brake pads JEEP CHEROKEE 1995 Service Repair Manual

hose unless the caliper must also be removed
for maintenance.Support the caliper with a
hanger to prevent brake fluid hose damage.
(2) Remove the dust cap, the cotter pin, the nut re-
tainer, the adjustment nut, and the thrust washer
from the spindle (Fig. 3). Discard the cotter pin.
(3) Remove the wheel outer bearing from the hub.
(4) Remove the wheel hub/disc brake rotor from
the spindle.
(5) Remove the seal and the inner wheel bearing
from the hub cavity.
(6) After removal, inspect both front wheel bearing
races for indications of pitting, brinelling and exces-
sive heat.
(7) Wipe the spindle clean and apply a small
amount of chassis/wheel bearing lubricant (NLGI
GC-LB lubricant) to prevent rust. Wipe the wheel
hub cavity clean.
CAUTION: Do not over-fill the wheel hub cavity with
lubricant. Excessive lubricant can cause overheat-
ing and bearing damage. Also, excessive lubricant
can be forced out of the wheel hub cavity and con-
taminate the brake rotor/pads.
(8) Partially fill the wheel hub cavity with chassis/
wheel bearing lubricant (NLGI GC-LB lubricant).
(9) Pack the wheel bearings with chassis/wheel
bearing lubricant (NLGI GC-LB lubricant). Ensure
that sufficient lubricant is forced between the bear-
ing rollers.
(10) Install the wheel inner bearing in the wheel
hub and install a replacement seal.
(11) Clean the disc brake rotor contact surfaces, if
necessary.
(12) Install the wheel hub/disc brake rotor on the
spindle.
(13) Install the wheel outer bearing, the thrust
washer, and the spindle nut.(14) Tighten the spindle nut with 28 Nzm (21 ft.
lbs.) torque while rotating the disc brake rotor to
seat the bearings.
(15) Loosen the spindle nut 1/2 turn. While rotat-
ing the disc brake rotor, tighten the spindle nut with
2Nzm (19 in. lbs.) torque.
(16) Install the nut retainer and a replacement cot-
ter pin.
(17) Clean the dust cap and apply wheel bearing
lubricant to the inside surface.Do not fill the dust
cap with lubricant.
(18) Install the dust cap.
(19) Install the disc brake caliper.
POWER STEERING SYSTEM
The power steering fluid level should be inspected
when other under hood service is performed. For
proper service procedures, refer to Group 19, Steer-
ing.
Inspect the power steering system (Fig. 4, and 5)
for the sources of fluid leaks, steering gear housing
cracks and ensure that the steering gear is securely
attached to the vehicle frame rail. Inspect the steer-
ing damper for leaks and loose connections.
FLUID SPECIFICATION
Use MOPAR Power Steering Fluid, or an equiva-
lent product.
POWER STEERING FLUID INSPECTION
WARNING: ENGINE MUST NOT BE RUNNING WHEN
INSPECTING POWER STEERING FLUID LEVEL,
PERSONAL INJURY CAN RESULT.
Fig. 3 2WD Front Wheel BearingsÐXJ Vehicles
Fig. 4 Power Steering SystemÐXJ Vehicles
JLUBRICATION AND MAINTENANCE 0 - 29

FLUID LEVEL
The fluid level indicator (dipstick) is attached to
the reservoir cap (Fig. 6). The fluid level in the res-
ervoir can be determined with the fluid either hot or
cold.
(1) Remove the cap from the reservoir.
(2) Depending on fluid temperature, if the level is
below the FULL HOT mark or the FULL COLD
mark on the dipstick, add power steering fluid.
(3) Install the cap on the reservoir.CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can re-
sult.
MANUAL STEERING GEAR
The manual steering gear should be inspected for
damage at the same time as the engine oil is
changed and the oil filter is replaced. Refer to Group
19, Steering for additional information and service
procedures.
POWER BRAKE SYSTEM
RECOMMENDED MAINTENANCE
The brake fluid level (Fig. 8) should be inspected
when other underhood service is done. With disc-
brakes, the fluid level can be expected to fall as the
brake pads wear. However, a low fluid level can also
be caused by a leak, and repair will then be neces-
sary. Refer to Group 5, Brakes for proper service pro-
cedures.
In addition, the brake system should be operation-
ally tested periodically to ensure that it is function-
ing normally.
