Jeep Wrangler TJ Manual

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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

VEHICLE
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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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Fig. 5 Thread Notation Chart – SAE and Metric

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TORQUE
,.-/10 230/14REFERENCES
576 8:9<;>[email protected][email protected];>EGFH57IJIJ?<51;[email protected]?B?<-/N9PO

0_-/J0 2d0_/[email protected]<;>=74? ^>C57;>EMFcW

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^>57EG09<-FADC57;>EO9<; EG9<;>[email protected]?a;>?PO?<;>?P-^b?PF-9<E6_0FcEG?P/0_-LEGC?
e3fhgji[klnmDoDlDpqsrqspjtVeDqsfum

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9

INTRODUCTION
˜™›š œašžœŸ
page

page

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GENERAL INFORMATION

• ß>×1ÝÍ ß>×7Ï_Ñ_ê
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VEHICLE
ËjÌ@ÍaÎDÍPÌIDENTIFICATION
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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
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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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Fig. 1 Vehicle Safety Certification Label—Typical

VEHICLE
SAFETY CERTIFICATION LABEL
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Fig. 2 Body Code Plate Location

BODY CODE PLATE
LOCATION
AND DECODING
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LQS‡bi=MIYAYTz=qEH=MPg;kACB=qACT3IYSMPpqGJLQACSMT3[’[email protected]pqGmLQACSMTdP=MGJbmE(IYPSMp
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Fig. 3 Body Code Plate Decoding

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GENERAL INFORMATION
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INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1
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30,000 Miles (48 000 km)
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9,000 Miles (14 000 km)
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36,000 Miles (58 000 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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105,000 Miles (168 000 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,
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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

> [email protected]#>

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CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.

HOISTING
í&îïAîðñ2ò’ñ/óRECOMMENDATIONS
î’ô~õö îð÷ øPù=úö ûúüLï ò
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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:

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s†'v:Š‹#š1{‚T‹=z›‘=†'„ ŒTzš*€t€„ƒ!{…~

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

zdzt‡„*tz-€ †g{†'v:tƒ!Š„*ƒ!ƒ
„€ t€ „x‹#v:t~
zdŽ1|z x{…v:tˆ~
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‹=ztƒ!„*€ tv=†'Š~
‘†'v:tƒ
Ž*z†`‰'v=ƒ!z~

NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
’T“” •%–
s—ŒTz „‰'xz-‰'v:t}:z-x„Ž1{z˜<„{™






ƒ!„#zdƒ
„xx~

sƒ!„*t‡2xzš1‹=€ƒ!{…›œŽ1†'v:Šzš*‰'€t{v:‰'{P€„ƒ!{…~
s{˜<„tš1‹=€ƒ
{›‘‰6v=ƒ!ƒ
„ƒ<€ „ƒ
{~

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

^&[email protected]`

SUSPENSION
Ä-ÅRÆdÇ ÈgÆ,ÇgÉ

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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
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CAUTION: Never attempt to modify suspension or
steering components by heating or bending.

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ëãä/å*ä æ:ø#çéè;çéï!çø#ä^ä ø#èäï,æ=éøëñ'æ=çåçéè;çéï!çø#ä

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}|~oG€G'‚€9ƒG„G…G†

Fig. 1 Wheel Alignment Measurements

j4k

‡1ˆ

‰VŠH‰V‹9ŒZ[‰GŽ [

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
“F”K•s–K—7”{˜Q™Lš—I™(›œ?Ÿž) ?”K”'¡¢š¡›£œ¥¤ ”Kœ?™L¦§™( ¥”¨•–'¡¡s–(ž)›œ?

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¾$›š £œ?–'˜Q›˜)¿F ?š —7™A•s–K—-š ¬O¬›™(›–Kœ¥š¡F›sœ¥•–K—7¤)š™L›–Kœ?¶
ÀIÁ´à œ?˜M©O”'ª7™A™(›—7”'˜)•–K—˜Q›ÄZ”wš œ?¬´™(—7”'š ¬Åž-”Kš — ¶
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WHEEL
“F”K•s–K—7”ÍALIGNMENT
”'š ª7 Õš ¡s›œ?¤ ”Kœ?™ —7”'š¬›sœ¥Ö™L ?”wËʔ' ?›ª7¡”͘M ?–K²?¡¬

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³ ²?¤ ©O”'— š ™4™L ?”ª7”'œ?™L”K—)š œ?¬×'–K²¥œ?ª7”™L ?”1ËʔK ¥›sªI¡s”²¥©š œ?¬
¬O–(ž)œÚ™L ?—7”'”z™L›s¤)”K˜Q¶£Û¡ ž)šM®Ê˜)—7”K¡”Kš ˜M”z™L ?”z³ ²?¤ ©”K—-›œÚ™L ?”
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š ¬L×'²¥˜Q™Lš ³¡”wš œ?¬´ª7šœ¥œ?–K™A³ ”wš ¡™(”'—7”K¬O¶
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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

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Ÿ" ¢¡

46587:9<;>=-?@BACAEDFGHFJI6ALKMDFNFJG$AEONFP[email protected]>QRONSTKMQHA>DUA>DFA>QHF
[email protected]];`:W/F_XYXL? Va$SZbdc6A>egDfhFP@[email protected][\AEQHFONS?S]A>@iQHGMAEDAEDF FGHQHFNjkI6DACAlKMKMDD[email protected]^mnON]@BA_QHA>AEQHOJDS F
A>DF"opGH]`:Prq[email protected]]@@8DOEKMS46sQRjtW/V u87:]S;rA>QRjtDA>FJSAEO_vw
f<x `h4Rvy^IRAEW/GHq@BW 7W/zT{|}~N€ }‚ƒ }‚„}~N}‚‚… †n‡‰ˆn„}~
† „‚lŠƒ {† ‡}Tˆ€ … † ‡rŠ‹Œ{"Ž‰‚… ‡ƒ ‚}† … † ‡
4687:‘dF QHI ’A>DF QRjtDA“A>ONF@BPFJopQHI6QHop]A>QRONS@”]S;A>? V S‰ONI6I
A>DF•FJSjtQRSV FJW V
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
NOTE: Alignment specifications are in degrees.

Fig. 4 Steering Linkage

ADJUSTMENT

PREFERRED

RANGE

MAX RT/LT DIFFERENCE

CASTER



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[\

]_^`]_acbed`]gf h`d

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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õ_ö‡õ_÷gøeù`õcú û`ù

üýžþ

SERVICE PROCEDURES
LUBRICATION
§

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REMOVAL AND INSTALLATION
SHOCK ABSORBER

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COIL SPRING

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µ6á>·„è9Ã=Â!ӎÃ,¿Æ¡ÆXÄ$Ê>Ë!»(¿¿#¹(Ë!½½-¾¹OÈ6Â!» ¿½ÉXÂ!» ÉX¹(Ì$Ì$¹ Ê>¾Ã=ÈK½
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µ6ß>·„êÄ$Ê>Ë!»(¿¿#¹(Ë!½9½/¾¹ÅÊ3½-Ã,Ñ=Ä$Ì$Ä$ëe¹(ÂOÑ,Ã,ÂOÌKÄ$¿ÓʖÃ,¿ÆxÊ3¾» Ë!Ó
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µ6Û>·„zÐ5¹ €½-¾¹‚Ã3ґÌK¹‚À¿½-Ä$Ì ½-¾¹šÊ>ÉXÂ!Ä$¿ÇÄ$Ê)ÈKÂ!¹(¹‚È6Â!» º£½-¾¹
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NOTE: Left coil spring has a retainer and bolt
which must be removed from the axle pad.

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

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ÞÀßhà ádâãádäåeæãáÝç èãæ
ëìí‚îïmðñ›ðòóõôòö÷ãðññð÷
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STEERING
79465T62?A9MO462?)_5'`+Q1*2)N+-2?246C'OBaDO'*MOT6DO.02:,;'*A
] 548)N24^L=C0T62:KNUCKLE

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2?.0C0'*2>

LOWER SUSPENSION ARM

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+-1*2462?,;&4 Lower
Aƒ'OM*+83C0'*BW2?4:Arms
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UPPER SUSPENSION ARM

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b 46,;T6DO2+8,;'*A&346,;F
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NOTE: Small holes in the side of the arm face
inboard.

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FRONT AXLE BUSHING

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leave Spacer 7932-3 in position for bushing installation.

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SPECIFICATIONS
TORQUE CHART

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SPECIAL TOOLS
FRONT SUSPENSION

Bolt, Special 7604

Remover/Installer Suspension Bushing 7932

Remover C-4150A

Nut, Long 7603

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Æ_ÇwÆRÈÉ(ÊwÆË ÌwÊ

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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
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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
–0—j˜™(šDIAGNOSIS
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"!$#&%('&) *'

REMOVAL AND INSTALLATION
SHOCK ABSORBER

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+-,

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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

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Fig. 1 Shock Absorber

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Ø Ú2üÝï/çæ9ß à:æ@çßdê"ä@óAß å,àâæcæ9ä;Ù `ý„þ îiØ ÿôæ@ìKêðÞì ÚYì


Fig. 2 Upper & Lower Suspension Arms

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COIL SPRING

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ç báåÜâê"Ý" é
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Ú täaóAß(åcæ9çß,Üëbêß,âàæ@Ý"êIæ9çß,ÞãåÝ"àï2Ý"ބô7åß ß,ô7åä(îÀæ9çß
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÷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
Ø7íÚkۉÜÝ"Þ߸æ9çß~Üëbê"߸Ý"àæ9ä¸ãä(ÞÝ"æ9Ýä(à€âàæ9Ý"êdæ@ç߸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:Üàáƒô7Ý"àï/ß å%æ@Ý"ï/çæ@ß(à
æ9çßhàâæ9Þì

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13254R6E8"2Š:=<>2p?:EFcMIMT™š2(CVcFCVC25:=FMG>25C[c6(I:E?œFG>H
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UPPER SUSPENSION ARM
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P0DO

Fig. 5 Stabilizer Bar Link

Fig. 4 Parking Brake Cable/Bracket And Wiring
Bracket
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Fig. 6 Stabilizer Bar
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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).
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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
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èßÖãêBÙ(ànÒë†×ì€åbíÔDå
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ÖÚ>Û
ßÙ5çRÞEâ"Ù;à=á>Ù;àEßÖãêvèÖߛå

Fig. 7 Rear Track Bar
ðñ"ò†ó€ÐÑBÑ5ÐBóbð Î-ñ
ÒDÓmÔ
ô9Ú>Øà=Öääà=á>Ù[à=ßÖãêqèÖß
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ô9Ú>Øà=Öäälà=á>ÙWàEßÖãê[èÖßX×ڜà=á>ÙWéßÖçRÙWßÖ×TäèßÖãêsÙ5à
ÖÚ>Û
äTÞ(Þ5ØÙ5ä ö[×Ú>Øà=Öää&àEáBكèÞ(äTà´ÖÚBۈÚ>ÜBàEå

NOTE: It may be necessary to pry the axle assembly over to install the track bar.
ÒîÔ
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TORQUE CHART

 
 


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DIFFERENTIAL AND DRIVELINE
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~ "ŽyO‚
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‘ ” % • ” ‡"†"†"‡"“–—%„ ˜Š–™ˆ"ˆ"ˆŠˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆŠˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆD~

