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

(3) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 41).
(4) Install yoke with Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fig. 42).
(5) Install yoke washer andnewnut on the pinion
gear. Tighten the nut to 271 N´m (200 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be
installed.
(6) Using yoke with Spanner Wrench 6958 and a
torque wrench set at 474 N´m (350 ft. lbs.), (Fig. 43)
slowly tighten the nut in 6.8 N´m (5 ft. lbs.) incre-
ments until the rotating torque is achieved. Measurethe rotating torque frequently to avoid over crushing
the collapsible spacer (Fig. 44).
NOTE: If more than 474 N´m (350 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
Fig. 40 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 41 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 42 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 43 PINION NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
3 - 74 REAR AXLE - 198RBIWJ
COLLAPSIBLE SPACER (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)

(5) Position the differential case on the Holding
Fixture 6965.
(6) Install lubricated Step Plate C-6960-3 in lower
side gear (Fig. 68).
(7) Install the upper side gear and clutch disc pack
(Fig. 68).
(8) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(9) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(10) Place pinion gears in position in side gears
and verify that the pinion mate shaft hole is aligned.
(11) Rotate case with Turning Bar C-6960-2 until
the pinion mate shaft holes in pinion gears align
with holes in case. It may be necessary to slightly
tighten the forcing screw in order to install the pin-
ion gears.
(12) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Raise and support vehicle.
(2) Remove differential case from axle housing.
(3) Remove bearings from the differential case
with Puller/Press C-293-PA, Adapter 8352 and Plug
SP-3289 (Fig. 69).
Fig. 68 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE
Fig. 69 Differential Bearing
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
WJREAR AXLE - 198RBI 3 - 83
DIFFERENTIAL-TRAC-LOC (Continued)

(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of the pinion bearing cups.
(2) Install pinion rear bearing cup with Installer
D-146 and Driver Handle C-4171 (Fig. 80) and verify
cup is seated.
(3) Install pinion front bearing cup with Installer
D-130 and Handle C-4171 (Fig. 81) and verify cup is
seated.(4) Install pinion front bearing and oil slinger, if
equipped.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 82).
(6) Install depth shim on the pinion gear.
(7) Install rear bearing and slinger if equipped, on
the pinion gear with Installer W-262 and a press
(Fig. 83).
Fig. 80 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 81 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 82 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 83 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
WJREAR AXLE - 198RBI 3 - 87
PINION GEAR/RING GEAR (Continued)

and therefore creates pressure in the pump. The tun-
ing of the front and rear axle orifices and valves
inside the gerotor pump is unique and each system
includes a torque-limiting pressure relief valve to
protect the clutch pack, which also facilitates vehicle
control under extreme side-to-side traction varia-
tions. The resulting pressure is applied to the clutch
pack and the transfer of torque is completed.
Under conditions in which opposite wheels are on
surfaces with widely different friction characteristics,
Vari-loktdelivers far more torque to the wheel on
the higher traction surface than do conventional
Trac-loktsystems. Because conventional Trac-lokt
differentials are initially pre-loaded to assure torque
transfer, normal driving (where inner and outer
wheel speeds differ during cornering, etc.) produces
torque transfer during even slight side-to-side speed
variations. Since these devices rely on friction from
this preload to transfer torque, normal use tends to
cause wear that reduces the ability of the differential
to transfer torque over time. By design, the Vari-lokt
system is less subject to wear, remaining more con-
sistent over time in its ability to transfer torque. The
coupling assembly is serviced as a unit. From a ser-
vice standpoint the coupling also benefits from using
the same lubricant supply as the ring and pinion
gears.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, tooth contact, worn/damaged
gears, or the carrier housing not having the proper
offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
3 - 92 REAR AXLE - 226RBAWJ
REAR AXLE - 226RBA (Continued)

