engine JEEP LIBERTY 2002 KJ / 1.G User Guide

JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
²DO NOT JUMP START WHEN BATTERY INDI-
CATOR DOT IS YELLOW OR BRIGHT COLOR. BAT-
TERY CAN EXPLODE.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCHING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW DISABLED VEHICLE'S
BATTERY TO EXCEED 16 VOLTS. PERSONAL
INJURY OR DAMAGE TO ELECTRICAL SYSTEM
CAN RESULT.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, turn off all accessories, place gear selector in
park or neutral, set park brake or equivalent and
operate engine at 1200 rpm.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake or equivalent. Turn
OFF all accessories.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result (Fig.
5). Review all warnings in this procedure.(5) On disabled vehicle, connect RED jumper cable
clamp to battery positive (+) terminal. Connect
BLACK jumper cable clamp to the engine as close to
the ground cable connection as possible (Fig. 5).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
STANDARD PROCEDURE - TOWING
A vehicle equipped with SAE approved wheel lift-
type towing equipment can be used to tow Jeep vehi-
cles. When towing a 4WD vehicle using a wheel-lift
Fig. 5 Jumper Cable Clamp Connections
1 - BOOSTER BATTERY
2 - NEGATIVE JUMPER CABLE
3 - ENGINE GROUND
4 - DO NOT ALLOW VEHICLES TO TOUCH
5 - BATTERY NEGATIVE CABLE
6 - DISCHARGED BATTERY
7 - POSITIVE JUMPER CABLE
0 - 6 LUBRICATION & MAINTENANCEKJ

STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT
Camber and caster angle adjustments involve
changing the position of the lower suspension arm
cam bolts. (Fig. 4)
STANDARD PROCEDURE - TOE ADJUSTMENT
4X4 SUSPENSION HEIGHT MESUREMENT MUST
BE PERFORMED BEFORE AN ALIGNMENT.
The wheel toe position adjustment is the final
adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the tie rod jam nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the tie
rod as necessary (Fig. 5).
(4)
Tighten the tie rod jam nut to 75 N´m (55 ft. lbs.).
(5) Verify the specifications
(6) Turn off engine.
STANDARD PROCEDURE - CAMBER, CASTER
AND TOE ADJUSTMENT
Camber and caster angle adjustments involve
changing the position of the lower suspension arm
cam bolts. (Fig. 4)
CASTER
Moving the rear position of the cam bolt in or out,
will change the caster angle significantly and camber
angle only slightly. To maintain the camber angle
while adjusting caster, move the rear of the cam bolt
in or out. Then move the front of the cam bolt
slightly in the opposite direction. (Fig. 4)
To increase positive caster angle, move the rear posi-
tion of the cam bolt outward (from the engine). Move
the front of cam bolt inward (toward the engine) slightly
until the original camber angle is obtained. (Fig. 4)
CAMBER
Move both of the cam bolts together in or out. This
will change the camber angle significantly and caster
angle slightly. (Fig. 4)
After adjustment is made tighten the cam bolt nuts
to proper torque specification.
TOE ADJUSTMENT
The wheel toe position adjustment is the final
adjustment.
(1)
Start the engine and turn wheels both ways before
straightening the wheels. Secure the steering wheel with
the front wheels in the straight-ahead position.
(2) Loosen the tie rod jam nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the tie
rod as necessary (Fig. 5).
(4)
Tighten the tie rod jam nut to 75 N´m (55 ft. lbs.).
(5) Verify the specifications
(6) Turn off engine.
Fig. 5 TIE ROD END
1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER
Fig. 4 LOWER CONTROL ARM
1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
3 - LOWER BALL JOINT NUT
4 - LOWER CONTROL ARM
5 - REAR CAM BOLT
KJWHEEL ALIGNMENT 2 - 5
WHEEL ALIGNMENT (Continued)

