brake JEEP XJ 1995 Service And Owner's Manual

(17) Tighten the track bar nut at the axle bracket
to 100 Nzm (74 ft. lbs.) torque.
(18) Check the front wheel alignment.
PINION SEAL REPLACEMENT
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Mark the propeller shaft yoke and pinion yoke
for installation alignment reference.
(4) Remove the propeller shaft from the yoke.
(5) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 2).
(6) Mark the positions of the yoke and pinion gear
for installation alignment reference.
(7) Use Remover 7794A and slide hammer to re-
move the pinion gear seal (Fig. 3).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer D-163
and Handle C-4171 (Fig. 4).
(2) Align the reference marks and install yoke on
the pinion gear with Installer W-162-D.
(3) Install a new pinion nut on pinion shaft.Tighten
the nut to 217-352 Nzm (160-260 ft. lbs.) (Fig. 5).
(4) Align the installation reference marks and at-
tach the propeller shaft to the yoke.
(5) Add API grade GL 5 hypoid gear lubricant to
the differential housing, if necessary.
(6) Install wheel and tire assemblies.
(7) Remove support and lower the vehicle.
HUB BEARING AND AXLE SHAFT
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake components from the axle,
refer to Group 5, Brakes.
(4) Remove the cotter pin, nut retainer and axle
hub nut (Fig. 6).
(5) Remove the hub to knuckle bolts (Fig. 6). Remove
the hub from the steering knuckle and axle shaft.
(6) Remove the disc brake rotor shield from the
bearing carrier (Fig. 6).
(7) On disconnect axles, remove vacuum shift mo-
tor housing. Refer to Vacuum Disconnect Axle in this
section.
(8) Remove the axle shaft from the housing.Avoid
damaging the axle shaft oil seals in the differen-
tial.
Fig. 2 Pinion Yoke Removal
Fig. 3 Seal Removal
Fig. 4 Pinion Seal Installation
JFRONT SUSPENSION AND AXLE 2 - 25

INSTALLATION
(1) Thoroughly clean the axle shaft (Fig. 6) and ap-
ply a thin film of Mopar Wheel Bearing Grease to the
shaft splines, seal contact surface, hub bore.
(2) Install the axle shaft into the housing and dif-
ferential side gears. Avoid damaging the axle shaft
oil seals in the differential.
(3) Install the hub bearing and brake dust shield
to the knuckle.
(4) Install the hub to knuckle bolts and tighten to
102 Nzm (75 ft. lbs.) torque.
(5) Install the hub washer and nut. Tighten the
hub nut to 237 Nzm (175 ft. lbs.) torque. Install the
nut retainer and a new cotter pin (Fig. 6).
(6) Install the brake components, refer to Group 5,
Brakes.
(7) Install the wheel and tire assembly.
(8) Remove support and lower the vehicle.
AXLE SHAFTÐCARDAN U-JOINT
DISASSEMBLY
Single cardan U-joints are not serviceable. If defec-
tive, they must be replaced as a unit. If the bearings,
seals, spider or bearing caps are damaged or worn,
replace the complete U-joint.
CAUTION: Clamp only the forged portion of the
yoke in the vise. Also, to avoid distorting the yoke,
do not over tighten the vise jaws.
(1) Remove the bearing cap retaining snap rings
(Fig. 7).
It can be helpful to saturate the bearing caps
with penetrating oil prior to removal.(2) Locate a socket that is larger in diameter than
the bearing cap. Place the socket (receiver) against
the yoke and around the perimeter of the bearing cap
to be removed. Locate a socket that is smaller in di-
ameter than the bearing cap. Place the socket (driv-
er) against the opposite bearing cap. Position the
yoke with the sockets in a vise (Fig. 8).
(3) Compress the vise jaws to force the bearing cap
into the larger socket (receiver).
(4) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(5) Repeat the above procedure for the remaining
bearing cap.
Fig. 6 Hub, Knuckle and Axle Shaft
Fig. 7 Axle Shaft Outer U-Joint
2 - 26 FRONT SUSPENSION AND AXLEJ

(4) Install the Hub Bearing and Axle Shaft accord-
ing to the installation procedure.
