2002 JEEP GRAND CHEROKEE Indicator

(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 17).
(9) Attach a Dial Indicator C-3339 to pilot stud.
Position the dial indicator plunger on a flat surface
between the ring gear bolt heads (Fig. 17).
(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 18).
(11) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 19).
(12) Add 0.152 mm (0.006 in.) to the zero end play
total. This new total represents the thickness of
shims to compress, or preload the new bearings when
the differential is installed.
(13) Rotate dial indicator out of the way on the
pilot stud.
(14) Remove differential case and dummy bearings
from the housing.
(15) Install the pinion gear in axle housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(16) Install differential case and Dummy Bearings
D-348 in the housing.
(17) Install a single dummy shim in the ring gear
side. Install bearing caps and tighten bolts snug.
(18) Seat ring gear side dummy bearing (Fig. 16).
(19) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads. (Fig. 17).(20) Push and hold differential case toward pinion
gear and zero dial indicator (Fig. 20).
(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 21). Add dummy shim thickness to this reading.
This will be the total shim thickness to achieve zero
backlash.
(22) Subtract 0.076 mm (0.003 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness
shim required to achieve proper backlash.
(23) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
Fig. 17 DIFFERENTIAL SIDE PLAY
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 18 ZERO DIAL INDICATOR
1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
4 - ZERO DIAL INDICATOR FACE
Fig. 19 DIFFERENTIAL TO RING GEAR SIDE
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
WJREAR AXLE - 198RBI 3 - 61
REAR AXLE - 198RBI (Continued)

the shim thickness required on the pinion side of the
housing.
(24) Rotate dial indicator out of the way on pilot
stud.
(25) Remove differential case and dummy bearings
from the housing.
(26) Install side bearings and cups on differential
case.(27) Install spreader W-129-B utilizing some items
from Adapter Set 6987, on the housing and spread
axle opening enough to receive differential case.
CAUTION: Never spread over 0.38 mm (0.015 in.). If
housing is over-spread, it could be distorted or
damaged.
(28) Place the bearing preload shims in the hous-
ing, against the axle tubes.
(29) Install differential case into the housing.
(30) Remove spreader from the housing.
(31) Install differential bearing caps in their origi-
nal locations.
(32) Install bearing cap bolts and tighten to 77
N´m (57 ft. lbs.).
(33) Rotate the differential case several times to
seat the side bearings.
(34) Position the indicator plunger against a ring
gear tooth (Fig. 22).
(35) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(36) Zero dial indicator face to pointer.
(37) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12-0.20 mm (0.005-0.008
in.). If backlash is not within specifications transfer
the necessary amount of shim thickness from one
side of the axle housing to the other (Fig. 23).
(38) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform
Gear Contact Pattern Analysis procedure.
Fig. 20 ZERO DIAL INDICATOR
1 - DIAL INDICATOR FACE
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 21 DIFFERENTIAL TO RING GEAR SIDE
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 22 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
3 - 62 REAR AXLE - 198RBIWJ
REAR AXLE - 198RBI (Continued)

SHIMS DUMMY 8107
SPREADER W-129-B
ADAPTER KIT 6987
PILOT STUDS C-3288-B
PULLER 6790
DIAL INDICATOR C-3339
SPLITTER BEARING 1130
INSTALLER 7913-A
3 - 68 REAR AXLE - 198RBIWJ
REAR AXLE - 198RBI (Continued)

(9) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing (Fig. 47) and zero the
indicator.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). If housing is over-spread, it could dis-
torted and damaged the housing.
(10) Spread housing enough to remove the differ-
ential case from the housing. Measure the distance
with the dial indicator (Fig. 48).
(11) Remove the dial indicator.
(12) While holding the differential case in position,
remove the differential bearing cap bolts and caps.
(13) Remove differential from the housing and tag
differential bearing cups to indicate location (Fig. 49).
(14) Remove spreader from housing.
Fig. 47 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 48 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
Fig. 49 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
3 - 76 REAR AXLE - 198RBIWJ
DIFFERENTIAL (Continued)

