r6=[0=[G:6
DJ6)7^r?bDJ6)F=@Gr?bKJyz8:6)9S90)B=@G:6{F7634=[GZ9SGr?b259<R j B1=[G:6{8:^r2 Y 6)D
?A9{4039<?A=@? Hp6)n9S^ Y =[DJ;>KJ==@Gr;7=Hp;>QA^:6\BDJ0)2=[G:6=[G:?AKJyz8:639<9{03B
=[G:65F6)4=[G9<G:?A25R j B1=@Gr658:^:2 Y 63Dl?A98r05KJG:;>8:]d65?A98r63KJt
639<9S;>DR
o lWr7Wk3 o¡¢£rrp` ¤p¢p¡okrp
6);>9S^:DJ6)25638:=[95;>DJ6=[;>yr6)8N?A=@G4?A8:?A038 Y 63;>DJ?A8:]
KJ^:479
;>8:F¥47?b8r?b0)8 Y 63;>DJ?A8:]u9O?A8:9<=@;>QAQA63F¦?b8P=@Gr6q;<§pQA6G:03^:9<?A8:]
N{?A=[G:03^r=s;>8¨9SGr?b259O4QA;7KJ6)F Y 63G:?A8:F©=[G:6ªDJ63;>Dx4?A8:?A038
Y 63;>DJ?A8:]KJ^:47RT;>yz6k2563;>9S^rDJ63256)8:=[9N{?A=[Gso?A8:?A038 «;7^:]u6
¬63=g>>7®
;78rF`}?b;>Q j 8:F?AKJ;>=@0)D/1tb¯7¯>¯>°_ao?A]dRe><h$R
_$*h5wU9<9S632 Y QA6©c?A8:?A038²±l63?A]dG:=W³1QA03KJy´g>>¯7°>no?A8:?A038
³1QA03KJy
g>>¯7¯>nµ;>8:FDJ6);>DU4?A8:?A038 Y 6);>DJ?b8r]\038r=@0¬pK$DJ6MNPg>>®µ
_ao?A]dRe><h$R
_<h j 8:9<63DJ=¦;79<9S6)2 Y QA63F"G:6)?b]uG:=¥]u;7^r]d6´KJ0)254038r638:=[9Sn
DJ6);7D Y 6);7DJ?A8:];78rF¶9SKJD$6MN·?A8:=[0O;<§pQA6xG:03^:9<?A8:]q=[G:DJ0)^:]dG
4?A8:?A0)8 Y 63;>DJ?A8:]KJ^:4795_bac?A]dRfe7¸<hiR

_e<h5wU9S9<632 Y QA6ª}?b;>Q j 8:F7?bKJ;>=[03Dx/1tb¯7¯>¯>°¥?A8:=[0ª¬KJ0)03=[63D
³1QA03KJy}t$3<e>t;>8:FZ9<63KJ^:DJ6\9<63=9<KJDJ6MNmR
_g<hZoQb;>KJ6»¬pKJ0)03=[63D³1QA03KJy)¼v}m?A;>Q j 8:F?AKJ;>=[03D?A8¶40)9S?A=[?b0)8
?A8O;<§pQA6`G:03^:9<?A8:] 9<0F7?b;>QU4DJ0 Y 6;>8:F¹9<KJ030)=[63D Y QA03KJyX;>DJ6
BQA^:9<G´;>]d;>?A8:9<=O=[G:6¦DJ63;>DN{;>DJF9S^:DJBb;7K$6¥0)Bs=[G:6¥47?b8r?b0)8
G:6)?b]uG:= Y QA03K$yk_ao?A]dR:e7<hiR±l03QAF\9<KJ030)=@6)D Y QA0)KJyk?A84QA;>KJ6;>8:F
½ 63DJ0s=[G:6sF?A;7Q{?A8:F7?bK$;7=[03D`B;>KJ6»=[0s=@Gr6»40)?A8:=[63DvR¾T?A]dG:=[638
F?A;>Q?A8:F?AKJ;>=[03DB;>KJ6\Qb0)KJy9SK$DJ6MNmR
_<h5¿?b=[G»9<KJ030)=@6)D Y QA0)KJys9<=@?AQAQ?A8»4039<?A=@?A0)8»;7]u;>?b8r9S==@Gr6
4?A8:?A038ÀGr63?A]dG:= Y Qb0)KJyzn{9<QA0MN{Q ¥9<QA?bF76X=[G:6XF?A;>Q\?A8:F7?bK$;7=[03D
4DJ0 Y 60@Hp6)D=[G:6\63F]u6\03B¾=@Gr647?A8:?A038G:63?A]dGr= Y QA0)KJyrR
_¸<hZ¬Qb?AF6»=@G:6¹F7?b;>Q5?b8rF?AKJ;>=@0)D47DJ0 Y 6¹;>KJDJ039<9 =[G:6¹]d;>4
Y 63=ÁN{6)638=@Gr64?A8:?A038G:6)?b]uG:= Y QA03KJyO;78rFO=[G:6;>D Y 03D Y ;>D
N{?A=[G=@G:69<KJ030)=@6)D Y QA0)KJyk;>]d;>?A8:9S==[G:647?b8r?b0)8G:63?A]dGr= Y Qb0)KJy
_ao?A]dRpg>ShiR>¿»G:638
=@G:6F?A;>Qf47DJ0 Y 6KJ0)8:=[;7KJ=[9l=[G:6;7D Y 0)D Y ;>Dvn
=[G:6´F?A;>Q403?A8:=[6)D¶N?AQbQ=[^:DJ8KJQA03K$y3N?b9<63Rx³1DJ?A8:]ÂF7?b;>Q
40)?b8r=@6)D Y ;>KJyª=[0 ½ 63DJ0»;>]d;>?A8:9S=
=[G:6»;>D Y 03D Y ;>DvnF0»8:0)=
=[^:DJ8ZF?A;>QB;>KJ63Rµ/1038r=@?A8:^:6{250@Hp?A8:]\=[G:6{F?A;>Q4D$0 Y 6{=@0{=[G:6
KJDJ6)9S=¾0)Bf=@G:6;>D Y 03D Y ;>D;>8:FDJ6)KJ03DJF=[G:6G:?A]dG:6)9S=DJ63;>F?A8:]dR
j Bf=@G:6F?A;>Qc?b8rF?AKJ;>=@0)DKJ;>88:03=¾;>KJG:?A6MH6=[G:6 ½ 63DJ0DJ63;>F?A8:]un
=[G:6{DJ6);>D Y 63;>DJ?A8:]\KJ^:4k03DU=[G:64?A8:?A038F634=[GZ]u;>^:]d69S63=V?A9
8:0)=?b8r9S=[;>QbQA6)F`KJ0)DJDJ63KJ=[Q R
_°<hZ¬63QA63KJ=l;9<G:?A2´63>^:;>QV=@0k=@G:6kF?A;>Q?A8:F?AKJ;>=[03D5DJ6);7F7t
?A8:]{4QA^:9=@G:6lFDJ? Hp647?b8r?b0)8]d63;>DmF6)4=[GHp;>DJ?A;78rKJ68:^:2 Y 63D
63=[KJG:6)FX?A8W=[G:6B;>KJ60)B=[G:647?A8:?A038W]u63;>D
_ao?A]dRe>e<h$Rac0)D
6M§;>254QA63n?AB=[G:6
F7634=[GH;7DJ?A;>8:KJ6?b9\>>n¾;>FF:>R >>?A8:R
=[0=[G:6\F?A;>Q?A8:F?AKJ;>=[03DDJ63;>F?A8:]uR

NOTE: If an oil slinger is used behind the inner pinion bearing, deduct the thickness of the slinger
from the dial indicator reading and use that total for
shim selection.

DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH

p£pl¢Ãc l
}m?ABBb63DJ6)8:=@?A;>Qc9<?AF6 Y 63;>DJ?A8:]547DJ63QA03;>F;>8:F]d6);>D Y ;>KJyzQA;79<G
?A9;>KJGr?b6@Hp6)F Y X9<63QA63KJ=[? Hp69SGr?b259\40)9S?A=[?A038:6)F Y 63G:?A8:F=[G:6
F?ABBb63DJ6)8:=@?A;>Qx9S?AF76 Y 63;>DJ?A8:]´K$038:6)9SRTVG:6¨47DJ0346)D©9SGr?b2
=[G:?AKJyr8r639<9XKJ;>8 Y 6WF6)=@6)DJ25?A8:6)F¦^r9S?A8:]ª9<Qb?A4tbB?A=F^r252
Y 63;>DJ?A8:]d9{}mt¯>®>¸Z?A84QA;>KJ60)BV=@G:6\F?ABB6)DJ638:=[?A;>Q¾9<?AF6 Y 63;>Dit
?A8:]d9
;>8:F¹;sF7?b;>QU?A8:F?AKJ;>=[03D/1tb¯>¯7¯>°>Rm³163Bb03DJ6`4DJ03K$6363F7?b8r]
N{?A=[G»=[G:6F?ABB6)DJ638:=[?A;>Q Y 6);>DJ?b8r]`4D$63QA03;>F;>8:F]d6);7D Y ;>KJyzt
QA;>9SGW2{63;>9S^:DJ6)25638r=@9<n2563;>9<^:DJ6=[G:64?A8:?A038O]d6);7DF6347=@G

GIH

JLKMMN'OLNQPLR,K S"TUSVPWJXJLOLK YZNTK PWN

[
\[]

^`_`a"bdcWefhgideckjl`m"n"oQpqn"r"s"t"u
132542760498":<;>=@?>:<13AB9CD;=E25;>40F>:

Fig. 58 Pinion Height Block—Typical

Fig. 57 Pinion Gear Depth Gauge Tools—Typical

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û òí[ì3ëí[î:ìðMüpì)ëJç>ôbôóSî:ïAýí@î:ïAùJúzè:ì)óSó5í[ðí@ç>úzìþ:êé7ïAòòì)ëJì3è:ø
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$
õ ïbòbòì3ëJì)è:í[ïAç7ô
óSîrïbý ý5ì)ç>óSþ:ëJì)ý5ì3è:í[óEç>ëJì ê7ì3ëJòð)ëJý5ì3
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ë ø 7ø ëJì)ý5ðMüpì)éõ
"! #$%'&(%*),+-! .0/

NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.

Ç
È>ÉÊ

ËLÌÍ'ÍÎÏLÎQÐLÑ,Ì ÒZÓ
ÒÔÐWËXËLÏLÌ ÕZÎÓ'Ì ÐWÎ

Ö0×

Ø`Ù`Ú"ÛdÜWÝÞhßàdÝÜkáâ`ã"ä"åQæqä"ç"è"é"ê
vwxzy<{*|~}V{ {{*DE{{*D }*| {*
{*("{
v xzy<{*|~}V{h }*D{*@D|~ }| {*{*D
"{*
v ¡xz¢£D¤D{¥}¦ {*{D¤{§D
¨D{*©}E}dª{* }D
v «xz¢£D¬D|~|{®{D¨0¯> ¡«°}z {*{D
"{*
v ±xz¢£D" {*{*D<{dh²V{dD}DD¨
v ³xz¢£DD{I|~´'{*d{D~ª3µD{*}*{
ª}}D-¢£D"Dz(D
D{d}*Ev ¶¨-³x

Fig. 59 Gauge Tools In Housing—Typical

Fig. 62 Tighten Bolts Holding Bearing Caps

v ·xz¸3D
z{ }£¹º5Vª{|~{*»L{*3D{ {*
{*(-D|E|©{*D¨`}E{*z{E}*LD{E²{~(}*D
Dµv ¶¨-³¡x`Dzv ¶-³«x

Fig. 60 Pinion Gear Depth Measurement—Typical

Fig. 63 Seat Pinion Gear Side Differential Dummy
Side Bearing

Fig. 61 Axle Adjustment Shim Locations

v °x~¼ D{*$({D$½<¡°° ¾¿D}À{*@}£{*
}*WD}{d{}¹º(
¨{*®v¶,¬³±x
v Áx~Â3À@®D}*z½< ¡¡¡Á@}ÃD{D
Ä }*}*ÅD{UD}ªD({*d}*Æh®D {
{*5¹E{{*©D{dDµ{®}*WD{Ev ¶¨-³±x

EGF

H+IJ,J,KML+KON+PQI RTSURVNCHWH+L+I XYK,S,I NCK

Z\[^],_

`?a?bTc=dCe0f:g0h=e0dji
k?lTmTnOopmTqTrTsTt

Fig. 64 Seat Ring Gear Side Differential Dummy
Side Bearing

Fig. 66 Hold Differential Case and Zero Dial
Indicator

Fig. 67 Hold Differential Case and Read Dial
Indicator

Fig. 65 Differential Side play Measurement

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Fig. 68 Hold Differential Case and Zero Dial
Indicator

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&}D|~.&|(¶u»¼1ªx

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.

Fig. 69 Hold Differential Case and Read Dial
Indicator

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.|C|(@¸%,={.}$%

Fig. 70 Ring Gear Backlash Measurement

CED

FHG4I%I%J
KHJ@LHMNG OQP.ORLFSFHKHG TUJ%P%G LJ

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GEAR CONTACT PATTERN ANALYSIS

Fig. 71 Backlash Shim Adjustment

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Fig. 72 Gear Tooth Contact Patterns

~

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SPECIFICATIONS
181 FBI AXLE
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Plug—SP-3289

181 FBI AXLE
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Adapter—C-293-39

SPECIAL TOOLS
181 FBI AXLE
Puller—C-452

Puller—C-293-PA

Wrench—C-3281

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Driver—C-3716-A

Remover—D-149

Installer—W-162-D

Cup—8109

Handle—C-4171

Remover/Installer—6289

Installer—D-146

132
GHIJKLM

45766898:;<5 =#>?=@:4

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Tool Set, Pinion Depth—6774
Installer—6761

Installer—6752

Installer Discs—8110

Gauge Block—6733

Spanner—6958

Turnbuckle—6797
Installer—C-3972-A

B
CEDF

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Spreader—W-129-B

Remover—C-4345

Adapter Kit—6987

Installer—D-130

Pilot Stud—C-3288-B

Installer—W-262

GIH

JLKMMNPOLNBQLRSK TFU*T<QVJJLOLK WNUK QVN

XZY?[\

194 RBI AXLE
|7}#~#

page
GENERAL INFORMATION
194 RBI AXLE . . . . . . . . . . . . . . . .
LUBRICANT SPECIFICATIONS . . . .
DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL . . . . . .
TRAC-LOK OPERATION . . . . . . . . .
DIAGNOSIS AND TESTING
BEARING NOISE . . . . . . . . . . . . . .
DRIVELINE SNAP . . . . . . . . . . . . .
GEAR NOISE . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . .
LOW SPEED KNOCK . . . . . . . . . . .
TRAC–LOK DIFFERENTIAL NOISE
TRAC–LOK TEST . . . . . . . . . . . . .
VIBRATION . . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . .
REMOVAL AND INSTALLATION
AXLE SHAFT . . . . . . . . . . . . . . . . .
AXLE SHAFT SEAL AND BEARING
COLLAPSIBLE SPACER . . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . . .

. . . . . . . . . . 49
. . . . . . . . . . 49
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61

GENERAL INFORMATION
194
RBI AXLE
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page
DIFFERENTIAL SIDE BEARINGS . . . . . . .
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . .
PINION GEAR . . . . . . . . . . . . . . . . . . . . .
PINION SHAFT SEAL . . . . . . . . . . . . . . . .
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . .
RING GEAR . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL . . . . . . . . . .
TRAC-LOK DIFFERENTIAL . . . . . . . . . . .
CLEANING AND INSPECTION
AXLE COMPONENTS . . . . . . . . . . . . . . . .
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH . . . . . . . . . . . . . . . . .
GEAR CONTACT PATTERN ANALYSIS . . .
PINION GEAR DEPTH . . . . . . . . . . . . . . .
SPECIFICATIONS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . .
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . .

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63

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TRAC–LOK

DIFFERENTIAL
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TRAC–LOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHICLE SUPPORTED. A TRAC–LOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE.

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CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

Fig. 5 Trac-lok Test —Typical

SERVICE PROCEDURES
LUBRICANT
!#"%$'&)("%*,CHANGE
+!&)-,./.1032546487,(:9;(7,$'<5='(3>

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$KX7,48(3*!4E7F(<50E9;(2dH%03='48&4E0BY: A P%¡vI48>='H%&)> 6480325%-,(3>
Fig. 6 Apply Sealant

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48(32*,03$'&)(<50A.1='"%$'*,4E>

REMOVAL AND INSTALLATION
REAR AXLE

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îï;ðñaò²óFó3òFñtî ôdï
NOTE: The weight of the vehicle must be supported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, vehicle ride
height and handling could be affected.

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PINION SHAFT SEAL
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Fig. 7 Pinion Yoke Removal

Fig. 8 Pinion Seal Installation

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CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.

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Fig. 10 Check Pinion Rotation Torque
Fig. 9 Pinion Yoke Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque
sequence will then have to be repeated.

