2002 JEEP GRAND CHEROKEE Workshop Manual

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Page 81 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual CAUTION: Boot must not be dimpled, stretched or
out of shape in any way. If not shaped correctly,
equalize pressure in boot and shape it by hand.
(5) Install the two boot clamps.
(6) Crimp the boot cl

Page 82 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the

INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings, then tap bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket in a vise.
(4) Tighten the vise to force the bearing caps into
the yoke. Force the caps enough to install the retain-
ing clips.
(5) Install the bearing cap retaining clips.
(6) Install axle shaft.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers, refer to 5
Brakes for procedures.
(4) Mark propeller shaft and pinion companion
flange for installation reference.
(5) Remove the propeller shaft from the pinion
companion flange.
(6) Rotate the pinion gear a minimum of ten times
and verify the pinion rotates smoothly.
(7) Record torque necessary to rotate the pinion
gear with a inch pound torque wrench.
(8) Using a short piece of pipe and Spanner
Wrench 6958 to hold the pinion companion flange
and remove the pinion nut and washer.
(9) Remove pinion companion flange with Remover
C-452 and Flange Wrench C-3281.
(10) Remove pinion seal with Remover 7794-A and
a slide hammer (Fig. 31).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 32).
(2) Install pinion companion flange on the pinion
gear with Installer W-162-D, Cup 8109 and Wrench
6958.
CAUTION: Never exceed the minimum tightening
torque 298 N´m (220 ft. lbs.) while installing pinion
nut at this point. Damage to collapsible spacer or
bearings may result.
(3) Install the pinion washer and anewnut on
the pinion gear.Tighten the nut only enough to
remove the shaft end play.
Fig. 29 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 30 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET
2 - VISE
3 - SMALL-DIAMETER SOCKET
WJFRONT AXLE - 186FBI 3 - 37
AXLE - U-JOINT (Continued)

Page 83 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
ins

Page 84 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (6) Install propeller shaft with installation refer-
ence marks aligned.
(7) Fill differential with gear lubricant.
(8) Install brake rotors and calipers.
(9) Install wheel and tire assemblies.
(10) L

(6) Install propeller shaft with installation refer-
ence marks aligned.
(7) Fill differential with gear lubricant.
(8) Install brake rotors and calipers.
(9) Install wheel and tire assemblies.
(10) Lower the vehicle.
COLLAPSIBLE SPACER
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to 5
Brakes for procedures.
(4) Mark the propeller shaft and pinion companion
flange for installation reference.
(5) Remove propeller shaft from the pinion com-
panion flange.
(6) Rotate pinion gear a minimum of ten times and
verify pinion rotates smoothly.
(7) Record pinion gear rotating torque with a
torque wrench for installation reference.
(8) Remove pinion nut and washer. Using a short
piece of pipe and Spanner Wrench 6958 to hold the
pinion companion flange.
(9) Remove pinion companion flange with Remover
C-452 and Flange Wrench C-3281.
(10) Remove pinion shaft seal with Remover
7794-A and slide hammer (Fig. 35).
(11) Remove front pinion bearing using a pair of
pick tools to pull the bearing straight off pinion
shaft.NOTE: If bearing becomes bound on the pinion
shaft, lightly tap the end of the pinion gear with a
rawhide/rubber mallet.
(12) Remove the collapsible spacer.
INSTALLATION
(1) Install anewcollapsible preload spacer on pin-
ion shaft.
(2) Install pinion front bearing.
(3) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 36).
(4) Install pinion companion flange with Installer
W-162-D, Cup 8109 and Flange Holder 6958.
(5) Install pinion washer and anewnut on the
pinion gear. Tighten the nut to 298 N´m (220 ft. lbs.)
minimum.Do not overtighten.Maximum torque is
500 N´m (368 ft. lbs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(6) Using Spanner Wrench 6958, a length of 1 in.
pipe and a torque wrench set at 500 N´m (368 ft. lbs.)
crush collapsible spacer until bearing end play is
taken up (Fig. 37).
(7) Slowly tighten the nut in 6.8 N´m (5 ft. lbs.)
increments until the required rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer.
(8) Rotate pinion gear a minimum of ten times and
verify pinion rotates smoothly. Check rotating torque
with an inch pound torque wrench. The rotating
torque should be the amount recorded during
removal plus:
²Original Bearings: 0.56 N´m (5 in. lbs.).
Fig. 35 PINION SEAL PULLER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 36 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
WJFRONT AXLE - 186FBI 3 - 39
PINION SEAL (Continued)

Page 85 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual ²New Bearings: 1.7 to 3.4 N´m (15 to 30 in. lbs.).
(9) Install propeller shaft with reference marks
aligned.
(10) Install brake rotors and calipers.
(11) Add gear lubricant if necessary.
(12) Instal

Page 86 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (9) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to stud. Load the lever adapter against the opposite
side of the housing (Fig. 40) and zero

Page 87 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual DISASSEMBLY
(1) Remove the ring gear.
(2) Drive out the roll pin holding pinion gear mate
shaft with a hammer and punch (Fig. 43).
(3) Remove pinion gear mate shaft from the differ-
ential case and th

Page 88 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing P

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