JEEP CJ 1953 Service Manual

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

N

13189

FIG.
N-36—PINION
SHAFT OIL
SEAL
INSTALLER
1—Tool
W-147
p.
Remove
the
sleeve
previously installed in
place

of
the yoke. Install the oil
seal
with
Tool
W-147 shown in Fig. N-36.
q. Install the yoke
with
Flange
Installer W-162,
as shown in Fig. N-3 7.

r.
Install pinion nut and cotter pin.
s. Install axle
shafts
and housing cover.
N-20.
POWR-LOK
DIFFERENTIAL

As
optional equipment, Powr-Lok was previously available on all
Jeep
Universal
models
equipped
with
semi-float
tapered
axle
shafts.
The Powr-Lok

differential
may be identified by a tag located on
the opposite
side
of the differential housing
from
the ratio tag (Fig. N-2) and
stamped
with
either a "T" or
with
the words, "USE
LIMITED
SLIP
FIG.
N-37—YOKE INSTALLING TOOL
DIFF.
LUBE
ONLY."
This differential is available

for
rear
axles
only.
Whenever a
replacement
or conversion Powr-Lok
differential
is to be installed in an axle which has

been
previously in
service
and acquired mileage, be
sure
to record the amount of backlash
between

the ring
gear
and pinion at the time of
disassembly.

When the axle is again
assembled
the ring
gear
and pinion must be set to this
same
amount of
back­

lash.

Axle
ratios and
speedometer
gear
application is very important. In
like
model
axles,
the ratio may
be
changed
by simply changing to the desired ring
gear
and pinion;
except
in the
case
of the
3.73:1

or higher ratios. When changing
from
a
3.73:1
or higher to 3.54 or lower ratio, or vice
versa,
the
differential
case
must
also
be
changed
on a
stand­

ard differential
assembly,
and the differential as­ sembly,
less
ring
gear
and pinion, when a Powr-Lok

differential
assembly
is involved. When changing
from
any ratio to
another,
it
will
also
be
necessary

to
change
speedometer
gears.
Speedometer
gears

for
Powr-Lok and
standard
differentials of the
same
ratio, are
interchangeable.
A complete
rear

axle
assembly
replacement
is
necessary,
if a con­
version
from
one type of differential
assembly
to
another
is desired.
Note: Powr-Lok differentials use a special
lubri­

cant.
Refer to the Lubrication Chart.

N-21.
Trouble Symptoms and
Possible
Causes
If
noises
such
as
chatter
are
detected,
when turning
a corner, the probable
reason
for this is that incor­
rect
gear
lubricant has
been
installed in the axle.

Axles
equipped
with
a
limited
slip differential require special lubricant. Refer to Lubrication
Sec­

tion,
Par. B-52.
Note: It may be
necessary
to use an additive to
attempt to eliminate
chatter.
If this is not
success­
ful
then
disassembly
and inspection of the differen­

tial
becomes
necessary.

Warning:
Extreme
care
must be exercised on a
Powr-Lok
equipped vehicle to be
sure
the transmis­
sion is in the neutral position
whenever
the
engine

is
started
with
one wheel jacked up. Otherwise the
vehicle may lurch unexpectedly and
fall
off the
jack.
N-22. Torque Test
Procedure
for testing torque Powr-Lok differentials

on
Jeep
Universal
Series
vehicles is as follows:
FIG.
N-38—POWR-LOK DIFFERENTIAL
1—
Differential
Case Flange
Half

2—
Disc
and Plate Set

3—
Side
Gear
Ring

4— Side
Gear
and Pinion Mate
Gear
Set
5—
Pinion
Mate
Cross
Shaft 6—
Differential
Case Button
Half
7—
Axle
Shaft Spacer
8—
Axle
Shaft Spacer
Roll
Pin 11564
301

N

REAR
AXLE a.
Place the transmission in neutral.

b.
Raise one wheel off the floor and place a block

in
front and at the
rear
of the
opposite
wheel.

c.
Apply a torque wrench to the axle shaft nut of
the elevated wheel.

d.
Turn
wheel with torque wrench. Disregard

breakaway
torque and observe torque required to
continuously
turn
wheel smoothly. Torque should
read
40 lb-ft [5,53 kg-m.] or more.