PROPELLER SHAFTS

ƒfšO›O‡ …
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
2
1
1

... 5
... 4
... 3

... 6
... 6

GENERAL INFORMATION
PROPELLER
SHAFTS
œ"žŸf ¡¢ £C¤f¥Q¡¦
¥QŸG§©¨&ª>¥

¨&žQ«f«¬žQª®­¯§9Ÿf£‹¤f­°£C¥£Cª §¡­¯±i¤¬£
¨&¥³²´ž ª‰Ÿ;ª ¥ ±µ¥ ¡ž¶¨&¥ ¤¬¡£·£C¥¸§¡¥Q£³"ž ªº¹‹œž¸­¯§Ÿ;£·¤¬­
»&žQ­¼¤¬½A¡"ž »y£³¥¾­¯ž ¡»y£C¥ ª ¿ ž¾Ÿ;ª ¥Q±À£Cž¾£Cª §¡­¼±i¤¬­¯­¼¤¬¥ ¡§¡»
£Cª §¡­¼Ÿfž ª0¢>§9­¯ž]£³¥]£Cž]»&ª ¤ Á%ž]§¯Â%«¬žQ­iÃfĤ¬½A¹)Å/Æ>¹
œ"žÇ¨&ª ¥ ¨9ž «¬«¬ž ª`­¼"§9Ÿf£È±i ­¯£È¥ ¨9ž ª §£CžÇ£³"ª ¥  ½#É¢>¥ ¡Ê
­¯£³§¡£C« ËÈ¢ §¡½A¤¬¡½[ª žQ«¬§9£C¤ Á%ž‹§¡½#«fžQ­ÍÌž £Î²´žQž ¡Ï£Cž‹£³ª>§9¡"­¼Ê
±i¤¬­¼­¯¤¬¥ ¡G§¡»]§¼ÂЫ¬ž ¹ÐÑÒ£O±i ­¯£Ó§«¬­¼¥Ìž¢ §¨&§Ì«¬ž¥QŸ¢ §¡½#¤f¡"½
«¬ž ¡½#£³i²´¤¬«¬ž´£³ª §¡­¯±i¤¬£³£C¤¬¡½c£C¥Qª ¿9 "ž ¹9œ"ži§¯Â%«¬ž´ª ¤¬»&ž ­­¼ "­¼Ê
¨&žQ¡»&žQ»Ô̼Ë7­¼¨&ª>¤f¡"½A­¤¬¡Í§]Ÿ;«¬¥ §£C¤f¡"½|±i¥ £C¤¬¥ ¡¹Aœž0¨&ª ¥Q¨&ž «¬«¬ž ª
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½A¥Q¤¬¡½e¥ÒÁ%žQªÕÁЧ9ª ¤¬¥Q ­¸ª ¥ §»Ö­¼ ª>Ÿ;§¢ ž ­¯¹×œ"¤f­¸¤¬­¸»&¥Q¡ž
£Cª ¥  "½A® ¡¤ Á%žQª ­¼§«&ØQ¥Q¤f¡"£³­¯Ù²0¤¬¢ ®¨&ž ª ±´¤f££³"žG¨&ª ¥Q¨&ž «¬«¬ž ª
­¯§Ÿ;£4£³¥¥Q¨&ž ª §£Cž§£4»&¤¬Ÿ;Ÿfž ª žQ¡£4§¡½A«¬ž ­¯¹6œž­¯«¬¤¬¨4ØÚ¥ ¤¬¡£C­Ãf¥ ª
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œ€ "Ì9 «¬§ª0¨&ª>¥ ¨&žQ«¬«fžQª0­¼"§9Ÿf£³­´§ª žç«¬§9¡"¢ ž »D̯Ë[£³ž]±i§¡Ê
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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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Ë%¥QÛ"ž0«¬ ½#­¤¬¡7«¬¤¬¡ž²0¤f£CÍž §¢ Í¥ £CžQª4²´"¤f¢>7¤¬­¢ §«¬«¬ž »ÔÝڞ ª ¥
¨&§­¯¤¬¡½A¹Aœ¤¬­»9ž ­¯¤f½#¡Í¨9ª ¥ »& ¢>ž ­ £³"ž0­¯±i¥ ¥Q£³"ž ­¼£Óª  "¡¡¤¬¡½
¢ ¥ ¡"»&¤¬£³¤¬¥Q¡Ù§9¡Þ¥  £CÊ;¥QŸ;Ê;¨&"§9­¯ž®­¯§Ÿ;£Ü¢ §¡©¢ § ­¼ž×§“ÁФf̪ §Ê
£C¤f¥Q¡¹
ß)à&áCâã6àyäåæà9ã#çâè"é>êºåëè“ìLà&íêºçîïà&ðémíàyñã6âñ
à&îïî/à9ã
íò è"á³é)èåæ¾émíàÔóô õAâêºåé òò íâäîïæ¾öàÔçâ6ì€à&ã6à&æ¾âé)ñã6à&ô
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ìLêºö%ã#è"é>êºâ"å÷
CAUTION: Use original equipment replacement
parts for attaching the propeller shafts. The specified torque must always be applied when tightening
the fasteners.

PROPELLER
œ"²0¥È»&¤¬ŸfŸ;ž ª žQ¡SHAFT
£¾£ÎË%¨&žQ­øJOINTS
¥QŸÍ¨9ª ¥ ¨&žQ«¬«fžQª°­¯§Ÿ;£ØQ¥

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Ìž]ª ž ¨&«¬§¢ ž »7§­´§Í¢ ¥Q±i¨&«¬ž £Cž]§9­¯­¼žQ±iÌ« Ë6¹

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“7”

Fig. 1 Propeller Shafts

Fig. 2 Single Cardan U-Joint

PROPELLER
 "!$#&%')SHAFT
(+*,-%/.0#1$JOINT
&2#43542)ANGLE
467(+8(9.0#1&1&#4:4#4;2<

-)>=+)?9-)(+@;A%7*,#4601&?9;A%7.0(+BAB4?92)>#4C460(D-;A)3E(+)35BA4F
[email protected])&BA(D6H3567-)&(+)35BA<I-)&BA(+603567-)&(+1&#J)8#*K(+)3LJ)M
BA(+6N(+.0.04BA60(+2;A#4O(D?P?.04BA60(+2;A#4O#*Q-)E:4#4;A)2F[email protected]);A%
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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.

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SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION
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PROPELLER
SHAFT
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Fig. 9 Front (Output) Angle Measurement (A)

Fig. 10 Propeller Shaft Angle Measurement (C)

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

Fig. 12 Universal Joint Angle Example



° ±g²

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REMOVAL AND INSTALLATION
FRONT PROPELLER SHAFT
1(24365(798:

Fig. 14 Reference Marks on Yokes

\; F=f¥(Ar€UOE`SBI¬E`UOSMOI4A R9SBPQCFG[Wˆ@[email protected]­EdPQG[IOCFZ\S+PtVQGJCFS
u[@BWDE`C|[email protected]b[•mq© e®;\b[œ•Z\E`a WDu[CYa =[email protected]+PQ«[MOSBa
;\“F=?¤}@†–|S+P"E`UOSqRTS+UOADVQWDSBa
Fig. 13 Front Propeller Shaft

;%<,=?>[email protected]N@+PQERTS+UOADVQWDS@BIXCYG[Z\S+E^]_CYE`G[IOKCFa
;\bF=?c9UOADZ\E(E`UOS6EdPQG[IOCFefADCYCFA@+IG[IOKE`PQGJI4CYZ\S+PgVQG[CYS+h9ADZiIOS+VQj
SBCFCYG[Pk]lh ADIOE`@EdU4SnmHSBMOE`PQG[W(N@+CYADE`A@+IOa
;\oF=?pqCFADIOrsGtCFMOADE`GJu[WDSvefG[PQwxSBPyh"efG[PQwzG{WDADIOSvG[[email protected]
E`UOSg][email protected]|G[EEdUOS|E`PQG[IOCYZSBPqVQGJCFSBh
EdUOS|WDADIOw|][email protected]+w4S+h}G[IOKN[email protected]
NS+WDWS+P?CYUOG[Z\E6][email protected]_G[E~E`UOS_PQS+G[[email protected]+Z|EdU4S_Z\[email protected]+IOE~N[email protected]+NS+WWDS+P
CFUOG[Z\EHZ\@+P"ADIOCFEdG[WDWDGJE`[email protected]SBPQS+IOVQS;\}Ar€a<FF=%a
;\F=?‚~GJPQw~GWDADIOSG[[email protected]N[email protected]CYUOG[ZE
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E`UOSEdPQG[IOCFZ\S+P"VQG[CFS6][email protected]
;\F=?c9SBNG[PQG[E`SŽE`UOSŽPQSBG[PMOI4A R9SBPQCFGJWˆ[email protected]+ADIOE‘Z[email protected]’E`UOS
E`PQG[IOCYZSBP"V%GJCFSq][email protected]+a
;\“F=?”}MOCYUzPQSBG[[email protected]N[email protected][Z\E•M4N–|G[[email protected]—VQWDSBG[P
E`PQG[IOCYZSBP"V%GJCFSq][email protected]+a
;\˜F=?c9SBNG[PQG[E`SnZ[email protected]MOIOA RTS+PQCYG[W™ˆ[email protected]+ADIOEHZ\[email protected]+ešZ[email protected]›TWDS+a
;%<FœF=?cTS+NG[PQG[EdS[email protected]S+WDWS+P"CFUOG[Z\EHZ\[email protected]+eR9SBUOADVQWDSBa
ž\ŸT }¡™8Œ:4:B84¡ ž 56Ÿ
;%<,=?”}@BCFAE`[email protected]¢Z[email protected]‹N[email protected]+NS+WWDS+PCYUOG[Z\E‹MOIOKJSBPsR9SBUOADVQWDS
–|ADE`ULPQSBG[P6MOIOA RTS+PQCYG[Wlˆ@BADIOE@†RTS+P6EdUOSfE`PQG[IOCFZ\SBP6VQG[CYSg][email protected]
;\bF=?”}WG[VQS~Z[email protected] RTS+PQCYG[W[ˆ[email protected]+AI4E6ADIOE`@~EdU4S~GF›TWDS~N[email protected]
][email protected]+wxSBa
;\oF=f£qWDADr™I efG[PQw@BI E`UOSPQSBG[PWDAI4w][email protected]+w4SG[IOKnMOI4A R9SBPQCFG[W
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;\F=?¤}@[email protected] ]sADIOCYE`G[WWqu[@+WE`C [email protected]@+WK‡MOIOA RTS+PQCYG[W9ˆ@[email protected]
E`PQG[IOCYZSBP"V%GJCFSq][email protected]+a
;\ƒF=f£qWDADr™IefG[[email protected]+IZ\[email protected](MOIOA R9SBPQCFGJWFˆ[email protected]+AI4E(E`@E`UOSefG[PQw
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;\ŠF=f¥(Ar€UOE`SBIE`UOStpqj ˆ[email protected]_CYE`PQG[N¦yVQWDG[efNu[@BWDE`C§G[E_E`UOS
GF›TWDSq][email protected]+w4SE`@¨<Y˜ mq© eš;%<F•ZEdaªWu[CFa =E`@BP%«JMOS+a

REAR PROPELLER SHAFT
1(24365(798:
;%<,=?c9UOADZ\EE`UOS‡E`PQG[IOCFefA[email protected]+I‘G[IOKsEdPQG[IOCFZ\S+P¨VQG[CYS¯ADIOE`@
mqS+MOE`PQGJWDa
;\bF=?>[email protected]GJI4KLCFMONN@+PQE[email protected]+IXCYG[Z\S+E^]_CYE`G[IOKCFa
;\oF=?c9VQPQADuJSG[WDADr™IOefS+IOE(efG[PQw4CHG[E(E`UOSN[email protected]CYU4GJZE(G[IOK
G[E6S+GJVQU_S+IOK¨@BZŒEdUOSnN[email protected]|CYU4GJZEdaO¥U4SBCFS~efG[PQw4C–|ADWDW
u[SMOCYS+KLZ@BPAI4CYE`G[WWDG[E`A@+I‰P%SBZ\S+PQSBIOVQS+a
;\F=?„…[email protected]‡E`UOS‡pqj ˆ@BADIOE CFEdP%GJN{u[@BWDE`C‰GJE E`UOS‡N[email protected]+I
CYU4GJZE][email protected]+w4S+a
;\ƒF=?”}Pk][email protected]+NS+I VQWDG[efN[email protected]ADIOr|E`UOSKMOCFE(u[@[email protected]+E(E`@mail protected]S+WDj
WDSBPCYUOG[Z\E ][email protected];\}ADr™a<FƒF=%a
;\ŠF=?c9WADKJSEdUOSCFWDADN­][email protected]@BZ[email protected]_E`UOSE`[email protected]¦
E`PQGJI4CYZSBPVQG[CYS•@+MOE`NMOECYUOG[Z\EG[[email protected]†RTS EdU4S•N[email protected]+NSBWDWDSBP
CYU4GJZEH;\}Ar€a<FŠF=%a

Fig. 15 Dust Boot Clamp




   
  



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$&%')(+*#,&-.,&/1032
/145 ,&-6-6,7582
(1/:9<;&=6>[email protected]>6C6D6E6F

Æ\ïFÈ?ý…ÍBØfÓdõT͋ÐYÕO×[ÑÿÖQËDÕOߙÐsÚ\ÖQÓ+Ø
Æ\â}ËDߙÝÇ  È%Ý

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Fig. 16 Rear Propeller Shaft

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Æ\ïFÈ?ð…ÖQËDØfÑ Û Ê×[ØfÑñÎdӑÏOÓ+ÊÌñÌÜOÐF·éJÓ+ÓB·Î`ÓzÑJÖQÓBÑJÍBÊDÊDÍBÖ
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Fig. 18 Remove Snap Ring

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Fig. 17 Crimping Dust Boot Clamp

DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT
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Fig. 19 Press Out Bearing

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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
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Fig. 22 Install Bearing On Trunnion

DOUBLE CARDAN JOINT
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 åWüã+ßõî\ðrö

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Fig. 23 Remove Snap Rings
ßøJáùtãWé‚éhêRãúåWî\ïRébî
ïªçUïªçUíZëgåAí1òíZãWóJó_åWí„ætî
óJã8û‚î\éhêªç
óJåWñZüãWéû‚êRåAópãýî\ïRópî\þãýþî\çUä8ãWéhãWíôî\ó.è\çgíZðrã°ãAïRåWÿRðrê

éhå

íZãAñZãWî æjãnéhêRãnëUãWçUíZî\ïRð)ñZçUò“òåWóJî\éPî\åAïRãWþ“ëUãWïvãWçUéPêìéhêRãnè\î\ïRü
 åAüãWö
ßJá‡è
çUñZã«ç

ópåAñZüãWé¢ûbî\éPê

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Fig. 25 Remove Bearing From Yoke
ßJáõ‡è
î\òuçUópóJãWä8ëUè 
çUïRþuíZãWògãWçUé8ùtéPãAòuø›ùtéPãAò›çUïRþ
ùtéPãAò
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çUïRþópògíZî\ïRð_ßõî\ðrö

