axle JEEP LIBERTY 2002 KJ / 1.G User Guide

SHOCK
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
CAUTION: Do not allow the axle to hang from the
upper suspension arm ball joint.
(2) Remove the upper nut and bolt from the frame
bracket (Fig. 2).
(3) Remove the lower nut and bolt from the axle
bracket. Remove the shock absorber.
INSTALLATION
(1) Install the shock absorber in the frame bracket
and install the bolt and nut (Fig. 2).
(2) Install the shock absorber in the axle bracket
and install the bolt and nut (Fig. 2).
(3) Remove the supports and lower the vehicle.
(4) Tighten the upper mounting nuts to 108 N´m
(80 ft. lbs.). Tighten the lower mounting nuts to 115
N´m (85 ft. lbs.).
SPRING
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
(2) Remove the shock absorber lower bolt from the
axle bracket.
(3) Lower the hydraulic jack and tilt the axle and
remove the coil spring (Fig. 3).
(4) Remove and inspect the upper and lower
spring isolators (Fig. 3).
INSTALLATION
(1) Install the upper isolator (Fig. 3).
(2) Install the lower isolator (Fig. 3).
(3) Pull down on the axle and position the coil
spring in the lower isolator.
CAUTION: Ensure the spring is positioned on the
lower isolator.
(4) Raise the axle with the hydraulic jack.
(5) Install the shock absorber to the axle bracket
and tighten to 115 N´m (85 ft. lbs.).
(6) Remove the supports and lower the vehicle.
(7) Tighten the stabilizer bar links to 99 N´m (73
ft. lbs.).
Fig. 2 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
Fig. 3 COIL SPRING
1 - UPPER INSULATOR
2 - JOUNCE BUMPER
3 - COIL SPRING
2 - 18 REARKJ

JOUNCE BUMPER
REMOVAL
(1) Remove the shock (Refer to 2 - SUSPENSION/
REAR/SHOCK - REMOVAL).
(2) Remove the coil spring (Refer to 2 - SUSPEN-
SION/REAR/SPRING - REMOVAL).
(3) Pull the jounce bumper downwards to remove.
(Fig. 4)
INSTALLATION
(1) Install the jounce bumper into the mount by
twisting the bumper into place (Fig. 4).
(2) Install the coil spring (Refer to 2 - SUSPEN-
SION/REAR/SPRING - INSTALLATION).
(3) Install the shock (Refer to 2 - SUSPENSION/
REAR/SHOCK - INSTALLATION).
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the stabilizer bar bolts from the lower
suspension arm. (Fig. 5).
(3) Remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar over the axle and
install the bolts to the lower suspension arm (Fig. 6).
Ensure the bar is centered with equal spacing on
both sides. Tighten the bolts to 99 N´m (73 ft. lbs.).
(2) Remove support and lower the vehicle.
Fig. 4 JOUNCE BUMPER
Fig. 5 REAR STABILIZER BAR
1 - MOUNTING HOLES
2 - STABILIZER BAR
Fig. 6 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
KJREAR 2 - 19

