JEEP CHEROKEE 1988 Service Repair Manual

Inspect bearings and races for wear and pitting. Replace bearing and
race together.
INSTALLATION
1) Install axle shaft through knuckle and engage in axle gear
splines. Pack bearings with multi-purpose grease and fill cavities in
bearing hub. Install new seals.
2) Press hub into bearings. Install hub assembly on axle
shaft and install bolts. To complete installation, reverse removal
procedure. See TORQUE SPECIFICATIONS table at end of this article.
INTERMEDIATE AXLE SHAFT R & I
REMOVAL (DISCONNECT AXLE MODELS)
1) Remove outer axle. See FRONT HUB, BEARING, SPINDLE & AXLE
SHAFT in this article.
2) Remove axle assembly inspection cover and drain fluid.
Remove vacuum and electrical connections at disconnect housing
assembly. Remove bolts and pull disconnect housing from axle tube. See
Fig. 1 .
3) Remove intermediate shaft retaining clip on inner end of
axle shaft. Carefully slide intermediate axle shaft through seal and
out end of axle tube. Remove shift collar.
4) Inspect intermediate shaft bearings and seals for wear. If
replacement of bearings or seal is necessary, use recommended tools.
5) On Jeep, use Tool Set (J-34659), Slide Adapter (J-34659-\
4)
and Over Rod (J-34659-3) to replace intermediate shaft bearings and
seal.
Fig. 1: View Of Axle Disconnect Assembly
Courtesy of Chrysler Motors.
INSTALLATION

1) Coat intermediate shaft with lubricant and carefully slide
through seal and engage in drive axle splines. Install retaining clip.
2) Install shift collar on axle shaft. Install outer axle
shaft and check for smooth operation of shift collar.
3) Apply bead of silicone sealer to inspection cover and
install cover. Fill axle housing with 2.5 pts. (1.2L) of 75W 90 gear
oil. Pour a small amount of gear oil on shift collar and install
disconnect housing. Ensure shifting fork is properly positioned in
shift collar.
4) To complete installation, reverse removal procedure.
Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS
table at end of this article.
FRONT AXLE ASSEMBLY R & I
REMOVAL (CHEROKEE, COMANCHE, WAGONEER)
1) Raise and support vehicle. Remove tire and wheel assembly.
Remove hubs, spindles and axles. See FRONT HUB, BEARING, SPINDLE &
AXLE SHAFT in this article.
2) Disconnect vacuum hoses and electrical connections from
shift motor. Disconnect stabilizer bar, track bar and steering damper.
3) Disconnect drive shaft at pinion yoke and tie to frame.
Remove left and right tie rod ends from knuckles.
4) Support axle assembly on floor jack. Remove lower shock
mounts. Disconnect axle housing-to-frame control arms at axle. Lower
floor jack slowly and remove axle assembly. Remove coil spring lower
bracket and coil spring.
INSTALLATION
1) Place axle housing on floor jack and position under
vehicle. Install coil springs and raise assembly into position. Ensure
top of coil springs seat in spring pocket.
2) Check all bushings and mounting hardware for wear or
damage. To complete installation, reverse removal procedure. Tighten
all bolts and nuts to specification. See TORQUE SPECIFICATIONS table
at end of this article. Fill axle assembly with gear oil. Check wheel
alignment.
REAR HUB, BEARINGS & AXLE SHAFTS R & I
1) Raise and support vehicle. Remove tire and wheel assembly.
Remove axle flange nuts or bolts. If nuts are used, rap center of axle
flange sharply with hammer to loosen tapered dowels. Remove bolts or
dowels and pull axle shaft out of hub.
2) Depending on application, bend back ears of lock washer,
or remove locking wedge from nut, or remove snap ring and key. Remove
bearing adjusting nut(s) and remove hub assembly.
3) Remove inner hub seal and bearing. Inspect bearings and
races for wear. To replace bearing, drive outer race from bearing hub
using a punch and hammer. Install new race being careful not to chip
or dent race. Ensure new race is seated in hub.
4) Pack bearings with multi-purpose grease. Install new seal.
Carefully install hub on axle spindle to avoid damaging seal lip and
spindle threads.
5) Install outer bearing and adjusting nut. Tighten bearing
adjusting nut in steps. See REAR HUB BEARING ADJUSTING SPECIFICATIONS
table. Install lock ring if used. Install spindle lock nut if used and
tighten to proper specification. See REAR HUB BEARING ADJUSTING
SPECIFICATIONS table.

REAR HUB BEARING ADJUSTING SPECIFICATIONS








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Application ( 1) Ft. Lbs. (N.m)
Adjusting Nut
Step 1 ............................... 50 (68)
Step 2 .......................... Back Off 45

Lock Nut ............................... 50 (68)
( 1) - While rotating hub.









