2002 JEEP LIBERTY Table of Contents

DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT......................1
HALF SHAFT...........................10
FRONT AXLE - 186FIA....................19REAR AXLE - 198RBI.....................49
REAR AXLE-81/4.......................86
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT...............................1
STANDARD PROCEDURES - PROPELLER
SHAFT ANGLE........................3
SPECIFICATIONS
PROPELLER SHAFT....................6
SPECIAL TOOLS........................6
PROPELLER SHAFT - FRONT
REMOVAL.............................6INSTALLATION..........................6
PROPELLER SHAFT - REAR
REMOVAL.............................7
INSTALLATION..........................7
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY..........................8
ASSEMBLY.............................9
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT
VIBRATION
Tires that are out-of-round, or wheels that are
unbalanced, will cause a low frequency vibration.
Brake rotors that are unbalanced will cause a
harsh, low frequency vibration.Driveline vibration can also result from loose or
damaged engine mounts.
Propeller shaft vibration increases as the vehicle
speed is increased. A vibration that occurs within a
specific speed range is not usually caused by a pro-
peller shaft being unbalanced. Defective joints or an
incorrect propeller shaft angle, are usually the cause
of such a vibration.
KJDIFFERENTIAL & DRIVELINE 3 - 1

HALF SHAFT
TABLE OF CONTENTS
page page
HALF SHAFT
CAUTION.............................10
DIAGNOSIS AND TESTING - HALF SHAFT....10
REMOVAL.............................10
INSTALLATION.........................11
SPECIFICATIONS
HALF SHAFT.........................11SPECIAL TOOLS.......................12
CV JOINT/BOOT-OUTER
REMOVAL.............................12
INSTALLATION.........................13
CV JOINT/BOOT-INNER
REMOVAL.............................15
INSTALLATION.........................17
HALF SHAFT
CAUTION
CAUTION:: Never grasp half shaft assembly by the
boots. This may cause the boot to pucker or crease
and reduce the service life of the boot.
Avoid over angulating or stroking the C/V joints
when handling the half shaft.
Half shafts exposed to battery acid, transmission
fluid, brake fluid, differential fluid or gasoline may
cause the boots to deteriorate.
DIAGNOSIS AND TESTING - HALF SHAFT
Check for grease at the inboard and outboard C/V
joint. This is a sign of boot or boot clamp damage.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise or a vibration in turns could be
caused by a damaged outer C/V or inner tripod joint
seal boot or seal boot clamps. This will result in the
loss/contamination of the joint grease, resulting in
inadequate lubrication of the joint. Noise could also
be caused by another component of the vehicle com-
ing in contact with the half shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of a damaged or worn
C/V joint. A torn boot or loose/missing clamp on the
inner/outer joint which has allowed the grease to be
lost will damage the C/V joint.
SHUDDER OR VIBRATION DURING ACCELERATION
This problem could be a result of a worn/damaged
inner tripod joint or a sticking tripod joint. Improper
wheel alignment may also cause a shudder or vibration.
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of out of balance
front tires or tire/wheel runout. Foreign material
(mud, etc.) packed on the backside of the wheel(s)
will also cause a vibration.
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove half shaft hub nut.
(4) Remove stabilizer link (Fig. 1).
Fig. 1 STABILIZER BAR LINK
1 - STABILIZER BAR
2 - STABILIZER BAR LINK
3 - 10 HALF SHAFTKJ

