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SERVICE MANUAL 2004 GRAND CHEROKEE To order the special service tools used and illustrated, please refer to the instructions on inside back cover.

NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION.

DaimlerChrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.

Litho in U.S.A. Copyright © 2002 DaimlerChrysler Corporation 7.0M1202

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CAUTION ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE ONLY. All test and repair procedures on components or assemblies in non-automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product. Proper service and repair is important to the safe, reliable, operation of all motor vehicles. The service procedures recommended and described in this publication were developed for professional service personnel and are effective methods for performing vehicle repair. Following these procedures will help assure efficient economical vehicle performance and service reliability. Some of these service procedures require the use of special tools designed for specific procedures. These special tools should be used when recommended throughout this publication. Special attention should be exercised when working with spring or tension loaded fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal may cause personal injury. Always wear safety goggles whenever working on vehicles or vehicle components.

It is important to note that this publication contains various Cautions and Warnings. These should be carefully read in order to minimize the risk of personal injury, or the possibility that improper service methods may damage the vehicle or render it unsafe. It is important to note that these Cautions and Warnings cover only the situations and procedures DaimlerChrysler Corporation has encountered and recommended. DaimlerChrysler Corporation could not possibly know, evaluate, and advise the service trade of all conceivable ways that service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler Corporation has not undertaken any such broad service review. Accordingly, anyone who uses a service procedure, or tool, that is not recommended in this publication must assure oneself thoroughly that neither personal safety, nor vehicle safety, be jeopardized by the service methods they select.

For other Service and Owner Manuals for Chrysler, Plymouth, Dodge, Dodge Truck, and JeepT vehicles, Call (800) 890-4038 or FAX (440) 572-0815 to place an order. Or, visit our website at techauthority.daimlerchrysler.com. Tech Authority Online at our website offers you service information on a subscription basis.

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DaimlerChrysler Corporation UNITED STATES and CANADA The special service tools referred to herein are required for certain service operations. These special service tools or their equivalent, if not obtainable through a local source, are available through the following outlet. 28635 Mound Road, Warren, Michigan 48092, U.S.A.

MILLER SPECIAL TOOLS SPX Corporation

Telephone 1-800-801-5420

FAX 1-800-578-7375

INTERNATIONAL The special service tools referred to herein are required for certain service operations. These special service tools or their equivalent, if not obtainable through a local source, are available through the following outlet. 28635 Mound Road, Warren, Michigan 48092, U.S.A.

MILLER SPECIAL TOOLS SPX Corporation

Telephone 1-507-455-7320

FAX 1-800-578-7375

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FOREWORD

The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain description, operation, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual. A Service Manual Comment form is included at the rear of this manual. Use the form to provide DaimlerChrysler Corporation with your comments and suggestions. Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed. DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

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GROUP TAB LOCATOR Introduction

0 2 3 5 7 8A 8B 8E 8F 8G 8H 8I 8J 8L 8M 8N 8O 8P 8Q 8R 8W 9 11 13 14 19 21 22 23 24 25

Lubrication & Maintenance Suspension Differential & Driveline Brakes Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame & Bumpers Fuel System Steering Transmission and Transfer Case Tires/Wheels Body Heating & Air Conditioning Emissions Control 4.0L/4.7L Component and System Index

Service Manual Comment Forms

(Rear of Manual)


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1

INTRODUCTION TABLE OF CONTENTS page BODY CODE PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .

...1 ...1

...3 ...3

FASTENER USAGE DESCRIPTION - FASTENER USAGE . . . . . THREADED HOLE REPAIR DESCRIPTION - THREADED HOLE REPAIR INTERNATIONAL SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .

....6 ....6 ...6 ....7 ....9

...3

BODY CODE PLATE DESCRIPTION A metal Body Code plate is located in the engine compartment and attached to the top of the right frame rail. The information listed on the plate (Fig. 1) is used for manufacturing and service purposes.

Fig. 1 Body Code Plate

page

VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) plate is attached to the top left side of the instrument panel. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the decoding chart to determine the identification of a vehicle.


2

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VEHICLE IDENTIFICATION NUMBER (Continued) VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION

INTERPRETATION

CODE = DESCRIPTION

1

Country of Origin

1 = Manufactured By DaimlerChrysler Corporation

2

Make

J = Jeep

3

Vehicle Type

4 = MPV Less Side Air Bags 8 = MPV With Side Air Bags

4

Gross Vehicle Weight Rating

G = 5001-6000 lbs.

5

Vehicle Line (WJ)

X = Grand Cherokee 4X2 (LHD) W = Grand Cherokee 4X4 (LHD)

5

Vehicle Line (WG)

2 = Grand Cherokee (LHD) 8 = Grand Cherokee (RHD)

6

Series

3 = Sport 4 = Laredo 5 = Limited 6 = Overland WG Family (With Euro Group) B = 4spd Auto Transmission E = 5spd Auto Transmission

7

Body Style

8 = 4dr Sport Utility

8

Engine

A = 2.7 Liter 20V Turbo Diesel Direct Injection S = 4.0 Liter Gasoline N = 4.7 Liter Gasoline J = 4.7 Liter Gasoline High Output

9

Check Digit

0 through 9 or X

10

Model Year

4=2004

11

Assembly Plant

C = Jefferson North Assembly Y = Chrysler Steyer Assembly

12 thru 17

Vehicle Build Sequence


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VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION All vehicles are equipped with a combined vehicle emission control information (VECI) label(s). The label is located in the engine compartment on the vehicle hood (Fig. 2). Two labels are used for vehicles built for sale in the country of Canada.

3

cle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards. The label also lists: • Month and year of vehicle manufacture. • Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure. • Vehicle Identification Number (VIN). • Type of vehicle. • Type of rear wheels. • Bar code. • Month, Day and Hour (MDH) of final assembly. • Paint and Trim codes. • Country of origin. The label is located on the driver-side door shutface.

Fig. 2 VECI Label Location 1 - VECI LABEL (CANADIAN) 2 - VECI LABEL 3 - HOOD

The VECI label(s) contain the following: • Engine family and displacement • Evaporative family • Emission control system schematic • Certification application • Spark plug and gap The label also contains an engine vacuum schematic. There are unique labels for vehicles built for sale in the state of California and the country of Canada. Canadian labels are written in both the English and French languages. These labels are permanently attached and cannot be removed without defacing information and destroying label.

VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION A vehicle safety certification label (Fig. 3) is attached to every DaimlerChrysler Corporation vehi-

Fig. 3 VEHICLE SAFETY CERTIFICATION LABEL TYPICAL

FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 4) and (Fig. 5).


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FASTENER IDENTIFICATION (Continued)

Fig. 4 FASTENER IDENTIFICATION


INTRODUCTION

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Fig. 5 FASTENER STRENGTH

5


6

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FASTENER USAGE

THREADED HOLE REPAIR

DESCRIPTION - FASTENER USAGE

DESCRIPTION - THREADED HOLE REPAIR

WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommendations for application and repair procedures.

INTERNATIONAL SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

INTERNATIONAL SYMBOLS 1 2 3 4 5 6 7 8 9 10 11 12

High Beam Fog Lamps Headlamp, Parking Lamps, Panel Lamps Turn Warning Hazard Warning Windshield Washer Windshield Wiper Windshield Wiper and Washer Windscreen Demisting and Defrosting Ventilating Fan Rear Window Defogger Rear Window Wiper

13 14 15 16 17 18 19 20 21 22 23 24

Rear Window Washer Fuel Engine Coolant Temperature Battery Charging Condition Engine Oil Seat Belt Brake Failure Parking Brake Front Hood Rear hood (Decklid) Horn Lighter


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The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million.

CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY

BY

TO GET

MULTIPLY

BY

TO GET

in-lbs

x 0.11298

= Newton Meters (N·m)

N·m

x 8.851

= in-lbs

ft-lbs

x 1.3558

= Newton Meters (N·m)

N·m

x 0.7376

= ft-lbs

Inches Hg (60° F)

x 3.377

= Kilopascals (kPa)

kPa

x 0.2961

= Inches Hg

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

mm

x 0.03937

= Inches

Feet

x 0.3048

= Meters (M)

M

x 3.281

= Feet

Yards

x 0.9144

= Meters

M

x 1.0936

= Yards

mph

x 1.6093

= Kilometers/Hr. (Km/h)

Km/h

x 0.6214

= mph

Feet/Sec

x 0.3048

= Meters/Sec (M/S)

M/S

x 3.281

= Feet/Sec

mph

x 0.4470

= Meters/Sec (M/S)

M/S

x 2.237

= mph

Kilometers/Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilometers/Hr. (Km/h)

COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters

1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter

1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter

1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m).

Also, use the chart to convert between millimeters (mm) and inches (in.) (Fig. 6).


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METRIC SYSTEM (Continued)

Fig. 6 METRIC CONVERSION CHART


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TORQUE REFERENCES

9

tions Chart for torque references not listed in the individual torque charts (Fig. 7).

DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica-

Fig. 7 TORQUE SPECIFICATIONS


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LUBRICATION & MAINTENANCE TABLE OF CONTENTS page INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . PARTS & LUBRICANT RECOMMENDATION STANDARD PROCEDURE - PARTS & LUBRICANT RECOMMENDATIONS . . . . . . FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE COOLANT . . . . . DESCRIPTION - HOAT COOLANT . . . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - ENGINE OIL . . . . . . . . . . DESCRIPTION - AXLE . . . . . . . . . . . . . . . . DESCRIPTION - TRANSFER CASE - NV147 DESCRIPTION - TRANSFER CASE - NV242 DESCRIPTION - TRANSFER CASE - NV247 DESCRIPTION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . DESCRIPTION - AUTOMATIC TRANSMISSION FLUID - NAG1 . . . . . . . . . DESCRIPTION - ENGINE OIL - DIESEL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . .

...1

...1

. . . . .

. . . . . . . .

.2 .2 .3 .4 .5 .5 .5 .5

...5 ...5

DESCRIPTION - POWER STEERING FLUID . . 6 OPERATION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FLUID CAPACITIES SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 6 FLUID FILL/CHECK LOCATIONS INSPECTION - FLUID FILL/CHECK LOCATIONS ..........................7 MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 LIFT POINTS STANDARD PROCEDURE - HOISTING AND JACKING RECOMMENDATIONS . . . . . . . . . . 14 JUMP STARTING STANDARD PROCEDURE - JUMP STARTING . 14 EMERGENCY TOW HOOKS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15 TOWING STANDARD PROCEDURE - TOWING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 16

...6

INTERNATIONAL SYMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).

Fig. 1 INTERNATIONAL SYMBOLS

page

PARTS & LUBRICANT RECOMMENDATION STANDARD PROCEDURE - PARTS & LUBRICANT RECOMMENDATIONS Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 2) on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality.


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PARTS & LUBRICANT RECOMMENDATION (Continued) insulation, causing temperatures to rise to as high as 149° C (300° F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22° C (-8° F ).

PROPYLENE-GLYCOL MIXTURES Fig. 2 NLGI Symbol 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS

When service is required, DaimlerChrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing DaimlerChrysler Corporation vehicles.

FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE COOLANT ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as

It’s overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F). 5° C higher than ethylene-glycol’s freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F ) at 96.5 kPa (14 psi), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol.

DESCRIPTION - HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection.


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FLUID TYPES (Continued) The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection.

tion against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.

COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling.

COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, yearround in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protec-

ENGINE OIL WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to this service grade.


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FLUID TYPES (Continued)

SAE VISCOSITY

DESCRIPTION - ENGINE OIL

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 3).

WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to this service grade.

Fig. 3 Temperature/Engine Oil Viscosity - 4.7L

ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

CONTAINER IDENTIFICATION

SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These oils are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 5).

Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 4).

Fig. 5 Temperature/Engine Oil Viscosity - 4.0L Fig. 4 API SYMBOL

ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.


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FLUID TYPES (Continued)

CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 6).

Fig. 6 API Symbol

DESCRIPTION - AXLE NOTE: DaimlerChrysler recommends using MoparT lubricants or lubricants of equal quality

FRONT AXLE • 186 FBI (Model 30) - Mopart Synthetic Gear Lubricant 75W-140 REAR AXLE • 194 RBI (Model 35) 80W-90 (Trailer Towing Lubricant 75W-140 • 226 RBA (Model 44) 80W-90 (Trailer Towing Lubricant 75W-140

Mopart Gear Lubricant Mopart Synthetic Gear Mopart Gear Lubricant Mopart Synthetic Gear

NOTE: Trac-lokT and Vari-lokT equipped axles require 118 ml (4 ounces) of Limited Slip Additive be added to the lubricant.

DESCRIPTION - TRANSFER CASE - NV147 Mopart Transfer Case Lubricant (P/N 05016796) is the only lubricant recommended for the NV147 transfer case.

DESCRIPTION - TRANSFER CASE - NV242 Recommended lubricant for the NV242 transfer case is Mopart ATF+4, Automatic Transmission Fluid.

DESCRIPTION - TRANSFER CASE - NV247 Mopart Transfer Case Lubricant (P/N 05016796) is the only lubricant recommended for the NV247 transfer case.

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID NOTE: Refer to Service Procedures in this group for fluid level checking procedures. Mopart ATF +4, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler automatic transmissions. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Mopart ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.

FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID - NAG1 NOTE: Refer to Service Procedures in this group for fluid level checking procedures. Shellt 3403 Automatic Transmission Fluid is the recommended fluid for the NAG1 DaimlerChrysler automatic transmission. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid.


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LUBRICATION & MAINTENANCE

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FLUID TYPES (Continued) Shellt 3403 Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal.

FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

OPERATION - AUTOMATIC TRANSMISSION FLUID The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case.

FLUID CAPACITIES SPECIFICATIONS - FLUID CAPACITIES DESCRIPTION

SPECIFICATION

FUEL TANK

20 U.S. Gallons (76 Liters)****

Engine Oil - with Filter 2.7L Diesel

6.5L (6.9 qts.)

Engine Oil - with Filter 4.0L

5.7 L (6.0 qts.)

Engine Oil - with Filter 4.7L

5.7 L (6.0 qts.)

SAE VISCOSITY GRADE

Cooling System - 2.7L Diesel

14.2L (15 qts.)***

CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation.

Cooling System - 4.0L

14.1 L (15 qts.)***

Cooling System - 4.7L

13.7 L (14.5 qts.)***

DESCRIPTION - ENGINE OIL - DIESEL ENGINES Use only Diesel Engine Oil meeting standard MIL2104C or API Classification CD or higher or CCML D4, D5.

To assure of properly formulated engine oils, it is recommended that SAE Grade 10W-40 engine oils that meet Chrysler material standard MS-6395, be used in accordance to ACEA B3, B4 specification. European Grade 10W-40 oils are also acceptable. Oils of the SAE 5W-40 grade number are preferred when minimum temperatures consistently fall below -15°C.

DESCRIPTION - POWER STEERING FLUID The recommended fluid for the power steering system is MOPAR Power Steering Fluid or equivalent. Do not use automatic transmission fluid and do not overfill.

POWER STEERING SYSTEM Power steering fluid capacities are dependent on engine/chassis options as well as steering gear/cooler options. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these capacities may vary. Refer to 19, Steering for proper fill and bleed procedures. AUTOMATIC TRANSMISSION Service Fill - 42RE

3.8 L (4.0 qts.)

Service Fill - 545RFE

2WD - 5.2 L (11 pts.) 4WD - 6.2 L (13 pts.)

Service Fill - NAG1

5.0 L (10.6 pts.)


LUBRICATION & MAINTENANCE

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0-7

FLUID CAPACITIES (Continued) DESCRIPTION

SPECIFICATION

O-haul Fill - 42RE

9.1-9.5 L (19-20 pts.)

O-haul Fill - 545RFE

13.33 L (28.0 pts.)

O-haul Fill - NAG1

7.7 L (16.3 pts)

Dry fill capacity Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. (Refer to appropriate 21 - TRANSMISSION/ AUTOMATIC/FLUID - STANDARD PROCEDURE). TRANSFER CASE NV147

1.6L (3.4 pts.)

NV242

1.35L (2.85 pts.)

NV247

1.6L (3.4 pts.)

FRONT AXLE ± 0.3 L (1 oz.) 186 FBI (Model 30)

1.18 L (2.5 pts.)*

* With Vari-Lok add 0.07 L (2.5 oz.) of Friction Modifier. REAR AXLE ± 0.3 L (1 oz.) 198 RBI (Model 35)

1.66 L (3.5 pts.)*

226 RBA (Model 44)

2.24 L (4.75 pts.)**

* With Trac-lok add 0.07 L (2.5 oz.) of Friction Modifier. ** With Trac-lok or Vari-Lok, add 0.07 L (2.5 oz.) of Friction Modifier. *** Includes 0.9L (1.0 qts.) for coolant reservoir. ****Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerance and refill procedure.

FLUID FILL/CHECK LOCATIONS INSPECTION - FLUID FILL/CHECK LOCATIONS The fluid fill/check locations and lubrication points are located in each applicable group.

MAINTENANCE SCHEDULES DESCRIPTION Maintenance Schedule Information not included in this section, is located in the appropriate Owner’s Manual. There are two maintenance schedules that show the required service for your vehicle. First is Schedule (B(. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule. • Day or night temperatures are below 0°C (32°F)

• Stop and go driving • Excessive engine idling • Driving in dusty conditions • Short trips of less than 16.2 km (10 miles) • More than 50% of your driving is at sustained high speeds during hot weather, above 32°C (90°F) • Trailer towing • Taxi, police, or delivery service (commercial service) • Off-road or desert driving • If equipped for and operated with E-85 (ethanol) fuel. NOTE: Most vehicles are operated under the conditions listed for Schedule “B.” NOTE: If ANY of these apply to you, change your engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first, and follow the maintenance recommendations in “Maintenance Schedule B.” Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule “B.” Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first. CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

At Each Stop for Fuel • Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark. • Check the windshield washer solvent, add as required. Once a Month • Check the tire pressure and look for unusual wear or damage. • Inspect the battery and clean and tighten the terminals as required. • Check the fluid levels of the coolant reservoir, brake master cylinder, power steering, and transmission, and add as needed. • Check all lights and all other electrical items for correct operation. At Each Oil Change • Change the engine oil filter. • Inspect the exhaust system. • Inspect brake hoses.


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MAINTENANCE SCHEDULES (Continued) • Check the coolant level, hoses, and clamps. • After completion of off-road operation, the underside of the vehicle should be thoroughly inspected. Examine threaded fasteners for looseness.

Schedule “B” Follow this schedule if you usually operate your vehicle under one or more of the following conditions. • Day or night temperatures are below 0°C (32°F) • Stop and go driving • Excessive engine idling • Driving in dusty conditions • Short trips of less than 16.2 km (10 miles) Miles (Kilometers) Change the engine oil and engine oil filter.

• More than 50% of your driving is at sustained high speeds during hot weather, above 32°C (90°F) • Trailer towing • Taxi, police, or delivery service (commercial service) • Off-road or desert driving • If equipped for and operated with E-85 (ethanol) fuel. NOTE: If ANY of these apply to you, change your engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first, and follow the maintenance recommendations in “Maintenance Schedule B.”

3,000

6,000

9,000

12,000

15,000

(5 000)

(10 000)

(14 000)

(19 000)

(24 000)

X

X

X

X

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

X

Drain and refill the front and rear axles.

X

Inspect the engine air cleaner filter, replace if necessary.

X

Inspect the brake linings.

X

Clean and lubricate the brake caliper pins.

X

Miles

18,000

21,000

24,000

27,000

30,000

(29 000)

(34 000)

(38 000)

(43 000)

(48 000)

Change the engine oil and engine oil filter.

X

X

X

X

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

(Kilometers)

X

Drain and refill the front and rear axles.

X

Inspect the brake linings.

X

Clean and lubricate the brake caliper pins.

X

X

Inspect the engine air cleaner filter, replace if necessary.

X

Inspect the PCV valve, replace if necessary (4.7L Only).L

X

Replace the spark plugs.

X

Drain and refill the automatic transmission fluid, change filter, and adjust bands (4.0L Only).

X

Drain and refill the automatic transmission fluid, and replace main sump filter (4.7L Only).

X

Drain the transfer case and refill (QuadraTrac Models Only).

X


LUBRICATION & MAINTENANCE

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MAINTENANCE SCHEDULES (Continued) Miles (Kilometers) Change the engine oil and engine oil filter.

33,000

36,000

39,000

42,000

45,000

(53 000)

(58 000)

(62 000)

(67 000)

(72 000)

X

X

X

X

X

Drain and refill the front and rear axles.

X

Inspect the brake linings.

X

Inspect the engine air cleaner filter, replace if necessary.

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

Clean and lubricate the brake caliper pins.

X

X

Inspect and replace drive belt, if necessary (4.0L Only). Miles

X

48,000

51,000

54,000

57,000

60,000

(77 000)

(82 000)

(86 000)

(91 000)

(96 000)

Change the engine oil and engine oil filter.

X

X

X

X

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

Clean and lubricate brake caliper pins.

X

(Kilometers)

X

X X

Inspect the engine air cleaner filter, replace if necessary.

X

Inspect the PCV valve, replace if necessary (4.7L Only).L

X

Replace the spark plugs.

X

Inspect the brake linings.

X

X

Drain and refill the front and rear axles.

X

X

Drain and refill the automatic transmission fluid, change filter, and adjust bands (4.0L Only).

X

Drain and refill the automatic transmission fluid, and replace main sump filter (4.7L Only).

X

Inspect the drive belt and replace as needed. Not required if belt was previously replaced (4.0L Only).

X

Drain and refill the transfer case fluid (Selec-Trac and Quadra-Trac Models).

X

Miles (Kilometers) Change the engine oil and engine oil filter. Lubricate the upper knuckle ball stud at steering & suspension ball joints.

63,000

66,000

69,000

72,000

75,000

(101 000)

(106 000)

(110 000)

(115 000)

(120 000)

X

X

X

X

X

X

X

Inspect the engine air cleaner filter, replace if necessary.

X

Inspect the brake linings.

X

Clean and lubricate the brake caliper pins.

X


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LUBRICATION & MAINTENANCE

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MAINTENANCE SCHEDULES (Continued) Miles (Kilometers)

63,000

66,000

69,000

72,000

75,000

(101 000)

(106 000)

(110 000)

(115 000)

(120 000)

Drain and refill the front and rear axle fluid.

X

Inspect the drive belt and replace as needed. Not required if belt was previously replaced (4.0L Only).

X

Inspect the drive belt and replace as needed (4.7L Only).

X

Miles (Kilometers)

78,000

81,000

84,000

87,000

90,000

(125 000)

(130 000)

(134 000)

(139 000)

(144 000)

Change the engine oil and engine oil filter.

X

X

X

X

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

X

X

Inspect the engine air cleaner filter, replace if necessary.

X

Inspect the PCV valve, replace if necessary (4.7L Only).L

X

Replace the spark plugs.

X

Drain and refill the transfer case fluid (Quadra-Trac Models Only).

X

Inspect the brake linings.

X

Clean and lubricate the brake caliper pins.

X

Drain and refill the front and rear axle fluid.

X

Drain and refill the automatic transmission fluid, change filter, and adjust bands (4.0L Only).

X

Drain and refill the automatic transmission fluid, replace main sump filter, and spin-on cooler return filter (if equipped) (4.7L Only).

X

Inspect the drive belt and replace as needed. Not required if belt was previously replaced.

X

Miles (Kilometers) Change the engine oil and engine oil filter. Lubricate the upper knuckle ball stud at steering & suspension ball joints.

93,000

96,000

99,000

100,000

102,000

105,000

(149 000)

(154 000)

(158 000)

(161 000)

(163 000)

(168 000)

X

X

X

X

X

X

Inspect the engine air cleaner filter, replace if necessary.

X

X

Inspect the brake linings.

X

Clean and lubricate the brake caliper pins.

X


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0 - 11

MAINTENANCE SCHEDULES (Continued) Miles (Kilometers)

93,000

96,000

99,000

100,000

102,000

105,000

(149 000)

(154 000)

(158 000)

(161 000)

(163 000)

(168 000)

Drain and refill the front and rear axle fluid.

X

Inspect the drive belt and replace as needed. Not required if belt was previously replaced.

X

Flush and replace the engine coolant. Miles (Kilometers)

X

108,000

111,000

114,000

117,000

120,000

(173 000)

(178 000)

(182 000)

(187 000)

(192 000)

Change the engine oil and engine oil filter.

X

X

X

X

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

X

X

Inspect the engine air cleaner filter, replace if necessary.

X

Inspect the PCV valve, replace if necessary (4.7L Only).L

X

Replace the spark plugs.

X

Inspect the brake linings.

X

X

Clean and lubricate the brake caliper pins.

X

X

Drain and refill the front and rear axle fluid.

X

X

Drain and refill the automatic transmission fluid, change filter, and adjust bands (4.0L Only).

X

Drain and refill the automatic transmission fluid, and replace main sump filter (4.7L Only).

X

Inspect the drive belt and replace as needed. Not required if belt was previously replaced.

X

Drain and refill the transfer case fluid (Selec-Trac and Quadra-Trac Models).

X

Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts. L This maintenance is recommended by the manufacturer to the owner, but is not required to maintain emissions warranty.

‡Off-highway operation, trailer towing, taxi, limousine, bus, snow plowing, or other types of commercial service or prolonged operation with heavy loading, especially in hot weather, require front and rear axle service indicated with a ‡ in Schedule “B”. Perform these services if the vehicle is usually operated under these conditions.


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MAINTENANCE SCHEDULES (Continued)

Schedule “A� Miles

6,000

12,000

18,000

24,000

30,000

(10 000)

(19 000)

(29 000)

(38 000)

(48 000)

[Months]

[6]

[12]

[18]

[24]

[30]

Change the engine oil and engine oil filter.

X

X

X

X

X

(Kilometers)

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

X

Inspect the brake linings.

X

Clean and lubricate the brake caliper pins.

X

Replace the engine air cleaner filter.

X

Replace the spark plugs.