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CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been damaged. Replace the collapsible spacer.

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¸ Â ²
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¸
½Á º Á ¸-¶¶¸-½L³(·!µ Ñ´"µ²
¾K¹Zº-»!¸Þµ²
¾ Â ²
³´1µ ¶¶J´1·
¸ Á ½º Á ¸¶¶¸½

³·
µÑ´Ç
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¸¾ Â ÑÑ¸-½¸²
´ Â µ ¶·
ºÀ!³ Â ²
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¸ÕE¸³(³µ½B¹cÇÓG¸Ñ¸½x´ºh´·
¸?ßÀ
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³fÑº½
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³´1µ ¶¶&´·
¸OÅ½µ»W¸O¾½À
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½
ã µ»W¸³(ÙHÑº-½ Á ½º Á ¸½ Á ½º-Õ¸¾ À
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®EÌÐ°±#²
³´µ¶¶Z¼h·!¸¸¶Gµ ²!¾&´ Â ½¸ µ ³³(¸-Ï?Å¶ Â ¸-³(Ç
®EÌ-ÌM°ßº#¼Q¸½3´·
¸+Ö¸· Â Õ¶¸Ç

Fig. 11 Tightening Pinion Shaft Nut

COLLAPSIBLE SPACER
ä4å!æxç4èéêgë&ìEíîï4î çxïÞîïZðñcéê!ê!å!ò
®EÌy°ÓGµ Â ³(¸ µ²
¾³(À ÁÁ º½´`´1·
¸+ÖZ¸-· Â Õ¶¸Ç
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®¯°ÓG¸Ï?ºÖZ¸"½¸µ½Å½µ»!¸"¾½À
Ï?³Ç+Ó4¸-Ñ¸-½´º"â*½ºÀ Á ÒÙ

½
ã µ»W¸³(ÙHÑº½ Á ½º Á ¸½ Á ½º-Õ¸¾À!½¸³Ç
®È°óUµ ½»Þ´1·
¸ Á ½Eº Á ¸-¶¶¸-½³(·
µÑ´Uµ²
¾ Á Â ² Â º-²2¹Zº-»!¸"Ñº½
²Â
³´µ¶¶µ ´ Â º²/½¸Ñ¸½¸-²
Õ¸Ç
®Ò°ÓG¸Ï?ºÖZ¸ ´1·
¸ Á ½º Á ¸¶¶¸½3³(·
µÑ´`Ñ½ºÏ~´1·
¸+¹Zº»W¸Ç
®×°ÓGº´1µ´¸ ´1·
¸ ÁÂ ² Â º-²"Ã¸-µ½Q´1·
½¸¸ º-½QÑºÀ
½3´ Â Ï?¸-³(Ç
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¸OµÏ?º-À
²
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¸ ÁÂ ² Â º²tÃ¸-µ ½2¼ Â ´1·{µi® Â ²
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Å ÆÇ
ÈÉÊ ËÊ ÌÍÎÌÏÐÊ ËËÊÐÎÈÌ Ñ"Ò ÓÔÕ'Ö(Ô×ØÙÚ
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-/E1032541AcbdA'X<ZYeA?BgfdhiOGFjk]F7:@ml[BWA?7:nWKofdh/pFjF.rqHJ<
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-xq1y1032541Az]41\:68HJ]O{F>8AzNOB|Q}H~<'<?><?B]g41>68@AK:]FXXA?B
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-xq'q03bdA'X<ZYeAH~K:ABW<?7:H=NO687:68<?7
{OA']FBW687:9\:4w687:9]NO]O68B
<?41\:68H~]F{F>8AN68nWTHJ<?<'>84HJ<N\:>8>HJK:A{OA']FBW67P9341H~BW]F689uKPH<'/
HJK:AN687:68<?79uA']OB4wKP]OH~aZH5X]1Q{FA7:A'nWA?414w]FB|QH~<>8689uK:HJ> Q
HJ]ONHJK:A A'7:@<?HJK:A N687:68<'79uA?]FB_`68HJK]BW]1_`K:68@A <'B^Bx\:{Fh
{FA?B`X]F>8>8A?H=68HJK:A{FA?]FBW687:9{FA'nW<?XA'4{F<?\:7:@<'7
H~KPAN687:h
68<?7[4wKP]OH~a
-xq1j103bdA?X<~YSAHJK:AnW<?>8>8]ONO4w68{F>8A41N]FnWA'Ba

Ã=Ä

/ S°r±uP?P± =Fig.
13 Remove Pinion Gear
-xq(03Z7:41HJ]O>8>]7:A~_}nW<?>8>8]FN416{F>8A`NBWA?>8<']O@4wNO]OnWA'B=<?73N687:h
68<?7[4wKP]OH^-/sr69aq1i10xa
-/j103ZNO687:68<?79A?]FB²_`]F4BWA'X<ZYeA?@Vt687:41H~]F>8>N687:68<?79A?]FB
687KP<?\:41687:9ua
P=eFig.
xr/12 =Pinion
zP=Yoke
P Removal
-xq(03bd]F684wA]F7:@34w\:NON<?BWH^HJK:A5YSA'K:68nW>8A?a
-/j103bdA?X`<ZYSA5_`KPA?A?>d]O7P@HJ68BWA]O414wA'X{F>86A'4wa
-/p103bdA?X`<ZYSABWA?]FB3{FBW]FTPA@BW\:X41a5bdA?/A'B3H~<vBW<'\:NGFV
BW]FTUA?4wV/<'BNBW<'NA?B NBW<'nWA?@O\:BWA?41a
-/i103]OBWTzHJK:A
NOBW<?NA'>8>A'B34wK:]FH]F7:@NO67P6<'7QS<'TPA/<?B
687:41H~]F>8>8]OHJ68<?7[BWA?A?BWA'7:nWA?a
-/G103bdA?X`<ZYSAHJK:ANBW<'NA?>8>8A?B 4wKP]OH^/BW<?X HJK:A5QS<?TUA'a
-/C103bd<?HJ]FHJAHJK:AN687:68<'79uA']FBHJK:BWA'A<'B<?\:B H~68XA'4wa
-/¡103A?]F4w\:BxAHJK:A]FX<'\:7:H<?[HJ<'BW¢O\PA7:A'nWA?414w]FB|Q£HJ<
BW<'H~]FHJAMHJK:AIN687:68<?7£9uA']OB_`68HJKo]¤-/687:a3>{F41a 0L@O6]F>8h/H¥QSNA
HJ<?BW¢F\:A_BWA?7:nWKPadbdA?nx<?BW@HJK:AHJ<?BW¢F\:ABWA']O@O687:9/<?B`687:41H~]F>8h
>8]FH~68<'7BWA'/A?BWA'7:nWA'a
-/.103bdA?X`<ZYSA
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KP<?\:41h
687:9ua
-/E1032541687:9z;=<?>8@A'BCFEOGF.¨H~<©K:<?>8@Qe<?TUA?VBWA'X<ZYeAªHJK:A
N687:68<'7Qe<?TUA7P\:H^]F7:@_`]F4wK:A'Ba
-xq1y103254167P9LbdA'X<ZYeA?B
fd«OiFGFjR]F7:@©l[BWA'7:nWKIfd«OpFjF.¬qwV
BWA'X<ZYSAHJK:AN687:68<?7QS<'TPABW<?X N687:68<?7[4wK:]FH^-/st689aq1jw0"a
-xq'q03bdA'X<ZYeALHJK:A¨N687:68<'7}9uA']FBª/Bx<?X®KP<?\:41687:9-st689ua
q1p10xafd]FH~nWKH~K:AN687:68<'7_`68HJKQS<'\:BK:]F7:@©H~<NBWAZYeA?7:H68H
/BW<'X¯]O>8>8687:9]F7:@{FA'67P9@O]OX`]O9A?@a
-xq1j103bdA?X<~YSAnW<?>8>8]FN416{F>8A4wNO]OnWA'BBW<?X N687:68<?7[4wK:]FH~a

/- p103Z7:41HJFig.
]O>8>NO1467P6Collapsible
<'7BW<?7:H{OA']OPreload
Bx67P9uV68²Spacer
7:A?nWA'4w41]FB|Qa
-/i10³5NNO> Q]
>8689uK:HnW<?]FH~687:9[<'=9A?]FB>8\:{FBW68nW]F7:H`<'7DHJK:A
>868N<?N687:68<?74wA']O>8aSZ7P4wHJ]F>>t41A?]F>_`68HJKZ7:41HJ]O>8>8A?Bfdh/pFEO¡FjFh ³
]F7:@3;]F7:@O>Afd«Fi¬q1¡rq`-st689uavq1Gw0"a

BDC
[]\^/_a`&b]cTb]d(egfd(hiGb]c5c5b2if_(dkjml]n5o5pqro5s5t5u5v

EGFHIHIJLKGJNMGOPF Q5R+QSM ETEGKGF UVJIRIF M J

WX&YIZ

Û/ö1
Ý 5à1é8ß:ûäSå'æUçê:å'ã÷Oç?íùFöFÜFîªâFß:÷ªâªáJå?í Oó:çè`íWç'ß:ìWê
àwç'áâFá
ÿ ÛFÜOõý/áJüã8þOà1ü ÝxñtìWíWó:àwêìWå'ãã8âFôà1é8þOã8çà1ôâFìWç?í
ó:ß:áJé8ãþFç?âFíWé8ß:ûç?ß:÷3ôã8â1ä
é8àáJâFæUç?ß[ó:ô3Û/úté8ûüï wÝ"ü
NOTE: If more than 474 N·m (350 ft. lbs.) of torque
is necessary to remove the bearing end play, the
collapsible spacer is defective and must be
replaced.

