1995 JEEP YJ frame

(6) Install the shock absorber and tighten the bolt
to 23 Nzm (17 ft. lbs.) torque.
(7) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 95 Nzm (70 ft. lbs.)
torque.
(8) Install the drag link and tie rod to the steering
knuckles and tighten the nuts to 47 Nzm (35 ft. lbs.)
torque. Install the steering damper to the axle
bracket and tighten the nut to 75 Nzm (55 ft. lbs.)
torque.
(9) Install the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(10) On 4WD vehicles, connect the vent hose to the
tube fitting.
(11) On 4WD vehicles, 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.
(12) Check differential lubricant and add if neces-
sary.
(13) Install the wheel and tire assemblies.
(14) Remove the supports and lower the vehicle.
(15) Tighten the upper suspension arm nuts to 75
Nzm (55 ft. lbs.) torque. Tighten the lower suspension
arm nuts to 115 Nzm (85 ft. lbs.) torque.
(16) Tighten the track bar bolt at the axle bracket
to 100 Nzm (74 ft. lbs.) torque.
(17) Check the front wheel alignment.
DRIVE AXLE ASSEMBLY REPLACEMENTÐYJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails behind the spring frame brack-
ets.
(2) Remove the front wheels.
(3) Remove the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(4) Disconnect the axle vent hose and axle shift
motor vacuum harness.
(5) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(6) Disconnect the stabilizer bar link at the axle
bracket.
(7) Disconnect the shock absorbers from axle
bracket.
(8) Disconnect the track bar from the axle bracket.
(9) Disconnect the tie rod from the steering
knuckle. Disconnect the steering damper from the
axle bracket.
(10) Support the axle with a hydraulic jack under
the differential. Raise the axle just enough to relieve
the axle weight from the springs.
(11) Remove the spring U-bolts from the plate
brackets.(12) Loosen BUT DO NOT REMOVE the bolts that
attach the spring rear pivot at the frame rail brack-
ets. This will allow the springs to pivot without bind-
ing on the bushings.
(13) Disconnect shackle from the springs and lower
the springs to the surface.
(14) 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 springs and install the spring shackle
bolts.Do not tighten at this time.
(3) Lower the axle and align the spring center
bolts with the locating holes in the axle pads and
plate brackets.
(4) Install the spring U-bolts through the plate
brackets and tighten to 122 Nzm (90 ft. lbs.) torque.
(5) Connect the track bar to the axle bracket and
install the bolt.Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con-
nected. If springs are not at their usual posi-
tion, the vehicle ride comfort could be affected.
(6) Install the shock absorber and tighten the nut
to 61 Nzm (45 ft. lbs.) torque.
(7) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 61 Nzm (45 ft. lbs.)
torque.
(8) Install the tie rod to the steering knuckles and
tighten the nuts to 47 Nzm (35 ft. lbs.) torque. Install
the steering damper to the axle bracket and tighten
the bolt to 75 Nzm (55 ft. lbs.) torque.
(9) Install the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(10) Connect the vent hose to the tube fitting and
axle shift motor vacuum harness.
(11) 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.
(12) Check differential lubricant and add if neces-
sary.
(13) Install the wheel and tire assemblies.
(15) Remove the supports and lower the vehicle.
(16) Tighten the spring rear pivot bolt/nut to 142
Nzm (105 ft. lbs.) torque. Tighten the spring shackle
bolt/nut to 135 Nzm (100 ft. lbs.) torque.
2 - 24 FRONT SUSPENSION AND AXLEJ

AXLE SPECIFICATIONS
MODEL 30 FRONT AXLE
Axle Type........................................................Hypoid
Lubricant................SAE Thermally Stable 80W-90
Lube Capacity
YJ .....................................................1.65 L (3.76 pts.)
XJ .....................................................1.48 L (3.13 pts.)
Axle Ratio...................................3.07 3.55 3.73 4.10
DifferentialSide Gear Clearance .0.12-0.20mm (0.005-0.008 in.)
Ring Gear
Diameter .....................................18.09 cm (7.125 in.)
Backlash.........................0-0.15 mm (0.005-0.008 in.)
Pinion Std. Depth...................92.1 mm (3.625 in.)
Pinion Bearing Preload
Original Bearing ..................1-2 Nzm (10-20 in. lbs.)
