Jeep Wrangler TJ Manual

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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Fig. 5 Thread Notation Chart – SAE and Metric

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REFERENCES
576 8:9<;>[email protected][email protected];>EGFH57IJIJ?<51;[email protected]?B?<-
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9

INTRODUCTION
˜™›š œašžœŸ
page

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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 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
:<;>[email protected]?3ACBDC=FEHGJIK=MLNOB=MPLQACIKACB[email protected]=MDWYX1ACZ\[^]`_aACE
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Fig. 2 Body Code Plate Location

BODY CODE PLATE
LOCATION
AND DECODING
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[email protected][email protected][3l?z=MP=GmPn="EH=“;>[email protected]šDCACT3=MEqSMI[email protected][email protected]šSMT
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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
CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 1
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INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1
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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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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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114,000 Miles (182 000 km)
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117,000 Miles (187 000 km)
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120,000 Miles (192 000 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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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.

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

HOISTING
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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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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
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NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
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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

^&[email protected]`

SUSPENSION
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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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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.

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Fig. 1 Wheel Alignment Measurements

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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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©O¡”'™(”'¬O¶¸·F”K•”'—¹™L–°º»²?˜Q©”Kœ?˜M›s–'œ¼š œ?¬½º»™L”K”K—7›œ?Ÿº£®»˜Q™L”K¤
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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ÀÈM´à œ?˜M©O”'ª7™•s—7–Kœ¥™Hž- ?”K”'¡s˜•–'—1”(Éʪ7”K˜M˜Q› Ë»”Å—7š ¬O›š ¡[–K—1¡š ™Lµ
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ÀÌM´à œ?˜M©O”'ª7™§³ š ¡¡Í˜Q™L²?¬O˜M¦#¡s›œ?ÎϚ £”ЩO› Ëʖ'™§©–K›œ?™L˜¹š œ?¬
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œ?–'›s˜M”K¶

WHEEL
“F”K•s–K—7”ÍALIGNMENT
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³ ²?¤©O”'—š ™4™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

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

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Ÿ" ¢¡

46587:9<;>=-?@BACAEDFGHFJI6ALKMDFNFJG$AEONFP[email protected]>QRONSTKMQHA>DUA>DFA>QHF
[email protected]];`:W/F_XYXL? Va$SZbdc6A>egDfhF
P@[email protected][\AEQHF
ONS?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

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[\

]_^`]_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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ÍÄpÁÍÇ>ÇEÍÓpÀÁNÔZÇEÅUÍÀÉÚ8Ò ÚÁJÍÄpËHÆÕtÈÝMÀËHÓpÀòÚÅJÏHÇ>ÈÇ>ÅÇ>ÀÁ cotter pin must be torqued to specification. Then if
ÑóÆÉÓpÑóÏHÁJÈ8ð¿¢ÀÁiÀÉÚBÒ ÚÁJÍÄpËHÆÕrËHÈÆÅJÇ:ÈBÁNČô\ËHÓpÁNÍÚÏHÁÍÆԉËHÈ the slot in the nut does not line up with the cotter
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vehicle
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of
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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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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
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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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LOWER SUSPENSION ARM

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UPPER SUSPENSION ARM

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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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SPECIFICATIONS
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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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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.

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LOWER SUSPENSION ARM

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Fig. 1 Shock Absorber

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NOTE: Springs can be install with either end up.

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Fig. 3 Upper & Lower Suspension Arms

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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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TRACK BAR
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Fig. 7 Rear Track Bar
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NOTE: It may be necessary to pry the axle assembly over to install the track bar.
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PROPELLER SHAFTS

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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

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

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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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b C60#4CBABA6%W)(+*@;%7CD60#C460B c^CD)(+%W4?/!>)_28cd#a
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LUBRICATION
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(+)??(+1&(+35&(+.0 2;A1&&-)Vih4);A.0BA&;%/%'6„id;A.0?FIk[*K%W4(DB
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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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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

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SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION
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PROPELLER
SHAFT
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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
FRONT PROPELLER SHAFT
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Fig. 14 Reference Marks on Yokes

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Fig. 13 Front Propeller Shaft

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Fig. 15 Dust Boot Clamp





  



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Fig. 16 Rear Propeller Shaft

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Æ\äFÈfå(Ë߀ÏOÎ`ÍBÕÎ`ÏOÍtæqç è+ÓBËDÕ4Î_ÐYÎ`ÖQ×[ÑÙ Û ÊD×[Øfяé[ÓBÊDÎ`Ч×[Î_Î`ÏOÍ
×FáTÊDÍqÒTÓ+Ô4ÍÎ`Ó¨ÇYê ëqì ؚÆ%ÇFí•ÚÎdݪÊé[ÐFÝ ÈÎ`ÓBÖ%îJÜOÍ+Ý
Æ\ïFÈ?ð…ÖQËDØfÑ Û Ê×[ØfÑñÎdӑÏOÓ+ÊÌñÌ
ÜOÐF·éJÓ+ÓB·Î`ÓzÑJÖQÓBÑJÍBÊDÊDÍBÖ
ÐFÏO×[Ú\ÎÒTÓ+Ô4ÍÆ\â}ËDߙÝÇFòFÈ%Ý
Æ\íFÈ?ó}ӆô|Í+Ö"Î`ÏOÍqõTÍ+ÏOË Û ÊDÍBÝ

