JEEP GRAND CHEROKEE 2002 WJ / 2.G Manual Online

CAUTION: Boot must not be dimpled, stretched or
out of shape in any way. If not shaped correctly,
equalize pressure in boot and shape it by hand.
(5) Install the two boot clamps.
(6) Crimp the boot clamps with Clamp Installer
C-4975A. Place clamp tool over bridge of clamp (Fig.
26).
(7) Tighten nut on the tool until jaws on tool are
closed completely together (Fig. 27) and (Fig. 28).
(8) Install the axle shaft.
AXLE - U-JOINT
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Do not over tighten the vise
jaws, to avoid distorting the yoke.
(1) Remove axle shaft.
(2) Remove the bearing cap retaining snap rings
(Fig. 29).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(3) Locate a socket with an inside diameter is
larger than the bearing cap. Place the socket (receiv-
er) against the yoke and around the perimeter of the
bearing cap to be removed.
(4) Locate a socket with an outside diameter is
smaller than the bearing cap. Place the socket (driv-
er) against the opposite bearing cap.
(5) Position the yoke with the sockets in a vise
(Fig. 30).
(6) Tighten the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(8) Repeat the above procedure for the remaining
bearing cap and remove spider from the propeller
shaft yoke.
Fig. 26 CRIMPING TOOL
1 - INSTALLER
2 - AXLE SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 27 SMALL BOOT CLAMP
1 - CLAMP
2 - INSTALLER
3 - AXLE SHAFT
4 - SEALING BOOT
Fig. 28 LARGE BOOT CLAMP
1 - CLAMP TOOL
2 - SEALING BOOT
3 - OUTER C/V JOINT
4 - BOOT CLAMP
3 - 36 FRONT AXLE - 186FBIWJ
AXLE - C/V JOINT (Continued)

INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings, then tap bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket in a vise.
(4) Tighten the vise to force the bearing caps into
the yoke. Force the caps enough to install the retain-
ing clips.
(5) Install the bearing cap retaining clips.
(6) Install axle shaft.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers, refer to 5
Brakes for procedures.
(4) Mark propeller shaft and pinion companion
flange for installation reference.
(5) Remove the propeller shaft from the pinion
companion flange.
(6) Rotate the pinion gear a minimum of ten times
and verify the pinion rotates smoothly.
(7) Record torque necessary to rotate the pinion
gear with a inch pound torque wrench.
(8) Using a short piece of pipe and Spanner
Wrench 6958 to hold the pinion companion flange
and remove the pinion nut and washer.
(9) Remove pinion companion flange with Remover
C-452 and Flange Wrench C-3281.
(10) Remove pinion seal with Remover 7794-A and
a slide hammer (Fig. 31).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 32).
(2) Install pinion companion flange on the pinion
gear with Installer W-162-D, Cup 8109 and Wrench
6958.
CAUTION: Never exceed the minimum tightening
torque 298 N´m (220 ft. lbs.) while installing pinion
nut at this point. Damage to collapsible spacer or
bearings may result.
(3) Install the pinion washer and anewnut on
the pinion gear.Tighten the nut only enough to
remove the shaft end play.
Fig. 29 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 30 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET
2 - VISE
3 - SMALL-DIAMETER SOCKET
WJFRONT AXLE - 186FBI 3 - 37
AXLE - U-JOINT (Continued)

CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
(4) Rotate pinion a minimum of ten time and ver-
ify pinion rotates smoothly. Rotate the pinion shaft
with an inch pound torque wrench. Rotating torque
should be equal to the reading recorded during
removal plus 0.56 N´m (5 in. lbs.) (Fig. 33).
(5) If the rotating torque is low, use Spanner
Wrench 6958 to hold the pinion companion flange
(Fig. 34), and tighten the pinion shaft nut in 6.8 N´m
(5 ft. lbs.) increments until proper rotating torque is
achieved.
CAUTION: If maximum tightening torque is reached
prior to reaching the required rotating torque, thecollapsible spacer may have been damaged.
Replace the collapsible spacer.
Fig. 31 PINION SEAL
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 32 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 33 PINION ROTATION TORQUE
1 - PINION YOKE/COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
Fig. 34 PINION SHAFT NUT
1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH
3 - 38 FRONT AXLE - 186FBIWJ
PINION SEAL (Continued)