Ûxï1õ1Ý3ëSã8å~è`ã äDáJé8ûuê:áJç?ßá~êPçß:óPáé8ßùOü
î
ÿ ÛÜ[ý/áJü²ã8þOà1ü Ý
é8ß:ìWíWç'ÿç?ß:áJàmó:ß:áJéãáJê:çcíWå?áJâFá~é8ß:û¤áJå?íFó:çcéàmâFìWê:é8çeç?÷ü
ç Fó:ç?ß:áJã äáJåâ Så?é8÷å Sç'í
ç'âFàwó:íWçá~êPçíWå?áJâFá~é8ß:ûá~å'í Fó:çý/íW
ìWíWó:à1ê:é8ß:ûá~êPçìxå?ã8ã8âOôOàwé8þFã8çà1ôâFìWç?í Û/úré8ûuüï1î1Ýxü

/Û Ü1Ý3ÞZß:à1áJâOã8Fig.
ãäeå?15
æUçPinion
è`é8á~ê¨ëSSeal
ìxíWçZèInstallation
îrï'ï1ðOñ^òdó:ôî¬ï1õFöOñ^âOßP÷
ø å?ã8÷ç'íùFöFÜFîÛ/úréûüï1ù1Ýxü

/Û ù1Ý3ÞZýáJê:çFig.
å?íWé8ûu16é8ß:âFPinion
ãôé8ß:é8å?Yoke
ßþFç?âFInstallation
íWé8ß:ûuàâFíWçþFç?é8ß:ûó:à1ç?÷ñ
é8ß:à1á~âFã8ã÷Oé8ý/ý/ç'íWç?ß:áJé8âFãâFà1àwç?ÿ`þOã äâFß:÷âeãç àwê:âFýá~à1ñ¬é8ýßPç?ìWç'à
à1âOí|ä ü
NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
Û 1Ý3ÞZß:à1áJâOã8ãáJê:çäSå?æUçè`âFàwêPç?íâFß:÷âß:ç~è£ß:ó:á=å'ßáJê:ç
ôé8ß:é8å'ßûuç'âFíü²é8ûê:á~ç'ßáJê:ç=ôé8ß:é8å?ßß:ó:ádó:ß:áJé8ã¬áJê:ç?íWç=é8à ¾ç'íWå
þFç?âFíWé8ß:ûç?ß:
÷ /ôã8â1äü
Û/î1Ý éûê:áJç?ß[á~êPçßPó:á^á~å ð ¬ï
ÿ Û/ðFõFõý/áJüã8þFàwü Ýxü

CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque
sequence will then have to be repeated.

Fig. 17 Tightening Pinion Nut
xÛ ï?ï(Ý3òdêPç?ìWæ
íWå?áJâFá~é8ß:û3áJå?íFó:ç è`é8á~êâÛ/é8ß:üã8þFàwü Ý`á~å'íOóPç
è`íWç'ß:ìWê
Û/úré8ûuü5ï1î1Ýxü!êPçá~å'íFó:çß:ç'ìWç?à1àwâFí|äáJåíWå?áJâFá~çáJê:ç
ôé8ß:é8å?ß[ûuç'âFíà1ê:å?ó:ã8÷3þFç#"
íWé8ûéßPâO&ã %dç?âFíWé8ß:û(à ')ê:çíWç?âF÷é8ß:ûíWç'ìWå?íW÷Oç?÷÷óPí
é8ß:û• íW$ ç?ÿå SâFã8ñôã8ó:àâFß[âF÷÷OéáJé8å?ß:âFãdõFü ÜFù
ÿ ÛÜé8ß:üã8þFàwü Ýxü
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è %dç'âFíWéßPûuà ' ðáJå+
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ÿ Ûxï1ÜáJ(å FÜé8ß:üã8þFà1ü Ý"ü
•
Ûxï1ð1Ý3ÞZß:à1á~âFã8ã÷Oéýý/ç?íWç'ß:áJé8âOã=âOà1àwç'ÿþFã äLâOß:÷ªâ Sã8ç[à1ê:âFý/áJàwñ
é8ý²ß:ç?ìWç'àwà1âOí|ä ü
Ûxï 1Ý ,5ã8éûß ÿâFíWæPà¨ÿâO÷OçôíWç Sé8å?ó:à1ã ä£å?ßmäeå?æUçâFß:÷
ôíWå'ôç?ã8ã8ç'íàwêPâOýá^âFß:÷é8ß:à1áJâOã8ãôOíWå?ôç'ã8ã8ç?íà1ê:âFý/áJü
Ûxï 1Ý3ÞZß:à1á~âFã8ãíWç'âOí3þFíWâFæPç
÷íWóPÿàwü -ç'ý/ç'íáJ/
å .víWå?óPôzÜFñ
%díWâFæPç'àwñý/å?í ôíWå'ôç?í ôíWå'ìWç?÷óPíWç?à1ü
Ûxï1Ü1Ý ,5÷÷ ûuç'âOíMã8ó:þFíWé8ìWâFß:á~ñé8ýß:ç?ìWç'àwà1âOí|ä 0
ü -ç'ý/ç'ícáJå
1 ó:þOíxéìWâFß:áëeôç'ìWéýé8ìWâOáJé8å?ßPàå'ý5áJê:é8àà1ç?ìWáJé8å?ß©ý/å?íãóPþOíxéìWâFß:á
íW#ç Fó:é8íWç'ÿç?ß:áJà1ü
Ûxï1ù1Ý3ÞZß:à1á~âFã8ãSè`êPç?ç?ãdâOßP÷áJé8íWçâOà1àwç'ÿþFã8éç'àwü
Ûxï 1Ý 1 å~è`ç?2í Sç'ê:é8ìWã8ç?ü

AXLE SHAFT
35476985:<;&=
-

Ûxï(Ý dâFé8àwçIâFß:÷kà1ó:ôôå'íW>
á eç?ê:é8ìWã8ç?ü?dß:à1ó:íWçIáJê:âFáDáJê:ç
áJíWâOßPàwÿé8à1àwé8å?ß[é8à`éß[ß:ç'ó:áJíWâOã8ü
Û/ð1
Ý -dç?ÿå Sç5è`êPç?ç?ãdâOßP÷áJé8íWçâOà1àwç'ÿþFã äü
Û 1
Ý -dç?ÿå Sç`þFíWâFæUç`÷íWó:ÿ@ü -dç?ý/ç'í=áJå.víWå'ó:ôÜFñA%díWâFæUç?à1ñ
ý/å'íôíxå?ôç'íôíxå?ìWç?÷Oó:íWç?ü

ÞßàIá

âGã~äLäIåIæGåNçGèPã éVêé@ç âTâGæGã ëVåIêLã ç å

ì9í

î]ïð/ñaò&ó]ôTó]õ(ög÷õ(øùGó]ô5ô5ó2ù÷ñ(õkúmû]ü5ý5þÿrý

Fig. 20 Axle Shaft C–Clip Lock

w³yÃ!¦I} <{~}(! }# {5#{~}
¨L }aI }
w²ºyÃ!¦I}#D{{~}
} ~!¤! D7 }ÄS{~}
7
>½!# ~!}#{~{~~!¾9 {~{~!Å !¦I~ ~!½DÃ
Æ¥#!}#}¶#!
~ ~#7¤}S~ ¾ 7}¶<{~}/! ( !Ç¢#
}# ~! !¤}# {57 }a}#¦
{ }I

