Jeep Wrangler/YJ 1987-1995 Repair Guide

Pinion Seal and Yoke

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REMOVAL & INSTALLATION



1987-90 Models

See Figures 1, 2, 3 and 4

  1. Raise and safely support the front end on jackstands.
  2.  
  3. Matchmark and disconnect the driveshaft from the yoke.
  4.  
  5. Using a yoke holding tool, such as J-8614-01, or its equivalent on the yoke, and remove the pinion nut.
  6.  
  7. Remove the yoke, using tools J-8614-01, -02, and -03, or their equivalents.
  8.  
  9. Using tool seal removal tool -25180, or its equivalent, remove the seal.
  10.  
  11. Coat the new seal's outer rim with sealer, then install it using a driver.
  12.  
  13. Install the yoke, pinion washer and a new pinion nut. Torque the nut to 210 ft. lbs. (285 Nm).
  14.  
  15. Connect the driveshaft, then check and refill the differential housing fluid as necessary.
  16.  



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Fig. Fig. 1: Yoke retaining nut removal-1987-90



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Fig. Fig. 2: Yoke removal-1987-90



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Fig. Fig. 3: Drive pinion gear shaft seal removal-1987-90



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Fig. Fig. 4: Drive pinion gear shaft seal installation-1987-90

1991-95 Models

See Figures 5, 6, 7 and 8

  1. Raise and support the vehicle safely.
  2.  
  3. Matchmark and remove the driveshaft.
  4.  
  5. Rotate the pinion gear three or four times with a torque wrench attached to the yoke nut. Measure the amount of torque necessary to rotate the pinion. Note for installation reference.
  6.  
  7. Matchmark the pinion yoke and gear for installation reference.
  8.  
  9. Using a holding tool, remove the pinion yoke nut and washer. Discard the nut.
  10.  
  11. Punch the seal with a pin punch and pry it from the seal bore.
  12.  

To install:
  1. Apply gear lubricant to the lip of the replacement seal and install using a seal installation tool.
  2.  
  3. Install the yoke, noting the reference marks. Tighten just enough to remove the end-play.
  4.  
  5. Set bearing preload as follows:
    1. The required pinion gear bearing preload torque is 6 inch lbs. (0.7 Nm) over the noted release torque as measured above.
    2.  
    3. Rotate the pinion gear three or four times with a torque wrench attached to the yoke nut. Measure the amount of torque necessary to rotate the pinion.
    4.  
    5. Using a holding tool and tighten the yoke nut in small increments and remeasure until the specified torque is obtained.
    6.  

  6.  
  7. Install the driveshaft. Torque the strap bolt nuts to 14 ft. lbs. (19 Nm).
  8.  

New strap bolts be used whenever the driveshaft is disconnected.

  1. Add lubricant if necessary. Lower vehicle.
  2.  



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Fig. Fig. 5: Yoke retaining nut removal-1991-95



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Fig. Fig. 6: Pinion seal removal-1991-95



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Fig. Fig. 7: Pinion seal installation-1991-95



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Fig. Fig. 8: Tightening the pinion shaft nut-1991-95

 
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