lamp JEEP GRAND CHEROKEE 2003 WJ / 2.G User Guide

(6) Remove the U-joint strap bolts at the pinion
shaft yoke (Fig. 10).
(7) Remove bolts holding rear universal joint to
the transfer case yoke.
(8) Separate the rear universal joint from the
transfer case yoke.
(9) Push rear of propeller shaft upward to clear
transfer case yoke.
(10) Separate front universal joint from front axle.
(11) Separate propeller shaft from vehicle.
INSTALLATION
(1) Position front propeller shaft under vehicle
with rear universal joint over the transfer case yoke.
(2) Place front universal joint into the axle pinion
yoke.
(3) Align mark on the rear link yoke and universal
joint to the mark on the transfer case yoke.
(4) Loosely install bolts to hold universal joint to
transfer case yoke.
(5) Align mark on front universal joint to the mark
on the axle pinion yoke.
(6) Tighten the U-joint strap/clamp bolts at the
axle yoke to 19 N´m (14 ft. lbs.).
(7) Tighten the universal joint to transfer case
bolts to 27 N´m (20 ft. lbs.).
(8) Lower the vehicle.
PROPELLER SHAFT - REAR
REMOVAL
(1) Raise and support vehicle on safety stands.
(2) Shift the transmission and transfer case if nec-
essary, to their neutral positions.
(3) Mark a line across the axle pinion yoke and the
propeller shaft yoke for installation reference.
(4) Remove the bolts holding the universal joint
clamps to the pinion yoke.
(5) Slide the slip yoke off of the transmission, or
transfer case, output shaft and remove the propeller
shaft (Fig. 11).
INSTALLATION
(1) Slide the slip yoke on the transmission, or
transfer case, output shaft.
(2) Align the installation reference marks made on
the propeller shaft and pinion yoke.
(3) Position universal joint into pinion yoke.
(4) Install the universal joint clamp and clamp
bolts to the pinion yoke. Tighten bolts to 19 N´m (14
ft. lbs.).
(5) Lower the vehicle.
Fig. 10 FRONT PROPELLER SHAFT - 4.7L
1 - FRONT AXLE
2 - BOOT
3 - PROPELLER SHAFT
4 - DOUBLE CARDAN U-JOINT
5 - TRANSFER CASE
6 - BOOT
7 - SLINGER
8 - CLAMP
9 - YOKE
Fig. 11 REAR PROPELLER SHAFT
1 - SLIDING YOKE
2 - PROPELLER SHAFT
3 - PINION YOKE
4 - CLAMP/STRAP
5 - BOLT
6 - OUTPUT SHAFT
WJPROPELLER SHAFT 3 - 7
PROPELLER SHAFT - FRONT 4.7L (Continued)

INSTALLER W-162-D
CUP 8109
SEAL INSTALLER 8110
TURNBUCKLE 6797
PINION DEPTH SET 6774
DUMMY SHIMS 8107
PINION BLOCK 8804
SEAL REMOVER 7794-A
CLAMP INSTALLER C-4975-A
SPANNER WRENCH 6958
3 - 32 FRONT AXLE - 186FBIWJ
FRONT AXLE - 186FBI (Continued)