N-23. Powr-Lok
Differential Disassembly
/
and Reassembly

Refer
to
Figs.
N-38 and N-39.
The
procedure for overhauling disc type
Powr-Lok

differentials is as follows:

a.
Remove axle shafts following procedure de­
scribed
in Par. N-2.

b.
Remove housing cover and gasket.

c.
Remove the
Powr-Lok
differential from the axle.
Do not remove the ring gear or bearing
cone
and

rollers
unless replacement is to be made.
Mark
the hearing cups so they may later be reassembled

with
the same bearing cones.
Mark
the differential
case halves for correct alignment at reassembly.
Each
pinion mate cross shaft should also be marked
so that each pin cam surface
will
match with the
same
V-ramp
in the case when reassembled.

d.
Separate the case halves. e. Remove the disc and plate
sets.
The illustration
(Fig.
N-39) shows the arrangement of plates and

discs.
When reassembling unit, discs and plates must be reinstalled in this arrangement. Be sure
to keep in mind which way the set
will
face toward the case.

^®(j)(j)CD©
® /'Ml
I
11
11 v

FIG.
N-39—PLATE
ASSEMBLY
ORPER
A—Model
44
B—Model
27 1—
Case
5—Disc

2—
Belleville
Plate
6—Thin
Plate

3—
Belleville
Disc
7—Sidegear
Ring

4—Plate
8—Side
Gear
f. Remove the pinion mate cross shafts, bevel
pinion mate gears, bevel side gears, and side gear

rings.

g.
Clean
all parts thoroughly in kerosene and dry

with
compressed air.

h.
Inspect all parts. Replace any items which ap­

pear
to be worn or damaged.

i.
Inspect the plate surfaces of the case halves, the
side gear rings, and the clutch friction plates and
discs for excessive wear or scoring.

j.
Inspect the pinion mate shaft and ramp
sur­

faces on the case for excessive wear and pitting,

k.
Inspect the pinion gear races that bear on the
side gear rings.

I.
Inspect the corresponding surfaces on the side
gear rings.

m.
Inspect the clutch plates and discs for cracks

and
distortion. In the
event
one or more of the

clutch
plates or discs
needs
replacing, replace the
entire stack of plates and discs on each side of
the pinions. These stacks are supplied in
sets.

The
differential case halves are not serviced. Should replacement be required, it is necesary to replace
the complete differential.

n.
Assemble the clutch friction plates, clutch
fric­

tion discs, and dished plates on the splined hub of each bevel side gear. Make sure the plates and
discs are installed in the proper relationship as shown in Fig. N-39. The dished plates in the plate

and
disc set are always assembled with the convex
side toward the case. As each part is reassembled

in
its proper position, it is necessary that it be lightly coated with
Powr-Lok
lubricant,

o.
Place each differential case
half
on its side and
install
the side gear rings with the plates and discs
assembled. The side gear ring
will
rotate with a slight drag when properly located in the case,
p.
With
the ring gear flange
half
of the differential
case in an upright position, assemble the bevel side gears, pinion mate cross shafts, and bevel pinion
mate gears.
Install
the remaining case
half
on the
ring
gear flange half. Make sure that all markings
coincide.

q.
Install
the differential case
bolts
and
turn
them

in
a few threads.

r.
Using axle shafts from the vehicle, align the
splines of the side gear, and the side gear
ring,

s.
With
these
axle shafts in position, tighten the

differential
case
bolts
evenly. Torque 35 to 45 lb-ft. [4,84 a 6,22 kg-m.].
t. Remove the axle shafts.

u.
Check
for proper assembly.
Each
pinion mate
cross shaft should be tight on its
ramp.
If there is

clearance
between
the cross shaft and the
ramp,

the clearance should be no more than .005" [0,127 mm.].

