2002 JEEP LIBERTY ECU

BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM BUSHING
(1) Remove the lower control arm (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Press the bushing out using special tools
8858-5 (Receiver), 8858-6 (Driver) and 8839 with the
threaded rod and the bearing as shown (Fig. 1)
REMOVAL - CLEVIS BRACKET BUSHING
(1) Remove the clevis bracket from the shock
(Refer to 2 - SUSPENSION/FRONT/CLEVIS
BRACKET - REMOVAL).
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
FRONT LOWER CONTROL ARM & CLEVIS
BUSHING REMOVER/INSTALLER - 8858
REAR LOWER CONTROL ARM BUSHING
REMOVER/INSTALLER - 8862
FRONT LOWER CONTROL BUSHING REMOVER/
INSTALLER - 8830
Fig. 1 LOWER CONTROL ARM BUSHING -
REMOVAL
1 - 8858-5 RECEIVER
2 - 8858-6 DRIVER
3 - 8839 THREADED ROD
2s - 2 SUSPENSIONKJ
FRONT (Continued)

(2) Press the bushing out using special tools
8858-1 (receiver), 8858-3 (driver) and 8839 with the
threaded rod 8839 and the bearing as shown (Fig. 2)
REMOVAL - UPPER CONTROL ARM BUSHINGS
(1) Remove the upper control arm (Refer to 2 -
SUSPENSION/FRONT/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the control arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Install bushing remover tools 8830-3, 8830-2
and 8830±4 with the threaded rod 8838 and the bear-
ing as shown (Fig. 3)
(4) Press out the bushing.
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.(1) Install the new lower control arm bushings into
the lower control arm using tools 8858-5 (driver),
8858-6 (receiver) and the bearing with the threaded
rod 8839 (Fig. 4) making sure to properly orient the
bushing in the control.
Fig. 2 CLEVIS BRACKET BUSHING
1 - 8839 THREADED ROD
2 - 8858-1 RECEIVER
3 - 8858-3 DRIVER
Fig. 3 UPPER CONTROL ARM BUSHING REMOVAL
1 - 8830-3
2 - 8830-2
3 - 8830-4
4 - 8838
Fig. 4 LOWER CONTROL ARM BUSHING -
INSTALLATION
1 - 8858-5 DRIVER
2 - 8858-6 RECEIVER
3 - 8839 THREADED ROD
KJSUSPENSION 2s - 3
BUSHINGS (Continued)

LOWER BALL JOINT
REMOVAL
(1) Remove the tire and wheel assembly.
(2) Remove the brake caliper and rotor (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(3) Disconnect the tie rod from the steering
knuckle (Refer to 19 - STEERING/LINKAGE/TIE
ROD END - REMOVAL).
(4) Remove the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - REMOVAL).
(5) Move the halfshaft to the side and support the
halfshaft out of the way (If Equipped).
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(6) Secure the steering knuckle in a vise.
(7) Press the ball joint from the steering knuckle
using special tools C-4212±F (PRESS), 8859-2
(RECEIVER) and 8859-1 (DRIVER) (Fig. 7).
INSTALLATION
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.(1) Install the ball joint into the steering knuckle
and press in using special tools C-4212±F (press),
8859-3 (driver) and 6761 (receiver) (Fig. 8).
(2) Install the ball joint boot.
(3) Remove the support for the halfshaft and
install into position (If Equipped).
(4) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(5) Install the tie rod end into the steering knuckle
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
INSTALLATION).
(6) Install and tighten the halfshaft nut to 136
N´m (100 ft. lbs.).
(7) Install the brake caliper and rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Check the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
(10) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 7 LOWER BALL JOINT
1 - 8859-1 DRIVER
2 - C-4212F PRESS
3 - 8859-2 RECEIVER
Fig. 8 LOWER BALL JOINT
1 - 6761 RECEIVER
2 - 8859-3 DRIVER
3 - C-4212F PRESS
KJSUSPENSION 2s - 5

REAR
SPECIAL TOOLS
REAR SUSPENSION
UPPER BALL JOINT
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint pinch bolt from the top of
the axle. (Fig. 9)(4) Separate the ball joint arm assembly from the
differential housing by prying upwards.
(5) Remove the upper suspension arm from the
vehicle (Refer to 2 - SUSPENSION/REAR/UPPER
CONTROL ARM - REMOVAL).
(6) Secure the suspension arm in a vise.
(7) Install special tools C-4212F (press), 8861-3
(driver) and 8861-2 (receiver) (Fig. 10)
(8) Press out the old ball joint.
INSTALLATION
(1) Install special tools C-4212F (press), 8861-1
(receiver) and 8861-2 (driver) with the ball joint in
place (Fig. 11).
BALL JOINT PRESS - C-4212F
REMOVER / INSTALLER REAR UPPER BALL JOINT
- 8861
REMOVAL / INSTALLATION REAR UPPER
CONTROL ARM BUSHINGS - 8860
Fig. 9 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 10 UPPER BALL JOINT - REMOVAL
1 - C-4212F PRESS
2 - 8861-3 DRIVER
3 - 8861-2 RECEIVER
2s - 6 SUSPENSIONKJ