AXLE SHAFT SEALS
REMOVAL
(1) Raise and support vehicle.
(2) Remove axle shafts.
(3) Remove differential assembly.
(4) Remove inner axle shaft seals with a pry bay.
INSTALLATION
(1) Remove any sealer remaining from original
seals.
(2) Install oil seals with Discs 8110 and Turn-
buckle 6797 (Fig. 24). Tighten tool until disc bottoms
in housing.
(3) Install differential and axle shafts.
(4) Fill differential with lubricant.
(5) Remove support and lower vehicle.
AXLE - C/V JOINT
REMOVAL
NOTE: The only service procedure to be performed
on the axle C/V joint, is the replacement of the joint
seal boot. If any failure of internal axle shaft com-
ponents is diagnosed during a vehicle road test, the
axle shaft must be replaced as an assembly.
(1) Remove axle shaft.
(2) Remove large and small C/V boot clamps (Fig.
25) and discard.
(3) Slid boot off the C/V joint housing and slide it
down the axle shaft.
(4) Remove C/V joint from axle then slid boot off
the axle.
(5) Thoroughly clean and inspect axle C/V joint
assembly and axle shaft for any signs of excessive
wear.
INSTALLATION
(1) Slidenewboot over axle shaft.
(2) Install C/V joint onto the axle shaft.
(3) Distribute 1/2 the amount of grease provided in
seal boot service package(DO NOT USE ANY
OTHER TYPE OF GREASE)into axle C/V joint
assembly housing. Put the remaining amount into
the sealing boot.
(4) Position boot on the axle locating grove and on
the C/V joint.
Fig. 24 AXLE SEAL TOOLS
1 - TURNBUCKLE
2 - DISCS
Fig. 25 OUTER C/V BOOT CLAMPS
1 - C/V JOINT HOUSING
2 - LARGE CLAMP
3 - AXLE SHAFT
4 - SMALL CLAMP
5 - SEALING BOOT
WJFRONT AXLE - 186FBI 3 - 35

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)

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)

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)

(7) Check rotating torque with an inch pound
torque wrench (Fig. 44). The rotating torque of the
pinion gear should be, the reading recorded during
removal plus an additional 0.56 N´m (5 in. lbs.).
(8) Install propeller shaft with reference marks
align.
(9) Install rear brake calipers and rotors (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS
- INSTALLATION).
(10) Add gear lubricant, if necessary.
(11) Install wheel and tire assemblies.
(12) Remove supports and lower vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove fill hole plug from the differential
housing cover.
(3) Remove differential housing cover and drain
fluid.
(4) Clean the housing cavity with flushing oil, light
engine oil or lint free cloth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
(5) Remove axle shafts.(6)
Note the reference letters stamped on the bearing
caps and housing machined sealing surface (Fig. 45).
(7) Loosen the differential bearing cap bolts.
(8) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes (Fig. 46). Install
holddown clamps and tighten the turnbuckle finger-
tight.
Fig. 44 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 45 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 46 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
WJREAR AXLE - 198RBI 3 - 75
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 pilot stud. Load the indicator plunger against the
opposite side of the housing (Fig. 47) and zero the
indicator.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). If housing is over-spread, it could dis-
torted and damaged the housing.
(10) Spread housing enough to remove the differ-
ential case from the housing. Measure the distance
with the dial indicator (Fig. 48).
(11) Remove the dial indicator.
(12) While holding the differential case in position,
remove the differential bearing cap bolts and caps.
(13) Remove differential from the housing and tag
differential bearing cups to indicate location (Fig. 49).
(14) Remove spreader from housing.
Fig. 47 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 48 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
Fig. 49 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
3 - 76 REAR AXLE - 198RBIWJ
DIFFERENTIAL (Continued)

DISASSEMBLY
(1) Remove pinion shaft lock screw (Fig. 50).
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove dif-
ferential pinions and thrust washers (Fig. 51).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion gears and thrust
washers.
(3) Install the pinion mate shaft.
(4) Align hole in the pinion mate shaft with the
hole in the differential case and install the pinion
mate shaft lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Position Spreader W-129-B with Adapter set
6987 on differential housing locating holes. Install
the holddown 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.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). If housing is over-spread, it could be dis-
torted or damaged.
(3) Spread housing enough to install the case in
the housing.
(4) Remove the dial indicator.
(5) Install differential case in housing (Fig. 52).
Verify differential bearing cups remain in position on
the bearings and preload shims are between the face
of the bearing cup and the housing. Tap the differen-
tial case to ensure bearings cups and shims are
seated in the housing.
CAUTION: On a Vari-lokTdifferential the oil feed
tube must be pointed at the bottom of the housing
(Fig. 53). If differential is installed with the oil feed
tube pointed at the top, the anti-rotation tabs will be
damaged.
(6) Install bearing caps in their original locations
(Fig. 54).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten bearing cap bolts in a criss-cross pat-
tern to 77 N´m (57 ft. lbs.).
(10) Install the axle shafts.
Fig. 50 SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 51 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
WJREAR AXLE - 198RBI 3 - 77
DIFFERENTIAL (Continued)