This
clearance should be equal on all four cross
shaft ends.
v. Reinstall the unit in the axle.

w.
Install
axle shafts as described in Par. N-2.
Other
service operations such as ring gear and
pinion replacement, or pinion and bearing adjust­ ments, are performed in the same manner as de- 302

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

N
scribed
in
Pars.
N-ll through N-l9 for standard
axles, with the exception of the following torque
recommendations. Torque the differential case
bearing
cap screws 70 to 90 lb-ft. [9,7 a 12,4 kg-m.]

and
the cover screws 15 to 25 lb-ft. [2,1 a 3,4
kg-m.].
The ring gear screws on axles with Powr-

Lok
differentials should be torqued as follows:

Model
30 and 44 axles 35 to 55 lb-ft. [4,84 a 7,60 kg-m.].

N-24. TRAC-LOK DIFFERENTIAL
As
optional equipment
Trac-Lok
Model 44 differen­
tial
is available on all Jeep Universal vehicles equipped with semi-float flanged axle shafts.
A
conventional differential transmits all of the
ring
gear torque through the differential gears to the axle shafts. Torque is at all
times
equal on the axle shafts, and if one wheel slips, the other wheel

can
only put out as much torque as the slipping
wheel.

The
Trac-Lok
differential is similar,
except
that

part
of the torque from the ring gear is trans­ mitted through clutch packs
between
the side gears

and
differential case. The multiple disc clutches

with
radial
grooves
on the plates and concentric
grooves
on the discs are
engaged
by a preload

from
Belleville springs, plus separating forces from
the side gears as torque is applied through the
ring
gear.

The
Trac-Lok
construction permits differential action when required for turning corners and trans­mits equal torque to both
wheels
when driving

straight
ahead. However, when one wheel tries to spin due to leaving the ground, a patch of ice,
etc., the clutch packs automatically provide more
torque to the wheel which is not trying to spin.
It
can be
seen
then that the
Trac-Lok
differential
resists wheel spin on bumpy roads and provides
more pulling power when one wheel tries to slip.
In
many cases of differences in traction, pulling
power
will
be automatically provided until both
wheels
start to slip.

In
diagnosis of vehicle operators' complaints, it
is important to recognize two things:

a.
If, with unequal traction, both
wheels
slip, the

Trac-Lok
has
done
all it can possibly do.

b.
In extreme cases of differences in traction, the
wheel with least traction may spin after the
Trac-

Lok
has transferred as much torque as possible
to the non-slipping wheel.
N-25.
Lubrication

The
Trac-Lok
differential requires a special
lubri­

cant
and ordinary multipurpose gear lubricants

MUST
NOT be used. Use only 'Jeep* Differential
Oil,
Part
No. 94557.

Trac-Lok
differential may be cleaned only by disassembling the unit and wiping with clean rags. Do not flush the
Trac-Lok
unit.

Note:
The
Trac-Lok
differential is serviced at the
same time intervals as the standard differential.
N-26.
Trouble
Symptoms

If
noises
or roughness, such as chatter, are present
in
turning corners, the probable cause is incorrect

or
contaminated lubricant.
Before any differential is removed and disassem­
bled for chatter complaints, the correctness of
lubri­

cant
can and should be determined.

A
complete
lubricant
drain,
and
refill
with specified

Limited
Slip Differential lubricant
will
usually
correct
chatter.

The
following procedure is recommended to ensure

complete
removal of old lubricant.

a.
Warm
the lubricant by vehicle road operation,

or
5 minutes of operation in gear at 30 mph with
both
wheels
off the ground on a hoist.

