1995 JEEP CHEROKEE seat

(10) Inspect the roller bearing contact surface on
the axle shaft for signs of brinelling, spalling and pit-
ting.
(11) If any of these conditions exist, the axle shaft
and bearing or seal must be replaced.
INSTALLATION
(1) Lubricate the bearing bore and seal lip with
gear lubricant. Insert the axle shaft through the seal,
bearing, and engage it with the side gear splines.
Use care to prevent the shaft splines from dam-
aging the axle shaft seal lip.
(2) Insert the C-clip lock in the end of the axle
shaft. Push the axle shaft outward to seat the C-clip
lock in the side gear.
(3) Insert the mate shaft into the case and through
the thrust washers and pinion gears. Align the hole
in shaft with the hole in the differential case and in-
stall the lock screw with Loctiteton the threads.
Tighten the screw to 19 Nzm (14 ft. lbs.) torque.
(4) Install the cover and add fluid. Refer to the
Drain and Refill in this section.
AXLE SHAFT SEAL AND BEARING
REMOVAL
(1) Remove the axle shaft. Refer to the Removal
procedures in this Group.
(2) Remove the axle shaft seal from the end of the
axle shaft tube with a small pry bar.
(3) Remove the bearing if it appears damaged.
The seal and bearing can be removed at the same
time with the bearing removal tool.
(4) Remove the axle shaft bearing from the tube
(Fig. 8) with Bearing Removal Tool Set 6310 (T.Ar
960-02).
(5) Inspect the axle shaft tube bore for roughness
and burrs. Remove as necessary.
CAUTION: Inspect the housing bore for burrs. Re-
move them if they exist.
INSTALLATION
Do not install the original axle shaft seal. Al-
ways install a new seal.
(1) Wipe the bore in the axle shaft tube clean.
(2) Install axle shaft bearing with Installer 6436
and Handle C-4171. Ensure part number on the
bearing must go against the Installer.
(3) Install the new axle shaft seal (Fig. 9) with In-
staller 6437 and Handle C-4171.
(4) Install the Axle Shaft. Refer to the installation
procedure.
Fig. 6 Mate Shaft Lock Screw
Fig. 7 Axle Shaft C-Clip Lock
Fig. 8 Axle Shaft Bearing Removal Tool
JREAR SUSPENSION AND AXLES 3 - 17

DIFFERENTIAL REMOVAL
To service the differential the axle shafts must be
removed. Refer to the removal procedures in this
Group.
(1) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 10).
(2) Remove the differential bearing caps.
(3) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 11). Install the
holddown clamps and tighten the tool turnbuckle fin-
ger-tight.
(4) Install a pilot stud at the left side of the differ-
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
side of the housing (Fig. 11) and zero the indicator.
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over-separated, it could be distorted
or damaged.(5) Separate the housing enough to remove the
case from the housing. Measure the distance with the
dial indicator (Fig. 11).
(6) Remove the dial indicator.
(7) Pry the differential case loose from the housing.
To prevent damage, pivot on housing with the end of
the pry bar against spreader (Fig. 12).
(8) Remove the case from housing. Mark or tag
bearing cups and outboard shim/spacer (selected
thickness) indicating which side they were removed.
Remove spreader from housing.
DIFFERENTIAL DISASSEMBLY
(1) Remove the bearings from the differential case
with Press C-293-PA, Plug SP3289, Adapter C-293-18
(Fig. 13).
Fig. 9 Axle Shaft Seal Installation
Fig. 10 Bearing Cap Identification
Fig. 11 Spread Differential Housing
Fig. 12 Differential Removal
3 - 18 REAR SUSPENSION AND AXLESJ

