1988 JEEP CHEROKEE Service Repair Manual

Fig. 6: Installing New Front Axle Shaft Seal
AXLE SHAFT OVERHAUL
NOTE: All front axle shafts except (Select-Trac) use Cardan "U"
joints and should be overhauled in same manner as drive
shaft "U" joints.
DISASSEMBLY (SELECT-TRAC)
1) Cut and remove both outer boot clamps. Slide boot off
outer CV joint.
2) Using a block of wood seated on inner race, tap joint from
shaft. If shaft is clamped in a vise, be sure to use protective vise
jaws.
3) Tap outer CV cage with a brass punch until cage is tilted

out far enough to remove first ball bearing. Remove remaining ball
bearings in same manner.
4) Rotate outer CV joint cage outward until it is at a 90
degree angle to installed position. Align 2 oblong holes in outer
joint cage with slots in interior wall of spindle housing and remove
cage and inner race.
5) Remove inner race from cage by aligning shoulder between
race grooves with inside of oblong cage holes. Rotate inner race out
of cage using larger of 2 openings in cage. Remove retaining ring,
spacer ring and outer boot.
Fig. 7: Exploded View of Jeep (Select-Trac) Drive Axle
Courtesy of Chrysler Motors.
CLEANING & INSPECTION
1) Wash all parts in solvent and dry. Inspect inner and outer
ball races for damage. Inspect splined stub shaft for wear, cracks and
twisted splines.
2) Inspect all 6 balls for pitting, cracking or scoring.
Dulling of surface is normal. If any damage is found, replace entire
CV joint assembly. Polished areas in races and on cage spheres are
normal and DO NOT require joint replacement.
REASSEMBLY
1) Apply a light coat of CV grease on ball grooves of inner
and outer races. Install inner race into cage using a rotating action
opposite of removal. Inner race snap ring should face axle side.
2) Be sure ball bearing retaining ring is installed on inner
race side facing small end of cage. Align windows of cage with outer
race lands, and pivot cage with inner race into tilted position
(opposite of removal).
3) Install ball bearings one at a time into outer CV joint as
cage is tilted and rotated. After balls are installed into cage, pivot
cage and inner race into installed position.
4) Slide new seal clamp for small end of boot seal, boot seal
and seal retainer onto axle shaft. Coat inside lip (large diameter end
of seal) with CV grease. Slide seal retainer on end of seal.
5) Spread ears of bearing race snap ring, and slide CV joint
onto axle shaft until snap ring seats in groove. Pack joint with
approximately 1/2 of grease provided in seal kit. Apply remaining
grease inside seal.
6) Slide seal toward joint until small end of seal is in
groove in axle shaft. Position small clamp over small end of seal and
into groove and tighten.

Fig. 8: Exploded View Of Dana Full-Floating Axle Assembly
AXLE ASSEMBLY OVERHAUL
DISASSEMBLY
1) Drain lubricant. Remove axle shafts and housing cover. If
no side play is found in the differential case assembly, mount dial
indicator on pilot stud with tip against back of ring gear. Measure
runout of ring gear, marking ring gear and case at point of maximum
runout.
2) If runout total exceeds .006" (.15 mm), ring gear could b\
e
loose or case could be damaged. Using .003" (.08 mm) feeler gauge, try\
to force feeler gauge between cap and race. If it does, bearing race
may have been turning in carrier.
3) If race has been turning, carrier could be damaged.
Observe identifying letters stamped into bearing caps and face of
carrier sealing surface. Use these matched letters for reassembly
reference.
4) Remove side bearing caps. Use Housing Spreader (W-129-A on\

Model 44; D-167 on Models 60, 61, 70 and 80) to spread differential
housing to .015" (.38 mm). See Fig. 9.
CAUTION: DO NOT spread housing more than .020" (.51 mm). Permanent
damage to housing could result.
Fig. 9: Correct Procedure for Spreading Housing
5) Pry differential case out of housing. Remove spreader to
prevent carrier taking set. On models with side bearing shims between
carrier and side bearing outer race, record sizes and positions of
shims. Be careful not to damage machined surfaces of housing.
6) Put case in soft-jawed vise and remove ring gear bolts and