(2) Press the ball joint in the upper suspension
arm.
(3) Remove the upper suspension arm from the
vise.
(4) Reinstall the upper suspension arm (Refer to 2
- SUSPENSION/REAR/UPPER CONTROL ARM -
INSTALLATION).
(5) Raise the rear axle with a hydraulic jack to
align the ball joint with the differential housing
bracket.
(6) Insert the ball joint into the differential hous-
ing bracket.
(7) Install the ball joint pinch bolt and tighten to
95 N´m (70 ft. lbs.). (Fig. 9).
(8) Remove the supports and lower the vehicle.
BUSHINGS
REMOVAL
REMOVAL - LOWER SUSPENSION ARM
BUSHING
(1) Remove the lower suspension arm (Refer to 2 -
SUSPENSION/REAR/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the suspension arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.(3) Install special tools 8862-4 (receiver), 8862-5
(spacer) and 8862-1 or 8862- 2 (driver) with the
threaded rod 8839 and the bearing as shown (Fig. 12)
(4) Press out the bushing.
REMOVAL - UPPER SUSPENSION ARM
BUSHING
(1) Remove the upper suspension arm (Refer to 2 -
SUSPENSION/REAR/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the suspension arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Install special tools 8853-3 (driver), 8860-1
(receiver) and with the threaded rod 8838 and the
bearing as shown (Fig. 13)
(4) Press out the bushing.
Fig. 11 UPPER BALL JOINT - INSTALLATION
1 - C-4212F PRESS
2 - 8861-1 RECEIVER
3 - 8861-2 DRIVER
Fig. 12 LOWER SUSPENSION ARM BUSHING
REMOVAL
1 - 8839 THREADED ROD
2 - 8862-4 RECEIVER
3 - 8862-5 SPACER
4 - 8862-1 OR 8862-2 DRIVERS
KJSUSPENSION 2s - 7
UPPER BALL JOINT (Continued)

(8) Place new clamps onto new boot and slide boot
onto the shaft to it's original position.
(9) Apply the rest of lubricant to the C/V joint and
boot.
(10) Install the joint onto the shaft. Push the joint
onto the shaft until the snap ring seats in the groove
(Fig. 15). Pull on the joint to verify the span ring has
engaged.
(11) Position the boot on the joint in it's original
position. Ensure that the boot is not twisted and
remove any excess air.
(12) Secure both boot clamps (Fig. 16) with Clamp
Installer C-4975A. Place tool on clamp bridge and
tighten tool until the jaws of the toll are closed.
CV JOINT/BOOT-INNER
REMOVAL
(1) Clamp shaft in a vise (with soft jaws) and sup-
port C/V joint.
(2) Remove clamps with a cut-off wheel or grinder.
CAUTION: Do not damage C/V housing or half
shaft.
(3) Slide the boot down the shaft (Fig. 17).
Fig. 15 OUTER C/V JOINT
1 - SNAP RING
2 - SHAFT TAPER
3 - SNAP RING GROVE
4 - BEARING HUB
Fig. 16 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
Fig. 17 INNER C/V BOOT
1 - HOUSING
2 - BOOT
3 - HOUSING SNAP RING
KJHALF SHAFT 3 - 15
CV JOINT/BOOT-OUTER (Continued)

(8) Apply grease to the housing bore (Fig. 25) then
install the bearing assmbly into the housing.(9) Install the housing snap ring and verify it is
seated in the groove.
(10) Fill the housing and boot with the remaining
grease.
(11) Slide the boot onto the C/V housing into it's
original position. Ensure boot is not twisted and
remove any excess air.
(12) Secure both boot clamps with Clamp Installer
C-4975A. Place tool on clamp bridge and tighten tool
until the jaws of the tool are closed.
Fig. 25 C/V COMPONENTS
1 - HOUSING
2 - BEARING ASSEMBLY
3 - HOUSING SNAP RING
4 - HOUSING BORE
3 - 18 HALF SHAFTKJ
CV JOINT/BOOT-INNER (Continued)

PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 10).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8804 and rear pinion bearing onto Screw 6741
(Fig. 10).
(2) Insert height gauge components into the hous-
ing through pinion bearing cups.
(3) Install front pinion bearing and hand tight
Cone-nut 6740 onto the screw.
(4) Position Arbor Disc 6732 and Arbor D-115-3
into the housing bearing cradles. Install differential
bearing caps on Arbor Discs and tighten bolts to 41
N´m (30 ft. lbs.) (Fig. 11).
NOTE: Arbor Discs 6732 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) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold the scooter block and
zero the dial indicator.
(7) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 12). Move the
scooter block till the dial indicator probe crests the
arbor and record the highest reading.
(8) Select a shim/oil slinger equal to the dial indi-
cator reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 8). For example,
if the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL
Differential bearing preload and gear backlash is
adjusted by the use of selective shims. The shims are
located between the differential bearing cups and the
differential housing. The proper shim thickness can
be determined using slip-fit Dummy Bearings D-348
in place of the differential side bearings and a Dial
Indicator C-3339. Before proceeding with the differ-
ential bearing preload and gear backlash measure-
ments, 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 mea-
sured, the pinion is installed, and the gear backlash
Fig. 10 PINION GEAR DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 11 DEPTH TOOLS IN HOUSING
1 - PINION HEIGHT BLOCK
2 - ARBOR DISC
3 - ARBOR
4 - PINION BLOCK
KJFRONT AXLE - 186FIA 3 - 27
FRONT AXLE - 186FIA (Continued)