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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

We have now removed the diff and replaced all the parts, and got the settings for the ring and pinion as close as we can to those required. We are now ready therefore for the final fitment!



1997 Jeep TJ Wrangler Rear Axle Rebuild.
Here is the diff with the slip bearing removed. The extra width of shims required for final instalment has been equally divided between the two sides.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
The correct new bearing is now being fitted. This time it's the permanent one!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Well that's this side done.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
The other half of the extra width of shims for the final fitment is added at this end.

Adding extra width to the diff will mean it can no longer just be lifted in and out!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Although we did not need a diff spreader when we removed the diff the first time (because it had been badly installed), we will need one now.

Time once again for one of those home made devices!

A bit of bar and a few nuts & bolts later and we have this home made diff spreader to fit a Dana 44. (with a couple more holes drilled in the bars we could soon make it fit the Dana 30 front axle if we needed it too.)

1997 Jeep TJ Wrangler Rear Axle Rebuild.
With the diff spreader fitted, in goes the diff.

(Don't forget the rubber seals for the ends! We did and had to take the diff out and pop it back in again with them on!)

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Hurray it worked, and it had only cost a few quid to make!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Those all important settings should be checked again just to confirm things are as they should be.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Paint was also put on the cogs to check the wear patterns.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
These seems the same as before, so things were all looking good.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
After several rotations the wear was as expected, now all we had to do was clean the paint off!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Cleaning the paint off was not easy, but at least we were still able to get more results each time the ring and pinion was rotated though a few more resolutions!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
Finally the diff is installed. Not forgetting to fasten up the nut on the ARB airlocking pipe!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
The diff cover & seal are both put back in place and bolted up.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
The pinion end is not yet completed though!

1997 Jeep TJ Wrangler Rear Axle Rebuild.
First insert the new washer...

1997 Jeep TJ Wrangler Rear Axle Rebuild.
...then the bearing seal (using some sealant too!)...

1997 Jeep TJ Wrangler Rear Axle Rebuild.
...then the bottom end of the u-joint.

1997 Jeep TJ Wrangler Rear Axle Rebuild.
and finally bolt the u-joint bracket back in place.

Things are not quite as finished as they may seem though! Don't forget we took those half shafts out of the rear axle earlier, so that we could take the diff out in the first place.

Well they will need refitting now too!

<<<Rear Axle Rebuild Page 3    >>>Rear Axle Rebuild Page 5





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