discard. Tap ring gear loose with soft mallet. If ring gear runout
measured earlier exceeded .006" (.15 mm), repeat runout measurement of\
case without ring gear. Total runout of case should not exceed .003"
(.08 mm).
7) Using Flange Holder Wrench (C-3281), remove drive pinion
nut and washer. Using holder wrench and Flange Puller (C-452), remove
drive pinion flange. Using Pinion Seal Puller (C0748), remove pinion
oil seal. Remove slinger, gasket, outer pinion bearing and preload
shim pack.
8) Remove drive pinion with inner bearing. Remove inner and
outer pinion bearing races. Remove and note thickness of shim pack
behind inner bearing race. Remove inner pinion bearing from pinion
shaft using Puller Press (DD-914-P) with Adapter Ring (DD-914-9) and\
Pinion Bearing Puller Plates (C-293-39 on Model 44; DD-914-37 on Model
60 and 61; DD-914-95 on Models 70 and 80).
NOTE: Pinion bearing adjusting shims may remain on pinion shaft,
stick to bearing or fall loose. Collect and save them for
reassembly.
9) Remove side bearings with Bearing Puller (C-293-PA),
Extension Plug (C-293-3 on Model 44; DD-914-7 on Models 60, 61, 70 and
80) and Puller Plates (C-293-18 on Model 44; DD-914-62 on Models 60,
61, 70 and 80). Record shim thickness and location for reassembly
reference.
10) If differential case is a one-piece unit, drive out lock
pin holding differential pinion shaft to case. Remove differential
pinion shaft, gears and thrust washers (one for each gear).
11) If differential case is a 2-piece unit, mark both
differential case halves to aid reassembly in correct position. Remove
bolts holding case halves together. Tap on top half of case to break
it loose from lower half. Remove top half of case. Remove pinion gear
spider, pinion gears, side gears and all thrust washers.
INSPECTION
1) Use cleaning solvent to rinse gears and bearings. Check
large end of bearing rollers where wear, if any, is evident. Check
pinion and flange splines for excessive wear. Ensure ring gear teeth
are in good condition.
2) Check differential case for cracks, scoring of side gears,
thrust washers and pinion thrust faces. Check fit of side gears to
case and to axle shaft splines. Look at pinion shaft and spacer for
scoring or excessive wear.
REASSEMBLY & ADJUSTMENTS
1) When reassembling and adjusting ring and pinion assembly,
pinion depth, pinion bearing preload, side bearing preload and
backlash between ring and pinion must be adjusted.
2) If only pinion shaft and ring gear are to be replaced and
carrier housing can be reused, compare pinion depth adjustment numbers
etched in faces of old and new pinion heads. See Fig. 10. Using
PINION DEPTH SHIM ADJUSTMENT SPECS table, correct shims can be
selected for new pinion shaft depth adjustment.

Fig. 10: Location of Pinion Gear Markings W/ Depth Adjustment Figures
NOTE: In order to use PINION DEPTH SHIM ADJUSTMENT SPECS table,
old pinion shaft shim pack dimensions MUST be determined
accurately. If original pinion shaft shim pack dimension
cannot be determined accurately, Pinion Depth Gauge Set
(D-271) must be used to properly determine pinion depth
setting. Depth gauge set must also be used if new carrier
housing is to be used.
PINION DEPTH SHIM ADJUSTMENT SPECS
PINION DEPTH SHIM ADJUSTMENT CHART (INCHES)








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Old  New Pinion Marking
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Marking -4  -3  -2  -1  0  +1  +2  +3  +4








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+4 +0.008+0.007+0.006+0.005+0.004+0.003+0.002+0.001 0








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+3 +0.007+0.006+0.005+0.004+0.003+0.002+0.001 0 -0.001








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+2 +0.006+0.005+0.004+0.003+0.002+0.001 0 -0.001-0.002








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+1 +0.005+0.004+0.003+0.002+0.001 0 -0.001-0.002-0.003








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0 +0.004+0.003+0.002+0.001 0 -0.001-0.002-0.003-0.004








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-1 +0.003+0.002+0.001 0 -0.001-0.002-0.003-0.004-0.005








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-2 +0.002+0.001 0 -0.001-0.002-0.003-0.004-0.005-0.006








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-3 +0.001 0 -0.001-0.002-0.003-0.004-0.005-0.006-0.007








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-4  0 -0.001-0.002-0.003-0.004-0.005-0.006-0.007-0.008








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PINION DEPTH SHIM ADJUSTMENT CHART (MILLIMETERS)



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Marking -10  -8  -5  -3  0  +3  +5  +8  +10








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+10 +0.20 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.03  0








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+8 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.03  0 -0.03








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+5 +0.15 +0.13 +0.10 +0.08 +0.05 +0.03  0 -0.03 -0.05








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+3 +0.13 +0.10 +0.08 +0.05 +0.03  0 -0.03 -0.05 -0.08








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0 +0.10 +0.08 +0.05 +0.03  0 -0.03 -0.05 -0.08 -0.10








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-3 +0.08 +0.05 +0.03  0 -0.03 -0.05 -0.08 -0.10 -0.13








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-5 +0.05 +0.03  0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15








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-8 +0.03  0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18








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-10  0 -0.03 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 -0.20








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3) The pinion depth adjustment number is determined by
manufacturer at time of assembly. Number represents distance best
running position of pinion shaft deviates from "nominal" or standard
distance between pinion gear face and center line of axle. See
Fig. 11 .
Fig. 11: Pinion Setting Standard Dimension
NOTE: Dimensions for Models 44, 61 and 80 not available.
NOTE: These are "nominal" distances from center of ring gear to

face of pinion shaft. Deviations are noted on pinion face.
4) Pinion Depth Gauge Set (D-271) allows shim pack
adjustments to be made without having to remove and replace
differential bearings. See Fig. 12.
Fig. 12: Pinion Depth Gauge Set (D-271)
NOTE: This set can be used on Models 44, 60, 61, 70 and 80.
5) Place differential case in holding fixture or vise.