FRONT AXLE - 186FIA
TABLE OF CONTENTS
page page
FRONT AXLE - 186FIA
DESCRIPTION.........................19
OPERATION...........................19
DIAGNOSIS AND TESTING - AXLE..........20
REMOVAL.............................24
INSTALLATION.........................24
ADJUSTMENTS........................25
SPECIFICATIONS - FRONT AXLE...........33
SPECIAL TOOLS
FRONT AXLE........................34
AXLE SHAFTS
REMOVAL.............................37
INSTALLATION.........................37
AXLE SHAFT SEALS
REMOVAL.............................37
INSTALLATION.........................38
AXLE BEARINGS
REMOVAL.............................38INSTALLATION.........................38
PINION SEAL
REMOVAL.............................38
INSTALLATION.........................39
DIFFERENTIAL
REMOVAL.............................40
DISASSEMBLY.........................41
ASSEMBLY............................41
INSTALLATION.........................42
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................43
INSTALLATION.........................44
PINION GEAR/RING GEAR
REMOVAL.............................44
INSTALLATION.........................46
FRONT AXLE - 186FIA
DESCRIPTION
The 186FIA (Model 30) axle consists of an alumu-
num center section with an axle tube extending from
one side. The tube is pressed into the differential
housing. The integral type housing, hypoid gear
design has the centerline of the pinion set below the
centerline of the ring gear.
The differential case is a one-piece design. The differ-
ential pinion mate shaft is retained with a roll-pin. Dif-
ferential bearing preload and ring gear backlash is
adjusted by the use of shims (select thickness). The
shims are located between the differential bearing cups
and the axle housing. Pinion bearing preload is set and
maintained by the use of a collapsible spacer.
The power is transferred from the axle through two
constant velocity (C/V) drive shafts to the wheel hubs.
The differential cover provides a means for inspec-
tion and service without removing the axle from the
vehicle. The cover has a vent tube used to relieve
internal pressure caused by vaporization and inter-
nal expansion.
OPERATION
The axle receives power from the transfer case through
the front propeller shaft. The front propeller shaft is con-
nected to the pinion gear which rotates the differential
through the gear mesh with the ring gear bolted to thedifferential case. The engine power is transmitted to the
axle shafts through the pinion mate and side gears. The
side gears are splined to the axle shafts.
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
Fig. 1 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - STRAIGHT AHEAD DRIVING
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
KJFRONT AXLE - 186FIA 3 - 19

REAR AXLE - 198RBI
TABLE OF CONTENTS
page page
REAR AXLE - 198RBI
DESCRIPTION.........................49
OPERATION...........................49
DIAGNOSIS AND TESTING - AXLE..........51
REMOVAL.............................54
INSTALLATION.........................54
ADJUSTMENTS
ADJUSTMENT........................55
SPECIFICATIONS - REAR AXLE............62
SPECIAL TOOLS
REAR AXLE..........................63
AXLE SHAFTS
REMOVAL.............................65
INSTALLATION.........................65
AXLE BEARING/SEAL
REMOVAL.............................66
INSTALLATION.........................67
PINION SEAL
REMOVAL.............................68INSTALLATION.........................68
COLLAPSIBLE SPACER
REMOVAL.............................70
INSTALLATION.........................70
DIFFERENTIAL
REMOVAL.............................71
INSTALLATION.........................73
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT.....74
DISASSEMBLY.........................75
CLEANING............................77
INSPECTION..........................77
ASSEMBLY............................77
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................79
INSTALLATION.........................79
PINION GEAR/RING GEAR/TONE RING
REMOVAL.............................79
INSTALLATION.........................82
REAR AXLE - 198RBI
DESCRIPTION
The Rear Beam-design Iron (RBI) axle housing has
an iron center casting (differential housing) with axle
shaft tubes extending from either side. The tubes are
pressed into and welded to the differential housing to
form a one-piece axle housing. The axles are
equipped with semi±floating axle shafts, meaning
that loads are supported by the axle shaft and bear-
ings. The axle shafts are retained by the unit bear-
ing, retainer plate and bolts.
The integral type, hypoid gear design, housing has
the centerline of the pinion set below the centerline
of the ring gear. The differential case is a one-piece
design. The differential pinion mate shaft is retained
with a threaded screw. Differential bearing preload
and ring gear backlash is adjusted by the use of
selective spacer shims. Pinion bearing preload is set
and maintained by the use of a collapsible spacer
(Fig. 1).
The cover provides a means for servicing the differ-
ential without removing the axle. The axle has a vent
hose to relieve internal pressure caused by lubricant
vaporization and internal expansion.
Axles equipped with a Trac-Loktdifferential are
optional. A Trac-Loktdifferential has a one-piece dif-ferential case, and the same internal components as
a standard differential, plus two clutch disc packs.
OPERATION
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
Fig. 1 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 - COLLAPSIBLE SPACER
KJREAR AXLE - 198RBI 3 - 49