Fig. 18 Remove Snap Ring

Æ\íFÈ?É9ÍBÎ"ÎdÏOÍ|ÒTÓBÔxÍ?ËDÕv×[Õv×[ÖQé[ÓBÖnÑ
ÖQÍ+ÐYÐ~ÓBÖ6õTËDÐFÍfô|ËDÎ`Ïv×
ÐYÓ Û ÔxÍBÎXô|ÏOÓ+ÐY͏ËDÕOÐYËDÌ
͏Ì
ËD×[ØfÍBÎ`ÍB֑ËDÐzÊD×JÖQ߀ÍÿÍ+ÕOÓBÜOß€Ï Î`Ó
ÖQÍ Û ÍBË õTÍÎ`ÏOÍéJÍ+×[ÖQËDÕOß Û ×JÑ?Ñ
Ó+ÐYËDÎ`ËÓ+ÕOÍ+ÌLé[ÍBÕ4ÍB×[ÎdÏXÎ`ÏOÍqÒTÓ+Ô4Í+Ý
Æ F

È }ÓBÐYËDÎ`ËDÓBÕàÎ`ÏOͯÒTÓBÔxͯô|ËDÎdÏÎdÏOÍtߙÖQÍ+×[ÐYÍtÚ\ËDÎdÎ`ËDÕOߙü~ËDÚ
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ÖQÍBÐFЕÎdÏOÍ Û ×[ÑvÎ`ÏOÖQÓ+ÜOߙϧÎdÏ4ÍnÒ9ÓBÔxͨÎdÓ
ÖQÍBÊDÍ+×JÐFÍÎdÏ4ÍÊÓdô|ÍBÖé[ÍB×[ÖQËDÕOß Û ×[ÑLÆâiËDߙÝgÇYêFÈ%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+ØfÑ
ÓBÕ4ÍBÕOÎ`ЯÓ+Ú Û ×JÖ%Ì
×[՝Ü4ÕOË õTÍBÖ%ÐY×[ʅèÓBËDÕOÎ`Ð
×[ÖQ͐ÕOÓBÎgÐYÍBÖ\õTË Û ÍB×[é[ÊDÍBÝ û Ú
ô"ÓBÖQÕ¨ÓBÖÊDÍB×[ÔxËÕ4ߙüªÎ`ÏOÍdÒ_ØfÜ4ÐYÎé[Í
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ÊD× Û Í+Ì?×JÐ|×[ÕX×JÐFÐYÍ+Øfé[Ê ÒlÝ
Æ%Ç,È?ý…ÍBØ|ӆõTÍÎ`ÏOÍÑ
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ÍBÊDÊDÍBÖÐYÏ4×JÚÎdÝ
Æ\äFÈ?æqÐFËDÕOß?רÐFÓBÚ\Î6Ì
ÖQËDÚ\Î`ü(Î`×[ÑXÎdÏ4ÍÓBÜOÎ`ÐFËÌJÍÓBÚgÎ`ÏOÍé[ÍB×[Öþç
ËDÕOß Û ×[ÑL×[ÐFÐYÍ+ØféJÊ Ò_Î`ÓnÊDÓ+ÓBÐFÍBÕXÐYÕO×[Ñ?ÖQËDÕOߙÝ

Fig. 19 Press Out Bearing

º»›¼½

¾¿\ÀÀÁÂÁÃÄ¿ ÅÆÅþ.¾Â¿ ÇÁÆ¿ ÃÁ

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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\[R]u^ZVU`q€NhfRXZ[mNhORQ
ijeAkQeM~tQWX‚VU[RlnoJNPXZVUY\]xOvNPQA[)NPOvQ^ZXZeAopoTY\[)NhORQ1eW`QA[)OReWc\QAy
{7ORQW[Rq#^ZVUXZQWL
fRc\c iƒ`XZQWoJoNhORQwQA[RlueWL„NhORQw^ZX…eWopo_fR[RNhY\c€NhORQ
XZQA}8VgY\[RY\[R]_SUQWVUXZY\[R]_^ZVU`w^…Vg[SUQ+XZQW}8eP~jQWlG†‡Y\]xyˆU‰JI…y

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
Š‡‹‹7ŒvŽ‡P
G…‘BI8’€``gc i“QP”jNhXZQW}8Q_`X…QWopoJfRXZQ_G•d–gI‚—€y ˜y ™#yšKPy6™›XZVUlQ)‘
eWXˆs]rXZQWVUopQTNPeTY\[RopY\lQTeWLjijeWkQTSgeAXZQWobNPeTVUY
lsY
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Y\NPœ
NhY\[R]xqY\LQWUfRY\``gQWlqž`eWY\[RNhY\[R]_fR`G†Y\]ryˆ‘ŸI<y
G JI–‡c
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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
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G¬JI–‡XZQWoJo­NPORQ®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
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G²JI³dQW`gQWVUNb´jNhQW`) |VU[Rl¨´tNPQA`¨¬|NhesY
[vopNhVgc\cNhORQseW``geWœ

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

oJY
NhQ‚SUQWVUXZY\[R]+^ZVU`yKMLNhORQžµeWY\[RN#Y\o„opNhY
L
LeWX€SUY\[RlY\[R]xqoJNPXZY\kQ

VUXZQT[ReWN›opQWX~jY\^ZQWVUSUc\QWyžKPLabeWXZ[neWXc\QWVUkvY\[R]rqžNhORQMi|}8fvopNSUQ

NhORQ#ijeWkQ#a‚Y\NhOV+opeWL
N7ORVU}8}8QWXNhe‚oJQWVUN7NhORQb[RQWQAlc\QbSgQAVUX…œ

XZQA`c\Vg^ZQAlVgo‚VU[VgoJopQA}8SUc i§y

Y\[R]xoJy
GHJI8’€ll]xXZQAVUopQ+Nhe1c\fRSUQ+LY\NhNPY\[R]rqY\LQWUfRY\``QAly
GzJIKM[RoJNhVgc\c6NhORQ+`XZeA`QAc
c\QAXboJORVULNPy

G…‘BI³dQW}8eP~jQ+NhORQ+`XZeA`QWc\c\QWX&opORVUL
NPy
GˆJI¹€oJY\[R]VnoJeWLN„lXZY\LNhq6NhVU`NPOvQ_eWfRNhoJY
lgQ_eWL›NhORQ_SUQWVUX<œ
Y\[R]_^ZVU`wVUoJopQW}‚Sgc i)Nhe1c\eAeWoJQW[op[RVU`XZY\[R]xy