New Bearing ......................1.5-4 Nzm (15-35 in. lbs.)
TORQUE SPECIFICATIONS
XJ FRONT SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Nut ......................................11 Nzm (8 ft. lbs.)
Lower Nut ....................................23 Nzm (17 ft. lbs.)
Suspension Arm Upper
Front Nut .....................................74 Nzm (55 ft. lbs.)
Rear Nut ......................................89 Nzm (66 ft. lbs.)
Suspension Arm Lower
Front and Rear Nut ..................115 Nzm (85 ft. lbs.)
Stabilizer Bar
Clamp Bolt ...................................54 Nzm (40 ft. lbs.)
Link Upper Nut ..........................36 Nzm (27 ft. lbs.)
Link Lower Nut ..........................95 Nzm (70 ft. lbs.)
Track Bar
Ball Stud Nut ..............................81 Nzm (60 ft. lbs.)
Axle Bracket Bolt ......................100 Nzm (74 ft. lbs.)
Track Bar Bracket
Bolts............................................125 Nzm (92 ft. lbs.)
Nut ..............................................100 Nzm (74 ft. lbs.)
Support Bolts ...............................42 Nzm (31 ft. lbs.)
YJ FRONT SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Nut ......................................13 Nzm (9 ft. lbs.)Lower Nut ....................................61 Nzm (45 ft. lbs.)
Stabilizer Bar
Clamp Bolt ...................................41 Nzm (30 ft. lbs.)
Link Nut ......................................61 Nzm (45 ft. lbs.)
Track Bar
Frame Bracket Nut.................142 Nzm (105 ft. lbs.)
Axle Bracket Nut ......................100 Nzm (74 ft. lbs.)
Spring
U-Bolt Nut .................................122 Nzm (90 ft. lbs.)
Front Shackle Bolt ..................135 Nzm (100 ft. lbs.)
Rear Pivot Bolt........................142 Nzm (105 ft. lbs.)
MODEL 30 AXLE
DESCRIPTION ................................................TORQUE
Fill Hole Plug...........................34 Nzm (25 ft. lbs.)
Diff. Cover Bolt........................41 Nzm (30 ft. lbs.)
Bearing Cap Bolt.....................61 Nzm (45 ft. lbs.)
Ring Gear Bolt.............95-122 Nzm (70-90 ft. lbs.)
Shift Motor Bolt.........................11 Nzm (8 ft. lbs.)
Axle Nut.................................237 Nzm (175 ft. lbs.)
Wheel Brg. Bolt......................102 Nzm (75 ft. lbs.)
Lower Ball Stud.....................108 Nzm (80 ft. lbs.)
Upper Ball Stud.....................101 Nzm (75 ft. lbs.)
ABS Sensor Bolt......................11 Nzm (96 in. lbs.)
JFRONT SUSPENSION AND AXLE 2 - 49

REAR SUSPENSION AND AXLES
CONTENTS
page page
8 1/4 AXLE............................ 30
AXLE NOISE/VIBRATION DIAGNOSIS......... 9
AXLE SPECIFICATIONS................... 51
GENERAL INFORMATION.................. 1
MODEL 35 AXLE........................ 13TORQUE SPECIFICATIONS................ 51
TRAC-LOK DIFFERENTIAL................. 45
XJ SUSPENSION......................... 3
YJ SUSPENSION......................... 6
GENERAL INFORMATION
SUSPENSION COMPONENTS
The Jeep rear suspension is comprised of;
²Drive axle
²Leaf springs
²Dual-action shock absorbers
²Track bar (YJ vehicles)
²Stabilizer bar (XJ vehicles)
²Jounce bumpers
The rear suspension design uses semi-elliptic
multi-leaf springs and a solid drive axle. The forward
end of the springs are mounted to the frame rail
hangers through rubber bushings. The bushings iso-
late road noise as the springs move. The rearward
end of the springs are attached to the frame by the
use of shackles. Again the spring and shackles use
rubber bushings to isolate road noise. The shackles
allow the springs to change their length as the vehi-
cle moves over various road conditions. The spring
and axle travel is limited through the use of bumpers
mounted on frame.
All suspension components that use bushings
should be tightened with the vehicle at normal ride
height. If the springs are not at normal ride position,
vehicle ride comfort could be affected. Rubber bush-
ings must never be lubricated.