Fig. 18 Check Pinion Gear Rotation Torque

wxyz|{~}# {~{9}#~
}#~ {9g!!~!/<}#
}#
wyA##}#!#!~! S} #{~ > ~{~! ~ !
!}7#!7
7<{}! 2! }#@ |}<}!#!¡
~!<}#¢
w£y |# }I~}}#7 ~ {¤ }¥ 7
0¦I~!~#§ }
} T! {~#¨}©ª~«
}#~ {} |}# S}{~¨
}©¬ !¦I~!~#® }/} ¤! ¯°
}#}#!~
{
}aw±P~²³y

ÈÉSÊAËÌ2Í7Í#Ì7Ë¹È Î9É
w²ryA! }¤
}
7/ #}¤ !Ï}# {{~~¦©~½}#
{~! ~ ! ¯Ã!}#0S{~}¥! 0!!} {¾¯ }# ~!¾
!}#!½
½}a ~!a~
}(½}# ¦I{~~!}#

NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip. Also, exercise care not to
damage the wheel speed sensor on vehicles
equipped with ABS brakes
w¸yÃ!}#z|· {~~¦Ð{~#¨®¥}#!#S{~}0! DµA!
S{~}a! #!Ñ© a}# z|· {~¦{~#¨>~~I}a½}# ¢
wÒyÃ!}#¦I~!~# }>! ~!>
}}#!~
{ }
! !#!½¶!!G© 7}# !¦I~!~#}

wxy¿{~~¤!{}¤! P©~ ¤7#{~}~¤!}I~}#}! {
}T
7~! {~{{~#¨*}©Ó©ÔA#~ }
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t 9{~
y
!}# I5Õ5~!}#®{~#¨Ð}©¬Ð²³ÅÖ× °wm²xÅ
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7
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¦I#¦I}¦I#}#
!}#
w´yÃ!
{~{S©!}#}{5 ! ~}#
w»yA©}&<}#!~{~}#

Fig. 19 Mate Shaft Lock Screw

w ´yµA!0S{~}! 9#© ¶ !}S}S{~}7

z|· {~¦{~#¨¤#*!}a<{}a! w±A~¹¸ ºy
w»y |}#S}]<{}D! <¼}]
}D ]¦
}S}!5I
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{~¾<©!~©~{{V}# ~0~
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}]!}
©7}#}#{]¦I}#}}!##/S}#7{~}>}À
!~¦
¦I}#©~ ¤¿Á|Â
¨7}

AXLE SHAFT SEAL AND BEARING
Ù5Ú7Û9Î5Ü<Ì&Í
w²ry |}# S}a!}aS{~}a!
w¸y |}# S}!}S{~}! }# {¹#!}}#7#|!}
S{~}a! ! }©~¶ {~{5¦IÝÆ/ ¢

®X¯
¿FÀ¤Á9Â\ÃÄFÅ¹ÄFÆÇÉÈMÆÊ¤Ë{ÄFÅÅÄfË[ÈMÂÆÌrÍFÎÏÐ,ÑSÏÒÓÔÕ

°{±M²D²D³©´{³µ{¶G± ·¸N·µH°¹°{´{± º³D¸D± µH³

»6¼½D¾

NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.

! #"%$# #&(')*+"&(,-
.$# 0/'132
#&(')*4
#65798 ,;:#7< =>.?')*
@BA #CD &FEG,H:#I< =KJMLNE7'*PORQI<STO

Fig. 22 Axle Shaft Seal Installation

Fig. 21 Axle Shaft Bearing Removal

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#) A $K.?&(&(OZ
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#U7< I< O
)?.&( F# FCK#&().[$# ,&H,)
\$K ,#&(')*%'M#*P#') H1? ') K &SO
V) KF 9) 1/ 9 #" ,Kf/'V) 1# &
:#U#K6K) A #) A \
#U7< I<E7'*PORQ#Q TO
U V) K \ \#"M1O
DIFFERENTIAL

?hgde
T<S
#' \#) A .CKCD&({ 'W( O
Q
1? +.$#&('W(K)?"'Y CD.*;"M&(
'A ""M &( ,)'M#?. 'M)?*6W(1 ,&yO

31 A '"" ,&( )'#?. 'M)?*W( &>#) A
#M1/".' A A &(#')O
U
\ \?K"M1 O
L B,1 1? ') 1#K')9&T " ,&( )W( 1 ,&(Y K[CK A
) $# ,K&T'M)?*+W(#CD#) A . ')*+KW(?'M)? A #')*
.&("#W( \E7'M*ORQ# TO
: 7 ) A '"" ,&( )'#$# #&(')*%W(#C$#O

Fig. 23 Bearing Cap Identification

7'')8CK&( A ,& !7< Q#¡#K2
¢;.1''£')*,[
'1 ,[¤"&(, @BA #CD1 ,&¥
:#¡#¦K#¢_/§'11? X, A 1/ ICK')
,#1 A ')1? XWTK')*§ ¤MEG'*PO?QKU TO?V)#I1? X? A J
A 1/)9W(K[CKYK) A '*P ,) 1.?&()$#.W(¨©M "M')*P &rJ
#1'*1O
¦ V) KR7'M,8. A
J#Q#¦K¦#JM2ª#1 "M' A "
A '"" ,&( )?1'#7,.')*O @ 1#W(6«'KIV) A 'W(#&¥
J#K#¡
CK'M,B. A O{7 A 1 ') A 'W(#&CKM.?)*P ,&#*P#')B
CKCD '1 ' A "§ .?')*!E7'*POBQ#L 6#) A £ &(
') A 'W(#&yO
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.

¡ 8CD&( A N,.')* ,).*1N&( ,[ N1 A 'M"MJ
" ,&( )'#6W(# 0"&(,¬ ;. ')*PO\% ,#.&( ;1 A 'J
K)?W( B/'1 A 'K
'M) A 'W(#1,&§E7'*PORQ#: TO
T< =
[1 \1? A 'K
'M) A 'W(#1,&yO
T<<S[!' , A ')*Y1 A '""M &( ,)'M#ZW(# §')CK 'M')¢
&( \ A '""M &( )?1'#$# #&(')*%W(#C$#,M#) A W(#CDO

1,2-34

5/6"7879:/9<;/=>6 ?A@,?B;C5D5/:/6 EA9@86 ;C9

FHG

IKJMLONQP'RKSDRKTVUXW*TVYMZ/RKS[S[RZ\W*NVT]_^K`[a[bdcea[f[g[h[i

Fig. 24 Install Axle Housing Spreader

Fig. 26 Spread Axle Housing

Fig. 25 Install Dial Indicator

êà?âMÜ3ä(Û #éâä(ÛÜÛåßêÜ[æ ø+ï(àæ#åëPÛ,ìÚ
ÛãÛ,ä\ßÝNßàÛ
âããÛ,äTû
Ûå?ß1âæ#
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Û,æ#ä(âMå?
ë Gä(Û,çÝæ#á4æKå?
á ¥Ûæ#
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áDéäTÛêâå0ß1à?âMêêÛ,ï(ß1âÝ,åßÝáDÛ,ßÛä(Ü[âåÛßàÛðDäTÝðDÛ,äê àâÜ
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ÖT×S
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ä 7× Ø
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áDÝ1öå9ï(çæKÜ[ðKêYæKå?áßâëPàßÛ,åßàÛßÝÝçß1é?ä(åî#éï(õ©çMÛãMâåëPÛärû
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à
âæKç åáDâï(æ#ßÝä (
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ßÝðKâMçÝ,ßBêßéáD/ì .7Ýæ#áß1àÛâåáDâï(æ#ßÝäðKçMé?åëPÛ,äæ#ëPæ#âåêßBßàÛ
ÝðKðDÝê âß1Ûê âáDÛÝã§ßàÛàÝé?êâåë!Öñ7âëPìBØ#ü Ù6æ#å0
á !Ûä(ÝßàÛ
âåáDâï(æ#ßÝäyì