÷
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íZåWä
éhêRãnåWÿvéPëUåWçUíZþ“óJî
þgãnåéhêRãnè\î\ïRü  åAüvãnãAïRåAÿRðxêìéhånðxíZçUópò
éhêRãëUãWçUíZî\ïRðwñZçUò_ûbî
éhêsæjî\ópã#úçJû‚ó1ßõ‡î\ðxö

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íZãAä8åMæjã+ðríZãWçUópã 
î
éhéhî
ïvðxó‚éhêRçUéî
ïvéPãAí ãWí…ã„ûbî\éPêíZãWä8åPæjçUè\ö

Fig. 26 Remove Centering Kit
ßJá‡íZãWóJóéhêRã‚íZãAä8çUî
ïvî
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ãWïvþ)åéhêRãè\î\ïRü
éhêRã+þî\ópçUóJópãWä‚ëgè  ö

Fig. 24 Press Out Bearing

 åAüvãçUó1þãWóJñZíZî\ëUãWþ|çgëUåMætãéPåñZåAä8òè\ãWéhã

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WYX*X[Z\^]Y_a`
bdcfehgjifkmlnnoqprts u&vCo#ifncfehoxwzyfl{w|wzyfoxlsRgRk{ifpo#ifw
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u

~{}*o‚l{ifƒ…„Yeh~{„Yo#ssRoqe†nyfl‡aw

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‰MŠR‹ŒŽ#q ’‘a“/”–• ‘—‘9#•M‘˜™˜›š{• ‘9‰œžq‹ ŸŽ¡ ¢*¡ £6¡¥¤a¡-£¦• §¨#‘IŠ
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”–·{‘|#• © #‘‘•9˜™·§ ° ”0 ©± ‘|‰´ ® «¸¡

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Fig. 29 Press In Bearing Cap
‰˛‹´Y ® x”a·{‘Í#• © #
 ‘‘•A˜™·{§ ° ” ©± ‘§ ¯ ¨
®"¯ ˜™”–§q ”–·{‘
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˜ ¯ §q• ®¯ «9‰´ ® «¸¡Èº̛‹M¡

Fig. 27 Install Cross In Yoke
‰º›‹Y"§µ ‘m§»²‘§• ® ¯ «¼µM§q
‘ •¾”a·{‘m”a•Mš ¯{¯{®©¯
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Fig. 30 Press In Bearing Cap
‰¹›‹´ ® ”­”–·{‘͏ ®¯{±  
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Fig. 28 Install Bearing Cap

W‚
”3•B–˜—™–˜–˜š˜›>œY=žŸ—™ X”Ÿ—™–˜–˜š˜›œ™=ž¢¡*£™¤¥¦ §¨¥©ª«¬

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Fig. 33 Install Remaining Cross

Fig. 31 Install Link Yoke

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Fig. 34 Press In Bearing Cap

CLEANING AND INSPECTION
SINGLE
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Fig. 35 Seat Snap Rings In Groove

Fig. 37 Adjustment Cam

SPECIFICATIONS
TORQUE

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SPECIAL TOOLS
PROPELLER SHAFT

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Fig. 36 Check Assembly

Inclinometer—7663

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181 FBI AXLE

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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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17
17
18
16
16
17
17

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27
31
21
23
27
30

GENERAL INFORMATION
181
FBI,/.0AXLE
')(+*,214365&798;:<*>[email protected]?BADCE*>FHGJIK7-LM365&7-ND14:<LJOP=HQSRJ*UT65>79A

F/G"F/8VFW5>XP=YT6=ZF/8G"35&7[[email protected]*>36*&798VGJ=ZR\(95&]9F/GJ79I_^BGJ8`(a=/QbRJ*
F/(9=ZXD8c8V]9dZ*&Fe*MQb8V*>79CEGJ79IfXD35&?a*&GJ8V(9*&3 F/GJCE*&gK'c(9*h8V]9dZ*&F=Z36*
i 36*>FHF/*&CPGJ798V5j8V(9*
CEGJXDX"*&36*>798VG"=ZR(+5&]9F/GJ79I\=Z79Ck^B*>RJCE*&[email protected]
')(+*lGJ798`*>IK36=ZRm8on i *l(95>]9FHGJ79Iqp<(&n i 5>G"CrIq*&=Z3BCE*>FHGJIK7s(9=ZF
8V(9*\T6*>798`*>36RJGJ79*\5&X8V(9* i GJ79GJ5&7UFH*>8dZ*&RJ5`^t8`(+*\T6*&798V*>36R"GJ79*
5&Xm8V(9*
36GJ79I;IK*&=Z3g
')(+*u=/QbRJ*v(9=ZFw=YXDGJ8V8`GJ79IxXD5>3y=wzb*>798(95>FH*v]9FH*>C{8V5
36*>R"GJ*`zb*PG"7+8`*>3679=ZR i 36*&F/FH]+36*|T6=Z]9F/*&C}dHnWRJ]9dZ36GJT6=Z798~zb= i 5&3A
GJ€=Z8`GJ5>7=Z79CPGJ798`*>3679=ZR*`Q i =Z79F/G"5>79g
')(+*x=HQSRJ*&Fv=Z36*x*&Z]9G iEi *&Cu^BGJ8V(‚F/*&?kGJƒZXDRJ5&=Z8VGJ79I„=HQSRJ*
F/(9=ZXD8`F/p…?k*>[email protected]+G"7+I;8V(9=Z8RJ5&=ZCEFh=Z36*fFH] [email protected] 5&368V*&C†d/ns8V(9*f(9]9d
dZ*&=Z36GJ79IKF/[email protected]'c(9*k=/QbRJ*BFH(9=ZX"8`F‡=Z36*k36*>8`=ZGJ79*>C\d/n27+]98`F‡=Z8)8`(9*
(9]9d-dZ*&=Z36GJ79IqFHg'c(9*W(9]+dxdZ*>[email protected]_=Z36*[email protected]>RJ8`*>Cˆ8V5W8V(9*
F/8`*>*&36GJ79Ik‰+7+]9T6‰ŠR"*=Z8m8`(+*h5>]98`dZ5>[email protected]Cl*&7+Cl5>X‹8V(9*=HQSRJ*h8V]9dZ*
nb5>‰Š*&g+'c(9*
(9]9d†dZ*>[email protected][email protected]*jF/*&3ŒzSGJT6*&[email protected]=Z72=ZFHF/*&?kdZR nqg
15>3yzS*&(9GJT6RJ*&Fw^hGJ8`(YŽe:<dZ36=Z‰Š*&F/p28V(9*yŽe:<‘^h(9*&*>R
F i *&*>CYF/*&79F/5&36F_=Z36*’=Z8V8`=ZT6(9*>CY8V5’8V(9*W‰+7+]9T6‰ŠR"*W=ZFHF/*&?kA
dZRJG"*>FHgE'c(9*f8V5&7+*f36GJ79IKFXD5>3‡8`(+*mŽe:<F“nbF/8`*>?”[email protected]* i 36*>FHF/*&C
5&7+8`5ˆ8V(9*ˆ=/QSR"*ˆF/(9=ZXD8Vg†•–‚—…–9˜w™š9›\š9œ+WžŸ~ ˜–9—…
¡P¢ E@£–+¤f˜ ¢ ;¥>E—…¥&–+¤ ¡P¢ E—}¤¦E›\–¦§©¨“—…œPš¦ª©£Œ;¥ ¢ š9«V˜¥>¬

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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20
25
32
22
31
27

. . . . . 36
. . . . . 36
. . . . . 37
. . . . . 37

. . . . . 38
. . . . . 43
. . . . . 37
. . . . . 45
. . . . . 45
. . . . . 45

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8V(9*l(95>]9FHGJ79I†T5Mzb*>3BdHnU=PT65MzS*&3BdZ5&RJ8Vg<:<]9GJRJCrCE=Z8V*lGJCE*&7+8`GJA
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XD*>36*&798VGJ=ZR i GJ79GJ5>[email protected]*yF/(9=ZXD8PGJF}36*>8`=ZGJ79*>CU^BGJ8`(Y=v365&RJR
i GJ79g…¯~GJXDX"*&36*>798`GJ=ZR<[email protected]*>[email protected]G"7+I i 36*&RJ5>[email protected]=Z79CP3G"7+I;IK*&=Z3dZ=ZT6‰+A
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LUBRICANT
³x´kµ9¶J·V¸J¹@º@µ9»6SPECIFICATIONS
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Ê ¼>»6´k½j·V¼\·VÀ9¾ Ê ¼&¶J¶J¼MÈh¸"Ç+Ã|½Hº@¾&Æ6¸ Ê ¸JÆ6ÄZ·V¸"¼>Ç9½j½/À9¼>µ9¶JÂÅ@¾;µ9½/¾&ÂEË
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CAUTION: If axle is submerged in water, lubricant
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DESCRIPTION AND OPERATION
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Fig. 2 Differential Operation—On Turns

DIAGNOSIS AND TESTING
GENERAL
INFORMATION
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w‚h`dje^`bTz† †d^Zvh`‰™acbed¨acvh`¬gted¨h`dE]‰ikjelsMvhyikjenƒa{]guk²
uk]ga{ikvEj‘h`dEsMdh`dEje^`dEz
XM´ƒ[
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XM¸ƒ[
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h`dE<v€”d1acbed1mikjeikvj6}vE_Td1X˜iklRz¦›„[@z

Fig. 7 Pinion Seal Installation

MX ‹ƒ[
Œ€jenƒac]uku }xv_d™vjŽacbed™mikjeikvEj•l’d]gh+wyika{bŽŒ€jenƒac]ukukdh
»‘²ZYƒ›‹gˆgÀÁ‡U—†tTm~´¿Yƒ½g¸‡¦]jT‰~¶WvEu‰dh+›¸gšg´XM˜PiklRzU´ƒ[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 Yƒ½ƒ[
µnƒd•] nƒteikac]fgukd•mh}¾a{vEvu¨vh«]£nƒuik‰dŽbe]g<<dh
<vEtejeacd‰
n„^`h`d{wºa{v1h`dE<v€”d1acbed1mikjeikvjŠn„dE]guz

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Œ€jenƒac]ukuacbed+mijTivEj‚wy]gn„bedEh]gje‰6]Âjed€w¡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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ç Ù$ØÖ×:èé“ê;Ù$Ðå*ÓÒ/éUæ Ø"Ù^×VÙ$Ø×VÓ"Ù^×VÙ$Ø"ÝDÓ"ÕVÖÙDÓ"Ò/ß
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Fig. 13 Collapsible Preload Spacer

Fig. 14 Pinion Seal Installation
Ì è Î LÔÒ ÚÐ ÞÞí3Ø"åNÓMâ]ÑÚÛ
LÔÒ ÚÐÞÞÓ"Ù¡ýò¶Í/îàò=éUû;Ö×FóÿÍ ú öé
ÐÔÕ:ÛØ"ÞÕVÓÙYîöèóFÌmÑ-ï>ß¨Í è ÎDß
Ì î
Î Læ¨ÚÛÓOØ"Ù$ÑïÑÔÐÞ× ÑÔÑØ"Ô{ã ÓÐÙ$ÑÔïҌÐÙ$ÓOãÓ"ÑÔï+ÖÒ Ó"ÕVé
ÑÔÒ/ÚÐÞÞUÕ Ñæ æ ÓÙ$Ó"ÔÚÑРގÐÒ/Ò Ó"á
ãÞ í+ÐÔÕPÐ õgÞ-Ó^Ò/ÛÐæ ÚÒ éÿÑæ“Ô*Ó"Ý$ÓÒ/ò
Ò/ÐÙ|í ß
Fig. 12 Remove Pinion Gear
É ÊĒÅ*Å"Ä“É ÂdÊ
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Ì ë
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NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
Ì ð
Î LÔÒ ÚÐ ÞގÚÛÓ^× Ñ-Ô*Ñ-ØÔYâ]ÐÒ/ÛÓÙMÐÔՌÐBÔÓLâuÔÖÚØ"ÔOÚÛ*Ó
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Fig. 15 Pinion Yoke Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded, a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
ijlk mnlo6pq rsct7uwvscxy*u$z {}|}~}j€}py€€‚s$z&ƒ*„u…†z‡ucpˆ‡v
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Fig. 17 Check Pinion Gear Rotation Torque—Typical

u$}n“„z&u–˜vu–z‡s$‚}˜o6pqT˜scz‡ƒ}„u–z‡ucƒ}„u$p‚x rw‚s–l©s$o6y s˜©ucz
«

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Å „’*z&oˆ‡}p°ž•ucˆ‡oo6ˆ‡*‚o6s$pnsc‚vo6nnlu$ˆ‡‚o6s$p¤s$zOx„’*z&oˆ‡}p
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Å

s˜…†u$zZ©ucvo6ˆ‡x6u$‘

HUB
BEARING AND AXLE SHAFT
¼ªŸ‚vuÆl½žxuÀn“v}Ç}pyVv„’È’}u$}z‡o6pqÉ}z‡uÀ’*uco6pq
z‡ucŒ sª©ucy¦o6p€s$z‡y*u$zT‚s nlu$zµ©žoˆ‡u }ps$‚vu$zTˆ&s$Œ •scpu$p˜”Z‚vu
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iŽlk Á®u$Œ s˜©uO‚vu…†vucu$xY}py ‚oz&uT}nln“ucŒ ’*x r‘
i‰lk Á®u$Œ s˜©uM˜vu¦’}z‡}tuMˆ‡}xo6•ucz—}py¡z‡sc˜scz(‘Á®u$u$z—‚s
z‡sc„• ~*”¸®z‡}tucn“”!s$zI•z‡s$•*u$zI•z‡s$ˆ&u$y„z&u$n“‘
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iÃlk Á®u$Œ s˜©u¿¸®™…†vucu$xBnl•ucu$y¦n“ucpn“scz(”o6pucˆ‡u$nln“}zµr‘