The springs are attached to the axle pads with U-
bolts and plates. The springs use a center bolt that
holds the spring leafs in position. The bolt is also
used to locate the spring assembly to the axle pad.
Ride control is accomplished through the use of du-
al-action shock absorbers. The shocks dampen the
jounce and rebound as the vehicle travels over vari-
ous road conditions. The top of shock absorbers are
bolted to the frame bracket. The bottom of the shocks
are bolted to the axle bracket.
The stabilizer bar on the XJ is used to minimize
vehicle rear sway during turns. The bar helps the ve-
hicle maintain a flat attitude to the road surface. The
bar extends across the underside of the chassis and
connects to the frame rails. The links are connectedto the axle brackets. All mounting points of the sta-
bilizer bar are isolated by bushings.
The track bar on the YJ is used to minimize rear
axle side-to-side movement. The track bar is attached
to the frame rail bracket and axle bracket and is iso-
lated with bushings.
The jounce bumpers are used to limit the jounce
and rebound travel of the suspension.
AXLES
The Model 35 axle is standard for XJ and YJ vehi-
cles. The 8 1/4 axle is available in XJ vehicles with-
out ABS brakes.
The Model 35 and 8 1/4 axle housings has a cast
iron center section. Two steel axle shaft tubes are
pressed into the differential housing and welded.
It is not necessary to remove the axle from the ve-
hicle for service. A removable differential cover is
provided for routine vehicle service. If the differential
housing is damaged, the complete axle assembly can
be removed.
For complete drive axle assembly removal and in-
stallation refer to Drive Axle Assembly Replacement
in this Group.
IDENTIFICATION
Model 35 axle has the assembly part number and
gear ratio listed on a tag. The tag is attached to the left
side of the housing cover (Fig. 1). Build date identifica-
tion codes on axles are stamped on the axle shaft tube
cover side. The Model 35 axle has a flat housing cover
gasket flange at the outer edge (Fig. 1).
The 8 1/4 axle has the build date code and gear ra-
tio tags attached to the housing cover (Fig. 2). The
housing cover gasket has a rolled gasket flange at
the outer edge (Fig. 2).
²The Model 35 axle has shaft tubes that are 2.625
inch (66.67 mm) in diameter.
²The 8 1/4 axle has axle shaft tubes that are 3.0-
inch (76.2 mm) in diameter.
JREAR SUSPENSION AND AXLES 3 - 1

SHOCK ABSORBER
REMOVAL
(1) Remove the shock absorber upper bolts from the
frame bracket (Fig. 1).
(2) Remove the lower attaching nut and washer
from the bracket stud. Remove the shock absorber.
INSTALLATION
(1) Install the shock absorber lower eye on the
spring bracket stud. Install the shock absorber and
upper bolts on the frame bracket (Fig. 1).
(2) Tighten the lower nut to 62 Nzm (46 ft. lbs.)
torque.
(3) Tighten the upper bolts to 23 Nzm (17 ft. lbs.)
torque.
LEAF SPRING
REMOVAL
(1) Raise vehicle at frame.
(2) Remove the wheel and tire assemblies.
(3) Support axle with hydraulic jack to relieve axle
weight.
(4) Disconnect the shock absorber from the axle
bracket or the spring bracket (Fig. 1).
(5) Disconnect the stabilizer bar link from the
spring bracket stud.(6) Remove nuts, U-bolts and spring bracket from
axle (Fig. 1).
(7) Remove nut and bolt attaching spring front eye
to shackle (Fig. 1).
(8) Remove nut and bolt from spring rear eye (Fig.
1).
(9) Remove spring from vehicle.
INSTALLATION
(1) Position the spring front eye in the bracket.
Loosely install the attaching bolt and nut (Fig. 1). Do
not tighten at this time.
(2) Position the rear eye in the shackle bracket.
Loosely install the attaching bolt and nut (Fig. 1). Do
not tighten at this time.
(3) Position the axle. Install the spring bracket,
U-bolts and nuts (Fig. 1). Tighten the nuts to 70 Nzm
(52 ft. lbs.) torque.
(4) Connect the stabilizer bar link to the spring
bracket.
(5) Connect the shock absorber to the axle bracket
or spring bracket.
(6) Remove the hydraulic jack.
(7) Lower the vehicle.