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ß
Já›íZçUóJò_éhêRãbòíZåAéPí…ÿRþî\ïRðTëUãWçUíZî\ïRðTë
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åWüã€û‚î\éhê|çsä‚çgè\è\ãWéçUïRþþíZî
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î\ïRü

ëUãWçUíZî\ïRð_ñZçUò
íZåWä­éPêRã


åWüã+ßõî\ðrö

÷ pá<ö

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

çUï

åWÿvéPóJî\þã«þî\çUä8ãWéhãWí

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

Fig. 25 Remove Bearing From Yoke
ßJáõ‡è
î\òuçUópóJãWä8ëUè

çUïRþuíZãWògãWçUé8ùtéPãAòuø›ùtéPãAò›çUïRþ
ùtéPãAò
éhå1íZãWä8åPæjã1éhêRã1åWòògåWóJî
éhã1ëUãWçUíZî\ïRðñZçUòö#êRî\óûbî
è\è
éhêRãWï|çUè\è\åMû­íZãAä8åMæjçUè6å7éhêRã1ñZíZåAópó‚ñZãWïRéhãWíZî\ïRð_üvî\é€çUóJópãAä
ëUè


çUïRþópògíZî\ïRð_ßõî\ðrö

÷
pá<ö

ëUãWçUíZî\ïRð+ñZçUòçUïRþ_òçUíZéPî\çUè\è
òíZãAópóåWïvã8ëUãAçgíZî\ïRð+ñZçUò
íZåWä
éhêRãnåWÿvéPëUåWçUíZþ“óJî
þgãnåéhêRãnè\î\ïRü
åAüvãnãAïRåAÿRðxêìéhånðxíZçUópò
éhêRãëUãWçUíZî\ïRðwñZçUò_ûbî
éhêsæjî\ópã#úçJû‚ó1ßõ‡î\ðxö

÷ øJá…ö
dãóJÿRíZãéhå

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

Fig. 26 Remove Centering Kit
ßJá‡íZãWóJóéhêRã‚íZãAä8çUî
ïvî
ïvð+ëUãWçUíZî\ïRð+ñZçUòó„åWÿvé#éhêRã‚åAéhêRãWí
ãWïvþ)åéhêRãè\î\ïRü
éhêRã+þî\ópçUóJópãWä‚ëgè
ö

Fig. 24 Press Out Bearing


åAüvãçUó1þãWóJñZíZî\ëUãWþ|çgëUåMætãéPåñZåAä8òè\ãWéhã

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ÕÖ&Ö#×#Ø

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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~iKwzyfo€sgji*}‚u
u

~{}*o‚l{ifƒ…„Yeh~{„Yo#ssRoqe†nyfl‡aw

‰ě‹Y•‘˜›˜€”a·{‘Ų‘§• ®¯ «Æµ§
”–·{‘† ©± ‘Dz © •‘
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§ • ®¯ «9‰´ ® «¬¡Èªɛ‹M¡
‰ʛ‹¤ ¯ ˜›”–§q-§.˜ ¯ §• ®¯ «¸¡

~{}Yol{eholsRgRk{ifo#ƒYˆ
‰MŠR‹ŒŽ#q ’‘a“/”–•‘—‘9#•M‘˜™˜›š{•‘9‰œžq‹ ŸŽ¡ ¢*¡ £6¡¥¤a¡-£¦•§¨#‘IŠ
© •ª.«¬•‘§˜™‘­” ­
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§ ® ¨

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”–·{‘|#• © #‘‘•9˜™·§ ° ”0 ©± ‘|‰´ ® «¸¡

ª¹›‹M¡

Fig. 29 Press In Bearing Cap
‰˛‹´Y ® x”a·{‘Í#• © #
 ‘‘•A˜™·{§ ° ” ©± ‘§ ¯ ¨
®"¯ ˜™”–§q”–·{‘
²‘§• ®¯ «µ§
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a
¡ ¤ ¯ ˜›”a§|§
©¯ ” ©
© # © ˜ ® ”–‘1”–•š ¯{¯®"©¯ 
˜ ¯ §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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§ ® « ¯
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#•‘ ½ ‘ ¯ ”0#• © #‘•=§˜™˜›‘—² ¬¡

Fig. 30 Press In Bearing Cap
‰¹›‹´ ® ”­”–·{‘͏ ®¯{±  
”–·{‘Í•‘—§ ® ¯{®¯ I
«
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‰À›‹¤ ¯ ˜›”–§q-˜ ¯ §• ®"¯ «¸˜™¡

Fig. 28 Install Bearing Cap

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

ƒ…„#††‡
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Fig. 33 Install Remaining Cross

Fig. 31 Install Link Yoke

ôõ›ö÷ùø{ú›û–üqýýHû–þ{ÿ

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Fig. 34 Press In Bearing Cap

CLEANING AND INSPECTION
SINGLE
*+ .K AND DOUBLE
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SPECIFICATIONS
TORQUE

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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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GENERAL INFORMATION
181
FBI,/.0AXLE
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5&7+8`5ˆ8V(9*ˆ=/QSR"*ˆF/(9=ZXD8Vg†•–‚—…–9˜w™š9›\š9œ+WžŸ~ ˜–9—…
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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. 8 Pinion Yoke Installation
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torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bearings may result.