X

Inspect transfer case fluid (Selec-Trac Models Only).

X

Drain the transfer case and refill (QuadraTrac Models Only).

X

Miles (Kilometers) [Months] Change the engine oil and engine oil filter.

36,000

42,000

48,000

54, 000

(58 000)

(67 000)

(77 000)

(86 000)

[36]

[42]

[48]

[54]

X

X

X

X

Inspect the brake linings.

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

Clean and lubricate the brake caliper pins.

X

Miles

X X X

60,000

66,000

72,000

78,000

(96 000)

(106 000)

(115 000)

(125 000)

[60]

[66]

[72]

[78]

Change the engine oil and engine oil filter.

X

X

X

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

Inspect and replace the drive belt if necessary (4.0L Only). Not required if belt was previously replaced.

X

Flush and replace the engine coolant.

X

Replace the engine air cleaner filter.

X

Inspect the PCV valve, replace if necessary (4.7L Only).L

X

Replace the spark plugs.

X

(Kilometers) [Months]

Inspect the brake linings.

X X

X

Clean and lubricate the brake caliper pins.

X

Inspect transfer case fluid (Selec-Trac Models Only).

X

Drain the transfer case and refill (Quadra-Trac Models Only).

X


LUBRICATION & MAINTENANCE

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0 - 13

MAINTENANCE SCHEDULES (Continued) Miles

84,000

90,000

96,000

100,000

102, 000

(134 000)

(144 000)

(154 000)

(161 000)

(163 000)

[84]

[90]

[96]

[102]

Change the engine oil and engine oil filter.

X

X

X

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

(Kilometers) [Months]

X

Clean and lubricate the brake caliper pins.

X

Inspect the brake linings.

X

Replace the engine air cleaner filter.

X

Inspect the PCV valve, replace if necessary (4.7L Only).L

X

Replace the spark plugs.

X

Inspect the drive belt, and replace as needed. Not required if previously replaced.

X

Flush and replace the engine coolant if not replaced at 60 months.

X

Drain and refill the automatic transmission fluid, change filter, and adjust bands (4.0L Only).

X

Drain and refill the automatic transmission fluid, replace main sump filter, and spin-on cooler return filter (if equipped) (4.7L Only).

X

Inspect the transfer case fluid (Selec-Trac Models Only).

X

Drain the transfer case and refill (QuadraTrac Models Only).

X

Miles

108,000

114,000

120,000

(173 000)

(182 000)

(192 000)

[108]

[114]

[120]

Change the engine oil and engine oil filter.

X

X

X

Lubricate the upper knuckle ball stud at steering & suspension ball joints.

X

Inspect the brake linings.

X

Clean and lubricate the brake caliper pins.

X

(Kilometers) [Months]

X

Replace the engine air cleaner filter.

X

Inspect the PCV valve, replace if necessary (4.7L Only).L

X

Replace the spark plugs.

X

Inspect and replace the drive belt if not previously replaced. Drain the transfer case and refill (Selec-Trac and Quadra-Trac Models). Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts. L This maintenance is recommended by the manufacturer to the owner, but is not required to maintain emissions warranty.

X

X X

WARNING: You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the proper equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.


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LUBRICATION & MAINTENANCE

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LIFT POINTS STANDARD PROCEDURE - HOISTING AND JACKING RECOMMENDATIONS FLOOR JACK When properly positioned, a floor jack can be used to lift a WJ vehicle (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: • An axle tube. • Aluminum differential. • A body side sill. • A steering linkage component. • A drive shaft. • The engine or transmission oil pan. • The fuel tank. • A front suspension arm.

HOIST A • • •

vehicle can be lifted with: A single-post, frame-contact hoist. A twin-post, chassis hoist. A ramp-type, drive-on hoist.

NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.

JUMP STARTING STANDARD PROCEDURE - JUMP STARTING WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN THE BATTERY SYSTEM SECTION OF THE SERVICE MANUAL. (Refer to 8 ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE) • DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.

Fig. 7 Correct Vehicle Lifting Locations • IF EQUIPPED, DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. • DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. • DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. • DO NOT USE OPEN FLAME NEAR BATTERY. • REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. • WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 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: • Battery cable clamp condition, clean if necessary. • Frozen battery.


LUBRICATION & MAINTENANCE

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0 - 15

JUMP STARTING (Continued) • • • •

Yellow or bright color test indicator, if equipped. Low battery fluid level. Generator drive belt condition and tension. Fuel fumes or leakage, correct if necessary.

CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. (2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. (3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 8). (6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery.

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. (7) 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 seconds, stop cranking engine and allow starter to cool (15 min.), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine ground on disabled vehicle. • When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. • Disconnect RED cable clamp from battery positive terminal on disabled vehicle.

EMERGENCY TOW HOOKS DESCRIPTION WARNING: REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS. THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY. Some Jeep vehicles are equipped with front emergency tow hooks (Fig. 9). The tow hooks should be used for EMERGENCYpurposes only. CAUTION: DO NOT use emergency tow hooks for tow truck hook-up or highway towing.

Fig. 8 Jumper Cable Clamp Connections 1 2 3 4 5 6 7

-

ENGINE GROUND NEGATIVE JUMPER CABLE BATTERY NEGATIVE CABLE POSITIVE JUMPER CABLE BATTERY POSITIVE CABLE BATTERY TEST INDICATOR (IF EQUIPPED)

Fig. 9 Emergency Tow Hooks 1 - TOW HOOK


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LUBRICATION & MAINTENANCE

TOWING STANDARD PROCEDURE - TOWING RECOMMENDATIONS A vehicle equipped with SAE approved wheel lifttype towing equipment can be used to tow WJ vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with flatbed device can also be used to transport a disabled vehicle (Fig. 10).

WJ

TWO-WHEEL-DRIVE VEHICLE TOWING DaimlerChrysler Corporation recommends that a vehicle be towed with the rear end lifted, whenever possible. WARNING: WHEN TOWING A DISABLED VEHICLE AND THE DRIVE WHEELS ARE SECURED IN A WHEEL LIFT OR TOW DOLLIES, ENSURE THE TRANSMISSION IS IN THE PARK POSITION (AUTOMATIC TRANSMISSION) OR A FORWARD DRIVE GEAR (MANUAL TRANSMISSION). WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING.

TWO WHEEL DRIVE TOWING-REAR END LIFTED CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

Fig. 10 Tow Vehicles With Approved Equipment

SAFETY PRECAUTIONS CAUTION: The following safety precautions must be observed when towing a vehicle: • Secure loose and protruding parts. • Always use a safety chain system that is independent of the lifting and towing equipment. • Do not allow towing equipment to contact the disabled vehicle’s fuel tank. • Do not allow anyone under the disabled vehicle while it is lifted by the towing device. • Do not allow passengers to ride in a vehicle being towed. • Always observe state and local laws regarding towing regulations. • Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. • Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. • Do not tow a heavily loaded vehicle. Use a flatbed device to transport a loaded vehicle.

2WD vehicles can be towed with the front wheels on the surface for extended distances at speeds not exceeding 48 km/h (30 mph). (1) Attach wheel lift device to rear wheels. (2) Place the transmission in neutral. (3) Raise vehicle to towing position. (4) Attach safety chains. Route chains so not to interfere with tail pipe when vehicle is lifted. (5) Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. (6) Secure steering wheel in straight ahead position with a clamp device designed for towing. (7) Place transmission in park.

TWO WHEEL DRIVE TOWING-FRONT END LIFTED CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. (1) Attach wheel lift device to rear wheels. (2) Place the transmission in neutral. (3) Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. (4) Attach wheel lift device to front wheels and raise vehicle to towing position. (5) Attach the safety chains. CAUTION: Do not use steering column lock to secure steering wheel during towing operation.


LUBRICATION & MAINTENANCE

WJ

0 - 17

TOWING (Continued) (6) Turn the ignition switch to the OFF position to unlock the steering wheel. (7) Secure steering wheel in straight ahead position with a clamp device designed for towing. (8) Place transmission in park.

FOUR-WHEEL-DRIVE VEHICLE TOWING DaimlerChrysler Corporation recommends that a 4WD vehicle be transported on a flat-bed device. A Wheel-lift device can be used provided the trailing wheels are off the ground and positioned in tow dollies. WARNING: WHEN AND THE DRIVE WHEEL LIFT OR TRANSMISSION IS

TOWING A DISABLED VEHICLE WHEELS ARE SECURED IN A TOW DOLLIES, ENSURE THE IN THE PARK POSITION.

CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended.

FOUR WHEEL DRIVE TOWING—REAR END LIFTED WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING. (1) Attach wheel lift device to front wheels. (2) Place the transmission in neutral. (3) Raise the front of the vehicle off the ground and install tow dollies under front wheels. (4) Attach wheel lift device to rear wheels and raise vehicle to towing position.

(5) Attach safety chains. Route chains so not to interfere with tail pipe when vehicle is lifted. (6) Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. (7) Secure steering wheel in straight ahead position with a clamp device designed for towing. (8) Place transmission in park.

FOUR WHEEL DRIVE TOWING—FRONT END LIFTED WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING. (1) Attach wheel lift device to rear wheels. (2) Place the transmission in neutral. (3) Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. (4) Attach wheel lift device to front wheels and raise vehicle to towing position. (5) Attach the safety chains. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. (6) Turn the ignition switch to the OFF position to unlock the steering wheel. (7) Secure steering wheel in straight ahead position with a clamp device designed for towing. (8) Place transmission in park.


SUSPENSION

WJ

2-1

SUSPENSION TABLE OF CONTENTS page

page

SUSPENSION DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM . . . . . . . . . . . . . . . . 1

WHEEL ALIGNMENT ......................3 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SUSPENSION DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM CONDITION FRONT END NOISE

EXCESSIVE PLAY IN STEERING

FRONT WHEELS SHIMMY

VEHICLE INSTABILITY

EXCESSIVE STEERING EFFORT

POSSIBLE CAUSES

CORRECTION

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Loose or worn steering gear.

3. Adjust or replace steering gear.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Tires worn or out of balance.

3. Replace or balance tires.

4. Alignment.

4. Align vehicle to specifications.

5. Leaking steering dampener.

5. Replace steering dampener.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Tire pressure.

3. Adjust tire pressure.

4. Alignment.

4. Align vehicle to specifications.

1. Loose or worn steering gear.

1. Adjust or replace steering gear.

2. Power steering fluid low.

2. Add fluid and repair leak.

3. Column coupler binding.

3. Replace coupler.

4. Tire pressure.

4. Adjust tire pressure.

5. Alignment.

5. Align vehicle to specifications.


2-2

SUSPENSION

WJ

SUSPENSION (Continued) CONDITION VEHICLE PULLS TO ONE SIDE DURING BRAKING

VEHICLE LEADS OR DRIFTS FROM STRAIGHT AHEAD DIRECTION ON UNCROWNED ROAD

KNOCKING, RATTLING OR SQUEAKING

IMPROPER TRACKING

POSSIBLE CAUSES

CORRECTION

1. Uneven tire pressure.

1. Adjust tire pressure.

2. Worn brake components.

2. Repair brakes as necessary.

3. Air in brake line.

3. Repair as necessary.

1. Radial tire lead.

1. Cross front tires.

2. Brakes dragging.

2. Repair brake as necessary.

3. Weak or broken spring.

3. Replace spring.

4. Uneven tire pressure.

4. Adjust tire pressure.

5. Wheel Alignment.

5. Align vehicle.

6. Loose or worn steering or suspension components.

6. Repair as necessary.

7. Cross caster out of spec.

7. Align vehicle.

1. Worn shock bushings.

1. Replace shock.

2. Loose, worn or bent steering/ suspension components.

2. Inspect, tighten or replace components as necessary.

3. Shock valve.

3. Replace shock.

1. Loose, worn or bent track bar.

1. Inspect, tighten or replace component as necessary.

2. Loose, worn or bent steering/ suspension components.

2. Inspect, tighten or replace components as necessary.


WHEEL ALIGNMENT

WJ

2-3

WHEEL ALIGNMENT TABLE OF CONTENTS page

page

WHEEL ALIGNMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STANDARD PROCEDURE STANDARD PROCEDURE - CAMBER . . . . . . . 4

STANDARD PROCEDURE - CASTER . . . . . . . 4 STANDARD PROCEDURE - TOE POSITION . . 4 SPECIFICATIONS ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WHEEL ALIGNMENT DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe position (Fig. 1). CAUTION: Never attempt to modify suspension or steering components by heating or bending. CAUTION: Components attached with a nut and cotter pin must be torqued to specification. Then if the slot in the nut does not line up with the cotter pin hole, tighten nut until it is aligned. Never loosen the nut to align the cotter pin hole. NOTE: Periodic lubrication of the front suspension/ steering system components may be required. Rubber bushings must never be lubricated, Refer to Lubrication And Maintenance for the recommended maintenance schedule.

OPERATION • CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle rearward provides positive caster. Tilting the top of the knuckle forward provides negative caster. Caster is a directional stability angle. This angle enables the front wheels to return to a straight ahead position after turns (Fig. 1). • CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. The angle is not adjustable, damaged component(s) must be replaced to correct the camber angle (Fig. 1). • WHEEL TOE POSITION is the difference between the leading inside edges and trailing inside edges of the front tires. Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear. The wheel toe position is the final front wheel alignment adjustment (Fig. 1). • STEERING AXIS INCLINATION ANGLE is measured in degrees and is the angle that the steering knuckles are tilted. The inclination angle has a fixed relationship with the camber angle. It will not change except when a spindle or ball stud is damaged or bent. The angle is not adjustable, damaged component(s) must be replaced to correct the steering axis inclination angle. • THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle (Fig. 1).


2-4

WHEEL ALIGNMENT

WJ

WHEEL ALIGNMENT (Continued)

Fig. 1 Wheel Alignment Measurements 1 2 3 4

-

WHEEL CENTERLINE NEGATIVE CAMBER ANGLE PIVOT CENTERLINE SCRUB RADIUS

STANDARD PROCEDURE STANDARD PROCEDURE - CAMBER Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down three times. Always release the bumper in the down position. To obtain an accurate alignment, a 4 wheel alignment machine must be used and the equipment calibration verified. The wheel camber angle is preset. This angle is not adjustable and cannot be altered.

STANDARD PROCEDURE - CASTER Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down three times. Always release the bumper in the down position.

5 6 7 8

-

TRUE VERTICAL KING PIN VERTICAL POSITIVE CASTER

To obtain an accurate alignment, a 4 wheel alignment machine must be used and the equipment calibration verified. The wheel caster angle is preset. This angle is not adjustable and cannot be altered.

STANDARD PROCEDURE - TOE POSITION Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down three times. Always release the bumper in the down position. To obtain an accurate alignment, a 4 wheel alignment machine must be used and the equipment calibration verified. NOTE: For an accurate wheel toe position adjustment the engine must be engine running. (1) Apply parking brakes.


WHEEL ALIGNMENT

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2-5

WHEEL ALIGNMENT (Continued) (2) Start the engine and turn wheels both ways before straightening the steering wheel. Center and secure the steering wheel. (3) Loosen the tie rod adjustment sleeve clamp bolts (Fig. 2). (4) Turn the sleeve to obtain the preferred positive TOE-IN specification. Position the clamp bolts as shown (Fig. 2) for proper clearance. (5) Tighten the clamp bolts to 68 N·m (50 ft. lbs.). NOTE: Make sure the toe setting does not change during clamp tightening.

SPECIFICATIONS ALIGNMENT NOTE: Specifications are in degrees.

FRONT WHEELS - STANDARD SUSPENSION SPECIFICATIONS DESCRIPTION

SPECIFICATION

PREFERRED

CASTER + 6.75°

CAMBER 2 0.37°

TOTAL TOE-IN + 0.20°

RANGE

+ 6.0° to + 7.5°

2 0.75° to + 0.5°

+ .14° to + .26°

MAX RT/LT DIFFERENCE

0.5°

0.5°

0.5°

(6) Verify alignment specifications, then turn the engine off.

FRONT WHEELS - UP-COUNTRY SUSPENSION SPECIFICATIONS DESCRIPTION

Fig. 2 Steering Linkage 1 - DRAG LINK ADJUSTMENT SLEEVE 2 - TIE ROD ADJUSTMENT SLEEVE

STEERING WHEEL CENTERING NOTE: The steering wheel can be centered without affecting the toe position. (1) Loosen the drag link adjustment sleeve clamp bolts. (2) Turn the adjustment sleeve to center the wheel. (3) Position the clamp bolts as shown (Fig. 2)for proper clearance. (4) Tighten the clamp bolts to 68 N·m (50 ft. lbs.). (5) Road test the vehicle to verify the wheel is centered.

SPECIFICATION

PREFERRED

CASTER + 6.5°

CAMBER 2 0.37°

TOTAL TOE-IN + 0.20°

RANGE

+ 5.7° to + 7.2°

2 0.75° to + 0°

+ 0.0° to + .36°

MAX RT/LT DIFFERENCE

0.5°

0.5°

0.06°

REAR AXLE SPECIFICATIONS DESCRIPTION

SPECIFICATION

PREFERRED

CAMBER –.37°

THRUST ANGLE 0°

TOTAL TOE-IN +.37°

RANGE

0° to –.75°

± 0.25°

0° to +.70°


2-6

FRONT

WJ

FRONT TABLE OF CONTENTS page

page

FRONT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STANDARD PROCEDURE - SERVICE WARNINGS AND CAUTIONS . . . . . . . . . . . . . . 6 SPECIFICATIONS TORQUE CHART ......................7 SPECIAL TOOLS FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 8 BUSHINGS REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 KNUCKLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOWER BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12

SHOCK DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . . SPRING DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . . STABILIZER BAR DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . . TRACK BAR DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . . UPPER BALL JOINT REMOVAL . . . . . . . . . UPPER CONTROL ARM DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . .

FRONT

CAUTION: Suspension components with rubber bushings must be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort will be affected and cause premature bushing wear.

DESCRIPTION The front suspension (Fig. 1) is a link/coil design comprised of : • Drive axle • Shock absorbers • Coil springs • Upper and lower suspension arms • Stabilizer bar • Track bar • Jounce bumpers CAUTION: Components attached with a nut and cotter pin must be torqued to specification. Then if the slot in the nut does not line up with the cotter pin hole, tighten nut until it is aligned. Never loosen the nut to align the cotter pin hole.

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STANDARD PROCEDURE - SERVICE WARNINGS AND CAUTIONS CAUTION: Suspension components with rubber bushings must be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort will be affected and cause premature bushing wear.


FRONT

WJ FRONT (Continued)

Fig. 1 Front 1 2 3 4 5 6

-

SHOCK COIL SPRING UPPER SUSPENSION ARM STABILIZER BAR LOWER SUSPENSION ARM TRACK BAR

SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Shock Absorber Upper Nut

35

26

Shock Absorber Lower Nut

28

250

Suspension Arm Upper Axle Bracket Nut

61

45

Suspension Arm Upper Frame Bracket Bolt

61

45

Suspension Arm Lower Axle Bracket Nut

163

120

Suspension Arm Lower Frame Bracket Bolt

156

115

Stabilizer Bar Retainer Bolts

92

68

Stabilizer Bar Link Upper Nut

106

78

Stabilizer Bar Link Lower Nut

106

78

Track Bar Frame Bracket Nut

108

80

Track Bar Axle Bracket Bolt

100

74

Hub Bearing Knuckle Bolts

102

75

2-7


2-8

FRONT

WJ

FRONT (Continued)

SPECIAL TOOLS FRONT SUSPENSION

Remover C-4150A

Remover/Installer Suspension Bushing 7932

Remover/Installer 6289

Spacer 8279

Reciever 6761

Nut, Long 7603

Installer 6752

Bolt, Special 7604


FRONT

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2-9

BUSHINGS REMOVAL (1) Remove the upper suspension arm from axle. (2) Position Spacer 8279 over the axle bushing on a 4x2 vehicle and right side on a 4x4 vehicle. (3) Place Receiver 7932-1 over flanged end of the bushing. (Fig. 2). (4) Place small end of Remover/Install 7932-2 against other side of the bushing. (5) Install bolt 7604 through remover, bushing and receiver. (6) Install Long Nut 7603 and tighten nut too pull bushing out of the axle bracket.

Fig. 3 Bushing Installation 1 2 3 4 5

- REMOVER/INSTALLER - AXLE BRACKET - BOLT - RECEIVER - LONG NUT

HUB / BEARING DESCRIPTION

Fig. 2 Bushing Removal 1 2 3 4 5

- RECEIVER - AXLE BRACKET - BOLT - REMOVER/INSTALLER - LONG NUT

(7) Remove nut, bolt, receiver, remover and bushing. NOTE: On 4x2 vehicle and right side of 4x4 vehicle, leave Spacer 8279 in position for bushing installation.

INSTALLATION (1) Place Receiver 7932-1on the other side of the axle bracket. (2) Position new bushing up to the axle bracket., and large end of Remover/Install 7932-2 against the bushing (Fig. 3). (3) Install bolt 7604 through receiver, bushing and installer. (4) Install Long Nut 7603 and tighten nut to draw the bushing into the axle bracket. (5) Remove tools and install the upper suspension arm.

The bearing used on the front hub of this vehicle is the combined hub and bearing unit type assembly. This unit assembly combines the front wheel mounting hub (flange) and the front wheel bearing into a one piece unit. The wheel mounting studs are the only replaceable component of the hub/bearing assembly.

OPERATION The hub/bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts accessible from the back of the steering knuckle. The hub/bearing unit is not serviceable and must be replaced as an assembly if the bearing or the hub is determined to be defective.

REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper, caliper anchor, rotor and ABS wheel speed sensor,(Refer to 5 - BRAKES/ ELECTRICAL/FRONT WHEEL SPEED SENSOR REMOVAL). (4) Remove the cotter pin, nut retainer and axle hub nut. (5) Remove the hub bearing mounting bolts from the back of the steering knuckle. Remove hub bearing (Fig. 4) from the steering knuckle and off the axle shaft.


2 - 10

FRONT

WJ

HUB / BEARING (Continued) (2) Remove the disc brake caliper and adapter (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ DISC BRAKE CALIPER ADAPTER - REMOVAL). (3) Remove the rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL). (4) Remove hub bearing (Fig. 5) (Refer to 2 - SUSPENSION/FRONT/HUB / BEARING - REMOVAL). (5) Disconnect the tie-rod or drag link from the steering knuckle arm, (Fig. 5)(Refer to 19 - STEERING/LINKAGE/TIE ROD END - REMOVAL). (6) Remove the cotter pins from the upper and lower ball studs (Fig. 5). (7) Remove the upper and lower ball stud nuts (Fig. 5).

Fig. 4 Hub Bearing & Knuckle 1 - HUB BEARING 2 - KNUCKLE

INSTALLATION (1) Install the hub bearing to the knuckle. (2) Install the hub bearing to knuckle bolts and tighten to 102 N路m (75 ft. lbs.). (3) Install the hub washer and nut. Tighten the hub nut to 237 N路m (175 ft. lbs.). Install the nut retainer and a new cotter pin. (4) Install the brake rotor, caliper anchor, caliper and ABS wheel speed sensor,(Refer to 5 - BRAKES/ ELECTRICAL/FRONT WHEEL SPEED SENSOR INSTALLATION). (5) Install the wheel and tire assembly (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). (6) Remove the support and lower the vehicle.

KNUCKLE DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing.

OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered.

REMOVAL Ball stud service procedures below require removal of the hub bearing. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Remove the tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).

Fig. 5 STEERING KNUCKLE 1 2 3 4 5 6 7

- UPPER BALL JOINT NUT - STEERING KNUCKLE - HUB/BEARING - AXLE NUT/COTTER PIN - LOWER BALL JOINT NUT - TIE ROD NUT/COTTER PIN - WHEEL SPEED SENSOR WIRE

(8) Strike the steering knuckle with a brass hammer to loosen knuckle from the ball studs. Remove knuckle from ball studs.

INSTALLATION (1) Position the steering knuckle on the ball studs. (2) Install and tighten the bottom retaining nut to 109 N路m (80 ft. lbs.) torque. Install new cotter pin. (Fig. 5). (3) Install and tighten the top retaining nut to 101 N路m (75 ft. lbs.) torque. Install new cotter pin. (Fig. 5). (4) Install the hub bearing (Fig. 5) (Refer to 2 SUSPENSION/FRONT/HUB / BEARING - INSTALLATION). (5) Connect the tie-rod or drag link end to the steering knuckle arm. (Fig. 5) (Refer to 19 - STEERING/LINKAGE/TIE ROD END - INSTALLATION).


FRONT

WJ

2 - 11

KNUCKLE (Continued) (6) Install the rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLATION). (7) Install the brake caliper and caliper adapter (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ DISC BRAKE CALIPER ADAPTER - INSTALLATION). (8) Install the tire and wheel assembly (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). (9) Check for an alignment (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

LOWER CONTROL ARM DESCRIPTION The lower suspension arms are hydroformed steel and use voided oval bushings at one end of the arm.

OPERATION The bushings provide isolation from the axle. The arms mount to the unibody frame rail bracket and the axle brackets. The arm and bushings provide location and react to loads from the axle.

REMOVAL

LOWER BALL JOINT REMOVAL Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Position tools as shown to remove and install ball stud (Fig. 6).

(1) Raise the vehicle and support the front axle. (2) Remove the lower suspension arm nut and bolt from the axle bracket (Fig. 7). (3) Remove the nut and bolt from the frame rail bracket and remove the lower suspension arm (Fig. 7).

Fig. 6 Lower 1 - SPECIAL TOOL 6289–12 2 - SPECIAL TOOL 6289–4 3 - SPECIAL TOOL 4212F

4 - SPECIAL TOOL 4212F 5 - SPECIAL TOOL 6289–1 6 - SPECIAL TOOL 6289–3


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FRONT

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LOWER CONTROL ARM (Continued)

OPERATION The shock absorbers dampen jounce and rebound motion of the vehicle over various road conditions and limit suspension rebound travel.

REMOVAL (1) Remove the nut, retainer and grommet from the shock stud in the engine compartment (Fig. 8).