Fig. 16 Tightening Pinion Nut

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Fig. 18 Hub, Knuckle and Axle Shaft

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Fig. 21 Steering Knuckle Removal/Installation

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Fig. 22 Upper Ball Stud Remove/Install

Fig. 23 Lower Ball Stud Remove/Install

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¦ÀŒ» ˆŠV•â£¥—»
…‡†Ýˆ½¿‘¥Œ˜¦¦/´¥—´¥£¥ÀÀ—V˜–•Ž‘¥¨ÆŒ³˜–‘µ™¯˜Þ0¦—Œ´¥˜«
Œ»

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

‡kˆ{‡+‰

Šp‹-ŒYŒ++Žpp‘I‹ ’”“k’ajŠxŠpŽp‹ •”+“Y‹ j

–—

˜™›š…œ)žŸxž ~¡£¢. ~¤›¥pžŸŸžf¥h¢.œ~ §¦¨©ª«¬ ª­®¯°

Fig. 28 Differential Case Removal

Fig. 30 Differential Bearing Cap Reference Letters

Fig. 29 Install Axle Housing Spreader

DIFFERENTIAL SIDE BEARINGS

  "!$#&%')(+*-,.,/"012435*.6879168:;),/01#"!<6;='7-)>4#"?4:;*[email protected]
/C; "!$#&%')35>4)D8"6801*[email protected]:$,/01#"!<35>4)(+*-,/,."01243F*-6879168:;
*
HI?47-7-"0/J5HK01":;:ML N/C8O8P8N/HQSRTL N/C8O8P8N/P8OUQS(+68V+35"0
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7
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1
9
Y
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Z
R
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W
b/c'dKeBf"eZb c
g ,01V+7-6891"!h243h(i*-,/,/01"2435*-6i7j:;*-(+[D8"6801*[email protected]:k#"0l(i*.,.,/0N
"23F*-687 9168:;m6i01mD8*.2@l*.2:n35687.7-(+Ro(i*.,.,/"012435*-6i7p:n*-(+mD86i0N
*[email protected]:;>4*-!r01s8?4*-01"!h243F:t!$6nuv91>6i2@B"Ak ",."0w3F#x35>4
y *-,/,."012435*.687 W "6801*[email protected]7-#"68(6824(_z{"680 W 6891XY7-68:n>|Vi01#"N
91(+?401:$*.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*[email protected]:;>4*-!h:$#"2435#~(i*.,.N

,/01"2435*-6879168:n)>4?4D8:;A
/C;S:;*[email protected] g 24:;3F687-7-"0L N/P8€a;iN Q‚6824(„ƒ6i2(+7-…L N/†a;€anR
*-24:n35687-7(+*-,/,."01243F*-687:;*-(+)Di6801*.2@B:$/`K*[email protected];A
/P; g 24:;356i7-7(i*.,.,/"0"2435*-6i7 *.2|6;='7-)>4#"?:n*[email protected]


!#"%$'&)(*#+*#,.-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$Ä&Ç'¿)Á+½-Î.Î/¿"Å1¿À4Æ5½.¼8ʼ8¾;¾n¿ÍhÏiÊ ÐÑË
¸/Ò;º» "
¿ Í$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"Ž.àE½.À¼iÊ
¾;¿"¼8Ê-¾nË
¸/Ì;º» ¿"Í$Ä&Ç'¿~¾n¿¼iÊ-¿Å$Î/Å1Ä"Ív¼;Ô'Ê-¿~ÆFÂ4Ï8¿~ÆFÄ~È4Ä"Â4¾;½-À4à{âÂ4À4É1ã
Æ5½-Ä"À4äZ½-ΔÀ4¿É1¿"¾;¾n¼8ÅØÐÑË
¸/Ò;ºå&À4¾;Æ5¼iÊ-ÊÓÄ"½-ÊÓ¾n¿¼8Ê.¾æÕ$½-Æ5Ȃç{½-¾nɾéèa¹"¹;êݼiÀÁìëZÂ4Å1Àã
Ï8Â4É1íYÊ-¿hî8ï8ðiïl¸/ñK½-àBËKÒ8ÒnºËi딽-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¿}Ž.Ààm¼8À4Á~Ã+½-À4½-Ä"ÀkàB¿¼8Å1¾S¼iÅ1¿¾;¿"ÅØǽ.É1¿½-Àk¼)Íh¼8ÆFÉ1È¿"Á
¾;¿"Æ5˛ç{Ä|ÀÄ"ÆmÅ1¿"ÃiÊ.¼8É1¿ÓÆFÈ¿|Å1½-À4à…àB¿"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.

±²³´µ¶·

¸¹ ºå&ÀÑÇ¿"Å1Æ}Æ5È4¿_Á+½-Î/Î.¿"Å1¿À4ÆF½-¼8ʛÉ1¼8¾;¿¼8À4Á…¾;ÆF¼8Å1Æ}ÆúÕ$Ä_Å1½-À4à
àB¿¼8ÅæÏ8ÄÊ.Æ5¾;˛ëfÈ4½-¾_Õ}½.Ê-Ê)Ã+Å1ÄFÇ'½-Á+¿ÖÉ1¼8¾;¿"ã/Æ5Äã/Å1½-À4àöàB¿¼8ŅÏiÄÊ-Æ
È4ÄÊ.¿)¼8Ê-½-àBÀ4Íh¿À4Æ5Ë
¸/Ì;ºå&ÀÑÇ¿"Å1ÆjÆ5È4¿)Á+½-Î/Î.¿"Å1¿À4ÆF½-¼8ÊÉ1¼8¾;¿~½-À|ÆFÈ¿SÇ'½-¾n¿Ë
¸/Ò;ºå&À4¾;Æ5¼iÊ-ÊæÀ4¿FÕûÅ1½-À4àüàB¿"¼8ÅxÏ8ÄÊ.Æ5¾ß¼iÀÁv¼8Ê-ÆF¿Å1À4¼8ÆF¿Ê Ð
Æ5½.àEÈ4Æ5¿"ÀéÆ5Äæðiý8þa¹;ÌiÌÖÿ Í
¸/ï8êiþ8ð8ê„Î.ÆFËÊ-Ïi¾;Ë ºÆFÄÅ Â4¿æ¸/ñK½.àEË
Ò8ý;ºË
¸/ó;ºå&À4¾;Æ5¼iÊ-Ê}Ái½.Î.Î/¿"Å1¿À4Æ5½-¼iÊ}½-Àt¼;Ô'Ê-¿…È4Ä"Â4¾;½-À4à÷¼iÀÁòÇ'¿Å1½-Î Ð
àB¿¼8Å}Íh¿¾nÈ|¼iÀÁ[É1ÄÀ4Æ5¼iÉ1ƛÃ+¼8ÆFÆ5¿"Å1ÀË

¸¹ º» ¿"Í$Ä&Ç'¿)Á+½-Î.Î/¿"Å1¿À4Æ5½.¼8ÊÎ.Å1Ä"Í<¼nÔÊ-¿~ÈÄ"Â4¾;½-À4àBË
¸/Ì;ºôKÊ.¼8É1¿|Á+½-Î/Î/¿Å1¿"ÀÆF½-¼8ÊõÉ1¼i¾;¿ò½-Àö¼÷¾;Â4½-ÆF¼8Ï8Ê-¿lÇ'½-¾;¿lÕ}½.Æ5È
¾;Ä"Î/ÆjÍh¿Æ5¼iÊB␼;Õ<ÃiÅ1Ä"Æ5¿"É1Æ5Ä"Å1¾;ËZ¸.ñI½-àBËoÒió;º
¸/Ò;º» ¿"Í$Ä&Ç'¿ÓÏ8Ä"Ê-Æ5¾_È4Ä"Ê-Á+½-À4à…Å1½-À4à…àB¿¼8ÅkÆ5ÄÓÁ+½-Î/Î/¿Å1¿"À4Æ5½-¼8Ê
É1¼8¾n¿Ë
¸/ó;ºøS¾;½-À4à]¼_¾;Ä"Î/ƛÈ4¼iÍ$Íh¿"ÅùäoÁ+Å1½ Ç'¿)Å1½-À4à]àE¿"¼8Å}Î.Å1Ä"Í<Á+½-Î/ã
Î/¿Å1¿"À4Æ5½-¼8ÊÉ1¼8¾n¿)¸/ñK½-àBËZÒ8ó;ºË





¬­l¬ ® ¯°T±± ² ³²´µ° ¶·¶©´¯¯³° ¸² ·° ´²
»#¼%½'¾)¿À#ÁÀ#Â.Ã0Ä
Â.Å%ÆÀ#ÁÁÀ3Æ4Ä
¾.Â6Ç8È#ÉÊË=Ì>ÊÍÎÏÐ

¹tº

Fig. 37 Pinion Yoke Removal

y ™ |~} E _ Ud\Eo`dDFER ITKQITUXKLjEXMOG•MOKQPŽ^JUXgTgTMhRhY[I ƒ gTEY[RhMO^JEXG
€GJU _ DQU=nQY‚I
KFL y
  ITLjc  œ | c%¡£Mh`a^JD˜`dDQEŽR ITKQITU=K'kmI
`aDi„UXnFG
DQMOKQP~`dU)RhGJE\E=KQ`IT`€GJU _ €
MhgTgTITKQLoMOKQP ƒ E=I
KFLPhM _ MOLWEXP c
Fig. 35 Ring Gear Bolt Installation

PINION
CDFEHGJI
GEAR
KFLNMOKQPSR ITKQITU=KVLWEXMOGJYZMOGJEHY[E=G]\IT^JEXPSMOYZM

_ OM `a^JDQEXPbY[E=`dceUfKFUX`GJEXRhgTMh^JE.`aDQE.R ITKQITUXKiLjEXMOGlkmIT`dDQU=nQ`
GJE=R gTMh^JITKQLo`aDQE)GJITKQLoLjE=MhG>c
pqFrtsuwvx
y{z>|~} E _ U\E'PhI
€
€E=GJEXKQ`aITMhg#MOY[Y‚E _4ƒ g „…€GJU _ M‚†wg
E'DFUXnQY‚‡
ITKQLjc
yˆ‚|~‰ MhGJŠ6R ITKQITUXK‹„U=ŠFESMOKQPŒRhGJUXR E=gTg
E=GY‚DQMO€`Z€
UXG
ITKQY‚`dMOgTgTMh`aITUXKŽMOg
ITLWK _ EXKQ`ac
y‚| elITY‚^JUXKQKFEX^J`R GJU=R EXgTgTE=G‘Y[DFMh€
`€GJU _ R ITKQITUXK…„U=ŠFE=c
’Y‚ITKQLfY‚nQIT`aM ƒ gTE%k“ITGJEX”`aITE•RhGJUXR E=gTg
E=GY‚DQMO€`l`aU•nQKFP EXG ƒ U=P„Wc
y–‚| ’Y‚ITKQL˜—tUXgTP E=Gi™Ošh›Oœ`dUž`dDFEŸDQU=g
P„UXŠE=”“GJE _ U\wE
`aDQE)R ITKQITUXKŽKQnQ`MOKQP4k“MOY‚DQEXG y  ITLWc  ™ | c
y › | ’Y‚ITKQL } E _ U\wEXGZ¡£¢ – › ˆ MOKQP0—tUXgTP EXGZ¡£‡ Oˆ œ z ”
GJE _ U\E)`aDQE)R ITKQITUXK.„U=ŠFE)€
GJU _ R ITKQITUXKŽY[DQMO€
` y  ITLWc O¤[| c

Fig. 38 Remove Pinion Gear

Fig. 36 Pinion Yoke Holder—Typical

y ¤‚|~} E _ Ud\E`aDQE€GJU=KQ`mR ITKQITU=K ƒ E=MhGJITKQL¥^JnFR ” ƒ EXMOGJITKQLW”
UXITgY‚g
ITKQLWEXG¦”wI
€§EX¨OnQITR RhEXP ”MOKQP.R ITKQITUXKY[E=Mhg kmI
`aD } E _ U\wEXG
¡£‡ –OO– ›MOKQPb—tMOKQP gTE)¡£¢ –©z[¤©z“y
  ITLjc  š | c
y œ |~} E _ Ud\Eo`dDFEGJE=MOG•R ITKQITUXK ƒ E=MOGJITKQLb^JnFRi€GJU _ M‚†gTE
DQU=nQY[ITKQL y  ITLjc –Oª‚| ct’Y[E } E _ U\E=G¥e‡ z‚– š‘MOKQP—tMOKQP gTE
¡£¢ –«z‚¤©z c
y š |~} E _ Ud\E#`aDQE#P E=R `aDY‚DQI _ Y€GJU _ GJE=MOGR ITKQITU=K ƒ EXMOG8‡
ITKQL.^{nQR ƒ UXGJE“ITKbM‚†gTE“DQUXnFY[ITKQLjc } E=^JUXGJPo`dDFE4`aDQIT^JŠKQEXY‚Y#U=€
`aDQE)P EXRh`dDŽY[DFI _ Y‚c

9;:

<>[email protected]?+?+ACB>AED>F
= GIHG0DJ<K<>B>= LMA+H+= DJA

N!OPN+N

QRSUTWVPXYKXZ\[^]@Z\_`>XYIYIX5`]@T\Zba#cdIeIfhgieIjIkIlIm

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

{Ñ Ò‚Ó‚Ô~Õ£ÖX×4ØdÙÖÛÚaÜQÖÛÝJØ=ÞTÞ
ßOà á‚âTãOÞ
֝à äJÖXÞTØ=ßhåæá‚à ßOÝJÖXäŸç
äJØX×
à âTèQâTØ=èiéWÖXßOämсê«âTéjëíì©Ò>Ô{ë
Ñ{Ò=Ò¦Ô~Õ£Ö=×4ØÙwÖ)ÚdÜFÖ)äJÖXßOä#à âTèQâTØXèŽãOÖ=ßhäJâTèQéfçäJØX×îÚaÜQÖ)à âTèQï
âTØXèñð“âTÚaÜóò«ôQÞTÞTÖXä]õ¦òä{ÖXá[á÷ö£øOùOúOûhï
òXü ßOèQåýüåhßhàhÚdÖ=äJá
ö£øOùOúhûOøOûOúсê«â
éWëíìOù‚Ô{ë
þ3ÿ  

©ÿ 
 
 
!"
#$%'&(") "+*

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.

