lock JEEP LIBERTY 2002 KJ / 1.G User Guide

PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT
Measurements are taken with pinion cups and pin-
ion bearings installed in the housing. Take measure-
ments with a Pinion Gauge Set, Pinion Block 6735,
Arbor Discs 6732 and Dial Indicator C-3339 (Fig. 11).
(1) Assemble Pinion Height Block 6739, PinionBlock 6735 and rear pinion bearing onto Screw 6741
(Fig. 11).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 12).
(3) Install front pinion bearing and Cone 6740
hand tight.
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 13).
Install differential bearing caps on Arbor Discs and
tighten cap bolts. Refer to the Torque Specifications.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
Fig. 11 PINION DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 12 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 56 REAR AXLE - 198RBIKJ
REAR AXLE - 198RBI (Continued)

(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(7) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 14). Move the
scooter block till the dial indicator probe crests the
arbor bar and record the highest reading. If the dial
indicator can not achieve the zero reading, the rear
bearing cup or the pinion depth gauge set is not
installed correctly.
(8) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
etched in the face of the pinion gear (Fig. 9) using
the opposite sign on the variance number. For exam-
ple, if the depth variance is ±2, add +0.002 in. to the
dial indicator reading.
(9) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD
Differential side bearing preload and gear backlash
is achieved by selective shims inserted between the
bearing cup and the housing. The proper shim thick-
ness can be determined using slip-fit Dummy Bear-
ings D-348 in place of the differential side bearings
and a Dial Indicator C-3339. Before proceeding with
the differential bearing preload and gear backlash
measurements, measure the pinion gear depth and
prepare the pinion gear for installation. Establishing
proper pinion gear depth is essential to establishing
gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential sideplay is measured, the pinion gear is installed and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading, starting point shim thickness and the pre-
load specification added together. The gear backlash
measurement determines the thickness of the shim
used on the ring gear side of the differential case.
Subtract the gear backlash shim thickness from the
total overall shim thickness and select that amount
for the pinion gear side of the differential (Fig. 15).
Fig. 13 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCKFig. 14 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 15 Shim Locations
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
KJREAR AXLE - 198RBI 3 - 57
REAR AXLE - 198RBI (Continued)

DIFFERENTIAL BEARING PRELOAD CHECK
The final check on the differential assembly before
installing the axles is torque to rotate pinion and dif-
ferential combined. This will verify the correct differ-
ential bearing preload.Torque to rotate the differential and pinion is the
torque to rotate the pinion plus:
Gear Ratio 3.73.......0.45-0.76 N´m (4-7 in. lbs.)
Gear Ratio 4.10......0.41-0.69 N´m (3.6-6 in. lbs.)
SPECIFICATIONS - REAR AXLE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73 4.10
Ring Gear Diameter 198 mm (7.795 in.)
Ring Gear Backlash 0.13-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 96.85 mm (3.813 in.)
Pinion Bearing Preload - New Bearings 1.69-2.82 N´m (15-25 in. lbs.)
Differential Side Gear Clearance 0-0.15 mm (0-0.006 in.)
Differential Bearing Preload 0.20 mm (0.008 in.)
Differential Bearing Preload Added To Pinion Torque To Rotate
3.73 Gear Ratio 0.45-0.76 N´m (4-7 in. lbs.)
4.10 Gear Ratio 0.41-0.69 N´m (3.6-6 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Ring Gear Bolts 129-142 95-105 -
Differential Bearing Cap
Bolts64-91 47-67 -
Differential Cover Bolts 38-45 28-33 -
Pinion Nut (Minimum) 271 200 -
Cross Shaft Lock Screw 11-22 8-16 -
3 - 62 REAR AXLE - 198RBIKJ
REAR AXLE - 198RBI (Continued)

