2002 JEEP GRAND CHEROKEE rings

(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 15).
(11) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 16).(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 the 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. 13).
(19) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 14).
(20) Push and hold differential case toward pinion
gear and zero dial indicator (Fig. 17).
Fig. 15 ZERO DIAL INDICATOR
1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - INDICATOR EXTENSION
4 - DIAL INDICATOR FACE
Fig. 16 RECORED DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
Fig. 17 ZERO DIAL INDICATOR
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
3 - 26 FRONT AXLE - 186FBIWJ
FRONT AXLE - 186FBI (Continued)

(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 18). 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
the shim thickness required on the pinion side of the
axle 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 with Adapter Set
6987 on the housing and spread axle opening enough
to receive differential case.
(28) Place the bearing preload shims in the axle
housing, against the axle tubes.
(29) Install differential case into the housing.
CAUTION: When installing a Vari-LokTdifferential,
the oil feed tube must point to the bottom of the
housing. If differential is forced in with the oil feed
towards the top, the anti-rotation tabs will be dam-
aged.
(30) Remove spreader from the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 19).
Fig. 18 RECORED DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 19 RING GEAR BACKLASH
1 - DIAL INDICATOR
WJFRONT AXLE - 186FBI 3 - 27
FRONT AXLE - 186FBI (Continued)

DIFFERENTIAL BEARING PRELOAD CHECK
The final check on the differential assembly before
installing the axles is torque to rotate pinion and dif-
ferential combined. This will verify the correct differ-
ential bearing preload.Torque to rotate the differential and pinion should
be the torque to rotate the pinion plus 0.79-1.24 N´m
(7-11 in. lbs.).
SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.31, 3.55, 3.73, 3.91
Differential Side Gear Clearance 0.13-0.20 mm (0.005-0.008 in.)
Differential Bearing Preload 0.152 mm (0.006 in.)
Ring Gear Diameter 186 mm (7.33 in.)
Ring Gear Backlash 0.13-0.20 mm (0.005-0.008 in.)
Pinion Gear Std. Depth 92.08 mm (3.625 in.)
Pinion Bearing Preload - Original Bearings 1-2 N´m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 1.7-3.4 N´m (15-30 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 61 45 -
Ring Gear Bolts 108 80 -
Axle Nut 237 175 -
Hub Bearing Bolts 102 75 -
3 - 30 FRONT AXLE - 186FBIWJ
FRONT AXLE - 186FBI (Continued)

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 clamps with Clamp Installer
C-4975A. Place clamp tool over bridge of clamp (Fig.
26).
(7) Tighten nut on the tool until jaws on tool are
closed completely together (Fig. 27) and (Fig. 28).
(8) Install the axle shaft.
AXLE - U-JOINT
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Do not over tighten the vise
jaws, to avoid distorting the yoke.
(1) Remove axle shaft.
(2) Remove the bearing cap retaining snap rings
(Fig. 29).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(3) Locate a socket with an inside diameter is
larger than the bearing cap. Place the socket (receiv-
er) against the yoke and around the perimeter of the
bearing cap to be removed.
(4) Locate a socket with an outside diameter is
smaller than the bearing cap. Place the socket (driv-
er) against the opposite bearing cap.
(5) Position the yoke with the sockets in a vise
(Fig. 30).
(6) Tighten the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(8) Repeat the above procedure for the remaining
bearing cap and remove spider from the propeller
shaft yoke.
Fig. 26 CRIMPING TOOL
1 - INSTALLER
2 - AXLE SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 27 SMALL BOOT CLAMP
1 - CLAMP
2 - INSTALLER
3 - AXLE SHAFT
4 - SEALING BOOT
Fig. 28 LARGE BOOT CLAMP
1 - CLAMP TOOL
2 - SEALING BOOT
3 - OUTER C/V JOINT
4 - BOOT CLAMP
3 - 36 FRONT AXLE - 186FBIWJ
AXLE - C/V JOINT (Continued)

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)

(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)

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) Install wheel and tire assemblies.
(13) Lower vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove lubricant fill hole plug from the differ-
ential housing cover.
(3) Remove differential cover and drain lubricant.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Never use water,
steam, kerosene or gasoline for cleaning.
(5) Remove hub bearings and axle shafts.
(6) Note installation reference letters stamped on
the bearing caps and housing machined sealing sur-
face (Fig. 38).
(7) Loosen the differential bearing cap bolts.
(8) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes (Fig. 39). Install
hold down clamps and tighten the tool turnbuckle
finger-tight.
Fig. 37 PINION COMPANION FLANGE
1 - COMPANION FLNAGE
2 - DIFFERENTIAL HOUSING
3 - SPANNER WRENCH
Fig. 38 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 39 DIFFERENTIAL SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - ADAPTER
3 - HOLD DOWN CLAMPS
4 - SPREADER
5 - TURNBUCKLE
3 - 40 FRONT AXLE - 186FBIWJ
COLLAPSIBLE SPACER (Continued)

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 Preload and Gear
Backlash) to determine the proper shim selection.
(1) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes. Install hold
down 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.
(3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator.
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could dis-
torted and damaged the housing.
(4) Remove the dial indicator.
(5) Install differential case in the housing (Fig.
46). Make sure the differential bearing cups remain
on the bearings and the preload shims remain
between the face of the bearing cup and housing. Tap
the differential case to ensure the bearings cups and
shims are fully seated in the housing.
CAUTION: On a Vari-lokTdifferential the oil feed
tube must be pointed at the bottom of the housing.
If differential is installed with the oil feed tube
pointed at the top, the anti-rotation tabs will be
damaged.
(6) Install the bearing caps at their original loca-
tions (Fig. 47).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten the bearing cap bolts to 61 N´m (45 ft.
lbs.).
(10) Install the hub bearings and axle shafts.
Fig. 46 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
Fig. 47 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
WJFRONT AXLE - 186FBI 3 - 43
DIFFERENTIAL (Continued)