Jeep UNIVERSAL CJ-2A - Page 210

'Jeep' UNIVERSAL and ' Jeep' DISPATCHER
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FIG. 265- PLATE ASSEMBLY ORDER
A- Towa rd Ca se
1- Be llv i ll e P late
2- Bellv i ll c Friction Di sc
3- Diff e rentia l C lu tch Fric ti on Plate
4- DifTer cntiol Clut ch Fri c ti o n Di sc
e. Clean all parts t horoughly in kerosene and dry
wit h compressed air . Inspect all parts and re place
any i tems which appea r to be worn or damaged.
Inspe ct the plate surfaces of the case halves, the
s ide gear ri ngs, and t he clutch plates and discs for
exces sive wear and scoring . Inspect the pinion
mate shaft V - surfaces, and the r amp surfaces, on
the case for excessive wear and pitting . Inspect
the side gear and pinion gear teeth. Inspect the
pinion gear races that bear on the side gear rings.
Inspect the corresponding surfaces on the side gear
rings. Inspec t the clutch plates and discs for cracks
and distortion .
In the event one or more of the clutch plates or
discs needs replacing, replace the entire st ac k of
plates and discs on each side of the pinions . These
st a cks are suppli ed in sets. Each set contains pl ates
and dis cs for one differential.
The differential case ha lv es are not servic ed .
Should replacemen t be required it will be necessary
to replace the complete differen tia l.
f. A ssemble the clutch fric t ion plates, clutch fric-
tion discs, a nd dished plates on the splined hub
of each bevel s ide gear. Make sure the plates and
discs are install ed a ccording to their ori g inal ar-
rangement, or Fig. 265 if t he new plate and disc
set is used. The dished plates in t he pl ate and di sc
set, are always assembled with the convex side
toward the case. As each par t is reassembled in its
proper position, it is neces sary that it be lightly
coated with Je ep " Powr-Lok " Differential Oil,
Part No . 94557.
g. Axle shaft spacers are installed at the center
of the cros s shaft pinion mate on all rea r P ow r -Lok
diff erent ials . On e spacer is installed from each side
by pres sin g it on to an axle shaft spacer pin whic h
is
first placed in the hole at the center of the cross
shaft pi ni on mate. During any axle repa ir which
req uir es removal of the axle sha ft or shafts, be
sure the axle sh aft spacers are in place b efore t he
shaft or sh afts are re in sta lled .
h . Hold each differe ntial case half on i ts side, and
install the s id e gear rings wit h t he plates an d discs
assemb l ed. The side gear ring will r otate with a
sli
ght drag when pro p er ly l ocated in the case .
i. Wi th th e ring gear flange half of the differential
case in an upright position, asse mb le the bevel
si de gears , pini on mate cro ss sh afts, and beve l
pinion mate gears. I nst all the remaining case half
on the ring gear flange half. M ake sure that all
markings coincide.
j . Insta ll t he diff erent i al case bolts a nd turn them
in a few t hr eads. Using axle shafts from the vehicle,
align the splinel' of the si de gea r and the s ide gea r
ring.
Wi th th ese ax le shafts in position, tig h ten the
differential case . bolts even ly and a dequat ely
torque to 35 to 45 lb - ft . [ 4,84 a 6,22 kg -m. ). R emo ve
the
axle shafts.
k. Check for proper assembly . E ach pin ion m ate
cross shaft can be tight on i ts ramp or, in the event
the re is clea r ance be t ween the cross shaft and
the ramp, the clearance should be on ly a f ew
thousandths of an i nch and it should be e qu al to
all four cross shaft end s.
I. R e in stall the unit in the axle. Other service
operatio n s, suc h as ring gear an d pinion replace-
ment, or pinion and bearing adjustments, are
pe rf ormed in the same m anne r prescribed for
standa rd ax les ea rli er in t his section.
N- 20. TROUBLE SHOOTING
N- 21. Troub le Shoo tin g Pow r-L ok
Note : Extr eme care must be exercised, on a
P
ow r- Lok e quipp ed vehicle, to be sure the trans-
mission is in t he neutral position whenever the
engine is started with on e wh ee l jac ked up . O ther-
wise inertia forces in the wheel may acuate the
diff ere ntial caus ing the ve hicle to lu r ch unex·
pectly and fall off the jack.
If trouble is expe rie nced with the ope r at i on of a
Po wr- Lok differential, one or more of t hr ee possible
cond i tions probably exists . Thes e cond it ions and
their remedies are discuss ed in Par. N-21A, N -2 1 D,
N -2 1E.
N-2 1A . Po wr -L ok Torq ue T es ts
Impr oper operation due to inadequate torqu e ma y
be determined by two different tests . T e ~ t O ne is
for Powr -L ok differentials known to ha ve dis h ed
plates; Test Two is for a ny Powr -Lok dilfe ren tial,
but T es t One is re comm ended if the u ni t I as di she d
plates . These tests are described in th e follow in g
two par ag r ap hs .
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