(5) Align the marks front and rear at the cam/
pivot bolts and tighten the bolts. Tighten the bolts to
170 N´m (125 ft.lbs.)
(6) Install the stabilizer link bolt at the lower con-
trol arm. Tighten the bolt to 136 N´m (100 ft.lbs.)
(7) Install the lower clevis bracket bolt at the
lower control arm. Tighten the bolt to 150 N´m (110
ft.lbs.)
(8) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(9) Perform a full wheel alignment (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
SHOCK
REMOVAL
REMOVAL - LEFT SIDE
(1) Disconnect the battery.
(2) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(3) Unclip the power center and move it to the side
out of the way.
(4) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(5) Disconnect the battery temperature sensor
from the battery tray.
(6) Remove the four upper shock mounting nuts.
(7) Raise and support the vehicle.(8) Remove the left tire and wheel assembly.
(9) Remove the lower bolt at the lower control
securing the clevis bracket.
(10) Remove the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - REMOVAL).
(11) Remove the lower ball joint nut.
(12) Seperate the lower ball joint from the lower
control arm using tool C-4150A.
(13) Rotate the lower control arm downward to
allow access.
(14) Remove the clevis bracket at the shock.
(15) Remove the shock assembly from the vehicle.
(Fig. 4)
(16) Remove the spring from the shock (if needed).
REMOVAL - RIGHT SIDE
(1) Remove the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(2) Remove the two cruise control servo mounting
nuts.
(3) Remove the upper shock mounting nuts.
(4) Raise and support the vehicle.
(5) Remove the right side tire assembly.
(6) Remove the lower bolt at the lower control
securing the clevis bracket.
(7) Remove the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - REMOVAL).
(8) Remove the lower ball joint nut.
(9) Seperate the lower ball joint from the lower
control arm using tool C-4150A.
(10) Rotate the lower control arm downward to
allow access.
Fig. 3 LOWER CONTROL ARM
1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
3 - LOWER BALL JOINT NUT
4 - LOWER CONTROL ARM
5 - REAR CAM BOLT
Fig. 4 SHOCK ASSEMBLY
1 - SPRING
2 - JOUNCE BUMPER
3 - SHOCK
4 - UPPER CONTROL ARM
KJFRONT 2 - 11
LOWER CONTROL ARM (Continued)

(11) Remove the clevis bracket at the shock. (Fig.
5)
(12) Remove the shock assembly from the vehicle.
(Fig. 5)
(13) Remove the spring from the shock (if needed).
(Refer to 2 - SUSPENSION/FRONT/SPRING -
REMOVAL).
INSTALLATION
INSTALLATION - LEFT SIDE
(1) Install the spring to the shock (if removed).
(2) Install the shock assembly to the vehicle.
(3) Install the four upper shock mounting nuts.
Tighten the nuts to 108 N´m (80 ft.lbs.).
(4) Install the clevis bracket at the shock. (Refer to
2 - SUSPENSION/FRONT/CLEVIS BRACKET -
INSTALLATION). Tighten the bolt to 88 N´m (65
ft.lbs.).
(5) Raise the lower control into place and recon-
nect the lower ball joint nut. Tighten the nut to 81
N´m (60 ft.lbs.).
(6) Install the clevis bracket at the lower control
arm. (Refer to 2 - SUSPENSION/FRONT/CLEVIS
BRACKET - INSTALLATION). Tighten the bolt to
150 N´m (110 ft.lbs.).(7) Install the lower stabilizer link at the lower
control arm. Tighten the bolt to 136 N´m (100 ft.lbs.)
(Refer to 2 - SUSPENSION/FRONT/STABILIZER
LINK - INSTALLATION).
(8) Install the left tire and wheel assembly. (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(9) Lower the vehicle.
(10) Reconnect the battery temperature sensor.
(11) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(12) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(13) Reconnect the battery cables.
INSTALLATION - RIGHT SIDE
(1) Install the spring to the shock (if removed).
(Refer to 2 - SUSPENSION/FRONT/SPRING -
INSTALLATION).
(2) Install the shock assembly to the vehicle.
(3) Install the four upper shock mounting nuts.
Tighten the nuts to 108 N´m (80 ft.lbs.).
(4) Install the clevis bracket at the shock. (Refer to
2 - SUSPENSION/FRONT/CLEVIS BRACKET -
INSTALLATION). Tighten the bolt to 88 N´m (65
ft.lbs.).
(5) Raise the lower control into place and recon-
nect the lower ball joint nut. Tighten the nut to 81
N´m (60 ft.lbs.).
(6) Install the clevis bracket at the lower control
arm. (Refer to 2 - SUSPENSION/FRONT/CLEVIS
BRACKET - INSTALLATION). Tighten the bolt to
150 N´m (110 ft.lbs.).
(7) Install the lower stabilizer link at the lower
control arm. Tighten the bolt to 136 N´m (100 ft.lbs.)
(Refer to 2 - SUSPENSION/FRONT/STABILIZER
LINK - INSTALLATION).
(8) Install the right tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(9) Lower the vehicle.
(10) Install the cruise control servo mounting nuts.
(11) Install the airbox (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION).
Fig. 5 SHOCK & CLEVIS ASSEMBLY
1 - FRONT CRADLE
2 - SPRING & SHOCK ASSEMBLY
3 - STEERING KNUCKLE
4 - CLEVIS BRACKET
5 - LOWER CONTROL ARM
2 - 12 FRONTKJ
SHOCK (Continued)

STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the upper stabilizer link bolts at the
stabilizer bar.
(4) Remove the stabilizer bar bushing clamps from
the frame (Fig. 8).
(5) Remove the stabilizer bar from the vehicle.
INSTALLATION
(1) Install the stabilizer bar to the vehicle.
(2) Install the stabilizer bar bushing clamps (Fig.
8). Tighten the nuts to 149 N´m (110 ft.lbs.).
(3) Install the upper stabilizer link bolts and
washer at the stabilizer bar. Tighten the bolt to 136
N´m (100 ft.lbs.).
(4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(5) Lower the vehicle.
STABILIZER LINK
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the lower stabilizer link bolt at the
lower control arm.
(4) Remove the upper stabilizer link bolt at the
stabilizer bar.
(5) Remove the stabilizer link. (Fig. 9)
INSTALLATION
(1) Install the stabilizer link (Fig. 9).
(2) Install the upper stabilizer link bolt and
washer at the stabilizer bar. Tighten the bolt to 136
N´m (100 ft.lbs.).
(3) Install the lower stabilizer link bolt and
washer at the lower control arm. Tighten the nut to
115 N´m (85 ft.lbs.).
(4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
UPPER CONTROL ARM
REMOVAL
REMOVAL - RIGHT SIDE
(1) Raise and support the vehicle.
(2) Remove the right side tire and wheel assembly.
(3) Remove the upper ball joint nut.
(4) Separate the upper ball joint from the steering
knuckle using tool C-4150A.
(5) Lower the vehicle.
(6) Remove the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(7) Remove the cruise control servo mounting nuts.
(8) Remove the upper control arm rear bolt.
(9) Remove the upper control arm front bolt.
(10) Remove the upper control arm from the vehi-
cle.
Fig. 8 SWAY BAR
1-SWAYBAR
2 - SWAY BAR BUSHINGS
Fig. 9 STABILIZER BAR LINK
1 - STABILIZER BAR
2 - STABILIZER BAR LINK
2 - 14 FRONTKJ