Caution:
Never place the transmission in gear with
the
engine
running when only one wheel of a

Limited
Slip Differential equipped vehicle is raised.
The
vehicle might drive itself off the
jack
and produce damage or
injury.

b.
Drain
lubricant while
warm.
Remove
drain
plug

or
cover to
drain
completely. If cover is removed,

it
may be necessary to replace gasket at this time.

c.
Refill
axle with specified
Limited
Slip Differen­

tial
lubricant.

d.
Operate the vehicle for approximately ten miles
[16,09
km.], making at least ten figure 8 turns
to flush the old lubricant out of the clutch packs.

e.
Repeat
steps
b, c, and d, making sure to replace
the cover gasket if required in
step
c.
f. It is possible that slight chatter, requiring ad­
ditional
vehicle operation, may remain after
step
e. If chatter persists after 100 miles
[160,9
km.]
of vehicle operation, or remains severe after
step

e above, disassembly and repair
will
be necessary.
N-27.
Unit
Inoperative

Proper
performance and capabilities of
Limited
Slip
Differentials are
often
misunderstood. No
precise
methods
of measuring
Limited
Slip Dif­

ferential
performance are generally available in the field. A functioning unit can be determined by
relatively
simple vehicle operational
tests,
as
follows:

a.
Place one wheel on
good
dry pavement, and the
other on ice, mud, grease, etc.

b.
Gradually
increase
engine
rpm to obtain maxi­

mum
traction
prior
to "break-a-way." The ability
to
move
the vehicle
effectively
will
demonstrate

proper
performance.

c.
If extremely slick surfaces, such as ice or grease,

are
used
some
question may exist as to proper per­
formance at
step
b. In
these
extreme cases a prop­

erly
performing
Limited
Slip Differential
will
pro­
vide greater "pulling" power by lightly applying
the parking brake.

N-23.
Trac-Lok
Differential Disassembly
and
Reassembly

It
is recommended that the
complete
axle assembly
be removed from the vehicle, when it
becomes
necessary to remove the
Trac-Lok
from the hous­

ing.
Refer to Par. N-3 and N-12 for removal of axle shafts and differential case from axle housing. 303

N

REAR
AXLE
With
the
Trac-Lok
unit removed from the axle
housing, proceed as follows:

N-29.
Disassembly

a.
Place the axle shaft, which was removed from the assembly, into a vise. Tighten shaft in vise
firmly.
The spline end of the shaft is not to extend beyond 23A" [7 cm.] above the top of the vise.

This
will
eliminate the shaft from fully entering into the side gear and causing interference with
the
step
plate tool during disassembly of the pinion
mate gears, etc. Refer to Fig. N-40.
FIG.
N-40—AXLE SHAFT POSITIONED
IN
VISE

b.
Assemble the differential case to the axle shaft

with
the ring gear screw heads up. Assembling the

differential
case
onto
the shaft
will
serve as a holding device to remove the ring gear and to disassemble the internal parts of the case.
FIG.
N-41—DIFFERENTIAL POSITIONED
ON
AXLE
SHAFT c.
Remove the ring gear screws and ring gear. It
is necessary to remove the ring gear to allow

clearance
for the removal of the cross pin. Place a
few shop
towels
over the top of the vise to protect
FIG.
N-42—REMOVING RING
GEAR

the gear
teeth
from becoming nicked after it is
free from the case. Tap ring gear with a rawhide
hammer
to free it from the case.

Note:
It is recommended that whenever the ring
gear screws are removed they are to be replaced

with
new screws.

d.
Remove differential case from axle shaft and remove ring gear.
e. All
Trac-Loks
are identified with a manufactur­
ing date, and the complete part number stamped on the
barrel
of the case. If the axle is equipped

with
Trac-Lok
Limited
Slip Differential, it
will
contain a tag requesting the use of
Limited
Slip

Lubricant.
FIG.
N-43—TRAC-LOK IDENTIFICATION

f. The
Trac-Lok
is identified with Vs" [3,18 mmj
high numbers stamped in the case. For example:

The
numbers 8-5-69A is the manufacturing or build
date of the
Trac-Lok
and is interpreted as follows.

