removal JEEP LIBERTY 2002 KJ / 1.G Owner's Guide

shim thickness is measured. The overall shim thick-
ness is the total of the dial indicator reading and the
preload specification added together. The gear back-
lash 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. 13). Differential shim measurements are per-
formed with spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove differential side bearings from differ-
ential case.
(2) Install ring gear on differential case and
tighten bolts to specification.
(3) Install Dummy Bearings D-348 on differential
case.
(4) Install differential case in the housing.
(5) Record the thickness of Dummy Shims 8107.
Insert the shims between the dummy bearings and
the differential housing (Fig. 14).
Fig. 12 PINION DEPTH MEASUREMENT
1 - SCOOTER BLOCK
2 - ARBOR
3 - DIAL INDICATOR
Fig. 13 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
Fig. 14 DUMMY SHIMS
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
3 - 28 FRONT AXLE - 186FIAKJ
FRONT AXLE - 186FIA (Continued)

AXLE SHAFTS
REMOVAL
(1) Place the transmission in Neutral.
(2) Raise and support vehicle.
(3) Remove right wheel and tire and assembly.
(4) Remove right half shaft from vehicle.
(5) Remove snap ring from axle shaft.
(6) Assemble Remover 8420A onto the shaft (Fig.
25). Thread slid hammer into remover and remove
shaft.
(7) Slide axle shaft out of the axle tube.
NOTE: Use care to prevent damage to axle shaft
bearing and seal, which will remain in axle shaft
tube.
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant. Insert axle shaft through seal, bearing
(Fig. 26) and engage it into side gear splines.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal.
(2) Push on the axle shaft until the axle shaft
snap-ring passes through the side gear.
(3) Install right half shaft.
(4) Install right wheel and tire assembly.
(5) Check differential fluid level.
(6) Lower vehicle.
AXLE SHAFT SEALS
REMOVAL
(1) Remove half shaft.
(2) Remove axle shaft for right side seal removal.
(3) Remove shaft seal with Remover 7794-A and a
slide hammer (Fig. 27).
Fig. 25 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 26 AXLE SHAFT SEAL
1 - BEARING
2 - SEAL
Fig. 27 SHAFT SEAL REMOVER
1 - SHAFT SEAL
2 - REMOVER
KJFRONT AXLE - 186FIA 3 - 37

INSTALLATION
(1) Apply a light coat of lubricant on the lip of the
shaft seal.
(2) Installnewshaft seal with Installer 8806 and
Handle C-4171 (Fig. 28).
(3) Install right axle shaft if removed.
(4) Install half shaft.
AXLE BEARINGS
REMOVAL
(1) Remove half shaft.
(2) Remove axle shaft for right side seal removal.
(3) Remove shaft seal with Remover 7794-A and a
slide hammer.
(4) Remove shaft bearing with Remover 7794-A
and a slide hammer (Fig. 29).
INSTALLATION
(1) Installnewshaft bearing with Installer 8805
and Handle C-4171.
(2) Apply a light coat of lubricant on the lip of the
shaft seal.
(3) Installnewshaft seal with an appropriate
installer.
(4) Install right axle shaft if removed.
(5) Install half shaft.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake calipers and rotors, refer to 5
Brakes for procedures.
(4) Mark propeller shaft and pinion companion
flange for installation reference.
(5) Remove propeller shaft from the pinion com-
panion flange.
(6) Rotate pinion gear a minimum of ten times and
verify the pinion rotates smoothly.
(7) Record the torque to rotate the pinion gear
(Fig. 30) with a inch pound torque wrench.
Fig. 28 SEAL INSTALLER
1 - SEAL BORE
2 - INSTALLER
Fig. 29 SHAFT BEARING REMOVER
1 - SHAFT BEARING
2 - REMOVER
Fig. 30 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
3 - 38 FRONT AXLE - 186FIAKJ
AXLE SHAFT SEALS (Continued)

