2002 JEEP LIBERTY Rear axle

(24) Rotate dial indicator out of the way on pilot
stud.
(25) Remove differential case and dummy bearings
from the housing.
(26) Install new side bearing cones and cups on
differential case.
(27) Install spreader W-129-B and some compo-
nents of Adapter Set 6987 on differential housing and
spread axle opening enough to receive differential
case.
(28) Place side bearing shims into the housing
against the axle tubes.
(29) Install differential case in the housing.
(30) Rotate the differential case several times to
seat the side bearings.
(31) Position the indicator plunger against a ring
gear tooth (Fig. 22).
(32) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(33) Zero dial indicator face to pointer.
(34) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.13-0.20 mm (0.005-0.008
in.). If backlash is not within specifications transfer
the necessary amount of shim thickness from one
side of the differential housing to the other (Fig. 23).
(35) 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 varymore than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform the
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
squeeze 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 necessary.
Fig. 22 RING GEAR BACKLASH
1 - DIAL INDICATOR
Fig. 23 BACKLASH SHIM
3 - 60 REAR AXLE - 198RBIKJ
REAR AXLE - 198RBI (Continued)

Fig. 24 GEAR TOOTH CONTACT PATTERNS
KJREAR AXLE - 198RBI 3 - 61
REAR AXLE - 198RBI (Continued)

DIFFERENTIAL BEARING PRELOAD CHECK
The final check on the differential assembly before
installing the axles is torque to rotate pinion and dif-
ferential combined. This will verify the correct differ-
ential bearing preload.Torque to rotate the differential and pinion is the
torque to rotate the pinion plus:
Gear Ratio 3.73.......0.45-0.76 N´m (4-7 in. lbs.)
Gear Ratio 4.10......0.41-0.69 N´m (3.6-6 in. lbs.)
SPECIFICATIONS - REAR AXLE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73 4.10
Ring Gear Diameter 198 mm (7.795 in.)
Ring Gear Backlash 0.13-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 96.85 mm (3.813 in.)
Pinion Bearing Preload - New Bearings 1.69-2.82 N´m (15-25 in. lbs.)
Differential Side Gear Clearance 0-0.15 mm (0-0.006 in.)
Differential Bearing Preload 0.20 mm (0.008 in.)
Differential Bearing Preload Added To Pinion Torque To Rotate
3.73 Gear Ratio 0.45-0.76 N´m (4-7 in. lbs.)
4.10 Gear Ratio 0.41-0.69 N´m (3.6-6 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Ring Gear Bolts 129-142 95-105 -
Differential Bearing Cap
Bolts64-91 47-67 -
Differential Cover Bolts 38-45 28-33 -
Pinion Nut (Minimum) 271 200 -
Cross Shaft Lock Screw 11-22 8-16 -
3 - 62 REAR AXLE - 198RBIKJ
REAR AXLE - 198RBI (Continued)

SPECIAL TOOLS
REAR AXLE
PULLER C-293-PA
ADAPTER 8352
ADAPTER C-293-39
PLUG SP-3289
PULLER C-452
WRENCH C-3281
SPANNER WRENCH 6958
HANDLE C-4171
INSTALLER C-3716-A
INSTALLER D-130
KJREAR AXLE - 198RBI 3 - 63
REAR AXLE - 198RBI (Continued)

INSTALLER D-146
REMOVER D-103
REMOVER D-149
INSTALLER W-262
PINION DEPTH 6774
TRAC-LOK TOOLS 6960
FIXTURE 6965
SHIMS DUMMY 8107
SPREADER W-129-B
ADAPTER KIT 6987
3 - 64 REAR AXLE - 198RBIKJ
REAR AXLE - 198RBI (Continued)

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)

AXLE BEARING/SEAL
REMOVAL
(1) Remove axle shaft from vehicle.
(2) Drill a shallow hole into soft steel axle bearing
retaining ring with a 3/8 in. drill bit (Fig. 25). Use a
drill depth stop to avoid marking the axle.
(3) With a cold chisel cut the retaining ring across
drilled hole. (Fig. 26)
(4) Slide retaining ring from axle shaft.
(5) Remove axle bearing from the shaft with a
press and Splitter 1130 placed between the seal and
bearing (Fig. 27).
(6) Remove seal from axle.
(7) Remove retaining plate from axle shaft.
Fig. 25 DRILL RETAINING RING
1 - DRILL BIT
2 - AXLE
3 - RETAINING PLATE
4 - RETAINING RING
Fig. 26 CUT RETAINING RING
1 - AXLE
2 - COLD CHISEL
3 - VISE
4 - RETAINING RING
Fig. 27 AXLE BEARING AND SEAL
1 - SPLITTER
2 - AXLE SHAFT
3 - BLOCKS
4 - BLOCKS
3 - 66 REAR AXLE - 198RBIKJ

INSTALLATION
NOTE: Verify axle shaft retaining plate is flat with a
straight edge. If the plate is warped replace the
plate.
(1) Install retaining plate on the axle shaft (Fig.
28).
(2) Apply a coat of multi-purpose grease on sealing
surface of axle seal.
(3) Install seal on the axle shaft with cavity away
from retaining plate (Fig. 28).
(4) Lubricate bearing with MopartWheel Bearing
Grease or equivalent. Wipe excess grease from the
bearing.
(5) Install bearing on the axle shaft with Installer
7913 and a press (Fig. 29).
(6) Press retaining ring onto axle shaft with
Installer 7913 and a press (Fig. 30).
(7) Install axle in vehicle.
Fig. 29 BEARING ON AXLE
1 - PRESS RAM
2 - INSTALLER - 7913
3 - AXLE BEARING
4 - SEAL
5 - RETAINING PLATE
6 - AXLE
Fig. 30 BEARING RETAINING RING ON AXLE
1 - PRESS
2 - AXLE
3 - AXLE BEARING
4 - INSTALLER
5 - SOFT METAL RETAINING RING
Fig. 28 AXLE BEARING AND SEAL COMPONENTS
1 - RETAINING RING
2 - SEAL
3 - AXLE
4 - RETAINING PLATE
5 - AXLE BEARING
KJREAR AXLE - 198RBI 3 - 67
AXLE BEARING/SEAL (Continued)