FLUID SPECIFICATION
Jeep power brake systems require MOPAR Heavy-
Duty Brake Fluid, or an equivalent product identified
as conforming to FMVSS No. 116, DOT-3 and SAE
J-1703 specifications.
Use brake fluid from properly sealed container
when adding fluid to the reservoir. Never use re-
claimed fluid or fluid that does not conform to the
DOT/SAE Standards.
CAUTION: Use of a brake fluid that has a lower ini-
tial boiling point then specified by FMVSS No. 116,
DOT 3 and SAE J-1703 could result in sudden brake
failure during hard, prolonged braking.
Do not allow petroleum base fluids to contaminate
the brake fluid. Seal damage will result.
BRAKE FLUID LEVEL
STANDARD POWER BRAKE SYSTEM
(1) Clean the cover and the sides of the brake fluid
reservoir.
(2) Detach the bail retainer from the reservoir
cover and remove the cover from the reservoir.
(3) The brake fluid level should be 6 mm (1/4 in)
below the rim of each reservoir well for XJ and YJ
Vehicles (Fig. 7 and 8). If not, add brake fluid as nec-
essary.
(4) Inspect the reservoir cover bail retainer for ten-
sion and the cover for proper fit. The cover should fit
tight and have a good seal.
Fig. 5 Power Steering SystemÐYJ Vehicles
Fig. 6 Power Steering Fluid Reservoir DipstickÐ
Typical
0 - 30 LUBRICATION AND MAINTENANCEJ

(5) Inspect the reservoir rubber diaphragm seal for
cracks, cuts and distortion.
(6) Inspect the brake fluid tubing fittings and the
master cylinder housing for indications of fluid leak-
age. Repair as necessary.
(7) Install the brake fluid reservoir cover.
ANTI-LOCK BRAKE SYSTEMÐXJ VEHICLES
The anti-lock brake system fluid reservoir for XJ
Vehicles is located in the engine compartment at the
left side of the dash panel.
(1) Turn the ignition switch ON and allow the
pump motor to operate until it automatically de-en-
ergizes.
(2) Clean the cover before removing it.
CAUTION: Over-filling could cause fluid overflow
and possible reservoir damage when the pump mo-
tor energizes.
(3) The brake fluid level should be no lower than
the ADD indicator on the side of the reservoir (Fig.
8). If not, add brake fluid as necessary. Raise the
fluid level to the FULL indicator only. Do not over-fill
the reservoir.
(4) Turn the ignition switch OFF.
BRAKE SYSTEM INSPECTION
A brake system inspection should be included with
all brake service procedures, and also each time the
vehicle is lubricated.
(1) Inspect the brake pads and linings for excessive
wear, cracks, charred surfaces and broken rivets.
(2) Inspect brake pads and linings for contamina-
tion from brake fluid, and/or other fluids.
(3) Replace the brake pads linings if they are worn
to within 0.78 mm (1/32 in) of the rivet head.
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for
ease of movement.
(5) Inspect the self-adjuster components for wear
or damage.
(6) Inspect the disc brake caliper dust boot for
damage and indications of brake fluid leakage. In-
spect the bushings and pins for corrosion, tears and a
binding condition.
(7) Pull the rear wheel cylinder dust boot back to
expose the wheel cylinder housing. Inspect for fluid
leaks. Inspect the pistons and cylinder bores.
(8) Inspect the brake differential warning valve
and housing for indications of leakage.
BRAKE FLUID HOSES/TUBING
The rubber brake fluid hoses should be inspected
for:
²Correct length
²Severe surface cracking
²Swelling
²Pulling
²Scuffing
²Excessively worn areas
If the hose has cracks or abrasions in the rub-
ber cover, the hose should be replaced.
(1) Inspect all the hoses for kinks, a distorted con-
dition and fluid leakage.
(2) Inspect the hose and tubing routing under the
vehicle. Verify that no hose/tubing is rubbing against
any exhaust or other underbody components.
PARKING BRAKE
(1) Engage the parking brake pedal and then re-
lease it.
(2) Test it for smooth operation and vehicle-holding
capability.
(3) Inspect the parking brake cables.
(4) With the parking brake released, the rear
wheels should
rotate without restriction. Adjust the parking brake
cable tension, if necessary (Fig. 9 and 10).