The
first number is the month, second number is
the day of the month,
third
number is the year,
the letter is the shift. For example: August 5, 1969 first shift The number stamped above the 304

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
N

FIG.
N-44—REMOVING
SNAP
RINGS
FROM
CROSS
PIN
manufacturing
date is the complete
Trac-Lok
as­
sembly part number.
g. It is recommended that when referring to the

Trac-Lok,
obtain the complete part number and
build
date. To do this it
will
be necessary to wipe
off the lubricant from the case. See Fig. N-43.

h.
Reposition differential case
onto
axle shaft as
shown. Remove the two snap rings from the cross

pin.
Use two screw drivers and push the rings free

from
the cross pin. Place a shop towel behind
the case to prevent the snap rings from flying out
of the case. Refer to Fig. N-44.
FIG.
N-45—REMOVING CROSS
PIN

i.
Remove the cross pin. Use a hammer and punch
as shown to remove the cross pin from the case.
Note: A gear rotating tool C-4142 is required to
service the
Trac-Lok
diferential. The Tool consists
of four parts: a Handle,
Pawl,
Forcing
Screw and Step Plate.

j.
Assemble the
step
plate tool into the bottom
side gear, as shown in Fig. N-4 6.

k.
Position the gear rotating tool into the top
side gear, as shown in Big. N-4 7. "S | 14342

FIG.
N-46—INSTALLING STEP
PLATE
TOOL

V
14351

FIG.
N-47—INSTALLING GEAR ROTATING TOOL

FIG.
N-48—THREADING FORCING SCREW INTO ROTATING TOOL
I.
Insert the forcing screw down through the top
of the case and thread into the gear rotating tool.
Note: Before using the forcing screw be sure the
threads are lubricated with a fine coat of oil. Also

apply
a small spot of grease to the centering hole
in
the
step
plate before it contacts the forcing

screw.
305

N

REAR
AXLE

FIG.
N-49—REMOVING
PINION
MATE
WASHERS
m.
Thread
forcing screw so that it becomes cen­
tered into the
step
plate. Torque forcing screw
tight.
This
will
move the side gears away from
the pinion mate gears, and relieve the load between
the gears, allowing only the pinion mate gears to
be
loose.

n.
Remove both pinion mate spherical washers. Use

a
shim stock of .030" [0,762 mm.] thickness or an
equivalent tool to push out the spherical washers.

Relieve
the tension of the Belleville spring by
loose­

ning
the forcing screw. Refer to Fig. N-49.

o.
Retighten forcing screw until a very slight move­ ment of the pinion mate gears is detected.
FIG.
N-50—-REMOVING
PINION
MATE
GEARS

p.
Insert the pawl rotating tool between one of
the side gear
teeth
as shown.
Pull
on handle so
the top side gear
will
rotate and also allow the
pinion mate gears to rotate. Also continue pulling
on tool until the gear hits the handle,
q.
Remove pawl from between the gear
teeth
and
repeat the above until the pinion mate gears can
be removed through the large opening of the case.

Note:
When attempting to rotate the side gear, it

will
probably be necessary to adjust the forcing
screw
by very slightly tightening or loosening until the required load is applied to the Belleville springs
to allow the side gear and pinion mate gears to
rotate. Refer to Fig. N-50.

r.
Retain the top side gear and clutch pack in
the case by holding hand on the bottom of the
rotating tool while removing forcing screw. Remove
rotating tool, top side gear, and clutch pack.

FIG.
N-51—-TRAC-LOK
UNIT
DISASSEMBLY

s. Remove the differential case from the axle shaft.

Turn
case with the flange or ring gear side up

and
allow the
step
plate tool side gear and clutch

pack
to be removed from the case. Remove the

retainer
clips from both clutch packs to allow
separation of the plates and discs. Refer to Fig.
N-51.