DISASSEMBLY
(1) Remove pinion shaft lock screw (Fig. 50).
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove dif-
ferential pinions and thrust washers (Fig. 51).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion gears and thrust
washers.
(3) Install the pinion mate shaft.
(4) Align hole in the pinion mate shaft with the
hole in the differential case and install the pinion
mate shaft lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Position Spreader W-129-B with Adapter set
6987 on differential housing locating holes. Install
the holddown clamps and tighten the tool turnbuckle
finger-tight.
(2) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). If housing is over-spread, it could be dis-
torted or damaged.
(3) Spread housing enough to install the case in
the housing.
(4) Remove the dial indicator.
(5) Install differential case in housing (Fig. 52).
Verify differential bearing cups remain in position on
the bearings and preload shims are between the face
of the bearing cup and the housing. Tap the differen-
tial case to ensure bearings cups and shims are
seated in the housing.
CAUTION: On a Vari-lokTdifferential the oil feed
tube must be pointed at the bottom of the housing
(Fig. 53). If differential is installed with the oil feed
tube pointed at the top, the anti-rotation tabs will be
damaged.
(6) Install bearing caps in their original locations
(Fig. 54).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten bearing cap bolts in a criss-cross pat-
tern to 77 N´m (57 ft. lbs.).
(10) Install the axle shafts.
Fig. 50 SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 51 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
WJREAR AXLE - 198RBI 3 - 77
DIFFERENTIAL (Continued)

PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set 6775 and Dial
Indicator C-3339 (Fig. 8).(1) Assemble Pinion Height Block 6739, Pinion
Block 8144 and rear pinion bearing onto Screw 6741
(Fig. 8).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 9).
(3) Install front pinion bearing and Cone-nut 6740
hand tight (Fig. 8).
(4) Place Arbor Disc 6927A on Arbor D-115-3 in
position in the housing side bearing cradles (Fig. 10).
Install differential bearing caps in their original posi-
tions on arbor discs and tighten cap bolts to 85 N´m
(63 ft. lbs.).
Fig. 8 PINION GEAR DEPTH GAUGE
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 9 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 98 REAR AXLE - 226RBAWJ
REAR AXLE - 226RBA (Continued)

NOTE: Arbor Discs 6927A has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position
in axle housing so dial probe and scooter block are
flush against the rearward surface of the pinion
height block (Fig. 8). Hold scooter block in place and
zero the dial indicator face to the pointer. Tighten
dial indicator face lock screw.
(7) With scooter block still in position against the
pinion height block, slowly slide the dial indicator
probe over the edge of the pinion height block.
(8) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 11). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
turn dial face. Continue moving the dial probe to the
crest of the arbor bar and record the highest reading.
If the dial indicator can not achieve the zero reading,
the rear bearing cup or the pinion depth gauge set is
not installed correctly.
(9) Select a depth shim equal to the dial indicator
reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 6). For example,
if the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL BEARING PRELOAD & GEAR
BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims positioned behind the
differential side bearing cones. The proper shim
thickness can be determined using slip-fit Dummy
Bearings 6929-A in place of the differential side bear-
ings and a Dial Indicator C-3339. Before proceeding
with the differential bearing preload and gear back-
lash measurements, measure the pinion gear depth
and prepare the pinion for installation. Establishing
proper pinion gear depth is essential to establishing
gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential side
play is measured, the pinion is installed, and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 12). Differential shim measurements
are performed with the spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove differential side bearings from differ-
ential case.
Fig. 10 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 11 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
WJREAR AXLE - 226RBA 3 - 99
REAR AXLE - 226RBA (Continued)

(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 17).
(9) Attach the Dial Indicator C-3339 to pilot stud
and position the indicator plunger on the flat surface
between the ring gear bolts (Fig. 17).(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 18).
(11) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 19).
(12) Add 0.0254 mm (0.001 in.) to the zero end
play total. This new total represents the thickness of
shims to compress, or preload the new bearings when
the differential is installed.
(13) Rotate dial indicator out of the way on the
pilot stud.
Fig. 16 SEAT DUMMY BEARING
1 - HOUSING
2 - HAMMER
3 - DIFFERENTIAL CASE
Fig. 17 DIFFERENTIAL SIDE PLAY MEASUREMENT
1 - DIFFERENTIAL CASE
2 - HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 18 DIFFERENTIAL CASE PINION GEAR SIDE
1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
4 - DIAL INDICATOR FACE
Fig. 19 DIFFERENTIAL CASE RING GEAR SIDE
1 - READ DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
WJREAR AXLE - 226RBA 3 - 101
REAR AXLE - 226RBA (Continued)