(5) Repair any parking brake malfunctions.
BRAKE OPERATIONAL TEST
(1) Drive the vehicle and test for proper brake ac-
tion.
Fig. 7 Reservoir Fluid LevelÐYJ (2.5L)
Fig. 8 Reservoir Fluid LevelÐYJ-XJ and Anti-Lock
Brake System
JLUBRICATION AND MAINTENANCE 0 - 31

CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle
has been recently driven.
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the dif-
ferential housing cover.
(3) Remove the differential housing cover and
drain the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the sealant from the housing and cover
surfaces. Use solvent to clean the mating surfaces.
(6) Apply a bead of MOPARtSilicone Rubber Seal-
ant to the housing cover (Fig. 1).Allow the sealant
to cure for a few minutes.
Install the housing cover within 5 minutes af-
ter applying the sealant. If not installed the
sealant must be removed and another bead ap-
plied.
(7) Install the cover and any identification tag.
Tighten the cover bolts in a criss-cross pattern to 41
Nzm (30 ft. lbs.) torque.
(8) Refill the differential with MOPARtHypoid
Gear Lubricant to bottom of the fill plug hole.
(9) Install the fill hole plug and lower the vehicle.
DRIVE AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails behind the lower suspension
arm frame brackets.
(2) Remove the front wheels.
(3) Remove the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(4) On 4WD vehicles, disconnect the axle vent
hose.
(5) On 4WD vehicles, mark the drive shaft yoke
and axle pinion yoke for alignment reference. Discon-
nect the drive shaft from the axle.
(6) Disconnect the stabilizer bar link at the axle
bracket.
(7) Disconnect the shock absorbers from axle
bracket.
(8) Disconnect the track bar from the axle bracket.
(9) Disconnect the tie rod and drag link from the
steering knuckle. Disconnect the steering damper
from the axle bracket.
(10) Support the axle with a hydraulic jack under
the differential.
(11) Disconnect the upper and lower suspension
arms from the axle bracket.
(12) Lower the jack enough to remove the axle.
The coil springs will drop with the axle.
(13) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.
(1) Install the springs and retainer clip. Tighten
the retainer bolts to 21 Nzm (16 ft. lbs.) torque.
(2) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(3) Raise the axle with a floor jack and align it
with the spring pads.
(4) Position the upper and lower suspension arm at
the axle bracket. Install bolts and nuts finger
tighten.
(5) Connect the track bar to the axle bracket and
install the bolt.Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con-
nected. If springs are not at their usual posi-
tion, vehicle ride comfort could be affected.
Fig. 1 Typical Housing Cover With Sealant
JFRONT SUSPENSION AND AXLE 2 - 23

(6) Install the shock absorber and tighten the bolt
to 23 Nzm (17 ft. lbs.) torque.
(7) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 95 Nzm (70 ft. lbs.)
torque.
(8) Install the drag link and tie rod to the steering
knuckles and tighten the nuts to 47 Nzm (35 ft. lbs.)
torque. Install the steering damper to the axle
bracket and tighten the nut to 75 Nzm (55 ft. lbs.)
torque.
(9) Install the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(10) On 4WD vehicles, connect the vent hose to the
tube fitting.
(11) On 4WD vehicles, align the reference marks
and connect the drive shaft to the axle yoke. Tighten
the U-joint clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(12) Check differential lubricant and add if neces-
sary.
(13) Install the wheel and tire assemblies.
(14) Remove the supports and lower the vehicle.
(15) Tighten the upper suspension arm nuts to 75
Nzm (55 ft. lbs.) torque. Tighten the lower suspension
arm nuts to 115 Nzm (85 ft. lbs.) torque.
(16) Tighten the track bar bolt at the axle bracket
to 100 Nzm (74 ft. lbs.) torque.
(17) Check the front wheel alignment.
DRIVE AXLE ASSEMBLY REPLACEMENTÐYJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails behind the spring frame brack-
ets.
(2) Remove the front wheels.
(3) Remove the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(4) Disconnect the axle vent hose and axle shift
motor vacuum harness.
(5) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(6) Disconnect the stabilizer bar link at the axle
bracket.
(7) Disconnect the shock absorbers from axle
bracket.
(8) Disconnect the track bar from the axle bracket.
(9) Disconnect the tie rod from the steering
knuckle. Disconnect the steering damper from the
axle bracket.
