REMOVAL
(1) Raise and support the vehicle.
(2) Position an axle lift under the axle and secure
it to the axle.
(3) Remove the wheels and tires.
(4) Remove RWAL sensor from the differential
housing, if necessary.
(5) Remove brake hose from the axle junction
block.
(6) Disconnect parking brake cables and cable
brackets.
(7) Remove vent hose from the axle shaft tube.
(8) Mark propeller shaft and yoke for installation
alignment reference.
(9) Remove propeller shaft.
(10) Remove shock absorbers from the axle brack-
ets.
(11) Remove spring clamps and spring brackets.
(12) Remove axle from the vehicle.
INSTALLATION
(1) Raise axle with lift and align to the leaf spring
centering bolts.
(2) Install spring clamps and spring brackets.
(3) Install shock absorbers and tighten to specifica-
tions.
(4) Install RWAL sensor to the differential hous-
ing, if necessary.
(5) Install parking brake cables and cable brackets
(6) Install brake hose to the axle junction block.
(7) Install axle vent hose.
(8) Install propeller shaft with reference marks
aligned.
(9) Install wheels and tires assemblies.
(10) Add gear lubricant, if necessary.
(11) Remove lift from the axle and lower the vehi-
cle.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
4). A plus (+) number, minus (±) number or zero (0) is
etched into the face of the pinion gear. This number
is the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched with a (0). The standard setting from the cen-
ter line of the ring gear to the back face of the pinion
is 127 mm (5.00 in.). The standard depth provides
the best gear tooth contact pattern. Refer to Back-
lash and Contact Pattern in this section for addi-
tional information.
Compensation for pinion depth variance is
achieved with a select shim. The shims are placed
between the rear pinion bearing and the pinion gear
head (Fig. 5).If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Depth Variance chart.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.
Fig. 4 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 5 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
BR/BEREAR AXLE - 248RBI 3 - 51
REAR AXLE - 248RBI (Continued)
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.
Use Socket DD-1241±JD to remove the adjustment
nut.
(5) Remove the hub assembly. The outer axle bear-
ing will slide out as the hub is being removed.
(6) Remove inner grease seal and discard. Use
Installer 5064 and Handle C-4171 to drive grease
seal and inner axle bearing from the hub.
(7) Remove the bearing cups from the hub bore.
Use a brass drift, or an appropriate removal tool, to
tap out the cups.
INSTALLATION
(1) Thoroughly clean both axle bearings and inte-
rior of the hub with an appropriate cleaning solvent.
(2) Install bearing cups with Installer 8151 and
Handle C-4171.
(3)Pack inner and outer bearings with
Mopar wheel bearing grease or equivalent.
(4) Apply grease to inner and outer bearing cup
surfaces.
(5) Install inner axle bearing in the hub.
(6) Installnewgrease seal in hub with Installer
8149 and Handle C-4171.
(7) Inspect bearing and seal contact surfaces on
the axle tube for burrs/roughness. Remove all the
rough contact surfaces from the axle tube.
(8) Carefully slide the hub onto the axle.
CAUTION: Do not let grease seal contact axle tube
threads during installtion.
(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. Then loosen
adjustment nut 1/8 to 1/3 of-a-turn to provide 0.025-
0.250mm (0.001-0.009 in.) wheel bearing end play.
(12) Tap locking wedge into the spindle keyway
and adjustment nut.
NOTE: Located locking wedge in a new position in
the adjustment nut.
(13) Install axle shaft and brake drum.
(14) Install the wheel and tire assembly.
Trac-lok Tools C-4487
Gauge Set 6730
Arbor Discs 6732
3 - 62 REAR AXLE - 248RBIBR/BE
REAR AXLE - 248RBI (Continued)
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark universal joint, pinion yoke and shaft for
installation reference.
(3) Disconnect the propeller shaft from the pinion
yoke.
(4) Remove the wheel and tire assemblies.
(5) Remove brake calipers to prevent any drag
that may cause a false bearing preload torque mea-
surement.
(6) Rotate pinion yoke three or four times.
(7) Record pinion gear rotating torque with an
inch pound torque wrench (Fig. 22).
(8) Hold yoke with Yoke Holder 6719A and remove
the pinion shaft nut and washer.
(9) Remove yoke with Remover C-452 (Fig. 23).
(10) Remove pinion seal with pry tool or slide-
hammer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Installnewpinion seal with an aproppriate
installer (Fig. 24).
(3) Install yoke on pinion shaft with Installer
C-3718 and Yoke Holder 6719.(4) Install pinion yoke washer with theconcave
surfaceagainst the yoke end.
(5) Installnewpinion nut.
CAUTION: Never exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer, if
equipped, or bearings may result.
(6) Hold pinion yoke with Yoke Holder 6719 and
tighten shaft nut to 291.5 N´m (215 ft. lbs.) (Fig. 25).
Rotate pinion shaft several revolutions to ensure the
bearing rollers are seated.
(7) Rotate pinion shaft with a inch pound torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal, plus an additional 0.56
N´m (5 in. lbs.) (Fig. 26).