Fig. 6 Pinion Yoke Removal

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Fig. 10 Tightening Pinion Shaft Nut—Typical
 
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Fig. 13 Collapsible Preload Spacer

Fig. 14 Pinion Seal Installation
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Fig. 12 Remove Pinion Gear
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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.
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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.
i
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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. 19 Hub Bearing Bolts

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KNUCKLE AND BALL STUDS
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57698%:

AXLE
BUSHING REPLACEMENT
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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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Fig. 21 Steering Knuckle Removal/Installation

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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

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’0”–•—˜™%Axle
—V•›šHousing
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Housing

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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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˜™›š…œ)žŸxž ~¡£¢. ~¤›¥pžŸŸžf¥h¢.œ~ §¦
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Fig. 28 Differential Case Removal

Fig. 30 Differential Bearing Cap Reference Letters

Fig. 29 Install Axle Housing Spreader

DIFFERENTIAL SIDE BEARINGS

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:;"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
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/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¶·
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¼ ½-¾n¿)¼8À4Á¾nÂ4ÃiÃ+Ä"Å1ÆpÇ¿"È4½-É1Ê-¿"Ë
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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-àBËKÒ8Ònº
Ëi딽-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¶·

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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
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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
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Fig. 37 Pinion Yoke Removal

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

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

_ OM `a^JDQEXPbY[E=`dceUfKFUX`
GJEXRhgTMh^JE.`aDQE.RITKQITUXKiLjEXMOGlkmIT`dDQU=nQ`
GJE=RgTMh^JITKQLo`aDQE)GJITKQLoLjE=MhG>c
pqFrtsuwvx
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€
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E=GY‚DQMO€`Z€
UXG
ITKQY‚`dMOgTgTMh`aITUXKŽMOg
ITLWK _ EXKQ`ac
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`€GJU _ RITKQITUXK…„U=ŠFE=c
’
Y‚ITKQLfY‚nQIT`aM ƒ gTE%k“ITGJEX”`aITE•RhGJUXRE=gTg
E=GY‚DQMO€`l`aU•nQKFPEXG ƒ U=P„Wc
y–‚| ’
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P„UXŠE=”“GJE _ U\wE
`aDQE)RITKQITUXKŽKQnQ`MOKQP4k“MOY‚DQEXG y  ITLWc  ™ | c
y › | ’
Y‚ITKQL } E _ U\wEXGZ¡£¢ – › ˆ MOKQP0—tUXgTPEXGZ¡£‡ Oˆ œ z ”
GJE _ U\E)`aDQE)RITKQITUXK.„U=ŠFE)€
GJU _ RITKQITUXKŽY[DQMO€
` y  ITLWc O¤[| c

Fig. 38 Remove Pinion Gear

Fig. 36 Pinion Yoke Holder—Typical

y ¤‚|~} E _ Ud\E`aDQE€GJU=KQ`mRITKQITU=K ƒ E=MhGJITKQL¥^JnFR” ƒ EXMOGJITKQLW”
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ITKQLWEXG¦”wI
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  ITLjc  š | c
y œ |~} E _ Ud\Eo`dDFEGJE=MOG•RITKQITUXK ƒ E=MOGJITKQLb^JnFRi€GJU _ M‚†gTE
DQU=nQY[ITKQL y  ITLjc –Oª‚| ct’
Y[E } E _ U\E=G¥e‡ z‚– š‘MOKQP—tMOKQPgTE
¡£¢ –«z‚¤©z c
y š |~} E _ Ud\E#`aDQE#PE=R`aDY‚DQI _ Y
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ITKQL.^{nQR ƒ UXGJE“ITKbM‚†gTE“DQUXnFY[ITKQLjc } E=^JUXGJPo`dDFE4`aDQIT^JŠKQEXY‚Y#U=€
`aDQE)PEXRh`dDŽY[DFI _ Y‚c

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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

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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

n.¦pr¢±‚{…tssP{}|v‹ywvty·x+~~z‰vtyw~Š$tƒzh~sž‚[email protected]~Š³vy(š
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tƒrt‚| zxrx+ywv‚‚„n.¬
[email protected]Š³6¥¦p

Fig. 43 Rear Pinion Bearing Cup Installation

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Fig. 46 Rear Pinion Bearing Installation

n.«pr¢±‚{…tss6tv}¤¹uwzsstx+‚[email protected]‰sv„x+ywvszhtƒ‹‚xtuwvhy8zrx+~ˆ
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tƒr§;zhsƒ+vy¦¶´º[email protected]¬
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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.
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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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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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Õ×ÇÑ&Ñ"ÏÖÕ'ÇÎÈVÛÎ Ð?Ê*Ì8ÌÇÕÇÎÈÊ*ÓFÇÈÛÎÐ-Ô9Ê*ÕÇÎÈÙ

AXLE
8

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

Fig. 55 Pinion Gear ID Numbers

Ä
ÅmÄÆ
Ç
ÈAÉzÉÊË
ÊÍÌ
ÎcÈ Ï¾Ð
ϵ̀ǶÇ
Ë
È Ñ¾ÊÐzÈ Ì€Ê
ÔÕÖ×\؀ÙÚÛÜ\ÙزÝ$ÞßàáÍâvàãäåæ
/1032547638:9<;>[email protected]?A038CB0)DE4?A8:?A038CF[email protected]H;7DJ?A;>8:KJ6L?A9
;>KJG:?A6MH63FON[email protected]<63QA6)KJ=9<G:?A259SRUTVG:6W9SG:?A259X;7DJ6W4QA;>KJ63F
Y 63G:?A8:FZ=[G:6\DJ63;>D4?A8:?A038 Y 6);>DJ?A8:]
K$^:4`_bac?A]dRfe>gShiR

