1995 JEEP YJ Service And Repair Manual

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Page 97 of 2158

JEEP YJ 1995 Service And Repair Manual (3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator (Fig. 58).
(4) Remove the dial indicator.
(5) Install case in the housing. Tap the differ

Page 98 of 2158

JEEP YJ 1995 Service And Repair Manual (3) Rotate the ring gear one complete revolution in
both directions while a load is being applied. Insert a
pry bar between the differential housing and the case
flange to load gears. This will produc

Page 99 of 2158

JEEP YJ 1995 Service And Repair Manual Fig. 63 Gear Tooth Contact Patterns
JFRONT SUSPENSION AND AXLE 2 - 47

Page 100 of 2158

JEEP YJ 1995 Service And Repair Manual Fig. 64 Typical Housing Cover With Sealant
2 - 48 FRONT SUSPENSION AND AXLEJ

Page 101 of 2158

JEEP YJ 1995 Service And Repair Manual AXLE SPECIFICATIONS
MODEL 30 FRONT AXLE
Axle Type........................................................Hypoid
Lubricant................SAE Thermally Stable 80W-90
Lube Capacity
YJ ..................

AXLE SPECIFICATIONS
MODEL 30 FRONT AXLE
Axle Type........................................................Hypoid
Lubricant................SAE Thermally Stable 80W-90
Lube Capacity
YJ .....................................................1.65 L (3.76 pts.)
XJ .....................................................1.48 L (3.13 pts.)
Axle Ratio...................................3.07 3.55 3.73 4.10
DifferentialSide Gear Clearance .0.12-0.20mm (0.005-0.008 in.)
Ring Gear
Diameter .....................................18.09 cm (7.125 in.)
Backlash.........................0-0.15 mm (0.005-0.008 in.)
Pinion Std. Depth...................92.1 mm (3.625 in.)
Pinion Bearing Preload
Original Bearing ..................1-2 Nzm (10-20 in. lbs.)
New Bearing ......................1.5-4 Nzm (15-35 in. lbs.)
TORQUE SPECIFICATIONS
XJ FRONT SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Nut ......................................11 Nzm (8 ft. lbs.)
Lower Nut ....................................23 Nzm (17 ft. lbs.)
Suspension Arm Upper
Front Nut .....................................74 Nzm (55 ft. lbs.)
Rear Nut ......................................89 Nzm (66 ft. lbs.)
Suspension Arm Lower
Front and Rear Nut ..................115 Nzm (85 ft. lbs.)
Stabilizer Bar
Clamp Bolt ...................................54 Nzm (40 ft. lbs.)
Link Upper Nut ..........................36 Nzm (27 ft. lbs.)
Link Lower Nut ..........................95 Nzm (70 ft. lbs.)
Track Bar
Ball Stud Nut ..............................81 Nzm (60 ft. lbs.)
Axle Bracket Bolt ......................100 Nzm (74 ft. lbs.)
Track Bar Bracket
Bolts............................................125 Nzm (92 ft. lbs.)
Nut ..............................................100 Nzm (74 ft. lbs.)
Support Bolts ...............................42 Nzm (31 ft. lbs.)
YJ FRONT SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Nut ......................................13 Nzm (9 ft. lbs.)Lower Nut ....................................61 Nzm (45 ft. lbs.)
Stabilizer Bar
Clamp Bolt ...................................41 Nzm (30 ft. lbs.)
Link Nut ......................................61 Nzm (45 ft. lbs.)
Track Bar
Frame Bracket Nut.................142 Nzm (105 ft. lbs.)
Axle Bracket Nut ......................100 Nzm (74 ft. lbs.)
Spring
U-Bolt Nut .................................122 Nzm (90 ft. lbs.)
Front Shackle Bolt ..................135 Nzm (100 ft. lbs.)
Rear Pivot Bolt........................142 Nzm (105 ft. lbs.)
MODEL 30 AXLE
DESCRIPTION ................................................TORQUE
Fill Hole Plug...........................34 Nzm (25 ft. lbs.)
Diff. Cover Bolt........................41 Nzm (30 ft. lbs.)
Bearing Cap Bolt.....................61 Nzm (45 ft. lbs.)
Ring Gear Bolt.............95-122 Nzm (70-90 ft. lbs.)
Shift Motor Bolt.........................11 Nzm (8 ft. lbs.)
Axle Nut.................................237 Nzm (175 ft. lbs.)
Wheel Brg. Bolt......................102 Nzm (75 ft. lbs.)
Lower Ball Stud.....................108 Nzm (80 ft. lbs.)
Upper Ball Stud.....................101 Nzm (75 ft. lbs.)
ABS Sensor Bolt......................11 Nzm (96 in. lbs.)
JFRONT SUSPENSION AND AXLE 2 - 49

Page 102 of 2158

JEEP YJ 1995 Service And Repair Manual REAR SUSPENSION AND AXLES
CONTENTS
page page
8 1/4 AXLE............................ 30
AXLE NOISE/VIBRATION DIAGNOSIS......... 9
AXLE SPECIFICATIONS................... 51
GENERAL INFORMATION..........