(6) Install propeller shaft with installation refer-
ence marks aligned.
(7) Fill differential with gear lubricant.
(8) Install brake rotors and calipers.
(9) Install wheel and tire assemblies.
(10) Lower the vehicle.
COLLAPSIBLE SPACER
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to 5
Brakes for procedures.
(4) Mark the propeller shaft and pinion companion
flange for installation reference.
(5) Remove propeller shaft from the pinion com-
panion flange.
(6) Rotate pinion gear a minimum of ten times and
verify pinion rotates smoothly.
(7) Record pinion gear rotating torque with a
torque wrench for installation reference.
(8) Remove pinion nut and washer. Using a short
piece of pipe and Spanner Wrench 6958 to hold the
pinion companion flange.
(9) Remove pinion companion flange with Remover
C-452 and Flange Wrench C-3281.
(10) Remove pinion shaft seal with Remover
7794-A and slide hammer (Fig. 35).
(11) Remove front pinion bearing using a pair of
pick tools to pull the bearing straight off pinion
shaft.NOTE: If bearing becomes bound on the pinion
shaft, lightly tap the end of the pinion gear with a
rawhide/rubber mallet.
(12) Remove the collapsible spacer.
INSTALLATION
(1) Install anewcollapsible preload spacer on pin-
ion shaft.
(2) Install pinion front bearing.
(3) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 36).
(4) Install pinion companion flange with Installer
W-162-D, Cup 8109 and Flange Holder 6958.
(5) Install pinion washer and anewnut on the
pinion gear. Tighten the nut to 298 N´m (220 ft. lbs.)
minimum.Do not overtighten.Maximum torque is
500 N´m (368 ft. lbs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(6) Using Spanner Wrench 6958, a length of 1 in.
pipe and a torque wrench set at 500 N´m (368 ft. lbs.)
crush collapsible spacer until bearing end play is
taken up (Fig. 37).
(7) Slowly tighten the nut in 6.8 N´m (5 ft. lbs.)
increments until the required rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer.
(8) Rotate pinion gear a minimum of ten times and
verify pinion rotates smoothly. Check rotating torque
with an inch pound torque wrench. The rotating
torque should be the amount recorded during
removal plus:
²Original Bearings: 0.56 N´m (5 in. lbs.).
Fig. 35 PINION SEAL PULLER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 36 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
WJFRONT AXLE - 186FBI 3 - 39
PINION SEAL (Continued)

²New Bearings: 1.7 to 3.4 N´m (15 to 30 in. lbs.).
(9) Install propeller shaft with reference marks
aligned.
(10) Install brake rotors and calipers.
(11) Add gear lubricant if necessary.
(12) Install wheel and tire assemblies.
(13) Lower vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove lubricant fill hole plug from the differ-
ential housing cover.
(3) Remove differential cover and drain lubricant.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Never use water,
steam, kerosene or gasoline for cleaning.
(5) Remove hub bearings and axle shafts.
(6) Note installation reference letters stamped on
the bearing caps and housing machined sealing sur-
face (Fig. 38).
(7) Loosen the differential bearing cap bolts.
(8) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes (Fig. 39). Install
hold down clamps and tighten the tool turnbuckle
finger-tight.
Fig. 37 PINION COMPANION FLANGE
1 - COMPANION FLNAGE
2 - DIFFERENTIAL HOUSING
3 - SPANNER WRENCH
Fig. 38 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 39 DIFFERENTIAL SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - ADAPTER
3 - HOLD DOWN CLAMPS
4 - SPREADER
5 - TURNBUCKLE
3 - 40 FRONT AXLE - 186FBIWJ
COLLAPSIBLE SPACER (Continued)

(9) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to stud. Load the lever adapter against the opposite
side of the housing (Fig. 40) and zero the indicator.
(10) Spread housing enough to remove the differ-
ential case from the housing. Measure the distance
with the dial indicator (Fig. 41).
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could dis-
torted and damaged the housing.
(11) Remove the dial indicator.
(12) Hold differential case in position and remove
differential bearing cap bolts and caps.
(13) Remove differential from the housing and tag
differential bearing cups to ensure location (Fig. 42).
(14) Remove differential case preload shims from
the axle housing.
(15) Remove spreader from housing. Tag differen-
tial bearing preload shims to ensure correct location.
Fig. 40 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUDFig. 41 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
Fig. 42 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
WJFRONT AXLE - 186FBI 3 - 41
DIFFERENTIAL (Continued)