(8) Tighten the spring front eye attaching bolts to
148 Nzm (109 ft. lbs.) torque.
(9) Tighten the spring rear eye attaching bolts to
108 Nzm (80 ft. lbs.) torque.
Fig. 1 Spring & Shock AbsorberÐXJ Vehicles
3 - 4 REAR SUSPENSION AND AXLESJ

LEAF SPRING EYE BUSHING REPLACEMENT
(1) Assemble tools shown (Fig. 2). Tighten the nut
located at the socket wrench end of the threaded rod
until the bushing is forced out.
(2) Assemble and align the bushing installation
tools.
(3) Align the bushing with the spring eye. Tighten
the nut located at the socket wrench end of the
threaded rod. Tighten until the bushing is forced into
the spring eye.
The bushing must be centered in the spring
eye. The ends of the bushing must be flush or
slightly recessed within the end surfaces of the
spring eye.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Disconnect stabilizer bar links from spring
brackets (Fig. 3).
(3) Disconnect the stabilizer bar brackets from the
frame rails. Remove the stabilizer bar and links.
INSTALLATION
(1) Position the stabilizer bar links at the spring
brackets (Fig. 3). Install the attaching bolts and nuts
and tighten to 74 Nzm (55 ft. lbs.) torque.
(2) Attach the stabilizer bar to the frame rail
brackets with the bolts. Tighten to 54 Nzm (40 ft.
lbs.).
(3) Remove the supports and lower the vehicle.
Fig. 2 Spring Eye Bushing Removal
Fig. 3 Stabilizer BarÐXJ Vehicles
JREAR SUSPENSION AND AXLES 3 - 5

SHOCK ABSORBER
REMOVAL
(1) Remove the upper attaching nut and washer
from the frame bracket stud (Fig. 1).
(2) Remove the lower attaching nut, washers and
bolt from the axle bracket. Remove the shock ab-
sorber (Fig. 1).
INSTALLATION
(1) Position the shock upper eye on the frame
bracket stud. Install the washer and nut (Fig. 1).
(2) Position the shock lower eye in the axle shaft
tube bracket. Install the lower attaching bolt, wash-
ers and nut (Fig. 1).
(3) Tighten the upper and lower shock bolts to 61
Nzm (45 ft. lbs.) torque.
LEAF SPRING
REMOVAL
(1) Raise the vehicle at the frame.
(2) Use a hydraulic jack to relieve the axle weight.
(3) Remove the wheel and tire.
(4) Remove the nuts, the U-bolts and spring
bracket from the axle (Fig. 1).
(5) Remove the nut and bolt that attaches the
spring rear eye to the shackle (Fig. 1).
(6) Remove the nut and bolt from the spring front
eye (Fig. 1).
(7) Remove the spring from the vehicle.
INSTALLATION
(1) Position the spring front eye in the bracket.
Loosely install the attaching bolt and nut (Fig. 1). Do
not tighten at this time.
(2) Position the rear eye in the shackle bracket.
Loosely install the attaching bolt and nut (Fig. 1). Do
not tighten at this time.
(3) Align the rear spring center bolt with the locat-
ing hole in the rear axle spring pad.
(4) Lower the rear axle until it is completely sup-
ported by the spring.
Ensure that the spring center bolt is seated in
the axle spring pad locating hole. Realign the
center bolt with the locating hole, if necessary.
(5) Position the axle. Install the spring bracket, U-
bolts and nuts (Fig. 1). Tighten the U-bolt nuts to
122 Nzm (90 ft. lbs.) torque.
(6) Remove the hydraulic jack.
(7) Remove the support stands and lower the vehi-
cle.
(8) Tighten the spring shackle plate bolts and front
spring eye bolt to 135 Nzm (100 ft. lbs.) torque.
LEAF SPRING EYE BUSHING REPLACEMENT
(1) Assemble tools shown (Fig. 2). Tighten the nut
located at the socket wrench end of the threaded rod
until the bushing is forced out.
(2) Assemble and align the bushing installation
tools.
(3) Align the bushing with the spring eye and
tighten the nut located at the socket wrench end of
the threaded rod. Tighten until the bushing is forced
into the spring eye.