ÒlÓ
_¯<h j 8:9<=[;7QAQ
BDJ038r=4?A8:?A038 Y 63;>DJ?A8:]k;>8:F/10)8:63tb8:^:=g>­>®>Ž
G:;>8:[email protected]?A]uG:=€_ao?A]dRe>­<h$R
_®<hZƒoQb;>KJ6cwlD Y 0)Dm}m?A9<Kmg>­>¯7{038wUD Y 03D}mt$Œ)ŒSe>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<[email protected];>QAQ€F?ABB6)DJ638:=[?A;>Q Y 63;>DJ?A8:]KJ;>49
0)8
wUD Y 03Dk}?b9<KJ9
;>8:F
=[?b]uG:=[638‰KJ;>4 Y 03QA=[9{[email protected]\®µŒ Uº 2¨_¯>ŽB=[RQ 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)[email protected][email protected])DJ?A]d?A8:;>Q;>8:FWDJ6)4QA;>KJ63t
256)8:=4?A8:?A038q]u63;>DvRowUFFx03DZ9<^ Y [email protected];>KJ==[G:6[email protected]:?AKJyz8:6)9S9`03B
=[G:603D$?b]u?A8:;7QoF6)4=[G
9SG:?A259U=[0KJ0)254638r9S;>=[6B03D=[G:6F7?bBbB63Dit
638rKJ6{?A8Z=[G:6F[email protected]{Hp;>DJ?A;78rKJ639<Ro|16)B6)[email protected]=[G:6{}634=[G5~1;>DJ?bt
;>8:KJ6\KJG:;>DJ=[R
 0)[email protected]€NG:63DJ6‚QbF;>8:F  [email protected]„ƒc?A8:?A038†…k;7DJyz?A8:]kKJ0)Qb^r258:9
?A8:=[63DJ9<63KJ=[R j [email protected])DJ9S6)[email protected]?A8:]‡B?A]u^:DJ6ˆDJ634D$639<638:=[9"4QA^:9"03D
25?A8:^:9{=[G:6\;>2503^:8r=€8:636)F63F7R
 0)[email protected]‰=[G:6‰63=[KJG:63FX8:^:2 Y 6)D0)8Š=[G:6‰B;>KJ6‰03B[email protected]F7DJ? H6
4?A8:?A0)8
]d63;>D_b‹oŒ<n‹>>npŽ>nŒSnr>n63=[KJR h$RuTGr68:^:2 Y 6)DJ9UDJ6)4t
DJ6)9S638r=[email protected]^:9<;>8:F903B;>8†?A8:KJG‰F76MH?b;>=[?A038†BDJ032‘=[G:6‚9S=[;>8:t
F;>DJFR j [email protected]’8:^:2 Y 6)Dm?A9€8:6)]d;>[email protected]? H63n:;>FF\=[G:;>=pH;>Qb^r6’=[0’=[G:6
DJ6)“7^r?bDJ6)F[email protected]?bKJyz8:6)9S9’0)B
[email protected]:6{F7634=[GZ9SGr?b259<R j B1=[G:6{8:^r2 Y 6)D
?A9{4039<[email protected]? Hp6)n9S^ Y =[DJ;>KJ=€[email protected];7=
Hp;>QA^:6\BDJ0)2=[G:6=[G:?AKJyz8:639<9{03B
=[G:65F6)4=[G†9<G:?A25R j [email protected]:^:2 Y 63Dl?A9Ž8r05KJG:;>8:]d65?A98r63KJt
639<9S;>D•”–R
—o˜™˜ šl™W›œr—7žWŸkœ3 o¡¢£œrŸœr™p` ™› ›¤p¢p¡oŸkœr™p
…6);>9S^:DJ6)25638:=[95;>DJ6=[;>yr6)8N[email protected]4?A8:?A038 Y 63;>DJ?A8:]
KJ^:479
;>8:F¥47?b8r?b0)8 Y 63;>DJ?A8:]u9O?A8:9<[email protected];>QAQA63F¦[email protected];<§pQA6ŠG: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:=[9€N{?A=[Gsƒo?A8:?A038 «;7^:]u6
¬63=€g>­>­7®
;78rF`}?b;>Q j 8:F?AKJ;>[email protected])D/1tb¯7¯>¯>°_ao?A]dRe>­<h$R
_$Œ*h5wU9<9S632 Y QA6©ƒc?A8:?A038²±l63?A]dG:=W³1QA03KJy´g>­>¯7°>n‰ƒo?A8:?A038
³1QA03KJy
g>­>¯7¯>nµ;>8:FDJ6);>DU4?A8:?A038 Y 6);>DJ?b8r]\[email protected]¬pK$DJ6MNPg>­>®µŒ
_ao?A]dRe>­<h$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:]Š;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$Œ3Œ<e>t;>8:FZ9<63KJ^:DJ6\9<63=€9<KJDJ6MNmR
_g<hZƒoQb;>KJ6»¬pKJ0)03=[63D‰³1QA03KJy)¼v}m?A;>Q j 8:F?AKJ;>=[03D‰?A8¶40)9S?A=[?b0)8
?A8O;<§pQA6`G:03^:9<?A8:] 9<0†F7?b;>QU4DJ0 Y 6†;>8:F¹9<KJ030)=[63D Y QA03KJyX;>DJ6
BQA^:9<G´;>]d;>?A8:9<=O=[G:6¦DJ63;>D•N{;>DJF‘9S^: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)[email protected])D Y QA0)KJyk?A84QA;>KJ6’;>8:F
½ 63DJ0s=[G:6sF?A;7Q{?A8:F7?bK$;7=[03D`B;>KJ6»=[[email protected]»40)?A8:=[63DvR¾T?A]dG:=[638
F?A;>Q?A8:F?AKJ;>=[03DB;>KJ6\Qb0)KJy†9SK$DJ6MNmR
_­<h5¿?b=[G»9<KJ030)[email protected])D Y QA0)KJys9<[email protected]?AQAQ?A8»4039<[email protected]?A0)8»;7]u;>?b8r9S=’[email protected]
4?A8:?A038ÀGr63?A]dG:= Y Qb0)KJyzn{9<QA0MN{Q ”¥9<QA?bF76X=[G:6XF?A;>Q\?A8:F7?bK$;7=[03D
4DJ0 Y 6[email protected])D=[G:6\63F]u6\03B¾[email protected]47?A8:?A038‰G:63?A]dGr= Y QA0)KJyrR
_¸<hZ¬Qb?AF6»[email protected]:6¹F7?b;>Q5?b8rF?AKJ;>[email protected])D47DJ0 Y 6¹;>KJDJ039<9 =[G:6¹]d;>4
Y 63=ÁN{6)638Š[email protected]4?A8:?A038ŠG:6)?b]uG:= Y QA03KJyO;78rFO=[G:6;>D Y 03D Y ;>D
N{?A=[G[email protected]:6’9<KJ030)[email protected])D Y QA0)KJyk;>]d;>?A8:9S==[G:6’47?b8r?b0)8G:63?A]dGr= Y Qb0)KJy
_ao?A]dRpg>ŽShiR>¿»G:638
[email protected]:6F?A;>Qf47DJ0 Y 6KJ0)8:=[;7KJ=[9l=[G:6;7D Y 0)D Y ;>Dvn
=[G:6´F?A;>QŠ403?A8:=[6)D¶N?AQbQŠ=[^:DJ8ˆKJQA03K$y3N?b9<63Rx³1DJ?A8:]ÂF7?b;>Q
40)[email protected])D Y ;>KJyª=[0 ½ 63DJ0»;>]d;>?A8:9S=
=[G:6»;>D Y 03D Y ;>Dvn’F0»8:0)=
=[^:DJ8ZF?A;>QB;>KJ63Rµ/[email protected]?A8:^:6{[email protected]?A8:]\=[G:6{F?A;>Q4D$0 Y 6{[email protected]{=[G:6
KJDJ6)9S=¾0)[email protected]:6;>D Y 03D Y ;>D€;>8:FDJ6)KJ03DJF=[G:6G:?A]dG:6)9S=DJ63;>F?A8:]dR
j [email protected]:6F?A;>Qc?b8rF?AKJ;>[email protected])D€KJ;>88:03=¾;>KJG:?A6MH6=[G:6 ½ 63DJ0DJ63;>F?A8:]un
=[G:6{DJ6);>D Y 63;>DJ?A8:]\KJ^:4k03DU=[G:64?A8:?A038F634=[GZ]u;>^:]d69S63=V?A9
8:0)=€?b8r9S=[;>QbQA6)F`KJ0)DJDJ63KJ=[Q ”–R
_°<hZ¬63QA63KJ=l;†9<G:?A2´63“>^:;>[email protected][email protected]:6kF?A;>Q?A8:F?AKJ;>=[03D5DJ6);7F7t
?A8:]{4QA^:9[email protected]:6lFDJ? Hp6’47?b8r?b0)8]d63;>DmF6)4=[GHp;>DJ?A;78rKJ6’8:^:2 Y 63D
63=[KJG:6)FX?A8W=[G:6†B;>KJ6‰0)B=[G:6‰47?A8:?A038W]u63;>D
_ao?A]dRe>e<h$Rac0)D
6M§;>254QA63n?AB=[G:6
F7634=[GH;7DJ?A;>8:KJ6?b9\‹>>n¾;>FF‰:Ž>R Ž>Ž>‰?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£pšl›¢Ãc˜ šl™
}m?ABBb63DJ6)8:[email protected]?A;>Qc9<?AF6 Y 63;>DJ?A8:]547DJ63QA03;>F;>8:F]d6);>D Y ;>KJyzQA;79<G
?A9;>[email protected])F Y ”X9<63QA63KJ=[? Hp69SGr?b259\40)9S?A=[?A038:6)F Y 63G:?A8:F‰=[G:6
F?ABBb63DJ6)8:[email protected]?A;>Qx9S?AF76 Y 63;>DJ?A8:]´K$038:6)9SRTVG:6¨47DJ0346)D©9SGr?b2
=[G:?AKJyr8r639<9XKJ;>8 Y 6WF6)[email protected])DJ25?A8:6)F¦^r9S?A8:]ª9<Qb?A4tbB?A=‰F^r252”
Y 63;>DJ?A8:]d9{}mt¯>®>¸Z?A84QA;>KJ60)[email protected]: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)[email protected]<n2563;>9<^:DJ6‰=[G:6†4?A8:?A038O]d6);7DF[email protected]