Fig. 22 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 23 PINION YOKE REMOVER
1 - PINION YOKE
2 - REMOVER
Fig. 24 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
BR/BEREAR AXLE - 248RBI 3 - 63
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new pin-ion nut and collapsible spacer, if equipped, must be
installed.
(8) If rotating torque is low, use Yoke Holder 6719
to hold the pinion yoke (Fig. 25) and tighten the pin-
ion shaft nut in 6.8 N´m (5 ft. lbs.) increments until
proper rotating torque is achieved.
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 reference marks
aligned.
(10) Add gear lubricant to the differential housing,
if necessary.
(11) Install wheel and tire assemblies and lower
the vehicle.
(12)
Pump the brake pedal before moving 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. 27).
Fig. 25 TIGHTEN PINION NUT
1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH
Fig. 26 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 27 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
3 - 64 REAR AXLE - 248RBIBR/BE
PINION SEAL (Continued)
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.).
(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 the unit for repair,
drain, flush and refill the axle with the specified
lubricant. A container of Mopar Trac-loktLubricant
(friction modifier) should be added after repair ser-
vice 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.
Fig. 33 DIFFERENTIAL CASE
1 - RAWHIDE HAMMER
Fig. 34 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 35 DIFFERENTIAL COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
BR/BEREAR AXLE - 248RBI 3 - 67
DIFFERENTIAL (Continued)
(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 (Fig. 36).
(6) If rotating torque is less than 41 N´m (56 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp side gear Holding Fixture 6965 in a vise
and position the differential case on the Holding Fix-
ture (Fig. 37).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-loktdifferential can be serviced
with the ring gear installed.
(3) Remove pinion gear mate shaft roll pin.
(4) Remove pinion gear mate shaft with a drift and
hammer.
(5) Install and lubricate Step Plate C-6960-3 (Fig.
38).
Fig. 36 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 37 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 38 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
3 - 68 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL - TRAC-LOK (Continued)
REAR AXLE - 267RBI
TABLE OF CONTENTS
page page
REAR AXLE - 267RBI
DESCRIPTION.........................78
OPERATION...........................78
DIAGNOSIS AND TESTING - AXLE..........80
REMOVAL.............................82
INSTALLATION.........................82
ADJUSTMENTS........................83
SPECIFICATIONS
REAR AXLE - 267RBI..................91
SPECIAL TOOLS
REAR AXLE - 267RBI..................91
AXLE SHAFTS
REMOVAL.............................94
INSTALLATION.........................94
AXLE BEARINGS
REMOVAL.............................94
INSTALLATION.........................94
PINION SEAL
REMOVAL.............................94INSTALLATION.........................95
DIFFERENTIAL
REMOVAL.............................96
DISASSEMBLY.........................97
ASSEMBLY............................97
INSTALLATION.........................97
DIFFERENTIAL - POWR-LOK
DIAGNOSIS AND TESTING - POWR-LOKT....99
DISASSEMBLY.........................99
ASSEMBLY............................99
DIFFERENTIAL CASE BEARINGS
REMOVAL............................102
INSTALLATION........................102
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................103
INSTALLATION........................104
REAR AXLE - 267RBI
DESCRIPTION
The Rear Beam-design Iron (RBI) axle housings
consist of an iron center casting (differential housing)
with axle shaft tubes extending from either side. The
tubes are pressed into the differential housing and
welded. The axles are full-floating axle shafts, sup-
ported by the axle housing tubes. The full-float shafts
are retained by bolts attached to the hub.
The differential case for the standard differential is
a one-piece design. Differential bearing preload and
ring gear backlash are adjusted by the use of shims
located between the differential bearing cones and
case. Pinion bearing preload is set and maintained by
the use of a solid shims. The differential cover pro-
vides a means for inspection and service.
Axles equipped with a Powr-loktdifferential are
optional. The differential has a two-piece differentialcase. The differential contains four pinion gears and
a two-piece pinion mate cross shaft to provide
increased torque to the non-slipping wheel through a
ramping motion in addition to the standard Trac-lokt
components.
OPERATION
STANDARD DIFFERENTIAL
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
through the pinion mate and side gears. The side
gears are splined to the axle shafts.
3 - 78 REAR AXLE - 267RBIBR/BE
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
2). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
POWR-LOKTDIFFERENTIAL
The differential clutches are engaged by two con-
current forces. The first being the preload force
exerted through Belleville spring washers within the
clutch packs. The second is the separating forces gen-
erated by the side gears as torque is applied through
the ring gear (Fig. 3).
This design provide the differential action needed
for turning corners and for driving straight ahead
during periods of unequal traction. When one wheel
looses traction, the clutch packs transfer additional
torque to the wheel having the most traction. The
Powr-loktdifferential additionally utilizes a ramping
action supplied by the cross shafts to increase the
force applied to the clutch packs to increase the
Fig. 1 Differential Operation - Straight Ahead Driving
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 2 Differential Operation - On Turns
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 3 Powr-LokTLimited Slip Differential
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
BR/BEREAR AXLE - 267RBI 3 - 79
REAR AXLE - 267RBI (Continued)