UPPER BALL JOINT
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint pinch bolt from the top of
the axle. (Fig. 7)
(4) Seperate the ball joint arm assembly from the
differential housing by prying upwards.
INSTALLATION
(1)Raise the rear axle with a hydraulic jack to align
the ball joint with the differential housing bracket.
(2) Insert the ball joint into the differential hous-
ing bracket.
(3) Install the ball joint pinch bolt and tighten to
95 N´m (70 ft. lbs.). (Fig. 7).
(4) Remove the supports and lower the vehicle.
UPPER CONTROL ARM
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The suspension arm uses vertical spool bushings to
isolate road noise. The suspension arm is bolted
through bushings to cage nuts in the body and a ball
joint to the top of the differential housing.
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The upper suspension arm provides fore/aft and
lateral location of the rear axle. The suspension arm
travel is limited through the use of jounce bumpers
in compression and shock absorbers in rebound.
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint pinch bolt from the top of
the differential housing bracket (Fig. 7).
(4) Remove partial nuts from the heat shield in
order to lower the shield down enough to get the
proper clearence to remove the right side bolt from
the body.
(5) Remove the upper suspension arm mounting
bolts from the body and remove the arm (Fig. 8).
(6) Remove the support bracket mounting bolts if
needed. (Fig. 9)
Fig. 7 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLTFig. 8 UPPER CONTROL ARM
1 - BODY MOUNTS
2 - UPPER BALL JOINT
3 - STABILIZER BAR
4 - UPPER CONTROL ARM
5 - LOWER CONTROL ARM
Fig. 9 BALL JOINT BRACKET
1 - UPPER BALL JOINT
2 - SUPPORT BRACKET BOLTS
2 - 20 REARKJ

INSTALLATION
(1) Position the upper suspension arm in the
frame rail brackets (Fig. 8).
(2) Install the mounting bolts and tighten to 100
N´m (74 ft. lbs.).
(3) Retighten the heat shield back into place.
(4) Pull the arm down on the differential housing
bracket and install the pinch bolt and nut. Tighten
the nut to 95 N´m (70 ft. lbs.) (Fig. 7).
(5) Remove the supports and lower the vehicle.
LOWER CONTROL ARM
DESCRIPTION
The lower suspension arms are stamped steel and
welded and use voided round bushings at the axle
end and solid rubber at the body end of the arm.
OPERATION
The bushings provide isolation from the axle. The
arms mount to the unibody frame rail bracket and
the axle brackets. The arm and bushings provide
location and react to loads.
REMOVAL
(1) Raise the vehicle and support the rear axle.
(2) Remove the stabilizer bar retaining bolts from
the suspension arm.
(3) Remove the lower suspension arm nut and bolt
from the axle bracket (Fig. 10).
NOTE: When removing the right side suspension
arm from the frame rail it will be necessary to pry
the exhaust over slightly to allow enough clearance
to remove the bolt.
(4) Remove the nut and bolt (Fig. 10) from the
frame rail and remove the lower suspension arm.
INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.NOTE: The end of the arm with the voided round
bushing attaches to the axle bracket.
(2) Install the axle bracket bolt and nut finger
tight (Fig. 10).
NOTE: When installing the right side suspension
arm to the frame rail it will be necessary to pry the
exhaust over slightly to allow enough clearance to
install the bolt.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
(4) Install the stabilizer bar retaining bolts to the
suspension arm.
(5) Remove the supports and lower the vehicle.
(6) With the vehicle on the ground tighten the nut
at the frame to 163 N´m (120 ft. lbs.). Tighten the
nut at the axle bracket to 163 N´m (120 ft. lbs.).
Fig. 10 LOWER SUSPENSION ARM
1 - AXLE BRACKET BOLT
2 - LOWER CONTROL ARM
3 - BODY BRACKET BOLT
KJREAR 2 - 21
UPPER CONTROL ARM (Continued)

REAR
SPECIAL TOOLS
REAR SUSPENSION
UPPER BALL JOINT
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint pinch bolt from the top of
the axle. (Fig. 9)(4) Separate the ball joint arm assembly from the
differential housing by prying upwards.
(5) Remove the upper suspension arm from the
vehicle (Refer to 2 - SUSPENSION/REAR/UPPER
CONTROL ARM - REMOVAL).
(6) Secure the suspension arm in a vise.
(7) Install special tools C-4212F (press), 8861-3
(driver) and 8861-2 (receiver) (Fig. 10)
(8) Press out the old ball joint.
INSTALLATION
(1) Install special tools C-4212F (press), 8861-1
(receiver) and 8861-2 (driver) with the ball joint in
place (Fig. 11).
BALL JOINT PRESS - C-4212F
REMOVER / INSTALLER REAR UPPER BALL JOINT
- 8861
REMOVAL / INSTALLATION REAR UPPER
CONTROL ARM BUSHINGS - 8860
Fig. 9 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 10 UPPER BALL JOINT - REMOVAL
1 - C-4212F PRESS
2 - 8861-3 DRIVER
3 - 8861-2 RECEIVER
2s - 6 SUSPENSIONKJ

