1953 JEEP DJ Service Manual

'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

Jeep'
UNIVERSAL SERIES SERVICE
MANUAL
N N-38.
REfiR flXLE SPECIFICATIONS

DJ MODELS
TAPERED AXLE SHAFT CJ MODELS
TAPERED AXLE SHAFT DJ and CJ MODELS
FLANGED AXLE SHAFT
Make
Model
Description Drive Pinion Offset (Vertical)
Number of Differential Pinions.......
Gear Ratio:
V6 Engine:
Standard
Optional
F4 Engine: Standard
Optional
Ring Gear Pitch Diameter
Pinion Adjustment
Pinion Bearing Adjustment Dana
27
Semifloating Hypoid Gears 1.38" [35 mm.] 2

3.73:1
4.88:1
4.56:1

7.75" [19,68 cm.] Shim
Shim Dana
44
Semifloating Hypoid Gears 1.50" [38,0 mm.] 2

3.73:1

4.88:1
4.27:1
5.38:1

8.50" [21,6 cm.] Shim Shim Dana
44
Semifloating Hypoid Gears 1.50" [38,0 mm.] 2

3.73:1

4.88:1
4.56:1
5.38:1

8.50" [21,6 cm.] Shim Shim 311