2002 JEEP LIBERTY Workshop Manual

(4) Rotate pinion a minimum of ten time and ver-
ify pinion rotates smoothly. Rotate the pinion shaft
with an inch pound torque wrench. Rotating torque
should be equal to the reading recorded during
removal plus 0.56 N´m (5 in. lbs.) (Fig. 35).
(5) If the rotating torque is low, use Spanner
Wrench 6958 to hold the pinion companion flange
and tighten the pinion shaft nut in 6.8 N´m (5 ft.
lbs.) increments until proper rotating torque is
achieved.
CAUTION: If maximum tightening torque is reached
prior to reaching the required rotating torque, the
collapsible spacer may have been damaged.
Replace the collapsible spacer.
(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.
DIFFERENTIAL
REMOVAL
(1) Remove axle from the vehicle.
(2) Remove differential housing cover (Fig. 36).
(3) Push right axle shaft out of side gear (Fig. 37)
and remove the shaft.
(4) Mark differential bearing caps for installation
reference.
(5) Loosen the bearing cap bolts.
Fig. 35 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCHFig. 36 DIFFERENTIAL COVER
1 - COVER
2 - VENT TUBE
Fig. 37 RIGHT SHAFT IN SIDE GEAR
1 - AXLE SHAFT
2 - SCREWDRIVER
3 - SIDE GEAR
3 - 40 FRONT AXLE - 186FIAKJ
PINION SEAL (Continued)

(6) Position Spreader W-129-B onto the differential
locating holes and install the safety holddown clamps
(Fig. 38). Tighten the tool turnbuckle finger-tight.
(7) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing and zero the indicator.
(8) Spread the housing to remove the differential
case from the housing. Measure the distance with the
dial indicator (Fig. 39).
CAUTION: Never spread the differential housing
over 0.34 mm (0.013 in). If housing is over-spread, it
could be distorted or damaged.
(9) Remove the dial indicator.
(10) Holding the differential case in position, and
remove bearing cap bolts and caps.
(11) Remove the differential from the housing (Fig.
40). Ensure differential bearing cups and shims
remain in position on the differential bearings.(12) Tag differential bearing cups and shims to
indicate their location.
(13) Remove spreader from housing.
DISASSEMBLY
(1) Remove ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft.
(4) Rotate differential side gears and remove the
pinion mate gears and thrust washers (Fig. 41).
(5) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft.
(4) Align hole in the pinion gear mate shaft with
the hole in the differential case.
Fig. 38 DIFFERENTIAL SPREADER
1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
Fig. 39 SPREAD DIFFERENTIAL CASE
1 - PILOT STUD
2 - DIAL INDICATOR
3 - SPREADER
KJFRONT AXLE - 186FIA 3 - 41
DIFFERENTIAL (Continued)

(5) Install the roll-pin in the differential case with
a hammer and punch (Fig. 42). Peen the edge of the
roll-pin hole in the differential case in two places
180É apart.
(6) Lubricate all differential components with
hypoid gear lubricant.
(7) Install ring gear.
INSTALLATION
NOTE: If differential bearings or differential case are
replaced, Refer to adjustments fore Differential
Bearing Preload and Gear Backlash procedures.
(1) Position Spreader W-129-B on differential loca-
tion holes and install safety holddown clamps.
Tighten the tool turnbuckle finger-tight.
(2) Install Pilot Stud C-3288-B to 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 to install the differential
case and preload shims in the housing. Measure the
distance with the dial indicator.
CAUTION: Never spread the differential housing
over 0.34 mm (0.013 in). If housing is over-spread, it
could be distorted or damaged.
Fig. 40 DIFFERENTIAL CASE
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - DIFFERENTIAL BEARINGS
Fig. 41 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 42 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
3 - 42 FRONT AXLE - 186FIAKJ
DIFFERENTIAL (Continued)

(4) Remove the dial indicator.
(5) Install differential case in the housing. Ensure
differential bearing cups remain on the bearings and
preload shims are seated in the housing. Tap differ-
ential case to ensure bearings cups are seated in the
housing.
(6) Install bearing caps to their original locations
and loosely install cap bolts.
(7) Remove differential housing spreader (Fig. 43).
(8) Tighten the bearing cap bolts in a criss-cross
pattern to 54-68 N´m (39-50 ft. lbs.).
(9) Install the right axle shaft.
(10) Apply a 6.38mm (1/4 in.) bead of red Mopar
Silicone Sealer or equivalent to the housing cover.
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.
(11) Install differential housing cover and tighten
bolts in a criss-cross pattern to 19-26 N´m (14-19 ft.
lbs.).(12) Install axle assembly in vehicle.
(13) Fill differential with lubricant and install fill
plug.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential from the housing.
(2) Remove bearings from the differential case
with Puller/Press C-293-PA, Adapters C-293-39 and
Plug SP-3289 (Fig. 44).
Fig. 43 DIFFERENTIAL SPREADER
1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
Fig. 44 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
KJFRONT AXLE - 186FIA 3 - 43
DIFFERENTIAL (Continued)

INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 45).
(2) Install differential into the housing.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Never replace ring gear without
replacing the matched pinion gear.
(1) Raise and support vehicle
(2) Mark pinion companion flange and propeller
shaft for installation alignment.
(3) Remove propeller shaft from pinion companion
flange and tie propeller shaft to underbody.
(4) Remove axle assembly from the vehicle.
(5) Remove differential from axle housing.
(6) Place differential case in a vise with soft metal
jaw (Fig. 46).
(7) Remove bolts holding ring gear to differential
case.
(8) Driver ring gear off the differential case with a
rawhide hammer (Fig. 46).(9) With Spanner Wrench 6958 and a short length
of 1 in. pipe, hold pinion companion flange and
remove pinion nut (Fig. 47).
Fig. 45 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 46 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 47 PINION COMPANION FLANGE
1 - SPANNER WRENCH
2 - PINION COMPANION FLANGE
3 - 44 FRONT AXLE - 186FIAKJ
DIFFERENTIAL CASE BEARINGS (Continued)

(10) Remove pinion companion flange from pinion
shaft with Remover C-452 and Flange Wrench
C-3281 (Fig. 48).
(11) Remove pinion gear and collapsible spacer
from housing (Fig. 49).(12) Remove front pinion bearing cup, bearing, oil
slinger and pinion seal with Remover C-149 and
Handle C-4171 (Fig. 50).
(13) Remove rear pinion bearing cup (Fig. 51) with
Remover C-4307 and Handle C-4171.
Fig. 48 PINION FLANGE REMOVER
1 - SPANNER WRENCH
2 - REMOVER
Fig. 49 PINION GEAR
1 - RAWHIDE HAMMER
Fig. 50 FRONT BPINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 51 REAR PINION BEARING CUP
1 - REMOVER
2 - HANDLE
KJFRONT AXLE - 186FIA 3 - 45
PINION GEAR/RING GEAR (Continued)

(14) Remove collapsible preload spacer from pinion
gear (Fig. 52).
(15) Remove rear pinion bearing from the pinion
with Puller/Press C-293-PA and Adapters C-293-39
(Fig. 53). Remove oil slinger/pinion depth shim from
the pinion shaft and record thickness.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing and the pinion gear head to
achieve proper ring and pinion gear mesh. If ring
and pinion gears are reused, the pinion oil slinger/
depth shim should not require replacement. Refer
to Adujstments (Pinion Gear Depth) to select the
proper thickness shim before installing pinion gear.
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of pinion bearing cups.
(2) Install rear bearing cup with Installer C-4308
and Handle C-4171 and verify cup is seated.
(3) Install front bearing cup with Installer D-146
and Handle C-4171 (Fig. 54) and verify cup is seated.
(4) Install front pinion bearing, and oil slinger if
equipped.
Fig. 52 COLLAPSIBLE PRELOAD SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 53 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 54 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 46 FRONT AXLE - 186FIAKJ
PINION GEAR/RING GEAR (Continued)

(5) Apply a light coating of gear lubricant on the
lip of pinion seal and intall seal with an appropriate
installer (Fig. 55).
(6) Install rear pinion bearing and oil slinger/depth
shim onto the pinion shaft with Installer 6448 and a
press (Fig. 56).(7) Install anewcollapsible spacer on pinion shaft
and install the pinion into the housing (Fig. 57).
(8) Install pinion companion flange, with Installer
W-162-D, Cup 8109 and Spanner Wrench 6958.
(9) Install pinion anewnut onto the pinion gear
and tighten the nut to 216 N´m (160 ft. lbs.).Do not
over-tighten.
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified
preload torque. If preload torque is exceeded a new
collapsible spacer must be installed.
Fig. 55 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 56 REAR PINION BEARING
1 - INSTALLER
2 - OIL SLINGER
3 - PINION GEAR
4 - REAR PINION BEARING
5 - PRESS
Fig. 57 COLLAPSIBLE PRELOAD SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
KJFRONT AXLE - 186FIA 3 - 47
PINION GEAR/RING GEAR (Continued)