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
ôAïAóSî:ïAè:ñ5ê7ëJð3êì)ëêïAè:ïAð3è
ñuì3ç>ëéì3êí[î
ïAóUì)óSó<ì3è:í[ïAç7ôoí[ðì3ó<í@ç>÷>ø
ôAïAóSî:ïAè:ñ©ñdì)ç7ëŠ÷>ç7ùJúzôAç>óSîç7èré‘í[ð3ð)í@îùJð3è:í[ç>ùJíXêç>í@í[ì3ëJèróSõ
û òí[ì3ëí[î:ìðMüpì)ëJç>ôbôóSî:ïAýí@î:ïAùJúzè:ì)óSó5í[ðí@ç>úzìþ:ê†é7ïAòòì)ëJì3è:ø
í[ïAç7ôÿóSïAéìÂê7ôb
ç ïAó´ý5ì)ç>óSþ:ëJì)é Ší@î:ìÂê7ïAè:ïAð3è‡ñdì)ç7ëïAó
ïAè:ó<í@ç>ôAôAì3é ç>è:éqí@î:ì¹ñuì3ç>ë‰÷7ç>ùJúzôAç>óSî¶óSîrïbý í[î:ïAùJúzè:ì3ó<ó ïAó
ý5ì)ç7ó<þ:ëJì)éõ Vî:ìkðMüpì)ëJç>ôAôVóSî:ïAý í@îrïbùJúzè:ì)óSó‚ïAó‚í[î:ìkí@ð)í@ç>ôVð)ò
í[î:ìé7ïbç>ômïAè:éïAùJç>í[ð3ë\ëJì)ç>éïAè:ñ†ç>è:éí@î:ì
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ô oïAñd
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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

