Page 177 of 2255
Installer C-4308
Installer C-4204
Remover C-4307
Remover D-159
Installer D-187-B
Installer D-191
Installer D-389
Spreader W-129-B
Pilot Studs C-3288-B
3 - 122 REAR AXLE - 286RBIBR/BE
REAR AXLE - 286RBI (Continued)
Page 178 of 2255

AXLE SHAFTS
REMOVAL
(1) Remove the axle shaft flange bolts.
(2) Slide the axle shaft out from the axle tube.
INSTALLATION
(1) Clean the gasket contact surface area on the
flange with an appropriate solvent. Install a new
flange gasket and slide the axle shaft into the tube.
(2) Install the bolts and tighten to 129 N´m (95 ft.
lbs.).
AXLE BEARINGS
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove brake drum.
(3) Remove the axle shaft.
(4) Remove the lock wedge and adjustment nut.
Remove adjustment nut with Socket DD-1241-JD.
(5) Remove the hub assembly. The outer axle bear-
ing will slide out as the hub is being removed.
(6) Drive grease seal and inner bearing out of the
hub with Installer 5064 and Handle C-4171.
(7) Remove bearing cups from the hub with a
brass drift and a hammer.
INSTALLATION
(1) Thoroughly clean both axle bearings and inte-
rior of the hub with an appropriate cleaning solvent.
(2) Install bearing cups with Installer 8153 and
Handle C-4171.
(3) Pack inner and outer bearings with Mopar
wheel bearing grease or equivalent
(4) Apply lubricant to surface area of the bearing
cup.
(5) Install inner axle bearing in the hub.
(6) Install anewbearing grease seal with
Installer 8152 and Handle C-4171.
(7) Inspect bearing and seal contact surfaces on
the axle tube spindle for burrs and/or roughness.
Remove all the rough contact surfaces from the axle
spindle.
CAUTION: Do not let grease seal contact the axle
tube threads during installation.
(8) Carefully slide the hub onto the axle.
(9) Install outer axle bearing.
(10) Install hub bearing adjustment nut with
Socket DD-1241±JD.
(11) Tighten adjustment nut to 163-190 N´m (120-
140 ft. lbs.) while rotating the wheel.(12) Loosen adjustment nut 1/8 of-a-turn to pro-
vide 0.001-inch to 0.010-inch wheel bearing end play.
(13) Tap the locking wedge into the spindle key-
way and adjustment nut.
NOTE: Locate locking wedge in a new position in
the adjustment nut.
(14) Install axle shaft and brake drum.
(15) Install wheel and tire assembly.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the universal joint, pinion yoke, and pin-
ion shaft for installation reference.
(3) Disconnect the propeller shaft from the pinion
yoke. Secure the propeller shaft in an upright posi-
tion to prevent damage to the rear universal joint.
(4) Remove wheel and tire assemblies.
(5) Remove brake calipers to prevent any drag.
The drag may cause a false bearing preload torque
measurement.
(6) Rotate pinion yoke three or four times.
(7) Record the amount of torque necessary to
rotate the pinion gear with an inch pound dial-type
torque wrench.
(8) Hold the yoke with Holder 6719A and remove
the pinion shaft nut and washer.
(9) Remove yoke from the pinion with Remover
C-452 (Fig. 22).
(10) Remove pinion shaft seal with suitable pry
tool or slide-hammer mounted screw.
Fig. 22 Yoke Removal
1 - PINION YOKE
2 - REMOVER
BR/BEREAR AXLE - 286RBI 3 - 123
Page 179 of 2255