TÖ × Ø ÙÚ
ÛÜ[Ý1ÞÛßàÛáDâããÛ,ä(Ûåßâæ#çªãä(Ý,ÜèßàÛàÝé?êâåëPì
í åê éä(Ûßàæ#ß§ß1àÛNáDâããÛ,ä(Ûå?ß1âæ#ç¤îKÛ,æKäTâMå?ëï(éðDêä(ÛÜ[æ#âå+âå
ðDÝ,êâßâÝåÝåß1àÛ\áKâMãMãÛä(Û,åßâæKç
îKÛ,æKäTâMå?ëPêÖñ7âMëìRØ#ò ÙTì
ÖT× ó Ùô%æ#ä(õoÝäNßæKë!ßàÛáKâããÛ,ä(Ûåßâæ#çFî#Ûæ#ä(âåë!ï(é?ðDêßÝ
âåáDâï(æ#ßÛ0ö§àâï(à3ê âáDÛ÷Ýãß1àÛ÷áDâãMãÛä(Û,åßâMæ#ç9ßàÛ1ø4ö§Ûä(Û
ä(Û,Ü[ÝÞÛ,áãä(ÝÜ[ì
ÖT× ù ÙÚ
Ûßä(âÛÞÛáKâMãMãÛäTÛåßâæKçHïTæKê ÛðDä(ÛçÝ,æKáê àâÜ[ê6ãMä(ÝÜ
æ úçÛàÝé?êâåëPìfô%æ#ä(õÝ,äßæ#ëßàÛáDâããMÛä(Û,åßâMæ#çHï(æ#ê ÛðDä(Ûû
çÝæ#á9êà?âMÜ[êßÝNâåáDâï(æ#ßÛöàâï(àêâáDÛNÝ,ãBßàÛNáDâãMãÛä(Û,åßâMæ#ç
ßàÛø%öÛ,ä(Û\ä(ÛÜ[Ý1ÞÛ,áãMä(ÝÜ[ì
ÖT× ü ÙÚ
ÛÜ[Ý1ÞÛ\êðKä(Ûæ#áDÛ,ä§ãäTÝÜlà?Ýéê âåëPì
ýþÿRý hþ
ãBä(ÛðDçæ#ï(Û,Ü[ÛåßáKâMãMãÛä(Û,åßâæKçHî#Û,æKäTâMå?ëPê%ÝäáDâããÛ,ä(Ûåßâæ#ç
ï(æ#êÛ æKä(Û îKÛ,âåëvâåêßæ#ççMÛ,á
áDâããÛ,ä(Ûåßâæ#ç9ê âáDÛ÷î#Ûæ#ä(âåë

Fig. 27 Differential Case Removal

Ò²Ó

Ô/Õ*ÖÖ×8Ø/×<Ù/Ú>Õ Û[ÜÛÙCÔDÔ/Ø/Õ ÝA×ÜÕ ÙC×

Þ,ß'àÞ

áKâMãOäQå'æKçDæKèVéXê*èVëMì/æKç[ç[æì\ê*äVèí_îKï[ð[ñdòeð[ó[ô[õ[ö

Fig. 29 Differential Bearing Cap Reference Letters

Fig. 28 Install Axle Housing Spreader
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.

jlknmoqprtsuvOwyxzsxz{d|z}+~"zsdz{|xwy{~*}+wyu*-wyxzstu}+s
~"wyxzsxz{|z}n~"zM&su}+|rtswyxzsv~"}+wyuztsV~*wyxwyxzsv~"u
~"zv~"tuwy{rKjl>~"+m_
jlnm s{sQwyxzsQv~"u[~"zv~"tuw{dr
jlnmz}nwyu"[v~"l*srtsdzwy~*u[tu}+sQ~"wyxzsVxz{d|z}n~* z}n|zrts
wyxzuwHwyxzs&v~"l*srtsdzw~"usdurt~"z,t|zp}rtsd\u~*O~"Op{d}+~"wy~*{d
{wyxzs v~"llsdrtszwy~"u¡sdurt~"z}uzv¢wyxzuwwyxzs prts"{duv
}nxz~"\}rtsd\u~" sw£sds wyxzs¤luts¤{\wyxzssdurt~"z¥t|zp
uzvwyxzs)xz{d|z}+~"z¦/upwxzs)v~"l*srtsdzw~"u'tu}+s)wy{,sdz}+|zr§s
wyxzs,surt~"z}Vt|zp}Quzv}+x~*\}Qurts,l|z" ¨¥}nsuwysv~"wyxzs
xz{d|z}+~"z
jlnmz}nwyu"Mwyxzssurt~"ztup})uwwyxzsd~*rV{drt~"~"zuM*{dtu©
wy~"{z}jl~"ªnm§
jl«nm¬{{}ns ¨O~"z}+wyu"[v~"l*srtsdzw~"u[surt~"z)tup¡{d"w}n
jlnm s{sQun®"sQxz{d|z}+~"z)}+prtsuvsdr
jlªnm\¦[~*xzwyswyxzssdurt~"zVtup{d"w}Kw{\««,¯±° j*«)lwy
"}+ m²w{drt³|zs
j§´nµnmz}nwu"[wyxzsQun®"sQ}+xzulwy}n

Fig. 30 Differential Bearing Removal

DIFFERENTIAL SIDE BEARINGS
¶[·¸H¹[ºq»'¼
j§´em s{sQv~"*lsrtsdzwy~*u[*rt{½u+®q"sVx{|z}n~"z
jlnm s{sQwyxzsQsurt~"z}lrt{½wyxzsQv~"l*srtsdzw~"u[tu}ns
~"wyx¿¾>|z""srÁÀ¾rts}n} Â ©lªk©l¾dÃ±Ä¡Â ©lªk©lkªÅ "{tÆ8}nÄ¡uzv
¾*|,oq¾>©*kªj*>~"Çkµnm§

ÈlÉÊË»¼¼»ËÈ ¹HÉ
j§´emÌ±}n~"zÍwy{{Â ©lk«B´n© ÃÎ~"wyxÏxzuzv"sÐÂ ©lB´n«B´+Ä
~"z}nwu"[v~"l*srtsdzw~"u[}n~"vsQsdurt~*}jl~"kB´em§
jlnmz}nwyu"[v~**lsr§szwy~"u ~*un®"sQxz{|}+~"z
RING
¦'xsrtGEAR
~"z\uzvVp~"z~"{,sdurt}HurtsK}nsrÁq~*tsK~",uQ\uwtxsv
}+sdwyMÑ-{{wrtsp*utswxsrt~"zOsur~*wyxz{d|zwrtsp"ut~"z
wyxzsQp~"z~"{sdure

H|

{{?{ B ¡¢H¡<b{{ £¢ <

¤X¥

¦§M¨G©ªr«¬b«%®¯%°M±{«¬¬«^±=¯©%²³´µ¶·µ¸¹º»

þ§ÿYZ
#;$F
2M0()
G()2;[: F*
*,\8()+M]^$(F:;@2

_0()QQ*6*,G84
$*,=+

þ-)YZ
#<$
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("+

þC)Y()4\2:`*a*,b8(c4&
d22 e
Bÿ
þ lm4igmn2+X84()+ 2o'¤þ A/*P+

*P$f\g4hi )-4-_jKk
CC)S+

þI)Y()4;
44;p)! G$'()*74&
5
e

*,;=("$14&
q040M@2&+

Fig. 31 Install Differential Side Bearings

÷[øùHú[ûqü'ý
þ§ÿ

"!#%$&'()*,+
þ-)./01
&2304()567()'289
()9:;$
()<=4,>?):
@40()+þ AB*,+DC4-)
þC)
E8(F$
*G*G*,HE

0("+

þI)JK()*LF()M$4 =OND

*L*P;
QþA/*,+RC-)S+

Q

0("

Fig. 33 Ring Gear Bolt Installation

PINION
GEAR
]r$&sS&*t
u@v*P(wd("x
0
uy
=20S$
q("2+{zr9&K@440%$%@5*,|:;$'
@40*L$*L*,O+

÷[øùHú[ûqü'ý
þ§ÿ=2

2$&%)! $'("*P+
þ-)}94~@ue ~&
@S@s()$a
()241*P=+

þC)z|()0&0\@@_("$&4\@e ~&+

JK()*9()'28<:;NB@4@3()$|'&
8
?eP+

þI)JK()*X
54gh627$
e#~N;=
72$&

@9e ~%&'<
=: ("$O+

þh)JK()*=
#fiIh-a
c10$di4C-Bÿ"N
@1("$Mþ AB*P+RCI"+
þ)=2
$ @q*PK$'("*Qþ AB*,+C4h)+

=
$@%e ~&

Fig. 32 Ring Gear Removal

üýýü&WRT úXU

TU V/W

CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.