Ï!ОÏ+Ñ

Ò>ÓÔCÔ+Õ+Ö>ÕE×>Ø
Ó ÙMÚ!Ù%×JÒKÒ>Ö>Ó ÛMÕ+ÚCÓ ×JÕ

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ÞßàUáWâPãäKãå\æ^ç@å\èé>ãäIäIã5éç@á\åbê#ëìIíIîhïiíIðIñIòIó
noiprq
[email protected]uwvWxywzx+vhy{}|~uw€Cvh‚‚„ƒvx+{…|)‚|~†‡~)ywvtyx+~ˆ

n.´p’“x+xs ”µtUs~Š3|{£uwzt{}~Š)zh 8Š³vtysŒ‰yw~uwt{„zh²{…|v

~z)‰vtyw~Š‹uwŒxr‰zhywvW~{…|vWtŽ0svW|zŒ‚~Š3

s~xz x+~~z!‚vhts0¢± ‚{…t[email protected]
‚vts+¤„~{…|¢±‚{…tssvy©™ˆ.­¶«‘ˆ ’

n.‘p’“x+xs ”–•zx+ty
zzhy!˜™t‚vhšzy‹v›Œ~ œtsvh{}šž‚{…~uw€
t —
sŒ‰yw~uwt{r{…zŸzŒ{…‚[email protected]ƒvŸ‚Œ yw .tuwvŸz \ywvhtyUx[email protected] [email protected]¡‰vtyw~Š

tƒr§;tƒ[email protected]©™ª¥%o«
[email protected]¬
~Š3¥´p#

ˆo¥¦\tƒ
—
yw~ œvy¨§;tƒ[email protected]©™ª¥%o«%o[email protected]¬
~Š3;¥­p#5®™vyw~  ”¡uwŒx–~‚uwzy#ˆ

—

uwŒx
¢}‚{…tss6{…|v£‰vht[email protected] ŠWuwŒx;¤„~{}|r¢}‚{…ts[email protected]
ywvhuw{}s ”U‚vht{}vhƒ+

Fig. 45 Pinion Seal Installation

n.¦pr¢±‚{…tssP{}|v‹ywvty·x+~~z‰vtyw~Š$tƒzh~sž‚[email protected]~Š³vy(š
~ Pvh›Œ~xx+vƒš™zhU{…|vx[email protected] [email protected]UŠ3vhtyž¤„~{}|¢±‚{…ts[email protected]ž¸Uˆ@‘¦‘
tƒrt‚| zxrx+ywv‚‚„n.¬
[email protected]Š³6¥¦p

Fig. 43 Rear Pinion Bearing Cup Installation

zzhy!˜™t‚vhšzy‹v›Œ~ œtsvh{}šž‚{…~uw€
t —
sŒ‰yw~uwt{{…zUzŒ{…‚[email protected]ƒvU‚Œ yw .tuwvUz „ @ywz{\x+~~z¯‰vtyw~Š
n.­p’“x+xs ”–•zx+ty

uwŒx
¢}‚{…tss6{…|v£‰vht[email protected] ŠWuwŒx;¤„~{}|r¢}‚{…ts[email protected]
§8tƒ+svW©™ª¥%o«%o„n.¬
~Š36¥¥p

—

ˆo­°\tƒ

Fig. 46 Rear Pinion Bearing Installation

n.«pr¢±‚{…tss6tv}¤¹uwzsstx+‚[email protected]‰sv„x+ywvszhtƒ‹‚xtuwvhy8zrx+~ˆ
~z‚|t .{5tƒ~‚{…tssx+~~zŠ3vty“~|zŒ‚~Š·n.¬
~Š³%¥«p
n.ºpr¢±‚{…tss”0zh€ vJ¤„~{}|)¢}‚{…ts[email protected]¸Uˆ#o¦‘ˆ.»™š©™Œxrº%o°¶š
tƒr§;zhsƒ+vy¦¶´º[email protected]¬
~Š3¥ºp

Fig. 44 Pinion Outer Bearing Cup Installation

n.¥pr¢±‚{…tssJ .ywzh{x[email protected] [email protected]²‰vtyw~Š3šPtƒz~sJ‚s~Š³vy(šP~ 
v›Œ~xx+vƒ+

n.¶pr¢±‚{…tss
{…|vx[email protected] [email protected]£¤„t‚|vhyJtƒ\t·v±¤¼Œ{Iz!{}| v
x+~~zrŠ3vhtyi+½I~Š3|{…vh${}| vŒ {ž{…z‘%o¦¾“¿ †Àno¦° .{…
[email protected]‰‚ p
†~~†Œ†JÁ8ÂÄÃÂŋÂ'Æ>Ç+È'ÉhÅÊ(Ë ÌÅÇÃÍJ•‹tŽ0~†Œ†^{}zhyw›Œv
~‚„­´‘¾J¿ †În.‘¦° .{…6s‰‚ p#

d\e

fhgi-i-j2khjmlhnog pbqpLlAfRfhkhg rsj-q-g lAj

tvuWt-w

xzyS{}|M~Wz€RzK‚„ƒK…S†hz€b€b‡†0ƒ|K‰ˆ7Šz‹bŒbŽŒbb‘b’b“

Fig. 47 Collapsible Preload Spacer

Fig. 49 Tightening Pinion Nut

ôõ&÷
NO1P% wúûüQwþ$ …úûüQ…þ 
„ú+$R ûKúû
,+þû…þ STû>¨ô!4
ú@ü5#U
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…þKþ$ $M$M,+úûúþû)ü; ùþÿ+
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ÿ+%ù# ÷(#

wúü³ú@û> ÿ\[O wúûü3ù]
Z

õ
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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.
ôõö÷rø“ùú@û üý8þhÿ 

û…þ ûô@ù 

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,+ÿ+ &/Uúù0$ 12û3,$ô4
úü5#)6 ÷7#

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ADJUSTMENTS
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Fig. 54 Typical Housing Cover With Sealant
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=[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£pšl›¢Ãc˜ šl™
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GIH

JLKMMN'OLNQPLR,K S"TUSVPWJXJLOLK YZNTK PWN

[
\[]

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

Fig. 58 Pinion Height Block—Typical

Fig. 57 Pinion Gear Depth Gauge Tools—Typical

ç>è:é»êëJì3ê7ç>ëJì†í[î:ì`êïAè:ïAð)èOñuì3ç>ëòbð3ëkïbèróSí[ç7ôAôAç>í[ïbð)è:õmö1ó<í@ç>÷>ø
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û òí[ì3ëí[î:ìðMüpì)ëJç>ôbôóSî:ïAýí@î:ïAùJúzè:ì)óSó5í[ðí@ç>úzìþ:ê†é7ïAòòì)ëJì3è:ø
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ë ø 7ø ŠëJì)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

ËL̆Í'ÍÎÏLÎQÐLÑ,Ì ÒZÓ
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v ³xz¢£ŠD‹Œ„Ž†Ž‹ŒžD{I|~‡‰´'{*d„{ˆ‡‰ƒ†ŠD‘~—„ª„3ƒ†Šµ‹ŒžD{*ƒ†‡—}*‡‰‡‰{ˆ—‰‹
ª}ˆ˜ƒ†‹Œƒ}ˆŠD™-¢£ŠD‹€Ž†Ž"ŠDz˜Š(­D‘
‹ŒžD{d}*Ž†‹ŒEv ¶ƒ‘¨™-³šx™

Fig. 59 Gauge Tools In Housing—Typical

Fig. 62 Tighten Bolts Holding Bearing Caps

v ·xz¸3ƒ†ŠD‘
z{ˆ„„• Ž†}£¹º‹5›Vª{|~Ž†Ž†{*‹Œ»L{*‹3‹ŒžD{ƒ†… …{*‡–•
{*Š(‹€ƒ†Ž-­D|E|›©{*‡‰ƒ†ŠD‘¨`‹Œ}E{*—‰žz˜ƒ†{E}*…L‹ŒžD{E˜²Ž†{~ž(}*­D•
ƒ†ŠD‘µv ¶ƒ‘¨™-³¡x`ŠDzv ¶ƒ†‘’™-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 žD‡‰{*$‘’­(ƒ„{˜‹Œ­D$½<•¡„š°°• ¾¿ƒ†ŠD‹€}À‡‰{*‡@—‰}£{*‡
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Ä }*˜ƒ†‹Œƒ†}*ŠÅ‹€žD{Uƒ†Žƒ†ŠDƒ†—‰‹€}ˆ‡ªŽ†­DŠ(‘’{*‡d}*ŠÆh…Ž‹®­D‡‰… —‰{
{*‹5¹E{ˆ{*Š©‹€žD{d‡‰ƒ†ŠD‘µ‘’{ˆ‡®}*Ž†‹WžD{ˆEv ¶ƒ‘¨™-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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Fig. 69 Hold Differential Case and Read Dial
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Fig. 70 Ring Gear Backlash Measurement

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Fig. 71 Backlash Shim Adjustment

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SPECIAL TOOLS
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Puller—C-452

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194 RBI AXLE
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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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GENERAL INFORMATION
194
RBI AXLE
‚Eƒ…„
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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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. . . . . 68
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. . . . . 75
. . . . . 77
. . . . . 73
. . . . . 79
. . . . . 79
. . . . . 79

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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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Fig. 6 Apply Sealant

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487,(°9;(37F$ <5='(>
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48(32*,03$'&)(<50A.1='"%$'*,4E>

REMOVAL AND INSTALLATION
REAR AXLE

¶·F¸d¹ºT»½¼
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[email protected]!¾”03&)$'48$'03*¿"U&)-F$ 48"%H%= (ª='$ I 4E$'*,KŽ+1(C9T$ <5(ª-,*,+1(2À4E7F(
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îï;ð”ñaò²óFó3òFñtî 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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³´1µ ¶¶¢´1·
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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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Fig. 11 Tightening Pinion Shaft Nut

COLLAPSIBLE SPACER
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ã µ»W¸³(ÙHѺ½ Á ½º Á ¸½ Á ½º-Õ¸¾À!½¸³Ç
®È°óUµ ½»Þ´1·
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› 13 Remove Pinion Gear
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›z‘P’=Yoke
“”‘Pœ Removal
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N687:68<'7Qe<?TUA7P\:H^]F7:@_`]F4wK:A'Bƒa
-xq1y103254167P9LbdA'X<ZYeA?B
fd«OiFGFjR]F7:@©l[BWA'7:nWKIfd«OpFjF.¬qwV
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‚/BW<'X¯‚]O>8>8687:9†]F7:@…{FA'67P9@O]OX`]O9­[email protected]a
-xq1j103bdA?X<~YSAnW<?>8>8]FN416{F>8A4wNO]OnWA'B‰‚BW<?X N687:68<?7[4wK:]F‚H~a

/- p103ŠZ7:41HJFig.
]O>8>NO1467P6Collapsible
<'7‡‚BW<?7:H {OA']OPreload
Bx67P9uV‹68‚²Spacer
7:A?nWA'4w41]FB|Q­a
-/i10³5NNO> Q]
>8689uK:H‰nW<?]FH~687:9[<'‚=9­A?]FB>8\:{FBW68nW]F7:H`<'7DHJK:A
>868N<?‚N687:68<?74wA']O>8aSŠZ7P4wHJ]F>>t41A?]F>_`68HJK„ŠZ7:41HJ]O>8>8A?B fdh/pFEO¡FjFh ³
]F7:@3;ˆ]F7:@O>Afd«Fi¬q1¡rq`-st689uavq1Gw0"a

