Jeep Cherokee (XJ): Rear axle. Pinion shaft seal. Collapsible spacer

Rear axle

REMOVAL

(1) Raise and support the vehicle.

(2) Position a suitable lifting device under the axle.

(3) Secure axle to device.

(4) Remove the wheels and tires.

(5) Remove the brake drums from the axle. Refer to Group 5, Brakes, for proper procedures.

(6) Disconnect parking brake cables from brackets and lever.

(7) Remove wheel speed sensors, if necessary.

Refer to Group 5, Brakes, for proper procedures.

(8) Disconnect the brake hose at the axle junction block. Do not disconnect the brake hydraulic lines at the wheel cylinders. Refer to Group 5, Brakes, for proper procedures.

(9) Disconnect the vent hose from the axle shaft tube.

(10) Mark the propeller shaft and yokes for installation alignment reference.

(11) Remove propeller shaft.

(12) Disconnect stabilizer bar links.

(13) Disconnect shock absorbers from axle.

(14) Remove the U-bolts which hold the axle to the spring brackets.

(15) Separate the axle from the vehicle.

INSTALLATION

NOTE: The weight of the vehicle must be supported by the springs before suspension arms and track bar fasteners can be tightened. If the springs are not at their normal ride position, vehicle ride height and handling could be affected.

(1) Raise the axle with lifting device and align the spring centering bolts with the mating holes in the axle spring perch.

(2) Install the U-bolts which hold the axle to the spring brackets. Tighten nuts to 70 N·m (52 ft. lbs.).

(3) Install shock absorbers and tighten nuts to 60 N·m (44 ft. lbs.) torque.

(4) Install stabilizer bar links and tighten nuts to 74 N·m (55 ft. lbs.) torque.

(5) Install the wheel speed sensors, if necessary.

Refer to Group 5, Brakes, for proper procedures.

(6) Connect parking brake cable to brackets and lever.

(7) Install the brake drums. Refer to Group 5, Brakes, for proper procedures.

(8) Connect the brake hose to the axle junction block. Refer to Group 5, Brakes, for proper procedures.

(9) Install axle vent hose.

(10) Align propeller shaft and pinion yoke reference marks. Install U-joint straps and bolts. Tighten to 19 N·m (14 ft. lbs.) torque.

(11) Install the wheels and tires.

(12) Add gear lubricant, if necessary. Refer to Lubricant Specifications in this section for lubricant requirements.

(13) Remove lifting device from axle and lower the vehicle.

Pinion shaft seal

REMOVAL

(1) Raise and support the vehicle.

(2) Remove wheel and tire assemblies.

(3) Remove the brake drums. Refer to Group 5, Brakes, for proper procedures.

(4) Mark the propeller shaft and pinion yoke for installation alignment reference.

(5) Remove the propeller shaft from the yoke.

(6) Rotate the pinion gear three or four times.

(7) Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.

(8) Using Holder 6958 to hold the pinion yoke, remove the pinion nut and washer.

(9) Use Remover C-452 and Wrench C-3281 to remove the pinion yoke (Fig. 7).

Fig. 7 Pinion Yoke Removal

1 - SPECIAL TOOL C-3281
2 - YOKE
3 - SPECIAL TOOL C-452

(10) Use a suitable pry tool or slide hammer mounted screw to remove the pinion gear seal.

INSTALLATION

(1) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972-A and Handle C-4171 (Fig. 8).

Fig. 8 Pinion Seal Installation

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3972-A

(2) Install yoke on the pinion gear with Screw 8112, Cup 8109, and Holder 6958 (Fig. 9).

CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke at this point.

Damage to the collapsible spacer or bearings may result.

(3) Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play.

(4) Tighten the nut to 271 N·m (200 ft. lbs.).

Fig. 9 Pinion Yoke Installation

1 - PINION YOKE
2 - AXLE HOUSING

CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated.

(5) Rotate the pinion shaft using a (in. lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 N·m (5 in. lbs.) (Fig. 10).

Fig. 10 Check Pinion Rotation Torque

1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH

(6) If the rotating torque is low, use Holder 6958 to hold the pinion yoke (Fig. 11), and tighten the pinion shaft nut in 6.8 N·m (5 ft. lbs.) increments until the proper rotating torque is achieved.

CAUTION: If the maximum tightening torque is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged.

Replace the collapsible spacer.

(7) Align the installation reference marks on the propeller shaft and yoke and install the propeller shaft.

(8) Add gear lubricant to the differential housing, if necessary. Refer to the Lubricant Specifications for gear lubricant requirements.

(9) Install the brake drums. Refer to Group 5, Brakes, for proper procedures.