(10) Support the axle with a hydraulic jack under
the differential. Raise the axle just enough to relieve
the axle weight from the springs.
(11) Remove the spring U-bolts from the plate
brackets.(12) Loosen BUT DO NOT REMOVE the bolts that
attach the spring rear pivot at the frame rail brack-
ets. This will allow the springs to pivot without bind-
ing on the bushings.
(13) Disconnect shackle from the springs and lower
the springs to the surface.
(14) Lower the jack enough to remove the axle.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.
(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(2) Raise the springs and install the spring shackle
bolts.Do not tighten at this time.
(3) Lower the axle and align the spring center
bolts with the locating holes in the axle pads and
plate brackets.
(4) Install the spring U-bolts through the plate
brackets and tighten to 122 Nzm (90 ft. lbs.) torque.
(5) Connect the track bar to the axle bracket and
install the bolt.Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con-
nected. If springs are not at their usual posi-
tion, the vehicle ride comfort could be affected.
(6) Install the shock absorber and tighten the nut
to 61 Nzm (45 ft. lbs.) torque.
(7) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 61 Nzm (45 ft. lbs.)
torque.
(8) Install the tie rod to the steering knuckles and
tighten the nuts to 47 Nzm (35 ft. lbs.) torque. Install
the steering damper to the axle bracket and tighten
the bolt to 75 Nzm (55 ft. lbs.) torque.
(9) Install the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(10) Connect the vent hose to the tube fitting and
axle shift motor vacuum harness.
(11) Align the reference marks and connect the
drive shaft to the axle yoke. Tighten the U-joint
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(12) Check differential lubricant and add if neces-
sary.
(13) Install the wheel and tire assemblies.
(15) Remove the supports and lower the vehicle.
(16) Tighten the spring rear pivot bolt/nut to 142
Nzm (105 ft. lbs.) torque. Tighten the spring shackle
bolt/nut to 135 Nzm (100 ft. lbs.) torque.
2 - 24 FRONT SUSPENSION AND AXLEJ

REAR SUSPENSION AND AXLES
CONTENTS
page page
8 1/4 AXLE............................ 30
AXLE NOISE/VIBRATION DIAGNOSIS......... 9
AXLE SPECIFICATIONS................... 51
GENERAL INFORMATION.................. 1
MODEL 35 AXLE........................ 13TORQUE SPECIFICATIONS................ 51
TRAC-LOK DIFFERENTIAL................. 45
XJ SUSPENSION......................... 3
YJ SUSPENSION......................... 6
GENERAL INFORMATION
SUSPENSION COMPONENTS
The Jeep rear suspension is comprised of;
²Drive axle
²Leaf springs
²Dual-action shock absorbers
²Track bar (YJ vehicles)
²Stabilizer bar (XJ vehicles)
²Jounce bumpers
The rear suspension design uses semi-elliptic
multi-leaf springs and a solid drive axle. The forward
end of the springs are mounted to the frame rail
hangers through rubber bushings. The bushings iso-
late road noise as the springs move. The rearward
end of the springs are attached to the frame by the
use of shackles. Again the spring and shackles use
rubber bushings to isolate road noise. The shackles
allow the springs to change their length as the vehi-
cle moves over various road conditions. The spring
and axle travel is limited through the use of bumpers
mounted on frame.
All suspension components that use bushings
should be tightened with the vehicle at normal ride
height. If the springs are not at normal ride position,
vehicle ride comfort could be affected. Rubber bush-
ings must never be lubricated.
The springs are attached to the axle pads with U-
bolts and plates. The springs use a center bolt that
holds the spring leafs in position. The bolt is also
used to locate the spring assembly to the axle pad.
Ride control is accomplished through the use of du-
al-action shock absorbers. The shocks dampen the
jounce and rebound as the vehicle travels over vari-
ous road conditions. The top of shock absorbers are
bolted to the frame bracket. The bottom of the shocks
are bolted to the axle bracket.
The stabilizer bar on the XJ is used to minimize
vehicle rear sway during turns. The bar helps the ve-
hicle maintain a flat attitude to the road surface. The
bar extends across the underside of the chassis and
connects to the frame rails. The links are connectedto the axle brackets. All mounting points of the sta-
bilizer bar are isolated by bushings.