(5) Reconnect the tie-rod or drag link end onto the
steering knuckle arm. Install the ABS sensor wire
and bracket to the knuckle, refer to Group 5 Brakes.
AXLE BUSHING REPLACEMENT
Refer to Axle Bushing Replacement in the Front
Suspension section.
DIFFERENTIAL REMOVAL
To service the differential the axle assembly and
axle shafts must be removed. Refer to the removal
procedures in this Group.
(1) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 22).
(2) Remove the differential bearing caps.
(3) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 23). Install the
holddown clamps and tighten the tool turnbuckle fin-
ger-tight.
(4) Install a pilot stud at the left side of the differ-
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
side of the housing (Fig. 23) and zero the indicator.CAUTION:Do not spread over 0.38 mm (0.015 in). If
the housing is over-separated, it could be distorted
or damaged.
(5) Separate the housing enough to remove the
case from the housing. Measure the distance with the
dial indicator (Fig. 23).
(6) Remove the dial indicator.
(7) Pry the differential case loose from the housing.
To prevent damage, pivot on housing with the end of
the pry bar against spreader (Fig. 24).
Fig. 21 Lower Ball Stud Remove/Install
Fig. 22 Bearing Cap Identification
2 - 34 FRONT SUSPENSION AND AXLEJ

REAR SUSPENSION AND AXLES
CONTENTS
page page
8 1/4 AXLE............................ 30
AXLE NOISE/VIBRATION DIAGNOSIS......... 9
AXLE SPECIFICATIONS................... 51
GENERAL INFORMATION.................. 1
MODEL 35 AXLE........................ 13TORQUE SPECIFICATIONS................ 51
TRAC-LOK DIFFERENTIAL................. 45
XJ SUSPENSION......................... 3
YJ SUSPENSION......................... 6
GENERAL INFORMATION
SUSPENSION COMPONENTS
The Jeep rear suspension is comprised of;
²Drive axle
²Leaf springs
²Dual-action shock absorbers
²Track bar (YJ vehicles)
²Stabilizer bar (XJ vehicles)
²Jounce bumpers
The rear suspension design uses semi-elliptic
multi-leaf springs and a solid drive axle. The forward
end of the springs are mounted to the frame rail
hangers through rubber bushings. The bushings iso-
late road noise as the springs move. The rearward
end of the springs are attached to the frame by the
use of shackles. Again the spring and shackles use
rubber bushings to isolate road noise. The shackles
allow the springs to change their length as the vehi-
cle moves over various road conditions. The spring
and axle travel is limited through the use of bumpers
mounted on frame.
All suspension components that use bushings
should be tightened with the vehicle at normal ride
height. If the springs are not at normal ride position,
vehicle ride comfort could be affected. Rubber bush-
ings must never be lubricated.
The springs are attached to the axle pads with U-
bolts and plates. The springs use a center bolt that
holds the spring leafs in position. The bolt is also
used to locate the spring assembly to the axle pad.
Ride control is accomplished through the use of du-
al-action shock absorbers. The shocks dampen the
jounce and rebound as the vehicle travels over vari-
ous road conditions. The top of shock absorbers are
bolted to the frame bracket. The bottom of the shocks
are bolted to the axle bracket.
The stabilizer bar on the XJ is used to minimize
vehicle rear sway during turns. The bar helps the ve-
hicle maintain a flat attitude to the road surface. The
bar extends across the underside of the chassis and
connects to the frame rails. The links are connectedto the axle brackets. All mounting points of the sta-
bilizer bar are isolated by bushings.
The track bar on the YJ is used to minimize rear
axle side-to-side movement. The track bar is attached
to the frame rail bracket and axle bracket and is iso-
lated with bushings.
The jounce bumpers are used to limit the jounce
and rebound travel of the suspension.
AXLES
The Model 35 axle is standard for XJ and YJ vehi-
cles. The 8 1/4 axle is available in XJ vehicles with-
out ABS brakes.
The Model 35 and 8 1/4 axle housings has a cast
iron center section. Two steel axle shaft tubes are
pressed into the differential housing and welded.
It is not necessary to remove the axle from the ve-
hicle for service. A removable differential cover is
provided for routine vehicle service. If the differential
housing is damaged, the complete axle assembly can
be removed.