Fig. 7 Lower Suspension Arm 1 - LOWER SUSPENSION ARM 2 - FRAME RAIL BRACKET 3 - AXLE BRACKET

INSTALLATION (1) Position the lower suspension arm in the axle bracket and frame rail bracket. NOTE: The end of the arm with the oval bushing attaches to the axle bracket. (2) Install the axle bracket bolt and nut finger tight. (3) Install the frame rail bracket bolt and nut finger tight. (4) Remove support and lower the vehicle. (5) With the vehicle on the ground tighten the frame bracket bolt to 156 N·m (115 ft. lbs.). Tighten the axle bracket nut to 163 N·m (120 ft. lbs.). (6) Check the alignment if new parts were installed.

Fig. 8 Upper Shock Mounting 1 2 3 4

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RETAINER STUD NUT GROMMET

(2) Raise and support the front axle. (3) Remove the lower mounting nuts from the axle bracket (Fig. 9). Remove the shock absorber.

SHOCK DESCRIPTION The top of the shock absorbers are bolted to the body. The bottom of the shocks are bolted to the axle brackets. The standard shocks have conventional twin tube construction and are low pressure gas charged. Gas charging prevents cavitation during rough road operation. Up-Country shocks are mono tube design and are high pressure gas charged.

Fig. 9 Lower Shock Mounting 1 - SHOCK ABSORBER 2 - MOUNTING NUTS


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2 - 13

SHOCK (Continued)

INSTALLATION (1) Position the lower retainer and grommet on the shock stud. Insert the shock absorber through the shock tower hole. (2) Install the lower shock studs into the axle bracket. (3) Install the mounting nuts and tighten to 28 N¡m (250 in. lbs.). (4) Remove support and lower the vehicle. (5) Install the upper grommet, retainer and nut on the stud in the engine compartment. Hold the shock stud with a 8 mm wrench and tighten the nut to 35 N¡m (26 ft. lbs.).

SPRING DESCRIPTION The coil springs mount up in the wheelhouse which is part of the unitized body bracket. A rubber doughnut isolator is located between the top of the spring and the body. The bottom of the spring seats on a axle isolator made of rubber with a steel insert.

OPERATION The coil springs control ride quality and maintain proper ride height. The isolators provide road noise isolation.

Fig. 10 Front Coil Spring 1 2 3 4

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UPPER ISOLATOR COIL SPRING LOWER ISOLATOR STABILIZER LINK

INSTALLATION (1) Install the upper isolator. (2) Install the lower isolator with the isolator locator nub in the axle pad hole (Fig. 11).

REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire assemblies. (3) Position a hydraulic jack under the axle to support it. (4) Remove shock absorbers lower mounting nuts from the axle brackets. (5) Remove the track bar mounting bolt from the axle bracket. NOTE: Make sure the lower part of the shock does not hold tension on the brake lines at the axle tube housing located at the lower shock mounting area. (6) Lower the axle until the spring is free from the upper mount and isolator (Fig. 10). (7) Remove the spring from the vehicle. (8) Remove and inspect the upper and lower spring isolators.

Fig. 11 Lower Isolator 1 2 3 4

- LOCATING NUB - LOWER ISOLATOR - AXLE SPRING PAD - LOCATING HOLE

(3) Position the coil spring on the axle spring pad.


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SPRING (Continued) CAUTION: Ensure the spring is positioned on the lower isolator with the end of the spring coil against the isolator spring locator (Fig. 12).

REMOVAL (1) Raise and support the vehicle. (2) Remove link nuts and bolts (Fig. 13) and remove the links. (3) Remove the stabilizer bar retainer bolts (Fig. 13)from the frame rails and remove the stabilizer bar.

Fig. 12 Isolator Spring Locator 1 - COIL SPRING 2 - SPRING LOCATOR 3 - LOWER ISOLATOR

(4) Raise the axle and guide the springs onto the spring upper mounts and lower shock studs into the axle brackets. (5) Install the shock absorbers lower mounting nuts. (6) Install the track bar to the axle bracket and install the mounting bolt. NOTE: It may be necessary to pry the axle assembly over to install the track bar bolt. (7) Remove the hydraulic jack from under the vehicle. (8) Tighten all suspension components to proper torque. (9) Install the wheel and tire assemblies. (10) Remove support and lower vehicle.

Fig. 13 Stabilizer Bar 1 2 3 4

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LINK STABILIZER BAR BUSHING RETAINER

INSTALLATION (1) Position the stabilizer bar on the frame rail and install the retainers and bolts. Ensure the bar is centered with equal spacing on both sides. Tighten the bolts to 92 N¡m (68 ft. lbs.). (2) Install the links onto the stabilizer bar and axle brackets and install the bolts and nuts finger tight. (3) Remove the supports and lower the vehicle. (4) With the vehicle on the ground tighten the stabilizer bar link nuts to 106 N¡m (78 ft. lbs.).

TRACK BAR STABILIZER BAR DESCRIPTION The bar extends across the front underside of the chassis and is mounted to the frame rails. Links are connected from the bar to the axle brackets. The stabilizer bar and links are isolated by rubber bushings.

OPERATION The stabilizer bar is used to control vehicle body roll during turns. The spring steel bar helps to control the vehicle body in relationship to the suspension.

DESCRIPTION The bar is attached to a frame rail bracket and axle bracket. The bar is forged and has non replaceable isolator bushings at both ends.

OPERATION The track bar is used to control front axle lateral movement and provides cross car location of the axle assembly.

REMOVAL (1) Raise and support the vehicle.


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2 - 15

TRACK BAR (Continued) (2) Remove the nut and bolt from the frame rail bracket (Fig. 14).

INSTALLATION (1) Install the track bar to the axle tube bracket. Install the retaining bolt finger tight. (2) Install track bar to the frame rail bracket. Install the bolt and nut finger tight. NOTE: It may be necessary to pry the axle assembly over to install the track bar to the frame rail bracket. (3) Remove the supports and lower the vehicle. (4) With the vehicle on the ground tighten the nut at the frame rail bracket and to the bolt at the axle bracket to 100 N¡m (74 ft. lbs.). (5) Check alignment specifications if a new track bar was installed.

Fig. 14 Track Bar Frame Rail Bracket 1 - FRAME RAIL 2 - TRACK BAR

(3) Remove the bolt from the axle shaft tube bracket (Fig. 15). Remove the track bar.

Fig. 15 Track Bar Axle Bracket 1 - AXLE BRACKET 2 - TRACK BAR

UPPER BALL JOINT REMOVAL Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Position tools as shown to remove and install ball stud (Fig. 16).


2 - 16

FRONT

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UPPER BALL JOINT (Continued)

Fig. 16 Upper

UPPER CONTROL ARM DESCRIPTION The upper suspension arms are hydroformed steel and use rubber bushings at each end of the arm.

OPERATION The arms mount to the unibody frame rail bracket and the axle brackets. The arm and bushings provide location and react to loads from the axle. The bushings provide isolation from the axle.

REMOVAL (1) Raise vehicle and support the axle. (2) Remove the upper suspension arm mounting nut and bolt (Fig. 17) from the axle bracket. (3) Remove the nut and bolt (Fig. 17) at the frame rail and remove the upper suspension arm.

INSTALLATION (1) Position the upper suspension arm at the axle and frame rail. (2) Install the bolts and finger tighten the nuts. (3) Remove the supports and lower the vehicle.

Fig. 17 Upper Suspension Arm 1 - UPPER SUSPENSION ARM 2 - FRAME BOLT 3 - AXLE BOLT

(4) With the vehicle on the ground tighten the axle bracket nut and the frame bracket bolt to 61 N¡m (45 ft. lbs.). (5) Check the alignment if new parts were installed.


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REAR TABLE OF CONTENTS page REAR DESCRIPTION . . . . . . . . . . . . . . . WARNING . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - REAR SUSPENSION . . . . . . . . . . . . . . SPECIFICATIONS TORQUE CHART . . . . . . . . . . . . SPECIAL TOOLS REAR SUSPENSION . . . . . . . . . LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . SHOCK DESCRIPTION . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . SPRING DESCRIPTION . . . . . . . . . . . . . . .

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page OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . STABILIZER BAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . UPPER BALL JOINT DESCRIPTION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT . . . . . . . . . OPERATION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . UPPER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . .

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REAR DESCRIPTION The rear suspension (Fig. 1) is comprised of : • Drive axle • Shock absorbers • Coil springs • Lower suspension arms • Upper suspension arm • Stabilizer bar CAUTION: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. This will maintain vehicle ride comfort and prevent premature bushing wear.

WARNING WARNING:: Suspension components with rubber bushings must be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fas-

Fig. 1 Rear Suspension 1 2 3 4 5

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SHOCK UPPER SUSPENSION ARM COIL SPRING STABILIZER BAR LOWER SUSPENSION ARM

teners are torqued. If springs are not at their normal ride position, vehicle ride comfort will be affected and cause premature bushing wear.


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REAR

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REAR (Continued)

DIAGNOSIS AND TESTING - REAR SUSPENSION CONDITION VEHICLE INSTABILITY

VEHICLE PULLS TO ONE SIDE

KNOCKING, RATTLING OR SQUEAKING

IMPROPER TRACKING

POSSIBLE CAUSES

CORRECTION

1. Loose or worn wheel bearings.

1. Replace wheel bearings.

2. Loose, worn or bent suspension components.

2. Inspect, tighten or replace components as necessary.

3. Tire pressure.

3. Adjust tire pressure.

1. Weak or broken spring.

1. Replace spring.

2. Alignment.

2. Align vehicle to specifications.

3.Tires.

3. Replace tires.

4. Brakes.

4. Repair as necassary.

1. Worn shock bushings.

1. Replace shock.

2. Loose shock mounting.

2. Tighten to specifications.

3. Shock valve.

3. Replace shock.

4. Loose upper ball joint.

4. Replace ball joint.

5. Loose, worn or bent suspension components.

5. Inspect, tighten or replace components as necessary.

1. Loose, worn or bent suspension components.

1. Inspect, tighten or replace components as necessary.

2. Bent axle.

2.Replace axle.

SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Shock Absorber Upper Nut

108

80

Shock Absorber Lower Nut

115

85

Suspension Arm Upper Ball Joint Nut

142

105

Suspension Arm Upper Frame Bolts

100

74

Ball Joint Plate Bolts

136

100

Suspension Arms Lower Axle Bracket Nut

163

120

Suspension Arms Lower Frame Bracket Nut

156

115

Stabilizer Bar Retainer Bolts

54

40

Stabilizer Bar Bar Link Nut

54

40

Stabilizer Bar Bracket Link Nut

92

68


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2 - 19

REAR (Continued)

SPECIAL TOOLS

INSTALLATION

REAR SUSPENSION

(1) Position the lower suspension arm in the axle bracket and frame rail bracket. NOTE: The end of the arm with the oval bushing attaches to the axle bracket. (2) Install the axle bracket bolt and nut finger tight. (3) Install the frame rail bracket bolt and nut finger tight. (4) Remove the supports and lower the vehicle. (5) With the vehicle on the ground tighten the nut at the frame to 156 N路m (115 ft. lbs.). Tighten the nut at the axle bracket to 163 N路m (120 ft. lbs.).

Remover 8278

LOWER CONTROL ARM

SHOCK

DESCRIPTION

DESCRIPTION

The lower suspension arms are hydroformed steel and use voided oval bushings at each end of the arm.

OPERATION The bushings provide isolation from the axle. The arms mount to the unibody frame rail bracket and the axle brackets. The arm and bushings provide location and react to loads.

The top of the shock absorbers are bolted to the body. The bottom of the shocks are bolted to the axle brackets. The standard shocks have conventional twin tube construction and are low pressure gas charged. Gas charging prevents cavitation during rough road operation. Up-Country shocks are mono tube design and are high pressure gas charged.

OPERATION

REMOVAL (1) Raise the vehicle and support the rear axle. (2) Remove the lower suspension arm nut and bolt from the axle bracket (Fig. 2). (3) Remove the nut and bolt (Fig. 2) from the frame rail and remove the lower suspension arm.

The shock absorbers dampen jounce and rebound motion of the vehicle over various road conditions and limit suspension rebound travel.

REMOVAL (1) Raise and support the vehicle. Position a hydraulic jack under the axle to support the axle. CAUTION: Do not allow the axle to hang from the upper suspension arm ball joint. (2) Remove the upper nut and bolt from the frame bracket (Fig. 3). (3) Remove the lower nut and bolt from the axle bracket. Remove the shock absorber.

INSTALLATION

Fig. 2 Lower Suspension Arm 1 - LOWER SUSPENSION ARM 2 - AXLE BRACKET 3 - FRAME BRACKET

(1) Install the shock absorber in the frame bracket and install the bolt and nut. (2) Install the shock absorber in the axle bracket and install the bolt and nut. (3) Tighten the upper mounting nuts to 108 N路m (80 ft. lbs.). Tighten the lower mounting nuts to 115 N路m (85 ft. lbs.). (4) Remove the supports and lower the vehicle.


2 - 20

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SHOCK (Continued)

Fig. 3 Shock Absorber 1 - SHOCK

SPRING

Fig. 4 Coil Spring 1 2 3 4

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COIL SPRING ISOLATOR STABILIZER LINK ISOLATOR

DESCRIPTION The coil springs mount up in the wheelhouse which is part of the unitized body bracket. A rubber doughnut isolator is located between the top of the spring and the body. The bottom of the spring seats on a axle isolator made of rubber with a steel insert. The isolators provide road noise isolation

OPERATION The coil springs control ride quality and maintain proper ride height.

REMOVAL (1) Raise and support the vehicle. Position a hydraulic jack under the axle to support the axle. (2) Remove the wheel and tire assemblies. (3) Remove the stabilizer bar link from the stabilizer bar (Fig. 4). (4) Remove the shock absorber lower bolt from the axle bracket. (5) Lower the hydraulic jack and tilt the axle and remove the coil spring (Fig. 4). (6) Remove and inspect the upper and lower spring isolators (Fig. 4).

INSTALLATION (1) Install the upper isolator. (2) Install the lower isolator with the isolator locator nub in the axle pad hole (Fig. 5). (3) Pull down on the axle and position the coil spring in the lower isolator.

Fig. 5 Isolator Locator Nub 1 - LOWER ISOLATOR 2 - LOCATOR NUB 3 - AXLE SPRING PAD

CAUTION: Ensure the spring is positioned on the lower isolator with the end of the spring coil against the isolator spring locator (Fig. 6). (4) Raise the axle with the hydraulic jack. (5) Install the shock absorber to the axle bracket and tighten to specification. (6) Install the stabilizer bar link to the stabilizer bar. (7) Install the wheel and tire assemblies. (8) Remove the supports and lower the vehicle. (9) Tighten the stabilizer bar links to specification.


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SPRING (Continued)

Fig. 6 Isolator Spring Locator - Typical 1 - LOWER ISOLATOR 2 - SPRING LOCATOR 3 - COIL SPRING

Fig. 7 Rear Stabilizer Bar 1 2 3 4

-

LINK RETAINER BUSHING STABILIZER BAR

STABILIZER BAR

UPPER BALL JOINT

DESCRIPTION

DESCRIPTION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT

The stabilizer bar extends across the back side of the rear axle. Links are connected between the bar and frame rail brackets. The stabilizer bar and links are isolated by rubber bushings.

OPERATION The stabilizer bar is used to control vehicle body roll, during turns. The bar helps control the vehicle body in relationship to the suspension.

REMOVAL (1) Raise and support the vehicle. (2) Remove the stabilizer bar links from stabilizer bar and frame mount. (Fig. 7). (3) Remove the stabilizer bar retainer bolts. (4) Remove the stabilizer bar.

INSTALLATION (1) Position the stabilizer bar on the axle and install the retainers and bolts. Ensure the bar is centered with equal spacing on both sides. Tighten the bolts to 54 N·m (40 ft. lbs.). (2) Install the links to the stabilizer bar and frame brackets. (3) Tighten the nuts at the stabilizer bar to 54 N·m (40 ft. lbs.). (4) Tighten the nuts at the frame brackets to 92 N·m (68 ft. lbs.). (5) Remove support and lower the vehicle.

The suspension arm uses vertical spool bushings to isolate road noise. The suspension arm is bolted through bushings to cage nuts in the body and a ball joint plate to the top of the differential housing.

OPERATION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT The upper suspension arm provides fore/aft and lateral location of the rear axle. The suspension arm travel is limited through the use of jounce bumpers in compression and shock absorbers in rebound.

REMOVAL (1) Raise and support the vehicle. (2) Support the rear axle with a hydraulic jack. (3) Remove the ball joint nut from the top of the upper suspension arm (Fig. 8). (4) Separate ball joint from the arm with Remover 8278 (Fig. 9). NOTE: It may be necessary to strike the upper control arm with a hammer to separate the ball joint from the arm. (5) Remove the ball joint mounting bolts (Fig. 10)from the differential housing. (6) Remove the ball joint from the differential housing.


2 - 22

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UPPER BALL JOINT (Continued)

Fig. 8 Ball Joint Nut 1 - BALL JOINT NUT 2 - UPPER SUSPENSION ARM

Fig. 10 Ball Joint Mounting Bolts 1 - BALL JOINT 2 - MOUNTING BOLTS

(5) Remove the supports and lower the vehicle.

UPPER CONTROL ARM DESCRIPTION The suspension arm uses vertical spool bushings to isolate road noise. The suspension arm is bolted through bushings to cage nuts in the body and a ball joint plate to the top of the differential housing.

OPERATION The upper suspension arm provides fore/aft and lateral location of the rear axle. The suspension arm travel is limited through the use of jounce bumpers in compression and shock absorbers in rebound.

Fig. 9 Separate Ball Joint 1 - REMOVER 2 - UPPER SUSPENSION ARM 3 - BALL JOINT STUD

INSTALLATION (1) Install the ball joint on the differential housing. (2) Install the ball joint mounting bolts and tighten to 136 N·m (100 ft. lbs.). (3) Raise the rear axle with a hydraulic jack to align the upper arm with the ball joint. (4) Pull the arm down on the ball joint stud and install a new nut. Tighten the nut to 142 N·m (105 ft. lbs.).

REMOVAL (1) Raise and support the vehicle. (2) Support the rear axle with a hydraulic jack. (3) Remove the park brake cables and brake hose from the arm (Fig. 11). (4) Remove the ball joint nut from the top of the upper suspension arm (Fig. 12). (5) Separate ball joint from the arm with Remover 8278 (Fig. 13). NOTE: It may be necessary to strike the upper control arm with a hammer to separate the ball joint from the arm. (6) Remove the upper suspension arm mounting bolts and remove the arm (Fig. 14).


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2 - 23

UPPER CONTROL ARM (Continued)

Fig. 11 Park Brake Cables And Brake Hose 1 - UPPER SUSPENSION ARM 2 - REAR BRAKE HOSE 3 - PARK BRAKE CABLES

Fig. 13 Separate Ball Joint 1 - REMOVER 2 - UPPER SUSPENSION ARM 3 - BALL JOINT STUD

Fig. 12 Ball Joint Nut 1 - BALL JOINT NUT 2 - UPPER SUSPENSION ARM

INSTALLATION (1) Position the upper suspension arm in the frame rail brackets. (2) Install the mounting bolts and tighten to 100 N·m (74 ft. lbs.). (3) Pull the arm down on the ball joint stud and install a new nut. Tighten the nut to 142 N·m (105 ft. lbs.).

Fig. 14 Upper Suspension Arm Mounting Bolt 1 - UPPER SUSPENSION ARM 2 - MOUNTING BOLT

(4) Install the park brake cables and brake hose to the arm. (5) Remove the supports and lower the vehicle.


DIFFERENTIAL & DRIVELINE

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3-1

DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page

page

PROPELLER SHAFT ......................1 FRONT TUBE AXLE . . . . . . . . . . . . . . . . . . . . . . 16 FRONT AXLE - 186FBI . . . . . . . . . . . . . . . . . . . . 17

REAR AXLE - 198RBI . . . . . . . . . . . . . . . . . . . . . 49 REAR AXLE - 226RBA . . . . . . . . . . . . . . . . . . . . 82

PROPELLER SHAFT TABLE OF CONTENTS page PROPELLER SHAFT DIAGNOSIS AND TESTING ....... STANDARD PROCEDURE . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . SPECIAL TOOLS ............... PROPELLER SHAFT - C/V FRONT REMOVAL .................... INSTALLATION . . . . . . . . . . . . . . . . . PROPELLER SHAFT - U-JOINT FRONT REMOVAL ....................

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.1 .4 .6 .6

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PROPELLER SHAFT DIAGNOSIS AND TESTING VIBRATION Tires that are out-of-round, or wheels that are unbalanced, will cause a low frequency vibration. (Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND TESTING) Brake rotors that are unbalanced will cause a harsh, low frequency vibration. (Refer to 5 - BRAKES - DIAGNOSIS AND TESTING)

page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PROPELLER SHAFT - REAR REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 10 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DOUBLE CARDAN UNIVERSAL JOINTS DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 11 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 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 propeller shaft being unbalanced. Defective universal joints, or an incorrect propeller shaft angle, are usually the cause of such a vibration.


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PROPELLER SHAFT

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PROPELLER SHAFT (Continued) DRIVELINE VIBRATION Drive Condition Propeller Shaft Noise

Universal Joint Noise

Possible Cause

Correction

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) Rear spring center bolt not in seat.

5) Loosen spring u-bolts and seat center bolt.

6) Worn U-joint bearings.

6) Install new U-joint.

7) Propeller shaft damaged or out of balance.

7) Installl new propeller shaft.

8) Broken rear spring.

8) Install new rear spring.

9) Excessive runout or unbalanced condition.

9) Re-index propeller shaft, test, and evaluate.

10) Excessive drive pinion gear shaft runout.

10) Re-index propeller shaft and evaluate.

11) Excessive axle yoke deflection.

11) Inspect and replace yoke if necessary.

12) Excessive transfer case runout.

12) Inspect and repair as necessary.

1) Loose U-joint clamp screws.

1) Install new clamps and screws and tighten to proper torque.

2) Lack of lubrication.

2) Replace U-joints as necessary.

BALANCE NOTE: Removing and re-indexing the propeller shaft 180° 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 propeller shaft and the universal joints. (3) Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the propeller shaft is bent, it must be replaced.

(4) Inspect the universal joints to ensure that they are not worn, are properly installed, and are correctly 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 90° apart. (8) Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine.


PROPELLER SHAFT

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3-3

PROPELLER SHAFT (Continued) (9) Install a screw clamp at position 1 (Fig. 1).

Fig. 3 CLAMP SCREWS SEPARATED Fig. 1 CLAMP SCREW POSITION 1 1 - CLAMP 2 - SCREWDRIVER

(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.

Fig. 2 TWO CLAMP SCREWS (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

1 - â „ INCH 12

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 perpendicular 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 specification, remove the propeller shaft, index the shaft 180°, 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 specifications, 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.


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PROPELLER SHAFT

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PROPELLER SHAFT (Continued) 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 PROCEDURE This procedure applies to the front and rear propeller shaft. To obtain front (output) angle on the C/V front propeller shaft, place Inclinometer 7663 on the machined ring of the pinion flange. To obtain propeller shaft angle measurement on the C/V front propeller shaft, place inclinometer on the propeller shaft tube.

PROPELLER SHAFT ANGLE

Fig. 4 OUTPUT YOKE ANGLE (A) 1 - SLIP YOKE BEARING CAP 2 - INCLINOMETER

(1) Raise and support the vehicle at the axles as level as possible. Allow the wheels and propeller shaft to turn. (2) Remove universal joint snap rings if equipped, so inclinometer base sits flat. (3) Rotate shaft until transmission/transfer case output yoke bearing cap is facing downward. NOTE: Always make measurements from front to rear and from the same side of the vehicle. (4) Place inclinometer on yoke bearing cap or pinion flange ring (A) parallel to the shaft (Fig. 4). Center bubble in sight glass and record measurement. NOTE: This measurement will give you the transmission or Output Yoke Angle (A). (5) Rotate propeller shaft 90 degrees and place inclinometer on yoke bearing cap or propeller shaft tube on C/V propeller shaft, parallel to the shaft (Fig. 5). Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. NOTE: This measurement will give you the propeller shaft angle (C). (6) Subtract smaller figure from larger (C minus A) to obtain transmission output operating angle.

Fig. 5 PROPELLER SHAFT ANGLE (C) 1 - SHAFT YOKE BEARING CAP 2 - INCLINOMETER


PROPELLER SHAFT

WJ PROPELLER SHAFT (Continued) (7) Rotate propeller shaft 90 degrees and place inclinometer on pinion yoke bearing cap parallel to the shaft (Fig. 6). Center bubble in sight glass and record measurement. NOTE: This measurement will give you the pinion shaft or input yoke angle (B). (8) Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules and example in (Fig. 7) for additional information.

RULES • Good cancellation of U-joint operating angles is within 1degree. • Operating angles less than 3 degrees. • Operating angles less than 10 degrees for double cardan U-joint. • At least 1/2 of one degree continuous operating (propeller shaft) angle. Fig. 6 INPUT YOKE ANGLE (B) 1 - PINION YOKE BEARING CAP 2 - INCLINOMETER

Fig. 7 UNIVERSAL JOINT ANGLE EXAMPLE 1 - 4.9° Angle (C) 2 - 3.2° Angle (B) 3 - Input Yoke

4 - 3.0° Angle (A) 5 - Output Yoke

3-5


3-6

PROPELLER SHAFT

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PROPELLER SHAFT (Continued)

SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Front C/V Shaft - Flange Bolts

32

24

-

Front U-Joint Shaft - Axle Yoke Nuts

19

14

-

Front U-Joint Shaft - Transfer Case Bolts

27

20

-

Rear Shaft - Yoke Nuts

19

14

-

Rear Shaft - Transfer Case Flange Bolts

32

24

-

SPECIAL TOOLS

INCLINOMETER 7663

PROPELLER SHAFT - C/V FRONT REMOVAL NOTE: Different length propeller shafts are used for different drivetrain applications. Ensure that the correct propeller shaft is used.