(4) Rotate pinion a minimum of ten time and ver-
ify pinion rotates smoothly. Rotate the pinion shaft
with an inch pound torque wrench. Rotating torque
should be equal to the reading recorded during
removal plus 0.56 N´m (5 in. lbs.) (Fig. 35).
(5) If the rotating torque is low, use Spanner
Wrench 6958 to hold the pinion companion flange
and tighten the pinion shaft nut in 6.8 N´m (5 ft.
lbs.) increments until proper rotating torque is
achieved.
CAUTION: If maximum tightening torque is reached
prior to reaching the required rotating torque, the
collapsible spacer may have been damaged.
Replace the collapsible spacer.
(6) Install propeller shaft with installation refer-
ence marks aligned.
(7) Fill differential with gear lubricant.
(8) Install brake rotors and calipers.
(9) Install wheel and tire assemblies.
(10) Lower the vehicle.
DIFFERENTIAL
REMOVAL
(1) Remove axle from the vehicle.
(2) Remove differential housing cover (Fig. 36).
(3) Push right axle shaft out of side gear (Fig. 37)
and remove the shaft.
(4) Mark differential bearing caps for installation
reference.
(5) Loosen the bearing cap bolts.
Fig. 35 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCHFig. 36 DIFFERENTIAL COVER
1 - COVER
2 - VENT TUBE
Fig. 37 RIGHT SHAFT IN SIDE GEAR
1 - AXLE SHAFT
2 - SCREWDRIVER
3 - SIDE GEAR
3 - 40 FRONT AXLE - 186FIAKJ
PINION SEAL (Continued)

(4) Remove the dial indicator.
(5) Install differential case in the housing. Ensure
differential bearing cups remain on the bearings and
preload shims are seated in the housing. Tap differ-
ential case to ensure bearings cups are seated in the
housing.
(6) Install bearing caps to their original locations
and loosely install cap bolts.
(7) Remove differential housing spreader (Fig. 43).
(8) Tighten the bearing cap bolts in a criss-cross
pattern to 54-68 N´m (39-50 ft. lbs.).
(9) Install the right axle shaft.
(10) Apply a 6.38mm (1/4 in.) bead of red Mopar
Silicone Sealer or equivalent to the housing cover.
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.
(11) Install differential housing cover and tighten
bolts in a criss-cross pattern to 19-26 N´m (14-19 ft.
lbs.).(12) Install axle assembly in vehicle.
(13) Fill differential with lubricant and install fill
plug.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential from the housing.
(2) Remove bearings from the differential case
with Puller/Press C-293-PA, Adapters C-293-39 and
Plug SP-3289 (Fig. 44).
Fig. 43 DIFFERENTIAL SPREADER
1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
Fig. 44 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
KJFRONT AXLE - 186FIA 3 - 43
DIFFERENTIAL (Continued)

INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 45).
(2) Install differential into the housing.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Never replace ring gear without
replacing the matched pinion gear.
(1) Raise and support vehicle
(2) Mark pinion companion flange and propeller
shaft for installation alignment.
(3) Remove propeller shaft from pinion companion
flange and tie propeller shaft to underbody.
(4) Remove axle assembly from the vehicle.
(5) Remove differential from axle housing.
(6) Place differential case in a vise with soft metal
jaw (Fig. 46).
(7) Remove bolts holding ring gear to differential
case.
(8) Driver ring gear off the differential case with a
rawhide hammer (Fig. 46).(9) With Spanner Wrench 6958 and a short length
of 1 in. pipe, hold pinion companion flange and
remove pinion nut (Fig. 47).
Fig. 45 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 46 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 47 PINION COMPANION FLANGE
1 - SPANNER WRENCH
2 - PINION COMPANION FLANGE
3 - 44 FRONT AXLE - 186FIAKJ
DIFFERENTIAL CASE BEARINGS (Continued)