BDC
[]\^/_a`&b]cTb]d(egfd(hiGb]c5c5b2i f_(dkjml]n5o5pqro5s5t5u5v

EGFHIHIJLKGJNMGOPF Q5R+QSM ETEGKGF UVJIRIF M J

WX&YIZ

Û/ö1
Ý 5à1é8ß:û„äSå'æUç‡ê:å'ã÷Oç?í„ùFöFÜFîªâFß:÷ªâªáJå?í Oó:çè`íWç'ß:ìWê
àwç'á âFá  
 ÿ ÛFÜOõ†ý/áJüã8þOà1ü ÝxñtìWíWó:àwêìWå'ãã8âFôà1é8þOã8çŽà1ôâFìWç?í
ó:ß:áJé8ãþFç?âFíWé8ß:û†ç?ß:÷3ôã8â1ä
é8àáJâFæUç?ß[ó:ô3Û/úté8û­ü ï 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?߀á~êPç„ß:óPá‰é8߀ùOü 
î
 ÿ ÛÜ[ý/áJü²ã8þOà1ü Ý
é8ß:ìWíWç'ÿç?ß:áJàmó:ß:áJéãŒáJê:çcíWå?áJâFá~é8ß:û¤áJå?íFó:çcéàmâFìWê:é8çeç?÷ü
ç Fó:ç?ß:áJã ä‡áJåŽâ Så?é8÷„å Sç'í
 ç'âFàwó:íWçá~êPçŽíWå?áJâFá~é8ß:ûá~å'í Fó:çŽý/íW
ìWíWó:à1ê:é8ß:û†á~êPçìxå?ã8ã8âOôOàwé8þFã8çà1ôâFìWç?í Û/úré8ûuü ï1î1Ýxü

/Û Ü1Ý3ÞZß:à1áJâOã8Fig.
ãäeå?15
æUçPinion
è`é8á~ê¨ëSSeal
ìxíWçZèInstallation
îrï'ï1ðOñ^òdó:ôî¬ï1õFöOñ^âOßP÷
ø å?ã8÷ç'í‰ùFöFÜFî„Û/úréû­ü ï1ù1Ýxü

/Û ù1Ý3ÞZý áJê:çFig.
å?íWé8ûu16é8ß:âFPinion
ãôé8ß:é8å?Yoke
߀þFç?âFInstallation
íWé8ß:ûuàâFíWçþFç?é8ß:û…ó:à1ç?÷ñ
é8ß:à1á~âFã8ã÷Oé8ý/ý/ç'íWç?ß:áJé8âFãâFà1àwç?ÿ`þOã ä…âFß:÷âeãç àwê:âFýá~à1ñ¬é8ý‹ßPç?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:çˆäSå?æUçˆè`âFàwêPç?íâFß:÷â…ß:ç~è£ß:ó:á=å'ߌáJê:ç
ôé8ß:é8å'߆ûuç'âFíƒü²é8û­ê:á~ç'߆áJê:ç=ôé8ß:é8å?ßß:ó:ádó:ß:áJé8ã¬áJê:ç?íWç=é8à ¾ç'íWå
þFç?âFíWé8ß:û†ç?ß:
÷ /ôã8â1ä­ü
Û/î1 Ý éû­ê:áJç?ß[á~êPçßPó:á^á~å ð ¬ï
 ÿ Û/ðFõFõ„ý/áJü‹ã8þFàwü 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~êŒâÛ/é8ß:üã8þFàwü Ý`á~å'íOóPç
è`íWç'ß:ìWê
Û/úré8ûuü5ï1î1Ýxü!êPçá~å'íFó:çß:ç'ìWç?à1àwâFí|ä€áJåíWå?áJâFá~çáJê:ç
ôé8ß:é8å?ß[ûuç'âFí‰à1ê:å?ó:ã8÷3þFç#"
íWé8û­éßPâO&ã %dç?âFíWé8ß:û­(à ')ê:ç†íWç?âF÷é8ß:û…íWç'ìWå?íW÷Oç?÷‡÷óPí 
é8ß:û• íW$ ç?ÿå SâFã8ñôã8ó:à‰âFß[âF÷÷OéáJé8å?ß:âFãdõFü ÜFù
 ÿ ÛÜé8ß:üã8þFàwü Ýxü
5ç~*
è %dç'âFíWéßPûuà ' ð„áJå+
Ü
 ÿ Ûxï1܄áJ(å F܄é8ß:ü‹ã8þFà1ü Ý"ü

Ûxï1ð1Ý3ÞZß:à1á~âFã8ãˆ÷Oéýý/ç?íWç'ß:áJé8âOã=âOà1àwç'ÿþFã äLâOß:÷ªâ Sã8ç[à1ê:âFý/áJàwñ
é8ý²ß:ç?ìWç'àwà1âOí|ä ü
Ûxï 1 Ý ,5ã8éû­ß ÿâFíWæPà¨ÿâO÷OçôíWç Sé8å?ó:à1ã ä£å?ßmäeå?æUçâFß:÷
ôíWå'ôç?ã8ã8ç'í‰àwêPâOýá^âFß:÷…é8ß:à1áJâOã8ãôOíWå?ôç'ã8ã8ç?í‰à1ê:âFý/áJü
Ûxï 1Ý3ÞZß:à1á~âFã8ã‰íWç'âOí3þFíWâFæPç
÷íWóPÿàwü -ç'ý/ç'í…áJ/
å .víWå?óPôzÜFñ
%díWâFæPç'àwñý/å?í ôíWå'ôç?í ôíWå'ìWç?÷óPíWç?à1ü
Ûxï1Ü1 Ý ,5÷÷ ûuç'âOíMã8ó:þFíWé8ìWâFß:á~ñŒé8ýß:ç?ìWç'àwà1âOí|ä 0
ü -ç'ý/ç'ícáJå
1 ó:þOíxéìWâFß:á‰ëeôç'ìWéýé8ìWâOáJé8å?ßPà†å'ý5áJê:é8à†à1ç?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:ô†ÜFñA%díWâFæUç?à1ñ
ý/å'í‰ôíxå?ôç'í‰ôíxå?ìWç?÷Oó:íWç?ü

ÞߘàIá

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

w³yÀ!¦I}Ž‰ Ÿ<{~}(‹! ‚‰ }# {5‚ƒ#„›{~}
¨L †‡}aƒ„›I ˆ  †‡}
w²ºyÀ!¦I}#Ž‰D„ƒ{{~}„œ•
} „…~€!†¤Žƒ€!‰  Ž‰DŒ7„‚ Ž}ƒ€ÄŸS{~}
‹7
‚‰ž‚ƒ„>…†½€!ƒ#‚ • „…~€!}#{~{~…~€!†‡¾9†‡ {~{…~€!†Å €!¦I…~‰Š‰ …~€!†½DÂ
 €Æ¥ƒ#‚›‰Š‹!}#}¶Žƒ#€!
…~‰ …~ƒ#€7¤}ŸS…~‰ ¾ ‰ ‹7}¶Ÿ<{~}/‹! ‚‰( €!Ç¢ƒ#„
• }# „…~€!†ž €!¤}# {5ˆ Œ7‰ • }a„}#¦
{ Ž}I

Fig. 18 Check Pinion Gear Rotation Torque

wxyz|{~}# € {~{9‚ƒ„}#…~†‡€ˆ
‰Š}#„…~ {9‚„ƒˆg‹!ƒŒ!…~€!†/Žƒ<}#„
 „}# 
w‘y’Aƒ#ƒ#}#€“‹!ƒ#Œ!…~€!†”Žƒ S}„–• ƒ#{~‰ >—˜„ …~€™{~Œ!• „…~Ž €!‰
‚„ƒˆš‰ ‹!}›‹7ƒ#Œ!…€7†œ
€7žŸ<{}›‹! ‚‰2‰ŠŒ!• }#@ |}ˆ ƒ<}›‹!ƒ#Œ!¡
…~€!†žŽƒ<}#„¢
w£y |ƒ#‰Š ‰Š}–I…~‚‚}„}#€7‰ …~ {¤Ž }–ƒ¥‰ ‹7
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Ž„}©¬ €!­¦I…~€!…~ƒ#€®ˆ  ‰ }/†‡} „¤‹! ‚‰¯‚„ƒˆ°
…‚‚}#„}#€!‰Š…~
{
Ž }aw±P…~†‡˜²³y

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w²ry’AŒ!• „…Ž ‰Š}¤•
}
„…€7†/• ƒ#„}¤ €!Ï}# {{~…~¦©…~‰Š‹­†½}# „
{~Œ!• „…~Ž €!‰ ¯Ã€!}#„‰0ŸS{~}¥‹! ‚‰0‰Š‹!„ƒŒ!†‡‹”} {¾¯• }# „…~€!†‡¾
 €!}#€!†½
†½}a…‰ …~€!‰Šƒa…~
}(†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¸yÀ!}#„‰žz|· Ž{~…~¦Ð{~ƒ#Ž¨®…€¥}#€!ƒ#‚ ŸS{~}0‹! ‚‰ŠDµAŒ!‹
ŸS{~}a‹! ‚‰ ƒ#Œ!‰Ñ© „‰ ƒa}# ‰ z|· Ž{~…¦{~ƒ#Ž¨>…~€…~I}a†½}# „¢
wÒyÀ!}#„‰ ¦I…~€!…~ƒ#€­ˆ  ‰Š}>‹! ‚‰œ…~€!‰Šƒ>
…‚‚}„}#€!‰Š…~
{Ž }
 €!‰ ‹!„ƒ#Œ!†½‹¶‰Š‹!„Œ!‰G© ‹7}#„ €!¦I…~€!…~ƒ#€†‡}
„
wxy ¿{~…~†‡€¤‹!ƒ{}…€¤‹! ‚‰P©…~‰ ‹¤‹7ƒ#{~} …~€¤‰Š‹!} I…~‚‚}#„}€!‰Š… {
Ž }T
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t ‚‰Š9{~•
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¾5Á|„ ¨7}¾
‚ƒ„›¦I„ƒ#¦I}„›¦I„ƒ#Ž}#
Œ!„}#
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{~{S©›‹!}#}{5 €!‰ …~„}#
w»y’Aƒ©}„&<}#‹!…~Ž{~}#

Fig. 19 Mate Shaft Lock Screw

w ´yµAŒ!‹0ŸS{~}ž‹! ‚‰9…€#© „¶ €!„}ˆ ƒS}žŸS{~}ž‹7
‚‰
z|· Ž{~…¦{~ƒ#Ž¨¤‚„ƒ#ˆ*‰Š‹!}aŸ<{}a‹! ‚‰ w±A…~†‡¹¸ ºy
w»y |}#ˆƒS}]Ÿ<{}D‹! ‚‰Š<¼}]Ž
„}D‰ ƒ]¦
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{~¾<©›‹!…~Ž‹©›…~{{V„}#ˆ  …~€0…~€
ŸS{~}›‹! ‚‰V‰ŠŒ!• }#N¿9{~ƒ#¾S} ŸS}#„Ž…}›Ž „}]€!ƒ#‰V‰Šƒ›

ˆ  †‡}]‰Š‹!}
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Œ!…~¦
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• „ ¨7}

AXLE SHAFT SEAL AND BEARING
Ù5Ú7Û9Î5Ü<Ì&Í
w²ry |}#ˆ ƒ S}a‰Š‹!}aŸS{~}a‹! ‚‰Š
w¸y |}#ˆ ƒ S} ‰Š‹!} ŸS{~} ‹! ‚‰˜}# {¹‚„ƒ#ˆ”‰Š‹!} }#€7ƒ#‚|‰Š‹!}
ŸS{~}a‹! ‚‰ ‰ Œ!• }©…~‰Š‹¶ˆ  {~{5¦I„ÝÆ/•  „¢

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°{±M²D²D³©´{³ƒµ{¶G± ·¸N·µH°¹°{´{± ºŽ³D¸D± µH³

»6¼½D¾

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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DIFFERENTIAL

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Q 
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Fig. 23 Bearing Cap Identification

 Œ  ž7'')Ÿ8CK&(  A ,& …!‹7< Q#¡#‹K2
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CKCD '1 † ' A †"§ †.?')*!E7'*POBQ#L 6#) A £ƒ &(†
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CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.