Fig. 8 MEASUREMENT 1 - C/V JOINT CUP 2 - C/V BOOT END 3 - MEASUREMENT

(1) Place vehicle on floor or drive-on hoist with full weight of vehicle on suspension. (2) Shift transmission and transfer case, if equipped into Neutral. (3) Measure distance from the face of the C/V joint cup to the end of the C/V joint boot (Fig. 8). (4) The correct length is 142.7 mm (5.61 in.). NOTE: If the measurement is not correct, the wrong shaft may have been installed or a mating component (front axle or transfer case) may be installed incorrectly. Investigate and correct as necessary. (5) Mark a line across the C/V joints and companion flanges (Fig. 9) for installation reference. (6) Remove bolts from C/V joints. (7) Push the propeller shaft forward to clear transfer case companion flange and remove the shaft.

Fig. 9 C/V FRONT PROPELLER SHAFT 1 2 3 4

- FRONT AXLE - TRANSFER CASE - TRANSFER CASE FLANGE - AXLE FLANGE


PROPELLER SHAFT

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3-7

PROPELLER SHAFT - C/V FRONT (Continued)

INSTALLATION NOTE: Different length propeller shafts are used for different drivetrain applications. Ensure that the correct propeller shaft is used. (1) Install the shaft between companion flanges. (2) The shaft should rotate freely in the pinion flange. (3) Align marks on the companion flanges with the marks on the C/V joints. (4) Install bolts to the front C/V joint and tighten bolts to 32 N路m (24 ft. lbs.). (5) Install the bolts to the rear C/V joint and tighten bolts to 32 N路m (24 ft. lbs.). (6) Verify propeller shaft length. (7) Lower vehicle.

(6) Remove the U-joint strap bolts at the pinion shaft yoke (Fig. 11). (7) Remove bolts holding rear universal joint to the transfer case yoke. (8) Separate the rear universal joint from the transfer case yoke. (9) Push rear of propeller shaft upward to clear transfer case yoke. (10) Separate front universal joint from front axle. (11) Separate propeller shaft from vehicle.

PROPELLER SHAFT - U-JOINT FRONT REMOVAL (1) Raise and support vehicle. (2) Remove crossmember/skid plate as necessary to gain access to the propeller shaft. (3) Shift transmission and transfer case, if necessary into Neutral. (4) Mark a line across the yoke at the transfer case, link yoke and propeller shaft yoke at the rear of the front propeller shaft for installation reference (Fig. 10). (5) Mark a line across the propeller shaft yoke and pinion shaft yoke for installation reference.

Fig. 11 FRONT PROPELLER SHAFT - 4.7L 1 2 3 4 5 6 7 8 9

-

FRONT AXLE BOOT PROPELLER SHAFT DOUBLE CARDAN U-JOINT TRANSFER CASE BOOT SLINGER CLAMP YOKE

INSTALLATION (1) Position front propeller shaft under vehicle with rear universal joint over the transfer case yoke. (2) Place front universal joint into the axle pinion yoke. (3) Align mark on the rear link yoke and universal joint to the mark on the transfer case yoke. (4) Loosely install bolts to hold universal joint to transfer case yoke. (5) Align mark on front universal joint to the mark on the axle pinion yoke. (6) Tighten the U-joint strap/clamp bolts at the axle yoke to 19 N路m (14 ft. lbs.). (7) Tighten the universal joint to transfer case bolts to 27 N路m (20 ft. lbs.). (8) Lower the vehicle.

Fig. 10 REFERENCE MARKS ON YOKES 1 - REFERENCE MARKS


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PROPELLER SHAFT

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PROPELLER SHAFT - REAR REMOVAL (1) Shift transmission and transfer case if necessary, into neutral. (2) Raise and support vehicle. (3) Mark pinion yoke, propeller shaft yoke (Fig. 12) and transfer case flange if equipped for installation reference.

Fig. 13 REAR PROPELLER SHAFT

Fig. 12 REFERENCE MARKS ON YOKES 1 - REFERENCE MARKS

(4) Remove universal joint clamps bolts from pinion yoke (Fig. 13) and C/V joint bolts from transfer case flange if equipped (Fig. 14). (5) Remove propeller shaft from vehicle.

1 2 3 4 5 6

-

SLIDING YOKE PROPELLER SHAFT PINION YOKE CLAMP/STRAP BOLT OUTPUT SHAFT

INSTALLATION (1) Install propeller shaft with reference marks aligned. (2) Install universal joint clamp bolts and tighten bolts to 19 N·m (14 ft. lbs.). Install transfer case C/V joint flange bolts if equipped and tighten to 32 N·m (24 ft. lbs.). (3) Lower the vehicle.


PROPELLER SHAFT

WJ PROPELLER SHAFT - REAR (Continued)

Fig. 14 4WD REAR PROPELLER SHAFTS 1 - SLIP YOKE 2 - CLAMP/STRAP

3 - PINION YOKE 4 - C/V JOINT

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PROPELLER SHAFT

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SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY NOTE: Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. (1) Remove propeller shaft. (2) Tap outside of the bearing cap assembly with a drift to loosen snap ring. (3) Remove snap rings from both sides of yoke (Fig. 15).

Fig. 16 PRESS OUT BEARING 1 - PRESS 2 - SOCKET

CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur.

Fig. 15 REMOVE SNAP RING 1 - SNAP RING

(4) Set yoke in an arbor press or vise with a socket with an inside diameter large enough to receive the bearing cap positioned beneath the yoke. (5) Position yoke with the grease fitting, if equipped, pointing up. (6) Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap (Fig. 16). (7) If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. (8) To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed (Fig. 17).

Fig. 17 PRESS OUT REMAINING BEARING 1 - CROSS 2 - BEARING CAP


PROPELLER SHAFT

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3 - 11

SINGLE CARDAN UNIVERSAL JOINTS (Continued)

ASSEMBLY (1) Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. (2) Position the cross in the yoke with its lube fitting, if equipped, pointing up (Fig. 18).

Fig. 19 INSTALL BEARING ON TRUNNION 1 - BEARING CAP 2 - TRUNNION

Fig. 18 CROSS IN YOKE 1 - CROSS 2 - YOKE

(2) Mark propeller shaft yoke and link yoke for assembly reference. (3) Tap outside of the bearing cap assembly with drift to loosen snap rings. (4) Remove all bearing cap snap rings (Fig. 20).

(3) Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 19). Keep the needle bearings upright in the bearing cap. (4) Press the bearing cap into the yoke bore enough to clear snap ring groove. (5) Install a snap ring. (6) Repeat Step 3 and Step 4 to install the opposite bearing cap. NOTE: If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. (7) Add grease to lube fitting, if equipped. (8) Install the propeller shaft.

DOUBLE CARDAN UNIVERSAL JOINTS DISASSEMBLY NOTE: Individual components of cardan universal joints are not serviceable they must be replaced as an assembly. (1) Remove propeller shaft.

Fig. 20 SNAP RINGS (5) Remove any grease fittings if equipped. (6) Position a socket on the press with an inside diameter large enough to receive the bearing cap under the link yoke.


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PROPELLER SHAFT

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DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (7) Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap. (8) Press one bearing cap from the outboard side of the link yoke enough to grasp the cap with vise jaws (Fig. 21).

(10) Flip assembly and repeat Step 6, Step 7, Step 8 and Step 9 to remove the opposite bearing cap. (11) Remove cross centering kit assembly and spring (Fig. 23).

Fig. 23 REMOVE CENTERING KIT

Fig. 21 PRESS OUT BEARING (9) Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bearing cap (Fig. 22).

(12) Press remaining bearing caps out of the other end of the link yoke.

ASSEMBLY CAUTION: All alignment marks on the link yoke and propeller shaft yoke must be aligned during assembled. (1) Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. (2) Fit cross into propeller shaft yoke (Fig. 24).

Fig. 22 REMOVE BEARING FROM YOKE Fig. 24 INSTALL CROSS IN YOKE


PROPELLER SHAFT

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3 - 13

DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (3) Place a bearing cap over trunnion and align cap with the yoke bore (Fig. 25).

(6) Flip propeller shaft yoke and install other bearing cap and snap ring (Fig. 27).

NOTE: Keep needle bearings upright in the bearing cap.

Fig. 27 PRESS BEARING CAP Fig. 25 INSTALL BEARING CAP (4) Press bearing cap into yoke bore enough to clear snap ring groove (Fig. 26). (5) Install a snap ring.

(7) Fit link yoke onto the remaining trunnions and press both bearing caps into place and install snap rings (Fig. 28).

Fig. 28 INSTALL LINK YOKE

Fig. 26 PRESS BEARING CAP


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PROPELLER SHAFT

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DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (8) Install centering kit assembly inside the link yoke (Fig. 29).

(10) Press remaining two bearing caps into place and install snap rings (Fig. 31).

NOTE: Making sure the spring is properly positioned.

Fig. 31 PRESS BEARING CAP Fig. 29 CENTERING KIT

(11) Tap snap rings to seat them into the grooves (Fig. 32).

(9) Place two bearing caps on opposite trunnions of the remaining cross. Fit open trunnions into the link yoke bores and the bearing caps into the centering kit (Fig. 30).

Fig. 32 SEAT SNAP RINGS Fig. 30 REMAINING CROSS


WJ

PROPELLER SHAFT

DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (12) Flexing the joint beyond center, the joint should snap over-center in both directions if correctly assembled (Fig. 33). (13) Install propeller shaft.

Fig. 33 VERIFY ASSEMBLY

3 - 15


3 - 16

FRONT TUBE AXLE

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FRONT TUBE AXLE TABLE OF CONTENTS page FRONT TUBE AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

FRONT TUBE AXLE REMOVAL (1) Raise and support the vehicle. (2) Position a lifting device under the axle and secure axle to lift. (3) Remove the wheels and tires. (4) Remove the brake rotors (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/ROTORS - REMOVAL) and calipers. (5) Disconnect wheel sensor wiring harness from the vehicle wiring harness. (6) Remove stabilizer bar links at the axle. (7) Remove shock absorbers from axle brackets. (8) Remove track bar. (9) Remove tie rod and drag link from the steering knuckle. (10) Remove steering damper from the axle bracket. (11) Remove upper and lower suspension arms from the axle brackets. (12) Lower the lift enough to remove the axle. The coil springs will drop with the axle. (13) Remove the coil springs from the axle.

INSTALLATION CAUTION: The weight of the vehicle must be supported by the springs before suspension arms and track bar fasteners are tightened. If not at their nor-

page INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 16

mal ride position, ride height and handling could be affected. (1) Install springs and retainer clips and tighten retainer bolts to 21 N·m (16 ft. lbs.). (2) Lift and position axle under the vehicle and align it with the spring pads. (3) Position upper and lower suspension arms in the axle brackets and loosely install bolts and nuts. (4) Install track bar to the axle bracket and loosely install bolt. (5) Install shock absorbers and tighten bolts to 23 N·m (17 ft. lbs.). (6) Install stabilizer bar links to the axle brackets and tighten nuts to 95 N·m (70 ft. lbs.). (7) Install drag link and tie rod to the steering knuckles. (8) Install steering damper to the axle bracket and tighten nut to 75 N·m (55 ft. lbs.). (9) Install the brake rotors and calipers. (10) Connect wheel speed sensor wiring harness, if equipped. (11) Install the wheel and tire assemblies. (12) Remove lift from the axle and lower the vehicle. (13) Tighten upper suspension arm nuts to 75 N·m (55 ft. lbs.). Tighten lower suspension arm nuts to 115 N·m (85 ft. lbs.). (14) Tighten track bar bolt at the axle bracket to 100 N·m (74 ft. lbs.). (15) Check the front wheel alignment.


FRONT AXLE - 186FBI

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3 - 17

FRONT AXLE - 186FBI TABLE OF CONTENTS page FRONT AXLE - 186FBI DESCRIPTION . . . . . . . . OPERATION . . . . . . . . . . DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . ADJUSTMENTS . . . . . . . SPECIFICATIONS . . . . . . SPECIAL TOOLS ...... AXLE SHAFTS REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . AXLE SHAFT SEALS REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . AXLE - C/V JOINT REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . AXLE - U-JOINT REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . PINION SEAL REMOVAL . . . . . . . . . . . .

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page INSTALLATION . . . . . . . . . . . . COLLAPSIBLE SPACER REMOVAL . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . DIFFERENTIAL DESCRIPTION . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . DIFFERENTIAL - VARI-LOK DESCRIPTION . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . DIAGNOSIS AND TESTING . . . DIFFERENTIAL CASE BEARINGS REMOVAL . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . PINION GEAR/RING GEAR REMOVAL . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . .

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FRONT AXLE - 186FBI

DIAGNOSIS AND TESTING

DESCRIPTION

GEAR NOISE

The Front Beam Iron (FBI) axle consists of a cast iron differential housing with axle shaft tubes extending from either side. The tubes are pressed into the differential housing and welded. The axles are semi-floating supported by the hub bearings. The axle shafts are retained by nuts at the hub bearings.

OPERATION The axle receives power from the transfer case through the front propeller shaft. The front 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.

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, tooth contact, worn/damaged gears or the carrier housing not having the proper offset and squareness. Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are acceleration, deceleration, coast or constant load. When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the noise stops or changes greatly check for: • Insufficient lubricant. • Incorrect ring gear backlash. • Gear damage. Differential side and pinions gears, usually do not cause noise during straight-ahead driving, when the gears are unloaded. The side gears are loaded during


3 - 18

FRONT AXLE - 186FBI

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FRONT AXLE - 186FBI (Continued) turns. A worn pinion mate shaft can also cause a snapping or a knocking noise.

BEARING NOISE Bearing noise can be either a whining or a growling sound. Pinion bearings have a constant high pitch noise, because it rotates at a faster rate. This noise changes with vehicle speed. If noise is heard under a load, the rear pinion bearing is the source. If noise is heard during a coast, the front pinion bearing is the source. Differential bearings usually produce a low pitch noise. The differential bearing noise is constant and varies only with vehicle speed. Axle shaft bearing noise generally changes when the bearings are loaded. Turn vehicle sharply to the left and the right during a road test. This will load and unload the bearings and change the noise level. If axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 m.p.h.

LOW SPEED KNOCK Low speed knock is generally caused by: • Worn U-joint. • Worn side-gear thrust washers. • Worn pinion shaft bore.

VIBRATION Vibration at the rear of the vehicle is usually caused by: • Damaged drive shaft. • Missing drive shaft balance weight(s). • Worn or out-of-balance wheels.

• Loose wheel lug nuts. • Worn U-joints/CV joint. • Loose/broken springs. • Damaged axle shaft bearing(s). • Loose pinion gear nut. • Excessive pinion yoke run out. • Bent axle shaft(s). Check for loose or damaged front-end components or engine/transmission mounts. These components can contribute to what appears to be a rear-end vibration. Also look at engine accessories, brackets and drive belts. NOTE: All driveline components should be examined before starting any repair.

DRIVELINE SNAP A snap or clunk noise when the vehicle is shifted into gear or the clutch engaged, can be caused by: • High engine idle speed. • Transmission shift operation. • Loose engine/transmission/transfer case mounts. • Worn U-joints/CV joint. • Loose spring mounts. • Loose pinion gear nut and yoke. • Excessive ring gear backlash. • Excessive side gear to case clearance. To determined the source of a snap/clunk noise, raise vehicle on a hoist with the wheels free to rotate. Have a helper shift the transmission into gear and listen for the noise.


FRONT AXLE - 186FBI

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3 - 19

FRONT AXLE - 186FBI (Continued) DIAGNOSTIC CHART Condition Wheel Noise

Axle Shaft Noise

Axle Shaft Broke

Differential Cracked

Differential Gears Scored

Possible Causes

Correction

1. Wheel loose.

1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing.

2. Replace bearing.

1. Misaligned axle tube.

1. Inspect axle tube alignment. Correct as necessary.

2. Bent or sprung axle shaft.

2. Inspect and correct as necessary.

3. End-play in pinion bearings.

3. Refer to pinion pre-load information and correct as necessary.

4. Excessive gear backlash between the ring gear and pinion.

4. Check adjustment of the ring gear and pinion backlash. Correct as necessary.

5. Improper adjustment of pinion gear bearings.

5. Adjust the pinion bearings pre-load.

6. Loose pinion yoke nut.

6. Tighten the pinion yoke nut.

7. Scuffed gear tooth contact surfaces.

7. Inspect and replace as necessary.

1. Misaligned axle tube.

1. Replace the broken shaft after correcting tube mis-alignment.

2 Vehicle overloaded.

2. Replace broken shaft and avoid excessive weight on vehicle.

3. Erratic clutch operation.

3. Replace broken shaft and avoid or correct erratic clutch operation.

4. Grabbing clutch.

4. Replace broken shaft and inspect and repair clutch as necessary.

1. Improper adjustment of the differential bearings.

1. Replace case and inspect gears and bearings for further damage. Set differential bearing pre-load properly.

2. Excessive ring gear backlash.

2. Replace case and inspect gears and bearings for further damage. Set ring gear backlash properly.

3. Vehicle overloaded.

3. Replace case and inspect gears and bearings for further damage. Avoid excessive vehicle weight.

4. Erratic clutch operation.

4. Replace case and inspect gears and bearings for further damage. Avoid erratic use of clutch.

1. Insufficient lubrication.

1. Replace scored gears. Fill differential with the correct fluid type and quantity.

2. Improper grade of lubricant.

2. Replace scored gears. Fill differential with the correct fluid type and quantity.

3. Excessive spinning of one wheel/tire.

3. Replace scored gears. Inspect all gears, pinion bores, and shaft for damage. Service as necessary.


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FRONT AXLE - 186FBI

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FRONT AXLE - 186FBI (Continued) Condition Loss Of Lubricant

Axle Overheating

Gear Teeth Broke

Axle Noise

Possible Causes

Correction

1. Lubricant level too high.

1. Drain lubricant to the correct level.

2. Worn axle shaft seals.

2. Replace seals.

3. Cracked differential housing.

3. Repair as necessary.

4. Worn pinion seal.

4. Replace seal.

5. Worn/scored yoke.

5. Replace yoke and seal.

6. Axle cover not properly sealed.

6. Remove, clean, and re-seal cover.

1. Lubricant level low.

1. Fill differential to correct level.

2. Improper grade of lubricant.

2. Fill differential with the correct fluid type and quantity.

3. Bearing pre-loads too high.

3. Re-adjust bearing pre-loads.

4. Insufficient ring gear backlash.

4. Re-adjust ring gear backlash.

1. Overloading.

1. Replace gears. Examine other gears and bearings for possible damage.

2. Erratic clutch operation.

2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation.

3. Ice-spotted pavement.

3. Replace gears and examine remaining parts for damage.

4. Improper adjustments.

4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct.

1. Insufficient lubricant.

1. Fill differential with the correct fluid type and quantity.

2. Improper ring gear and pinion adjustment.

2. Check ring gear and pinion contact pattern.

3. Unmatched ring gear and pinion.

3. Replace gears with a matched ring gear and pinion.

4. Worn teeth on ring gear and/or pinion.

4. Replace ring gear and pinion.

5. Loose pinion bearings.

5. Adjust pinion bearing pre-load.

6. Loose differential bearings.

6. Adjust differential bearing pre-load.

7. Mis-aligned or sprung ring gear.

7. Measure ring gear run-out. Replace components as necessary.

8. Loose differential bearing cap bolts.

8. Inspect differential components and replace as necessary. Ensure that the bearing caps are torqued tot he proper specification.

9. Housing not machined properly.

9. Replace housing.


FRONT AXLE - 186FBI

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3 - 21

FRONT AXLE - 186FBI (Continued)

REMOVAL (1) Raise and support the vehicle. (2) Position a suitable lifting device under the axle. (3) Secure axle to lift. (4) Remove the wheels and tires. (5) Remove the brake calipers and rotors (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL) from the axle. (6) Disconnect the wheel sensor wiring harness from the vehicle wiring harness. (7) Disconnect the vent hose from the axle shaft tube. (8) Mark propeller shaft and yoke/pinion flange for installation alignment reference. (9) Remove propeller shaft. (10) Disconnect stabilizer bar links at the axle. (11) Disconnect shock absorbers from axle brackets. (12) Disconnect track bar. (13) Disconnect the tie rod and drag link from the steering knuckle. (14) Disconnect the steering damper from the axle bracket. (15) Disconnect the upper and lower suspension arms from the axle brackets. (16) Lower the lifting device enough to remove the axle. The coil springs will drop with the axle. (17) Remove the coil springs from the axle.

INSTALLATION CAUTION: The weight of the vehicle must be supported by the springs before suspension arms and track bar fasteners can be tightened. If springs are not at their normal ride position, ride height and handling could be affected. (1) Install the springs and retainer clips. Tighten the retainer bolts to 21 N·m (16 ft. lbs.). (2) Support the axle on a lifting device and position axle under the vehicle. (3) Raise the axle and align it with the spring pads. (4) Position the upper and lower suspension arms in the axle brackets. Loosely install bolts and nuts to hold suspension arms to the axle brackets. (5) Install vent hose to the axle shaft tube. (6) Install track bar in the axle bracket and install the bolt loosely. (7) Install shock absorbers and tighten the bolts to 23 N·m (17 ft. lbs.). (8) Install stabilizer bar links to the axle brackets and tighten the nuts to 95 N·m (70 ft. lbs.). (9) Install drag link and tie rod to the steering knuckles.

(10) Install steering damper to the axle bracket and tighten the nut to 75 N·m (55 ft. lbs.). (11) Install the brake rotors (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/ROTORS - INSTALLATION) and calipers. (12) Connect the wheel speed sensor wiring harness to the vehicle wiring harness. (13) Align the previously made marks on the propeller shaft and the yoke/pinion flange. (14) Install propeller shaft to pinion flange bolts , if equipped. (15) Install propeller shaft to yoke straps and bolts, if equipped. (16) Check and fill axle lubricant. (17) Install the wheel and tire assemblies. (18) Remove the lifting device from the axle and lower the vehicle. (19) Tighten the upper suspension arm nuts to 75 N·m (55 ft. lbs.). Tighten the lower suspension arm nuts to 115 N·m (85 ft. lbs.). (20) Tighten the track bar bolt at the axle bracket to 100 N·m (74 ft. lbs.). (21) Check the front wheel alignment.

ADJUSTMENTS Ring and pinion gears are supplied as matched sets. Identifying numbers for the ring and pinion gear are etched onto each gear (Fig. 1). A plus (+) number, minus (–) number or zero (0) is etched into the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion etched with a (0). The standard depth provides the best gear tooth contact pattern.

Fig. 1 PINION GEAR ID NUMBERS 1 - PRODUCTION NUMBERS 2 - DRIVE PINION GEAR DEPTH VARIANCE 3 - GEAR MATCHING NUMBER


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FRONT AXLE - 186FBI (Continued) Compensation for pinion depth variance is achieved with a select shim/oil slinger. The shims are placed between the rear pinion bearing and the pinion gear head (Fig. 2). If installing a new gear, note the depth variance number of the original and replacement pinion. Add or subtract this number from the original depth shim/oil slinger to compensate for the difference in the depth variances. The numbers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the required thickness of the depth shims. If the number is positive, subtract that value from the thickness of the depth shim. Pinion Gear Depth Variance Chart: Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or minus the amount needed.

Fig. 2 ADJUSTMENT SHIM LOCATIONS 1 2 3 4 5

-

PINION DEPTH SHIM/OIL SLINGER DIFFERENTIAL BEARING SHIM RING GEAR DIFFERENTIAL BEARING SHIM COLLAPSIBLE SPACER

PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance

Replacement Pinion Gear Depth Variance 24

23

22

21

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

0

20.001

+2

+0.006

+0.005

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

+1

+0.005

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

0

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

20.004

21

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

20.004

20.005

22

+0.002

+0.001

0

20.001

20.002

20.003

20.004

20.005

20.006

23

+0.001

0

20.001

20.002

20.003

20.004

20.005

20.006

20.007

24

0

20.001

20.002

20.003

20.004

20.005

20.006

20.007

20.008


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3 - 23

FRONT AXLE - 186FBI (Continued)

PINION DEPTH MEASUREMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with Pinion Gauge Set and Dial Indicator C-3339 (Fig. 3).

Fig. 4 PINION HEIGHT BLOCK 1 - PINION BLOCK 2 - PINION HEIGHT BLOCK

Fig. 3 PINION GEAR DEPTH TOOLS 1 2 3 4 5 6 7 8

- DIAL INDICATOR - ARBOR - PINION HEIGHT BLOCK - CONE - SCREW - PINION BLOCK - SCOOTER BLOCK - ARBOR DISC

(1) Assemble Pinion Height Block 6739, Pinion Block 6733 and rear pinion bearing onto Screw 6741 (Fig. 3). (2) Insert assembled height gauge components, rear bearing and screw into the housing through pinion bearing cups (Fig. 4). (3) Install front pinion bearing and Cone-nut 6740 hand tight (Fig. 3). (4) Place Arbor Disc 6732 on Arbor D-115-3 in position, in the housing side bearing cradles (Fig. 5). Install differential bearing caps on Arbor Discs and tighten cap bolts to 41 N·m (30 ft. lbs.). NOTE: Arbor Discs 6732 has different step diameters 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. (6) Position Scooter Block/Dial Indicator so dial probe and scooter block are flush on the surface of

Fig. 5 GAUGE TOOLS IN HOUSING 1 2 3 4

- ARBOR DISC - PINION BLOCK - ARBOR - PINION HEIGHT BLOCK

the pinion height block (Fig. 3). Hold scooter block and zero the dial indicator. (7) Hold scooter block against the pinion height block and slowly slide across the pinion height block to the arbor (Fig. 6). Move the scooter block till the dial probe crests the arbors and record the highest reading. (8) Select a shim/oil slinger equal to the dial indicator reading plus the pinion depth variance number etched in the face of the pinion (Fig. 1). For example, if the depth variance is –2, add +0.002 in. to the dial indicator reading.


