Diagnosis And Testing - Front Axle - 216FBI: Notes

WARNING: This page is about a different car, the 2016 Jeep Wrangler and 2015 Jeep Wrangler. However, it is still accessible from the selected car via links, so may be relevant.

DIAGNOSTIC CHART

Condition	Possible Causes	Correction
Wheel Noise	1. Wheel loose.	1. Tighten loose nuts.
Wheel Noise	2. Faulty, brinelled wheel bearing.	2. Replace bearing.
Axle Shaft Noise	1. Misaligned axle tube.	1. Inspect axle tube alignment. Correct as necessary.
	2. Bent or sprung axle shaft.	2. Inspect and correct as necessary.
	3. End play in pinion bearings.	3. Refer to pinion pre-load information and correct as necessary.
	4. Excessive ring and pinion gear backlash.	4. Check and adjustment ring and pinion gear backlash.
	5. Improper pinion bearing adjustments.	5. Adjust the pinion bearings pre-load.
	6. Loose pinion flange nut.	6. Tighten pinion flange nut to specifications.
	7. Scuffed gear tooth contact surfaces.	7. Inspect and replace as necessary.
Axle Shaft Broke	1. Misaligned axle tube.	1. Replace broken shaft after correcting tube mis-alignment.
	2 Vehicle overloaded.	2. Replace broken shaft and avoid excessive weight on vehicle.
	3. Erratic clutch operation.	3. Replace broken shaft and avoid or correct erratic clutch operation.
	4. Grabbing clutch.	4. Replace broken shaft and inspect and repair clutch as necessary.
Differential Cracked	1. Improper differential bearing adjustment.	1. Replace case, inspect gears and bearings for further damage. Set differential bearing pre-load properly.
	2. Excessive ring gear backlash.	2. Replace case and inspect gears and bearings for further damage. Set ring gear backlash.
	3. Vehicle overloaded.	3. Replace case and inspect gears and bearings for further damage. Avoid excessive vehicle weight.
	4. Erratic clutch operation.	4. Replace case and inspect gears and bearings for further damage. Avoid erratic use of clutch.
Differential Gears Scored	1. Insufficient lubrication.	1. Replace scored gears. Fill differential with the correct fluid type and quantity.
	2. Improper grade of lubricant.	2. Replace scored gears. Fill differential with the correct fluid type and quantity.
	3. Excessive spinning of one wheel/tire.	3. Replace scored gears. Inspect all gears, pinion bores, and shaft for damage. Service as necessary.
Loss Of Lubricant	1. Lubricant level too high.	1. Drain lubricant to the correct level.
	2. Worn axle shaft seals.	2. Replace seals.
	3. Cracked differential housing.	3. Repair as necessary.
	4. Worn pinion seal.	4. Replace seal.
	5. Worn/scored flange.	5. Replace flange and seal.
	6. Differential cover not sealed.	6. Remove, clean, and seal cover.
Axle Overheating	1. Lubricant level low.	1. Fill differential to correct level.
	2. Improper grade of lubricant.	2. Fill differential with the correct fluid type and quantity.
	3. Bearing pre-loads too high.	3. Adjust bearing pre-loads.
	4. Insufficient ring gear backlash.	4. Adjust ring gear backlash.
Gear Teeth Broke	1. Overloading.	1. Replace gears. Examine other gears and bearings for possible damage.
	2. Erratic clutch operation.	2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation.
	3. Ice-spotted pavement.	3. Replace gears and examine remaining parts for damage.
	4. Improper adjustments.	4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct.
Axle Noise	1. Insufficient lubricant.	1. Fill differential with the correct fluid type and quantity.
	2. Improper ring and pinion gear adjustment.	2. Check ring and pinion gear contact pattern.
	3. Unmatched ring gear and pinion.	3. Replace gears with a matched ring gear and pinion.
	4. Worn teeth on ring and pinion gears.	4. Replace ring and pinion gears.
	5. Loose pinion bearings.	5. Adjust pinion bearing pre-load.
	6. Loose differential bearings.	6. Adjust differential bearing pre-load.
	7. Loose or sprung ring gear.	7. Measure ring gear run-out. Replace components as necessary.
	8. Loose differential bearing cap bolts.	8. Inspect differential components and replace as necessary. Ensure bearing caps are torqued to the proper specification. Refer to SPECIFICATIONS .
	9. Housing not machined properly.	9. Replace housing.