(10) Remove pinion seal with Remover 7794-A and
a slide hammer (Fig. 33).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate in
installer (Fig. 34).
(2) Install yoke on the pinion gear with Installer
C-3718 and Spanner Wrench 6958 (Fig. 35).
(3) Install anewnut on the pinion gear.Tighten
the nut only enough to remove the shaft end
play.
CAUTION: Do not exceed the minimum tightening
torque 298 N´m (220 ft. lbs.) when installing the pin-
ion yoke retaining nut at this point. Damage to col-
lapsible spacer or bearings may result.(4) Rotate the pinion a minimum of ten times and
verify pinion rotates smoothly. Rotate the pinion
shaft using an inch pound torque wrench. Rotating
torque should be equal to the reading recorded dur-
ing removal, plus 0.56 N´m (5 in. lbs.) (Fig. 36).
Fig. 33 Pinion Seal Remover
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 34 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 35 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - DIFFERENTIAL HOUSING
4 - SPANNER WRENCH
Fig. 36 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 112 REAR AXLE - 226RBAWJ
PINION SEAL (Continued)

(9) Remove pinion shaft seal with Remover 7794-A
and slide hammer (Fig. 40).
(10)
Remove front pinion bearing using a pair of pick
tools to pull the bearing off the pinion gear shaft.
NOTE: If the pinion bearing becomes bound on the
pinion shaft, lightly tap the end of the shaft with a
rawhide/rubber mallet.
(11) Remove the collapsible spacer.
INSTALLATION
(1) Install anewcollapsible spacer on pinion
shaft.
(2) Install pinion front bearing on the pinion shaft.
(3) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 41).
(4) Install yoke with Installer C-3718 and Spanner
Wrench 6958 (Fig. 42).(5) Install yoke washer andnewnut on the pinion
gear. Tighten the nut to 271 N´m (200 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be installed.
(6) Using yoke with Spanner Wrench 6958 and a
torque wrench set at 380 N´m (280 ft. lbs.), (Fig. 43)
slowly tighten the nut in 6.8 N´m (5 ft. lbs.) incre-
ments until the rotating torque is achieved. Measure
the rotating torque frequently to avoid over crushing
the collapsible spacer (Fig. 44).
Fig. 43 PINION NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
Fig. 40 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 41 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 42 Pinion Yoke Installer
1 - INSTALLER
2 - PINION YOKE
3 - DIFFERENTIAL HOUSING
4 - SPANNER WRENCH
3 - 114 REAR AXLE - 226RBAWJ
COLLAPSIBLE SPACER (Continued)

NOTE: If more than 380 N´m (280 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
(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 rotors and calipers.
(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 - 226RBA 3 - 115
COLLAPSIBLE SPACER (Continued)

(6) Install lubricated Step Plate C-6960-3 in lower
side gear (Fig. 68).
(7) Install the upper side gear and clutch disc pack
(Fig. 68).
(8) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(9) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(10) Place pinion gears in position in side gears
and verify that the pinion mate shaft hole is aligned.
(11) Rotate case with Turning Bar C-6960-2 until
the pinion mate shaft holes in pinion gears align
with holes in case. It may be necessary to slightly
tighten the forcing screw in order to install the pin-
ion gears.
(12) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Install pinion gear mate shaft and align holes
in shaft and case.(16) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove side bearings from the differential case
with Puller/Press C-293-PA, Adapters 8353 and Plug
C-293-3 (Fig. 69).
INSTALLATION
NOTE: If differential side bearings or differential
case are replaced, differential side bearing shim
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.
Fig. 68 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE
Fig. 69 Differential Bearing Removal
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
WJREAR AXLE - 226RBA 3 - 123
DIFFERENTIAL - TRAC-LOK (Continued)

(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of pinion bearing cups.
(2) Install pinion rear bearing cup with Installer
C-4308 and Driver Handle C-4171 (Fig. 80) and ver-
ify cup is seated.
(3) Install pinion front bearing cup with Installer
D-129 and Handle C-4171 (Fig. 81) and verify cup is
seated.(4) Install pinion front bearing and oil slinger, if
equipped.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
(Fig. 82).
(6) Install depth shim on the pinion gear.
(7) Install rear bearing on the pinion gear with
Installer 6448 and a press (Fig. 83).
Fig. 80 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 81 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 82 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 83 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
WJREAR AXLE - 226RBA 3 - 127
PINION GEAR/RING GEAR (Continued)