N-30.
Inspection
a.
Plates and discs —
If
any one member of either

stack
shows evidence of excessive wear or scoring,
then the complete stack is to be replaced on both
sides.

b.
Side gears and pinion mate gears —
The
gear

teeth
of
these
parts should be checked for extreme

wear
or possible
cracks.
The external
teeth
of the side gear which holds the clutch pack should also
be checked for wear or
cracks.
If replacement of one gear is required due to wear, etc., then both
side gears, pinion mate gears, and washers are to
be replaced.

c.
Cross
pin
— If excessive wear is evident, then
the cross pin should be replaced.

d.
Clutch
retainer clips — If wear is evident on
any
one of the retainer clips, it is
suggested
that

all
four clips be replaced.
e. Differential case — If scoring, wear, or metal
pick-up
is evident on the machined surfaces, then replacement of the case is necessary.

I.
Example of
radial
groove plate (A) and the con­

centric
groove disc (B) shown in Fig. N-52.

N-31.
Reassembly
a.
Assemble plates and discs in exactly the same position as they were removed, regardless of
whether they are new parts or the original parts. 306

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

N

FIG.
N-52—PLATE
AND
DISC
IDENTIFICATION

I 14340

FIG.
N-S3—LUBRICATING
TRAC-LOK

COMPONENTS
b.
Prelubricate the thrust face of the side
gear,

assemble
the plates and discs to the side
gear
splines, prelubing each part as shown
with
the

specified
lubricant.
Both
stacks. See Fig. N-53.
FIG.
N-54—INSTALLING
PLATE
RETAINER
CLIPS

c. Assemble the retainer clips to the
ears
of the
plates. Make
sure
both
stacks
are completely as­ sembled or
seated
onto the
ears
of the plates.

d.
With
the
differential
case
positioned as shown,
assemble
the
clutch
pack and side
gear
into
the

case.
Make
sure
the
clutch
pack
stays
assembled
to
the side
gear
splines and that the retainer clips
are completely
seated
into
the pockets of the
case.

To
prevent pack
from
falling
out of the
case
it
will

be
necessary
to
hold
them in place by hand
while

assembling the
case
onto the axle shaft.
FIG.
N-55—INSTALL
DIFFERENTIAL
CASE

ON
AXLE
SHAFT
e. Assemble
differential
case
onto the axle shaft

in
the position as shown in Fig. N-55.

Caution:
When assembling the
differential
case
onto
the axle shaft, be
sure
that the splines of the side
gears
are
lined
up
with
those
of the axle shaft.

Also
make
sure
that the
clutch
pack is
still
properly
assembled
into
the
case
after assembling the
case

onto the shaft.
f. Assemble the
step
plate
tool
into
the side
gear
as shown in Fig. N-4 6.
Apply
a small dab of
grease

into
the centering hole of the
step
plate
tool.
FIG.
N-56—INSTALLING
CLUTCH
PACK

AND
SIDE
GEAR

307

N

REAR
AXLE

FIG.
N-57—POSITIONING GEAR ROTATING TOOL
g. Assemble the other clutch pack and side gear
exactly as shown. Be sure the clutch pack stays
assembled
onto
the side gear splines and that the
retainer
clips are completely seated into the pockets
of the case. Refer to Fig. N-56.

h.
Position the gear rotating tool into the top side
gear.
FIG.
N-58—THREADING FORCING SCREW
INTO ROTATING TOOL

FIG.
N-59—STARTING PINION MATE GEARS INTO CASE
i.
Keep side gear and rotating tool in position
by holding with hand. Insert the forcing screw down
through the top of the case, and thread into the
rotating tool. Refer to Fig. N-58.
j.
Position both pinion mate gears exactly as
shown. Be sure the holes of the gears are lined up

with
each other. Hold gears in place by hand. See

Fig.
N-59.

k.
Tighten forcing screw so that the Belleville
springs
will
compress and allow clearance between
the
teeth
of the pinion mate gears and side gears.
FIG.
N-60—ROTATING PINION MATE GEARS
INTO POSITION
I.
While holding the pinion mate gears in place,

insert
the pawl of the rotating tool between one
of the side gear
teeth
as shown.
Pull
on handle
so that the top side gear
will
rotate and allow the pinion mate gears to rotate and enter into the case.