20$2$&F@4&: $e#'$4&
GF@4

&*H
8*L
=*,
+

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2$&b@84&*0'@a: 2$

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;QICIhF
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!#"$"$%'&!%)(!*+ ,.-,(/0!&! 12%$-$ (/%

3465$7

8:9<;>=@?6A:B0A:CEDGF#CEH<I!A:B.B.AIJF#=ECLKNM:O.P.QRSP.T.U.V.W

Fig. 34 Pinion Yoke Removal

Fig. 36 Front Bearing Cup Removal

Fig. 35 Remove Pinion Gear

¼S½)¾)¿ÀÁÂ=Ã2Ä ÁÅ2ÆÁÇÁÈ4Ç7ÉÁÈ4ÇSÊË&ÌÍÎÏcÐÇÃÂÑÆÃÎÒ)ÊËÌ
¼Ó/ÊÌ,ÔRÕÖ)¿SÔR×<Ò"ÁÀÁÂ ÃÄ ÁÇ;ØrÙS½)Ú4ÛHÈ4Ë&ÜqÝXÈËÜÞÁßàÚ/½)Ö½)Ô
¼S½½O¿ÀÁÂ=ÃÄ#ÁÅÆÁfÍÃÞÞÈÏÒ)ÊÉÞÁfÏÇÁÞÃÈ4ÜáÒ)ÏÈÍÁÇn¼ÓBÊÌ,Ô
Õâ)¿SÔ
¼S½)ã)¿ÀÁÂ=Ã2Ä Á;ÅÆÁ;ÇÁÈÇKÉÁÈ4ÇÊËÌÐÇSÃÂÅÆÁ;ÏÊËÊÃË=ä;ÊÅÆ
å ÎÞÞÁÇxæ å ÇÁÒ"Ò\ßÙãÛÕ4Ù åç

È4Ë&Ü
ç

ÜÈÏÅÁÇÒßÙãÛÕÙÚ¾f¼ÓBÊÌ,Ô

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è^éxêë4ì9í9ê&îBêï/ðSì4ñ=òéxóëôBõõóFðSöDì"÷îBóFøDóðMî/êùHêúì
ðöDìqòì4êñZûOøDú1ë4ê&úìü
¼S½)Õ)¿ÀÁÂ=Ã2Ä Á=ÅÆÁ ÜÁÏ4Å2ÆqÒ)ÆÊÂ=ÒÐÇÃÂaÅÆÁ=Ï4ÊË&ÊÃËqÌ,ÁÈ4Ç
Ò)ÆÈÐÅ2ÔDÀÁÍÃÇÜqÅÆÁÅÆÊÍýËÁÒ)Ò ÃÐÅ2Æ&Á%Ü4ÁÏÅÆ1Ò"ÆÊÂ=Ò)Ô

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t

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ÞÎÉÇÊÍÈËÅ<Å2ÃÃÎÅÒ"ÊÜÁÒ"Î&ÇÐÈÍÁÃÐÉÁÈÇÊËÌLÍÎÏÔ

Fig. 37 Rear Bearing Cup Removal

ËÒ)ÅÈ4ÞÞaÅÆÁÏÊËÊÃË ÇÁÈÇÉÁÈÇÊËÌ ÍÎÏvä;ÊÅÆ
ËÒ)Å2ÈÞÞÁÇØ|ÙS½)ÚF
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t

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ÈGÞÊÌ,ÆÅ;ÍÃÈÅ2ÊËÌ1ÃÐXÌPÁÈÇ9ÞÎÉÇÊÍÈËÅ ÃË_ÅÆÁ
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Fig. 38 Collapsible Spacer

Fig. 40 Pinion Rear Bearing Cup Installation

Fig. 41 Pinion Front Bearing Cup Installation

Fig. 39 Rear Bearing Removal
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
bearing.

X Y[Z\]#^_a`cbedf`cgihaj g$`hkbedflm_an'of`pqpr$`g$bedspqdflmtuj osbedf`
g$lmoflmj owv`^hx
Xy[Zz{ofp[be^i]m]|bedf`}ha`^h~` ^halmofv^ofrpq]mlmofv`hulm
` flmg$gi` r$jobedf`g$lmoflmj o0v` ^hlmbd0z{ofpqbe^]m]m` h
Xlmvx[Zx
X[Zz{ofp[be^i]m]^of`_aj ]m]m^g$p[l#~]m`g$ha` ]mj^irkpqgi^i_a`hj og$lmof
lmj opqdf^b^ofrlmofpqbe^]m]g$lmoflmj ov` ^hlmodfj fp[lmofvX+lmvxi[Zx
X[[Zz{ofp[b^]m].g$lmoflmjov` ^hlmowdfj fp[lmofvx
X SZz{opqbe^]#]< jn`lmbed0z{ofp[b^]m]m` hw¡_aha`¢y[i:£¤fg
y[i^ofrdfj]#ri` h:i¥yXlmvx¥[Zx
X[[Zz{ofp[b^]m]bedf`¦ jn`¦^p[df` h^ior^Eof`{§offb6jocbedf`
g$lmoflmj o¨v`^h:^ofrblmvdb`owbedf`g$lmoflmj o¨offb<foblm]¤bedf` ha`lmp
© ` haj@~`^ihalmofvk`ofr$gi]#^[ ªx
X[[ZJ«2lmvdfb`obedf`@offb<bj@Y¬ t®X#i#bx]#~p[x Zx

346587:91;<*;=?>A@=?B6C;<&<&;DCE@7?=GFIHJ&K&LNMOK&P&Q&R&S

!"# $&%'$()* +,% )

-/.102

Fig. 42 Pinion Seal Installation

Fig. 44 Collapsible Preload Spacer

Fig. 43 Shaft Rear Bearing Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque
sequence will then have to be repeated.

ÔÕ[Ö[×ØÙ[Ú#ÛÜJÝÞ ß'àkáfÞâmã$à äJåæçiècéÛfãwé¨êeÞ äaëìfà:íäaà Ûfîaá
Ù[à ê<éê<ÖïÖðñ òóÔôçiõköêe÷âmøÙq÷ ×ù+îaäaìfÙqá¨îaÞâ#âméú$Ù[ÚmøiâmàÙ[ú$éîaà ä
ìfÛfêeÚmâ.øà éäaÚmÛfÜkà Ûãcú$âmé[Ý>ÚmÙêéß'à ÛwìfúÔû+ÚmÜ÷Öåq×N÷
NOTE: If the spacer requires more than 474 N·m
(350 ft. lbs.) torque to crush, the collapsible spacer
is defective and must be replaced.

Fig. 45 Pinion Yoke Installation

Ô Õ[ç[×üâmÞíâ ÝsêeÚmÜáfêeà ÛýêáàÛfìêÚmÛýåi÷ èwðñ òþÔ#çwöêe÷2âmøiÙ[÷ ×
ÚmÛfîaäaàòJà ÛfêeÙìfÛfêeÚ#âÿêeáfà äaÞ êeéêÚmÛfÜ êeÞ äaëìfà Ú#ÙéîaáfÚmà à ã$÷
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Fig. 46 Tightening Pinion Nut

Fig. 48 Typical Housing Cover With Sealant

DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL

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Fig. 47 Check Pinion Gear Rotating Torque

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CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

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e Fig.
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6 ý¬þ 6 fû(7yDIFFERENTIAL

ícî#îDï¬ðsñcògFig.
ó 50 Pinion Mate Gear Removal
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Fig. 51 Trac–lok Differential Components

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Fig. 54 Mate Shaft Removal

Fig. 52 Differential Case Holding Tool

Fig. 53 Mate Shaft Lock Screw

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Fig. 55 Step Plate Tool Installation

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NOTE: The clutch discs are replaceable as complete sets only. If one clutch disc pack is damaged,
both packs must be replaced.

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Fig. 56 Threaded Adapter Installation

Fig. 57 Tighten Belleville Spring Compressor Tool

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Fig. 58 Remove Pinion Gear Thrust Washer

Fig. 59 Pinion Gear Removal

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Fig. 60 Side Gear & Clutch Disc Removal

Fig. 61 Clutch Disc Pack

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Fig. 62 Clutch Discs & Lower Side Gear Installation

Fig. 63 Upper Side Gear & Clutch Disc Pack
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m

Fig. 64 Pinion Gear ID Numbers

´
x y{z(p
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Fig. 65 Shim Locations

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Fig. 66 Pinion Gear Depth Gauge Tools—Typical

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NOTE: Arbor Discs 6732 have different step diameters to fit other axle sizes. Pick correct size step for
axle being serviced.

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Fig. 67 Pinion Height Block—Typical

ÖJð
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ü è2çÜ æ&úÛRáEùiÞ"ÛRúçò9Úà"ãû
Fig. 69 Pinion Gear Depth Measurement—Typical

DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
ß!à üKü Ûè2Ûãæ7à"áÞYÚEà"äÛ$ÝÛáè2à"ãû-ø/è2ÛÞ"çáä%áãä%ûÛáèTÝáå2ïHÞ"á/ÚEú

Fig. 68 Gauge Tools In Housing—Typical

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Fig. 70 Axle Adjustment Shim Locations

NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.