AXLE BEARING/SEAL
REMOVAL
(1) Remove axle shaft from vehicle.
(2) Drill a shallow hole into soft steel axle bearing
retaining ring with a 3/8 in. drill bit (Fig. 25). Use a
drill depth stop to avoid marking the axle.
(3) With a cold chisel cut the retaining ring across
drilled hole. (Fig. 26)
(4) Slide retaining ring from axle shaft.
(5) Remove axle bearing from the shaft with a
press and Splitter 1130 placed between the seal and
bearing (Fig. 27).
(6) Remove seal from axle.
(7) Remove retaining plate from axle shaft.
Fig. 25 DRILL RETAINING RING
1 - DRILL BIT
2 - AXLE
3 - RETAINING PLATE
4 - RETAINING RING
Fig. 26 CUT RETAINING RING
1 - AXLE
2 - COLD CHISEL
3 - VISE
4 - RETAINING RING
Fig. 27 AXLE BEARING AND SEAL
1 - SPLITTER
2 - AXLE SHAFT
3 - BLOCKS
4 - BLOCKS
3 - 66 REAR AXLE - 198RBIKJ

(6) Install the bearing caps in their original loca-
tions (Fig. 50).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten the bearing cap bolts to 64-91 N´m
(47-67 ft. lbs.).
(10) Install the axle shafts.
(11) Apply a 6.35mm (1/4 in.) bead of red Mopar
Silicone Rubber Sealant or equivalent to the housing
cover (Fig. 51).
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.
(12) Install the cover and tighten cover bolts in a
criss-cross pattern to 38-45 N´m (28-33 ft. lbs.).
(13) Refill the differential with lubricant and
install fill plug.
(14) Remove support and lower the vehicle.
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. 52).
(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. 50 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 51 DIFFERENTIAL COVER - TYPICAL
1 - SEALING SURFACE
2 - SEALANT BEAD
3 - SEALANT THICKNESS
3 - 74 REAR AXLE - 198RBIKJ
DIFFERENTIAL (Continued)

DISASSEMBLY
(1) Clamp side gear Fixture 6965 in a vise and set
differential case on the fixture (Fig. 53).
(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 (Fig.
54).(4) Remove pinion gear mate shaft with a drift and
hammer.
(5) Install and lubricate Step Plate 6960-3 (Fig.
55).
Fig. 52 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 53 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 54 MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 55 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
KJREAR AXLE - 198RBI 3 - 75
DIFFERENTIAL - TRAC-LOK (Continued)

(3) Position assembled clutch disc packs on the
side gear hubs.
(4) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 62).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
(5) Position the differential case on the Holding
Fixture 6965.
(6) Install lubricated Step Plate 6960-3 in lower
side gear (Fig. 63).
(7) Install the upper side gear and clutch disc pack
(Fig. 63).
(8) Hold assembly in position. Insert Threaded
Adapter 6960-1 into top side gear.
(9) Install Forcing Screw 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 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.
(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.
Fig. 62 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - SIDE GEAR AND CLUTCH PACK
Fig. 63 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE
3 - 78 REAR AXLE - 198RBIKJ
DIFFERENTIAL - TRAC-LOK (Continued)