REAR AXLE - 198RBI
TABLE OF CONTENTS
page page
REAR AXLE - 198RBI
DESCRIPTION.........................49
OPERATION...........................49
DIAGNOSIS AND TESTING - AXLE..........51
REMOVAL.............................54
INSTALLATION.........................54
ADJUSTMENTS
ADJUSTMENT........................55
SPECIFICATIONS - REAR AXLE............62
SPECIAL TOOLS
REAR AXLE..........................63
AXLE SHAFTS
REMOVAL.............................65
INSTALLATION.........................65
AXLE BEARING/SEAL
REMOVAL.............................66
INSTALLATION.........................67
PINION SEAL
REMOVAL.............................68INSTALLATION.........................68
COLLAPSIBLE SPACER
REMOVAL.............................70
INSTALLATION.........................70
DIFFERENTIAL
REMOVAL.............................71
INSTALLATION.........................73
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT.....74
DISASSEMBLY.........................75
CLEANING............................77
INSPECTION..........................77
ASSEMBLY............................77
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................79
INSTALLATION.........................79
PINION GEAR/RING GEAR/TONE RING
REMOVAL.............................79
INSTALLATION.........................82
REAR AXLE - 198RBI
DESCRIPTION
The Rear Beam-design Iron (RBI) axle housing has
an iron center casting (differential housing) with axle
shaft 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
that loads are supported by the axle shaft and bear-
ings. The axle shafts are retained by the unit bear-
ing, retainer plate and bolts.
The integral type, hypoid gear design, housing has
the centerline of the pinion set below the centerline
of the ring gear. The differential case is a one-piece
design. The differential pinion mate shaft is retained
with a threaded screw. Differential bearing preload
and ring gear backlash is adjusted by the use of
selective spacer shims. Pinion bearing preload is set
and maintained by the use of a collapsible spacer
(Fig. 1).
The cover provides a means for servicing the differ-
ential without removing the axle. The axle has a vent
hose to relieve internal pressure caused by lubricant
vaporization and internal expansion.
Axles equipped with a Trac-Loktdifferential are
optional. A Trac-Loktdifferential has a one-piece dif-ferential case, and the same internal components as
a standard differential, plus two clutch disc packs.
OPERATION
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
Fig. 1 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 - COLLAPSIBLE SPACER
KJREAR AXLE - 198RBI 3 - 49

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. 5).
(11) Remove upper control arm ball joint pinch
bolt from bracket (Fig. 6).
(12) Remove shock absorbers from axle brackets
(Fig. 7).
(13) Loosen all lower control arms mounting bolts
(Fig. 8).
(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. 5 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
Fig. 6 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 7 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
3 - 54 REAR AXLE - 198RBIKJ
REAR AXLE - 198RBI (Continued)

PRELOAD SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove side bearings from differential case.
(2) Install ring gear, if necessary, on differential
case and tighten bolts to specification.
(3) Install Dummy Bearings D-348 on differential
case.
(4) Install differential case in the housing.
(5) Insert Dummy Shims 8107 (0.118 in. / 3.0 mm)
starting point shims between the dummy bearing
and the housing (Fig. 16).
(6) Install bearing caps in their correct positions
and snug the bolts.
(7) Use a dead-blow hammer to seat the differen-
tial dummy bearings to each side of the housing (Fig.
17) and (Fig. 18).
Fig. 16 DUMMY SHIMS
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
Fig. 17 SEAT DUMMY BEARING PINION GEAR SIDE
Fig. 18 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - DEAD-BLOW HAMMER
3 - DIFFERENTIAL CASE
3 - 58 REAR AXLE - 198RBIKJ
REAR AXLE - 198RBI (Continued)

AXLE SHAFTS
REMOVAL
(1) Place transmission in neutral and raise and
support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake drum.
(4) Remove axle retainer plate nuts from the rear
of the axle flange.
(5) Pull axle shaft from the axle with Slide Ham-
mer 7420 and Adapter 6790. Mount the adapter to
the axle with lug nuts.
NOTE: It is normal that the axle bearing race is
loose in the axle tube.
INSTALLATION
(1) Insall axle into the axle tube with the flat area
of the retainer plate upward.
(2) Insert retaining plate studs into the brake
backing plate and axle tube flange.
(3) Install retainer nuts and tighten to 47-75 N´m
(35-55 ft. lbs.).
(4) Install the brake drum.
(5) Install wheel and tire.
(6) Check and fill the differential with gear lubri-
cant.
(7) Lower vehicle.
PILOT STUDS C-3288-B
PULLER 6790
DIAL INDICATOR C-3339
INSTALLER C-3718
KJREAR AXLE - 198RBI 3 - 65
REAR AXLE - 198RBI (Continued)