axle JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

(6) Install adjuster locks on the bearing caps.
(7) Install axle shafts.
(8) Apply a bead of red Mopar silicone rubber axle
sealant or equivalent to the housing cover (Fig. 33).
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.
(9) Install cover and tighten bolts in a criss-cross
pattern to 41 N´m (30 ft. lbs.).
(10) Fill differential with gear lubricant to bottom
of the fill plug hole.
(11) Install the fill hole plug.
(12) Install wheel and tire assemblies.
(13) Remove support and lower vehicle.
(14) Trac-loktdifferential equipped 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.DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT
The most common problem is a chatter noise when
turning corners. Before removing the unit for repair,
drain, flush and refill the axle with the specified
lubricant. A container of Mopar Trac-loktLubricant
(friction modifier) should be added after repair ser-
vice or during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. This
will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 34).
(6) If rotating torque is less than 41 N´m (56 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
Fig. 33 Differential Cover Sealant
1 - SEALANT
2 - DIFFERNTIAL COVER
Fig. 34 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 106 REAR AXLE-81/4KJ
DIFFERENTIAL (Continued)

DISASSEMBLY
(1) Clamp side gear Fixture 8138 in a vise and set
differential case on the fixture (Fig. 35).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-loktdifferential can be serviced
with the ring gear installed.
(3) Remove pinion gear mate shaft lock screw.
(4) Remove pinion gear mate shaft with a drift and
hammer.
(5) Install Discs 8140 without threaded hole in the
lower side gear (Fig. 36).
(6) Install Disc 8140 with threaded hole in the
upper side gear. Thread Forcing Screw 6960-4
through the upper disc until it becomes centered in
lower disc.
(7) Insert a screw driver in slot of upper disc (Fig.
37) to prevent disc from turning.
Fig. 36 LOWER DISC
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
Fig. 37 TRAK-LOCTTOOLS
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - LOWER DISC
5 - THREADED ROD
6 - UPPER DISC
Fig. 35 DIFFERENTIAL CASE FIXTURE
1 - FIXTURE
2 - VISE
3 - DIFFERENTIAL
KJREAR AXLE - 8 1/4 3 - 107
DIFFERENTIAL - TRAC-LOK (Continued)

(8) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress Belleville springs in clutch
packs (Fig. 38).
(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 39).
(10) Insert Turning Bar 6960-2 into the pinion
mate shaft hole in the case (Fig. 40).(11) Loosen the Forcing Screw in small increments
until the clutch pack tension is relieved and the dif-
ferential case can be turned using Turning Bar.
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
(14) Remove Forcing Screw and discs.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in order during removal
(Fig. 41).
Fig. 38 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 39 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 40 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 41 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
3 - 108 REAR AXLE-81/4KJ
DIFFERENTIAL - TRAC-LOK (Continued)

(16) Remove differential case from the fixture.
Remove side gear, clutch pack retainer and clutch
pack. Keep plates in order during removal.
CLEANING
Clean all components in cleaning solvent and dry
components with compressed air.
INSPECTION
Inspect clutch pack plates for wear, scoring or dam-
age. Replace both clutch packs if any one component
in either pack is damaged. Inspect side and pinion
gears for cracks chips or damage and replace as nec-
essary. Inspect differential case and pinion shaft and
replace if worn or damaged.
ASSEMBLY
Lubricate each component with gear lubricant
before assembly.
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 42).
(2) Install assembled clutch disc packs on the side
gear hubs.(3) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 43).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
(4) Set differential case on Fixture 8138.
(5) Install lubricated Disc 8140 without the hole in
lower side gear (Fig. 44).
(6) Install the upper side gear and clutch disc pack
(Fig. 44).
(7) Hold assembly in position. Insert Disc 8140
with threaded hole into top side gear.
(8) Install Forcing Screw 6960-4 and tighten screw
to slightly compress clutch disc.
(9) Place pinion gears in position in side gears and
verify that the pinion mate shaft hole is aligned.
(10) Rotate case with Turning Bar 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 pinion gears.
(11) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(12) 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.
(13) Remove forcing screw and discs.
Fig. 42 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 43 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
KJREAR AXLE - 8 1/4 3 - 109
DIFFERENTIAL - TRAC-LOK (Continued)

(14) Install pinion gear mate shaft and align holes
in shaft and case.
(15) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(16) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle.
(2) Remove differential bearings from the case
with Puller/Press C-293-PA and Adapters C-293-48
and Plug SP-3289 (Fig. 45).
INSTALLATION
(1) Install differential side bearings with Installer
C-4340 and Handle C-4171 (Fig. 46).
(2) Install differential case in axle.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
CAUTION: The ring and pinion gears are serviced in
a matched set. Never replace one gear without
replacing the other matched gear.
(1) Mark pinion yoke and propeller shaft for
installation reference.
(2) Remove propeller shaft from pinion yoke and
tie propeller shaft to underbody.
(3) Remove differential from axle housing.
(4) Place differential case in a vise with soft metal
jaw (Fig. 47).
(5) Remove bolts holding ring gear to differential
case.
(6) Drive ring gear from the differential case with
a rawhide hammer.
Fig. 44 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 45 Differential Bearing Puller
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
3 - 110 REAR AXLE-81/4KJ
DIFFERENTIAL - TRAC-LOK (Continued)

