2012 Jeep Wrangler JK Factory Service Manual 03 - Differential and Driveline

CASE ASSEMBLY, Differential

REMOVAL

REMOVAL

Special Tools: Click to display a list of tools used in this procedure

  1. Remove differential fill plug (2).

    2.  
  2. Remove differential cover (1) and drain fluid.

    3.  
  3. Remove axle shafts.

    4.  
  4. Note reference letters stamped (1,2) on the bearing caps and housing machined sealing surface.

    5.  
  5. Loosen differential bearing cap (1) bolts.

    6.  
  6. Position Spreader W-129-B (4) with Adapter Kit 6987B (2) on differential locating holes. Install hold-down clamps (3) and tighten the turnbuckle (5) finger-tight.

    7.  
  7. Install a Pin C-3288-B (5) at the left side of the differential housing. Attach Dial Indicator C-3339A (2) to pin. Load indicator plunger against the opposite side of the housing and zero the indicator.

    8.  
  8. Spread housing while measuring the distance with the dial indicator (1).

    CAUTION:

    Never spread housing over 0.50 mm (0.020 in). Failure to follow these instructions will damage the housing.



    9.  
  9. Remove dial indicator.

    10.  
  10. Holding differential case (2) in position, remove differential bearing caps.

    11.  
  11. Remove differential case (2) from housing (1) and tag differential bearing cups (3) and shims location.

    12.  
  12. Remove spreader from housing.

    13.  
  13. Clean the housing cavity with flushing oil, light engine oil or lint free cloth.

    14.  


NOTE:

Do not use water, steam, kerosene or gasoline for cleaning.

DISASSEMBLY

DISASSEMBLY

  1. Remove ring gear bolts (1) and ring gear (2) from differential.

    2.  
  2. Remove pinion mate shaft (1) roll pin with a punch (2) and hammer.

    3.  
  3. Remove pinion mate shaft (1) from differential and pinion gears (2).

    4.  
  4. Rotate pinion gears (1) with thrust washers (2) to differential windows (3).

    5.  
  5. Remove pinion gears (1) with thrust washers (2) through differential windows (3).

    6.  
  6. Remove first side gear (1) with thrust washer (2) through differential window.

    7.  
  7. Remove second side gear (1) with thrust washer (2) through differential window.

    8.  

ASSEMBLY

ASSEMBLY

NOTE:

If same gears and thrust washers are being used, install them into their original locations.

  1. Lubricate all differential components with axle lubricant.

    2.  
  2. Install first side gear (1) with thrust washer (2) through differential window.

    3.  
  3. Install second side gear (1) with thrust washer (2) through differential window.

    4.  
  4. Install pinion gears (1) with thrust washers (2) through differential windows (3).

    5.  
  5. Rotate pinion gears (1) with thrust washers (2) and align gears to pinion mate shaft hole.

    6.  
  6. Install pinion mate shaft (1) in differential and pinion gears (2).

    7.  
  7. Install pinion mate shaft (2) roll pin (1).

    8.  
  8. Install ring gear (2) and bolts (1) on differential.

    9.  

INSTALLATION

INSTALLATION

Special Tools: Click to display a list of tools used in this procedure



NOTE:

If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection.

  1. Position Spreader W-129-B (1) and with dowel pins from Adapter Kit 6987B seated in housing locating holes. Install hold-down clamps (2) and tighten turnbuckle finger-tight.

    2.  
  2. Install Pin C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339A (1) to pin. Load the indicator plunger (2) against the opposite side of the housing and zero the indicator.

    3.  
  3. Spread the housing while measuring the distance with the dial indicator.

    CAUTION:

    Never spread housing over 0.50 mm (0.020 in). Failure to follow these instructions will damage the housing.


    4.  
  4. Remove the dial indicator.

    5.  
  5. Install differential case (2) into the housing (1) with bearing cups (3) and preload shims. Tap the differential case to ensure the bearings cups (3) are seated in the housing.

    6.  
  6. Install bearing caps with reference marks (1,2) in their original locations.

    7.  
  7. Loosely install differential bearing cap bolts.

    8.  
  8. Remove axle housing spreader.

    9.  
  9. Tighten bearing cap (1) bolts to 61 N·m (45 ft. lbs.).

    10.  
  10. Install axle shafts.

    11.  
  11. Install differential cover (1).

    12.