Hey guys new to the forum but you guys have helped me many times from me browsing.i recently purchased my first jeep (xj 96) and when i put it in 4x4i have a loud whining sound coming from the front that gets louder with speed.before i get posts telling me to do this i already replaced front diff fluid with 75-140 lucas (has friction modifiers)and the transfer case with dexron 3.the gears up fron r look good no chips marks so im asuming punion bearings.anyone that has a write up please let me know.

 

The process is so complicated, I say try to find a reputable mechanic to do it at reasonable price. You could try to just replace the bearings only (not the races) and hope the pinion depth/backlash do not change, but you will still need to then set the preload. This is still a major amount of work, and if it is wrong, will have to be done again.

Or you could try to find a used axle housing and swap it in.

 

I know in in for a task and i have done my homework online too.i am mechamically enclined i have always done my own work plus im a machinist so i have micrometers to measure spacers and a dial indicator that reads as low as 1/10 of one thousandth for measuring backlash.along with a torque wrench that goes up to 200ft pounds that i will need for the back nut.and a 20 ton press sitting in the garage so im all set just searching for a write up if there is one on here

 

Bleepin jeep on you tube has some good vids maybe check him out
i dont know if he has one doing a ring and pinion tho...

 

This guy explains it pretty well.

http://www.jeepforum.com/forum/f8/cj...art-i-1121189/

I also recommend getting the FSM.

So you have to take off the diff cover, let it drain, pull the axle shafts, undo the carrier caps (make sure to take note of the side and position as they have to be put back the same way), then remove the carrier.

Now disconnect the drive shaft from the yoke, remove pinion nut, pull the yoke, tap on the pinion to push it out towards the front (be ready to catch it on the other end in case it pops out) making sure to take note of all the washers, slingers and preload shims that are on the pinion. Take pictures, lots of picture. Now you should have the outer bearing left behind in the housing and the inner bearing on the pinion head.

See the link above on how to replace the bearing, set depth, backlash and preload.

Check backlash before taking it apart, and if you want to match pattern, you can paint it yellow and see the pattern before taking it apart (take pictures of the pattern so you can try to match when putting it back together).

Patience is key here. Good luck.