Jeep Wrangler 1997 Manual page 230

3-104
DIFFERENTIAL AND DRIVELINE
DISASSEMBLY AND ASSEMBLY (Continued)
(15) Remove tool C-4487 from differential case.
(16) Remove top side gear and clutch pack. Keep
plates in correct order during removal (Fig. 62) .
SIDE GEAR DIFFERENTIAL
AND CLUTCH DISC CASE
PACK
SPECIAL TOOL
RETAINER C-4487-1
Fig. 62 Side Gear & Clutch Disc Removal
J9203Z
(17) Lift differential case from holding tool .
(18) Remove bottom side gear and clutch pack
from differential case .
(19) Mark each clutch pack for installation refer-
ence .
ASSEMBLY
The clutch discs are replaceable as complete sets
only. If one clutch disc pack is damaged, both
packs must be replaced.
Lubricate each component with Mopar, gear lubri-
cant before assembly.
(1) Assemble the clutch discs into packs and
secure disc packs with retainers (Fig. 63) .
(2) Position assembled clutch disc packs on the
side gear hubs .
(3) Insert side gear and clutch pack into ring gear
side of differential case (Fig. 64) . Guide clutch pack
retainers into recesses in differential case.
(4) Place differential case on holder 6963-A.
(5) Install lubricated Step Plate C-4487-1 on bot-
tom clutch pack (Fig. 65) .
(6) Insert and hold side gear and clutch pack into
upper side of differential case (Fig . 65) . Guide clutch
pack retainers into recesses in differential case.
(7) Insert Step Plate C-4487-3 into top side gear,
install forcing Screw C-4487-2 .
(8) Tighten forcing screw tool to slightly compress
Belleville washer in clutch packs .
CLUTCH PACK
RETAINER
Fig. 63 Clutch Disc Pack
J8903-50
TJ
LOWER
SIDE GEAR
AND
CLUTCH DISC
PACK
J9003-4
Fig. 64 Clutch Discs and Ring Gear Side Gear
Installation
(9) Place pinion gears in position in side gears and
verify that mate shaft hole line up.
(10) Rotate case with Handle C-4487-4 until mate
shaft holes in pinion gears align with holes in differ-
ential case.
(11) Tighten forcing screw to - 122 N-m (90 ft. lbs .)
to compress the Belleville sprigs.
(12) Lubricate and insert thrust washers behind pin-
ion gears. Align washers with a small screw driver .
(13) Install pinion gear mate shaft in differential
case.
(14) Install roll pin to hold mate shaft in differen-
tial case (Fig. 66).
(15) Remove tool C-4487 from differential case.
(16) Lubricate all differential components with
hypoid gear lubricant .