1995 JEEP YJ Service And Repair Manual

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Page 81 of 2158

JEEP YJ 1995 Service And Repair Manual DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS
JFRONT SUSPENSION AND AXLE 2 - 29

Page 82 of 2158

JEEP YJ 1995 Service And Repair Manual DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONTD)
2 - 30 FRONT SUSPENSION AND AXLEJ

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JEEP YJ 1995 Service And Repair Manual SHIFT MOTORÐREMOVAL/DISASSEMBLY
(1) Disconnect the vacuum and wiring connector
from the shift housing.
(2) Remove indicator switch.
(3) Remove the shift motor housing cover, gasket
and shield from th

SHIFT MOTORÐREMOVAL/DISASSEMBLY
(1) Disconnect the vacuum and wiring connector
from the shift housing.
(2) Remove indicator switch.
(3) Remove the shift motor housing cover, gasket
and shield from the housing (Fig. 11).
(4) Remove the E-clips from the shift motor hous-
ing and shaft. Remove shift motor and shift fork from
the housing (Fig. 12).
(5) Remove the O-ring seal from the shift motor
shaft.
(6) Clean and inspect all components. If any com-
ponent is excessively worn or damaged, it should be
replaced.
ASSEMBLY/INSTALLATION
(1) Install a new O-ring seal on the shift motor
shaft.
(2) Insert the shift motor shaft through the hole in
the housing and shift fork. The shift fork offset
should be toward the differential.(3) Install the E-clips on the shift motor shaft and
housing.
(4) Install the shift motor housing gasket and
cover.Ensure the shift fork is correctly guided
into the shift collar groove.
(5) Install the shift motor housing shield and at-
taching bolts. Tighten the bolts to 11 Nzm (101 in.
lbs.) torque.
(6) Add 148 ml (5 ounces) of API grade GL 5 hy-
poid gear lubricant to the shift motor housing. Add
lubricant through indicator switch mounting hole.
(7) Install indicator switch, electrical connector
and vacuum harness.
INTERMEDIATE AXLE SHAFTÐREMOVAL/
DISASSEMBLY
Service to the Disconnect axle seals and bearing re-
quire the use of Tool Set 6288 (J34659) and Seal In-
staller 6228.
(1) Remove the vacuum motor housing. Refer to
Shift Motor Removal in this section.
(3) Remove the outer axle shaft. Refer to Hub
Bearing and Axle Shaft in this section.
(4) Remove shift collar and intermediate axle
shaft.
(5) Remove the inner axle shaft seal from the shift
motor housing (Fig. 13).
(6) Remove the intermediate axle shaft bearing
(Fig. 14).
ASSEMBLY/INSTALLATION
(1) Position the bearing on installation tool. Seat
the bearing in the housing bore (Fig. 15).
(2) Clean the inside perimeter of the axle shaft
tube with fine crocus cloth.
(3) Apply a light film of oil to the inside lip of the
new axle shaft seal.
(4) Install the inner axle seal (Fig. 16, 17).
The axle shaft seal primary installation tool
6228-1 will only force the seal partially into the
Fig. 11 Shift Motor Housing and Shift Collar
Fig. 12 Vacuum Shift Motor ComponentsFig. 13 Axle Shaft Inner Seal Removal
JFRONT SUSPENSION AND AXLE 2 - 31

Page 84 of 2158

JEEP YJ 1995 Service And Repair Manual axle shaft tube bore. The axle shaft seal second-
ary installation tool 6228-3 must be used to
completely seat the seal in the axle shaft tube
bore. After seal installation, inspect that the
seal is N

Page 85 of 2158

JEEP YJ 1995 Service And Repair Manual The lower ball stud has two different designs. For
this reason installer 6752 will also be needed. Check
installers for proper fit.
KNUCKLE REMOVAL
(1) Remove hub bearing and axle shaft refer to the
R

Page 86 of 2158

JEEP YJ 1995 Service And Repair Manual (4) Install the Hub Bearing and Axle Shaft accord-
ing to the installation procedure.
(5) Reconnect the tie-rod or drag link end onto the
steering knuckle arm. Install the ABS sensor wire
and bracket

Page 87 of 2158

JEEP YJ 1995 Service And Repair Manual (8) Remove the case from housing. Mark or tag
bearing cups indicating which side they were re-
moved. Remove spreader from housing.
INNER AXLE SHAFT OIL SEAL REPLACEMENT
SELECT-TRAC
(1) Remove the inn

Page 88 of 2158

JEEP YJ 1995 Service And Repair Manual Place adapter rings so they do not damage
the bearing cage.
(2) Remove bearing shims from case hubs and
mark them (with hub identity) for assembly refer-
ence. Record the thickness of the shims.
(3) C

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