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FRONT AXLE - 186FBI (Continued)

Fig. 6 PINION GEAR DEPTH MEASUREMENT 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR

DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differential side bearing cones. The proper shim thickness can be determined using slip-fit Dummy Bearings D-348 in place of the differential side bearings and a Dial Indicator C-3339. Before measuring differential bearing preload and gear backlash, measure pinion gear depth and prepare pinion for installation. Pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After measuring shim thickness to take up differential side play, install pinion and measure gear backlash shim thickness. Overall shim thickness is the dial indicator reading and preload specification added together. The gear backlash measurement determines the shim thickness used on the ring gear side of the differential case. Subtract gear backlash shim thickness from overall shim thickness to determine shim thickness for pinion gear side of the differential (Fig. 7). Differential shim measurements are performed with spreader W-129-B removed.

Fig. 7 ADJUSTMENT SHIM LOCATIONS 1 2 3 4 5

-

PINION DEPTH SHIM/OIL SLINGER DIFFERENTIAL BEARING SHIM RING GEAR DIFFERENTIAL BEARING SHIM COLLAPSIBLE SPACER

(4) Install differential case in the housing. CAUTION: When installing a Vari-LokT differential, the oil feed tube must point to the bottom of the housing. If differential is forced in with the oil feed towards the top, the anti-rotation tabs will be damaged (Fig. 8).

PRELOAD 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 differential case. (2) Install ring gear on differential case and tighten bolts to specification. (3) Install dummy side bearings D-348 on differential case.

Fig. 8 VARI-LOK 1 - ANTI-ROTATION TAB 2 - OIL FEED TUBE


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3 - 25

FRONT AXLE - 186FBI (Continued) (5) Record the thickness of Dummy Shims 8107. Insert the shims between the dummy bearings and the differential housing (Fig. 9).

(7) With a dead-blow hammer, seat the differential dummy bearings to each side of the housing (Fig. 11) and (Fig. 12).

Fig. 11 SEAT DUMMY BEARING PINION SIDE 1 - HAMMER 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE

Fig. 9 DUMMY SHIM LOCATION 1 2 3 4

-

DUMMY SHIM DIFFERENTIAL HOUSING DIFFERENTIAL CASE DUMMY BEARINGS

(6) Install the bearing caps in their correct positions and snug the bolts (Fig. 10).

Fig. 12 SEAT DUMMY BEARING RING GEAR SIDE 1 - DIFFERENTIAL HOUSING 2 - HAMMER 3 - DIFFERENTIAL CASE

Fig. 10 BEARING CAP BOLTS 1 - BEARING CAP 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE


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FRONT AXLE - 186FBI (Continued) (8) Thread Pilot Stud C-3288-B into rear cover bolt hole below ring gear (Fig. 13). (9) Attach a dial indicator C-3339 to Pilot Stud. Position the dial indicator plunger on a flat surface between the ring gear bolt heads (Fig. 13).

(11) Push and hold differential case to ring gear side of the housing and record dial indicator reading (Fig. 15).

Fig. 15 RECORD DIAL INDICATOR READING 1 - DIAL INDICATOR 2 - DIFFERENTIAL CASE TO RING GEAR SIDE 3 - DIFFERENTIAL HOUSING

Fig. 13 DIAL INDICATOR LOCATION 1 2 3 4

-

DIFFERENTIAL CASE DIFFERENTIAL HOUSING PILOT STUD DIAL INDICATOR

(10) Push and hold differential case to pinion gear side of the housing and zero dial indicator (Fig. 14).

Fig. 14 ZERO DIAL INDICATOR 1 2 3 4

-

HOLD DIFFERENTIAL CASE TO PINION GEAR SIDE PILOT STUD INDICATOR EXTENSION DIAL INDICATOR FACE

(12) Add 0.152 mm (0.006 in.) to the zero end play total. This new total represents the thickness of shims to compress or preload the new bearings when the differential is installed. (13) Rotate dial indicator out of the way on the pilot stud. (14) Remove differential case and dummy bearings from the housing. (15) Install the pinion gear in the housing. Install the pinion yoke and establish the correct pinion rotating torque. (16) Install differential case and Dummy Bearings D-348 in the housing. (17) Install a single dummy shim in the ring gear side. Install bearing caps and tighten bolts snug. (18) Seat ring gear side dummy bearing (Fig. 12). (19) Position the dial indicator plunger on a flat surface between the ring gear bolt heads (Fig. 13). (20) Push and hold differential case toward pinion gear and zero dial indicator (Fig. 16). (21) Push and hold differential case to ring gear side of the housing and record dial indicator reading (Fig. 17). Add dummy shim thickness to this reading. This will be the total shim thickness to achieve zero backlash. (22) Subtract 0.076 mm (0.003 in.) from the dial indicator reading to compensate for backlash between ring and pinion gears. This total is the thickness shim required to achieve proper backlash. (23) Subtract the backlash shim thickness from the total preload shim thickness. The remainder is the shim thickness required on the pinion side of the axle housing.


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3 - 27

FRONT AXLE - 186FBI (Continued) (26) Install side bearings and cups on differential case. (27) Install spreader W-129-B with Adapter Set 6987 on the housing and spread axle opening enough to receive differential case. CAUTION: Never spread the housing over 0.38 mm (0.015 in.). If housing is over spread, it could distorted or damaged. (28) Place the bearing preload shims in the axle housing, against the axle tubes. (29) Install differential case into the housing.

Fig. 16 ZERO DIAL INDICATOR 1 2 3 4 5

-

DIAL INDICATOR HOLD DIFFERENTIAL CASE TO PINION GEAR SIDE PINION GEAR DIFFERENTIAL HOUSING DIFFERENTIAL CASE

CAUTION: When installing a Vari-LokT differential, the oil feed tube must point to the bottom of the housing. If differential is forced in with the oil feed towards the top, the anti-rotation tabs will be damaged. (30) Remove spreader from the housing. (31) Rotate the differential case several times to seat the side bearings. (32) Position the indicator plunger against a ring gear tooth (Fig. 18).

Fig. 17 RECORD DIAL INDICATOR READING 1 2 3 4 5

-

DIAL INDICATOR HOLD DIFFERENTIAL CASE TO RING GEAR SIDE PINION GEAR DIFFERENTIAL HOUSING DIFFERENTIAL CASE

(24) Rotate dial indicator out of the way on pilot stud. (25) Remove differential case and dummy bearings from the housing.

Fig. 18 RING GEAR BACKLASH 1 - DIAL INDICATOR

(33) Push and hold ring gear upward while not allowing the pinion gear to rotate. (34) Zero dial indicator face to pointer.


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FRONT AXLE - 186FBI (Continued) (35) Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading should be between 0.13 - 0.20 mm (0.005 0.008 in.). If backlash is not within specifications transfer the necessary amount of shim thickness from one side of the housing to the other (Fig. 19). (36) Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective. After the proper backlash is achieved, check the torque to rotate for differential bearing preload. If within specification perform Gear Contact Pattern Analysis procedure.

NOTE: If the PROFILE across the tooth is the same it is a 3 Axis cut gear. If the PROFILE across the tooth is tapered it is a 2 Axis cut gear.

Fig. 20 GEAR DESCRIPTION 1 2 3 4 5

-

TOP LAND PROFILE TOE HEEL ROOT

(1) Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth. (2) Wrap, twist and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion. This will provide a more distinct contact pattern. (3) With a boxed end wrench on a ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel.

Fig. 19 BACKLASH SHIM ADJUSTMENT

GEAR CONTACT PATTERN The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns. The TOP LAND of the gear tooth is the top surface of the tooth. The PROFILE of the gear tooth is the depth of the tooth. The TOE of the gear is the portion of the tooth surface at the end towards the center. The HEEL of the gear is the portion of the tooth at the outer-end. The ROOT of the gear tooth is the lowest portion of the tooth (Fig. 20).


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3 - 29

FRONT AXLE - 186FBI (Continued) The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart (Fig. 21) and adjust pinion depth and gear backlash as necessary.

ferential combined. This will verify the correct differential bearing preload. Torque to rotate the differential and pinion should be the torque to rotate the pinion plus 0.79-1.24 N·m (7-11 in. lbs.).

Fig. 21 PATTERN INTERPRETATION (GEAR CUT 2 AXIS)

DIFFERENTIAL BEARING PRELOAD CHECK The final check on the differential assembly before installing the axles is torque to rotate pinion and dif-

SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION

SPECIFICATION

Axle Ratio

3.55, 3.73

Differential Side Gear Clearance

0.13-0.20 mm (0.005-0.008 in.)

Differential Bearing Preload

0.152 mm (0.006 in.)

Ring Gear Diameter

186 mm (7.33 in.)

Ring Gear Backlash

0.13-0.20 mm (0.005-0.008 in.)

Pinion Bearing Preload - Original Bearings

1-2 N·m (10-20 in. lbs.)

Pinion Bearing Preload - New Bearings

1.7-3.4 N·m (15-30 in. lbs.)


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FRONT AXLE - 186FBI

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FRONT AXLE - 186FBI (Continued) TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Fill Hole Plug

34

25

-

Differential Cover Bolts

41

30

-

Bearing Cap Bolts

61

45

-

Ring Gear Bolts

108

80

-

Pinion Nut Min / Max

217 - 500

160 - 368

-

Axle Nut

237

175

-

Hub Bearing Bolts

102

75

-

SPECIAL TOOLS

FLANGE WRENCH C-3281 PULLER C-293-PA

DIAL INDICATOR C-3339 PLUG SP-3289

INSTALLER C-3716-A

ADAPTER C-293-39

PULLER C-452 HANDLE C-4171


FRONT AXLE - 186FBI

WJ FRONT AXLE - 186FBI (Continued)

INSTALLER D-146 TURNBUCKLE 6797

REMOVER C-4345

PINION DEPTH SET 6774

DUMMY SHIMS 8107 INSTALLER W-162-D

PINION BLOCK 6733 CUP 8109

SEAL REMOVER 7794-A

SEAL INSTALLER 8110

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FRONT AXLE - 186FBI (Continued)

CLAMP INSTALLER C-4975-A

SPANNER WRENCH 6958

SPREADER W-129-B

ADAPTER KIT 6987B

PILOT STUD C-3288-B

REMOVER D-149

INSTALLER D-130

INSTALLER W-262


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3 - 33

AXLE SHAFTS REMOVAL If the axle shaft and hub bearing are being removed in order to service another component, the axle shaft and hub bearing can be removed as an assembly. (1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove brake caliper, rotor and ABS wheel speed sensor. (4) Remove cotter pin, nut retainer and axle nut. (5) Remove the hub bearing bolts (Fig. 22).

Fig. 23 HUB BEARING AND AXLE ASSEMBLY 1 2 3 4

- AXLE - KNUCKLE - HUB BEARING - AXLE SHAFT

INSTALLATION

Fig. 22 HUB BEARING BOLTS 1 2 3 4

- AXLE SHAFT - AXLE - KNUCKLE - HUB BEARING

(6) Remove hub bearing and axle shaft assembly (Fig. 23). Avoid damaging the axle shaft oil seals in the axle housing. (7) Remove brake rotor shield from the hub bearing or knuckle.

(1) Thoroughly clean the axle shaft and apply a thin film of Mopar Wheel Bearing Grease or equivalent to the shaft splines, seal contact surface and hub bore. (2) Install brake rotor shield to the knuckle. (3) Install hub bearing and axle shaft assembly or axle shaft into the housing and differential side gears. Avoid damaging the axle shaft oil seals in the axle housing. (4) Install the hub bearing. (5) Install hub bearing bolts and tighten to 102 N·m (75 ft. lbs.). (6) Install axle hub washer and nut and tighten nut to 237 N·m (175 ft. lbs.). Install the nut retainer and a new cotter pin. (7) Install ABS wheel speed sensor, brake rotor and caliper. (8) Install the wheel and tire assembly. (9) Remove support and lower the vehicle.


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AXLE SHAFT SEALS

AXLE - C/V JOINT

REMOVAL

REMOVAL

(1) (2) (3) (4)

Raise and support vehicle. Remove axle shafts. Remove differential assembly. Remove inner axle shaft seals with a pry bay.

INSTALLATION (1) Remove any sealer remaining from original seals. (2) Install oil seals with Discs 8110 and Turnbuckle 6797 (Fig. 24). Tighten tool until disc bottoms in housing.

NOTE: The only service procedure to be performed on the axle C/V joint, is the replacement of the joint seal boot. If any failure of internal axle shaft components is diagnosed during a vehicle road test, the axle shaft must be replaced as an assembly. (1) Remove axle shaft. (2) Remove large and small C/V boot clamps (Fig. 25) and discard. (3) Slid boot off the C/V joint housing and slide it down the axle shaft.

Fig. 25 OUTER C/V BOOT CLAMPS 1 2 3 4 5

Fig. 24 AXLE SEAL TOOLS 1 - TURNBUCKLE 2 - DISCS

(3) Install differential and axle shafts. (4) Fill differential with lubricant. (5) Remove support and lower vehicle.

- C/V JOINT HOUSING - LARGE CLAMP - AXLE SHAFT - SMALL CLAMP - SEALING BOOT

(4) Remove C/V joint from axle then slid boot off the axle. (5) Thoroughly clean and inspect axle C/V joint assembly and axle shaft for any signs of excessive wear.


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3 - 35

AXLE - C/V JOINT (Continued)

INSTALLATION (1) Slide new boot over axle shaft. (2) Install C/V joint onto the axle shaft. (3) Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into axle C/V joint assembly housing. Put the remaining amount into the sealing boot. (4) Position boot on the axle locating grove and on the C/V joint. CAUTION: Boot must not be dimpled, stretched or out of shape in any way. If not shaped correctly, equalize pressure in boot and shape it by hand. (5) Install the two boot clamps. (6) Crimp the boot clamps with Clamp Installer C-4975A. Place clamp tool over bridge of clamp (Fig. 26).

Fig. 27 SMALL BOOT CLAMP 1 2 3 4

- CLAMP - INSTALLER - AXLE SHAFT - SEALING BOOT

Fig. 26 CRIMPING TOOL 1 2 3 4

- INSTALLER - AXLE SHAFT - CLAMP - SEALING BOOT

(7) Tighten nut on the tool until jaws on tool are closed completely together (Fig. 27) and (Fig. 28). (8) Install the axle shaft.

AXLE - U-JOINT REMOVAL CAUTION: Clamp only the narrow forged portion of the yoke in the vise. Do not over tighten vise jaws, to avoid distorting the yoke. (1) Remove axle shaft. (2) Remove bearing cap retaining snap rings (Fig. 29).

Fig. 28 LARGE BOOT CLAMP 1 2 3 4

-

CLAMP TOOL SEALING BOOT OUTER C/V JOINT BOOT CLAMP

NOTE: Saturate the bearing caps with penetrating oil prior to removal. (3) Locate a socket with an inside diameter is larger than the bearing cap. Place the socket (receiver) against the yoke and around the perimeter of the bearing cap to be removed. (4) Locate a socket with an outside diameter is smaller than the bearing cap. Place the socket (driver) against the opposite bearing cap. (5) Position the yoke with the sockets in a vise (Fig. 30). (6) Tighten vise to force the bearing cap into the larger socket (receiver).


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AXLE - U-JOINT (Continued)

INSTALLATION (1) Pack the bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (EP), lithium-base lubricant to aid in installation. (2) Position the spider in the yoke. Insert the seals and bearings, then tap bearing caps into the yoke bores far enough to hold the spider in position. (3) Place the socket (driver) against one bearing cap. Position the yoke with the socket in a vise. (4) Tighten the vise to force the bearing caps into the yoke. Force the caps enough to install the retaining clips. (5) Install the bearing cap retaining clips. (6) Install axle shaft.

PINION SEAL REMOVAL Fig. 29 AXLE SHAFT OUTER U-JOINT 1 2 3 4 5 6 7 8 9

-

SHAFT YOKE BEARING CAP SNAP RINGS BEARING CAP SPINDLE YOKE BEARING BEARING CAP SNAP RINGS BEARING CAP

(1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove brake rotors and calipers. (4) Mark propeller shaft and pinion companion flange for installation reference. (5) Remove propeller shaft from the pinion companion flange. (6) Rotate pinion gear a minimum of ten times and verify the pinion rotates smoothly. (7) Record torque necessary to rotate the pinion gear with a inch pound torque wrench. (8) Using a short piece of pipe and Spanner Wrench 6958 to hold the pinion companion flange and remove the pinion nut and washer. (9) Remove pinion companion flange with Remover C-452 and Flange Wrench C-3281. (10) Remove pinion seal with Remover 7794-A and a slide hammer (Fig. 31).

Fig. 30 YOKE BEARING CAP 1 - LARGE-DIAMETER SOCKET 2 - VISE 3 - SMALL-DIAMETER SOCKET

(7) Release the vise. Remove sockets and bearing cap that was partially forced out of the yoke. (8) Repeat the procedure for the remaining bearing cap and remove spider from the propeller shaft yoke.

Fig. 31 PINION SEAL REMOVER 1 - REMOVER 2 - SLIDE HAMMER 3 - PINION SEAL


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3 - 37

PINION SEAL (Continued)

INSTALLATION (1) Apply a light coating of gear lubricant on the lip of pinion seal and install seal with an appropriate installer. (2) Install pinion companion flange on the pinion gear with Installer W-162-D, Cup 8109 and Wrench 6958.

(5 ft. lbs.) increments until proper rotating torque is achieved. CAUTION: If maximum tightening torque of 500 N路m (386 ft. lbs.) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Replace the collapsible spacer.

CAUTION: Never exceed the minimum tightening torque 217 N路m (160 ft. lbs.) while installing pinion nut at this point. Damage to collapsible spacer or bearings may result. (3) Install new nut on the pinion gear. Tighten the nut only enough to remove the shaft end play. CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. (4) Rotate pinion a minimum of ten time and verify 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路m (5 in. lbs.) (Fig. 32).

Fig. 33 PINION SHAFT NUT 1 - PINION FLANGE 2 - FRONT AXLE 3 - SPANNER WRENCH

(6) Install propeller shaft with installation reference marks aligned. (7) Fill differential with gear lubricant. (8) Install brake rotors and calipers. (9) Install wheel and tire assemblies. (10) Lower the vehicle.

COLLAPSIBLE SPACER REMOVAL

Fig. 32 PINION ROTATION TORQUE 1 - PINION YOKE/COMPANION FLANGE 2 - INCH POUND TORQUE WRENCH

(5) If the rotating torque is low, use Spanner Wrench 6958 to hold the pinion companion flange (Fig. 33), and tighten the pinion shaft nut in 6.8 N路m

(1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove brake rotors and calipers. (4) Mark the propeller shaft and pinion companion flange for installation reference. (5) Remove propeller shaft from the pinion companion flange. (6) Rotate pinion gear a minimum of ten times and verify pinion rotates smoothly. (7) Record pinion gear rotating torque with a torque wrench for installation reference.


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FRONT AXLE - 186FBI

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COLLAPSIBLE SPACER (Continued) (8) Remove pinion nut and washer. Using a short piece of pipe and Spanner Wrench 6958 to hold the pinion companion flange. (9) Remove pinion companion flange with Remover C-452 and Flange Wrench C-3281. (10) Remove pinion shaft seal with Remover 7794-A and slide hammer (Fig. 34).

Fig. 35 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER

NOTE: New collapsible spacers require high initial torque to start the collapsing of the spacer. This may reach 678 N·m (500 ft. lbs.).

Fig. 34 PINION SEAL REMOVER 1 - REMOVER 2 - SLIDE HAMMER 3 - PINION SEAL

(11) Remove front pinion bearing using a pair of pick tools to pull the bearing straight off pinion shaft.

(6) Using Spanner Wrench 6958, a length of 1 in. pipe and a torque wrench set at 500 N·m (368 ft. lbs.) crush collapsible spacer until bearing end play is taken up (Fig. 36). (7) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the required rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer.

NOTE: If bearing becomes bound on the pinion shaft, lightly tap the end of the pinion gear with a rawhide/rubber mallet. (12) Remove the collapsible spacer.

INSTALLATION (1) Install new collapsible preload spacer on pinion shaft. (2) Install pinion front bearing. (3) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with an appropriate installer (Fig. 35). (4) Install pinion companion flange with Installer W-162-D, Cup 8109 and Flange Holder 6958. (5) Install pinion new nut on the pinion gear. Tighten the nut to 217 N·m (160 ft. lbs.) minimum. Do not overtighten. Maximum torque is 500 N·m (368 ft. lbs.). CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed.

Fig. 36 PINION COMPANION FLANGE 1 - COMPANION FLNAGE 2 - DIFFERENTIAL HOUSING 3 - SPANNER WRENCH


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COLLAPSIBLE SPACER (Continued) (8) Rotate pinion gear a minimum of ten times and verify pinion rotates smoothly. Check rotating torque with an inch pound torque wrench. The rotating torque should be the amount recorded during removal, plus 0.56 N¡m (5 in. lbs.). (9) Install propeller shaft with reference marks aligned. (10) Install brake rotors and calipers. (11) Add gear lubricant if necessary. (12) Install wheel and tire assemblies. (13) Lower vehicle.

accomplish this, the differential allows the axle shafts to turn at unequal speeds (Fig. 38). In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed.

DIFFERENTIAL DESCRIPTION The differential case is a one-piece design. Differential bearing preload and ring gear backlash is adjusted by the use of shims located between the differential bearing cups and housing. Pinion bearing preload is set and maintained by the use of a collapsible spacer. A differential cover provides a means for inspection and servicing.

OPERATION During straight-ahead driving, the differential pinion 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. 37).

Fig. 38 DIFFERENTIAL-ON TURNS 1 - PINION GEARS ROTATE ON PINION SHAFT

REMOVAL (1) Raise and support the vehicle. (2) Remove lubricant fill hole plug from the differential housing cover. (3) Remove differential cover and drain lubricant. (4) Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Never use water, steam, kerosene or gasoline for cleaning. (5) Remove hub bearings and axle shafts. (6) Note installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 39).

Fig. 37 DIFFERENTIAL-STRAIGHT AHEAD DRIVING 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED 2 - PINION GEAR 3 - SIDE GEAR 4 - PINION GEARS ROTATE WITH CASE

When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns. To

Fig. 39 BEARING CAP IDENTIFICATION 1 - REFERENCE LETTERS 2 - REFERENCE LETTERS


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DIFFERENTIAL (Continued) (7) Loosen the differential bearing cap bolts. (8) Position Spreader W-129-B with Adapter Kit 6987B on differential locating holes (Fig. 40). Install hold down clamps and tighten the tool turnbuckle finger-tight.

Fig. 41 DIAL INDICATOR LOCATION 1 2 3 4 5

-

CLAMP DIAL INDICATOR LEVER ADAPTER SPREADER PILOT STUD

Fig. 40 DIFFERENTIAL SPREADER LOCATION 1 2 3 4 5

- DIFFERENTIAL HOUSING - ADAPTER - HOLD DOWN CLAMPS - SPREADER - TURNBUCKLE

(9) Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to stud. Load the lever adapter against the opposite side of the housing (Fig. 41) and zero the indicator. (10) Spread housing enough to remove the differential case from the housing. Measure the distance with the dial indicator (Fig. 42). CAUTION: Never spread the housing over 0.38 mm (0.015 in). If housing is over-spread, it could distorted and damaged the housing. (11) Remove the dial indicator. (12) Hold differential case in position and remove differential bearing cap bolts and caps. (13) Remove differential from the housing and tag differential bearing cups to ensure location (Fig. 43). (14) Remove differential case preload shims from the axle housing. (15) Remove spreader from housing. Tag differential bearing preload shims to ensure correct location.

Fig. 42 SPREAD DIFFERENTIAL HOUSING 1 - DIAL INDICATOR 2 - SPREADER

DISASSEMBLY (1) Remove the ring gear. (2) Drive out the roll pin holding pinion gear mate shaft with a hammer and punch (Fig. 44). (3) Remove pinion gear mate shaft from the differential case and the pinion mate gears. (4) Rotate differential side gears and remove the pinion mate gears and thrust washers (Fig. 45).


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DIFFERENTIAL (Continued)

Fig. 43 DIFFERENTIAL CASE REMOVAL 1 - DIFFERENTIAL HOUSING 2 - DIFFERENTIAL CASE 3 - BEARING CUPS

Fig. 45 PINION MATE GEAR 1 - THRUST WASHER 2 - SIDE GEAR 3 - PINION MATE GEAR

(4) Install the roll pin in the differential case (Fig. 46).

Fig. 44 MATE SHAFT ROLL PIN 1 - PUNCH 2 - LOCKPIN 3 - MATE SHAFT

(5) Remove differential side gears and thrust washers.

ASSEMBLY (1) Install differential side gears and thrust washers. (2) Install pinion mate gears and thrust washers. (3) Install pinion gear mate shaft. Align the roll pin holes in shaft and the differential case.

Fig. 46 MATE SHAFT ROLL PIN 1 - PUNCH 2 - PINION MATE SHAFT 3 - MATE SHAFT LOCKPIN

(5) Install the ring gear.


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DIFFERENTIAL (Continued) (6) Lubricate all differential hypoid gear lubricant.

components

with

INSTALLATION

CAUTION: On a Vari-lokT differential the oil feed tube must be pointed at the bottom of the housing (Fig. 48). If differential is installed with the oil feed tube pointed at the top, the anti-rotation tabs will be damaged.

NOTE: If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection. (1) Position Spreader W-129-B with Adapter Kit 6987B on differential locating holes. Install hold down clamps and tighten the tool turnbuckle fingertight. (2) Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator. (3) Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator. CAUTION: Never spread the housing over 0.38 mm (0.015 in.). If housing is over-spread, it could distorted and damaged the housing. (4) Remove the dial indicator. (5) Install differential case in the housing (Fig. 47). Make sure the differential bearing cups remain on the bearings and the preload shims remain between the face of the bearing cup and housing. Tap the differential case to ensure the bearings cups and shims are fully seated in the housing.

Fig. 48 VARI-LOK 1 - ANTI-ROTATION TAB 2 - OIL FEED TUBE

(6) Install the bearing caps at their original locations (Fig. 49).