For complete drive axle assembly removal and in-
stallation refer to Drive Axle Assembly Replacement
in this Group.
IDENTIFICATION
Model 35 axle has the assembly part number and
gear ratio listed on a tag. The tag is attached to the left
side of the housing cover (Fig. 1). Build date identifica-
tion codes on axles are stamped on the axle shaft tube
cover side. The Model 35 axle has a flat housing cover
gasket flange at the outer edge (Fig. 1).
The 8 1/4 axle has the build date code and gear ra-
tio tags attached to the housing cover (Fig. 2). The
housing cover gasket has a rolled gasket flange at
the outer edge (Fig. 2).
²The Model 35 axle has shaft tubes that are 2.625
inch (66.67 mm) in diameter.
²The 8 1/4 axle has axle shaft tubes that are 3.0-
inch (76.2 mm) in diameter.
JREAR SUSPENSION AND AXLES 3 - 1

MODEL 35 AXLE
INDEX
page page
Axle Shaft............................... 16
Axle Shaft Seal and Bearing................. 17
Backlash and Contact Pattern Analysis......... 27
Cleaning/Inspection........................ 20
Differential Assembly....................... 21
Differential Disassembly.................... 18
Differential Measurement and Installation........ 25
Differential Removal....................... 18
Drive Axle Assembly ReplacementÐXJ Vehicles . . 14Drive Axle Assembly ReplacementÐYJ Vehicles . . 14
Final Assembly........................... 29
General Information....................... 13
Lubricant Change......................... 13
Lubricant Specifications..................... 13
Pinion Gear Depth Information............... 21
Pinion Measurement and Assembly............ 22
Pinion Removal/Disassembly................. 19
Pinion Shaft Seal Replacement............... 15
GENERAL INFORMATION
The Model 35 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 integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline
of the ring gear.
The axle has a vent hose to relieve internal pres-
sure caused by lubricant vaporization and internal
expansion.
The axles are equipped with semi-floating axle
shafts, meaning that loads are supported by the axle
shaft and bearings. The axle shafts are retained by
C-clips in the differential side gears.
The cover provides a means for servicing the differ-
ential without removing the axle.
Axles may be equipped with drum or disc brakes.
The axles that are equipped with ABS brake have a
tone ring pressed on the axle shaft. Use care when
removing axle shafts as NOT to damage the tone
wheel or the sensor.
The Model 35 axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
the housing cover. Build date identification codes are
stamped on the axle shaft tube cover side.
The differential case is a one-piece design. The dif-
ferential pinion mate shaft is retained with a
threaded roll pin. Differential bearing preload and
ring gear backlash is adjusted by the use of spacer
shims. Pinion bearing preload is set and maintained
by the use of a collapsible spacer.
For complete drive axle assembly removal
and installation refer to Drive Axle Assembly
Replacement in this Group.
LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be
used for Model 35 axle. The lubricant should haveMIL-L-2105C and API GL 5 quality specifications.
MOPAR Hypoid Gear Lubricant conforms to both of
these specifications.
²Lubricant for Model 35 axle is a thermally stable
SAE 80W-90 gear lubricant.
²Lubricant for Model 35 axle with Trailer Tow is
SAE 75W-140 SYNTHETIC gear lubricant.
²Trac-Lok differentials add 4 oz. of friction modifier.
²Lubricant quantity is 1.66 L (3.50 pts.).
Refer to Group 0, Lubrication and Maintenance for
additional information.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle
has been recently driven.
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the dif-
ferential housing cover.
(3) Remove the differential housing cover and
drain the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the sealant from the housing and cover
surfaces.
(6) Apply a bead of MOPARtSilicone Rubber Seal-
ant to the housing cover (Fig. 1).Allow the sealant
to cure for a few minutes.
Install the housing cover within 5 minutes af-
ter applying the sealant. If not installed the
sealant must be removed and another bead ap-
plied.
(7) Install the cover and any identification tag.
Tighten the cover bolts to 41 Nzm (30 ft. lbs.) torque.
(8) Refill differential with Mopar Hypoid Gear Lu-
bricant to bottom of the fill plug hole.
JREAR SUSPENSION AND AXLES 3 - 13

CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
Trac-Lok Differentials; A container of Trac-Lok lu-
bricant (friction modifier) should be added after re-
pair service or a lubricant change.