The track bar on the YJ is used to minimize rear
axle side-to-side movement. The track bar is attached
to the frame rail bracket and axle bracket and is iso-
lated with bushings.
The jounce bumpers are used to limit the jounce
and rebound travel of the suspension.
AXLES
The Model 35 axle is standard for XJ and YJ vehi-
cles. The 8 1/4 axle is available in XJ vehicles with-
out ABS brakes.
The Model 35 and 8 1/4 axle housings has a cast
iron center section. Two steel axle shaft tubes are
pressed into the differential housing and welded.
It is not necessary to remove the axle from the ve-
hicle for service. A removable differential cover is
provided for routine vehicle service. If the differential
housing is damaged, the complete axle assembly can
be removed.
For complete drive axle assembly removal and in-
stallation refer to Drive Axle Assembly Replacement
in this Group.
IDENTIFICATION
Model 35 axle has the assembly part number and
gear ratio listed on a tag. The tag is attached to the left
side of the housing cover (Fig. 1). Build date identifica-
tion codes on axles are stamped on the axle shaft tube
cover side. The Model 35 axle has a flat housing cover
gasket flange at the outer edge (Fig. 1).
The 8 1/4 axle has the build date code and gear ra-
tio tags attached to the housing cover (Fig. 2). The
housing cover gasket has a rolled gasket flange at
the outer edge (Fig. 2).
²The Model 35 axle has shaft tubes that are 2.625
inch (66.67 mm) in diameter.
²The 8 1/4 axle has axle shaft tubes that are 3.0-
inch (76.2 mm) in diameter.
JREAR SUSPENSION AND AXLES 3 - 1

CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
Trac-Lok Differentials; A container of Trac-Lok lu-
bricant (friction modifier) should be added after re-
pair service or a lubricant change.
(9) Install the fill hole plug and lower the vehicle.
LIMITED SLIP DIFFERENTIAL vehicles should
be road tested by making 10 to 12 slow figure-eight
turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
ter noise complaint.
DRIVE AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails slightly in front the springs.
(2) Remove the rear wheels.
(3) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(4) Disconnect the axle vent hose.
(5) Disconnect the parking brake cables at the
equalizer or backing plate.
(6) Disconnect the shock absorbers from the axle
brackets.
(7) Disconnect the brake hose at the axle junction
block.Do not disconnect the wheel cylinder tub-
ing fittings.
(8) If equipped, disconnect ABS wiring connections
at the axle.(9) Support the axle with a hydraulic jack under
the differential.
(10) Remove the spring U-bolts from the plate
brackets.
(11) Lower the jack enough to remove the axle.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.
(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(2) Raise the axle and align the spring center bolts
with the locating holes in the axle pads and plate
brackets.
(3) Install the spring U-bolts through the plate
brackets and tighten to 70 Nzm (52 ft. lbs.) torque.
(4) Install ABS wiring connections (if equipped) at
the axle.
(5) Connect the brake hose at the axle junction
block.
(6) Install the shock absorbers to the axle brackets
and tighten to 62 Nzm (46 ft. lbs.) torque.
(7) Connect the parking brake cables at the equal-
izer or backing plate.
(8) Connect the vent hose to the tube fitting.
(9) Align the reference marks and connect the
drive shaft to the axle yoke. Tighten the U-joint
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(10) Check differential lubricant and add if neces-
sary.
(11) Install the wheel and tire.
(12) Bleed the brakes.
(13) Remove the supports and lower the vehicle.
DRIVE AXLE ASSEMBLY REPLACEMENTÐYJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails slightly in front the springs.
(2) Remove the rear wheels.
(3) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(4) Disconnect the axle vent hose.
(5) Disconnect the parking brake cables at the
equalizer or backing plate.
(6) Disconnect the shock absorbers from the plate
brackets.
Fig. 1 Typical Housing Cover With Sealant
3 - 14 REAR SUSPENSION AND AXLESJ

(7) Disconnect the brake hose at the axle junction
block.Do not disconnect the wheel cylinder tub-
ing fittings.
(8) Disconnect the track bar at the axle bracket.
(9) Support the axle with a hydraulic jack under
the differential. Raise the axle just enough to relieve
the axle weight from the springs.
(10) Remove the spring U-bolts from the plate
brackets.
(11) Loosen BUT DO NOT REMOVE the bolts that
attach the spring front pivot at the frame rail brack-
ets. This will allow the springs to pivot without bind-
ing on the bushings.