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" ,&( )'#6W(# 0"&(,¬ ;. ')*PO\­% ,#.&( ;1 A 'J
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&(  \ A '""M &( )?1'#$# #&(')*%W(#C$#,M#) A W(#CDO

1,2-3 4

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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

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æ úçÛ àÝé?êâåëPìfô%æ#ä(õ”Ý,ä™ßæ#ë†ßàÛ áDâããMÛä(Û,åßâMæ#çHï(æ#ê Û ðDä(Ûû
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Fig. 27 Differential Case Removal

Ò²Ó

Ô/Õ*Ö Ö ×8Ø/×<Ù/Ú>Õ Û[ÜەÙCÔDÔ/Ø/Õ ÝA× Ü Õ ÙC×

Þ,ß'à Þ

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.

jlknmoqp rtsuvOwyxzsxz{d|z}+~"z€sdz{|€x‚wy{~*}+wyuƒ*ƒ-wyxzs„tu}+s
~"…wyxzsxz{|z}n~"z€†M‡&su}+|rtswyxzsv ~"}+wyuz„tsVˆ‰~*wyx…wyxzsv ~"uƒ
~"zv ~"„tuwy{rKjlŠ>~"€‹†ŒŽ+m_†
jlnm s‘’{”“•sQwyxzsQv ~"uƒ[~"zv ~"„tuw–{dr—†
jl˜nm™”z}nwyuƒ"ƒ[v ~"šlš*srtsdzwy~*uƒ[„tu}+sQ~"›wyxzsVxz{d|z}n~*€†œ z}n|zrts
wyxzuwHwyxzs&v ~"šlš*srtsdzw–~"uƒsdurt~"z€,„t|zp }žrtsd‘\u~*O~"Op {d}+~"wy~*{d
{Ÿwyxzs v ~"šlšlsdrtszwy~"uƒ¡sdurt~"z€}uzv¢wyxzuwwyxzs p rtsƒ"{duv
}nxz~"‘\}›rtsd‘\u~" sw£ˆ’sds wyxzs¤šlu„ts¤{š\wyxzssdurt~"z€¥„t|zp
uzv›wyxzs)xz{d|z}+~"z€‹†•¦/upw–xzs)v ~"šlš*srtsdzw–~"uƒ'„tu}+s)wy{,sdz}+|zr§s
wyxzs,surt~"z€‹}V„t|zp }Quzv›}+x~*‘\}Qurts,šl|zƒ"ƒ ¨¥}nsuwysv›~"wyxzs
xz{d|z}+~"z€‹†
jlŽnm™”z}nwyuƒ"ƒMwyxzssurt~"z€„tup})uw’wyxzsd~*rV{drt~"€~"zuƒMƒ*{d„tu©
wy~"{z}’jlŠ~"€†Œªnm§†
jl«nm¬{{}nsƒ ¨O~"z}+wyuƒ"ƒ[v ~"šlš*srtsdzw–~"uƒ[surt~"z€)„tup¡{dƒ"w–}n†
jl­nm s‘’{”“•sQun®•ƒ"sQxz{d|z}+~"z€)}+prtsuv sdr—†
jlªnm\¦[~*€‹xzwyswyxzsžsdurt~"z€V„tup{dƒ"w–}Kw–{\««,¯±° ‘Ÿj*˜«)šlwy†
ƒ"}+† m²w–{drt³|zs†
j§´nµnm™”z}nw–uƒ"ƒ[wyxzsQun®•ƒ"sQ}+xzušlwy}n†

Fig. 30 Differential Bearing Removal

DIFFERENTIAL SIDE BEARINGS
¶[·¸H¹[ºq»'¼
j§´em s‘’{”“•sQv ~"š*šlsrtsdzwy~*uƒ[š*rt{‘½u+®qƒ"sVx{|z}n~"z€†
jlŒnm s‘’{”“•sQwyxzsQsurt~"z€‹}’šlrt{‘½wyxzsQv ~"šlš*srtsdzw–~"uƒ[„tu}ns
ˆ’~"wyx¿¾>|zƒ"ƒ"srÁÀ—¾rts}n} Â ©lŒªk©l¾dñġ ©lŒªk©lkªÅ ƒ"{„tÆ8}nÄ¡uzv
¾ƒ*|€,oq¾>©*kŒ­ªj*Š>~"€†Çkµnm§†

ÈlɕÊË»¼¼»ËÈ ¹HÉ
j§´em̱}n~"z€Íwy{{ƒŸÂ ©lk«B´nŽ© ÃΈ’~"wyxÏxzuzv ƒ"sР©lB´n«B´+Ä
~"z}nw–uƒ"ƒ[v ~"šlš*srtsdzw–~"uƒ[}n~"v sQsdurt~*€}’jlŠ~"€†kB´em§†
jlŒnm™”z}nwyuƒ"ƒ[v~*š*šlsr§szwy~"uƒ ~*un®•ƒ"sQxz{|}+~"z€†
RING
¦'xs‰rtGEAR
~"z€\uzvVp ~"z~"{,€sdurt}HurtsK}nsrÁ“q~*„tsK~",uQ‘\uw–„txsv
}+sdwy†MÑ-{{wžrtspƒ*u„tsw–xsrt~"z€O€sur‰ˆ‰~*wyxz{d|zwžrtsp ƒ"u„t~"z€
wyxzsQp ~"z~"{€sdure†

–H—|˜™

š{›œŠœž{?Ÿ{ B› ¡’¢H¡Ÿ<šbš{ž{› £’¢Š› Ÿ<

¤X¥

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q040[email protected]2&+

Fig. 31 Install Differential Side Bearings

÷[øùHú[ûqü'ý
þ§ÿ 

 "!#%$&'()*,+
þ-)./01
&2304()567()'289
()9:;$
()<=4,>?):
@40()+þ AB*,+DC4-)
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þI)JK()*LF()M$4 =OND

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Q

0("

Fig. 33 Ring Gear Bolt Installation

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

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 2$&%)! $'("*P+
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@S@s()$a
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þC)z|()0&0\@@_("$&4\‚@ƒe ~&+

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8
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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.

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8:9<;>[email protected]?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

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¼S½½O¿ÀÁÂ=à Ä#ÁƒÅÆÁfÍÃÞÞÈÏÒ)ÊÉÞÁfÏÇÁÞÃÈ4ÜáÒ)ÏÈÍÁÇn¼ÓBÊÌ,Ô
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¼S½)ã)¿ÀÁÂ=Ã2Ä Á;ÅÆÁ;ÇÁÈÇKÉÁÈ4ÇÊË̄ÐÇSËÅÆÁ;ÏÊËÊÃË=ä;ÊÅÆ
å ÎÞÞÁÇxæ å ÇÁÒ"Ò\ßÙãÛÕ4Ù åç

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¼S½)Õ)¿ÀÁÂ=Ã2Ä Á=ÅÆÁ ÜÁÏ4Å2ÆqÒ)ÆÊÂ=ҐÐÇÃÂaÅÆÁ=Ï4ÊË&ÊÃËqÌ,ÁÈ4Ç
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Fig. 37 Rear Bearing Cup Removal

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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.

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g$lmoflmj owv`^hx
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Xlmvx’‘“[Z”x
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yž[Ÿi•‚’^ofrdfj]#ri` h:i•¥yXlmvx’‘¥[Z”x
X”ž[Ž[Zz{ofp[b^]m]’bedf`¦ jn`¦‰—^p[df` hš^ior^Eof`{‰§of…fb6jocbedf`
g$lmoflmj o¨v`^h:^ofrblmvdb`owbedf`›g$lmoflmj o¨of…fb<…foblm]¤bedf` ha`›lmp
© ` [email protected]~`^ihalmofvk`ofr$Œgi]#^[ ªx
X”ž[“[ZJ«2lmvœdfb`obedf`@of…fb<b[email protected]ŽYž—¬š­ t®X#ŽiŸŸƒ#bx™]#~p[x Z”x

 
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-/.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.

ԔÕ[Ö[×ؚÙ[Ú#ÛÜJÝÞ ß'àkáfÞâmã$à äJåæçiècéÛfãwé¨êeÞ äaëìfà:í†äaà Ûfîaá
Ù[à ê<éê<ÖïÖðšñ òóÔôçiõköêe÷™âmøÙq÷ הù+îaäaìfÙqá¨îaÞâ#âméú$Ù[Úmøiâmà›Ù[ú$éîaà ä
ìfÛfêeÚmâ.øà éäaÚmÛfÜkà Ûãcú$âmé[Ý>Úmٗêéß'à ÛwìfúÔû+Úmܜ÷’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

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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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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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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
Installation

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CLEANING AND INSPECTION

ADJUSTMENTS

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Fig. 65 Shim Locations

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Fig. 66 Pinion Gear Depth Gauge Tools—Typical

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Fig. 67 Pinion Height Block—Typical

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Fig. 69 Pinion Gear Depth Measurement—Typical

DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
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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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SPECIFICATIONS
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ü ÐÃdÌË × Ëöç,Ð ÙÙ ÌÅ Ù ÊzÈ Ù Å ÐÕ ÉÉÉÉÉYÞÉ äXå6Ë.Ë é ÞÉ Þô%Þ.ÌNÒÉ ì

194 RBI AXLE
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½`¾oºcýoþ·
ñ,Ï ÄÑ(î ï ÌðNðÉ5ç,Ï"ÿdÅ Ù ÉÉÉÉÉÉ[ÉÉÉÉÉÉÉYæå6ù`ú Ë éNê Þ ðNÑÉ5Ä Ø ëÉ ì
ñ,Ï ÄÑ(î5ñ,ÅÐ Ù ÌÒ5Ó$ç,ÐÈÉÉÉÉÉ[ÉÉÉÉÉÉÉYãã ù`ú Ë é ä%ã ðNÑÉ5Ä Ø ëÉ ì
ù × Ñî5òXÌÒ5ÌÏ Ò ÉÉÉÉÉÉÉYôãXåÍæã%æ.ù`ú Ë é ôÞÞÍ ê äÞ ðÑ(É5Ä Ø ëÉ ì
ÊdÚ Ù Å"áî5òXÌÒ5ÌÏ Ò ü ÐÑ(ÅoÊdÜ5ÐðÑ Ö Ï Úõ ÉÉÉÉ[ÉÉÉÉåèÉ ôä ù`ú Ë
é åô.ðÑÉÄ Ø ëÉ ì
ñ,Ï ÄÑ(î5í,ÌÒ5Ó$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<;>=[email protected]@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

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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

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Hub Puller—6790

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Dial Indicator—C-3339

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216 RBI REAR AXLE

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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
. . . . . . . . . . 85
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93
92
94
95

GENERAL INFORMATION
216
º»½¼¿RBI
¾/ÀÂÁAAXLE
Ãļ¹ÅÇÆ6Èļ¹ÅÇÉËÊ<Ì ¼IÍÏÎ(ÐÒÑÓÔÆÖÕIÑ×<ÃÄÈÄÓÙØ6ÅÂÚÛ(¼>»ÜչݽÍÏÎ(ÑÜÐ

»ÜÅÇÍ>ÅÇÑÞÎ(ÆÖÕIÑÞßÖ¼IÑÜàá¼¹ÆßDÅâÍÂàãÎ(ÑÜÐä×Ì Î(å<å<¼IÆÖ¼¹ÑÜàáÎ(ÅÇÛ»ÜչݽÍÏÎ(ÑÜÐÖØÄæ¿Îàá»
ÅÂÚÛ(¼çÍÏ»ÜÅÇåàèàãÝÜéǼIÍê¼ÔÚàá¼¹Ñ½Ì Î(ÑÜÐëå<ÆÖÕ¹Éì¼¹Î(àá»Ü¼¹ÆíÍÏÎ(Ì ¼Iîïºð»Ü¼
àáÝÜéǼ¹ÍñÅÇÆÖ¼èòâÆÖ¼¹ÍÂÍϼIÌêÅÇÑÜÌóæô¼¹Û(Ì ¼IÌêÎ(ÑÜàáÕõà㻽¼èÌâÎåå<¼IÆÖ¼¹ÑÜàáÎ(ÅâÛ
»ÜÕIÝÜÍÏÎ(ÑÜÐ:àáÕAå<Õ¹ÆÖÉöÅÕIÑܼ¹Ê<òâÎ(¼¹ßÖ¼AÅÂÚÛ(¼A»ÜÕ¹ÝÜÍÂÎ(ÑÜÐÒî
º»½¼÷Î(ÑÜàã¼IÐÒÆÖÅÇÛàÙøùò ¼÷»ÜÕIÝÜÍÏÎ(ÑÜÐûúÄ»¹øò ÕIÎÌÞÐû¼¹ÅÇÆôÌ ¼IÍÏÎ(ÐÒÑü»ÜÅÇÍ
àá»Ü¼¿ßÖ¼¹ÑÜàá¼¹ÆÛ(Î(Ñܼ¿Õ¹åýà㻽¼ôòâÎ(ÑÜÎ(Õ¹ÑÍϼ¹àéâ¼IÛ(ÕÔæþà㻽¼ôßÖ¼IÑÜàá¼¹ÆÛÎ(Ñܼ
Õ¹åàá»Ü¼AÆÖÎ(ÑÜÐ:ÐÒ¼¹ÅÇÆÿî
º»½¼ÅÏÚùÛ¼»½ÅâÍä
Å ¼¹Ñ½à>»ÜչͼàãÕÆÖ¼IÛ(Î(¼ ¼Î(ÑÜàá¼¹ÆÖѽÅâÛò ÆÖ¼¹ÍÂÊ
ÍÂÝÜÆÖ¼óßÖÅâݽÍϼ¹Ì éÂøçÛ(ÝÜéÇÆÖÎ(ßÖÅÇÑÜ
à ÅÇò ÕIÆÖÎ ÅÇàãÎ(Õ¹ÑêÅÇÑÜÌíÎ(ÑÜàá¼¹ÆDÑÜÅÇÛ
¼ÔÚùò ÅÇÑÜÍÂÎÕIÑÜî
º»½¼çÅÏÚùÛ¼IÍêÅÇÆÖ¼ç¼ ÇÝÜÎ(ò ò ¼IÌ æ¿Î(àã» ÍϼIÉËÎ(Ê<å<Û(ÕIÅâàáÎ(ÑÜÐëÅÂÚÛ(¼
Í»ÜÅÇå<àãÍÂî º»Ü
¼ ù¼¹»ÜÎ(ßÖÛ(¼Aæô¼IÎ(ÐÒ»ÜàËÎÍÍÏÝÜòâò Õ¹ÆÖàá¼¹Ì éÂø àá»Ü¼ÞÅÂÚÛ(¼
Í»ÜÅÇå<àôÅÇÑÜÌñéǼ¹ÅÇÆÖÎ(ÑÜÐûÍÏî º»½¼ ÅÂÚÛ(¼ Í»ÜÅâåàãÍ÷ÅÇÆÖ¼ ÆÖ¼¹àáÅÇÎ(Ñܼ¹ÌñéÂø
ò Û(ÅÇàá¼¹ÍôéÇÕ¹Û(àá¼¹Ì àãÕAàá»Ü¼A¼¹ÑÜÌ å<Û(ÅÇÑÜÐû¼¹ÍôÕ¹åàá»Ü¼AÅÏÚùÛ(¼äàáÝÜéǼIÍÏî
º»½¼>ßÖÕ ¼IÆ6ò ÆÖÕ Î(Ì ¼IÍ ÅËÉ˼¹ÅÇÑÜÍå<ÕIÆ6ÍϼI Æ Î(ßÖÎ(ÑÜÐôàá»Ü¼>ÌâÎ(å<å<¼IÆDÊ
¼¹Ñ½àãÎ(ÅÇÛæôÎ(àá»ÜÕIÝÜàÆÖ¼¹ÉËÕ Î(ÑÜÐ:àá»Ü¼AÅÏÚùÛ¼A»½Õ¹ÝÜÍÂÎѽÐÒî