Note:
As mentioned before, it
will
probably be
necessary to adjust the forcing screw by very
slightly loosening or tightening until the required load is applied to the Belleville plates or discs to allow the side gear and pinion mate gears to rotate.
FIG.
N-61—INSTALLING PINION MATE WASHERS

308

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

N
m.
Pull
on tool until the handle hits the gear.
Remove pawl from
between
the
gear
teeth, reposi­
tion handle and pawl. Repeat the same operation
until
the
holes
of both pinion mate gears are lined
up exactly with
those
of the case,
n.
Prelubricate both sides of the pinion mate

spherical
washers with the specified lubricant,

o.
Apply torque to the forcing screw to allow

clearance
to assemble the spherical washers,
p.
Assemble washers into case. Use a very small

screw
driver to push washers into place, as shown

in
Fig. N-61.

Caution:
Be sure the
holes
of the washers and gears

are
lined up exactly with
those
of the case.

q.
Remove forcing screw, rotating tool, and
step

plate.
FIG.
N-62—INSTALLING
CROSS
PIN

r.
Prelubricate the cross pin with the specified

lubricant.
Assemble cross pin into case. Use a
hammer
as shown. Be sure the snap ring
grooves

of the cross pin are
exposed
to allow assembly of
the snap rings. Refer to Fig. N-62. s. Assemble snap rings.
FIG.
N-63—TORQUING
RING
GEAR
SCREWS
t.
Remove case from axle shaft. Assemble ring gear
to case.

u.
Line
up the ring gear screw
holes
with
those

of the case. Assemble ring gear screws finger tight,

v.
Reposition differential case
onto
axle shaft as shown.
Draw
screws up evenly.

Note:
Use new ring gear screws and torque to 45-
50 ft. lbs.
w.
This
completes
the service procedure for the

Trac-Lok
assembly.
Install
Trac-Lok
differential case assembly into axle housing. Follow the service
procedure given in Par. N-8 and
N-l
7 through

N-l9,
to complete the differential and axle assembly
servicing.

N-32.
Complete
Trac-Lok
Assembly Replacement

a.
If inspection reveals that the replacement of the
Trac-Lok
as a unit is required, the following

steps
should be followed.

b.
Remove both differential bearing
cones
and

shims.
Mark
or tag each side bearing
cone
and

shim
pack as it is removed to indicate from which
side of the case they were removed.

c.
To remove ring gear from case, follow the
same
steps
as illustrated in Fig. N-42.

d.
Assemble ring gear to new
Trac-Lok
case.
Fol­

low the same
steps
as illustrated in
Fig.
N-63.
Make

sure
the gear flange on the differential case is free
of nicks,
burrs,
etc.
e. Inspect shims and bearings which were removed

from
the old case. If shims on bearings show exces­
sive wear or damage, they should be replaced.
Make
sure they are used on exactly the same sides
of the new case as they were removed from the
old case. Assemble shims and differential bearing cones. Use
step
plate on
bottom
bearing to protect
the bearing from becoming damaged during as­ sembly of the top bearing. To completely seat
the bearings use the proper bearing driver tool.
f. Prelubricate differential bearing
cones
with the
specified lubricant, and assemble case into axle
housing. Follow the service procedure given in
Par.
N-8 and N-l7 through N-19 to complete the

differential
and axle assembly servicing.
N-33.
INSTALLING
REAR
AXLE

All
service replacement axle assemblies are shipped

from
the factory without lubricant in the differ­
ential.
Lubricant
must be added to the differential
before the axles are installed in vehicles. Use the grade and quantity of lubricant specified in the

Lubrication
Chart.