INSTALLATION
(1) Clean the seal contact surface in the housing
bore.
(2) Apply a light coating of gear lubricant on the
lip of pinion seal.
(3) Installnewpinion shaft seal with an appropri-
ate Installer.
(4) Position pinion yoke on the end of the shaft
with the reference marks aligned.
(5) Install the yoke with Installer D-191 and Yoke
Holder 6719A (Fig. 23).
(6) Install the pinion yoke washer and nut.
(7) Hold pinion yoke with Yoke Holder 6719A and
tighten shaft nut to 597 N´m (440 ft. lbs.) (Fig. 24).
Rotate pinion shaft several revolutions to ensure the
bearing rollers are seated.
(8) Rotate pinion shaft using an inch pound torque
wrench. Rotating resistance torque should be equal
to the reading recorded, plus a small amount for the
drag the new seal will have (Fig. 25).
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(9) Install propeller shaft with the installation ref-
erence marks aligned.
(10) Install the brake calipers.(11) Add gear lubricant to the differential housing,
if necessary.
Fig. 23 Pinion Yoke Installation
1 - INSTALLER
2 - YOKE HOLDER
Fig. 24 Tightening Pinion Shaft Nut
1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH
Fig. 25 Pinion Rotating Torque
1 -TORQUE WRENCH
2 - PINION YOKE
3 - 124 REAR AXLE - 286RBIBR/BE
PINION SEAL (Continued)
Page 180 of 2255

(12) Install wheel and tire assemblies and lower
the vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove fill hole plug from the differential
housing cover.
(3) Remove differential housing cover and drain
lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove axle shafts.
(6) Note the orientation of the installation refer-
ence letters stamped on the bearing caps and hous-
ing machined sealing surface (Fig. 26).
(7) Remove the differential bearing caps.
(8) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 27).
(9) Install the hold down clamps and tighten the
tool turnbuckle finger-tight.
(10) Install a Pilot Stud C-3288-B at the left side
of the differential housing. Attach dial indicator to
housing pilot stud. Load the indicator plunger
against the opposite side of the housing (Fig. 27) and
zero the indicator.
(11) Spread the housing enough to remove the case
from the housing. Measure the distance with the dial
indicator (Fig. 27).
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could be dis-
torted or damaged.(12) Remove the dial indicator.
(13) Pry the differential case loose from the hous-
ing. To prevent damage, pivot on housing with the
end of the pry bar against spreader (Fig. 28).
Fig. 26 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 27 SPREAD DIFFERENTIAL HOUSING
1 - SPREADER
2 - DIAL INDICATOR
3 - DIFFERENTIAL
4 - DIFFERENTIAL HOUSING
5 - PILOT STUD
Fig. 28 DIFFERENTIAL REMOVAL
1 - DIFFERENTIAL
2-PRYBAR
BR/BEREAR AXLE - 286RBI 3 - 125
PINION SEAL (Continued)
Page 181 of 2255

(14) Remove the case from housing. Tag bearing
cups to indicate their location.
DISASSEMBLY
(1) Remove roll-pin holding mate shaft in housing.
(2) Remove pinion gear mate shaft (Fig. 29).
(3) Rotate differential side gears and remove pin-
ion mate gears and thrust washers (Fig. 30).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft.
(4) Align hole in the pinion gear mate shaft with
hole in the differential case.
(5) Install and seat pinion mate shaft roll-pin in
the differential case and mate shaft with a punch
and hammer (Fig. 31). Peen the edge of the roll-pin
hole in the differential case slightly in two places
180É apart.
(6) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and GearBacklash) procedures to determine proper shim
selection.
Fig. 29 PINION MATE SHAFT
1 - PINION MATE GEAR
2 - PINION MATE SHAFT
3 - SIDE GEAR
4 - DRIFT
Fig. 30 Pinion Mate/Side Gear
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 31 Pinion Mate Shaft Roll-Pin
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
3 - 126 REAR AXLE - 286RBIBR/BE
DIFFERENTIAL (Continued)
Page 182 of 2255

(1) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes. Install the hold
down clamps and tighten the tool turnbuckle finger-
tight.
(2) Install a Pilot Stud C-3288-B at the left side of
the differential housing and attach dial indicator to
the pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the dial indica-
tor.
(3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator.
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could be dis-
torted or damaged.
(4) Remove the dial indicator.
(5) Install differential into the housing. Tap the
differential case with a rawhide/rubber hammer to
ensure the bearings are seated in housing (Fig. 32).
(6) Remove the spreader.
(7) Install bearing caps in their original locations
(Fig. 33) and tighten bearing cap bolts in a criss-
cross pattern to 109 N´m (80 ft. lbs.).
(8) Install axle shafts.
(9) Install the hub bearings.
(10) Apply a bead of red Mopar Silicone Rubber
Sealant or equivalent to the housing cover (Fig. 34).CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied or adhesion quality will be compro-
mised.
(11) Install the cover and tighten bolts in a criss-
cross pattern to 47 N´m (35 ft. lbs.).
Fig. 32 DIFFERENTIAL CASE
1 - RAWHIDE HAMMER
Fig. 33 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 34 DIFFERENTIAL COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
BR/BEREAR AXLE - 286RBI 3 - 127
DIFFERENTIAL (Continued)
Page 183 of 2255