(9) Install the fill hole plug and lower the vehicle.
LIMITED SLIP DIFFERENTIAL vehicles should
be road tested by making 10 to 12 slow figure-eight
turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
ter noise complaint.
DRIVE AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails slightly in front the springs.
(2) Remove the rear wheels.
(3) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(4) Disconnect the axle vent hose.
(5) Disconnect the parking brake cables at the
equalizer or backing plate.
(6) Disconnect the shock absorbers from the axle
brackets.
(7) Disconnect the brake hose at the axle junction
block.Do not disconnect the wheel cylinder tub-
ing fittings.
(8) If equipped, disconnect ABS wiring connections
at the axle.(9) Support the axle with a hydraulic jack under
the differential.
(10) Remove the spring U-bolts from the plate
brackets.
(11) Lower the jack enough to remove the axle.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.
(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(2) Raise the axle and align the spring center bolts
with the locating holes in the axle pads and plate
brackets.
(3) Install the spring U-bolts through the plate
brackets and tighten to 70 Nzm (52 ft. lbs.) torque.
(4) Install ABS wiring connections (if equipped) at
the axle.
(5) Connect the brake hose at the axle junction
block.
(6) Install the shock absorbers to the axle brackets
and tighten to 62 Nzm (46 ft. lbs.) torque.
(7) Connect the parking brake cables at the equal-
izer or backing plate.
(8) Connect the vent hose to the tube fitting.
(9) Align the reference marks and connect the
drive shaft to the axle yoke. Tighten the U-joint
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(10) Check differential lubricant and add if neces-
sary.
(11) Install the wheel and tire.
(12) Bleed the brakes.
(13) Remove the supports and lower the vehicle.
DRIVE AXLE ASSEMBLY REPLACEMENTÐYJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails slightly in front the springs.
(2) Remove the rear wheels.
(3) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(4) Disconnect the axle vent hose.
(5) Disconnect the parking brake cables at the
equalizer or backing plate.
(6) Disconnect the shock absorbers from the plate
brackets.
Fig. 1 Typical Housing Cover With Sealant
3 - 14 REAR SUSPENSION AND AXLESJ

(7) Disconnect the brake hose at the axle junction
block.Do not disconnect the wheel cylinder tub-
ing fittings.
(8) Disconnect the track bar at the axle bracket.
(9) Support the axle with a hydraulic jack under
the differential. Raise the axle just enough to relieve
the axle weight from the springs.
(10) Remove the spring U-bolts from the plate
brackets.
(11) Loosen BUT DO NOT REMOVE the bolts that
attach the spring front pivot at the frame rail brack-
ets. This will allow the springs to pivot without bind-
ing on the bushings.
(12) Disconnect shackle from the springs and lower
the springs to the surface.
(13) Lower the jack enough to remove the axle.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.
(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(2) Raise the springs and install the spring shackle
bolts.Do not tighten at this time.
(3) Lower the axle and align the spring center
bolts with the locating holes in the axle pads and
plate brackets.
(4) Install the spring U-bolts through the plate
brackets and tighten to 122 Nzm (90 ft. lbs.) torque.
(5) Connect the track bar to the axle bracket and
install the bolt. Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con-
nected. If the springs are not at their usual po-
sition, vehicle ride comfort could be affected.
(6) Connect the brake hose at the axle junction
block.
(7) Install the shock absorbers to the axle brackets
and tighten to 61 Nzm (45 ft. lbs.) torque.
(8) Connect the parking brake cables at the equal-
izer or backing plate.
(9) Connect the vent hose to the tube fitting.
(10) Align the reference marks and connect the
drive shaft to the axle yoke. Tighten the U-joint
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(11) Check differential lubricant and add if neces-
sary.
(12) Install the wheel and tire.
(13) Bleed the brakes.
(14) Remove the supports and lower the vehicle.(15) Tighten the spring front pivot bolt/nut to 142
Nzm (105 ft. lbs.) torque. Tighten the spring shackle
bolt/nut to 135 Nzm (100 ft. lbs.) torque.
(16) Tighten the track bar bolt at the axle bracket
to 142 Nzm (105 ft. lbs.) torque.
