differential JEEP CHEROKEE 1988 Service Manual PDF

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Pages: 1378, PDF Size: 19.9 MB

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Page 1208 of 1378

JEEP CHEROKEE 1988 Service Manual PDF intermediate clutch shaft snap ring from mainshaft.
5) Remove clutch shaft thrust ring. Remove intermediate
clutch shaft. Remove differential retaining snap ring. Remove
differential assembly

Page 1209 of 1378

JEEP CHEROKEE 1988 Service Manual PDF 1) Clean all parts with solvent. Dry with compressed air.
Replace all oil seals, "O" rings and snap rings. Check all parts for
wear or damage. Replace all worn or damaged parts. Apply Dexron

1) Clean all parts with solvent. Dry with compressed air.
Replace all oil seals, "O" rings and snap rings. Check all parts for
wear or damage. Replace all worn or damaged parts. Apply Dexron II to
all parts before installing.
2) Inspect low range annulus gear inside front case. If gear
is worn or damaged, replace case and gear as an assembly. Replace oil
pump as an assembly if any part is damaged or worn.
NOTE: When installing bearings, ensure bearing bores are aligned
with oil feed holes.
TRANSFER CASE REASSEMBLY
1) Install front output shaft front bearing, snap ring and
oil seal. Install snap ring on input gear bearing. Using a wooden
block and press, install input gear until snap ring is against case.
2) Install input gear pilot bearing. Assemble low range gear,
thrust washers, input gear and retainer. Install low range gear snap
ring. Ensure snap ring is seated properly in groove.
3) Start input gear shaft through the bearing in front case.
Using a press, install input gear shaft through bearing. Ensure
adapter is positioned properly before pressing shaft.
NOTE: Ensure proper size tool is used to press input gear shaft;
wrong size tool can damage case and thrust washers and will
move pilot bearing too far into gear bore.
4) Install input gear snap ring. Install front bearing
retainer oil seal. Apply 1/8" bead of silicone sealant to front
bearing retainer mating surface. Install front bearing retainer on
front case. Install sector shaft "O" ring and bushing. Install shift
sector.
5) Install detent pin, spring and plug. Install low range
fork pads. Assemble low range fork and hub. Ensure low range fork pin
is engaged in shift sector slot. Install differential sprocket gear in
lower differential case. Install planet gears and new thrust washers
on lower case pins.
6) Ensure thrust washers are positioned on top and bottom of
each planet gear. Install mainshaft gear. Align marks on upper and
lower differential case. Install bolts and tighten to specifications.
See TORQUE SPECIFICATIONS . Install needle bearing spacer on mainshaft.
7) Using petroleum jelly to hold needles, install bearings on
mainshaft. Install other spacer. Install differential assembly. Ensure
all needle bearings are in place. Install differential snap ring.
Install intermediate clutch shaft. Install thrust washer and snap
ring. Install mode shift sleeve in mode fork.
8) Install mode fork assembly on mainshaft. Ensure mode shift
sleeve splines engage with differential splines. Install mode fork and
mainshaft assembly in case. If necessary, rotate mainshaft slightly to
engage mainshaft with low range components.
9) Install mode fork pin into shift sector slot. Install
shift rail. Ensure shift rail is seated in shift forks. Rotate shift
sector so lock pin can be installed. Install lock pin so tapered end
is in fork and rail. Install plug. Install shift lever and nut on
shift sector shaft.
10) Install detent plunger, spring and plug. Install front
output shaft. Install drive chain and sprocket. Install drive sprocket
snap ring. Install front output shaft rear bearing.
11) Install oil seal in oil pump housing. Assemble oil pump
gears in housing. Ensure oil feed hole is aligned with hole in
housing. Install oil pump screws. Tighten to specification. Install

Page 1263 of 1378

JEEP CHEROKEE 1988 Service Manual PDF Excessive Noise Loose pump-to-drive Tighten screws
assembly screws
Loose tube on pump assembly Tighten tube
Valves not functioning