When
adding differential lubricant, suspend the axle with the axle shafts horizontal and the yoke
end of the pinion housing hanging down, then
turn

the pinion shaft several times to assure that the

lubricant
gets
into the pinion shaft bearings.

Procedure
for installing the
rear
axle on Jeep
Universal
Series vehicles is as follows:

a.
Position the axle assembly under the vehicle.

b.
Position springs to axle pads, and install spring

clips
and nuts. 309

m

REAR AXLE
c. Attach the brake line
hose
at tee fitting on top
of housing.

d.
Attach parking brake cables at rear of brake
backing plate. DJ
models
only.
e. Connect the shock absorbers at the axle mount­
ing pads.
f. Connect the propeller shaft at the rear universal
joint.
g. Adjust and bleed brakes. (See Section P).

h.
Install
wheels
and lower vehicle to floor.
i.
Check parking brake as described in Section P.

j.
Fill
the axle housing with the proper lubricant.

For
correct lubricant refer to the
Lubrication
Chart.

N-34.
TROUBLE
SHOOTING

The
following problems can be present with either the conventional differential,
Powr-Lok
or
Trac-
Lok
differential.
N-35. Backlash

Excessive
backlash in the vehicle drive line may be the results of
excessive
backlash in the trans­
mission, propeller shaft spline, universal joint, ring gear and pinion, the axle shaft spline, or the dif­
ferential.
Excessive
backlash in the differential may be meas­

ured
as follows:
a.
Jack
up one rear wheel.
b. Put the transmission in gear.
c. Measure the travel of the jacked-up wheel on
a
10"
[25,40
cm.] radius from the wheel center.

This
total
movement
should not
exceed
IVi" [3,17 cm.] in a new unit. In order to restrict the

backlash
to the axles only, make sure that the
yoke of the propeller shaft
does
not
move
during
the check.

d.
If all causes of backlash mentioned
above
have

been
eliminated with the exception of the differen­

tial
and that still
exceeds
the maximum allowable
movement, overhaul the differential.
N-36.
Rear
Wheel
Noise

Looseness of the rear axle shaft nut on semifloat- ing tapered rear axles may produce a clicking or
creaking
noise.
This
noise
can usually be
stopped

by torquing the wheel hub nut 150 to 175 lb-ft. [20,7 a 24,2 kg-m.]. If the condition has continued
for
some
time, slight wear may have resulted allow­
ing the
noise
to persist. In this case, coat the hub,
key, and keyway on tapered axle shafts with white
lead and torque the nut as specified. If the
noise
persists after this treatment, replace the worn parts.

N-37.
SERVICE DIAGNOSIS

SYMPTOMS

Axle
Noisy on Pull and
Coast
Excessive
Back
Lash
Bevel
Gear
and Pinion. . . . . Adjust

End
Play Pinion Shaft Adjust

Worn
Pinion Shaft Bearing Adjust
Pinion
Set too Deep in Bevel
Gear
too Tight..... Adjust

Wrong
Lubricant
Being Used
(Powr-Lok
or
Trac-Lok
Differential) . Replace

Axle
Noisy on
Pull
Pinion
and Bevel
Gear
Improperly Adjusted Adjust

Pinion
Bearings Rough....................... Adjust

Pinion
Bearings Loose Adjust

Axle
Noisy on Coast
Excessive
Back
Lash
in Bevel
Gear
and Pinion. . . Adjust

End
Play in Pinion Shaft. . Adjust

Improper
Tooth Contact.
....................
Adjust
Rough Bearings Replace

Back
Lash
Worn
Differential Pinion
Gear
Washers Adjust
Excessive
Back
Lash
in Bevel
Gear
and Pinion. . . Adjust

Worn
Universal Joints Replace
PROBABLE REMEDY

310