DISASSEMBLY
(1) Remove the ring gear.
(2) Drive out the roll pin holding pinion gear mate
shaft with a hammer and punch (Fig. 43).
(3) Remove pinion gear mate shaft from the differ-
ential case and the pinion mate gears.
(4) Rotate differential side gears and remove the
pinion mate gears and thrust washers (Fig. 44).
(5) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft. Align the roll
pin holes in shaft and the differential case.
(4) Install the roll pin in the differential case (Fig.
45).
(5) Install the ring gear.
(6) Lubricate all differential components with
hypoid gear lubricant.
Fig. 43 MATE SHAFT ROLL PIN
1 - PUNCH
2 - LOCKPIN
3 - MATE SHAFT
Fig. 44 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 45 MATE SHAFT ROLL PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
3 - 42 FRONT AXLE - 186FBIWJ
DIFFERENTIAL (Continued)

INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes. Install hold
down clamps and tighten the tool turnbuckle finger-
tight.
(2) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.
(3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator.
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could dis-
torted and damaged the housing.
(4) Remove the dial indicator.
(5) Install differential case in the housing (Fig.
46). Make sure the differential bearing cups remain
on the bearings and the preload shims remain
between the face of the bearing cup and housing. Tap
the differential case to ensure the bearings cups and
shims are fully seated in the housing.
CAUTION: On a Vari-lokTdifferential the oil feed
tube must be pointed at the bottom of the housing.
If differential is installed with the oil feed tube
pointed at the top, the anti-rotation tabs will be
damaged.
(6) Install the bearing caps at their original loca-
tions (Fig. 47).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten the bearing cap bolts to 61 N´m (45 ft.
lbs.).
(10) Install the hub bearings and axle shafts.
Fig. 46 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
Fig. 47 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
WJFRONT AXLE - 186FBI 3 - 43
DIFFERENTIAL (Continued)

(11) Apply a bead 6.35mm (1/4 inch) of red Mopar
Silicone Rubber Sealant or equivalent to the housing
cover (Fig. 48).
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(12) Install differential cover and tighten cover
bolts in a criss-cross pattern to 41 N´m (30 ft. lbs.).
(13) Fill differential with gear lubricant to bottom
of the fill plug hole.
(14) Tighten fill plug to 34 N´m (25 ft. lbs.).
(15) Remove support and lower the vehicle.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from housing.
(2) Remove bearings from the differential case
with Puller C-293-PA, Adapters 8352 and Plug
SP-3289 (Fig. 49).
INSTALLATION
NOTE: If replacement differential side bearings or
differential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
CAUTION: Vari-lokTplenum must be fully seated
against the differential case prior to installing the
ring gear side differential bearing.
(1) Install differential side bearings with Handle
C-4171 and Installer C-3726-A (Fig. 50).
(2) Install differential in housing.
Fig. 48 DIFFERENTIAL COVER
1 - COVER
2 - SEALANT
3 - SEALANT BEADFig. 49 DIFFERENTIAL CASE BEARING
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
3 - 44 FRONT AXLE - 186FBIWJ
DIFFERENTIAL (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Nevar replace one gear without replac-
ing the other matching gear.
(1) Raise and support vehicle
(2) Mark pinion companion flange and propeller
shaft for installation alignment.
(3) Remove propeller shaft from pinion companion
flange and tie propeller shaft to underbody.
(4) Remove differential from axle housing.
(5) Place differential case in a vise with soft metal
jaw (Fig. 51).
(6) Remove bolts holding ring gear to differential
case.
NOTE: On Veri-LokTdifferential the side bearing
and oil feed plenum must be removed before
removing the ring gear bolts.
(7) Driver ring gear off the differential case with a
rawhide hammer (Fig. 51).(8) With Spanner Wrench 6958 and a short length
of 1 in. pipe, hold pinion companion flange and
remove pinion nut and washer (Fig. 52).
(9) Remove pinion companion flange from pinion
shaft with Remover C-452 and Flange Wrench
C-3281.
Fig. 50 DIFFERENTIAL CASE BEARING
1 - INSTALLER
2 - HANDLE
Fig. 51 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 52 Pinion Flange
1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH
WJFRONT AXLE - 186FBI 3 - 45
DIFFERENTIAL CASE BEARINGS (Continued)