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ÒÔÐWËXËLÏLÌ ÕZÎÓ'Ì ÐWÎ

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xz¢£ŠD
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Fig. 59 Gauge Tools In Housing—Typical

Fig. 62 Tighten Bolts Holding Bearing Caps

v ·
xz¸3
ƒ†ŠD‘
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•
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°
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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. 71 Backlash Shim Adjustment

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181 FBI AXLE
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SPECIAL TOOLS
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Cup—8109

Handle—C-4171

Remover/Installer—6289

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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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51
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59
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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
67
64
56
55
63

. . . . . 68
. . . . . 69
. . . . . 73
. . . . . 73

. . . . . 75
. . . . . 77
. . . . . 73
. . . . . 79
. . . . . 79
. . . . . 79

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TRAC–LOK


DIFFERENTIAL
 !" $#"NOISE
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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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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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$?!,ý8ü !(û 5ü U1ý 5ü $h#
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þ )#,û@ý8ù 'üIGY0R :Y [
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 üIGY5”ö :öBõ |”ú ;[email protected]÷ 
Fig. 7 Pinion Yoke Removal

Fig. 8 Pinion Seal Installation

õ @÷)#,û@ý8ù gA
'³üO-Uý8þ,üo1ú,ú aüù /Bú'ý8þ~e
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ôfõ

 
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ö†÷øøùWú†ùVû†üŒ÷ ý4þ6ýZû`öOö†ú†÷ ÿùþ÷ û`ù




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.

®¯°±#²
³´1µ ¶¶¢´1·
¸f¹Zº»W¸f¼hµ³(·!¸½?µ²
¾¿µ&²
¸¼t²
À
´xº-²2´1·
¸
²
Á  º-²/ø-µ½3µ²
¾6´  ÷!´¸-²/´1·
¸ Á ²  º²¿²
À
´À
²!´ Â ¶G´1·
¸½E¸  ³
Ä ¸½EºrŸ-µ ½  ²
ÃJ¸-²
¾Æ Á ¶µ¹CÇ
®È°?É Â Ãc·
´1¸²/´·!¸r²!À
´`´ºÊːÌhÍ+Î Ï~®ÊÐÐ6Ñ´1Ç;¶Å³(Ç °EÇ

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.

®Ò°ÓGº´1µ´1¸h´·
¸ Á ²  º²³(·!µ Ñ´šÀ
³ Â ²!ÃµU® Â ²
ǐ¶Å³(Ç °`´1º½ÔÀ
¸
¼h½¸-²
Õ·
ÇÓGº-´µ´ Â ²
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ºÀ!¶¾JŸ?¸-ÔÀ
µ¶;´ºh´1·
¸?½¸-µ¾Æ
 ²
ý¸ÕEº½¾¸-¾/¾À
½ Â ²
ý¸-Ï?º#ÖZµ¶ Á ¶À
³µ²2µ ¾ ¾ Â ´ Â º-²
µ ¶¢ÐÇ Ò ×
Í+Î Ï~®Ò Â ²
Ç;¶Å³Ç °f®Ø  ÃÇÌаEÇ
®×°±#Ñ´·
¸x½º´1µ´  ²
ÃQ´º-½ÔÀ
¸  ³`¶º¼*Ù
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³(¸xÚfº-¶¾¸½*×ÛÒÜg´1º
·
º-¶¾U´1·
¸ Á  ²  º²?¹
º»W¸Q®Ø  ÃcǏÌÌy°Eِµ²
¾U´  ÷!´¸-²´1·
¸ Á ²  º²
³·
µÑ´`²
À
´  ²/×ÇvÜ6Í+Î Ï~®Ò6Ñ´1Ç;¶Å³Ç °  ²
Õ½¸-Ï?¸²
´1³?À!²
´ Â ¶4´1·
¸
Á ½º Á ¸-½Q½º-´µ´  ²!ô1º½EÔ À
¸ Â ³hµÕ· Â ¸#Ö
¸¾Ç
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.

®Ë°?Ý+¶  òu´1·
¸ Â ²
³´µ¶¶µ ´  º²u½¸-Ѹ-½¸²
Õ¸"Ï?µ½»!³&º²u´1·
¸
½Á º Á ¸-¶¶¸-½L³(·!µ Ñ´"µ²
¾K¹Zº-»!¸Þµ²
¾ Â ²
³´1µ ¶¶J´1·
¸ Á ½º Á ¸¶¶¸½

³·
µÑ´Ç
®Ü°?Ý+¾¾"ø-µ½¶À
Ž  յ²
´3´1º´·
¸¾  ÑѸ-½¸²
´  µ ¶š·
ºÀ!³  ²
ÃÙ
ÑÂ G²
¸ÕE¸³(³µ½B¹cÇÓG¸Ñ¸½x´ºh´·
¸?ßÀ
Ž  յ²
´*à Á ¸Õ Â Ñ Â Õµ ´  º²
³fѺ½
ø-µ½Q¶À
Ž  յ²
´`½¸ÔÀ  ½¸-Ï?¸²
´1³(Ç
®Û°±#²
³´1µ ¶¶&´·
¸OŽµ»W¸O¾½À
Ï?³Ç6ÓG¸-Ѹ-½á´1ºOâ*½º-À Á ÒÙ

½
ã µ»W¸³(ÙHѺ-½ Á ½º Á ¸½ Á ½º-Õ¸¾ À
½¸³Ç
®EÌа±#²
³´µ¶¶Z¼h·!¸¸¶Gµ ²!¾&´  ½¸µ ³³(¸-Ï?Ŷ  ¸-³(Ç
®EÌ-ÌM°ßº#¼Q¸½3´·
¸+Ö
¸·  ն¸Ç