(1) Assemble Pinion Gauge Set, Pinion Block and
pinion bearings. Install assembly into differential
pinion gear bore and hand tighten cone (Fig. 26).
(2) Place Arbor Disc 6732 on Arbor D-115-3 and po-
sition in the bearing cradles (Fig. 27). Install differ-
ential bearing caps on Arbor Discs and tighten caps
snug only.
Arbor Discs have different steps to fit other
axle sizes. Pick correct size step for axle being
serviced.
(3) Firmly place Scooter Block and Dial Indicator
on pinion height block tool and zero the dial indicator
pointer.
(4) Slide the Scooter Block across the arbor while
observing indicator (Fig. 28). Record the longest
travel distance, whether inward (-) or outward (+),
indicated by the pointer.
The plunger travel distance indicated, plus or
minus the variance etched in the gear is the re-
quired thickness for the depth shims.
(5) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary fortotal required shim pack thickness.Include oil
slinger or baffle thickness with the total shim
pack thickness.
(6) Remove the measurement tools from the differ-
ential housing.
PINION GEAR ASSEMBLY/INSTALLATION
In production depth select shims are placed be-
tween the inner pinion bearing cone and pinion gear.
For service the select shims are placed under the in-
ner bearing cup.
(1) Place the depth shims (and baffle if equipped)
in the pinion gear rear bearing bore. Install the bear-
ing cup with Installer D-146 and Driver Handle
C-4171 (Fig. 29). Ensure cup is correctly seated.
Fig. 26 Pinion Height Block
Fig. 27 Gauge Tools In Housing
Fig. 28 Pinion Gear Depth Measurement
Fig. 29 Pinion Rear Bearing Cup Installation
JREAR SUSPENSION AND AXLES 3 - 23

(6) Attach a dial indicator to the housing. Position
the indicator plunger so that it contacts the ring gear
mating surface (Fig. 38).
(7) Pry the differential case to one side and zero
the dial indicator pointer.
(8) Pry the differential case to the opposite side
and record indicator reading. Reading is additional
shim thickness needed for zero end play. For exam-
ple, if reading was 0.008 inch (0.20 mm), an addi-
tional 0.004-inch (0.10-mm) thick shim will be
needed at each side zero end play.
(9) Install zero end-play shims on each side of
case.
The differential bearings must be preloaded
to compensate for heat and load during opera-
tion.
(10) Add an additional 0.004-inch (0.1-mm) to each
outboard shim/spacer for bearing preload.
RING GEAR INSTALLATION
(1) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(2) Install new ring gear bolts and alternately
tighten to 95-122 Nzm (70-90 ft. lbs.) torque (Fig. 39).
DIFFERENTIAL INSTALLATION
(1) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 40). Install the
holddown clamps and tighten the tool turnbuckle fin-
ger-tight.
(2) Install a pilot stud at the left side of the differ-
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
side of the housing (Fig. 40) and zero the indicator.CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over-separated, it could be distorted
or damaged.
(3) Separate the housing enough to install the case
in the housing. Measure the distance with the dial
indicator (Fig. 40).
(4) Remove the dial indicator.
(5) Install differential and outboard shim/spacer
(selected thickness) in housing.
(6) Install case in the housing. Tap the differential
case to ensure the bearings are fully seated (Fig. 41).
Remove the spreader.
(7) Install the bearing caps at their original loca-
tions (Fig. 42). Tighten the bearing cap bolts to 77
Nzm (57 ft. lbs.) torque.
Fig. 38 Shim Measurement
Fig. 39 Ring Gear Bolt Installation
Fig. 40 Spread Differential Housing
3 - 26 REAR SUSPENSION AND AXLESJ

BACKLASH AND CONTACT PATTERN ANALYSIS
(1) Rotate assembly several revolutions to seat
bearings. Measure backlash at three equally spaced
locations around the perimeter of the ring gear with
a dial indicator (Fig. 43).
The ring gear backlash must be within 0.12 -
0.20 mm (0.005 - 0.008 inch). It cannot vary
more than 0.05 mm (0.002 inch) between the
points checked.
If backlash must be adjusted, spacers are available
in various thicknesses. Adjust the backlash accord-
ingly (Fig. 44).DO NOT INCREASE THE TOTAL
SHIM PACK THICKNESS, EXCESSIVE BEAR-
ING PRELOAD AND DAMAGE WILL OCCUR.
The ring gear teeth contact patterns will show if
the pinion gear depth shim(s) have the correct thick-ness. It will also show if the ring gear backlash has
been adjusted correctly. The backlash must be main-
tained within the specified limits until the correct
tooth contact patterns are obtained.
(2) Apply a thin coat of hydrated ferric oxide, or
equivalent, to the drive and coast side of the ring
gear teeth.
(3) Rotate the ring gear one complete revolution in
both directions while a load is being applied. Insert a
pry bar between the differential housing and the case
flange. This will produce distinct contact patterns on
both the drive side and coast side of the ring gear
teeth.
(4) Note patterns in compound. Refer to (Fig. 45)
for interpretation of contact patterns and adjust ac-
cordingly.
Fig. 41 Differential Installation
Fig. 42 Differential Bearing Cap Reference Letters
Fig. 43 Ring Gear Backlash Measurement
Fig. 44 Backlash Shim Adjustment
JREAR SUSPENSION AND AXLES 3 - 27

