light JEEP CHEROKEE 1988 Service Workshop Manual

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.

PINION DEPTH
1) Depth Gauge Set (D-271) is used to determine pinion depth\
.
Place Master Pinion Block (D-139 on Model 44; D-120 on Model 60 and
61; D-137 on Model 70; T80T-4020-F42 on Model 80) in pinion bore of
carrier. Put Arbor Discs (D-115-4-44 on Model 44; D-116-2 on Models
60,61 and 70; (T88T-4020-A) on Arbor (D-115-3). Install arbor in
carrier with discs riding in bearing bore.
2) Put Pinion Height Block (D-115-1-44 on Model 44; D-116-1
on Models 60, 61, 70 and 80) on top of master pinion block with side
against arbor. Place Scooter Block (115-2) with Dial Indicator (D-106\
-
5) on small step of pinion height block. Zero dial indicator with
scooter block flat on pinion height block.
3) Move scooter block so dial indicator tip touches arbor.
Move block back and forth (perpendicular to arbor) to get highest
reading. This reading, plus or minus value etched on pinion head, is
thickness of shim pack necessary for pinion bearing.
4) On Model 80, Use Gauge Tube (D81T-4020-F51) and Gauge
Block (D81T-4020-F56) to determine required thickness of shim pack.
5) On all models, measure shims separately with micrometer.
If baffle is used, its thickness must be included in shim pack. This
is also true if slinger is used between inner bearing and head of
pinion shaft. Place pinion height shim pack in carrier bore for inner
bearing race. Drive bearing race into carrier, making sure cup is
fully seated.
PINION BEARING PRELOAD
1) Drive outer pinion bearing into carrier housing. Press
inner pinion bearing onto pinion shaft using Press Tube (C-3095-A).
Ensure bearing seats fully. Insert pinion shaft into carrier. Install
outer bearing, slinger (if equipped), flange, washer and nut.
NOTE: Pinion preload shims and oil seal should NOT be installed at
this time.
2) Using an INCH lb. torque wrench, tighten pinion nut until
10 INCH lbs. (1.13 N.m) rotational torque is required to move pinion
shaft. Recheck pinion depth with arbor and discs at this time. Place
pinion height block on face of pinion shaft.
3) Place dial indicator on small step of height block for
Model 44, 60 and 61 axles. Place dial indicator on high step of block
for Models 70 and 80 axles. Zero dial indicator and move it across
arbor to get highest reading. If reading is within .002" (.05 mm) of
etching on pinion face, pinion depth is correct.
NOTE: If pinion depth is not with .002" (.05 mm) of etched number
on face of pinion, shim pack under inner bearing race must
be changed before proceeding with differential settings.
4) Remove pinion nut, washer, flange, slinger and outer
bearing. Place preload shims (removed during disassembly) on pinion.
Install bearing and slinger. After lightly coating lips with gear oil,
install pinion seal in carrier housing. Install flange, washer and NEW
pinion nut. Tighten nut to specification. See TORQUE SPECIFICATIONS
table at end of this article.
5) Using an INCH lb. torque wrench, measure preload
(rotational torque) of pinion shaft. Rotational torque required to
keep pinion shaft turning freely and smoothly should be 20-40 INCH
lbs. (2.3-4.5 N.m). If preload needs to be increased, remove a few
shims and recheck. To decrease preload, add a few shims and recheck.
See Fig. 14 .

lubricant to axle flange bearing bore and install axle.
YOKE & PINION OIL SEAL
Removal
1) Raise and support vehicle. Remove wheels and brake drums.
Mark and remove drive shaft. Using an INCH lb. torque wrench, record
torque required to rotate pinion several revolutions.
2) Hold yoke from turning and remove pinion nut. Mark drive
pinion shaft and yoke for reassembly reference. Remove yoke and pinion
oil seal.
Installation
1) Coat new seal with rear axle lubricant and install. Align
marks made at disassembly and install yoke. Install new pinion nut and
tighten just enough to remove end play.
CAUTION: DO NOT overtighten pinion nut. If desired preload is
exceeded, a new collapsible pinion spacer sleeve must be
installed and drive pinion preload reset.
2) Using an INCH lb. torque wrench, check torque required to
turn pinion. Refer to torque reading recorded during disassembly and
add 5 INCH lbs. (.6 N.m) for correct preload. Tighten pinion nut
slightly and recheck preload. Repeat procedure until desired preload
is obtained.
REAR AXLE ASSEMBLY
Removal
1) Raise and support vehicle. Remove wheels and brake drums.
Disconnect brake hose-to-axle connection and plug line.
2) Disconnect parking brake cable at brake equalizer. Mark
and remove drive shaft. Disconnect track bar at axle bracket (if
equipped). Remove axle vent tube at axle. Support axle assembly.
Remove spring "U" bolts and tie plates.
3) Loosen, but do not remove, bolts which attach front of
rear spring to frame brackets. Lift axle to relieve axle weight from
springs and remove bolts retaining springs to shackles. Lower springs
to floor. Lower jack and remove axle assembly.
NOTE: Factory axles are shipped without lubricant. When adding
lubricant, position axle horizontally with yoke end of
pinion housing facing downward. Turn pinion shaft several
times to lubricate bearings.
Installation
1) To install, support axle assembly with jack and slide axle
into place. Raise, align and install spring-to-frame and shackle
bolts. Tighten spring-to-frame and shackle bolts to 111 ft. lbs. (150
N.m). Install brake hose, axle vent tube and parking brake cable.
Align and connect drive shaft.
2) Bleed hydraulic system and adjust parking brake cable.
Ensure axle is filled with 75-90W gear lubricant. Ensure spring
centering bolt heads are seated in axle spring seat before tightening
"U" bolts.
OVERHAUL
DISASSEMBLY
NOTE: It is not necessary to remove axle assembly from vehicle to