(10) Install wheel and tire assemblies.

Fig. 11 Tightening Pinion Shaft Nut-Typical

1 - SPECIAL TOOL 6958
2 - 1 in. PIPE
3 - 3/4 DRIVE TORQUE WRENCH

(11) Lower the vehicle.

Collapsible spacer

REMOVAL W/PINION INSTALLED

(1) Raise and support the vehicle.

(2) Remove wheel and tire assemblies.

(3) Remove rear brake drums. Refer to Group 5, Brakes, for proper procedures.

(4) Mark the propeller shaft and pinion yoke for installation reference.

(5) Remove the propeller shaft from the yoke.

(6) Rotate the pinion gear three or four times.

(7) Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.

(8) Using Holder 6958 to hold the pinion yoke, remove the pinion nut and washer.

(9) Use Remover C-452 and Wrench C-3281 to remove the pinion yoke (Fig. 12).

(10) Use a suitable pry tool or a slide hammer mounted screw to remove the pinion shaft seal.

(11) Remove the front pinion bearing using a pair of suitable pick tools to pull the bearing straight off the pinion gear shaft. It may be necessary to lightly tap the end of the pinion gear with a rawhide or rubber mallet if the bearing becomes bound on the pinion shaft.

(12) Remove the collapsible spacer.

REMOVAL W/PINION REMOVED

(1) Raise and support the vehicle.

(2) Remove wheel and tire assemblies.

(3) Remove rear brake drums. Refer to Group 5, Brakes, for proper procedures.

(4) Mark the propeller shaft and pinion yoke for installation reference.

Fig. 12 Pinion Yoke Removal

1 - SPECIAL TOOL C-3281
2 - YOKE
3 - SPECIAL TOOL C-452

(5) Remove the propeller shaft from the yoke.

(6) Rotate the pinion gear three or four times.

(7) Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.

(8) Remove differential assembly from axle housing.

(9) Using Holder 6958 to hold yoke, remove the pinion yoke nut and washer.

(10) Using Remover C-452 and Wrench C-3281, remove the pinion yoke from pinion shaft (Fig. 12).

(11) Remove the pinion gear from housing (Fig.

13). Catch the pinion with your hand to prevent it from falling and being damaged.

(12) Remove collapsible spacer from pinion shaft.

INSTALLATION

(1) Install a new collapsible preload spacer on pinion shaft (Fig. 14).

(2) If pinion gear was removed, install pinion gear in housing.

(3) Install pinion front bearing, if necessary.

(4) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972-A and Handle C-4171 (Fig. 15).

(5) Install yoke with Screw 8112, Cup 8109, and Holder 6958 (Fig. 16).

(6) If the original pinion bearings are being used, install differential assembly and axle shafts, if necessary.

Fig. 13 Remove Pinion Gear

1 - RAWHIDE HAMMER

Fig. 14 Collapsible Preload Spacer

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING

Fig. 15 Pinion Seal Installation

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3972-A

NOTE: If new pinion bearings were installed, do not install the differential assembly and axle shafts until after the pinion bearing preload and rotating torque are set.

Fig. 16 Pinion Yoke Installation

1 - PINION YOKE
2 - AXLE HOUSING

7) Install the yoke washer and a new nut on the pinion gear. Tighten the pinion nut until there is zero bearing end-play.

(8) Tighten the nut to 271 N·m (200 ft. lbs.).

CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated.

(9) Using yoke holder 6958 and a torque wrench set at 474 N·m (350 ft. lbs.), crush collapsible spacer until bearing end play is taken up (Fig. 17).

NOTE: If more than 474 N·m (350 ft. lbs.) of torque is necessary to remove the bearing end play, the collapsible spacer is defective and must be replaced.

(10) 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. 18).

Fig. 17 Tightening Pinion Nut-Typical

1 - SPECIAL TOOL 6958
2 - 1 in. PIPE
3 - 3/4 DRIVE TORQUE WRENCH

(11) Check rotating torque with a (in. lbs.) torque wrench (Fig. 18). The torque necessary to rotate the pinion gear should be:

•  Original Bearings - The reading recorded during removal, plus an additional 0.56 N·m (5 in. lbs.).
•  New Bearings - 1.5 to 4 N·m (15 to 35 in. lbs.).

(12) Install differential assembly and axle shafts, if necessary.

(13) Align marks made previously on yoke and propeller shaft and install propeller shaft.

(14) Install rear brake drums. Refer to Group 5, Brakes, for proper procedures.

(15) Add gear lubricant, if necessary. Refer to Lubricant Specifications of this section for lubricant requirements.

(16) Install wheel and tire assemblies.

(17) Lower vehicle.