Excessive Noise Loose pump-to-drive Tighten screws
assembly screws
Loose tube on pump assembly Tighten tube
Valves not functioning Replace valves
properly
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Oil Leakage Loose end plug Tighten end plug
Bad seal crimp Remove and re-crimp
seal
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MANUAL TRANSMISSION
MANUAL TRANSMISSION TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING
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Condition Possible Cause\
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Noisy In Forward Gears .Low gear oil level,
.Loose bell housing bolts,
.Worn bearings or gears
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Clunk On Deceleration
(FWD Only) .Loose engine mounts,
.Worn inboard CV joints,
.Worn differential pinion shaft,
.Side gear hub counterbore
in case worn oversize
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Gear Clash When Shifting
Forward Gears .Clutch Out Of Adjustment,
.Shift linkage damaged or
out of adjustment,
.Gears or synchronizers damaged,
.Low gear oil level
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Transmission Noisy When
Moving (RWD Only) Quiet In
Neutral With Clutch Engaged .Worn rear outputshaft bearing
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Gear Rattle .Worn bearings,
.Wrong gear oil,
.Low gear oil,
.Worn gears
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Steady Ticking At Idle
(Increases With RPM) .Broken tooth on gear
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Gear Clash When Shifting
Forward Gears .Worn or broken synchronizers
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Loud Whine In Reverse .Normal condition ( 1)\
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Page 1268 of 1378

JEEP CHEROKEE 1988 Service Manual PDF In certain conditions, the pitch of the exhaust gases may
sound like gear whine. At other times, it may be mistaken for a wheel
bearing rumble.
Tires, especially radial and snow, can

In certain conditions, the pitch of the exhaust gases may
sound like gear whine. At other times, it may be mistaken for a wheel
bearing rumble.
Tires, especially radial and snow, can have a high-pitched
tread whine or roar, similar to gear noise. Also, some non-standard
tires with an unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or
excessive driveline play that can be improperly diagnosed as drive
axle problems.
Trim and moldings also can cause a whistling or whining
noise. Ensure none of these components are causing the noise before
disassembling the drive axle.
Gear Noise
A "howling" or "whining" noise from the ring and pinion gear
can be caused by an improper gear pattern, gear damage, or improper
bearing preload. It can occur at various speeds and driving
conditions, or it can be continuous.
Before disassembling axle to diagnose and correct gear
noise, make sure that tires, exhaust, and vehicle trim have been
checked as possible causes.
Chuckle
This is a particular rattling noise that sounds like a stick
against the spokes of a spinning bicycle wheel. It occurs while
decelerating from 40 MPH and usually can be heard until vehicle comes
to a complete stop. The frequency varies with the speed of the
vehicle.
A chuckle that occurs on the driving phase is usually caused
by excessive clearance due to differential gear wear, or by a damaged
tooth on the coast side of the pinion or ring gear. Even a very small
tooth nick or a ridge on the edge of a gear tooth is enough the cause
the noise.
This condition can be corrected simply by cleaning the gear
tooth nick or ridge with a small grinding wheel. If either gear is
damaged or scored badly, the gear set must be replaced. If metal has
broken loose, the carrier and housing must be cleaned to remove
particles that could cause damage.
Knock
This is very similar to a chuckle, though it may be louder,
and occur on acceleration or deceleration. Knock can be caused by a
gear tooth that is damaged on the drive side of the ring and pinion
gears. Ring gear bolts that are hitting the carrier casting can cause
knock. Knock can also be due to excessive end play in the axle shafts.
Clunk
Clunk is a metallic noise heard when an automatic
transmission is engaged in Reverse or Drive, or when throttle is
applied or released. It is caused by backlash somewhere in the
driveline, but not necessarily in the axle. To determine whether
driveline clunk is caused by the axle, check the total axle backlash
as follows:
1) Raise vehicle on a frame or twinpost hoist so that drive
wheels are free. Clamp a bar between axle companion flange and a part
of the frame or body so that flange cannot move.
2) On conventional drive axles, lock the left wheel to keep
it from turning. On all models, turn the right wheel slowly until it
is felt to be in Drive condition. Hold a chalk marker on side of tire
about 12" from center of wheel. Turn wheel in the opposite direction
until it is again felt to be in Drive condition.
3) Measure the length of the chalk mark, which is the total