REAR AXLE-81/4
TABLE OF CONTENTS
page page
REAR AXLE-81/4
DESCRIPTION.........................86
OPERATION...........................86
DIAGNOSIS AND TESTING - AXLE..........88
REMOVAL.............................91
INSTALLATION.........................91
ADJUSTMENTS........................92
SPECIFICATIONS
REAR AXLE..........................98
SPECIAL TOOLS
8 1/4 AXLE..........................98
AXLE SHAFTS
REMOVAL............................101
INSTALLATION........................101
AXLE SHAFT SEALS
REMOVAL............................101
INSTALLATION........................102
AXLE BEARINGS
REMOVAL............................102
INSTALLATION........................102PINION SEAL
REMOVAL............................102
INSTALLATION........................103
DIFFERENTIAL
REMOVAL............................104
DISASSEMBLY........................105
ASSEMBLY...........................105
INSTALLATION........................105
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT....106
DISASSEMBLY........................107
CLEANING...........................109
INSPECTION.........................109
ASSEMBLY...........................109
DIFFERENTIAL CASE BEARINGS
REMOVAL............................110
INSTALLATION........................110
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................110
INSTALLATION........................112
REAR AXLE-81/4
DESCRIPTION
The axle housings consist of a cast iron center sec-
tion with axle tubes extending from either side. The
tubes are pressed into and welded to the differential
housing to form a one-piece axle housing. The axles
are equipped with semi-floating axle shafts, meaning
vehicle loads are supported by the axle shaft and
bearings. The axle shafts are retained by C-locks in
the differential side gears.
The differential case is a one-piece design. The dif-
ferential pinion mate shaft is retained with a
threaded pin. Differential bearing preload and ring
gear backlash are set and maintained by threaded
adjusters at the outside of the differential housing.
Pinion bearing preload is set and maintained by the
use of a collapsible spacer.
The differential cover provides a means for inspec-
tion and service without removing the complete axlefrom the vehicle. A vent hose is used to relieve inter-
nal pressure caused by lubricant vaporization and
internal expansion.
Axles equipped with a Trac-Loktdifferential are
optional. A differential has a one-piece differential
case, and the same internal components as a stan-
dard differential, plus two clutch disc packs.
OPERATION
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential 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.
3 - 86 REAR AXLE-81/4KJ

REMOVAL
(1) Raise and support the vehicle.
(2) Position a lift/jack under the axle and secure
axle to device.
(3) Remove wheels and tires.
(4) Mark propeller shaft and pinion yoke for
installation reference.
(5) Remove propeller shaft and suspend under the
vehicle.
(6) Remove brake drums, parking brake cables and
speed sensor from the axle.
(7) Disconnect the brake hose at the body junction
block.
(8) Remove brakes and backing plates.
(9) Remove vent hose from the axle shaft tube.
(10) Remove the stabilizer bar (Fig. 4).
(11) Remove upper control arm ball joint pinch
bolt from bracket (Fig. 5).
(12) Remove shock absorbers from axle brackets
(Fig. 6).
(13) Loosen all lower control arms mounting bolts
(Fig. 7).
(14) Lower axle enough to remove coil springs and
spring insulators.
(15) Remove lower control arm bolts from the axle
brackets.
(16) Lower and remove the axle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.(1) Raise the axle under the vehicle.
(2) Install lower control arms onto the axle brack-
ets and loosely install the mounting bolts.
(3) Install coil spring isolators and spring.
(4) Raise axle up until springs are seated.
(5) Install upper control arm ball joint into axle
bracket and tighten pinch bolt to torque specification.
(6) Install shock absorbers and tighten nuts to
torque specification.
(7) Install stabilizer bar and tighten nuts to torque
specification.
(8) Install brake backing plates, parking brake
cables, brake drums and speed sensor.
(9) Install brake hose to the body junction block
and bleed the brakes.
Fig. 4 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
Fig. 5 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 6 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
KJREAR AXLE - 8 1/4 3 - 91
REAR AXLE - 8 1/4 (Continued)

PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups and
pinion bearings installed in the housing. Take measure-
ments with Pinion Gauge Set and Dial Indicator C-3339.
(1) Assemble Pinion Height Block 6739, Pinion
Block 8540 and rear pinion bearing onto Screw 6741
(Fig. 10).(2) Insert assembled height gauge components,
rear bearing, and screw into the housing through
pinion bearing cups (Fig. 11).
(3) Install front pinion bearing and Cone-Nut 6740
hand tight (Fig. 10).
(4) Place Arbor Disc 8541 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 12).
Install differential bearing caps on Arbor Discs and
tighten cap bolts to 41 N´m (30 ft. lbs.).
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
Fig. 10 Pinion Depth Gauge Tools
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOOK
8 - ARBOR DISC
Fig. 11 Pinion Height Block
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
KJREAR AXLE - 8 1/4 3 - 93
REAR AXLE - 8 1/4 (Continued)