Fig. 49 Bearing Cap Reference Fig. 47 DIFFERENTIAL CASE REMOVAL 1 - DIFFERENTIAL HOUSING 2 - DIFFERENTIAL CASE 3 - BEARING CUPS

1 - REFERENCE LETTERS 2 - REFERENCE LETTERS

(7) Loosely install differential bearing cap bolts. (8) Remove axle housing spreader.


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DIFFERENTIAL (Continued) (9) Tighten the bearing cap bolts to 61 N·m (45 ft. lbs.). (10) Install the hub bearings and axle shafts. (11) Apply a bead 6.35mm (1/4 inch) of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 50).

OPERATION A gerotor pump and clutch pack are used to provide the torque transfer capability. One axle shaft is splined to the gerotor pump and one differential side gears, this provides input to the pump. As a wheel begins to lose traction, the speed differential is transmitted from one side of the differential to the other through the side gears. The motion of one side gear relative to the other turns the inner rotor of the pump. Since the outer rotor of the pump is grounded to the differential case, the inner and outer rotors are moving relative to each other, which creates pressure in the pump. The tuning of the front and rear axle orifices and valves inside the gerotor pump are unique. Each system has a torque-limiting pressure relief valve to protect the clutch pack, which also facilitates vehicle control under extreme side-to-side traction variations. The resulting pressure is applied to the clutch pack and the transfer of torque is completed. Vari-lokt system is less subject to wear, remaining more consistent over time in its ability to transfer torque.

DIAGNOSIS AND TESTING

Fig. 50 DIFFERENTIAL COVER 1 - COVER 2 - SEALANT 3 - SEALANT BEAD

CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised. (12) Install differential cover and tighten cover bolts in a criss-cross pattern to 41 N·m (30 ft. lbs.). (13) Fill differential with gear lubricant to bottom of the fill plug hole. (14) Tighten fill plug to 34 N·m (25 ft. lbs.). (15) Remove support and lower the vehicle.

DIFFERENTIAL - VARI-LOK DESCRIPTION The optional Vari-Lokt differential has a one-piece differential case which contains the gerotor pump assembly and the clutch mechinism. This unit is serviced as an assembly only.

(1) Park the vehicle on a level surface or raise vehicle on hoist so that the vehicle is level. (2) Remove the axle fill plug. (3) Verify that the axle fluid level is correct. The fluid level is correct if the fluid is level with the bottom of the fill hole. (4) Shift the transfer case into the 4WD full-time position. (5) Drive the vehicle in a tight circle for 2 minutes at 5mph to fully prime the pump. (6) Block the tires opposite the axle to be tested to prevent the vehicle from moving. (7) Shift the transfer case into the 4WD Low position and the transmission into the Park position. (8) Raise both the wheels of the axle to be tested off of the ground. (9) Rotate the left wheel by hand at a minimum of one revolution per second while an assistant rotates the right wheel in the opposite direction. (10) The left wheel should spin freely at first and then increase in resistance within 5 revolutions until the wheels cannot be continuously rotated in opposite directions. (11) The Vari-lokt differential has engaged properly if the wheels cannot be rotated in opposite directions for a moment. After the wheels stop rotating for a moment, the fluid pressure will drop in the differential and the wheels begin to rotate once again. (12) If the system does not operate properly, replace the Vari-lokt differential.


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(1) Install differential side bearings with Handle C-4171 and Installer C-3716-A (Fig. 52).

REMOVAL (1) Remove (2) Remove with Puller SP-3289 (Fig.

differential case from housing. bearings from the differential case C-293-PA, Adapters 8352 and Plug 51).

Fig. 52 DIFFERENTIAL CASE BEARING 1 - INSTALLER 2 - HANDLE

(2) Install differential in housing.

PINION GEAR/RING GEAR REMOVAL Fig. 51 DIFFERENTIAL CASE BEARING 1 2 3 4 5

- ADAPTERS - BEARING - DIFFERENTIAL - PLUG - PULLER

INSTALLATION NOTE: If differential case or side bearings are replaced, differential side bearing shim requirements may change. Refer to Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection. CAUTION: Vari-lokT plenum must be seated against the differential case, prior to installing the ring gear side differential bearing.

NOTE: The ring gear and pinion are serviced as a matched set. Nevar replace one gear without replacing the other matching 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 differential from axle housing. (5) Place differential case in a vise with soft metal jaw (Fig. 53). (6) Remove bolts holding ring gear to differential case. NOTE: On Veri-LokT differential the side bearing and oil feed plenum must be removed before removing the ring gear bolts.


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PINION GEAR/RING GEAR (Continued) (7) Driver ring gear off the differential case with a rawhide hammer (Fig. 53).

(10) Remove pinion gear and collapsible spacer from housing (Fig. 55).

Fig. 53 RING GEAR 1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER

(8) With Spanner Wrench 6958 and a short length of 1 in. pipe, hold pinion companion flange and remove pinion nut and washer (Fig. 54). (9) Remove pinion companion flange from pinion shaft with Remover C-452 and Flange Wrench C-3281.

(11) Remove front pinion bearing cup, bearing, oil slinger and pinion seal with Remover C-4345 and Handle C-4171 (Fig. 56).

Fig. 54 Pinion Flange

Fig. 56 FRONT PINION BEARING CUP

1 - PINION FLANGE 2 - FRONT AXLE 3 - SPANNER WRENCH

Fig. 55 REMOVE PINION GEAR 1 - DEAD-BLOW HAMMER

1 - REMOVER 2 - HANDLE


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PINION GEAR/RING GEAR (Continued) (12) Remove rear pinion bearing cup (Fig. 57) with Remover D-149 and Handle C-4171.

(14) Remove rear pinion bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-39 (Fig. 59). Remove oil slinger/pinion depth shim from the pinion shaft and record thickness.

Fig. 57 REAR PINION BEARING CUP 1 - REMOVER 2 - HANDLE

(13) Remove collapsible preload spacer from pinion gear (Fig. 58).

Fig. 59 REAR PINION BEARING 1 2 3 4

- PULLER - VISE - ADAPTERS - PINION GEAR SHAFT

INSTALLATION NOTE: Pinion depth shims are placed between the rear pinion bearing cone and the pinion head to achieve proper ring and pinion gear mesh. If ring and pinion gears are reused, the pinion oil slinger/ depth shim should not require replacement. Refer to Adjustments (Pinion Gear Depth) to select the proper thickness shim before installing pinion gear.

Fig. 58 COLLAPSIBLE SPACER 1 2 3 4 5

-

COLLAPSIBLE SPACER SHOULDER PINION GEAR DEPTH SHIM REAR BEARING

(1) Apply Mopar Door Ease or equivalent lubricant to outside surface of pinion bearing cups. (2) Install rear bearing cup with Installer D-146 and Handle C-4171 and verify cup is seated (Fig. 60). (3) Install bearing cup with Installer D-130 and Handle C-4171 (Fig. 61) and verify cup is seated. (4) Install front pinion bearing, and oil slinger if equipped. (5) Apply a light coating of gear lubricant on the lip of pinion seal and install seal with Installer 8890. (6) Install rear pinion bearing and oil slinger/depth shim onto the pinion shaft with Installer W262 and a press (Fig. 62). (7) Install a new collapsible spacer on pinion shaft and install the pinion into the housing (Fig. 63). (8) Install pinion companion flange, with Installer W-162-B, Cup 8109 and Spanner Wrench 6958.


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PINION GEAR/RING GEAR (Continued)

Fig. 60 REAR PINION BEARING CUP 1 - INSTALLER 2 - HANDLE

Fig. 62 REAR PINION BEARING 1 2 3 4 5

-

INSTALLER OIL SLINGER PINION GEAR REAR PINION BEARING PRESS

1 2 3 4 5

-

COLLAPSIBLE SPACER SHOULDER PINION GEAR DEPTH SHIM REAR BEARING

Fig. 61 FRONT PINION BEARING CUP 1 - INSTALLER 2 - HANDLE

(9) Install pinion washer and a new nut onto the pinion gear and tighten the nut to 298 N·m (220 ft. lbs.). Do not over-tighten. CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed. NOTE: New collapsible spacers require high initial torque to start the collapsing of the spacer. This may reach 678 N·m (500 ft. lbs.).

Fig. 63 COLLAPSIBLE PRELOAD SPACER


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PINION GEAR/RING GEAR (Continued) (10) Use Flange Wrench 6958, a length of 1 in. pipe and a torque wrench set at 500 N·m (368 ft. lbs.) and crush collapsible spacer until bearing end play is taken up (Fig. 64). (11) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the required rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 65).

Fig. 65 PINION ROTATING TORQUE 1 - TORQUE WRENCH 2 - PINION YOKE/FLANGE

Fig. 64 PINION NUT 1 - PINION FLANGE 2 - FRONT AXLE 3 - SPANNER WRENCH

(12) Rotate the pinion a minimum of ten times. Verify pinion rotates smoothly and check rotating torque with an inch pound torque wrench (Fig. 65). Pinion gear rotating torque is: • Original Bearings: 1 to 2.25 N·m (10 to 20 in. lbs.). • New Bearings: 1.7 to 3.4 N·m (15 to 30 in. lbs.). (13) Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (14) Invert the differential case in the vise. (15) Install new ring gear bolts and alternately tighten to 108 N·m (80 ft. lbs.) (Fig. 66). CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage. NOTE: If equipped with Veri-LokT differential install oil feed plenum and side bearing. (16) Install differential in housing and verify differential bearing preload, gear mesh and contact pattern. Refer to Adjustment for procedure.

Fig. 66 RING GEAR BOLTS 1 2 3 4

-

TORQUE WRENCH RING GEAR BOLTS RING GEAR DIFFERENTIAL CASE

(17) Install differential cover and fill with gear lubricant. (18) Install propeller shaft with reference marks aligned. (19) Remove supports and lower vehicle.


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REAR AXLE - 198RBI TABLE OF CONTENTS page REAR AXLE - 198RBI DESCRIPTION . . . . . . . . OPERATION . . . . . . . . . . DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . ADJUSTMENTS . . . . . . . SPECIFICATIONS . . . . . . SPECIAL TOOLS ...... AXLE SHAFTS REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . AXLE BEARINGS/SEALS REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . PINION SEAL REMOVAL . . . . . . . . . . . .

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REAR AXLE - 198RBI DESCRIPTION The Rear Beam Iron (RBI) axle has a cast iron differential housing with axle shaft tubes extending from either side. The tubes are pressed into differential housing and welded. The axles are semi-floating supported by the axle shaft and bearings. The axle shafts are retained by bearing retainer plates on the axles which are bolted to flanges at the outboard end of the axle tubes.

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.

DIAGNOSIS AND TESTING GEAR NOISE Axle gear noise can be caused by insufficient lubricant, incorrect backlash, tooth contact, worn/damaged gears, or the carrier housing not having the proper offset and squareness.

page INSTALLATION . . . . . . . . . . . . COLLAPSIBLE SPACER REMOVAL . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . DIFFERENTIAL DESCRIPTION . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . DIFFERENTIAL CASE BEARINGS REMOVAL . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . PINION GEAR/RING GEAR REMOVAL . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . .

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Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are acceleration, deceleration, coast, or constant load. When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the noise stops or changes greatly check for: • Insufficient lubricant. • Incorrect ring gear backlash. • Gear damage. Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause noise during straight-ahead driving when the gears are unloaded. The side gears are loaded during vehicle turns. A worn pinion mate shaft can also cause a snapping or a knocking noise.

BEARING NOISE The axle shaft, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be either a whining, or a growling sound. Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing noise will be higher pitched because it rotates at a faster rate. Drive the vehicle and load the differential. If bearing noise occurs, the rear pinion bearing is the source of the noise. If the bearing noise is


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REAR AXLE - 198RBI (Continued) heard during a coast, the front pinion bearing is the source. Differential bearings usually produce a low pitch noise. Differential bearing noise is similar to pinion bearing noise. The pitch of differential bearing noise is also constant and varies only with vehicle speed. Axle shaft bearings produce noise and vibration when worn or damaged. The noise generally changes when the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and to the right. This will load the bearings and change the noise level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 mph.

LOW SPEED KNOCK Low speed knock is generally caused by: • Worn U-joint. • Worn side-gear thrust washers. • Worn pinion shaft bore.

VIBRATION Vibration at the rear of the vehicle is usually caused by a: • Damaged drive shaft. • Missing drive shaft balance weight(s). • Worn or out-of-balance wheels. • Loose wheel lug nuts. • Worn U-joint(s). • Loose/broken springs.

• Damaged axle shaft bearing(s). • Loose pinion gear nut. • Excessive pinion yoke run out. • Bent axle shaft(s). Check for loose or damaged front-end components or engine/transmission mounts. These components can contribute to what appears to be a rear end vibration. Do not overlook engine accessories, brackets and drive belts. All driveline components should be examined before starting any repair.

DRIVELINE SNAP A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged), can be caused by: • High engine idle speed. • Transmission shift operation. • Loose engine/transmission/transfer case mounts. • Worn U-joints. • Loose spring mounts. • Loose pinion gear nut and yoke. • Excessive ring gear backlash. • Excessive side gear to case clearance. The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.

DIAGNOSTIC CHART Condition Wheel Noise

Axle Shaft Noise

Possible Causes

Correction

1. Wheel loose.

1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing.

2. Replace bearing.

1. Misaligned axle tube.

1. Inspect axle tube alignment. Correct as necessary.

2. Bent or sprung axle shaft.

2. Inspect and correct as necessary.

3. End-play in pinion bearings.

3. Refer to pinion pre-load information and correct as necessary.

4. Excessive gear backlash between the ring gear and pinion.

4. Check adjustment of the ring gear and pinion backlash. Correct as necessary.

5. Improper adjustment of pinion gear bearings.

5. Adjust the pinion bearings pre-load.

6. Loose pinion yoke nut.

6. Tighten the pinion yoke nut.

7. Scuffed gear tooth contact surfaces.

7. Inspect and replace as necessary.


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REAR AXLE - 198RBI (Continued) Condition Axle Shaft Broke

Differential Cracked

Differential Gears Scored

Loss Of Lubricant

Axle Overheating

Possible Causes

Correction

1. Misaligned axle tube.

1. Replace the broken shaft after correcting tube mis-alignment.

2 Vehicle overloaded.

2. Replace broken shaft and avoid excessive weight on vehicle.

3. Erratic clutch operation.

3. Replace broken shaft and avoid or correct erratic clutch operation.

4. Grabbing clutch.

4. Replace broken shaft and inspect and repair clutch as necessary.

1. Improper adjustment of the differential bearings.

1. Replace case and inspect gears and bearings for further damage. Set differential bearing pre-load properly.

2. Excessive ring gear backlash.

2. Replace case and inspect gears and bearings for further damage. Set ring gear backlash properly.

3. Vehicle overloaded.

3. Replace case and inspect gears and bearings for further damage. Avoid excessive vehicle weight.

4. Erratic clutch operation.

4. Replace case and inspect gears and bearings for further damage. Avoid erratic use of clutch.

1. Insufficient lubrication.

1. Replace scored gears. Fill differential with the correct fluid type and quantity.

2. Improper grade of lubricant.

2. Replace scored gears. Fill differential with the correct fluid type and quantity.

3. Excessive spinning of one wheel/tire.

3. Replace scored gears. Inspect all gears, pinion bores, and shaft for damage. Service as necessary.

1. Lubricant level too high.

1. Drain lubricant to the correct level.

2. Worn axle shaft seals.

2. Replace seals.

3. Cracked differential housing.

3. Repair as necessary.

4. Worn pinion seal.

4. Replace seal.

5. Worn/scored yoke.

5. Replace yoke and seal.

6. Axle cover not properly sealed.

6. Remove, clean, and re-seal cover.

1. Lubricant level low.

1. Fill differential to correct level.

2. Improper grade of lubricant.

2. Fill differential with the correct fluid type and quantity.

3. Bearing pre-loads too high.

3. Re-adjust bearing pre-loads.

4. Insufficient ring gear backlash.

4. Re-adjust ring gear backlash.


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REAR AXLE - 198RBI (Continued) Condition Gear Teeth Broke

Axle Noise

Possible Causes

Correction

1. Overloading.

1. Replace gears. Examine other gears and bearings for possible damage.

2. Erratic clutch operation.

2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation.

3. Ice-spotted pavement.

3. Replace gears and examine remaining parts for damage.

4. Improper adjustments.

4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct.

1. Insufficient lubricant.

1. Fill differential with the correct fluid type and quantity.

2. Improper ring gear and pinion adjustment.

2. Check ring gear and pinion contact pattern.

3. Unmatched ring gear and pinion.

3. Replace gears with a matched ring gear and pinion.

4. Worn teeth on ring gear and/or pinion.

4. Replace ring gear and pinion.

5. Loose pinion bearings.

5. Adjust pinion bearing pre-load.

6. Loose differential bearings.

6. Adjust differential bearing pre-load.

7. Mis-aligned or sprung ring gear.

7. Measure ring gear run-out. Replace components as necessary.

8. Loose differential bearing cap bolts.

8. Inspect differential components and replace as necessary. Ensure that the bearing caps are torqued tot he proper specification.

9. Housing not machined properly.

9. Replace housing.

REMOVAL (1) Raise and support the vehicle. (2) Position a lifting device under the axle and secure axle. (3) Remove the wheels and tires. (4) Remove brake calipers and rotors. (5) Disconnect parking brake cables from brackets and lever. (6) Remove wheel speed sensors. (7) Remove brake hose at the axle junction block. Do not disconnect the brake hydraulic lines at the calipers. (8) Disconnect the vent hose from the axle shaft tube. (9) Mark propeller shaft and yokes for installation reference. (10) Remove propeller shaft. (11) Disconnect stabilizer bar links.

(12) Remove upper suspension arm rear axle ball joint nut. (13) Separate rear axle ball joint from the upper suspension arm with Remover 8278 (Fig. 1). (14) Disconnect shock absorbers from axle. (15) Disconnect track bar. (16) Disconnect lower suspension arms from the axle brackets. (17) Separate the axle from the vehicle.

INSTALLATION CAUTION: The weight of the vehicle must be supported by the springs before suspension arms and track bar fasteners are tightened. If springs are not at their normal ride position, vehicle ride height and handling could be affected. (1) Raise axle with lift and align coil springs.


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REAR AXLE - 198RBI (Continued)

Fig. 1 BALL JOINT REMOVER 1 - REMOVER 2 - UPPER SUSPENSION ARM 3 - BALL JOINT STUD

(2) Install lower suspension arms in axle brackets. Install nuts and bolts, do not tighten bolts at this time. (3) Install upper suspension arm on rear axle ball joint. (4) Install rear axle ball joint nut and tighten to 122 N·m (90 ft.lbs.) (Fig. 2).

(5) Install track bar and attachment bolts, do not tighten bolts at this time. (6) Install shock absorbers and tighten nuts to 60 N·m (44 ft. lbs.). (7) Install stabilizer bar links and tighten nuts to 36 N·m (27 ft. lbs.). (8) Install wheel speed sensors. (9) Connect parking brake cable to brackets and lever. (10) Install brake rotors and calipers. (11) Install the brake hose to the axle junction block. (12) Install axle vent hose. (13) Align propeller shaft and pinion yoke reference marks. Install U-joint straps and nuts tighten to 19 N·m (14 ft. lbs.). (14) Install the wheels and tires. (15) Add gear lubricant, if necessary. (16) Remove support and lower the vehicle. (17) Tighten lower suspension arm bolts to 177 N·m (130 ft. lbs.). (18) Tighten track bar bolts to 100 N·m (74 ft. lbs.).

ADJUSTMENTS Ring and pinion gears are supplied as matched sets only. The identifying numbers for the ring and pinion gear are etched into the face of each gear (Fig. 3). A plus (+) number, minus (–) number or zero (0) is etched into the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion etched with a (0). The standard depth provides the best gear tooth contact pattern.

Fig. 2 REAR BALL JOINT NUT 1 - UPPER SUSPENSION ARM 2 - REAR AXLE BALL JOINT 3 - REAR AXLE

Fig. 3 PINION GEAR ID NUMBERS 1 - PRODUCTION NUMBERS 2 - PINION GEAR DEPTH VARIANCE 3 - GEAR MATCHING NUMBER


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REAR AXLE - 198RBI (Continued) Compensation for pinion depth variance is achieved with a select shim. The shims are placed between the rear pinion bearing and the pinion gear head (Fig. 4). If a new gear set is being installed, note the depth variance etched into both the original and replacement pinion. Add or subtract this number from the thickness of the original depth shim/oil slinger to compensate for the difference in the depth variances. Refer to the Pinion Gear Depth Variance chart. Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or minus the amount needed. Note the etched number on the face of the pinion gear head (–1, –2, 0, +1, +2, etc.). The numbers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the required thickness of the depth shims. If the number is positive, subtract that value from the thickness of the depth shim.

Fig. 4 ADJUSTMENT SHIM LOCATIONS 1 2 3 4 5

-

PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM RING GEAR DIFFERENTIAL BEARING SHIM COLLAPSIBLE SPACER

PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance

Replacement Pinion Gear Depth Variance 24

23

22

21

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

0

20.001

+2

+0.006

+0.005

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

+1

+0.005

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

0

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

20.004

21

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

20.004

20.005

22

+0.002

+0.001

0

20.001

20.002

20.003

20.004

20.005

20.006

23

+0.001

0

20.001

20.002

20.003

20.004

20.005

20.006

20.007

24

0

20.001

20.002

20.003

20.004

20.005

20.006

20.007

20.008


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REAR AXLE - 198RBI (Continued)

PINION DEPTH MEASUREMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with Pinion Gauge Set and Dial Indicator C-3339 (Fig. 5).

Fig. 6 PINION HEIGHT BLOCK 1 - PINION BLOCK 2 - PINION HEIGHT BLOCK

Fig. 5 PINION DEPTH GAUGE TOOLS 1 2 3 4 5 6 7 8

- DIAL INDICATOR - ARBOR - PINION HEIGHT BLOCK - CONE - SCREW - PINION BLOCK - SCOOTER BLOCK - ARBOR DISC

(1) Assemble Pinion Height Block 6739, Pinion Block 6735 and rear pinion bearing onto Screw 6741. (2) Insert assembled height gauge components, rear bearing and screw into the housing through pinion bearing cups (Fig. 6). (3) Install front pinion bearing and Cone-nut 6740 hand tight (Fig. 5). (4) Place Arbor Disc 6732 on Arbor D-115-3 in position in the housing side bearing cradles (Fig. 7). Install differential bearing caps on Arbor Discs and tighten cap bolts to 41 N·m (30 ft. lbs.). NOTE: Arbor Discs 6732 has different step diameters to fit other axles. Choose proper step for axle being serviced.

Fig. 7 GAUGE TOOLS IN HOUSING 1 2 3 4

- ARBOR DISC - PINION BLOCK - ARBOR - PINION HEIGHT BLOCK

(5) Assemble Dial Indicator C-3339 into Scooter Block D-115-2 and secure set screw. (6) Place Scooter Block/Dial Indicator in position in the housing so dial probe and scooter block are flush against the pinion height block (Fig. 5). Hold scooter block in place and zero the dial indicator.


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REAR AXLE - 198RBI (Continued) (7) Slide the dial indicator probe across the gap between the pinion height block and the arbor bar with the scooter block against the pinion height block (Fig. 8). Continue moving the dial indicator probe to the crest of 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 reading plus the pinion depth variance number etched in the face of the pinion (Fig. 3). For example, if the depth variance is –2, add +0.002 in. to the dial indicator reading.

measured, the pinion is installed, and the gear backlash shim thickness is measured. The overall shim thickness is the total of the dial indicator reading and the preload 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. 9). Differential shim measurements are performed with the spreader W-129-B removed.

Fig. 9 ADJUSTMENT SHIM LOCATIONS Fig. 8 PINION GEAR DEPTH MEASUREMENT 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR

DIFFERENTIAL Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differential bearing cups. The proper shim thickness can be determined using slip-fit Dummy Bearings 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 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 side play is

1 2 3 4 5

-

PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM RING GEAR DIFFERENTIAL BEARING SHIM COLLAPSIBLE SPACER

PRELOAD 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 differential 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.


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REAR AXLE - 198RBI (Continued) (5) Record the thickness of Dummy Shims 8107. Insert the shims between the dummy bearings and the differential housing (Fig. 10).

(7) Using a dead-blow type hammer seat the differential dummy bearings to each side of the housing (Fig. 12) and (Fig. 13).

Fig. 12 SEAT DUMMY BEARING PINION SIDE 1 - HAMMER 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE

Fig. 10 DUMMY SHIM LOCATION 1 2 3 4

-

DUMMY SHIM DIFFERENTIAL HOUSING DIFFERENTIAL CASE DUMMY BEARINGS

(6) Install the marked bearing caps in their correct positions. Install and snug the bolts (Fig. 11).

Fig. 13 SEAT DUMMY BEARING RING GEAR SIDE 1 - DIFFERENTIAL HOUSING 2 - HAMMER 3 - DIFFERENTIAL CASE

Fig. 11 BEARING CAP BOLTS 1 - BEARING CAP 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE


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REAR AXLE - 198RBI (Continued) (8) Thread Pilot Stud C-3288-B into rear cover bolt hole below ring gear (Fig. 14). (9) Attach a Dial Indicator C-3339 to pilot stud. Position the dial indicator plunger on a flat surface between the ring gear bolt heads (Fig. 14).

(11) Push and hold differential case to ring gear side of the housing and record dial indicator reading (Fig. 16).

Fig. 16 RECORD DIAL INDICATOR READING 1 - DIAL INDICATOR 2 - HOLD DIFFERENTIAL CASE TO RING GEAR SIDE 3 - DIFFERENTIAL HOUSING

Fig. 14 DIAL INDICATOR LOCATION 1 2 3 4

-

DIFFERENTIAL CASE DIFFERENTIAL HOUSING PILOT STUD DIAL INDICATOR

(10) Push and hold differential case to pinion gear side of the housing and zero dial indicator (Fig. 15).