PINION SHAFT SEAL REPLACEMENT
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Mark the drive shaft yoke and pinion yoke for
installation alignment reference.
(4) Remove the drive shaft from the yoke.
(5) Rotate the pinion gear three or four times.
Make sure brakes are not dragging during this
procedure.
(6) Measure the amount of torque (in Newton-
meters or inch-pounds) necessary to rotate the pinion
gear with a torque wrench. Note the torque for in-
stallation reference.It must be known to properly
adjust the pinion gear bearing preload torque
after seal installation.
(7) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 2).
(8) Mark the positions of the yoke and pinion gear
for installation alignment reference.
(9) Use Remover 7794A and slide hammer to re-
move the pinion gear seal (Fig. 3).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer D-163
and Handle C-4171 (Fig. 4).
(2) Align the installation reference marks and in-
stall yoke on the pinion gear with Installer W-162-D.
(3) Install a new nut on the pinion gear.Tighten
the nut only enough to remove the shaft end
play.
Fig. 2 Pinion Yoke Removal
JREAR SUSPENSION AND AXLES 3 - 15

CAUTION: Exercise care during the bearing preload
torque adjustment. Do not over-tighten, or loosen
and then re-tighten the nut. Do not exceed the bear-
ing preload torque. The collapsible preload spacer
on the shaft will have to be replaced. The bearing
preload torque will be re-adjusted afterward.
(4) Install a socket and inch-pound torque wrench
on the pinion nut.
(5) Rotate the shaft with the torque wrench and
note the torque.
The required preload torque is equal to the
amount recorded during removal plus an addi-
tional 0.56 Nzm (5 in. lbs.).
(6) Use Flange Wrench C-3281 to retain the yoke
and shaft (Fig. 5). Tighten the shaft nut in very
small increments.(7) Continue tightening the shaft nut in small in-
crements until the correct bearing preload torque is
attained.
(8) Align the installation reference marks and at-
tach the drive shaft to the yoke.
(9) Add API grade GL 5 hypoid gear lubricant to
the differential housing, if necessary.
(10) Install wheel and tire assemblies.
(10) Lower the vehicle.
AXLE SHAFT
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire.
(3) Remove the brake drum.
(4) Clean all the foreign material from housing
cover area.
(5) Loosen the housing cover bolts. Drain the lubri-
cant from the housing and the axle shaft tubes. Re-
move the housing cover.
(6) Rotate the differential case so that the pinion
mate gear shaft lock screw is accessible. Remove the
lock screw and the pinion mate gear shaft from the
case (Fig. 6).
(7) Force the axle shaft in toward the center of the
vehicle. Remove the axle shaft C-clip lock from the
axle shaft (Fig. 7).
(8) Remove the axle shaft. Use care to prevent
damage to the axle shaft bearing and seal, which will
remain in the axle shaft tube.
(9) Inspect axle shaft seal for leakage or damage.
Fig. 3 Seal Removal
Fig. 4 Pinion Seal Installation
Fig. 5 Tightening Pinion Shaft Nut
3 - 16 REAR SUSPENSION AND AXLESJ

LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be
used in the 8 1/4 inch axle. The lubricant should
have MIL-L-2105C and API GL 5 quality specifica-
tions. MOPARtHypoid Gear Lubricant conforms to
both of these specifications.
²The factory installed lubricant for the 8 1/4 inch
rear axle is SAE 80W 90 gear lubricant.
²The factory installed lubricant quantity is 6762
fluid oz.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
Refer to Group 0, Lubrication and Maintenance for
additional information.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
DRIVE AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES
REMOVAL
(1) Raise the vehicle. Position support stands un-
der the frame rails slightly in front the springs.
(2) Remove the rear wheels.
(3) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(4) Disconnect the axle vent hose.
(5) Disconnect the parking brake cables at the
equalizer or backing plate.
(6) Disconnect the shock absorbers from the axle
brackets.
(7) Disconnect the brake hose at the axle junction
block.Do not disconnect the wheel cylinder tub-
ing fittings.
(8) If equipped, disconnect ABS wiring connections
at the axle.
(9) Support the axle with a hydraulic jack under
the differential.