REMOVAL - LEFT SIDE
(1) Raise and support the vehicle.
(2) Remove the left side tire and wheel assembly.
(3) Remove the upper ball joint nut.
(4) Separate the upper ball joint from the steering
knuckle using tool C-4150A.
(5) Lower the vehicle.
(6) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(7) Unclip the power center and move it to the side
out of the way.
(8) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(9) Disconnect the battery temperature sensor
from the battery tray.
(10) Remove the upper control arm rear bolt by
using a ratchet and extension under the steering
shaft and positioned by the power steering reservoir.
(Fig. 10)
(11) Remove the upper control arm front bolt.
(12) Remove the upper control arm from the vehi-
cle.
INSTALLATION
INSTALLATION - RIGHT SIDE
(1) Install the upper control arm to the vehicle.
(2) Install the upper control arm front bolt.
Tighten the bolt to 122 N´m (90 ft.lbs.).
(3) Install the upper control arm rear bolt. Tighten
the bolt to 122 N´m (90 ft.lbs.).
(4) Install the cruise control servo mounting nuts.(5) Install the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION).
(6) Install the upper ball joint nut. Tighten the nut
to 81 N´m (60 ft.lbs.).
(7) Install the right side tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(8) Lower the vehicle.
(9) Set the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
INSTALLATION - LEFT SIDE
(1) Install the upper control arm to the vehicle.
(2) Install the upper control arm front bolt (Fig.
11). Tighten the bolt to 122 N´m (90 ft.lbs.).
(3) Install the upper control arm rear bolt (Fig.
11). Tighten the bolt to 122 N´m (90 ft.lbs.).
(4) Reconnect the battery temperature sensor to
the battery tray.
(5) Install the battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(7) Reclip and mount the power center.
(8) Install the upper ball joint nut (Fig. 11).
Tighten the nut to 81 N´m (60 ft.lbs.).
(9) Install the left side tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(10) Lower the vehicle.
(11) Set the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
Fig. 10 REAR BOLT
1 - STEERING SHAFT
2 - REAR BOLT
3 - RATCHET WITH AN EXTENSION
Fig. 11 UPPER CONTROL ARM
KJFRONT 2 - 15
UPPER CONTROL ARM (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)

FRONT AXLE - 186FIA
TABLE OF CONTENTS
page page
FRONT AXLE - 186FIA
DESCRIPTION.........................19
OPERATION...........................19
DIAGNOSIS AND TESTING - AXLE..........20
REMOVAL.............................24
INSTALLATION.........................24
ADJUSTMENTS........................25
SPECIFICATIONS - FRONT AXLE...........33
SPECIAL TOOLS
FRONT AXLE........................34
AXLE SHAFTS
REMOVAL.............................37
INSTALLATION.........................37
AXLE SHAFT SEALS
REMOVAL.............................37
INSTALLATION.........................38
AXLE BEARINGS
REMOVAL.............................38INSTALLATION.........................38
PINION SEAL
REMOVAL.............................38
INSTALLATION.........................39
DIFFERENTIAL
REMOVAL.............................40
DISASSEMBLY.........................41
ASSEMBLY............................41
INSTALLATION.........................42
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................43
INSTALLATION.........................44
PINION GEAR/RING GEAR
REMOVAL.............................44
INSTALLATION.........................46
FRONT AXLE - 186FIA
DESCRIPTION
The 186FIA (Model 30) axle consists of an alumu-
num center section with an axle tube extending from
one side. The tube is pressed into the differential
housing. The integral type housing, hypoid gear
design has the centerline of the pinion set below the
centerline of the ring gear.
The differential case is a one-piece design. The differ-
ential pinion mate shaft is retained with a roll-pin. Dif-
ferential bearing preload and ring gear backlash is
adjusted by the use of shims (select thickness). The
shims are located between the differential bearing cups
and the axle housing. Pinion bearing preload is set and
maintained by the use of a collapsible spacer.
The power is transferred from the axle through two
constant velocity (C/V) drive shafts to the wheel hubs.
The differential cover provides a means for inspec-
tion and service without removing the axle from the
vehicle. The cover has a vent tube used to relieve
internal pressure caused by vaporization and inter-
nal expansion.
OPERATION
The axle receives power from the transfer case through
the front propeller shaft. The front propeller shaft is con-
nected to the pinion gear which rotates the differential
through the gear mesh with the ring gear bolted to thedifferential case. The engine power is transmitted to the
axle shafts through the pinion mate and side gears. The
side gears are splined to the axle shafts.
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
Fig. 1 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - STRAIGHT AHEAD DRIVING
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
KJFRONT AXLE - 186FIA 3 - 19