Fig. 15 ZERO DIAL INDICATOR 1 2 3 4

-

HOLD DIFFERENTIAL CASE TO PINION GEAR SIDE PILOT STUD DIAL INDICATOR EXTENSION DIAL INDICATOR

(12) Add 0.152 mm (0.006 in.) to the zero end play total. This new total represents the thickness of shims to compress, or preload the new bearings when the differential is installed. (13) Rotate dial indicator out of the way on the pilot stud. (14) Remove differential case and dummy bearings from the housing. (15) Install the pinion gear in axle housing. Install the pinion yoke and establish the correct pinion rotating torque. (16) Install differential case and Dummy Bearings D-348 in the housing. (17) Install a single dummy shim in the ring gear side. Install bearing caps and tighten bolts snug. (18) Seat ring gear side dummy bearing (Fig. 13). (19) Position the dial indicator plunger on a flat surface between the ring gear bolt heads. (Fig. 14). (20) Push and hold differential case toward pinion gear and zero dial indicator (Fig. 17). (21) Push and hold differential case to ring gear side of the housing and record dial indicator reading (Fig. 18). Add dummy shim thickness to this reading. This will be the total shim thickness to achieve zero backlash. (22) Subtract 0.076 mm (0.003 in.) from the dial indicator reading to compensate for backlash between ring and pinion gears. This total is the thickness shim required to achieve proper backlash. (23) Subtract the backlash shim thickness from the total preload shim thickness. The remainder is the shim thickness required on the pinion side of the housing.


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REAR AXLE - 198RBI (Continued) (27) Install spreader W-129-B utilizing some items from Adapter Set 6987, on the housing and spread axle opening enough to receive differential case. CAUTION: Never spread over 0.38 mm (0.015 in.). If housing is over-spread, it could be distorted or damaged.

Fig. 17 ZERO DIAL INDICATOR 1 2 3 4 5

-

DIAL INDICATOR HOLD DIFFERENTIAL CASE TO PINION GEAR SIDE PINION GEAR DIFFERENTIAL HOUSING DIFFERENTIAL CASE

(28) Place the bearing preload shims in the housing, against the axle tubes. (29) Install differential case into the housing. (30) Remove spreader from the housing. (31) Install differential bearing caps in their original locations. (32) Install bearing cap bolts and tighten to 77 N·m (57 ft. lbs.). (33) Rotate the differential case several times to seat the side bearings. (34) Position the indicator plunger against a ring gear tooth (Fig. 19). (35) Push and hold ring gear upward while not allowing the pinion gear to rotate. (36) Zero dial indicator face to pointer. (37) Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading should be between 0.12-0.20 mm (0.005-0.008 in.). If backlash is not within specifications transfer the necessary amount of shim thickness from one side of the axle housing to the other (Fig. 20). (38) Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective. After the proper backlash is achieved, perform Gear Contact Pattern Analysis procedure.

Fig. 18 RECORD DIAL INDICATOR READING 1 2 3 4 5

-

DIAL INDICATOR HOLD DIFFERENTIAL CASE TO RING GEAR SIDE PINION GEAR DIFFERENTIAL HOUSING DIFFERENTIAL CASE

(24) Rotate dial indicator out of the way on pilot stud. (25) Remove differential case and dummy bearings from the housing. (26) Install side bearings and cups on differential case.

Fig. 19 RING GEAR BACKLASH MEASUREMENT 1 - DIAL INDICATOR


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REAR AXLE - 198RBI (Continued)

Fig. 21 GEAR DESCRIPTION 1 2 3 4 5

Fig. 20 BACKLASH SHIM LOCATION

GEAR CONTACT PATTERN The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns. The TOP LAND of the gear tooth is the top surface of the tooth. The PROFILE of the gear tooth is the depth of the tooth. The TOE of the gear is the portion of the tooth surface at the end towards the center. The HEEL of the gear is the portion of the tooth at the outer-end. The ROOT of the gear tooth is the lowest portion of the tooth (Fig. 21). NOTE: If the PROFILE across the tooth is the same it is a 3 Axis cut gear. If the PROFILE across the tooth is tapered it is a 2 Axis cut gear. (1) Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth. (2) Wrap, twist and hold a shop towel around the pinion yoke to increase the turning resistance of the

-

TOP LAND PROFILE TOE HEEL ROOT

pinion. This will provide a more distinct contact pattern. (3) With a boxed end wrench on a ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel. The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart (Fig. 22) and adjust pinion depth and gear backlash as necessary.

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 differential bearing preload. Torque to rotate the differential and pinion should be the torque to rotate the pinion plus 0.15 N¡m (6 in. lbs.).


REAR AXLE - 198RBI

WJ REAR AXLE - 198RBI (Continued)

Fig. 22 PATTERN INTERPRETATION (3 AXIS GEAR CUT)

SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION

SPECIFICATION

Axle Ratio

3.55, 3.73

Differential Bearing Preload

0.15 mm (0.006 in.)

Ring Gear Diameter

198 mm (7.795 in.)

Ring Gear Backlash

0.12-0.20 mm (0.005-0.008 in.)

Pinion Bearing Preload - Original Bearings

1-2 N·m (10-20 in. lbs.)

Pinion Bearing Preload - New Bearings

1.7-3.9 N·m (15-35 in. lbs.)

TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Differential Cover Bolts

41

30

-

Bearing Cap Bolts

77

57

-

Ring Gear Bolts

129-142

95-105

-

Pinion Nut Min / Max

271 - 474

200 - 350

-

Pinion Mate Shaft Screw

16.25

12

-

Axle Bearing Retainer Plate Nuts

61

45

-

3 - 61


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REAR AXLE - 198RBI (Continued)

SPECIAL TOOLS

WRENCH C-3281 PULLER C-293-PA

ADAPTER C-293-39

ADAPTER C-293-40

SPANNER WRENCH 6958

INSTALLER 8112

CUP 8109 PLUG SP-3289

PULLER C-452

HANDLE C-4171


REAR AXLE - 198RBI

WJ REAR AXLE - 198RBI (Continued)

INSTALLER C-3716-A INSTALLER W-262

INSTALLER D-130

PINION DEPTH 6774

INSTALLER D-146

FIXTURE 6965

REMOVER C-4345 SHIMS DUMMY 8107

REMOVER D-149 SPREADER W-129-B

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REAR AXLE - 198RBI (Continued)

INSTALLER 7913-A

ADAPTER KIT 6987

AXLE SHAFTS REMOVAL PILOT STUDS C-3288-B

PULLER 6790

(1) Place transmission in neutral. (2) Raise and support vehicle. (3) Remove wheel and tire assembly. (4) Remove brake caliper and rotor. (5) Remove nuts holding axle retainer plate to axle tube from the rear of the axle flange. (6) Pull axle shaft from the axle with Slide Hammer 7420 and Adapter 6790. Mount the adapter to the axle with lug nuts. NOTE: The axle bearing race is normally loose in the axle tube.

INSTALLATION

DIAL INDICATOR C-3339

SPLITTER BEARING 1130

(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 nuts to 61 N·m (45 ft. lbs.). (4) Install the brake rotor and caliper. (5) Install wheel and tire. (6) Check and fill the differential with gear lubricant. (7) Lower vehicle.


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AXLE BEARINGS/SEALS

3 - 65

(3) With a cold chisel cut the retaining ring across drilled hole. (Fig. 24)

REMOVAL (1) Remove axle shaft from vehicle. NOTE: The axle bearing race is normally loose in the axle tube. (2) Drill a shallow hole into soft steel axle bearing retaining ring with a 3/8 in. drill bit (Fig. 23). Use a drill depth stop to avoid marking the axle.

Fig. 24 RETAINING RING 1 2 3 4

- AXLE - COLD CHISEL - VISE - RETAINING RING

(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. 25).

Fig. 23 DRILL RETAINING RING 1 2 3 4

- DRILL BIT - AXLE - RETAINING PLATE - RETAINING RING

Fig. 25 AXLE BEARING AND SEAL 1 2 3 4

- SPLITTER - AXLE - BLOCKS - PRESS PLATES

(6) Remove seal from axle. (7) Remove retaining plate from axle shaft.


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AXLE BEARINGS/SEALS (Continued)

INSTALLATION (1) Verify axle shaft retaining plate is flat with a straight edge. NOTE: If the plate is warped or the studs are loose in the plate replace the retaining plate. (2) Install retaining plate on the axle shaft (Fig. 26). (3) Apply a coat of multi-purpose grease on sealing surface of axle seal. (4) Install seal on the axle shaft with cavity away from retaining plate (Fig. 26).

Fig. 27 PRESS BEARING ON AXLE 1 2 3 4 5 6

- PRESS RAM - INSTALLER - AXLE BEARING - SEAL - RETAINING PLATE - AXLE

1 2 3 4 5

- PRESS - AXLE - AXLE BEARING - INSTALLER - METAL RETAINING RING

Fig. 26 AXLE BEARING AND SEAL COMPONENTS 1 2 3 4 5

- RETAINING RING - SEAL - AXLE - RETAINING PLATE - AXLE BEARING

(5) Lubricate bearing with Mopar Wheel Bearing Grease or equivalent. Wipe excess grease from the bearing. (6) Install bearing on the axle shaft with Installer 7913 and a press (Fig. 27). (7) Press metal retaining ring onto axle shaft with Installer 7913 and a press (Fig. 28). (8) Install axle in vehicle.

Fig. 28 BEARING RETAINING RING


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PINION SEAL

(10) Remove pinion gear seal 7794-A and slide hammer (Fig. 31).

with

3 - 67

Remover

REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove brake calipers and rotors. (4) Mark propeller shaft and pinion yoke for installation reference. (5) Remove propeller shaft from the yoke. (6) Rotate pinion gear a minimum of ten times and verify pinion rotates smoothly. (7) Record rotating torque of the pinion gear with an inch pound dial-type torque wrench, for installation reference. (8) Hold the pinion yoke with Spanner Wrench 6958 and remove the pinion nut and washer (Fig. 29).

Fig. 31 PINION SEAL REMOVER 1 - REMOVER 2 - SLIDE HAMMER 3 - PINION SEAL

INSTALLATION (1) Apply a light coating of gear lubricant on the lip of pinion seal and install seal with an appropriate installer (Fig. 32).

Fig. 29 PINION YOKE SPANNER 1 2 3 4

-

PIPE PINION YOKE SPANNER WRENCH LOWER CONTROL ARM

(9) Remove pinion yoke with Remover C-452 and Wrench C-3281 (Fig. 30).

Fig. 32 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER

Fig. 30 PINION YOKE REMOVER 1 - FLANGE WRENCH 2 - YOKE 3 - YOKE PULLER


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PINION SEAL (Continued) (2) Install yoke on pinion gear with Screw 8112, Cup 8109 and Spanner Wrench 6958 (Fig. 33).

Fig. 33 PINION YOKE INSTALLER 1 2 3 4

-

INSTALLER PINION YOKE DIFFERENTIAL HOUSING SPANNER WRENCH

CAUTION: Do not exceed the minimum tightening torque 271 N路m (200 ft. lbs.) when installing the pinion yoke at this point. Damage to the collapsible spacer or bearings may result.

Fig. 34 PINION ROTATING TORQUE 1 - TORQUE WRENCH 2 - PINION YOKE

(3) Install yoke and a new nut on the pinion gear and tighten the nut until there is zero bearing endplay. (4) Tighten the nut to 271 N路m (200 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. (5) Rotate the pinion gear a minimum of ten times and verify pinion rotates smoothly. Rotate pinion shaft an inch pound torque wrench. Rotating torque should be equal to recorded reading plus an additional 0.56 N路m (5 in. lbs.) (Fig. 34). (6) If the rotating torque is low, use Spanner Wrench 6958 to hold the pinion yoke (Fig. 35), and tighten the pinion nut in 6.8 N路m (5 ft. lbs.) increments until the proper rotating torque is achieved. CAUTION: If maximum tightening torque is reached prior to reaching required rotating torque, the collapsible spacer may have been damaged. Replace the collapsible spacer. (7) Install the propeller shaft with reference marks aligned.

Fig. 35 PINION SHAFT NUT 1 - SPANNER WRENCH 2 - PIPE 3 - TORQUE WRENCH

(8) Add gear lubricant to the differential if necessary. (9) Install brake rotors and calipers. (10) Install wheel and tire assemblies. (11) Lower the vehicle.


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COLLAPSIBLE SPACER

3 - 69

(9) Remove pinion shaft seal with Remover 7794-A and slide hammer (Fig. 38).

REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove rear brake calipers and rotors. (4) Mark propeller shaft and pinion yoke for installation reference and remove propeller shaft. (5) Rotate pinion gear a minimum of ten times and verify pinion rotates smoothly. (6) Record rotate torque of the pinion gear, with an inch pound torque wrench. (7) Hold pinion yoke with Spanner Wrench 6958 and remove pinion nut and washer (Fig. 36).

Fig. 38 PINION SEAL REMOVER 1 - REMOVER 2 - SLIDE HAMMER 3 - PINION SEAL

(10) Remove front pinion bearing using a pair of pick tools to pull the bearing off the pinion gear shaft.

Fig. 36 PINION YOKE HOLDER 1 2 3 4

-

1 in. PIPE PINION YOKE SPANNER WRENCH LOWER CONTROL ARM

(8) Remove pinion yoke with Remover C-452 and Wrench C-3281 (Fig. 37).

Fig. 37 PINION YOKE REMOVER 1 - WRENCH 2 - PINION YOKE 3 - PULLER

NOTE: If the pinion bearing becomes bound on the pinion shaft, lightly tap the end of the shaft with a rawhide/rubber mallet. (11) Remove the collapsible spacer.

INSTALLATION (1) Install a new collapsible spacer on pinion shaft. (2) Install pinion front bearing on the pinion shaft. (3) Apply a light coating of gear lubricant on the lip of pinion seal and install seal with an appropriate installer (Fig. 39).

Fig. 39 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER


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COLLAPSIBLE SPACER (Continued) (4) Install yoke with Screw 8112, Cup 8109 and Spanner Wrench 6958 (Fig. 40).

Fig. 41 PINION NUT 1 - SPANNER WRENCH 2 - PIPE 3 - TORQUE WRENCH

Fig. 40 PINION YOKE INSTALLER 1 - INSTALLER 2 - PINION YOKE 3 - SPANNER WRENCH

(5) Install yoke and new nut on the pinion gear. Tighten the nut to 271 N·m (200 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. NOTE: New collapsible spacers require high initial torque to start the collapsing of the spacer. This may reach 678 N·m (500 ft. lbs.). (6) Using Spanner Wrench 6958, a length of 1 in. pipe and a torque wrench set at 474 N·m (350 ft. lbs.), (Fig. 41) slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 42). (7) Check rotating torque with an inch pound torque wrench (Fig. 42). The rotating torque of the pinion gear should be, the reading recorded during removal plus an additional 0.56 N·m (5 in. lbs.). (8) Install propeller shaft with reference marks align.

Fig. 42 PINION ROTATING TORQUE 1 - TORQUE WRENCH 2 - PINION YOKE

(9) Install rear brake calipers and rotors (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLATION). (10) Add gear lubricant, if necessary. (11) Install wheel and tire assemblies. (12) Remove supports and lower vehicle.


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DIFFERENTIAL DESCRIPTION The differential case is a one-piece design. 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. A differential cover provides a means for inspection and service.

OPERATION During straight-ahead driving, the differential pinion 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. 43).

Fig. 44 DIFFERENTIAL ON TURNS 1 - PINION GEARS ROTATE ON PINION SHAFT

REMOVAL (1) Raise and support vehicle. (2) Remove fill hole plug from the differential housing cover. (3) Remove differential housing cover and drain fluid. (4) Clean the housing cavity with flushing oil, light engine oil or lint free cloth. NOTE: Do not use water, steam, kerosene or gasoline for cleaning.

Fig. 43 STRAIGHT AHEAD DRIVING 1 2 3 4

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(5) Remove axle shafts. (6) Note the reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 45).

WHEELS ROTATE AT CASE SPEED PINION GEAR SIDE GEAR PINION GEARS ROTATE WITH CASE

When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns. To accomplish this, the differential allows the axle shafts to turn at unequal speeds (Fig. 44). In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed.

Fig. 45 Differential Bearing Cap Reference Letters 1 - REFERENCE LETTERS 2 - REFERENCE LETTERS


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DIFFERENTIAL (Continued) (7) Loosen the differential bearing cap bolts. (8) Position Spreader W-129-B with Adapter Kit 6987B on differential locating holes (Fig. 46). Install holddown clamps and tighten the turnbuckle fingertight.

Fig. 47 Install Dial Indicator 1 2 3 4 5

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CLAMP DIAL INDICATOR LEVER ADAPTER SPREADER PILOT STUD

Fig. 46 Install Axle Housing Spreader 1 2 3 4 5

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DIFFERENTIAL HOUSING DOWEL SAFETY HOLD DOWN SPREADER TURNBUCKLE

(9) Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing (Fig. 47) and zero the indicator. CAUTION: Never spread the housing over 0.38 mm (0.015 in). If housing is over-spread, it could distorted and damaged the housing. (10) Spread housing enough to remove the differential case from the housing. Measure the distance with the dial indicator (Fig. 48). (11) Remove the dial indicator. (12) While holding the differential case in position, remove the differential bearing cap bolts and caps.

Fig. 48 Spread Axle Housing 1 - DIAL INDICATOR 2 - SPREADER


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DIFFERENTIAL (Continued) (13) Remove differential from the housing and tag differential bearing cups to indicate location (Fig. 49).

Fig. 49 Differential Case Removal 1 - DIFFERENTIAL HOUSING 2 - DIFFERENTIAL CASE 3 - BEARING CUPS

(14) Remove spreader from housing.

DISASSEMBLY (1) Remove pinion shaft lock screw (Fig. 50).

Fig. 51 PINION MATE GEAR REMOVAL 1 - THRUST WASHER 2 - SIDE GEAR 3 - DIFFERENTIAL PINION

(2) Install differential pinion gears and thrust washers. (3) Install the pinion mate shaft. (4) Align hole in the pinion mate shaft with the hole in the differential case and install the pinion mate shaft lock screw. (5) Lubricate all differential components with hypoid gear lubricant.

INSTALLATION NOTE: If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection.

Fig. 50 Pinion Mate Shaft Lock Screw 1 - LOCK SCREW 2 - PINION SHAFT

(2) Remove pinion shaft. (3) Rotate differential side gears and remove differential pinions and thrust washers (Fig. 51). (4) Remove differential side gears and thrust washers.

ASSEMBLY (1) Install differential side gears and thrust washers.

(1) Position Spreader W-129-B with Adapter set 6987 on differential housing locating holes. Install the holddown clamps and tighten the tool turnbuckle finger-tight. (2) Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator. CAUTION: Never spread the housing over 0.38 mm (0.015 in). If housing is over-spread, it could be distorted or damaged.


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DIFFERENTIAL (Continued) (3) Spread housing enough to install the case in the housing. (4) Remove the dial indicator. (5) Install differential case in housing (Fig. 52). Verify differential bearing cups remain in position on the bearings and preload shims are between the face of the bearing cup and the housing. Tap the differential case to ensure bearings cups and shims are seated in the housing.

Fig. 53 VARI-LOK 1 - ANTI-ROTATION TAB 2 - OIL FEED TUBE

Fig. 52 Install Axle Housing Spreader 1 2 3 4 5

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DIFFERENTIAL HOUSING DOWEL SAFETY HOLD DOWN SPREADER TURNBUCKLE

CAUTION: On a Vari-lokT differential the oil feed tube must be pointed at the bottom of the housing (Fig. 53). If differential is installed with the oil feed tube pointed at the top, the anti-rotation tabs will be damaged. (6) Install bearing caps in their original locations (Fig. 54). (7) Loosely install differential bearing cap bolts. (8) Remove axle housing spreader. (9) Tighten bearing cap bolts in a criss-cross pattern to 77 N·m (57 ft. lbs.). (10) Install the axle shafts.

Fig. 54 Differential Bearing Cap Reference Letters 1 - REFERENCE LETTERS 2 - REFERENCE LETTERS


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DIFFERENTIAL (Continued) (11) Apply a 6.35mm (1/4 in.) bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 55).

DIFFERENTIAL CASE BEARINGS REMOVAL (1) (2) (3) with Plug

Raise and support vehicle. Remove differential case from axle housing. Remove bearings from the differential case Puller/Press C-293-PA, Adapter C-293-39 and SP-3289 (Fig. 56).

Fig. 55 DIFFERENTIAL COVER - TYPICAL 1 - COVER 2 - SEALANT 3 - SEALANT BEAD

CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised. (12) Install cover and tighten bolts in a criss-cross pattern to 41 N·m (30 ft. lbs.). (13) Refill the differential with Mopar Hypoid Gear Lubricant or equivalent to bottom of the fill plug hole. (14) Install fill hole plug. (15) Remove support and lower the vehicle.

Fig. 56 DIFFERENTIAL CASE BEARING 1 2 3 4 5

- ADAPTERS - BEARING - DIFFERENTIAL - PLUG - PULLER


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DIFFERENTIAL CASE BEARINGS (Continued)

INSTALLATION NOTE: If differential side bearings or differential case are replaced, differential side bearing shim requirements may change. Refer to Adjustments (Differential Bearing Preload and Gear Backlash) for procedures.

(6) Remove bolts holding ring gear to differential case. (7) Drive ring gear from differential case with a rawhide hammer (Fig. 58).

(1) Install differential case bearings with Installer C-3716-A and Handle C-4171 (Fig. 57).

Fig. 58 Ring Gear Removal 1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER

(8) Hold the pinion yoke with Spanner Wrench 6958 and remove the pinion yoke nut and washer (Fig. 59).

Fig. 57 DIFFERENTIAL SIDE BEARING 1 - INSTALLER 2 - HANDLE

(2) Install differential in axle housing. (3) Remove support and lower vehicle.

PINION GEAR/RING GEAR REMOVAL NOTE: The ring and pinion gears are serviced as a matched set. Never replace one gear without the other gear. (1) Raise and support vehicle. (2) Mark pinion yoke and propeller shaft for installation reference. (3) Disconnect propeller shaft from pinion yoke and tie shaft to underbody. (4) Remove differential from the housing. (5) Place differential case in a vise with soft metal jaw.

Fig. 59 Pinion Yoke Holder—Typical 1 2 3 4

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1 in. PIPE PINION YOKE HOLDER LOWER CONTROL ARM


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PINION GEAR/RING GEAR (Continued) (9) Remove pinion yoke from pinion shaft with Remover C-452 and Flange Wrench C-3281 (Fig. 60).

(11) Remove pinion seal with Remover 7794-A and a slide hammer (Fig. 62).

Fig. 62 Seal Removal Fig. 60 Pinion Yoke Removal 1 - FLANGE WRENCH 2 - YOKE 3 - REMOVER

(10) Remove pinion gear from housing (Fig. 61).

1 - REMOVER 2 - SLIDE HAMMER 3 - PINION SEAL

(12) Remove oil slinger, if equipped, and front pinion bearing. (13) Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 63).

Fig. 61 Remove Pinion Gear 1 - RAWHIDE HAMMER

Fig. 63 Front Bearing Cup Removal 1 - REMOVER 2 - HANDLE


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PINION GEAR/RING GEAR (Continued) (14) Remove rear bearing cup (Fig. 64) with Remover D-149 and Handle C-4171.

(16) Remove rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-40 (Fig. 66).

Fig. 64 Rear Bearing Cup Removal 1 - REMOVER 2 - HANDLE

(15) Remove collapsible preload spacer (Fig. 65).

Fig. 66 Rear Bearing Removal 1 2 3 4

- PULLER - VISE - ADAPTERS - PINION GEAR SHAFT

(17) Remove depth shims from the pinion gear shaft and record shim thickness.

INSTALLATION NOTE: A pinion depth shim/oil slinger is placed between the rear pinion bearing cone and the pinion head to achieve proper ring gear and pinion mesh. If ring gear and pinion are reused, the pinion depth shim/oil slinger should not require replacement. Refer to Adjustment (Pinion Gear Depth) to select the proper thickness shim/oil slinger if ring and pinion gears are replaced.

Fig. 65 Collapsible Preload Spacer 1 2 3 4 5

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COLLAPSIBLE SPACER SHOULDER PINION GEAR SHIM REAR BEARING


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PINION GEAR/RING GEAR (Continued) (1) Apply Mopar Door Ease or equivalent lubricant to outside surface of the pinion bearing cups. (2) Install pinion rear bearing cup with Installer D-146 and Driver Handle C-4171 (Fig. 67) and verify cup is seated.

(4) Install pinion front bearing and oil slinger, if equipped. (5) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with an appropriate installer (Fig. 69).

Fig. 69 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER

(6) Install depth shim on the pinion gear. (7) Install rear bearing and slinger if equipped, on the pinion gear with Installer W-262 and a press (Fig. 70).

Fig. 67 REAR PINION BEARING CUP 1 - INSTALLER 2 - HANDLE

(3) Install pinion front bearing cup with Installer D-130 and Handle C-4171 (Fig. 68) and verify cup is seated.

Fig. 70 REAR PINION BEARING

Fig. 68 PINION FRONT BEARING CUP 1 - INSTALLER 2 - HANDLE

1 2 3 4

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PRESS INSTALLER PINION GEAR PINION BEARING


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PINION GEAR/RING GEAR (Continued) (8) Install a new collapsible preload spacer on pinion shaft and install pinion gear in the housing (Fig. 71).

Fig. 72 PINION YOKE INSTALLER 1 - INSTALLER 2 - PINION YOKE 3 - SPANNER WRENCH

Fig. 71 COLLAPSIBLE SPACER 1 2 3 4 5

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COLLAPSIBLE SPACER SHOULDER PINION GEAR DEPTH SHIM REAR BEARING

NOTE: If more than 474 N·m (350 ft. lbs.) torque is required to crush the collapsible spacer, the spacer is defective and must be replaced.