BEARING AND SEAL INSTALLATION
Do not install the original axle shaft seal. Al-
ways install a new seal.
(1) Wipe the bore in the axle shaft tube clean.
(2) If the original bearing is not reusable, install a
new bearing. Place the axle shaft bearing on the pilot
of Bearing Installer C-4198 and Handle C-4171.
CAUTION: DO NOT use the new axle shaft seal to
position or seat the bearing in the axle shaft bore.
(3) Insert the bearing into the tube. Ensure that
the bearing is not cocked and is seated firmly against
the tube shoulder.
(4) Install the new axle shaft seal (Fig. 6) with In-
staller C-4198 and Handle C-4171. The flat side of
the installation tool must face the seal.
(5) When the tool contacts the end of the tube
(face), the seal will be at the correct position and
depth.
AXLE SHAFT INSTALLATION
(1) Lubricate the bearing bore and seal lip. Insert
the axle shaft and engage the splines with the side
gear. Use care to prevent the shaft splines from dam-
aging the axle shaft seal lip.
(2) Insert the C-clip lock in the recessed groove(Fig. 4). Push the axle shaft outward to seat the C-
clip lock.
(3) Insert the pinion gear mate shaft in the case.
Install through the thrust washers and pinion gears.
Align the hole in the shaft with the lock screw hole.
Install the lock screw with Loctiteton the threads.
Tighten the screw to 11 Nzm (8 ft. lbs.) torque (Fig.
3).
(4) Clean the cover and apply a bead of sealant.
Refer to the Drain and Refill in this section.
(5) Install the brake drum and wheel and tire.
(6) Raise or lower the hoist until the vehicle is
level.
(7) Remove the fill hole plug. Fill the differential
housing with lubricant. Refer to the Specifications
chart for the type and the quantity. Install the fill
hole plug.
(8) Lower the vehicle and test the brakes and axle
for correct operation.
PINION SEAL REPLACEMENT
CAUTION: The following procedures must be used
so the correct pinion bearing preload torque is re-
tained. If this procedure is not followed completely,
it may result in premature failure of the rear axle.
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
(3) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft in an upright position to
prevent damage to the rear U-joint.
(4) Remove the rear wheels and brake drums to
prevent any drag. The drag can cause a possible false
bearing preload torque measurement.
(5) Use a Newton-meter or an inch-pound torque
wrench to measure the pinion bearing preload. Ro-
tate the pinion shaft several times with the torque
wrench. Note the indicated torque as the wrench is
moved through several revolutions.
This measurement is very important because
the bearing preload torque must be carefully
re-adjusted after the new seal is installed.
(6) Retain the yoke with Wrench C-3281. Remove
the pinion shaft nut and Belleville washer.
(7) Make reference marks and remove the yoke
with a puller.
(8) Lower the rear of the vehicle to prevent lubri-
cant leakage.
(9) Remove the pinion shaft seal with Puller
C-748. Clean the seal contact surface in the housing
bore.
Fig. 5 Axle Shaft Bearing Removal
Fig. 6 Axle Shaft Seal Installation
JREAR SUSPENSION AND AXLES 3 - 33