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6) Install new axle flange gasket or apply silicone sealer.
Install axle and tighten bolts or nuts to proper specification. See
TORQUE SPECIFICATIONS table at end of this article.
Fig. 2: Rear Hub & Bearing Adjuster
REAR AXLE ASSEMBLY R & I

REMOVAL
1) Raise and support vehicle. Remove wheels, hubs and axles.
See REAR HUB, BEARINGS AND AXLE SHAFTS.
2) Remove lower shock mounts and stabilizer bar mount.
Disconnect drive shaft and tie up. Remove hydraulic brake line at
junction and plug.
3) Disconnect park brake cables and hydraulic brake lines to
wheel cylinders or calipers. Remove brake backing plate or caliper.
4) Support axle housing with floor jack and remove leaf
spring "U" bolts. Carefully lower axle housing and remove from
vehicle.
INSTALLATION
Place axle housing on floor jack. Raise axle and install "U"
bolts and nuts. To complete installation, reverse removal procedure.
Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS
table at the end of this article and REAR HUB BEARING ADJUSTING
SPECIFICATIONS table.
PINION SEAL & YOKE R & I
REMOVAL
1) Raise and support vehicle. Mark drive shaft-to-yoke
contact area for reassembly reference. Remove drive shaft-to-yoke
attaching nuts/strap bolts. Discard used strap bolts. Remove drive
shaft.
2) Using a breaker bar and Pinion Nut Remover (8614-01),
remove pinion nut and washer. See Fig. 3. Using Yoke Pullers (8614-
01), (8614-02) and (8614-03), remove yoke. See Fig. 4. Using Pinion
Seal Remover (J-9233 or J-7583), remove pinion seal from front
differential housing. See Fig. 5.
Fig. 3: Removing Pinion Nut & Washer

Fig. 4: Removing Front Drive Axle Yoke

Fig. 5: Removing Pinion Seal
INSTALLATION
Using Seal Installer (J22661), drive new seal into front
differential housing. See Fig. 6. Tighten yoke attaching nut to 210
ft. lbs. (285 N.m). Using NEW strap bolts, align and install drive
shaft. Tighten strap bolts to 14 ft. lbs. (19 N.m). Fill differential
with SAE 75W-90 gear lubricant.

Fig. 6: Installing New Front Axle Shaft Seal
AXLE SHAFT OVERHAUL
NOTE: All front axle shafts except (Select-Trac) use Cardan "U"
joints and should be overhauled in same manner as drive
shaft "U" joints.
DISASSEMBLY (SELECT-TRAC)
1) Cut and remove both outer boot clamps. Slide boot off
outer CV joint.
2) Using a block of wood seated on inner race, tap joint from
shaft. If shaft is clamped in a vise, be sure to use protective vise
jaws.
3) Tap outer CV cage with a brass punch until cage is tilted

out far enough to remove first ball bearing. Remove remaining ball
bearings in same manner.
4) Rotate outer CV joint cage outward until it is at a 90
degree angle to installed position. Align 2 oblong holes in outer
joint cage with slots in interior wall of spindle housing and remove
cage and inner race.
5) Remove inner race from cage by aligning shoulder between
race grooves with inside of oblong cage holes. Rotate inner race out
of cage using larger of 2 openings in cage. Remove retaining ring,
spacer ring and outer boot.
Fig. 7: Exploded View of Jeep (Select-Trac) Drive Axle
Courtesy of Chrysler Motors.
CLEANING & INSPECTION
1) Wash all parts in solvent and dry. Inspect inner and outer
ball races for damage. Inspect splined stub shaft for wear, cracks and
twisted splines.
2) Inspect all 6 balls for pitting, cracking or scoring.
Dulling of surface is normal. If any damage is found, replace entire
CV joint assembly. Polished areas in races and on cage spheres are
normal and DO NOT require joint replacement.
REASSEMBLY
1) Apply a light coat of CV grease on ball grooves of inner
and outer races. Install inner race into cage using a rotating action
opposite of removal. Inner race snap ring should face axle side.
2) Be sure ball bearing retaining ring is installed on inner
race side facing small end of cage. Align windows of cage with outer
race lands, and pivot cage with inner race into tilted position
(opposite of removal).
3) Install ball bearings one at a time into outer CV joint as
cage is tilted and rotated. After balls are installed into cage, pivot
cage and inner race into installed position.
4) Slide new seal clamp for small end of boot seal, boot seal
and seal retainer onto axle shaft. Coat inside lip (large diameter end
of seal) with CV grease. Slide seal retainer on end of seal.
5) Spread ears of bearing race snap ring, and slide CV joint
onto axle shaft until snap ring seats in groove. Pack joint with
approximately 1/2 of grease provided in seal kit. Apply remaining
grease inside seal.
6) Slide seal toward joint until small end of seal is in
groove in axle shaft. Position small clamp over small end of seal and
into groove and tighten.

Fig. 8: Exploded View Of Dana Full-Floating Axle Assembly
AXLE ASSEMBLY OVERHAUL
DISASSEMBLY
1) Drain lubricant. Remove axle shafts and housing cover. If
no side play is found in the differential case assembly, mount dial
indicator on pilot stud with tip against back of ring gear. Measure
runout of ring gear, marking ring gear and case at point of maximum
runout.
2) If runout total exceeds .006" (.15 mm), ring gear could b\
e
loose or case could be damaged. Using .003" (.08 mm) feeler gauge, try\
to force feeler gauge between cap and race. If it does, bearing race
may have been turning in carrier.
3) If race has been turning, carrier could be damaged.
Observe identifying letters stamped into bearing caps and face of
carrier sealing surface. Use these matched letters for reassembly
reference.
4) Remove side bearing caps. Use Housing Spreader (W-129-A on\

Model 44; D-167 on Models 60, 61, 70 and 80) to spread differential
housing to .015" (.38 mm). See Fig. 9.
CAUTION: DO NOT spread housing more than .020" (.51 mm). Permanent
damage to housing could result.
Fig. 9: Correct Procedure for Spreading Housing
5) Pry differential case out of housing. Remove spreader to
prevent carrier taking set. On models with side bearing shims between
carrier and side bearing outer race, record sizes and positions of
shims. Be careful not to damage machined surfaces of housing.
6) Put case in soft-jawed vise and remove ring gear bolts and