Fig. 1 Spring & Shock AbsorberÐYJ Vehicles
JREAR SUSPENSION AND AXLES 3 - 7

The bushing must be centered in the spring
eye. The ends of the bushing must be flush or
slightly recessed within the end surfaces of the
spring eye.
TRACK BAR
REMOVAL
(1) Raise the vehicle. Position a hydraulic jack un-
der the axle and raise the axle to relieve the springs
of axle weight.(2) Remove the fasteners that attach the track bar
to the frame bracket and axle bracket (Fig. 3).
(3) Remove the track bar from the vehicle.
INSTALLATION
(1) Position the ends of the track bar in the frame
and axle brackets (Fig. 3).
(2) Install and tighten the track bar attaching nuts
to 168 Nzm (125 ft. lbs.) torque.
(3) Remove the supports and lower the vehicle.
Fig. 2 Spring Eye Bushing Removal
Fig. 3 Track BarÐYJ Vehicles
3 - 8 REAR SUSPENSION AND AXLESJ

This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion gear shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft
²Missing drive shaft balance weight
²Worn, out-of-balance wheels
²Loose wheel lug nuts
²Worn U-joint
²Loose spring U-bolts
²Loose/broken springs
²Damaged axle shaft bearings
²Loose pinion gear nut
²Excessive pinion yoke run out
²Bent axle shaft
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear-end vi-
bration. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined be-
fore starting any repair.
Refer to Group 22, Wheels and Tires for additional
information.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed
²Loose engine/transmission/transfer case mounts
²Worn U-joints
²Loose spring mounts
²Loose pinion gear nut and yoke
²Excessive ring gear backlash
²Excessive side gear\ase clearance
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the ve-
hicle on a hoist with the wheels free to rotate.
Instruct the helper to shift the transmission into
gear. Listen for the noise, a mechanics stethoscope is
helpful in isolating the source of a noise.
REAR AXLE ALIGNMENT
MEASUREMENT
The following procedure can be used to determine
if abnormal rear tire tread wear is the result of a
bent or deformed rear axle shaft.
(1) Raise both rear wheels off the surface with a
frame contact hoist.
(2) Attach a one-inch long piece of masking tape at
the center of each tire tread for use as reference marks.
(3) Rotate the rear wheels until both reference
marks face the front of the vehicle. Measure the dis-
tance between the outside edges of the two pieces of
tape. Record this measurement as the front of tire
(FTR) measurement.
(4) Rotate the rear wheels until both reference
marks face the rear of the vehicle. Measure the dis-
tance between the outside edges of the two pieces of
tape. Record this measurement as the rear of tire
(RTR) measurement.
(5) Subtract the (RTR) measurement from the
(FTR) measurement to obtain the amount of wheel
toe. The acceptable rear wheel toe-in position is 1/16
inch (1.6 mm) to 3/16 inch (4.8 mm) toe-out.
(6) Rotate the rear wheels until the reference
marks are facing downward. Measure the distance
between the outside edges of the two pieces of tape.
Record this measurement as the bottom of tire (BTR)
measurement.
(7) Average the (FTR) and the (RTR) distance mea-
surements. Subtract the (BTR) measurement from
this average distance to obtain the camber. The ac-
ceptable amount of camber is 1/16 inch to 3/32 inch
(1.6 to 2.4 mm).
(FTR + RTR) DIVIDED BY 2 (TWO) MINUS
BTR EQUALS CAMBER
If the (BTR) distance measurement is less
than the average FTR and RTR distance mea-
surement, the camber will be positive(+).If
the (BTR) distance measurement is greater
than the average FTR and RTR distance, the
camber will be negative(-).
If the toe position or camber is not acceptable, a bent
or deformed rear axle shaft is most likely the cause.
LIMITED SLIP DIFFERENTIAL
Under normal traction conditions, engine torque is di-
vided evenly. With low-traction surfaces, engine torque
is transferred to the wheel with the most tire traction.
When diagnosing a limited-slip differential the wheel
with the least traction can continue spinning.
The most common problem is a chatter noise when
turning corners. Check for incorrect or contaminated
lubricant. Replace the gear lubricant if necessary.
²With Trac-LokŸ differentials add a container of
MOPAR Trac-Lok Lubricant.
This will correct the condition in most instances. If
the chatter persists, clutch damage could have oc-
curred.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches.
3 - 10 REAR SUSPENSION AND AXLESJ