Jeep Cherokee (XJ): 181 FBI pinion shaft seal. 186 FBI pinion shaft seal. Collapsible spacer

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Differential and driveline > Tube, 181, and 186 FBI axle > Removal and installation > 181 FBI pinion shaft seal. 186 FBI pinion shaft seal. Collapsible spacer

181 FBI pinion shaft seal

REMOVAL

  1.  Raise and support the vehicle.
  2.  Remove wheel and tire assemblies.
  3.  Remove brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures.
  4.  Mark the propeller shaft and pinion yoke for installation reference.
  5.  Remove the propeller shaft from the yoke.
  6.  Rotate the pinion gear three or four times.
  7.  Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.
  8.  Using Holder 6958 to hold the pinion yoke, remove the pinion nut and washer.
  9.  Use Remover C-452 and Wrench C-3281 to remove the pinion yoke (Fig. 6).
  10.  Use a suitable pry tool or a slide hammer mounted screw to remove the pinion shaft seal.

INSTALLATION

  1. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972-A and Handle C-4171 (Fig. 7).
  2.  Install yoke on the pinion gear with Installer W-162-D, Cup 8109, and Holder 6958 (Fig. 8).

Pinion Yoke Removal
Fig. 6 Pinion Yoke Removal

1 - SPECIAL TOOL C-3281
2 - YOKE
3 - SPECIAL TOOL C-452

Pinion Seal InstallationБЮ Fig. 7 Pinion Seal Installation

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3972-A

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

  1.  Install the pinion washer and a new nut on the pinion gear. Tighten the nut only enough to remove the shaft end play.
  2.  Tighten pinion nut to 217 N·m (160 ft. lbs.).
  3. Rotate the pinion shaft using a (in. lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 0.56 N·m (5 in. lbs.) (Fig. 9).
  4.  If the rotating torque is low, use Holder 6958 to hold the pinion yoke, and tighten the pinion shaft nut in 6.8 N·m (5 ft. lbs.) increments until proper rotating torque is achieved.

Pinion Yoke Installation
Fig. 8 Pinion Yoke Installation

1 - PINION YOKE
2 - AXLE HOUSING

Check Pinion Rotation Torque
Fig. 9 Check Pinion Rotation Torque

1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH

  1. Align the installation reference marks on the propeller shaft and yoke, and install the propeller shaft.
  2.  Check and fill the gear lubricant. Refer to the Lubricant Specifications for gear lubricant requirements.
  3.  Install the brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures.
  4.  Install wheel and tire assemblies.
  5.  Lower the vehicle.

186 FBI pinion shaft seal

REMOVAL

  1.  Raise and support the vehicle.
  2.  Remove wheel and tire assemblies.
  3.  Remove brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures.
  4.  Mark the propeller shaft and pinion yoke for installation reference.
  5.  Remove the propeller shaft from the yoke.
  6.  Rotate the pinion gear three or four times.
  7.  Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.
  8.  Using Holder 6958 to hold the pinion yoke, remove the pinion nut and washer.
  9.  Use Remover C-452 and Wrench C-3281 to remove the pinion yoke (Fig. 10).

Fig. 10 Pinion Yoke Removal
Fig. 10 Pinion Yoke Removal

1 - SPECIAL TOOL C-3281
2 - YOKE
3 - SPECIAL TOOL C-452

  1. Use a suitable pry tool or a slide hammer mounted screw to remove the pinion seal.

INSTALLATION

  1.  Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972-A and Handle C-4171 (Fig. 11).
  2.  Install yoke on the pinion gear with Installer W-162-D, Cup 8109, and Holder 6958 (Fig. 12).

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. 11 Pinion Seal Installation
Fig. 11 Pinion Seal Installation

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3972-A

Fig. 12 Pinion Yoke Installation
Fig. 12 Pinion Yoke Installation

1 - PINION YOKE
2 - AXLE HOUSING

  1. Install the pinion washer and a new nut on the pinion gear. Tighten the nut only enough to remove the shaft end play.
  2.  Rotate the pinion shaft using a (in. lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 0.56 N·m (5 in. lbs.) (Fig. 13).
  3.  If the rotating torque is low, use Holder 6958 to hold the pinion yoke (Fig. 14), and tighten the pinion shaft nut in 6.8 N·m (5 ft. lbs.) increments until proper rotating torque is achieved. 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.
  4.  Align the installation reference marks on the propeller shaft and yoke and install the propeller shaft

Fig. 13 Check Pinion Rotation Torque
Fig. 13 Check Pinion Rotation Torque

1 - PINION YOKEБЮ 2 - INCH POUND TORQUE WRENCH

Fig. 14 Tightening Pinion Shaft Nut-Typical
Fig. 14 Tightening Pinion Shaft Nut-Typical

1 - PINION FLANGE
2 - FRONT AXLE
3 - TOOL 6958

  1. Check and fill the gear lubricant. Refer to the Lubricant Specifications for gear lubricant requirements.
  2.  Install the brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures.
  3.  Install wheel and tire assemblies.
  4.  Lower the vehicle.