ÕI Æ ù¼¹»ÜÎ(ßÖÛ(¼¹Í÷ ¼ ÇÝÜÎ(ò ò ¼IÌæ¿Îàá
»
È èéÇÆÖÅ ½¼IÍÏúà㻽¼ ÅÂÚùÛ¼IÍ
»ÜÅ ¼óÅ àáÕIÑܼ ÆÖÎ(ÑÜÐ òâÆÖ¼¹ÍÂÍϼIÌíÕ¹ÑÜàáÕ àá»Ü¼óÅÏÚùÛ(¼ ÍÏ»½Åâåàã
î  ͼ
ßÖÅÇÆÖ¼÷濻ܼ¹Ñ ÆÖ¼IÉËÕ ùÎ(ÑÜÐóÅÂÚÛ(¼ Í»ÜÅÇå<àáÍ àáÕ ¼IÑÜÍÏݽÆÖ¼ àá»ÜÅÇàäàá»Ü¼
àáÕ¹ÑܼÆÖÎ(ÑÜÐôÕIÆ6àá»Ü¼æô»Ü¼I¼¹Û/ÍÏò ¼I¼¹ÌAÍϼIÑÜÍÂÕ¹Æ#ÅâÆÖ¼ÑÜÕIàÌ ÅÇÉËÅÇÐÒ¼IÌ î
º»½¼Þ¾/ÀÂÁñÃÄÈÄÓAÅÂÚÛ(¼ »ÜÅÇÍàã»Ü¼ ÅÇÍÏͼ¹ÉËéÇÛ ø ò ÅÇÆÖàËÑÜÝÜÉËéǼ¹Æ
ÅÇÑÜÌÐÒ¼IÅâÆ3ÆÖÅÇàáÎÕËÛ(Î(ÍÏàá¼IÌÕIÑ Å:àáÅâÐûî ºð»Ü¼ËàáÅâÐäÎ(Í>ÅÇàáàãÅÇßֻܼIÌàáÕ

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

àá»Ü¼ Ì Î(å<å<¼IÆÖ¼¹ÑÜàáÎ(ÅÇÛ»ÜչݽÍÏÎ(ÑÜÐñéÂø Å ßDÕ¼IÆéÇÕ¹Û(àáîÈÄÝÜÎ(Û(ÌèÌâÅâàá¼
Î(Ì ¼¹Ñ½àãÎ(å<Î(ßÖÅÇàáÎ(Õ¹Ñ ßÖÕ¹Ìâ¼¹ÍËÅÇÆÖ¼äÍÂàáÅâÉËòâ¼¹Ì ÕIÑüàá»Ü¼AßÖÕ¼IÆ¿ÍÏÎ(Ì ¼äÕIå
ÅÇÑ ÅÂÚÛ(¼AÍ»ÜÅÇå<ààáÝÜéǼ¹î
º»½¼ËÌâÎåå<¼¹ÆÖ¼IÑÜàáÎ(ÅâÛýßÖÅÇͼËÎ(ÍÅ÷չѽ¼¹Ê<òâμIßÖ¼ôÌ ¼¹ÍÂÎ(ÐÒÑÜîâºð»Ü¼ôÌ Î(å<Ê
å<¼IÆÖ¼¹ÑÜàáÎ(ÅÇÛ¿ò Î(ÑÜÎ(Õ¹ÑíÉËÅâàá¼üÍÏ»ÜÅÇå<à÷Î(ÍÞÆÖ¼¹àáÅÇÎѽ¼¹Ì æôÎ(àã»íÅèÆÖÕ¹Û(Û(Ê
ò Î(ÑÜî Îåå<¼¹ÆD¼¹ÑÜàáÎ(ÅâÛ ÍÂÎ(Ì ¼ éâ¼IÅÇÆÖÎѽÐüò ÆD¼¹Û(Õ¹ÅÇÌ ÅÇÑÜÌóÆÖÎ(ÑÜÐüÐû¼¹ÅÇÆ
éÇÅÇß ½Û(ÅÇÍÏ»Î(Í ÅÇÌ ÝÜÍÏàá¼IÌäéÏø Í»ÜÎ(ÉËÍ ò ÕIÍÏÎ(àáÎ(Õ¹ÑܼIÌäéǼ¹à æô¼¹¼IÑà㻽¼
ÍÏÎ(Ìâ¼ÞéǼ¹ÅÇÆÖÎ(ÑÜÐüßÖչѽ¼ÞÅÇÑÜÌ Ì Î(å<å<¼IÆÖ¼¹Ñ½àãÎ(ÅÇÛ3ßDÅâͼ¹î Î(ÑÜÎ(ÕIÑ ÐÒ¼¹ÅÇÆ
Ì ¼Iò àá»êÎ(Í ÅÇÌ ÝÜÍÏàá¼IÌ éÂøÍ»ÜÎ(ÉËÍ ò ÕIÍÏÎ(àãÎ(ÕIÑܼ¹Ì éǼ¹à æô¼I¼¹Ñ àá»Ü¼
ÅÂÚÛ(¼»½Õ¹ÝÜÍÂÎ(ÑÜÐ ÅÇÑÜÌ àá»Ü¼:Î(ÑÜÑܼ¹ÆËò Î(ÑÜÎ(Õ¹ÑóéǼIÅâÆÖÎ(ÑÜÐ ßÖÝÜò î  Î(ÑÜÊ
Î(Õ¹Ñ éǼ¹ÅÇÆÖÎ(ÑÜÐ ò ÆÖ¼¹Û(ÕIÅâÌþÎ(Í ÉËÅÇÎѽàãÅÇÎ(Ñܼ¹ÌþéÂø Í»ÜÎ(ÉËÍ ò ÕIÍÏÎ(Ê
àáÎÕIÑܼ¹Ì éǼIàÙ濼¹¼¹Ñ àá»Ü¼ñò Î(ÑÜÎ(ÕIÑêÐû¼¹ÅÇÆ ÍÏ»ÜÅÇå<à÷ÍÏ»ÜÕIÝÜÛ(Ì ¼¹Æ ÅÇÑÜÌ
àá»Ü¼AÕ¹ÝÜàá¼¹Æ>éǼ¹ÅÇÆÖÎ(ÑÜÐ:ßÖÕ¹ÑܼIîý×
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LUBRICANT
 "!$#%&('()*!$+)-SPECIFICATIONS
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Fig. 1 Axle Adjustment Shims

[ƒ „$…†‡(ˆS‰-Š$‹EŒ†Ž‰05‘’R‡Š$‹‘Š$“*‘ “”Œ(†Ž•$‘‰–9—5˜“*„B‹™—š†
‹†‰‡(‘ †F‹›œ„$’‘8‡’ŽŸžd ¢¡-£¤¦¥[§¨©¦Mª¬«­¯®  5­±°²¢³9‘ ‰-†
„$…†‡ˆ‰Š$‹´
­¬†‰-ˆS˜µT“*‡Œ(Œ‘†‘ Š$‹‡(‰’I†‘¶„$‡†‘Ž‹•$‘Ž‰“*“*‡‹‡( Š· Œd¨h¸{´
Œ[Œ†‡ˆ‹‡( ŠI¹" “*‡Œ‡‘†‹º‹•$‘ ‰05‘º„$…†‡ˆ‰-ŠB‹´4­±•$‘º»^§¼"½¾°
‰M‘ „$…†‡ˆ‰Š$‹¿ˆ‰À*‰ˆ‡(‹g—Á‡’§0´ ÃăÆŨ´ ©ÇÀ-‹’´ Èɋ‹‰(Ê
‡Š$ˆ„$“*‡Š$³I‹•$‘Œ†‡ˆ‹‡Š8¹"“*‡Œ(‡(‘ †‡Œ@Š$‘ˆ‘ ’0’‰† —Ÿ´


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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‹†‰0–5‘"‰É³Ÿ†‘‰‹‘ †8“*‡’0‹‰Š$ˆ‘T‹•$‰ŠO‹•$‘¦‡(ŠB’0‡“*‘Ž›•$‘‘ ;‹
ˆ¹AÀ*‘‹‘‰‹„$†ŠB´9­±•$‘“*‡ŒŒ(‘†‘ Š$ˆ‘¹"„$’‹@…‘ˆ ¹"À*‘ŠB’0‰‹‘“
Œ †Ž‹HÀ*†‘–M‘Š$‹E‹•$‘h‹‡†‘’GŒ† ¹Ô’0ˆ„$Œ(Œ‡Š$³T‰Š$“U’µw‡(“-“*‡Š$³
‹•$†„B³9•¢‹„B†Š$’0´­Q”‰ˆˆ¹"À-‡(’•¢‹•B‡(’Ê‹•$‘”“-‡(Œ(Œ‘†‘ Š$‹‡‰-
‰Õ (›A’d‹•$‘‰05‘’•$‰Œ‹’d‹‹„$†ŠF‰‹@„$Š$‘¶„$‰Q’À*‘ ‘“*’dÅÒ[‡³9´
ÈS´±°Š¿‹•$‡’‡Š$’0‹‰Š$ˆ‘ ʱ‹•$‘f‡Š$À*„$‹‹†S¶-„B‘Ž‰À*À-‡(‘ “h‹f‹•$‘
À*‡Š$‡Š8³9‘ ‰-†’A‡’AŠ$‹“*‡ –M‡“-‘“G‘ ¶„$‰( —4´B­¯•B‘EÀ*‡Š$‡ ŠH³9‘ ‰†’
Š$›Ö†‹‰‹‘E‰† „$Š$“G‹•$‘EÀ*‡Š$‡ ŠH¹"‰-‹‘E’•$‰Œ‹d‡ŠH À*À* ’0‡‹‘
“*‡†‘ ˆ‹‡ Š$’0´Q­¯•$‡’F‰(›A’F‹•$‘G’0‡“*‘G³Ÿ‘‰†I‰Š$“¦‰M‘G’0•$‰Œ‹
‰‹‹‰ˆ•$‘ “U‹H‹•$‘H„$‹’0‡“-‘I›A•$‘ ‘‹h†‹‰‹‘H‰-‹E‰¿Œ‰’0‹‘†
’0À-‘‘ “*´

DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL

­¯•B‘Ë“*‡ŒŒ(‘†‘ Š$‹‡(‰R³9‘ ‰†É’Ì—5’0‹‘¹Í“-‡ –5‡(“-‘’W‹•B‘Ë‹†¶„$‘
…‘‹g›A‘ ‘ŠC‹•$‘I‰M‘I’•$‰Œ‹’0´°‹º‰›A’;‹•$‘‰05‘I’0•$‰Œ(‹’‹
† ‹‰‹‘E‰‹“-‡(Œ(Œ‘†S‘Š$‹’À*‘‘ “*’›A•$‘ Š8‹„$†ŠB‡(ŠB³Fˆ †Š$‘ †’0´
 ‰ˆ•Ë“*‡ŒŒ(‘†‘ Š$‹‡‰;’0‡“-‘¿³9‘ ‰†H‡’C’À*‡Š$‘“W‹T‰ŠË‰M‘
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Fig. 3 Differential Operation—On Turns

TRAC-LOK
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Fig. 4 Trac-lok Limited Slip Differential Operation

DIAGNOSIS AND TESTING
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