2002 JEEP LIBERTY brake

AXLE SHAFTS
REMOVAL
(1) Place transmission in neutral and raise and
support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake drum.
(4) Remove axle retainer plate nuts from the rear
of the axle flange.
(5) Pull axle shaft from the axle with Slide Ham-
mer 7420 and Adapter 6790. Mount the adapter to
the axle with lug nuts.
NOTE: It is normal that the axle bearing race is
loose in the axle tube.
INSTALLATION
(1) Insall axle into the axle tube with the flat area
of the retainer plate upward.
(2) Insert retaining plate studs into the brake
backing plate and axle tube flange.
(3) Install retainer nuts and tighten to 47-75 N´m
(35-55 ft. lbs.).
(4) Install the brake drum.
(5) Install wheel and tire.
(6) Check and fill the differential with gear lubri-
cant.
(7) Lower vehicle.
PILOT STUDS C-3288-B
PULLER 6790
DIAL INDICATOR C-3339
INSTALLER C-3718
KJREAR AXLE - 198RBI 3 - 65
REAR AXLE - 198RBI (Continued)

PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove rear brake rotors drums.
(4) Mark propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate pinion gear three or four times and ver-
ify that pinion rotates smoothly.
(7) Measure and record torque to rotate the pinion
gear with an inch pound dial-type torque wrench.
(8) With a short piece of pipe and Spanner Wrench
6958 remove the pinion nut and washer (Fig. 31).
(9) Remove pinion companion flange with Remover
C-452 and Flange Wrench C-3281. (Fig. 32)
(10) Remove pinion seal with Remover 7794-A and
a slide hammer (Fig. 33).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
seal installer (Fig. 34).
(2) Install yoke on the pinion gear with Installer
C-3718 and Spanner Wrench 6958 (Fig. 35).(3) Install anewnut on the pinion gear.Tighten
the nut only enough to remove the shaft end
play.
CAUTION: Do not exceed the minimum torque 271
N´m (200 ft. lbs.) when installing the pinion yoke
retaining nut at this point. Damage to collapsible
spacer or bearings may result.
(4) Rotate the pinion a minimum of ten times and
verify pinion rotates smoothly.
(5) Measure and recore pinion torque to rotate
with an inch pound torque wrench. Torque to rotate
should be equal to the reading recorded during
removal, plus 0.56 N´m (5 in. lbs.) (Fig. 36).
Fig. 31 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 32 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 33 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
3 - 68 REAR AXLE - 198RBIKJ

(8) Fill differential with gear lubricant.
(9) Install the brake drums
(10) Install wheel and tire assemblies.
(11) Lower the vehicle.
COLLAPSIBLE SPACER
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove rear brake drums.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure and record torque to rotate the pinion
gear with an inch pound dial-type torque wrench.
(8) Hold pinion yoke with Spanner Wrench 6958
and remove pinion nut and washer.
(9) Remove the pinion yoke with Remover C-452
and Flange Wrench C-3281 (Fig. 38).
(10) Remove pinion shaft seal with a pry tool or a
slide hammer mounted screw.
(11) Remove front pinion bearing using a pair of
pick tools. Pull the bearing straight off the pinion
gear shaft. If the bearing becomes bound on the pin-
ion shaft, lightly tap the end of the pinion gear with
a rawhide/rubber hammer.
(12) Remove the collapsible spacer.
INSTALLATION
(1) Install anewcollapsible preload spacer on pin-
ion shaft.
(2) Install pinion front bearing.(3) Apply a light coating of gear lubricant on the
lip of pinion seal and install anewseal with an
appropriate installer (Fig. 39).
(4) Install yoke with Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fig. 40).
(5) Install yoke washer andnewnut on the pinion
gear. Tighten the nut to 271 N´m (200 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. If preload torque
or rotating torque is exceeded a new collapsible
spacer must be installed.
Fig. 38 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - REMOVER
Fig. 39 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 40 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - WRENCH
3 - 70 REAR AXLE - 198RBIKJ
PINION SEAL (Continued)

(6) Using yoke with Spanner Wrench 6958 and a
torque wrench set at 474 N´m (350 ft. lbs.), (Fig. 41)
slowly tighten the nut in 6.8 N´m (5 ft. lbs.) incre-
ments until the rotating torque is achieved. Measure
the rotating torque frequently to avoid over crushing
the collapsible spacer (Fig. 42).
NOTE: If more than 474 N´m (350 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
(7) Check rotating torque with an inch pound
torque wrench (Fig. 42). The rotating torque of the
pinion gear should be, the reading recorded during
removal plus an additional 0.56 N´m (5 in. lbs.).
(8) Install propeller shaft with reference marks
aligned.
(9) Install rear brake drums.
(10) Add gear lubricant, if necessary.
(11) Install wheel and tire assemblies.
(12) Remove supports and lower vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove differential cover and drain fluid.
(3) Clean the housing cavity with flushing oil, light
engine oil or lint free cloth.NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
(4) Remove axle shafts.
(5)
Note the reference letters stamped on the bearing
caps and housing machined sealing surface (Fig. 43).
Fig. 41 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 42 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 43 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
KJREAR AXLE - 198RBI 3 - 71
COLLAPSIBLE SPACER (Continued)

(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)

REMOVAL
(1) Raise and support the vehicle.
(2) Position a lift/jack under the axle and secure
axle to device.
(3) Remove wheels and tires.
(4) Mark propeller shaft and pinion yoke for
installation reference.
(5) Remove propeller shaft and suspend under the
vehicle.
(6) Remove brake drums, parking brake cables and
speed sensor from the axle.
(7) Disconnect the brake hose at the body junction
block.
(8) Remove brakes and backing plates.
(9) Remove vent hose from the axle shaft tube.
(10) Remove the stabilizer bar (Fig. 4).
(11) Remove upper control arm ball joint pinch
bolt from bracket (Fig. 5).
(12) Remove shock absorbers from axle brackets
(Fig. 6).
(13) Loosen all lower control arms mounting bolts
(Fig. 7).
(14) Lower axle enough to remove coil springs and
spring insulators.
(15) Remove lower control arm bolts from the axle
brackets.
(16) Lower and remove the axle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.(1) Raise the axle under the vehicle.
(2) Install lower control arms onto the axle brack-
ets and loosely install the mounting bolts.
(3) Install coil spring isolators and spring.
(4) Raise axle up until springs are seated.
(5) Install upper control arm ball joint into axle
bracket and tighten pinch bolt to torque specification.
(6) Install shock absorbers and tighten nuts to
torque specification.
(7) Install stabilizer bar and tighten nuts to torque
specification.
(8) Install brake backing plates, parking brake
cables, brake drums and speed sensor.
(9) Install brake hose to the body junction block
and bleed the brakes.
Fig. 4 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
Fig. 5 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 6 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
KJREAR AXLE - 8 1/4 3 - 91
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)