REAR AXLE-81/4
TABLE OF CONTENTS
page page
REAR AXLE-81/4
DESCRIPTION.........................86
OPERATION...........................86
DIAGNOSIS AND TESTING - AXLE..........88
REMOVAL.............................91
INSTALLATION.........................91
ADJUSTMENTS........................92
SPECIFICATIONS
REAR AXLE..........................98
SPECIAL TOOLS
8 1/4 AXLE..........................98
AXLE SHAFTS
REMOVAL............................101
INSTALLATION........................101
AXLE SHAFT SEALS
REMOVAL............................101
INSTALLATION........................102
AXLE BEARINGS
REMOVAL............................102
INSTALLATION........................102PINION SEAL
REMOVAL............................102
INSTALLATION........................103
DIFFERENTIAL
REMOVAL............................104
DISASSEMBLY........................105
ASSEMBLY...........................105
INSTALLATION........................105
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT....106
DISASSEMBLY........................107
CLEANING...........................109
INSPECTION.........................109
ASSEMBLY...........................109
DIFFERENTIAL CASE BEARINGS
REMOVAL............................110
INSTALLATION........................110
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................110
INSTALLATION........................112
REAR AXLE-81/4
DESCRIPTION
The axle housings consist of a cast iron center sec-
tion with axle tubes extending from either side. The
tubes are pressed into and welded to the differential
housing to form a one-piece axle housing. The axles
are equipped with semi-floating axle shafts, meaning
vehicle loads are supported by the axle shaft and
bearings. The axle shafts are retained by C-locks in
the differential side gears.
The differential case is a one-piece design. The dif-
ferential pinion mate shaft is retained with a
threaded pin. Differential bearing preload and ring
gear backlash are set and maintained by threaded
adjusters at the outside of the differential housing.
Pinion bearing preload is set and maintained by the
use of a collapsible spacer.
The differential cover provides a means for inspec-
tion and service without removing the complete axlefrom the vehicle. A vent hose is used to relieve inter-
nal pressure caused by lubricant vaporization and
internal expansion.
Axles equipped with a Trac-Loktdifferential are
optional. A differential has a one-piece differential
case, and the same internal components as a stan-
dard differential, plus two clutch disc packs.
OPERATION
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
through the pinion mate and side gears. The side
gears are splined to the axle shafts.
3 - 86 REAR AXLE-81/4KJ

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 32
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION..........................2
WARNING.............................2
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................3
STANDARD PROCEDURE
STANDARD PROCEDURE - PRESSURE
BLEEDING............................5
STANDARD PROCEDURE - MANUAL
BLEEDING............................6
SPECIFICATIONS
BRAKE COMPONENTS..................6
TORQUE.............................7
SPECIAL TOOLS
BASE BRAKES........................7
BRAKE LINES
DESCRIPTION..........................8
DIAGNOSIS AND TESTING - BRAKE LINE
AND HOSES..........................8
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING....................8
STANDARD PROCEDURE - ISO FLARING . . . 8
REMOVAL
REMOVAL - FRONT HOSE...............9
REMOVAL - REAR BRAKE HOSE..........9
INSTALLATION
INSTALLATION - FRONT BRAKE HOSE....10
INSTALLATION - REAR BRAKE HOSE......10
BRAKE PADS / SHOES
DESCRIPTION - REAR DRUM BRAKE.......10
OPERATION - REAR DRUM BRAKE.........11
REMOVAL
REMOVAL - FRONT BRAKE PADS.........11
REMOVAL - DRUM BRAKE SHOES........11
INSTALLATION
INSTALLATION - FRONT BRAKE PADS.....11INSTALLATION - DRUM BRAKE SHOES....11
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE......12
DISC BRAKE CALIPERS
DESCRIPTION.........................13
OPERATION...........................14
REMOVAL.............................14
DISASSEMBLY.........................14
CLEANING............................16
INSPECTION..........................16
ASSEMBLY............................16
INSTALLATION.........................17
DISC BRAKE CALIPER ADAPTER
REMOVAL.............................18
INSTALLATION.........................18
ROTORS
DIAGNOSIS AND TESTING - DISC BRAKE
ROTOR .............................18
STANDARD PROCEDURE - DISC BRAKE
ROTOR .............................19
REMOVAL.............................19
INSTALLATION.........................19
JUNCTION BLOCK
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING -
PROPORTIONING VALVE...............20
REMOVAL.............................20
INSTALLATION.........................20
PEDAL
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
POWER BRAKE BOOSTER
DESCRIPTION.........................21
OPERATION...........................21
KJBRAKES 5 - 1