(10) Remove the spring U-bolts from the plate
brackets.
(11) Lower the jack enough to remove the axle.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(2) Raise the axle and align the spring center bolts
with the locating holes in the axle pads and plate
brackets.
(3) Install the spring U-bolts through the plate
brackets and tighten to 70 Nzm (52 ft. lbs.) torque.
(4) Install ABS wiring connections (if equipped) at
the axle.
(5) Connect the brake hose at the axle junction
block.
(6) Install the shock absorbers to the axle brackets
and tighten to 62 Nzm (46 ft. lbs.) torque.
(7) Connect the parking brake cables at the equal-
izer or backing plate.
(8) Connect the vent hose to the tube fitting.
(9) Align the reference marks and connect the
drive shaft to the axle yoke. Tighten the U-joint
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(10) Check differential lubricant and add if neces-
sary.
(11) Install the wheel and tire.
(12) Bleed the brakes.
(13) Remove the supports and lower the vehicle.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle
has been recently driven.
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the dif-
ferential housing cover.
(3) Remove the differential housing cover and
drain the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the sealant from the housing and cover
surfaces. Use solvent to clean the mating surfaces.
(6) Apply a bead of MOPARtSilicone Rubber Seal-
ant to the housing cover (Fig. 2). Allow the sealant to
cure for a few minutes.
Install the housing cover within 5 minutes after
applying the sealant. If not installed the sealant
must be removed and another bead applied.
(7) Install the cover and any identification tag.
Tighten the cover bolts in a criss-cross pattern to 47
Nzm (35 ft. lbs.) torque.
(8) Refill the differential with Mopar Hypoid Gear
Lubricant 13 mm (1/2 in.) below the fill plug hole.
With Trac-Lok differentials, add a container of Mopar
Hypoid Gear Lubricant Additive.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(9) Install the fill hole plug and lower the vehicle.
JREAR SUSPENSION AND AXLES 3 - 31

AXLE SHAFT, SEAL AND BEARING SERVICE
CAUTION: When rear axle service is necessary,
both rear wheels must be raised off the surface so
that they are free to rotate. Be cautious when the
tires are being rotated by the engine or by other
means.
AXLE SHAFT REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire.
(3) Remove the brake drum.
(4) Clean all the foreign material from housing
cover area.
(5) Loosen the housing cover bolts and drain the
lubricant from the housing. Remove the housing
cover.
(6) Rotate the differential case so that the pinion
mate gear shaft lock screw is accessible. Remove the
lock screw and the pinion mate gear shaft from the
case (Fig. 3).
(7) Push the axle shaft in toward the center of the
vehicle. Remove the axle shaft C-clip lock from the
axle shaft (Fig. 4).
(8) Remove the axle shaft. Use care to prevent
damage to the axle shaft bearing, which will remain
in the axle shaft tube.
(9) Inspect the axle shaft bearing contact surface
area for indications of brinelling, spalling, and pit-
ting.
If any of these conditions exist, the axle shaft
and bearing should be replaced. Normal bear-ing contact on the shaft will be a dull gray and
it could appear to be lightly dented.
(10) If any of these conditions exist, the axle shaft
and bearing must be replaced.
The normal appearance (from roller bearing
contact) will be a dull gray surface area that
could appear slightly dented.
AXLE SHAFT SEAL AND BEARING REMOVAL
(1) Remove the axle shaft seal with a small pry
bar.
(2) Remove the bearing if it appears damaged or
the axle shaft shows any of the conditions described
above.
(3) Remove the bearing with Remover C-4167 (Fig.
5). Attach Slide Hammer 7420 and Adapter 7420-8 to
the end of the removal tool.
(4) Inspect the axle shaft seal surface and tube
bore for roughness and burrs.Polish each axle
shaft with No. 600 crocus cloth. This can re-
move slight surface damage. Do not reduce the
diameter of the axle shaft seal contact surface.
When polishing, the crocus cloth should be
moved around the circumference of the shaft
(not in-line with the shaft).
Fig. 2 Typical Housing Cover With Sealant
Fig. 3 Pinion Mate Shaft Lock Screw
Fig. 4 Axle Shaft C-Clip Lock
3 - 32 REAR SUSPENSION AND AXLESJ