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1997 Jeep TJ Wrangler Rear Axle Rebuild.


1997 Jeep TJ Wrangler Rear Axle Rebuild.
1997 Jeep TJ Wrangler Rear Axle Rebuild.

Car: 1997 Jeep TJ Wrangler 4.0 Sport

Rear Axle Rebuild Page 1 Page 2 Page 3 Page 4 Page 5

So far we have removed the rear diff from the Jeep and removed the bearings and ring gear from the diff.

Next is the pinion gear...



1997 Jeep TJ Wrangler Rear Axle Rebuild.
To remove the pinion gear the rear drive shaft was disconnected.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
After securing the rear drive shaft out of the way. This simple homemade device was fitted to the remaining part of the u-joint at the front of the rear diff housing.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Using a strongarm against the ground to hold the u-joint in a firm position, this allowed the nut to be fairly easily undone.

Without it, this would of been a very difficult nut to undo! and it will come in very handy at refitting time, when this bolt may have to be fitted and undone several times!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
After the nut has been removed the u-joint lifts off to reveal the top of the pinion.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Tap the top of the pinion with a rubber or nylon mallet to remove it.

Don't worry if you can't catch it, a new one's going in!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Here is the removed pinion gear.

The pinion gear has two roller bearings, this one that comes out with it, and the other which remains in the diff housing.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
To remove the bearing from the diff housing, first remove the bearing cap...

1997 Jeep TJ Wrangler Rear Axle Rebuild.
...then remove the washer and roller bearing.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
We can see daylight at last! ...not finished yet though!
The outer bearings are still in their.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Here is the first one knocked out.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
That looks better from this side, but...

1997 Jeep TJ Wrangler Rear Axle Rebuild.
...the one on this side still needs removing!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
...and finally the last piece of the jigsaw! What do you mean we have to put it all back together before I can say that, I thought we were done!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
...If I put this bit back together showing where the shims were, does that count?

The shims on the left in the photo being below rather than above the bearing where they should be. It seems nothing was fitted correctly by the experts!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Here's a pic showing the damaged tooth on the pinion as well as the worst teeth on the ring gear.
It was a wonder that it was still able to drive anywhere really!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
At last some new parts to play with!

Here a new roller bearing is being pressed onto the new pinion gear.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Comparing the new pinion gear to the old one, you can see that they have different markings on them.

Ring & Pinions are matched at manufacturer and should only be used with the set they are produced in.

The 'zero' figure on the new pinion and the 'two' on the old pinion, should make it very easy to add or deduct the correct number of shims for the require thickness, but with the old ring & pinion all being fitted wrongly in the first place, we do not have that luxury this time!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
The outer bearings for the pinion are pushed in first.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Here is the next one in place.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
The top bearing is put into position.

The bottom bearing already being in position on the pinion as shown earlier.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Some shims were fitted onto the pinion and the pinion was put in place.
The amount of shims required can be changed later if needed.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
The universal joint was fitted back on to keep the pinion held in place.

Next fit the diff...

<<<Rear Axle Rebuild Page 1    >>>Rear Axle Rebuild Page 3





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