2002 JEEP LIBERTY Rear axle

FIXTURE 8138
INSTALLER C-4345
REMOVER C-4307
INSTALLER C-4308
INSTALLER D-130
INSTALLER 6448
TRAC-LOKŸ TOOLS 8140
TRAC-LOKŸ TOOLS 6960
PINION BLOCK 8540
ARBOR DISCS 8541
PINION GAUGE SET
3 - 100 REAR AXLE-81/4KJ
REAR AXLE - 8 1/4 (Continued)

AXLE SHAFTS
REMOVAL
(1) Place the transmission in NEUTRAL and raise
and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake drum.
(4) Remove the housing cover and drain lubricant.
(5) Rotate differential case to access the pinion
shaft lock screw. Remove lock screw and pinion shaft
from differential case (Fig. 19).
(6) Push axle shaft inward then remove axle shaft
C-lock (Fig. 20).(7) Remove axle shaft being carefull not to damage
shaft bearing and seal.
(8) Inspect axle shaft seal for leakage or damage.
(9) Inspect axle shaft bearing contact surface for
signs of brinelling, galling and pitting.
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant. Insert axle shaft through seal, bearing and
engage it into side gear splines.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(2) Insert C-lock in end of axle shaft. Push axle
shaft outward to seat C-lock in side gear.
(3) Insert pinion shaft into differential case and
through thrust washers and differential pinions.
(4) Align hole in shaft with hole in the differential
case and install lock screw with Loctiteton the
threads. Tighten lock screw to 11 N´m (8 ft. lbs.).
(5) Install cover and fill with gear lubricant to the
bottom of the fill plug hole.
(6) Install brake drum.
(7) Install wheel and tire assemblies.
(8) Remove support and lower vehicle.
AXLE SHAFT SEALS
REMOVAL
(1) Raise and support vehicle.
(2) Remove axle shaft.
(3) Remove axle shaft seal from the axle tube with
a small pry bar (Fig. 21).
Fig. 19 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 20 Axle Shaft C-Lock
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEARFig. 21 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3-PRYBAR
KJREAR AXLE - 8 1/4 3 - 101

INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Install anewaxle seal with Installer C-4076-B
and Handle C-4735-1. When the tool contacts the
axle tube, the seal is installed to the correct depth.
(3) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(4) Install the axle shaft.
(5) Check and fill gear lubricant.
(6) Install wheel and tire assembly.
(7) Remove support and lower vehicle.
AXLE BEARINGS
REMOVAL
(1) Raise and support vehicle.
(2) Remove axle shaft.
(3) Remove axle shaft seal from the axle tube with
a small pry bar (Fig. 22).
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(4) Remove axle shaft bearing with Bearing
Removal Tool Set 6310 and Adapter Foot 6310-9 (Fig.
23).
INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Install axle shaft bearing with Installer C-4198
and Handle C-4171.NOTE: Install bearing with part number against the
installer.
(3) Install anewaxle seal with Installer C-4198
and Handle C-4171. When the tool contacts the axle
tube, the seal is installed to the correct depth.
(4) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(5) Install the axle shaft.
(6) Check and fill gear lubricant.
(7) Install wheel and tire assembly.
(8) Remove support and lower vehicle.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the universal joint, pinion yoke and pin-
ion shaft for installation reference.
(3) Remove propeller shaft from pinion yoke.
(4) Remove the wheel and tire assemblies.
(5) Remove the brake drums.
(6) Rotate the pinion yoke three or four times.
Fig. 22 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3-PRYBAR
Fig. 23 Axle Shaft Bearing
1 - NUT
2 - GUIDE PLATE
3 - GUIDE
4 - THREADED ROD
5 - ADAPTER
6 - FOOT
7 - AXLE TUBE
3 - 102 REAR AXLE-81/4KJ
AXLE SHAFT SEALS (Continued)

(7) Measure rotating torque of the pinion gear
with an inch pound torque wrench and record the
reading for installation reference.
(8) Hold the pinion yoke with Holder 6719 and
remove the pinion nut and washer.
(9) Remove yoke with Remover C-452 (Fig. 24).
(10) Remove pinion seal with a pry tool or screw
mounted to a slide-hammer mounted.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.
(2) Install thenewpinion seal (Fig. 25) with
Installer C-4076-A and Handle C-4735.
(3) Install pinion yoke on the shaft with the refer-
ence marks aligned.
(4) Seat yoke on pinion shaft with Installer C-3718
and Holder 6719A.
(5) Remove the tools and install the pinion yoke
washer. The convex side of the washer must face out-
ward.
(6) Using yoke Holder 6719A tighten shaft nut to
285 N´m (210 ft. lbs.) (Fig. 26). Rotate the pinion sev-
eral revolutions to ensure the bearing rollers are
seated.
(7) Rotate the pinion using an inch pound torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal, plus an additional 0.56
N´m (5 in. lbs.) (Fig. 27).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.
(8) If the rotating torque is low, use Holder 6719A
(Fig. 26) and tighten the pinion nut in 6.8 N´m (5 ft.
Fig. 24 Pinion Yoke
1 - PINION YOKE
2 - REMOVER
Fig. 25 Pinion Seal Installer
1 - HANDLE
2 - DIFFERENTIAL HOUSING
3 - INSTALLER
Fig. 26 Tightening Pinion Nut
1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH
KJREAR AXLE - 8 1/4 3 - 103
PINION SEAL (Continued)