(2) Press the ball joint in the upper suspension
arm.
(3) Remove the upper suspension arm from the
vise.
(4) Reinstall the upper suspension arm (Refer to 2
- SUSPENSION/REAR/UPPER CONTROL ARM -
INSTALLATION).
(5) Raise the rear axle with a hydraulic jack to
align the ball joint with the differential housing
bracket.
(6) Insert the ball joint into the differential hous-
ing bracket.
(7) Install the ball joint pinch bolt and tighten to
95 N´m (70 ft. lbs.). (Fig. 9).
(8) Remove the supports and lower the vehicle.
BUSHINGS
REMOVAL
REMOVAL - LOWER SUSPENSION ARM
BUSHING
(1) Remove the lower suspension arm (Refer to 2 -
SUSPENSION/REAR/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the suspension arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.(3) Install special tools 8862-4 (receiver), 8862-5
(spacer) and 8862-1 or 8862- 2 (driver) with the
threaded rod 8839 and the bearing as shown (Fig. 12)
(4) Press out the bushing.
REMOVAL - UPPER SUSPENSION ARM
BUSHING
(1) Remove the upper suspension arm (Refer to 2 -
SUSPENSION/REAR/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the suspension arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Install special tools 8853-3 (driver), 8860-1
(receiver) and with the threaded rod 8838 and the
bearing as shown (Fig. 13)
(4) Press out the bushing.
Fig. 11 UPPER BALL JOINT - INSTALLATION
1 - C-4212F PRESS
2 - 8861-1 RECEIVER
3 - 8861-2 DRIVER
Fig. 12 LOWER SUSPENSION ARM BUSHING
REMOVAL
1 - 8839 THREADED ROD
2 - 8862-4 RECEIVER
3 - 8862-5 SPACER
4 - 8862-1 OR 8862-2 DRIVERS
KJSUSPENSION 2s - 7
UPPER BALL JOINT (Continued)

DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT......................1
HALF SHAFT...........................10
FRONT AXLE - 186FIA....................19REAR AXLE - 198RBI.....................49
REAR AXLE-81/4.......................86
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT...............................1
STANDARD PROCEDURES - PROPELLER
SHAFT ANGLE........................3
SPECIFICATIONS
PROPELLER SHAFT....................6
SPECIAL TOOLS........................6
PROPELLER SHAFT - FRONT
REMOVAL.............................6INSTALLATION..........................6
PROPELLER SHAFT - REAR
REMOVAL.............................7
INSTALLATION..........................7
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY..........................8
ASSEMBLY.............................9
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT
VIBRATION
Tires that are out-of-round, or wheels that are
unbalanced, will cause a low frequency vibration.
Brake rotors that are unbalanced will cause a
harsh, low frequency vibration.Driveline vibration can also result from loose or
damaged engine mounts.
Propeller shaft vibration increases as the vehicle
speed is increased. A vibration that occurs within a
specific speed range is not usually caused by a pro-
peller shaft being unbalanced. Defective joints or an
incorrect propeller shaft angle, are usually the cause
of such a vibration.
KJDIFFERENTIAL & DRIVELINE 3 - 1

DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1. Undercoating or other foreign
material on shaft.1. Clean exterior of shaft and wash
with solvent.
2. Loose U-joint clamp screws. 2. Install new clamps and screws
and tighten to proper torque.
3. Loose or bent U-joint yoke or
excessive runout.3. Install new yoke.
4. Incorrect driveline angularity. 4. Measure and correct driveline
angles.
5. Worn joint. 5. Install new joint.
6. Propeller shaft damaged or out
of balance.6. Installl new propeller shaft.
7. Broken rear spring. 7. Install new rear spring.
8. Excessive runout or unbalanced
condition.8. Re-index propeller shaft, test, and
evaluate.
9. Excessive drive pinion gear shaft
runout.9. Re-index propeller shaft and
evaluate.
10. Excessive axle yoke deflection. 10. Inspect and replace yoke if
necessary.
11. Excessive transfer case runout. 11. Inspect and repair as necessary.
Joint Noise 1. Loose U-joint clamp screws. 1. Install new clamps and screws
and tighten to proper torque.
2. Lack of lubrication. 2. Replace joints as necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180É relative to the yoke may eliminate some
vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas.If the pro-
peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, are properly installed, and are cor-
rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque.
(6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90É apart.
(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.(9) Install a screw clamp at position 1 (Fig. 1).
Fig. 1 CLAMP AT POSITION 1
1 - CLAMP
2 - SCREWDRIVER
3 - 2 PROPELLER SHAFTKJ
PROPELLER SHAFT (Continued)

(10) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
clamp to one of the other three positions. Repeat the
vibration test.
(11) If there is no difference in vibration at the
other positions, the source of the vibration may not
be propeller shaft.
(12) If the vibration decreased, install a second
clamp (Fig. 2) and repeat the test.
(13) If the additional clamp causes an additional
vibration, separate the clamps (1/4 inch above and
below the mark). Repeat the vibration test (Fig. 3).
(14) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
(15) If the vibration remains unacceptable, apply
the same steps to the front end of the propeller shaft.
(16) Install the wheel and tires. Lower the vehicle.RUNOUT
(1) Remove dirt, rust, paint and undercoating from
the propeller shaft surface where the dial indicator
will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft sufficiently far away from weld areas to ensure
that the effects of the weld process will not enter into
the measurements.
(4) Refer to Runout Specifications chart.
(5) If the propeller shaft runout is out of specifica-
tion, remove the propeller shaft, index the shaft 180É,
and re-install the propeller shaft. Measure shaft
runout again.
(6) If the propeller shaft runout is now within
specifications, mark the shaft and yokes for proper
orientation.
(7) If the propeller shaft runout is not within spec-
ifications, verify that the runout of the transmission/
transfer case and axle are within specifications.
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURES - PROPELLER
SHAFT ANGLE
The procedure applies to both the front propeller
shafts and the rear propeller shaft. To obtain the
front (output) angle on the C/V front propeller shaft,
the inclinometer is placed on the machined ring of
the pinion flange. To obtain the propeller shaft angle
measurement on the C/V front propeller shaft, the
inclinometer is placed on the propeller shaft tube.
(1) Raise and support the vehicle at the axles as
level as possible. Allow the wheels and propeller
shaft to turn.
(2) Remove any external bearing snap rings from
universal joint if equipped, so the inclinometer base
will sits flat.
Fig. 2 TWO CLAMPS AT SAME POSITION
Fig. 3 CLAMPS SEPARATED
1 - ó INCH
KJPROPELLER SHAFT 3 - 3
PROPELLER SHAFT (Continued)

(8) Subtract smaller figure from larger (C minus
B) to obtain axle Input Operating Angle.
Refer to rules given below and the example in (Fig.
7) for additional information.
²Good cancellation of U-joint operating angles
(within 1É).²Operating angles less than 3É.
²Operating angles less than 10É for double cardan
U-joint.
²At least 1/2 of one degree continuous operating
(propeller shaft) angle.
Fig. 7 U-JOINT ANGLE EXAMPLE
1 - 4.9É Angle (C)
2 - 3.2É Angle (B)
3 - Input Yoke4 - 3.0É Angle (A)
5 - Output Yoke
KJPROPELLER SHAFT 3 - 5
PROPELLER SHAFT (Continued)