Collapsible spacer

REMOVAL W/PINION INSTALLED

  1.  Raise and support the vehicle.
  2.  Remove wheel and tire assemblies.
  3.  Remove brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures.
  4.  Mark the propeller shaft and pinion yoke for installation reference.
  5.  Remove the propeller shaft from the yoke.
  6.  Rotate the pinion gear three or four times.
  7.  Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.
  8.  Using Holder 6958 to hold the pinion yoke, remove the pinion nut and washer.
  9.  Use Remover C-452 and Wrench C-3281 to remove the pinion yoke (Fig. 15).
  10.  Use a suitable pry tool or a slide hammer mounted screw, remove the pinion seal.
  11.  Remove the front pinion bearing using a pair of suitable pick tools to pull the bearing straight off the pinion gear shaft. It may be necessary to lightly tap the end of the pinion gear with a rawhide or rubber mallet if the bearing becomes bound on the pinion shaft.
  12.  Remove the collapsible spacer.

Fig. 15 Pinion Yoke Removal
Fig. 15 Pinion Yoke Removal

1 - SPECIAL TOOL C-3281
2 - YOKE 3 - SPECIAL TOOL C-452

REMOVAL W/PINION REMOVED

  1.  Raise and support the vehicle.
  2.  Remove wheel and tire assemblies.
  3.  Remove brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures.
  4.  Mark the propeller shaft and pinion yoke for installation reference.
  5.  Remove the propeller shaft from the yoke.
  6.  Rotate the pinion gear three or four times.
  7.  Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.
  8.  Remove differential assembly from axle housing.
  9.  Using Holder 6958 to hold yoke, remove the pinion nut and washer.
  10.  Using Remover C-452 and Wrench C-3281, remove the pinion yoke from pinion shaft (Fig. 15).
  11.  Remove the pinion gear from housing (Fig. 16). Catch the pinion with your hand to prevent it from falling and being damaged.
  12.  Remove collapsible spacer from pinion shaft.

Fig. 16 Remove Pinion Gear
Fig. 16 Remove Pinion Gear

1 - RAWHIDE HAMMER

INSTALLATION

  1.  Install a new collapsible preload spacer on pinion shaft (Fig. 17).
  2.  If pinion gear was removed, install pinion gear in housing.
  3.  Install pinion front bearing, if necessary.

Fig. 17 Collapsible Preload Spacer
Fig. 17 Collapsible Preload Spacer

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING

  1. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972-A and Handle C-4171 (Fig. 18), if necessary.

Fig. 18 Pinion Seal Installation
Fig. 18 Pinion Seal Installation

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3972-A

  1. Install yoke with Installer W-162-D, Cup 8109, and holder 6958 (Fig. 19).
  2.  If the original pinion bearings are being used, install differential assembly and axle shafts, if necessary.

Fig. 19 Pinion Yoke Installation
Fig. 19 Pinion Yoke Installation

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.

  1.  Install the pinion washer and a new nut on the pinion gear. Tighten the nut to 217 N·m (160 ft. lbs.) minimum. Do not over-tighten. Maximum torque is 353 N·m (260 ft. lbs.). 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.
  2.  Using yoke holder 6958 and a torque wrench set at 353 N·m (260 ft. lbs.), crush collapsible spacer until bearing end play is taken up (Fig. 20). If more than 353 N·m (260 ft. lbs.) is needed to begin to collapse the spacer, the spacer is defective and must be replaced.
  3.  Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 21).
  4.  Check rotating torque with an inch pound torque wrench (Fig. 21). The torque necessary to rotate the pinion gear should be:
  •  Original Bearings - The reading recorded during removal, plus an additional 0.56 N·m (5 in. lbs.).
  •  New Bearings - 1.5 to 4 N·m (15 to 35 in. lbs.).
  1.  Install differential assembly and axle shafts, if necessary.
  2.  Align marks made previously on yoke and propeller shaft and install propeller shaft.

Fig. 20 Tightening Pinion Nut
Fig. 20 Tightening Pinion Nut

1 - PINION FLANGE
2 - FRONT AXLE
3 - TOOL 6958

Fig. 21 Check Pinion Gear Rotation Torque-Typical
Fig. 21 Check Pinion Gear Rotation Torque-Typical

1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH

  1. Install brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures.

Fig. 22 Hub, Knuckle and Axle ShaftБЮ Fig. 22 Hub, Knuckle and Axle Shaft

1 - BRAKE SHIELD
2 - WASHER
3 - RETAINER
4 - COTTER PIN
5 - NUT
6 - HUB AND BEARING ASSEMBLY
7 - STEERING KNUCKLE
8 - BOLT
9 - TONE WHEEL (ABS)

  1. Add gear lubricant, if necessary. Refer to Lubricant Specifications of this section for lubricant requirements.
  2.  Install wheel and tire assemblies.
  3.  Lower vehicle.

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