REAR SUSPENSION AND AXLES
CONTENTS
page page
8 1/4 AXLE............................ 30
AXLE NOISE/VIBRATION DIAGNOSIS......... 9
AXLE SPECIFICATIONS................... 51
GENERAL INFORMATION.................. 1
MODEL 35 AXLE........................ 13TORQUE SPECIFICATIONS................ 51
TRAC-LOK DIFFERENTIAL................. 45
XJ SUSPENSION......................... 3
YJ SUSPENSION......................... 6
GENERAL INFORMATION
SUSPENSION COMPONENTS
The Jeep rear suspension is comprised of;
²Drive axle
²Leaf springs
²Dual-action shock absorbers
²Track bar (YJ vehicles)
²Stabilizer bar (XJ vehicles)
²Jounce bumpers
The rear suspension design uses semi-elliptic
multi-leaf springs and a solid drive axle. The forward
end of the springs are mounted to the frame rail
hangers through rubber bushings. The bushings iso-
late road noise as the springs move. The rearward
end of the springs are attached to the frame by the
use of shackles. Again the spring and shackles use
rubber bushings to isolate road noise. The shackles
allow the springs to change their length as the vehi-
cle moves over various road conditions. The spring
and axle travel is limited through the use of bumpers
mounted on frame.
All suspension components that use bushings
should be tightened with the vehicle at normal ride
height. If the springs are not at normal ride position,
vehicle ride comfort could be affected. Rubber bush-
ings must never be lubricated.
The springs are attached to the axle pads with U-
bolts and plates. The springs use a center bolt that
holds the spring leafs in position. The bolt is also
used to locate the spring assembly to the axle pad.
Ride control is accomplished through the use of du-
al-action shock absorbers. The shocks dampen the
jounce and rebound as the vehicle travels over vari-
ous road conditions. The top of shock absorbers are
bolted to the frame bracket. The bottom of the shocks
are bolted to the axle bracket.
The stabilizer bar on the XJ is used to minimize
vehicle rear sway during turns. The bar helps the ve-
hicle maintain a flat attitude to the road surface. The
bar extends across the underside of the chassis and
connects to the frame rails. The links are connectedto the axle brackets. All mounting points of the sta-
bilizer bar are isolated by bushings.
The track bar on the YJ is used to minimize rear
axle side-to-side movement. The track bar is attached
to the frame rail bracket and axle bracket and is iso-
lated with bushings.
The jounce bumpers are used to limit the jounce
and rebound travel of the suspension.
AXLES
The Model 35 axle is standard for XJ and YJ vehi-
cles. The 8 1/4 axle is available in XJ vehicles with-
out ABS brakes.
The Model 35 and 8 1/4 axle housings has a cast
iron center section. Two steel axle shaft tubes are
pressed into the differential housing and welded.
It is not necessary to remove the axle from the ve-
hicle for service. A removable differential cover is
provided for routine vehicle service. If the differential
housing is damaged, the complete axle assembly can
be removed.
For complete drive axle assembly removal and in-
stallation refer to Drive Axle Assembly Replacement
in this Group.
IDENTIFICATION
Model 35 axle has the assembly part number and
gear ratio listed on a tag. The tag is attached to the left
side of the housing cover (Fig. 1). Build date identifica-
tion codes on axles are stamped on the axle shaft tube
cover side. The Model 35 axle has a flat housing cover
gasket flange at the outer edge (Fig. 1).
The 8 1/4 axle has the build date code and gear ra-
tio tags attached to the housing cover (Fig. 2). The
housing cover gasket has a rolled gasket flange at
the outer edge (Fig. 2).
²The Model 35 axle has shaft tubes that are 2.625
inch (66.67 mm) in diameter.
²The 8 1/4 axle has axle shaft tubes that are 3.0-
inch (76.2 mm) in diameter.
JREAR SUSPENSION AND AXLES 3 - 1

Page 103 of 2158

JEEP YJ 1995 Service And Repair Manual STANDARD DIFFERENTIAL OPERATION
The differential gear system divides the torque be-
tween the axle shafts. It allows the axle shafts to ro-
tate at different speeds when turning corners.
Each differen

Page 104 of 2158

JEEP YJ 1995 Service And Repair Manual XJ SUSPENSION
INDEX
page page
Leaf Spring............................... 4
Leaf Spring Eye Bushing Replacement.......... 5
Shock Absorber........................... 4Spring and Shock Diagnosis........

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