1995 JEEP CHEROKEE torque

(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

FINAL ASSEMBLY
(1) Install the axle shafts. Refer to Axle Shaft In-
stallation within this group.
(2) Scrape the residual sealant from the housing
and cover mating surfaces. Clean the mating surfaces
with mineral spirits. Apply a bead of MOPARtSili-
cone Rubber Sealant on the housing cover (Fig. 46).
Allow the sealant to cure for a few minutes.
Install the housing cover within 5 minutes af-
ter applying the sealant. If not installed the
sealant must be removed and another bead ap-
plied.
(3) Install the cover on the differential with the at-
taching bolts. Install the identification tag. Tighten
the cover bolts to 41 Nzm (30 ft. lbs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(4) Refill the differential housing with the specified
quantity of MOPARtHypoid Gear Lubricant.
(5) Install the fill hole plug and tighten to 34 Nzm
(25 ft. lbs.) torque. Axles equipped with rubber fill
plug install plug into cover.
Fig. 46 Typical Housing Cover With Sealant
JREAR SUSPENSION AND AXLES 3 - 29

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

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

(8) Center the tool. Place a piece of 0.002 inch
shim stock at each end of the arbor tool. Install the
bearing caps on the arbor tool. Tighten the cap bolts
to 14 Nzm (10 ft. lbs.) torque.
(9) Trial fit depth shim(s) between the arbor tool
and gauge block tool (Fig. 22).The depth shim(s)
fit must be snug but not tight (drag friction of a
feeler gauge blade).
Depth shims are available in 0.001-inch incre-
ments from 0.020 inch to 0.038 inch.
(10) Note the etched number on the face of the pin-
ion gear. 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 shim(s). If the number is + (positive),subtract that value from the thickness of the depth
shim(s). If the number is 0, no change is necessary.
(11) Remove tools from differential housing.
(12) Position depth shim(s) on the pinion gear. In-
stall rear bearing with Installer C-4040 (Fig. 23). Be
sure the contact surfaces are clean and without for-
eign particles.
(13) Lubricate pinion gear front and rear bearings
with gear lubricant.
(14) Install pinion gear into the housing. Install
new collapsible spacer at the end of the pinion gear.
Install pinion gear front bearing.
(15) Install pinion yoke with Remover/Installer
C-3718 and Wrench C-3281 (Fig. 24).
Fig. 22 Depth Shim(s) Selection
PINION GEAR DEPTH VARIANCE
Fig. 21 Seating Pinion Bearings
JREAR SUSPENSION AND AXLES 3 - 39

It is necessary to use the tools (above) to cor-
rectly seat the front bearing on the drive pin-
ion gear shaft (Fig. 24).
CAUTION: Use care to prevent collapsing preload
collapsible spacer during installation of the yoke
and seating the front bearing.
(16) Remove yoke and tools from the pinion gear.
(17) Install the pinion seal with Seal Installer
C-4076-A and Handle C-4735-1 (Fig. 25).
The outer perimeter of the seal is pre-coated
with a special sealant. An additional applica-
tion of sealant is not required.
(18) Install pinion yoke with Remover/Installer
C-3718 and Wrench C-3281.(19) Remove the tools. Install the Belleville
washer. The convex side of the washer must face out-
ward. Install the pinion nut.
(20) Retain pinion yoke with Wrench C-3281. Ini-
tially tighten the pinion gear shaft nut enough to re-
move the bearing end play. While tightening, rotate
the pinion shaft to ensure the bearing rollers are cor-
rectly seated.
(21) Tighten the pinion nut (Fig. 26) to 285 Nzm
(210 ft. lbs.) torque (minimum).
(22) Remove the tools from the shaft. Rotate the
pinion several revolutions to seat the bearing rollers.
Fig. 23 Shaft Rear Bearing Installation
Fig. 24 Pinion Yoke Installation
Fig. 25 Pinion Gear Seal Installation
Fig. 26 Tightening Pinion Gear Nut
3 - 40 REAR SUSPENSION AND AXLESJ