size end play shims on each side of differential case. Position and
install ring gear on differential case. Install replacement ring gear
bolts and tighten standard axle ring gear bolts to 70-90 ft. lbs.
(95-122 N.m). Tighten heavy duty drive axle bolts to 105 ft. lbs.
(142 N.m).
4) Check ring gear backlash. See RING GEAR BACKLASH in
ADJUSTMENTS. Lightly lubricate differential bearings, cups, gears and
thrust washers with axle lubricant. Install bearing cups on
differential bearings. Install differential in axle housing.
5) Using a soft faced hammer, tap outer edges of differential
bearing cups to seat them in housing. Install differential bearings
caps and tighten cap bolts to 57 ft. lbs. (77 N.m).
6) Recheck and verify ring gear backlash has not changed.
Install axle housing cover. Tighten cover bolts to 14 ft. lbs. (19 N.
m). Refill axle with 75-90W gear lubricant.
ADJUSTMENTS
DRIVE PINION DEPTH
1) Check numbers painted on drive pinion and ring gear. First
number on pinion must match number on ring gear. Second number on
pinion is pinion depth variance. If number is preceded by a plus sign,
add that number to standard pinion depth. If number is preceded by a
minus sign, subtract that amount from standard pinion depth. This will
give desired pinion depth. Record this measurement for future
reference.
2) If numbers painted on drive gear and ring gear do not
match, gears are not a matched set and should not be used. Some
factory installed sets may have .01" (.25 mm) or .02" (.50 mm)
machined off pinion end face.
3) Identifying numbers will appear as "+23". Number "2"
indicates .02" (.50 mm) was removed from end face and number "3" is
pinion depth variance. If marked "+16", number "1" indicates .010"
(.25 mm) was removed from end face and number "6" is pinion depth
variance.
4) Standard pinion depth on standard drive axle is 2.095"
(53.21 mm). Standard pinion depth on heavy duty drive axle is 2.547"
(64.69 mm).
Fig. 3: Pinion Depth & Preload Shim Location
5) Measure thickness of original pinion depth shim. Note
pinion depth variance numbers marked on old and new pinion gears.
Refer to PINION DEPTH SHIM ADJUSTMENT SPECIFICATIONS at end of this

FLYWHEEL INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Cracked (other than
mounting area) ......... A ...... (1) Require resurfacing or
replacement.
Cracks in mounting area . B ............ Require replacement.
Hard spots .............. B .. Require repair or replacement.
Ring gear broken ........ A ..... Require replacement of ring
gear.
Ring gear teeth worn,
affecting performance .. A ..... Require replacement of ring
gear.
Runout exceeds
specifications ......... B .. Require repair or replacement.
Scored .................. B .. Require repair or replacement.
Surface cracks after
resurfacing to
manufacturer's minimum
specifications ......... B ............ Require replacement.
Wear exceeds
specifications ......... B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Some manufacturers allow slight surface cracking in the
friction surface.









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FORCE MOTORS
See ACTUATORS (ELECTRICAL) .
GUIDES
See DOWEL PINS, GUIDES AND PILOT HOLES .
HALF SHAFTS
See DRIVE SHAFTS AND HALF SHAFTS .
HOSES, LINES AND TUBES
HOSE, LINE AND TUBE INSPECTION








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Condition Code Procedure

B+ Latch Relay On center of right front
wheelwell.
Choke Relay On right front wheelwell.
Door Lock/Unlock Relays Under dash, behind right kick
panel.
Fog Light Relay Behind right headlight, on
wheelwell.

Rear Window Defogger Relay Under instrument panel, to
right of steering column.
Rear Wiper Relay In tailgate, next to wiper
motor.
Starter Relay (Graphic 1) Behind right headlight, on
wheelwell.

Starter Relay (Graphic 2) Behind right headlight, on
wheelwell.
Timer Delay Relay Above starter relay, behind
battery.
Trailer Towing Relays,
Brake/Stop Light Relay (Cherokee) Above left rear wheelwell.

Ignition Control Module In engine compartment, on
right wheelwell.
Intermittent Wiper Module Under left side of dash, above
brake pedal.
Keyless Entry Receiver Between sun visors.
Maint. Reminder Module Under dash, to right of
steering column.
Sentinel Light Module Under left side of dash, near
headlight switch.

Automatic Load Leveling Sw. On compressor bracket, in
engine compartment.
Back-Up Light Sw. (Man. Trans.) On left side of transmission
case.
Back-Up/Neutral Sw. (Auto. Trans.) On left side of transmission
case.
Brake/Stop Light (Cruise) Switch On brake pedal bracket.
Brake Warning Switch On brake pressure differential
valve, below master cylinder.
Closed Throttle (Idle) Switch An integral part of ISA motor.\
Command Track Switch On left side of transmission.
Parking Brake Switch Under center console, at base
of parking brake lever.