2002 JEEP LIBERTY The

(6) Install the bearing caps in their original loca-
tions (Fig. 50).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten the bearing cap bolts to 64-91 N´m
(47-67 ft. lbs.).
(10) Install the axle shafts.
(11) Apply a 6.35mm (1/4 in.) bead of red Mopar
Silicone Rubber Sealant or equivalent to the housing
cover (Fig. 51).
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.
(12) Install the cover and tighten cover bolts in a
criss-cross pattern to 38-45 N´m (28-33 ft. lbs.).
(13) Refill the differential with lubricant and
install fill plug.
(14) Remove support and lower the vehicle.
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. 52).
(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. 50 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 51 DIFFERENTIAL COVER - TYPICAL
1 - SEALING SURFACE
2 - SEALANT BEAD
3 - SEALANT THICKNESS
3 - 74 REAR AXLE - 198RBIKJ
DIFFERENTIAL (Continued)

DISASSEMBLY
(1) Clamp side gear Fixture 6965 in a vise and set
differential case on the fixture (Fig. 53).
(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 (Fig.
54).(4) Remove pinion gear mate shaft with a drift and
hammer.
(5) Install and lubricate Step Plate 6960-3 (Fig.
55).
Fig. 52 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 53 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 54 MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 55 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
KJREAR AXLE - 198RBI 3 - 75
DIFFERENTIAL - TRAC-LOK (Continued)

(6) Assemble Threaded Adapter 6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
(7) Position a small screw driver in slot of
Threaded Adapter Disc 6960-3 (Fig. 56) to prevent
adapter from turning.
(8) Install Forcing Screw 6960-4 and tighten screw
to 122 N´m (90 ft. lbs.) maximum to compress
Belleville springs in clutch packs (Fig. 57).
(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 58).
Fig. 56 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - STEP PLATE
5 - THREADED ROD
6 - ADAPTER DISC
Fig. 57 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 58 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
3 - 76 REAR AXLE - 198RBIKJ
DIFFERENTIAL - TRAC-LOK (Continued)

(10) Insert Turning Bar 6960-2 into the pinion
mate shaft hole in the case (Fig. 59).
(11) Loosen the Forcing Screw in small increments
until the clutch pack tension is relieved and the dif-
ferential case can be turned using Turning Bar.
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in order during removal
(Fig. 60).
(16) Remove differential case from the Holding
Fixture. Remove side gear, clutch pack retainer and
clutch pack. Keep plates in order during removal.
CLEANING
Clean all components in cleaning solvent and dry
components with compressed air.
INSPECTION
Inspect clutch pack plates for wear, scoring or dam-
age. Replace both clutch packs if any one component
in either pack is damaged. Inspect side and pinion
gears for cracks chips or damage and replace as nec-
essary. Inspect differential case and pinion shaft and
replace if worn or damaged.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.(1) Lubricate components with gear lubricant.
(2) Assemble clutch discs into packs and secure
disc packs with retaining clips (Fig. 61).
NOTE: Dished plate is position with the convex side
against the side gear.
Fig. 59 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 60 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 61 CLUTCH PACK
1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
6 - PLATES
KJREAR AXLE - 198RBI 3 - 77
DIFFERENTIAL - TRAC-LOK (Continued)

(3) Position assembled clutch disc packs on the
side gear hubs.
(4) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 62).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
(5) Position the differential case on the Holding
Fixture 6965.
(6) Install lubricated Step Plate 6960-3 in lower
side gear (Fig. 63).
(7) Install the upper side gear and clutch disc pack
(Fig. 63).
(8) Hold assembly in position. Insert Threaded
Adapter 6960-1 into top side gear.
(9) Install Forcing Screw 6960-4 and tighten screw
to slightly compress clutch disc.
(10) Place pinion gears in position in side gears
and verify that the pinion mate shaft hole is aligned.(11) Rotate case with Turning Bar 6960-2 until the
pinion mate shaft holes in pinion gears align with
holes in case. It may be necessary to slightly tighten
the forcing screw in order to install the pinion gears.
(12) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.
Fig. 62 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - SIDE GEAR AND CLUTCH PACK
Fig. 63 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE
3 - 78 REAR AXLE - 198RBIKJ
DIFFERENTIAL - TRAC-LOK (Continued)

DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove side bearings from the differential case
with Puller/Press C-293-PA, Adapters 8352 and Plug
SP-3289 (Fig. 64).
INSTALLATION
NOTE: If differential side bearings or differential
case are replaced, differential side bearing shim
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.
(1) Install differential side bearings with Installer
C-3716-A and Handle C-4171 (Fig. 65).
(2) Install differential case in housing.
(3) Remove support and lower vehicle.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without the
other gear.
(1) Raise and support vehicle.
(2) Mark pinion yoke and propeller shaft for
installation reference.
(3) Disconnect propeller shaft from pinion yoke
and tie shaft to underbody.
(4) Remove differential from housing.
(5) Place differential case in a vise with soft metal
jaw.
(6) Remove bolts holding ring gear to differential
case.
Fig. 64 DIFFERENTIAL CASE BEARING
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
Fig. 65 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
KJREAR AXLE - 198RBI 3 - 79

(16) Remove rear bearing from the pinion with
Puller/Press C-293-PA and Adapters C-293-39 (Fig.
74).
(17) Remove depth shims from pinion gear shaft
and record shim thickness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Apply MopartDoor Ease or equivalent lubri-
cant to outside surface of bearing cup.
(2) Install pinion rear bearing cup with Installer
C-146 and Driver Handle C-4171 (Fig. 75) and verify
cup is seated.
(3) Apply MopartDoor Ease or equivalent lubri-
cant to outside surface of bearing cup.
(4) Install pinion front bearing cup with Installer
D-130 and Handle C-4171 (Fig. 76) and verify cup is
seated.
(5) Install pinion front bearing and oil slinger, if
equipped.
Fig. 74 REAR PINION BEARING PULLER
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 75 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 76 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 82 REAR AXLE - 198RBIKJ
PINION GEAR/RING GEAR/TONE RING (Continued)

(6) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 77).
(7) Install pinion depth shim on the pinion gear.
(8) Install rear bearing on the pinion gear with
Installer W-262 and a press (Fig. 78).
(9) Install anewcollapsible preload spacer on pin-
ion shaft and install pinion gear in the housing (Fig.
79).
(10) Install yoke with Installer C-3718 and Span-
ner Wrench 6958 (Fig. 80).
Fig. 77 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 78 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION GEAR REAR BEARING
Fig. 79 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 80 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - WRENCH
KJREAR AXLE - 198RBI 3 - 83
PINION GEAR/RING GEAR/TONE RING (Continued)