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION.........................32
OPERATION...........................32
DIAGNOSIS AND TESTING - ANTILOCK
BRAKING SYSTEM....................33
STANDARD PROCEDURE - ABS BRAKE
BLEEDING...........................33
SPECIFICATIONS.......................33
ELECTRICAL
DESCRIPTION.........................34
OPERATION...........................34FRONT WHEEL SPEED SENSOR
REMOVAL.............................34
INSTALLATION.........................34
REAR WHEEL SPEED SENSOR
REMOVAL.............................35
INSTALLATION.........................35
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................35
OPERATION...........................35
REMOVAL.............................36
INSTALLATION.........................36
BRAKES - ABS
DESCRIPTION
ANTILOCK BRAKING SYSTEM
The purpose of the antilock system is to prevent
wheel lockup during periods of high wheel slip. Pre-
venting lockup helps maintain vehicle braking action
and steering control.
The antilock CAB activates the system whenever
sensor signals indicate periods of high wheel slip.
High wheel slip can be described as the point where
wheel rotation begins approaching 20 to 30 percent of
actual vehicle speed during braking. Periods of high
wheel slip occur when brake stops involve high pedal
pressure and rate of vehicle deceleration.
Battery voltage is supplied to the CAB ignition ter-
minal when the ignition switch is turned to Run posi-
tion. The CAB performs a system initialization
procedure at this point. Initialization consists of a
static and dynamic self check of system electrical
components.
The static check occurs after the ignition switch is
turned to Run position. The dynamic check occurs
when vehicle road speed reaches approximately 30
kph (18 mph). During the dynamic check, the CAB
briefly cycles the pump and solenoids to verify oper-
ation.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
ELECTRONIC BRAKE DISTRIBUTION
The electronic brake distribution (EBD) functions
like a rear proportioning valve. The EBD system usesthe ABS system to control the slip of the rear wheels
in partial braking range. The braking force of the
rear wheels is controlled electronically by using the
inlet and outlet valves located in the HCU.
OPERATION
ANTILOCK BRAKING SYSTEM
During normal braking, the master cylinder, power
booster and wheel brake units all function as they
would in a vehicle without ABS. The HCU compo-
nents are not activated.
During antilock braking fluid pressure is modu-
lated according to wheel speed, degree of slip and
rate of deceleration. A sensor at each wheel converts
wheel speed into electrical signals. These signals are
transmitted to the CAB for processing and determi-
nation of wheel slip and deceleration rate.
The ABS system has three fluid pressure control
channels. The front brakes are controlled separately
and the rear brakes in tandem. A speed sensor input
signal indicating a high slip condition activates the
CAB antilock program. Two solenoid valves are used
in each antilock control channel. The valves are all
located within the HCU valve body and work in pairs
to either increase, hold, or decrease apply pressure as
needed in the individual control channels. The sole-
noid valves are not static during antilock braking.
They are cycled continuously to modulate pressure.
Solenoid cycle time in antilock mode can be mea-
sured in milliseconds.
ELECTRONIC BRAKE DISTRIBUTION
Upon entry into EBD the inlet valve for the rear
brake circuit is switched on so that the fluid supply
from the master cylinder is shut off. In order to
decrease the rear brake pressure the outlet valve for
5 - 32 BRAKES - ABSKJ

BRAKES
TABLE OF CONTENTS
page page
POWER BRAKE BOOSTER
REMOVAL - RHD........................1INSTALLATION - RHD.....................1
POWER BRAKE BOOSTER
REMOVAL - RHD
(1) Remove the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(2) Relocate the cruise control servo to gain access
to the booster for removal.
(3) Remove the brake lines from the master cylin-
der.
(4) Remove the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL).
(5) Disconnect vacuum hose from booster check
valve.
(6) Remove knee blocker under the steering colum-
n,(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(7) Remove the brake light switch.(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL)
(8) Remove retaining clip that secures booster
push rod to brake pedal (Fig. 1).
(9) Remove nuts attaching booster to the dash
panel (Fig. 2).(10) In engine compartment, slide booster studs
out of dash panel, tilt booster upward, and remove
booster from engine compartment.
INSTALLATION - RHD
(1) Align and position booster on the dash panel.
(2) Install booster mounting nuts. Tighten nuts
just enough to hold booster in place.
(3) Slide booster push rod onto the brake pedal.
Then secure push rod to pedal pin with retaining
clip.
NOTE: Lubricate the pedal pin with Mopar multi-
mileage grease before installation.
(4) Tighten booster mounting nuts to 39 N´m (29
ft. lbs.).
(5) Install the brake light switch.
(6) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
(7) If original master cylinder is being installed,
check condition of seal at rear of master cylinder.
Replace seal if cut, or torn.
(8) Clean cylinder mounting surface of brake
booster. Use shop towel wetted with brake cleaner for
Fig. 1 BOOSTER PUSH ROD
1 - BRAKE PEDAL
2 - BOOSTER ROD
Fig. 2 BOOSTER MOUNTING
1 - BRAKE BOOSTER
KJBRAKES 5s - 1