(12) Disconnect shackle from the springs and lower
the springs to the surface.
(13) Lower the jack enough to remove the axle.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.
(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(2) Raise the springs and install the spring shackle
bolts.Do not tighten at this time.
(3) Lower the axle and align the spring center
bolts with the locating holes in the axle pads and
plate brackets.
(4) Install the spring U-bolts through the plate
brackets and tighten to 122 Nzm (90 ft. lbs.) torque.
(5) Connect the track bar to the axle bracket and
install the bolt. Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con-
nected. If the springs are not at their usual po-
sition, vehicle ride comfort could be affected.
(6) Connect the brake hose at the axle junction
block.
(7) Install the shock absorbers to the axle brackets
and tighten to 61 Nzm (45 ft. lbs.) torque.
(8) Connect the parking brake cables at the equal-
izer or backing plate.
(9) Connect the vent hose to the tube fitting.
(10) Align the reference marks and connect the
drive shaft to the axle yoke. Tighten the U-joint
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(11) Check differential lubricant and add if neces-
sary.
(12) Install the wheel and tire.
(13) Bleed the brakes.
(14) Remove the supports and lower the vehicle.(15) Tighten the spring front pivot bolt/nut to 142
Nzm (105 ft. lbs.) torque. Tighten the spring shackle
bolt/nut to 135 Nzm (100 ft. lbs.) torque.
(16) Tighten the track bar bolt at the axle bracket
to 142 Nzm (105 ft. lbs.) torque.
PINION SHAFT SEAL REPLACEMENT
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Mark the drive shaft yoke and pinion yoke for
installation alignment reference.
(4) Remove the drive shaft from the yoke.
(5) Rotate the pinion gear three or four times.
Make sure brakes are not dragging during this
procedure.
(6) Measure the amount of torque (in Newton-
meters or inch-pounds) necessary to rotate the pinion
gear with a torque wrench. Note the torque for in-
stallation reference.It must be known to properly
adjust the pinion gear bearing preload torque
after seal installation.
(7) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 2).
(8) Mark the positions of the yoke and pinion gear
for installation alignment reference.
(9) Use Remover 7794A and slide hammer to re-
move the pinion gear seal (Fig. 3).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer D-163
and Handle C-4171 (Fig. 4).
(2) Align the installation reference marks and in-
stall yoke on the pinion gear with Installer W-162-D.
(3) Install a new nut on the pinion gear.Tighten
the nut only enough to remove the shaft end
play.
Fig. 2 Pinion Yoke Removal
JREAR SUSPENSION AND AXLES 3 - 15

LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be
used in the 8 1/4 inch axle. The lubricant should
have MIL-L-2105C and API GL 5 quality specifica-
tions. MOPARtHypoid Gear Lubricant conforms to
both of these specifications.
²The factory installed lubricant for the 8 1/4 inch
rear axle is SAE 80W 90 gear lubricant.
²The factory installed lubricant quantity is 6762
fluid oz.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
Refer to Group 0, Lubrication and Maintenance for
additional information.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
DRIVE AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES
REMOVAL
(1) Raise the vehicle. Position support stands un-
der the frame rails slightly in front the springs.
(2) Remove the rear wheels.
(3) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(4) Disconnect the axle vent hose.
(5) Disconnect the parking brake cables at the
equalizer or backing plate.
(6) Disconnect the shock absorbers from the axle
brackets.
(7) Disconnect the brake hose at the axle junction
block.Do not disconnect the wheel cylinder tub-
ing fittings.
(8) If equipped, disconnect ABS wiring connections
at the axle.
(9) Support the axle with a hydraulic jack under
the differential.
(10) Remove the spring U-bolts from the plate
brackets.
(11) Lower the jack enough to remove the axle.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(2) Raise the axle and align the spring center bolts
with the locating holes in the axle pads and plate
brackets.
(3) Install the spring U-bolts through the plate
brackets and tighten to 70 Nzm (52 ft. lbs.) torque.
(4) Install ABS wiring connections (if equipped) at
the axle.
(5) Connect the brake hose at the axle junction
block.
(6) Install the shock absorbers to the axle brackets
and tighten to 62 Nzm (46 ft. lbs.) torque.
(7) Connect the parking brake cables at the equal-
izer or backing plate.
