That being said, here's a general overview of the process. This is NOT a complete, step-by-step instruction manual. You'll need a detailed repair manual specific to your 1994 Jeep Wrangler's axle type (Dana 30 front, Dana 35 rear are common, but there might be variations).
1. Preparation:
* Gather Tools and Parts: You'll need a complete set of differential installation tools including a gear setup tool, a torque wrench, a bearing packer, a dial indicator, and various sockets, wrenches, and other hand tools. You'll also need the new 4.10 gears, shims, bearings, seals, and any other necessary replacement parts. A good quality repair manual is crucial.
* Safety First: Jack up the Jeep securely and support it on jack stands. Disconnect the battery's negative terminal. Wear safety glasses and gloves.
* Determine Axle Type: Identify the specific type of differentials you have (Dana 30, Dana 35, etc.) to ensure you get the correct parts.
2. Differential Removal:
* Drain the Differential: Drain the gear oil from the differential housing.
* Disconnect Driveshaft(s): Disconnect the driveshaft(s) from the differential.
* Remove Brake Components: Remove the brake calipers and rotors (if necessary depending on access).
* Remove Axle Housing: Remove the axle housing bolts and carefully lower the axle housing. This often requires separating the axle shafts from the differential.
* Remove Differential: Once the axle housing is removed, you'll need to remove the differential from the housing. This involves removing the carrier retaining bolts.
3. Gear Installation:
* Setup the Gears: This is the most crucial and delicate part of the process. You'll need to use the gear setup tool and a dial indicator to precisely measure the backlash and mesh pattern of the ring and pinion gears. Incorrect setup will result in premature gear wear and failure. This requires patience and precision. The manual is your guide.
* Install Bearings and Seals: Install new bearings and seals in the differential carrier and axle shafts.
* Install Shims: Carefully install the correct shims to achieve proper gear mesh. This is determined by the measurements taken during the setup process.
* Assemble the Differential: Assemble the differential carrier, gears, and bearings according to your repair manual.
4. Reinstallation:
* Install Differential: Carefully reinstall the differential into the axle housing.
* Reinstall Axle Housing: Reinstall the axle housing and secure it with bolts, torqued to specifications.
* Reconnect Driveshaft(s): Reconnect the driveshaft(s).
* Reconnect Brake Components: Reinstall the brake calipers and rotors.
* Refill with Gear Oil: Fill the differential with the correct type and amount of gear oil.
5. Verification:
* Check for Leaks: Inspect for any leaks after reinstalling everything.
* Test Drive: Carefully test drive the vehicle to ensure proper operation. Listen for any unusual noises.
Important Considerations:
* Professional Installation: Again, this is a complex process. Unless you have significant experience with differential work, professional installation is highly recommended. The cost of a professional installation will be far less than the cost of replacing a damaged differential.
* Parts Quality: Use high-quality parts from a reputable supplier. Cheap parts can lead to premature failure.
* Torque Specifications: Strictly adhere to the torque specifications outlined in your repair manual.
This is a vastly simplified overview. Obtain a detailed repair manual for your specific year and model Jeep Wrangler before attempting this. Improper installation can lead to serious damage and potential injury. Safety first!
