Jeep Wrangler 1997 Manual page 231

TJ
DISASSEMBLY AND ASSEMBLY (Continued)
AXLE COMPONENTS
Fig. 66 Mate Shaft Roll Pint Installation
(17) Install differential case in axle housing .
CLEANING AND INSPECTION
UPPER SIDE
GEAR AND CLUTCH
DISC PACK
DIFFERENTIAL
CASE
SPECIAL TOOL
C-4487-1
J9203-6
Fig. 65 Upper Side Gear & Clutch Disc Pack
Installation-Shown With 6063-A Holder
and dry with compressed air. Do not steam clean
the differential components. 1
DIFFERENTIAL AND DRIVELINE 3-105
Wash bearings with solvent and towel dry, or dry
with compressed air. DO NOT spin bearings with
compressed
air. Cup and bearing must be
replaced as matched sets only.
Clean axle shaft tubes and oil channels in housing .
Inspect for ;
" Smooth appearance with no broken/dented sur-
faces on the bearing rollers or the roller contact sur-
faces
" Bearing cups must not be distorted or cracked
" Machined surfaces should be smooth and with-
out any raised edges
" Raised metal on shoulders of cup bores should
be removed with a hand stone
" Wear and damage to pinion gear mate shaft,
pinion gears, side gears and thrust washers . Replace
as a matched set only .
" Ring and pinion gear for worn and chipped teeth
" Ring gear for damaged bolt threads . Replaced as
a matched set only.
" Pinion yoke for cracks, worn splines, pitted
areas, and a rough/corroded seal contact surface .
Repair or replace as necessary .
" Preload shims for damage and distortion . Install
new shims if necessary.
TRAC-LOK
(1)
Clean all components in cleaning solvent . Dry
components with compressed air.
(2) Inspect clutch pack plates for wear, scoring or
damage . Replace both clutch packs if any one compo-
nent in either pack is damaged.
(3) Inspect side and pinion gears. Replace any gear
that is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft.
Replace if worn or damaged .
PRESOAK PLATES AND DISC
Plates and discs with fiber coating (no grooves or
lines) must be presoaked in Friction Modifier before
assembly. Soak plates and discs for a minimum of 20
minutes . Add remaining Friction Modifier to differen-
tial after assembly.
ADJUSTMENTS
PINION GEAR DEPTH
Wash differential components K with cleaning solvent
GENERAL INFORMATION
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
67) . A plus (+) number, minus (-) number or zero (0)
is etched into the face of the pinion gear. This num-
ber is the amount (in thousandths of an inch) the
depth varies from the standard depth setting of a