(12) Fill the differential with Mopar Hypoid Gear
Lubricant or equivalent to bottom of the fill plug
hole.
(13) Install fill hole plug and tighten to 34 N´m (25
ft. lbs.).
(14) Remove support and lower vehicle.
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT
The most common problem is a chatter noise when
turning corners. Before removing a Trac-lokŸ unit
for repair, drain, flush and refill the axle with the
specified lubricant. A container of Mopar Trac-lokŸ
Lubricant (friction modifier) should be added after
repair service or during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. This
will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque.
(6) If rotating torque is less than 22 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
The Trac-Loktdifferential on this axle has a one-
piece cross shaft and uses one dished disc, regular 5
disc and 7 plates.
NOTE: Pay attention to the clutch pack arrangement
during disassembly. Note the direction of the con-
cave and convex side of the plates and discs.
(1) Mark the ring gear half and cover half for
installation reference (Fig. 35).
(2) Remove case attaching bolts and remove the
button cover half (Fig. 36).
(3) Remove top clutch pack.
(4) Remove top side gear clutch ring.(5) Remove top side gear.
(6) Remove pinion mate gears and cross shaft.
(7) Remove the same parts listed above from the
ring gear flange half of the case. Keep these parts
Fig. 35 CASE MARKED
1 - REFERENCE MARKS
Fig. 36 COVER HALF REMOVAL
1 - CLUTCH PLATES
2 - BUTTON HALF
3 - FLANGE HALF
3 - 128 REAR AXLE - 286RBIBR/BE
DIFFERENTIAL (Continued)
Page 184 of 2255

with the flange cover half for installation in their
original positions.
ASSEMBLY
The Trac-Loktdifferential for this axle has a one-
piece cross shaft and uses one dished disc, 5 regular
disc and 7 plates for each clutch pack.
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubricate each component with gear lube before
assembly and installation.
(1) Saturate the clutch plates with Mopar Hypoid
Gear Lubricant or Additive.
(2) Assembly the discs and plates on the side gear
(Fig. 37) in the following order.
(a) Install dished disc on side gear.
(b) Install one disc on side gear.
(c) Install one plate on side gear.
(d) Install one disc on side gear.
(e) Install one plate on side gear.
(f) Install three discs on side gear.
(g) Install five plates on side gear.
(3) Line up the plate ears and install the assem-
bled pack into the flange half (Fig. 38). Verify clutch
plate lugs enter the slots in the case and clutch pack
bottoms out in the case.(4) Install pinion mate shafts and pinion mate
gears (Fig. 39).Verify shafts are correctly
installed according to the alignment marks.
(5) Lubricate and install the other side gear and
clutch pack (Fig. 38).
(6) Correctly align and assemble button half to
flange half. Install case body screws finger tight.
(7) Tighten body screws alternately and evenly to
122-136 N´m (90-100 ft. lbs.) (Fig. 40).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from the housing.
(2) Remove bearings from the differential case
with bridge and bearing splitter (Fig. 41).
INSTALLATION
(1) Install differential bearings with Installer
C-4190 and Handle C-4171 (Fig. 42).
(2) Install differential in the housing.
Fig. 37 CLUTCH PACK ASSEMBLY
1 - CLUTCH PLATES
2 - SIDE GEAR
3 - CLUTCH RING
Fig. 38 CLUTCH PACK
1 - LUGS
2 - FLANGE HALF
3 - SIDE GEAR
BR/BEREAR AXLE - 286RBI 3 - 129
DIFFERENTIAL - TRAC-LOK (Continued)