2002 JEEP LIBERTY differential

(6) Install the bearing caps in their correct posi-
tions and snug the bolts (Fig. 15).
(7) With a dead-blow hammer, seat the differential
dummy bearings to each side of the axle housing
(Fig. 16) and (Fig. 17).(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear.
(9) Attach a Dial Indicator C-3339 to the Pilot
Stud. Position the dial indicator plunger on flat sur-
face between the ring gear bolts.
(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 18).
Fig. 15 BEARING CAP BOLTS
Fig. 16 SEAT DUMMY BEARINGS PINION SIDE
1 - HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL
Fig. 17 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTAIL HOUSING
2 - HAMMER
3 - RING GEAR
Fig. 18 DIFFERENTIAL PINION GEAR SIDE
1 - PINION SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
KJFRONT AXLE - 186FIA 3 - 29
FRONT AXLE - 186FIA (Continued)

(11) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 19).
(12) Add 0.152 mm (0.006 in.) to the zero end play
total. This new total represents the thickness of
shims to compress or preload the new bearings when
the differential is installed.
(13) Rotate dial indicator out of the way on the
pilot stud.
(14) Remove differential case and dummy bearings
from the housing.
(15) Install the pinion gear in the housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(16) Install differential case and Dummy Bearings
D-348 in the housing.
(17) Install a single dummy shim in the ring gear
side. Install bearing caps and tighten bolts snug.
(18) Seat ring gear side dummy bearing (Fig. 17).
(19) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads.
(20) Push and hold differential case toward pinion
gear and zero dial indicator (Fig. 20).
(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 21). Add dummy shim thickness to this reading.
This will be the total shim thickness to achieve zero
backlash.
(22) Subtract 0.076 mm (0.003 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness
shim required to achieve proper backlash.
(23) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
axle housing.(24) Rotate dial indicator out of the way on pilot
stud.
(25) Remove differential case and dummy bearings
from the housing.
(26) Install side bearings and cups on differential
case.
(27) Install spreader W-129-B with Adapter Set
6987 on the housing and spread axle opening enough
to receive differential case.
CAUTION: Never spread the differential housing
over 0.34 mm (0.013 in.). If the housing is over-
spread, it could be distorted or damaged.
Fig. 19 DIFFERENTIAL RING GEAR SIDE
1 - DIAL INDICATOR
2 - DIFFERENTIAL HOUSING
Fig. 20 DIFFERENTIAL PINION GEAR SIDE
1 - DIAL INDICATOR
2 - PINION GEAR
3 - RING GEAR
Fig. 21 DIFFERENTIAL RING GEAR SIDE
1 - DIAL INDICATOR
2 - PINION GEAR
3 - RING GEAR
3 - 30 FRONT AXLE - 186FIAKJ
FRONT AXLE - 186FIA (Continued)

(28) Place the bearing preload shims in the axle
housing, against the axle tubes.
(29) Install differential case into the housing.
(30) Remove spreader from the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 22).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the housing to the other (Fig.
23).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform
Gear Contact Pattern Analysis procedure.
GEAR CONTACT PATTERN
The ring gear and pinion teeth contact patterns
will show if the pinion depth is correct in the hous-
ing. It will also show if the ring gear backlash has
been adjusted correctly. The backlash can be adjusted
within specifications to achieve desired tooth contact
patterns.
(1) Apply a thin coat of hydrated ferric oxide or
equivalent to the drive and coast side of the ring gear
teeth.
(2) Wrap, twist and hold a shop towel around the
pinion yoke to increase the turning resistance of the
pinion. This will provide a more distinct contact pat-
tern.
(3) With a boxed end wrench on a ring gear bolt,
rotate the differential case one complete revolution in
both directions while a load is being applied from
shop towel.
The areas on the ring gear teeth with the greatest
degree of contact against the pinion teeth will squee-
gee the compound to the areas with the least amount
of contact. Note and compare patterns on the ring
gear teeth to Gear Tooth Contact Patterns chart (Fig.
24)and adjust pinion depth and gear backlash as nec-
essary.Fig. 22 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 23 BACKLASH SHIMS
KJFRONT AXLE - 186FIA 3 - 31
FRONT AXLE - 186FIA (Continued)

DIFFERENTIAL BEARING PRELOAD CHECK
The final check on the differential assembly before
installing the axles, is torque to rotate pinion and
differential combined. This will verify the correct dif-
ferential bearing preload.
Torque to rotate the differential and pinion is the
torque to rotate the pinion plus:Gear Ratio 3.73....0.45-0.75 N´m (3.9-6.6 in. lbs.)
Gear Ratio 3.91....0.43-0.72 N´m (3.8-6.4 in. lbs.)
Gear Ratio 4.10....0.41-0.69 N´m (3.6-6.0 in. lbs.)
SPECIFICATIONS - FRONT AXLE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 3.92, 4.10
Ring Gear Diameter 186 mm (7.33 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 92.1 mm (3.625 in.)
Pinion Bearing Preload 1.69-2.82 N´m (15-25 in. lbs.)
Differential Bearing Preload
Added To Pinion Torque To Rotate
Gear Ratio 3.73 0.45-0.75 N´m (3.9-6.6 in. lbs.)
Gear Ratio 3.92 0.43-0.72 N´m (3.8-6.4 in. lbs.)
Gear Ratio 4.10 0.41-0.69 N´m (3.6-6.0 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Ring Gear Bolts 95-122 70-90 -
Differential Bearing Cap
Bolts54-67 39-50 -
Differential Cover Bolts 19-26 14-19 -
Pinion Nut 217-352 160-260 -
Left Axle Bracket Bolts 61 45 -
Front Axle Bracket Bolts 61 45 -
Right Axle Bracket Bolts 88 65 -
Axle Brackets To Frame
Bolts88 65 -
KJFRONT AXLE - 186FIA 3 - 33
FRONT AXLE - 186FIA (Continued)

AXLE SHAFTS
REMOVAL
(1) Place the transmission in Neutral.
(2) Raise and support vehicle.
(3) Remove right wheel and tire and assembly.
(4) Remove right half shaft from vehicle.
(5) Remove snap ring from axle shaft.
(6) Assemble Remover 8420A onto the shaft (Fig.
25). Thread slid hammer into remover and remove
shaft.
(7) Slide axle shaft out of the axle tube.
NOTE: Use care to prevent damage to axle shaft
bearing and seal, which will remain in axle shaft
tube.
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant. Insert axle shaft through seal, bearing
(Fig. 26) and engage it into side gear splines.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal.
(2) Push on the axle shaft until the axle shaft
snap-ring passes through the side gear.
(3) Install right half shaft.
(4) Install right wheel and tire assembly.
(5) Check differential fluid level.
(6) Lower vehicle.
AXLE SHAFT SEALS
REMOVAL
(1) Remove half shaft.
(2) Remove axle shaft for right side seal removal.
(3) Remove shaft seal with Remover 7794-A and a
slide hammer (Fig. 27).
Fig. 25 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 26 AXLE SHAFT SEAL
1 - BEARING
2 - SEAL
Fig. 27 SHAFT SEAL REMOVER
1 - SHAFT SEAL
2 - REMOVER
KJFRONT AXLE - 186FIA 3 - 37

(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)