(7) Hold pinion yoke with Holder 6719A and
remove pinion yoke nut and washer.
(8) Remove pinion yoke from pinion shaft with
Remover C-452 (Fig. 48).
(9) Remove pinion from the housing (Fig. 49).
Fig. 46 Differential Bearing Installer
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 47 Ring Gear
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 48 Pinion Yoke
1 - PINION YOKE
2 - REMOVER
Fig. 49 Pinion Gear
1 - RAWHIDE HAMMER
KJREAR AXLE - 8 1/4 3 - 111
PINION GEAR/RING GEAR/TONE RING (Continued)

(10) Remove pinion shaft seal with a pry tool or
slide-hammer mounted screw.
(11) Remove oil slinger, if equipped, and front pin-
ion bearing.
(12) Remove front pinion bearing cup with
Remover C-4345 and Handle C-4171 (Fig. 50).
(13) Remove rear bearing cup from housing (Fig.
51) with Remover C-4307 and Handle C-4171.
(14) Remove collapsible preload spacer (Fig. 52).
(15) Remove rear bearing from the pinion (Fig. 53)
with Puller/Press C-293-PA and Adapters C-293-47.
(16) Remove depth shims from the pinion shaft
and record the shims thickness.
INSTALLATION
NOTE: A pinion depth shim/oil baffle is placed
between the rear pinion bearing cone and pinion
gear. If the ring and pinion gears are reused, the
original pinion depth shim/oil baffle can be used.
Refer to Adjustments (Pinion Gear Depth) to select
the proper shim thickness if ring and pinion gear
are replaced.
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of pinion bearing cups.
(2) Install rear pinion bearing cup (Fig. 54) with
Installer C-4308 and Handle C-4171 and verify cup is
seated.(3) Install front pinion bearing cup (Fig. 55) with
Installer D-130 and Handle C-4171 and verify cup is
seated.
Fig. 50 Front Pinion Bearing Cup
1 - REMOVER
2 - HANDLE
Fig. 51 Rear Pinion Bearing Cup
1 - DRIVER
2 - HANDLE
Fig. 52 Collapsible Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
3 - 112 REAR AXLE-81/4KJ
PINION GEAR/RING GEAR/TONE RING (Continued)

(4) Install pinion front bearing and oil slinger, if
equipped.(5) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with Installer
C-4076-B and Handle C-4735 (Fig. 56).
(6) Place proper thickness depth shim on the pin-
ion.
(7) Install rear bearing and slinger if equipped, on
the pinion shaft (Fig. 57) with Installer 6448 and a
press.
(8) Install anewcollapsible preload spacer on pin-
ion shaft and install pinion in housing (Fig. 58).
(9) Install pinion in housing.
(10) Install yoke with Installer C-3718 and Yoke
Holder 6719A.
Fig. 53 Rear Pinion Bearing Puller
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 54 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 55 Front Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 56 Pinion Seal
1 - HANDLE
2 - DIFFERENTIAL HOUSING
3 - INSTALLER
KJREAR AXLE - 8 1/4 3 - 113
PINION GEAR/RING GEAR/TONE RING (Continued)

(11) Install yoke washer and a new nut on the pin-
ion. The convex side of the washer must face out-
ward.
(12) Tighten the nut to 285 N´m (210 ft. lbs.).
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.
(13) Holding the yoke with Holder 6719A slowly
tighten the nut in 6.8 N´m (5 ft. lbs.) increments
until the desired rotating torque is achieved. Mea-
sure the rotating torque frequently to avoid over
crushing the spacer (Fig. 59).
(14) Check bearing rotating torque with an inch
pound torque wrench (Fig. 59). The pinion gear rotat-
ing torque should be:
²Original Bearings: 1 to 2 N´m (10 to 20 in. lbs.).
²New Bearings: 1 to 5 N´m (10 to 30 in. lbs.).
Fig. 57 Rear Pinion Bearing
1 - PRESS
2 - INSTALLATION
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 58 Collapsible Preload Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 59 Pinion Rotating Torque
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 114 REAR AXLE-81/4KJ
PINION GEAR/RING GEAR/TONE RING (Continued)

(15) Invert the differential case.
(16) Install ring gear on the differential case and
start two ring gear bolts. This will provide case-to-
ring gear bolt hole alignment.
(17) Invert the differential case in the vise.
(18) Installnewring gear bolts and alternately
tighten to 102 N´m (75 ft. lbs.) (Fig. 60).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(19) Install differential in axle housing and verify
gear mesh refer to Adjustments (Gear Contact Pat-
tern).
(20) Install differential cover fill with gear lubri-
cant.
(21) Install the propeller shaft with reference
marks aligned.
(22) Install wheel and tire assemblies and lower
the vehicle.
Fig. 60 Ring Gear
1 - TORQUE WRENCH
2 - BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
KJREAR AXLE - 8 1/4 3 - 115
PINION GEAR/RING GEAR/TONE RING (Continued)