(8) Connect the vent hose to the tube fitting.
(9) Align the reference marks and connect the
drive shaft to the axle yoke. Tighten the U-joint
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(10) Check differential lubricant and add if neces-
sary.
(11) Install the wheel and tire.
(12) Bleed the brakes.
(13) Remove the supports and lower the vehicle.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle
has been recently driven.
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the dif-
ferential housing cover.
(3) Remove the differential housing cover and
drain the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the sealant from the housing and cover
surfaces. Use solvent to clean the mating surfaces.
(6) Apply a bead of MOPARtSilicone Rubber Seal-
ant to the housing cover (Fig. 2). Allow the sealant to
cure for a few minutes.
Install the housing cover within 5 minutes after
applying the sealant. If not installed the sealant
must be removed and another bead applied.
(7) Install the cover and any identification tag.
Tighten the cover bolts in a criss-cross pattern to 47
Nzm (35 ft. lbs.) torque.
(8) Refill the differential with Mopar Hypoid Gear
Lubricant 13 mm (1/2 in.) below the fill plug hole.
With Trac-Lok differentials, add a container of Mopar
Hypoid Gear Lubricant Additive.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(9) Install the fill hole plug and lower the vehicle.
JREAR SUSPENSION AND AXLES 3 - 31

Do not hone cylinder bores or polish pistons.
Replace cylinder as an assembly if bore is dam-
aged.
(8) Install bleed screw.
(9) Coat cylinder bore, pistons, cups and expander
with brake fluid and reassemble cylinder compo-
nents. Be sure piston cup lips face expander.
WHEEL CYLINDER INSTALLATION
(1) Apply small bead of silicone sealer around cyl-
inder mounting surface of support plate.
(2) Start brakeline in wheel cylinder fitting by
hand.
(3) Align and seat wheel cylinder on support plate
(Fig. 10).
(4) Install cylinder mounting bolts (Fig. 10).
Tighten bolts to 10 Nzm (90 in. lbs.) torque.(5) Tighten brakeline fitting to 15 Nzm (132 in.
lbs.) torque.
(6) Install brakeshoes. Adjust shoes to drum with
brake gauge.
(7) Install brake drums and lower vehicle.
(8) Fill master cylinder and bleed brakes.
SUPPORT PLATE REPLACEMENT
The support plate should cleaned and inspected
whenever the drum brake components are being ser-
viced.
Check the support plate for wear, or rust through
at the contact pads and replace the plate if necessary.
Be sure to lubricate the contact pads with Mopar
multi-mileage grease before shoe installation. Lubri-
cation will avoid noisy operation and shoe bind.
(1) Raise vehicle and remove wheel/tire assembly.
(2) Remove brake drum, brakeshoes, and wheel
cylinder.
(3) Remove axle shaft as described in Group 3.
(4) Remove support plate attaching nuts and re-
move support plate.
(5) Clean axle tube flange. If gasket is not used on
flange, apply thin bead of silicone adhesive/sealer to
flange.
(6) Position new support plate on axle tube flange.
(7) Apply Mopar Lock N9Seal, or Loctite 242 to
support plate attaching nuts. Then install and
tighten nuts.
(8) Apply light coat of Mopar multi-mileage grease
to contact pads of new support plate.
(9) Install wheel cylinder and brakeshoes.
(10) Adjust brakeshoes to drums. Refer to proce-
dure in this section.
(11) Bleed brakes.
(12) Install wheel and tire assembly.
(13) Adjust parking brake cable tensioner. Refer to
procedure in Parking Brake section.
(14) Lower vehicle and verify proper service brake
and parking brake operation.
BRAKE DRUM REFINISHING
Brake drums can be machined to restore the brak-
ing surface. Use a brake lathe to clean up light scor-
ing and wear.
CAUTION: Never refinish a brake drum if machining
will cause the drum to exceed maximum allowable
brake surface diameter.
Brake drums that are warped, distorted, or se-
verely tapered should be replaced. Do not refinish
drums exhibiting these conditions. Brake drums that
are heat checked or have hard spots should also be
replaced.
Fig. 8 Wheel Cylinder (9-Inch Brake)
Fig. 9 Wheel Cylinder (10-Inch Brake)
Fig. 10 Wheel Cylinder Mounting
5 - 58 DRUM BRAKESJ