JEEP LIBERTY 2002 KJ / 1.G Manual Online

Fig. 24 GEAR TOOTH CONTACT PATTERNS
3 - 32 FRONT AXLE - 186FIAKJ
FRONT AXLE - 186FIA (Continued)

DIFFERENTIAL BEARING PRELOAD CHECK
The final check on the differential assembly before
installing the axles, is torque to rotate pinion and
differential combined. This will verify the correct dif-
ferential bearing preload.
Torque to rotate the differential and pinion is the
torque to rotate the pinion plus:Gear Ratio 3.73....0.45-0.75 N´m (3.9-6.6 in. lbs.)
Gear Ratio 3.91....0.43-0.72 N´m (3.8-6.4 in. lbs.)
Gear Ratio 4.10....0.41-0.69 N´m (3.6-6.0 in. lbs.)
SPECIFICATIONS - FRONT AXLE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 3.92, 4.10
Ring Gear Diameter 186 mm (7.33 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 92.1 mm (3.625 in.)
Pinion Bearing Preload 1.69-2.82 N´m (15-25 in. lbs.)
Differential Bearing Preload
Added To Pinion Torque To Rotate
Gear Ratio 3.73 0.45-0.75 N´m (3.9-6.6 in. lbs.)
Gear Ratio 3.92 0.43-0.72 N´m (3.8-6.4 in. lbs.)
Gear Ratio 4.10 0.41-0.69 N´m (3.6-6.0 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Ring Gear Bolts 95-122 70-90 -
Differential Bearing Cap
Bolts54-67 39-50 -
Differential Cover Bolts 19-26 14-19 -
Pinion Nut 217-352 160-260 -
Left Axle Bracket Bolts 61 45 -
Front Axle Bracket Bolts 61 45 -
Right Axle Bracket Bolts 88 65 -
Axle Brackets To Frame
Bolts88 65 -
KJFRONT AXLE - 186FIA 3 - 33
FRONT AXLE - 186FIA (Continued)

SPECIAL TOOLS
FRONT AXLE
PULLER C-293-PA
PLUG SP-3289
ADAPTER C-293-39
PULLER C-452
DIAL INDICATOR C-3339
INSTALLER C-3716-A
HANDLE C-4171
INSTALLER D-146
REMOVER D-149
INSTALLER W-162-D
3 - 34 FRONT AXLE - 186FIAKJ
FRONT AXLE - 186FIA (Continued)

CUP 8109
PINION DEPTH SET 6774
PINION BLOCK 8804
SPANNER WRENCH 6958
SPREADER W-129-B
ADAPTER KIT 6987B
PILOT STUD C-3288-B
REMOVER C-4307
INSTALLER C-4308
INSTALLER 6448
KJFRONT AXLE - 186FIA 3 - 35
FRONT AXLE - 186FIA (Continued)

ADAPTER C-293-42
INSTALLER 8805
INSTALLER 8806
REMOVER 8420A
REMOVER 7794-A
3 - 36 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)

(8) Using a short piece of pipe and Spanner
Wrench 6958 to hold the pinion companion flange
(Fig. 31) and remove the pinion nut.
(9) Remove pinion companion flange (Fig. 32) with
Remover C-452 and Spanner Wrench 6958.
(10) Remove pinion seal with Remover 7794-A and
a slide hammer (Fig. 33).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 34).
(2) Install pinion companion flange on the pinion
gear with Installer W-162-D, Cup 8109 and Wrench
6958.CAUTION: Do not exceed the minimum tightening
torque 216 N´m (160 ft. lbs.) while installing pinion
nut at this point. Damage to collapsible spacer or
bearings may result.
(3) Install anewnut on the pinion gear.Tighten
the nut only enough to remove the shaft end
play.
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.
Fig. 31 PINION FLANGE NUT
1 - SPANNER WRENCH
2 - PINION COMPANION FLANGE
Fig. 32 PINION FLANGE REMOVER
1 - SPANNER WRENCH
2 - REMOVER
Fig. 33 PINION SEAL
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 34 PINION SEAL INSTALLATION
1 - HANDLE
2 - INSTALLER
KJFRONT AXLE - 186FIA 3 - 39
PINION SEAL (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)

(6) Position Spreader W-129-B onto the differential
locating holes and install the safety holddown clamps
(Fig. 38). Tighten the tool turnbuckle finger-tight.
(7) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing and zero the indicator.
(8) Spread the housing to remove the differential
case from the housing. Measure the distance with the
dial indicator (Fig. 39).
CAUTION: Never spread the differential housing
over 0.34 mm (0.013 in). If housing is over-spread, it
could be distorted or damaged.
(9) Remove the dial indicator.
(10) Holding the differential case in position, and
remove bearing cap bolts and caps.
(11) Remove the differential from the housing (Fig.
40). Ensure differential bearing cups and shims
remain in position on the differential bearings.(12) Tag differential bearing cups and shims to
indicate their location.
(13) Remove spreader from housing.
DISASSEMBLY
(1) Remove ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft.
(4) Rotate differential side gears and remove the
pinion mate gears and thrust washers (Fig. 41).
(5) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft.
(4) Align hole in the pinion gear mate shaft with
the hole in the differential case.
Fig. 38 DIFFERENTIAL SPREADER
1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
Fig. 39 SPREAD DIFFERENTIAL CASE
1 - PILOT STUD
2 - DIAL INDICATOR
3 - SPREADER
KJFRONT AXLE - 186FIA 3 - 41
DIFFERENTIAL (Continued)