(9) Install yoke with Installer C-3718 and Spanner Wrench 6958 (Fig. 72). (10) Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play. (11) Tighten the nut to 271 N·m (200 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. NOTE: New collapsible spacers require high initial torque to start the collapsing of the spacer. This may reach 678 N·m (500 ft. lbs.). (12) Using Spanner Wrench 6958 and a torque wrench set at 474 N·m (350 ft. lbs.), (Fig. 73) slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 74).

Fig. 73 PINION SHAFT NUT 1 - SPANNER WRENCH 2 - PIPE 3 - TORQUE WRENCH


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PINION GEAR/RING GEAR (Continued) (13) Check bearing rotating torque with a inch pound torque wrench (Fig. 74). The pinion gear rotating torque should be: • Original Bearings: 1 to 2.25 N·m (10 to 20 in. lbs.). • New Bearings: 1.7 to 3.9 N·m (15 to 35 in. lbs.).

CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage.

Fig. 75 RING GEAR

Fig. 74 CHECK PINION ROTATION TORQUE 1 - PINION YOKE/COMPANION FLANGE 2 - INCH POUND TORQUE WRENCH

(14) Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (15) Invert the differential case in the vise. (16) Install new ring gear bolts and alternately tighten to 136 N·m (100 ft. lbs.) (Fig. 75).

1 2 3 4

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TORQUE WRENCH RING GEAR BOLT RING GEAR CASE

(17) Install differential in housing and verify differential bearing preload, gear mesh and contact pattern. Refer to Adjustments for procedure. (18) Install differential cover and fill with gear lubricant. (19) Install the propeller shaft with the reference marks aligned. (20) Remove supports and lower vehicle.


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REAR AXLE - 226RBA TABLE OF CONTENTS page

page

REAR AXLE - 226RBA DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 82 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 82 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 87 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 94 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 95 AXLE SHAFTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 98 AXLE BEARINGS/SEALS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 99 PINION SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101 COLLAPSIBLE SPACER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102 DIFFERENTIAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 104

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 104 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 106 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106 DIFFERENTIAL - TRAC-LOK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 108 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 108 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 108 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 109 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 DIFFERENTIAL - VARI-LOK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 113 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 113 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 113 DIFFERENTIAL CASE BEARINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 114 PINION GEAR/RING GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 116

REAR AXLE - 226RBA

DIAGNOSIS AND TESTING

DESCRIPTION

GEAR NOISE

The Rear Beam Aluminum (RBA) axle housing has a cast aluminum center ifferential housing with axle shaft tubes extending from either side. The tubes are pressed into the differential housing. The axles are semi-floating supported by the axle shaft and bearings.

OPERATION The axle receives power from the transfer case through the front propeller shaft. The front 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.

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, tooth contact, worn/damaged gears, or the carrier housing not having the proper offset and squareness. Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are acceleration, deceleration, coast, or constant load. When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the noise stops or changes greatly check for: • Insufficient lubricant. • Incorrect ring gear backlash. • Gear damage. Differential side and pinions gears, usually do not cause noise during straight-ahead driving, when the gears are unloaded. The side gears are loaded during


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REAR AXLE - 226RBA (Continued) turns. A worn pinion mate shaft can also cause a snapping or a knocking noise.

BEARING NOISE Bearing noise can be either a whining or a growling sound. Pinion bearings have a constant high pitch noise, because it rotates at a faster rate. This noise changes with vehicle speed. If noise is heard under a load, the rear pinion bearing is the source. If noise is heard during a coast, the front pinion bearing is the source. Differential bearings usually produce a low pitch noise. The differential bearing noise is constant and varies only with vehicle speed. Axle shaft bearing noise generally changes when the bearings are loaded. Turn vehicle sharply to the left and the right during a road test. This will load and unload the bearings and change the noise level. If axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 m.p.h.

LOW SPEED KNOCK Low speed knock is generally caused by: • Worn U-joint. • Worn side-gear thrust washers. • Worn pinion shaft bore.

VIBRATION Vibration at the rear of the vehicle is usually caused by a: • Damaged drive shaft. • Missing drive shaft balance weight(s). • Worn or out-of-balance wheels. • Loose wheel lug nuts.

• Worn U-joint(s). • Loose/broken springs. • Damaged axle shaft bearing(s). • Loose pinion gear nut. • Excessive pinion yoke run out. • Bent axle shaft(s). Check for loose or damaged front-end components or engine/transmission mounts. These components can contribute to what appears to be a rear-end vibration. Also look at engine accessories, brackets and drive belts. NOTE: All driveline components should be examined before starting any repair.

DRIVELINE SNAP A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged), can be caused by: • High engine idle speed. • Transmission shift operation. • Loose engine/transmission/transfer case mounts. • Worn U-joints. • Loose spring mounts. • Loose pinion gear nut and yoke. • Excessive ring gear backlash. • Excessive side gear to case clearance. The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.


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REAR AXLE - 226RBA (Continued) DIAGNOSTIC CHART Condition Wheel Noise

Axle Shaft Noise

Axle Shaft Broke

Differential Cracked

Differential Gears Scored

Possible Causes

Correction

1. Wheel loose.

1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing.

2. Replace bearing.

1. Misaligned axle tube.

1. Inspect axle tube alignment. Correct as necessary.

2. Bent or sprung axle shaft.

2. Inspect and correct as necessary.

3. End-play in pinion bearings.

3. Refer to pinion pre-load information and correct as necessary.

4. Excessive gear backlash between the ring gear and pinion.

4. Check adjustment of the ring gear and pinion backlash. Correct as necessary.

5. Improper adjustment of pinion gear bearings.

5. Adjust the pinion bearings pre-load.

6. Loose pinion yoke nut.

6. Tighten the pinion yoke nut.

7. Scuffed gear tooth contact surfaces.

7. Inspect and replace as necessary.

1. Misaligned axle tube.

1. Replace the broken shaft after correcting tube mis-alignment.

2 Vehicle overloaded.

2. Replace broken shaft and avoid excessive weight on vehicle.

3. Erratic clutch operation.

3. Replace broken shaft and avoid or correct erratic clutch operation.

4. Grabbing clutch.

4. Replace broken shaft and inspect and repair clutch as necessary.

1. Improper adjustment of the differential bearings.

1. Replace case and inspect gears and bearings for further damage. Set differential bearing pre-load properly.

2. Excessive ring gear backlash.

2. Replace case and inspect gears and bearings for further damage. Set ring gear backlash properly.

3. Vehicle overloaded.

3. Replace case and inspect gears and bearings for further damage. Avoid excessive vehicle weight.

4. Erratic clutch operation.

4. Replace case and inspect gears and bearings for further damage. Avoid erratic use of clutch.

1. Insufficient lubrication.

1. Replace scored gears. Fill differential with the correct fluid type and quantity.

2. Improper grade of lubricant.

2. Replace scored gears. Fill differential with the correct fluid type and quantity.

3. Excessive spinning of one wheel/tire.

3. Replace scored gears. Inspect all gears, pinion bores, and shaft for damage. Service as necessary.


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REAR AXLE - 226RBA (Continued) Condition Loss Of Lubricant

Axle Overheating

Gear Teeth Broke

Axle Noise

Possible Causes

Correction

1. Lubricant level too high.

1. Drain lubricant to the correct level.

2. Worn axle shaft seals.

2. Replace seals.

3. Cracked differential housing.

3. Repair as necessary.

4. Worn pinion seal.

4. Replace seal.

5. Worn/scored yoke.

5. Replace yoke and seal.

6. Axle cover not properly sealed.

6. Remove, clean, and re-seal cover.

1. Lubricant level low.

1. Fill differential to correct level.

2. Improper grade of lubricant.

2. Fill differential with the correct fluid type and quantity.

3. Bearing pre-loads too high.

3. Re-adjust bearing pre-loads.

4. Insufficient ring gear backlash.

4. Re-adjust ring gear backlash.

1. Overloading.

1. Replace gears. Examine other gears and bearings for possible damage.

2. Erratic clutch operation.

2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation.

3. Ice-spotted pavement.

3. Replace gears and examine remaining parts for damage.

4. Improper adjustments.

4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct.

1. Insufficient lubricant.

1. Fill differential with the correct fluid type and quantity.

2. Improper ring gear and pinion adjustment.

2. Check ring gear and pinion contact pattern.

3. Unmatched ring gear and pinion.

3. Replace gears with a matched ring gear and pinion.

4. Worn teeth on ring gear and/or pinion.

4. Replace ring gear and pinion.

5. Loose pinion bearings.

5. Adjust pinion bearing pre-load.

6. Loose differential bearings.

6. Adjust differential bearing pre-load.

7. Mis-aligned or sprung ring gear.

7. Measure ring gear run-out. Replace components as necessary.

8. Loose differential bearing cap bolts.

8. Inspect differential components and replace as necessary. Ensure that the bearing caps are torqued tot he proper specification.

9. Housing not machined properly.

9. Replace housing.


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REAR AXLE - 226RBA (Continued)

REMOVAL

INSTALLATION

(1) Raise and support the vehicle. (2) Position a lifting device under the axle and secure axle. (3) Remove the wheels and tires. (4) Remove brake calipers and rotors. (5) Disconnect parking brake cables from brackets and lever. (6) Remove wheel speed sensors. (7) Remove brake hose at the axle junction block. Do not disconnect the brake hydraulic lines at the calipers. (8) Disconnect the vent hose from the axle shaft tube. (9) Mark propeller shaft and yokes for installation reference. (10) Remove propeller shaft. (11) Disconnect stabilizer bar links. (12) Remove upper suspension arm rear axle ball joint nut. (13) Separate rear axle ball joint from the upper suspension arm with Remover 8278 (Fig. 1).

CAUTION: The weight of the vehicle must be supported by the springs before suspension arms and track bar fasteners are tightened. If springs are not at their normal ride position, vehicle ride height and handling could be affected. (1) Raise axle with lift and align coil springs. (2) Install lower suspension arms in axle brackets. Install nuts and bolts, do not tighten bolts at this time. (3) Install upper suspension arm on rear axle ball joint. (4) Install rear axle ball joint nut and tighten to 122 N路m (90 ft.lbs.) (Fig. 2).

Fig. 2 REAR BALL JOINT NUT 1 - UPPER SUSPENSION ARM 2 - REAR AXLE BALL JOINT 3 - REAR AXLE

Fig. 1 REAR BALL JOINT 1 - REMOVER 2 - UPPER SUSPENSION ARM 3 - BALL JOINT STUD

(14) Disconnect shock absorbers from axle. (15) Disconnect track bar. (16) Disconnect lower suspension arms from the axle brackets. (17) Separate the axle from the vehicle.

(5) Install track bar and attachment bolts, do not tighten bolts at this time. (6) Install shock absorbers and tighten nuts to 60 N路m (44 ft. lbs.). (7) Install stabilizer bar links and tighten nuts to 36 N路m (27 ft. lbs.). (8) Install wheel speed sensors. (9) Connect parking brake cable to brackets and lever. (10) Install brake rotors and calipers. (11) Install the brake hose to the axle junction block. (12) Install axle vent hose. (13) Align propeller shaft and pinion yoke reference marks. Install U-joint straps and nuts tighten to 19 N路m (14 ft. lbs.). (14) Install the wheels and tires. (15) Add gear lubricant, if necessary. (16) Remove support and lower the vehicle.


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REAR AXLE - 226RBA (Continued) (17) Tighten lower suspension arm bolts to 177 N·m (130 ft. lbs.). (18) Tighten track bar bolts to 100 N·m (74 ft. lbs.).

placed between the rear pinion bearing and the pinion gear head (Fig. 4).

ADJUSTMENTS Ring and pinion gears are supplied as matched sets. Identifying numbers for the ring and pinion gear are etched into the face of each gear (Fig. 3). A plus (+) number, minus (–) number or zero (0) is etched into the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion etched with a (0). The standard depth provides the best gear tooth contact pattern.

Fig. 4 ADJUSTMENT SHIM LOCATIONS 1 2 3 4 5

Fig. 3 PINION GEAR ID NUMBERS 1 - PRODUCTION NUMBERS 2 - DRIVE PINION GEAR DEPTH VARIANCE 3 - GEAR MATCHING NUMBER

Compensation for pinion depth variance is achieved with a select shim/oil baffle. The shims are

-

PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM RING GEAR DIFFERENTIAL BEARING SHIM COLLAPSIBLE SPACER

If installing a new gear, note the depth variance number of the original and replacement pinion. Add or subtract this number from the original depth shim/oil slinger to compensate for the difference in the depth variances. The numbers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the required thickness of the depth shims. If the number is positive, subtract that value from the thickness of the depth shim.


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REAR AXLE - 226RBA (Continued) Pinion Gear Depth Variance Chart: Note where Old and New Pinion Marking columns intersect.

Intersecting figure represents plus or minus the amount needed.

PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance

Replacement Pinion Gear Depth Variance 24

23

22

21

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

0

20.001

+2

+0.006

+0.005

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

+1

+0.005

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

0

+0.004

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

20.004

21

+0.003

+0.002

+0.001

0

20.001

20.002

20.003

20.004

20.005

22

+0.002

+0.001

0

20.001

20.002

20.003

20.004

20.005

20.006

23

+0.001

0

20.001

20.002

20.003

20.004

20.005

20.006

20.007

24

0

20.001

20.002

20.003

20.004

20.005

20.006

20.007

20.008

PINION DEPTH MEASUREMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with Pinion Gauge Set 6775 and Dial Indicator C-3339 (Fig. 5).

(1) Assemble Pinion Height Block 6739, Pinion Block 8144 and rear pinion bearing onto Screw 6741. (2) Insert assembled height gauge components, rear bearing and screw into the housing through pinion bearing cups (Fig. 6). (3) Install front pinion bearing and Cone-nut 6740 hand tight.

Fig. 6 PINION HEIGHT BLOCK Fig. 5 PINION GEAR DEPTH GAUGE 1 2 3 4 5 6 7 8

- DIAL INDICATOR - ARBOR - PINION HEIGHT BLOCK - CONE - SCREW - PINION BLOCK - SCOOTER BLOCK - ARBOR DISC

1 - PINION BLOCK 2 - PINION HEIGHT BLOCK


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REAR AXLE - 226RBA (Continued) (4) Place Arbor Disc 6927A on Arbor D-115-3 in position in the housing side bearing cradles (Fig. 7). Install differential bearing caps in their original positions on arbor discs and tighten cap bolts to 85 N¡m (63 ft. lbs.). NOTE: Arbor Discs 6927A has different step diameters to fit other axles. Choose proper step for axle being serviced.

Fig. 8 PINION GEAR DEPTH MEASUREMENT 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR

Fig. 7 GAUGE TOOLS IN HOUSING 1 2 3 4

- ARBOR DISC - PINION BLOCK - ARBOR - PINION HEIGHT BLOCK

(5) Assemble Dial Indicator C-3339 into Scooter Block D-115-2 and secure set screw. (6) Place Scooter Block/Dial Indicator in position in axle housing so dial probe and scooter block are flush against the rearward surface of the pinion height block (Fig. 5). Hold scooter block in place and zero the dial indicator face to the pointer. (7) Slide the dial indicator probe across the gap between the pinion height block and the arbor bar with the scooter block against the pinion height block (Fig. 8). Continue moving the dial indicator probe to the crest of the arbor bar and record the highest reading. (8) Select a depth shim equal to the dial indicator reading plus the pinion depth variance number etched in the face of the pinion (Fig. 3). For example, if the depth variance is –2, add +0.002 in. to the dial indicator reading.

DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differential side bearing cones. The proper shim

thickness can be determined using slip-fit Dummy Bearings 6929-A in place of the differential side bearings and a Dial Indicator C-3339. Before measuring differential bearing preload and gear backlash, measure pinion gear depth and prepare pinion for installation. Pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After measuring shim thickness to take up differential side play, install pinion and measure gear backlash shim thickness. Overall shim thickness is the dial indicator reading and preload specification added together. The gear backlash measurement determines the shim thickness used on the ring gear side of the differential case. Subtract gear backlash shim thickness from overall shim thickness to determine shim thickness for pinion gear side of the differential (Fig. 9). Differential shim measurements are performed with the 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 differential case. (2) Install ring gear on differential case and tighten bolts to specification. (3) Install Dummy Bearings 6929-A on differential case. (4) Install differential case in the housing.


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REAR AXLE - 226RBA (Continued) (5) Record the thickness of Dummy Shims 8107, then insert the shims between the dummy bearings and the differential housing (Fig. 11).

Fig. 9 ADJUSTMENT SHIM LOCATIONS 1 2 3 4 5

-

PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM RING GEAR DIFFERENTIAL BEARING SHIM COLLAPSIBLE SPACER

CAUTION: On a Vari-lokT differential the oil feed tube must be pointed at the bottom of the housing (Fig. 10). If differential is installed with the oil feed tube pointed at the top, the anti-rotation tabs will be damaged.

Fig. 11 DUMMY SHIM LOCATION 1 2 3 4

-

DUMMY SHIMS HOUSING DIFFERENTIAL CASE DUMMY BEARINGS

(6) Install the bearing caps in their original positions and snug the bolts (Fig. 12).

Fig. 10 VARI-LOK 1 - ANTI-ROTATION TAB 2 - OIL FEED TUBE

Fig. 12 BEARING CAP BOLTS 1 - BEARING CAPS 2 - HOUSING 3 - DIFFERENTIAL CASE


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REAR AXLE - 226RBA (Continued) (7) With a dead-blow hammer, seat the differential dummy bearings to each side of the housing (Fig. 13) and (Fig. 14).

Fig. 13 SEAT DUMMY BEARING PINION GEAR SIDE 1 - HAMMER 2 - HOUSING 3 - DIFFERENTIAL CASE

Fig. 15 DIFFERENTIAL SIDE PLAY MEASUREMENT 1 2 3 4

-

DIFFERENTIAL CASE HOUSING PILOT STUD DIAL INDICATOR

Fig. 14 SEAT DUMMY BEARING RING GEAR SIDE 1 - HOUSING 2 - HAMMER 3 - DIFFERENTIAL CASE

(8) Thread Pilot Stud C-3288-B into rear cover bolt hole below ring gear (Fig. 15). (9) Attach the Dial Indicator C-3339 to pilot stud and position the indicator plunger on the flat surface between the ring gear bolts (Fig. 15). (10) Push and hold differential case to pinion gear side of the housing and zero dial indicator (Fig. 16).

Fig. 16 ZERO DIAL INDICATOR 1 2 3 4

-

HOLD DIFFERENTIAL CASE TO PINION GEAR SIDE PILOT STUD DIAL INDICATOR DIAL INDICATOR FACE


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REAR AXLE - 226RBA (Continued) (11) Push and hold differential case to ring gear side of the housing and record dial indicator reading (Fig. 17).

Fig. 18 ZERO DIAL INDICATOR

Fig. 17 RECORD DIAL INDICATOR READING 1 - DIAL INDICATOR 2 - HOLD DIFFERENTIAL CASE TO RING GEAR SIDE 3 - DIFFERENTIAL HOUSING

(12) Add 0.0254 mm (0.001 in.) to the zero end play total. This new total represents the thickness of shims to preload the new bearings when the differential is installed. (13) Rotate dial indicator out of the way on the pilot stud. (14) Remove differential case and dummy bearings from the housing. (15) Install the pinion gear in the housing. Install the pinion yoke and establish the correct pinion rotating torque. (16) Install differential case and Dummy Bearings 6929-A in the housing. (17) Install a single dummy shim in the ring gear side. Install bearing caps and tighten bolts snug. (18) Seat ring gear side dummy bearing. (19) Position the dial indicator plunger on a flat surface between the ring gear bolt heads. (Fig. 15). (20) Push and hold differential case toward pinion gear and zero dial indicator (Fig. 18). (21) Push and hold differential case to ring gear side of the housing and record dial indicator reading (Fig. 19). Add Dummy Shim thickness to this reading. This will be the total shim thickness to achieve zero backlash. (22) Subtract 0.152 mm (0.006 in.) from the dial indicator reading to compensate for backlash between ring and pinion gears. This total is the thickness shim required to achieve proper backlash. (23) Subtract backlash shim thickness from the total preload shim thickness. The remainder is the shim thickness required on the pinion side of the housing.

1 2 3 4 5

-

DIAL INDICATOR FACE HOLD DIFFERENTIAL CASE TO PINION GEAR SIDE PINION GEAR HOUSING DIFFERENTIAL CASE

Fig. 19 RECORD DIAL INDICATOR READING 1 2 3 4 5

-

READ DIAL INDICATOR HOLD DIFFERENTIAL CASE TO RING GEAR SIDE PINION GEAR DIFFERENTIAL HOUSING DIFFERENTIAL CASE

(24) Rotate dial indicator out of the way on pilot stud. (25) Remove differential case and dummy bearings from the housing. (26) Install side bearings and cups on differential case. (27) Install spreader W-129-B, utilizing some items from Adapter Set 6987, on the housing and spread axle opening enough to receive differential case. (28) Place the bearing preload shims in the housing against the axle tubes. (29) Install differential case into the housing.


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REAR AXLE - 226RBA (Continued) (30) Remove spreader from housing. (31) Rotate the differential case several times to seat the side bearings. (32) Position the indicator plunger against a ring gear tooth (Fig. 20). (33) Push and hold ring gear upward while not allowing the pinion gear to rotate. (34) Zero dial indicator face to pointer. (35) Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading should be between 0.076 mm (0.003 in.) and 0.15 mm (0.006 in.). If backlash is not within specifications transfer the necessary amount of shim thickness from one side of the housing to the other (Fig. 21). (36) Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective. After the proper backlash is achieved, perform Gear Contact Pattern procedure.

Fig. 21 BACKLASH SHIM ADJUSTMENT NOTE: If the PROFILE across the tooth is the same it is a 3 Axis cut gear. If the PROFILE across the tooth is tapered it is a 2 Axis cut gear.

Fig. 20 RING GEAR BACKLASH 1 - DIAL INDICATOR

GEAR CONTACT PATTERN The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the axle housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns. The TOP LAND of the gear tooth is the top surface of the tooth. The PROFILE of the gear tooth is the depth of the tooth. The TOE of the gear is the portion of the tooth surface at the end towards the center. The HEEL of the gear is the portion of the tooth at the outer-end. The ROOT of the gear tooth is the lowest portion of the tooth (Fig. 22).

Fig. 22 GEAR DESCRIPTION 1 2 3 4 5

-

TOP LAND PROFILE TOE HEEL ROOT

(1) Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth. (2) Wrap, twist and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion. This will provide a more distinct contact pattern.


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REAR AXLE - 226RBA (Continued) (3) With a boxed end wrench on a ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel. The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart (Fig. 23) and adjust pinion depth and gear backlash as necessary.

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 differential bearing preload. Torque to rotate the differential and pinion should be the torque to rotate the pinion plus 0.79-1.24 N·m (7-11 in. lbs.).

Fig. 23 PATTERN INTERPRETATION (GEAR CUT 3 AXIS)

SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION

SPECIFICATION

Axle Ratio

3.55, 3.73

Differential Bearing Preload

0.025 mm (0.001 in.)

Ring Gear Diameter

226 mm (8.9 in.)

Ring Gear Backlash

0.076.-0.15 mm (0.003-0.006 in.)

Pinion Bearing Preload - Original Bearings

1-2 N·m (10-20 in. lbs.)

Pinion Bearing Preload - New Bearings

2.8-4 N·m (25-35 in. lbs.)


REAR AXLE - 226RBA

WJ REAR AXLE - 226RBA (Continued) TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Differential Cover Bolts

41

30

-

Bearing Cap Bolts

85

63

-

Ring Gear Bolts

136

100

-

Pinion Nut Min / Max

298-380

220-280

-

Pinion Mate Shaft Screw

17.6

13

-

Axle Bearing Retainer Plate Nuts

61

45

-

SPECIAL TOOLS

FLANGE WRENCH C-3281 PULLER C-293-PA

ADAPTER 8353

INSTALLER C-3718

PLUG C-293-3

HANDLE C-4171

PULLER C-452

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REAR AXLE - 226RBA (Continued)

REMOVER C-4307

INSTALLER C-3972-A

INSTALLER C-4308

INSTALLER D-129

INSTALLER C-4340

REMOVER D-103

PILOT STUDS C-3288-B

SPREADER W-129-B

DIAL INDICATOR C-3339

INSTALLER 6448

TRAC-LOK TOOLS C-4487


REAR AXLE - 226RBA

WJ REAR AXLE - 226RBA (Continued)

PULLER 6790

PINION DEPTH SET 6955

SPANNER WRENCH 6958

FIXTURE 6963

REMOVER 7794-A DIFFERENTIAL TOOL SET 6956

SPLITTER 1130 PINION BLOCK 8144

DUMMY SHIMS 8107 INSTALLER 7913-A

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AXLE SHAFTS REMOVAL (1) Place transmission in neutral. (2) Raise and support vehicle. (3) Remove wheel and tire assembly. (4) Remove brake caliper and rotor. (5) Remove nuts holding axle retainer plate to axle tube from the rear of the axle flange. (6) Pull axle shaft from the axle with Slide Hammer 7420 and Puller 6790. Mount the adapter to the axle with lug nuts. NOTE: The axle bearing race is normally loose in the axle tube.

INSTALLATION (1) Install 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 nuts to 61 N·m (45 ft. lbs.). (4) Install the brake rotor and caliper. (5) Install wheel and tire. (6) Check and fill the differential with gear lubricant. (7) Lower vehicle.

AXLE BEARINGS/SEALS

Fig. 24 DRILL RETAINING RING 1 2 3 4

- DRILL BIT - AXLE - RETAINING PLATE - RETAINING RING

REMOVAL (1) Remove axle shaft from vehicle. NOTE: The axle bearing race is normally loose in the axle tube. (2) Drill a shallow hole into soft steel axle bearing retaining ring with a 3/8 in. drill bit (Fig. 24). Use a drill depth stop to avoid marking the axle. (3) With a cold chisel cut the retaining ring across drilled hole. (Fig. 25) (4) Slide retaining ring from axle shaft.

Fig. 25 RETAINING RING 1 2 3 4

- AXLE - COLD CHISEL - VISE - RETAINING RING


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2004 jeep grand cherokee service repair manual  
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