Page 1269 of 1378

JEEP CHEROKEE 1988 Service Manual PDF axle backlash. If backlash is one inch or less, drive axle is not the
source of clunk noise.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle.
It is usually c

axle backlash. If backlash is one inch or less, drive axle is not the
source of clunk noise.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle.
It is usually caused by malfunctioning pinion bearings. Pinion
bearings operate at drive shaft speed. Roller wheel bearings may whine
in a similar manner if they run completely dry of lubricant. Bearing
noise will occur at all driving speeds. This distinguishes it from
gear whine, which usually comes and goes as speed changes.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. It is
usually caused by a malfunctioning wheel bearing. The lower pitch is
because the wheel bearing turns at only about 1/3 of drive shaft
speed.
Chatter On Turns
This is a condition where the entire front or rear of vehicle
vibrates when vehicle is moving. The vibration is plainly felt as well
as heard. Extra differential thrust washers installed during axle
repair can cause a condition of partial lock-up that creates this
chatter.
Axle Shaft Noise
Axle shaft noise is similar to gear noise and pinion bearing
whine. Axle shaft bearing noise will normally distinguish itself from
gear noise by occurring in all driving modes (Drive, cruise, coast and
float), and will persist with transmission in Neutral while vehicle is
moving at problem speed.
If vehicle displays this noise condition, remove suspect
axle shafts, replace wheel seals and install a new set of bearings.
Re-evaluate vehicle for noise before removing any internal components.
Vibration
Vibration is a high-frequency trembling, shaking or grinding
condition (felt or heard) that may be constant or variable in level
and can occur during the total operating speed range of the vehicle.
The types of vibrations that can be felt in the vehicle can
be divided into 3 main groups:
* Vibrations of various unbalanced rotating parts of the
vehicle.
* Resonance vibrations of the body and frame structures caused
by rotating of unbalanced parts.
* Tip-in moans of resonance vibrations from stressed engine or
exhaust system mounts or driveline flexing modes.
DRIVE AXLE - RWD TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing. For definitions
of listed noises or sounds, see DRIVE AXLE - NOISE DIAGNOSIS
under POWERTRAIN.
DRIVE AXLE (RWD) TROUBLE SHOOTING
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CONDITION POSSIBLE CAUSE CORRECTION

Page 1270 of 1378

$JEEP CHEROKEE 1988 Service Manual PDF ��\ ��\ ��\ ��\ ��\ ��\ ��\ �� Knocking or Clunking Differe$

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Knocking or Clunking
Differential Side Gear
Clearance Check Clearance
Worn Pinion Shaft Replace Pinion Shaft
Axle Shaft End Play Check End Play
Missing Gear Teeth Check Differential/
Replace Gear
Wrong Axle Backlash Check Backlash
Misaligned Driveline Realign Driveline
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Clinking During Engagement
Side Gear Clearance Check Clearance
Ring and Pinion Backlash Check Backlash
Worn/Loose Pinion Shaft Replace Shaft/Bearing
Bad "U" Joint Replace "U" Joint
Sticking Slip Yoke Lube Slip Yoke
Broken Rear Axle Mount Replace Mount
Loose Drive Shaft Flange Check Flange
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Click/Chatter On Turns
Differential Side Gear
Clearance Check Clearance
Wrong Turn On Plates (1) Replace Clutch Plates
Wrong Differential
Lubricant ( 1) Change Lubricant
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Knock Or Click Flat Spot on Rear
Wheel Bearing Replace Wheel Bearing
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Low Vibration At All Speeds
Faulty Wheel Bearing Replace Wheel Bearing
Faulty "U" Joint Replace "U" Joint
Faulty Drive Shaft Balance Drive Shaft
Faulty Companion Flange Replace Flange
Faulty Slip Yoke Flange Replace Flange
( 1) - Limited slip differential only.
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FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to

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