Fig. 11 Tightening Pinion Shaft Nut

COLLAPSIBLE SPACER
ä4å!æxç4è
éšêgë&ìEíîï4î çxïÞîïZðñcéšê!ê!å!ò
®EÌy°ÓGµ Â ³(¸µ²
¾³(À ÁÁ º½´`´1·
¸+ÖZ¸-·  ն¸Ç
®Ê°ÓG¸Ï?ºÖZ¸+¼h·!¸¸¶Gµ ²!¾&´  ½¸µ ³³(¸-Ï?Ŷ  ¸-³(Ç
®¯°ÓG¸Ï?ºÖZ¸"½¸µ½Å½µ»!¸"¾½À
Ï?³Ç+Ó4¸-Ѹ-½´º"â*½ºÀ Á ÒÙ

½
ã µ»W¸³(ÙHѺ½ Á ½º Á ¸½ Á ½º-Õ¸¾À!½¸³Ç
®È°óUµ ½»Þ´1·
¸ Á ½Eº Á ¸-¶¶¸-½³(·
µÑ´Uµ²
¾ Á  ²  º-²2¹Zº-»!¸"Ѻ½
²Â
³´µ¶¶µ ´  º²/½¸Ñ¸½¸-²
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¸ Á ½º Á ¸¶¶¸½3³(·
µÑ´`ѽºÏ~´1·
¸+¹Zº»W¸Ç
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¸ Á ²  º-²"ø-µ½Q´1·
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Ç¶Å³Ç °u¾  µ¶Æ´v¹ Á ¸
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Å ÆÇ
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HJK:AN687:68<?7‡9uA']OB‰4wKP]O‚H~a‹ŠZH5X]1Q€{FA7:A'nWA?414w]FB|QŒH~<>8689uK:HJ> Q
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Ã=Ä

/š ›S°r±u•–P–?•P±‹š “=Fig.
› 13 Remove Pinion Gear
-xq(03ŠZ7:41HJ]O>8>‹]7:A~_}nW<?>8>8]FN416{F>8A`NBWA?>8<'][email protected]†4wNO]OnWA'B=<?73N687:h
68<?7[4wKP]O‚H^-/sr69­aq1i10xa
-/j103ŠZ‚NO687:68<?79­A?]FB²_`]F4‰BWA'X<[email protected]Vt687:41H~]F>8>N687:68<?79­A?]FB
687‡KP<?\:41687:9ua
‘P’=“”e•–Ž—…Fig.
˜x™rš/›12š “=Pinion
›z‘P’=Yoke
“”‘Pœ Removal
-xq(03bd]F684wA]F7:@34w\:NON<?BWH^HJK:A5YSA'K:68nW>8A?a
-/j103bdA?X`<ZYSA5_`KPA?A?>d][email protected]…HJ68BWA]O414wA'X{F>86A'4wa
-/p103bdA?X`<ZYSA‡BWA?]FB3{FBW]FTPA‡@BW\:X41a5bdA?‚/A'B3H~<‡vBW<'\:NGFV
ž BW]FTUA?4wV‚/<'B‰NBW<'NA?B NBW<'[email protected]\:BWA?41a
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687:41H~]F>8>8]OHJ68<?7[BWA?‚A?BWA'7:nWA?a
-/G103bdA?X`<ZYSAHJK:ANBW<'NA?>8>8A?B 4wKP]O‚H^‚/BW<?X HJK:A5QS<?TUA'a
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/- 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?Bfdh/pFEO¡FjFh ³
]F7:@3;ˆ]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:û„äSå'æUç‡ê:å'ã÷Oç?í„ùFöFÜFîªâFß:÷ªâªáJå?í Oó:çè`íWç'ß:ìWê
àwç'áâFá
 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
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ç Fó:ç?ß:áJã ä‡áJåŽ
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/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/úréû­üï1ù1Ýxü

/Û ù1Ý3ÞZýáJê: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:÷â
eãç 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
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 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
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AXLE SHAFT
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Fig. 20 Axle Shaft C–Clip Lock

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Fig. 18 Check Pinion Gear Rotation Torque

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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
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Fig. 19 Mate Shaft Lock Screw

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AXLE SHAFT SEAL AND BEARING
Ù5Ú7Û9Î5Ü<Ì&Í
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NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.

 
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Fig. 22 Axle Shaft Seal Installation

Fig. 21 Axle Shaft Bearing Removal

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DIFFERENTIAL

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Fig. 23 Bearing Cap Identification

 Œ ž7'')Ÿ8CK&( A ,& …!‹7< Q#¡#‹K2
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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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1,2-34

5/6"7879:/9<;/=>6 [email protected],?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

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Fig. 27 Differential Case Removal

Ò²Ó

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

Þ,ß'àÞ

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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}+~"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 prtsƒ"{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
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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€)}+prtsuvsdr—†
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
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Fig. 33 Ring Gear Bolt Installation

PINION
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Fig. 32 Ring Gear Removal

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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. 34 Pinion Yoke Removal

Fig. 36 Front Bearing Cup Removal

Fig. 35 Remove Pinion Gear

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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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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.

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Þ 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
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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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ÚmÛfîaäaàòJà ÛfêeهìfÛfêeÚ#âÿêeáfà äaÞ êeéêÚmÛfÜ êeÞ äaëìfà Ú#هéîaáfÚmà
à ã$÷
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FINAL
ԔÕS×ü îaASSEMBLY
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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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ƒ…„ UW€†lyhˆly\‡y] ‰eŠ_t h \^y`W^y[VYz&o]m\N{ U |(^y`\N[VYz&o[}VgX\~Xo bUW[€ufo|‚\]
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CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

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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. 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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Fig. 65 Shim Locations

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Fig. 66 Pinion Gear Depth Gauge Tools—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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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
. . . . . . . . . . 85
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93
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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

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Fig. 4 Trac-lok Limited Slip Differential Operation

DIAGNOSIS AND TESTING
GENERAL
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