lbs.) increments until proper rotating torque is
achieved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, it indicates a binding
condition.
(9) The seal replacement is unacceptable if the
final pinion nut torque is less than 285 N´m (210 ft.
lbs.).
(10) Install the propeller shaft with the installa-
tion reference marks aligned.
(11) Install the brake drums.
(12) Check the differential housing lubricant level.
(13) Install wheel and tire assemblies and lower
the vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove fill hole plug from the differential
housing cover.
(3) Remove differential housing cover and drain
housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.(5) Remove the axle shafts.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark the differential housing and bearing caps
for installation reference (Fig. 28).
(7) Remove bearing threaded adjuster locks from
each bearing cap.
(8) Loosen bearing cap bolts, them loosen the
threaded adjusters with Wrench C-4164 (Fig. 29).
Fig. 27 Pinion Rotation Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH
Fig. 28 Reference Mark
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP
Fig. 29 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
3 - 104 REAR AXLE-81/4KJ
PINION SEAL (Continued)

(9) Hold the differential case while removing bear-
ing caps and adjusters.
(10) Remove the differential case.
NOTE: Tag bearing cups and threaded adjusters
location, for installation reference.
DISASSEMBLY
(1) Remove pinion shaft lock screw (Fig. 30).
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove dif-
ferential pinions and thrust washers (Fig. 31).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion and thrust washers.
(3) Install the pinion shaft.
(4) Align the hole in the pinion shaft with the hole
in the differential case and install the pinion shaft
lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
(1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups and threaded
adjusters. A dab of grease can be used to keep the
adjusters in position. Carefully position the assem-
bled differential case in the housing.
(2) Install differential bearing caps in their origi-
nal locations (Fig. 32).(3) Install bearing cap bolts and tighten the upper
bolts to 14 N´m (10 ft. lbs.). Tighten the lower bolts
finger-tight until the bolt head is seated.
(4) Perform the differential bearing preload and
adjustment procedure.
(5) Tighten bearing cap bolts in a criss-cross pat-
tern to 95 N´m (70 ft.lbs).
Fig. 30 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 31 Differential Case
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
Fig. 32 Bearing Caps & Bolts
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP
KJREAR AXLE - 8 1/4 3 - 105
DIFFERENTIAL (Continued)

(6) Install adjuster locks on the bearing caps.
(7) Install axle shafts.
(8) Apply a bead of red Mopar silicone rubber axle
sealant or equivalent to the housing cover (Fig. 33).
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(9) Install cover and tighten bolts in a criss-cross
pattern to 41 N´m (30 ft. lbs.).
(10) Fill differential with gear lubricant to bottom
of the fill plug hole.
(11) Install the fill hole plug.
(12) Install wheel and tire assemblies.
(13) Remove support and lower vehicle.
(14) Trac-loktdifferential equipped vehicles should
be road tested by making 10 to 12 slow figure-eight
turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
ter noise complaint.DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT
The most common problem is a chatter noise when
turning corners. Before removing the unit for repair,
drain, flush and refill the axle with the specified
lubricant. A container of Mopar Trac-loktLubricant
(friction modifier) should be added after repair ser-
vice or during a lubricant change.
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. This
will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 34).
(6) If rotating torque is less than 41 N´m (56 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
Fig. 33 Differential Cover Sealant
1 - SEALANT
2 - DIFFERNTIAL COVER
Fig. 34 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 106 REAR AXLE-81/4KJ
DIFFERENTIAL (Continued)

DISASSEMBLY
(1) Clamp side gear Fixture 8138 in a vise and set
differential case on the fixture (Fig. 35).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-loktdifferential can be serviced
with the ring gear installed.
(3) Remove pinion gear mate shaft lock screw.
(4) Remove pinion gear mate shaft with a drift and
hammer.
(5) Install Discs 8140 without threaded hole in the
lower side gear (Fig. 36).
(6) Install Disc 8140 with threaded hole in the
upper side gear. Thread Forcing Screw 6960-4
through the upper disc until it becomes centered in
lower disc.
(7) Insert a screw driver in slot of upper disc (Fig.
37) to prevent disc from turning.
Fig. 36 LOWER DISC
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
Fig. 37 TRAK-LOCTTOOLS
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - LOWER DISC
5 - THREADED ROD
6 - UPPER DISC
Fig. 35 DIFFERENTIAL CASE FIXTURE
1 - FIXTURE
2 - VISE
3 - DIFFERENTIAL
KJREAR AXLE - 8 1/4 3 - 107
DIFFERENTIAL - TRAC-LOK (Continued)