INSTALLATION
(1) Examine the splines on the pinion shaft for
burrs or wear.
(2) Remove any burrs and clean the shaft.
(3) Inspect the pinion yoke for cracks, worn splines
and a worn seal contact surface. Repair or replace
the yoke as necessary.
The outer perimeter of the seal is pre-coated
with a special sealant. An additional applica-
tion of sealant is not required.
(4) Install the replacement pinion shaft seal (Fig.
7) with Seal Installer C-4076-A and Handle C-4735-1.
The seal is correctly installed when the seal
flange contacts the face of the differential hous-
ing flange.
(5) Position the pinion yoke on the end of the shaft
with the reference marks aligned.
(6) Seat the yoke on the pinion shaft with Installer
C-3718 and Wrench C-3281.
(7) Remove the tools. Install the Belleville washer.
The convex side of the washer must face outward.
(8) Retain the pinion yoke with Wrench C-3281.
Tighten the shaft nut to 285 Nzm (210 ft. lbs.) torque
(Fig. 8). Rotate the pinion shaft several complete rev-
olutions to ensure that the bearing rollers are seated.
Use a Newton-meter or an inch-pound torque
wrench to measure the pinion gear bearing pre-
load torque.
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing preload torque and never ex-
ceed specified preload torque. If preload torque is
exceeded a new collapsible spacer must be in-
stalled. The torque sequence will have to be re-
peated.
(9) Continue tightening and measuring the bearing
preload torque until it is the same as the original.The bearing preload torque should never be
greater than 1 Nzm (10 in. lbs.) more than the
recorded value.
The bearing preload torque should be con-
stant during a complete revolution of the pin-
ion gear. If the preload torque varies, this
indicates a binding condition. This condition
must be corrected before the installation of the
drive shaft.
(10) If the specified torque is not obtained, tighten
the nut in small increments until the preload torque
is obtained.
(11) Seal replacement is unacceptable if final nut
torque is less than 285 Nzm (210 ft. lbs.) torque.
(12) Install the drive shaft with the installation
reference marks aligned. Tighten the U-joint yoke
clamp screws to 19 Nzm (14 ft. lbs. or 170 in. lbs.)
torque.
(13) Install the brake drums, wheels and tires.
(14) Adjust the hoist so that the vehicle is in a
level position. Check the differential housing lubri-
cant level. If necessary, add MOPARtHypoid Gear
Lubricant.
DIFFERENTIAL SERVICE
SERVICE INFORMATION
It is not necessary to remove the complete axle to
service the differential.
CAUTION: When differential service is necessary,
both rear wheels must be raised off the surface.
They must be free to rotate.
Fig. 7 Pinion Shaft Seal Installation
Fig. 8 Tightening Pinion Shaft Nut
3 - 34 REAR SUSPENSION AND AXLESJ

(6) If removed, heat ring gear with a heat lamp or
by immersing in a hot fluid. The temperature should
not exceed 149ÉC (300ÉF).Do not use a torch to
heat the ring gear.
(7) Position heated rear gear on case. Use two
equally spaced Pilot Studs C-3288-B to align the gear
with the flange holes (Fig. 18).
(8) Install replacement ring gear bolts (with left
hand threads). Alternately and evenly tighten each
bolt to 95 Nzm (70 ft. lbs.) torque.
CAUTION: When installing a differential bearing,
never apply force to the bearing cage because bear-
ing damage will result.
(9) Install a differential bearing on each hub with
Installer C-4340 and Handle C-4171 (Fig. 19).PINION DEPTH MEASUREMENT AND
ADJUSTMENT WITH GAUGE SET 6575
(1) Use pinion gear adjustment gauge set 6575
(Fig. 20) and continue the assembly:
(2) Install front (outer) bearing cup use Installer
D-130 and Handle C-4171.
(3) Install rear (inner) bearing cup use Installer
C-4308 and Handle C-4171.
Assemble tools as described;
²Position Spacer (SP-6030) over Shaft (SP-5385)
²Position pinion rear bearing on shaft
²Position tools (with bearing) in the housing
²Install Sleeve (SP-5382)
²Install pinion front bearing
²Install Spacer (SP-6022)
²Install Sleeve (SP-3194-B), Washer (SP-534) and
Nut (SP-3193)
(4) Prevent compression sleeve tool from turning
with Wrench C-3281.
Tighten the nut to seat the pinion bearings in the
housing (Fig. 21). Allow the sleeve to turn several
times during the tightening to prevent brinelling the
bearing cups or bearings.
Depth shim(s) are positioned between the pin-
ion gear rear bearing and pinion gear. The re-
quired thickness of the depth shim(s) is
determined according to the following informa-
tion.
(5) Loosen the compression nut tool. Lubricate the
pinion gear front and rear bearings with gear lubri-
cant. Re-tighten the compression nut tool to 1 to 3
Nzm (15 to 25 in. lbs.) torque. Rotate the pinion gear
several complete revolutions to align the bearing roll-
ers.
(6) Install Gauge Block SP-5383 at the end of SP-
5385. Install Cap Screw (SP-536) and tighten.
(7) Position Arbor (SP-6029) in the differential
housing (Fig. 22).
Fig. 18 Case-To-Ring Gear Alignment
Fig. 19 Differential Bearing Installation
Fig. 20 Axle Adjustment ToolsÐ8 1/4
3 - 38 REAR SUSPENSION AND AXLESJ