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72 Differential Side play Measurement
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SPECIFICATIONS
194 RBI AXLE
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ÖX×5ØÙ ÌNÚBÐ%ÒÑIÉ[ÉÉÉÉÉÉÉYÊ8Â`ÛÆ-Ü5Å Ù Ë ÐÄÄ ÇFÊdÑÐ Ø ÄÅoÝÞß<ÍàÞ
ÖX×5ØÙ ÌNÚBÐ%ÒÑzÆ Ù ÐÌÄÅ Ù ÆXÏ"áâÉÉÉÉ[ÉÉÉÉ]ÊJÇzÒÑÜ5ÅÑ(ÌNÚ-ã%äßIÍXåæÞ
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ï ÌðNðÅ Ù ÅÒ5Ñ(ÌNÐÄÊdÌÕ_ÅóÅ Ð Ù ç,ÄNÅÐ Ù Ð%ÒÚÅIÉÉÉÉÉÉYÞ%ÍÞÉWåä Ë Ë
é ÞÍ%ÞÉ ÞÞè ÌÒ5É ì
í,ÌÒ5Ó$óÅ Ð Ù-ï ÌÐË Å Ñ(Å Ù É[ÉÉÉÉÉÉÉÉÉ-åàÉô ÚBË é ãÉ äè%ô.ÌNÒÉ ì
í,ÌÒ5Ó$óÅ Ð Ù ñ,Ð%Úõ[ÄÐëÜÉÉÉYÞ%ÍÞÉWåä.Ë Ë é ÞÉ ÞÞä%ÍÞÉ ÞÞ%Ý ÌÒ5É ì
òXÌNÒÌNÏÒÊdÑ(Õ_É ï ÅÈ_Ñ(ÜöÉÉÉÉÉÉÉÉ[ÉÉ]àôÉ Þ%Ý Ë Ë éê É èô%ä ÌÒ5É ì
òXÌNÒÌNÏÒñ,ÅÐ Ù ÌNÒÓ.ò Ù Å ÄÏÐ%Õ%÷ø Ù ÌÓ8ÌÒ5ÐÄñ,ÅÐ Ù ÌNÒÓ8ëÉ-åÍô ù`ú Ë
é åÞÍô%Þ ÌÒ5ÉÄ Ø ëÉ ì
òXÌNÒÌNÏÒñ,ÅÐ Ù ÌNÒÓ.ò Ù Å ÄÏÐ%Õ%÷ù`Åáûñ,ÅÐ Ù ÌÒ5ÓJë]ÉÉÉåÉ äÍæ ù`ú Ë
é åäÍ ê ä ÌÒ5ÉÄ Ø ëÉ ì
ü ÐÃdÌË × Ëöç,Ð ÙÙ ÌÅ Ù ÊzÈ Ù Å ÐÕÉÉÉÉÉYÞÉ äXå6Ë.Ë é ÞÉ Þô%Þ.ÌNÒÉ ì

194 RBI AXLE
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ñ,Ï ÄÑ(î5ñ,ÅÐ Ù ÌÒ5Ó$ç,ÐÈÉÉÉÉÉ[ÉÉÉÉÉÉÉYãã ù`ú Ë é ä%ã ðNÑÉ5Ä Ø ëÉ ì
ù × Ñî5òXÌÒ5ÌÏ Ò ÉÉÉÉÉÉÉYôãXåÍæã%æ.ù`ú Ë é ôÞÞÍ ê äÞ ðÑ(É5Ä Ø ëÉ ì
ÊdÚ Ù Å"áî5òXÌÒ5ÌÏ Ò ü ÐÑ(ÅoÊdÜ5ÐðÑ Ö Ï Úõ ÉÉÉÉ[ÉÉÉÉåèÉ ôä ù`ú Ë
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ñ,Ï ÄÑ(î5í,ÌÒ5Ó$óÅÐ Ù ÉÉÉÉÉ[ÉÉ]àäÍåôô ù`ú Ë é ãÞ%ÍàÞ ðÑ(É5Ä Ø ëÉ ì
ñ,Ï ÄÑ(îÂ`ñ,ÊFÊzÅÒ5ëÏ Ù ÉÉÉÉÉÉÉÉ[ÉÉÉÉÉYÝ ù`ú Ë é ã%Þ ÌÒ5É5Ä Ø ëÉ ì

Adapter—C-293-39

Adapter—C-293-40

SPECIAL TOOLS
Plug—SP-3289

194 RBI AXLE

Puller—C-293-PA

Puller—C-452

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4656768:9<;>=?6@A@A=4CBD8>EFGIHJFKLMN

132

Cup—8109
Wrench—C-3281

Installer—C-3972-A

Handle—C-4171

Spanner—6958

Driver—C-3716-A

Installer Screw—8112

Installer—D-130

OP
_6`6a6b:c<d>ef6gAgAe_ChDb>ijkIlJjmnop

Installer—D-146

QRS S T UTVWR XYXVQQUR ZT Y R VT

Installer—6436

Remover—C-4345

Installer—6437

Remover—D-149

Disc, Axle Arbor—6732

Installer—W-262

Gauge Block—6735

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Tool Set, Pinion Depth—6774
Spreader—W-129-B

Trac-lok Tool Set—6960
Adapter Kit—6987

Holder—6965
Guide Pin—C-3288-B

Starting Point Shim—8107
Bearing Remover Tool Set—6310

¢6£6¤6¥:¦<§>¨©6ªAªA¨¢C«D¥>¬®I¯J°±²³

Hub Puller—6790

Dial Indicator—C-3339

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216 RBI REAR AXLE

´µ¶·¹¸
page
GENERAL INFORMATION
216 RBI AXLE . . . . . . . . . . . . . . . .
LUBRICANT SPECIFICATIONS . . . .
DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL . . . . . .
TRAC-LOK OPERATION . . . . . . . . .
DIAGNOSIS AND TESTING
BEARING NOISE . . . . . . . . . . . . . .
DRIVELINE SNAP . . . . . . . . . . . . .
GEAR NOISE . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . .
LOW SPEED KNOCK . . . . . . . . . . .
TRAC–LOK DIFFERENTIAL NOISE
TRAC–LOK TEST . . . . . . . . . . . . .
VIBRATION . . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . .
REMOVAL AND INSTALLATION
AXLE BEARING AND SEAL . . . . . .
AXLE SHAFT . . . . . . . . . . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . . .
DIFFERENTIAL SIDE BEARINGS . .

. . . . . . . . . . 84
. . . . . . . . . . 84
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86
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93
92
94
95

GENERAL INFORMATION
216
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page
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 100
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 97
PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . 91
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . 101
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . . 101
CLEANING AND INSPECTION
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . 105
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 108
GEAR CONTACT PATTERN ANALYSIS . . . . . . . 111
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 106
SPECIFICATIONS
216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 113
216 RBI TORQUE . . . . . . . . . . . . . . . . . . . . . . . 113
SPECIAL TOOLS
216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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Fig. 1 Axle Adjustment Shims

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CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.

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Fig. 2 Differential Operation—Straight Ahead Driving

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DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL

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Fig. 3 Differential Operation—On Turns

TRAC-LOK
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DIAGNOSIS AND TESTING
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SNAP

ÒEÓNÔÕ

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õ õB÷5ï<økóù7ð9õlò9óúó2îAó2ô-;
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TRAC–LOK
LNMOPRQ%S.TNUDIFFERENTIAL
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TRAC–LOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHICLE SUPPORTED. A TRAC–LOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE.

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Fig. 5 Trac-lok Test —Typical

SERVICE PROCEDURES
LUBRICANT
CHANGE
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Fig. 6 Apply Sealant

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CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
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REMOVAL AND INSTALLATION
REAR AXLE
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NOTE: The weight of the vehicle must be supported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, vehicle ride
height and handling could be affected.

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Fig. 7 Pinion Yoke Removal
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PINION SHAFT SEAL
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Fig. 8 Pinion Seal Installation
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Fig. 9 Pinion Yoke Installation
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to the pinion bearings may
result.

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prevailing torque nuts can loosen, causing a dangerous condition.

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Fig. 13 Cut Retaining Ring

Fig. 14 Axle Bearing and Seal Remove

Fig. 12 Drill Retaining Ring

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Fig. 15 Axle Bearing and Seal Components

Fig. 17 Press Bearing Retaining Ring On Axle

Fig. 16 Press Bearing On Axle

DIFFERENTIAL

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Fig. 18 Bearing Cap Identification

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CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.

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