2002 JEEP LIBERTY differential

(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) Loosen the differential bearing cap bolts.
(7) With Spreader W-129-B and adapters from
Adapter set 6987, position the adapters in the differ-
ential holes (Fig. 44). Install hold-down clamps and
tighten the tool turnbuckle finger-tight.
(8) Install Pilot Stud C-3288-B at 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 (Fig. 45) and zero the
indicator.
(9) Spread the housing while measuring the dis-
tance with the dial indicator. Spread the housing
enough to remove the differential case (Fig. 46).
CAUTION: Do not spread over 0.38 mm (0.015 in). If
housing is over-spread, it could be distorted or
damaged.
(10) Remove the dial indicator and pilot stud.
(11) Remove differential bearing cap bolts and caps
while holding the case.
Fig. 44 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - ADAPTER
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 45 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 46 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
3 - 72 REAR AXLE - 198RBIKJ
DIFFERENTIAL (Continued)

(12) Remove differential from the housing. Ensure
that the differential bearing cups remain in position
on the differential bearings (Fig. 47).
(13) Remove bearing cups from the differential and
tag them to indicate their location.
(14) Remove differential case preload shims from
the housing and tag them to indicate their location.
(15) Remove spreader from housing.
INSTALLATION
NOTE: If differential bearings or differential case are
replaced, differential bearing preload shim require-
ments may change. Refer Adjustments (Differential
Bearing Preload and Gear Backlash) to determine
the proper shim selection.
(1) With Spreader W-129-B and adapters from
Adapter set 6987, position the adapters in the differ-
ential holes (Fig. 48). Install the hold-down clamps
and tighten the tool turnbuckle finger-tight.
(2) Install a Pilot Stud C-3288-B at 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 while measuring the dis-
tance with the dial indicator. Spread the housing
enough to install the differential case.
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over±spread, it could be distorted or
damaged.
(4) Remove the dial indicator.(5) Install differential case in the housing (Fig. 49)
with bearing cups and preload shims in their original
locations. Tap the differential case to ensure the
bearings cups and shims are fully seated in the hous-
ing.
Fig. 47 DIFFERENTIAL CASE
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPSFig. 48 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - ADAPTER
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 49 DIFFERENTIAL CASE
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
KJREAR AXLE - 198RBI 3 - 73
DIFFERENTIAL (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)

DISASSEMBLY
(1) Clamp side gear Fixture 6965 in a vise and set
differential case on the fixture (Fig. 53).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-loktdifferential can be serviced
with the ring gear installed.
(3) Remove pinion gear mate shaft lock screw (Fig.
54).(4) Remove pinion gear mate shaft with a drift and
hammer.
(5) Install and lubricate Step Plate 6960-3 (Fig.
55).
Fig. 52 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 53 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 54 MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 55 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
KJREAR AXLE - 198RBI 3 - 75
DIFFERENTIAL - TRAC-LOK (Continued)

(6) Assemble Threaded Adapter 6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
(7) Position a small screw driver in slot of
Threaded Adapter Disc 6960-3 (Fig. 56) to prevent
adapter from turning.
(8) Install Forcing Screw 6960-4 and tighten screw
to 122 N´m (90 ft. lbs.) maximum to compress
Belleville springs in clutch packs (Fig. 57).
(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 58).
Fig. 56 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - STEP PLATE
5 - THREADED ROD
6 - ADAPTER DISC
Fig. 57 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 58 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
3 - 76 REAR AXLE - 198RBIKJ
DIFFERENTIAL - TRAC-LOK (Continued)

(10) Insert Turning Bar 6960-2 into the pinion
mate shaft hole in the case (Fig. 59).
(11) Loosen the Forcing Screw in small increments
until the clutch pack tension is relieved and the dif-
ferential case can be turned using Turning Bar.
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in order during removal
(Fig. 60).
(16) Remove differential case from the Holding
Fixture. Remove side gear, clutch pack retainer and
clutch pack. Keep plates in order during removal.
CLEANING
Clean all components in cleaning solvent and dry
components with compressed air.
INSPECTION
Inspect clutch pack plates for wear, scoring or dam-
age. Replace both clutch packs if any one component
in either pack is damaged. Inspect side and pinion
gears for cracks chips or damage and replace as nec-
essary. Inspect differential case and pinion shaft and
replace if worn or damaged.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.(1) Lubricate components with gear lubricant.
(2) Assemble clutch discs into packs and secure
disc packs with retaining clips (Fig. 61).
NOTE: Dished plate is position with the convex side
against the side gear.
Fig. 59 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 60 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 61 CLUTCH PACK
1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
6 - PLATES
KJREAR AXLE - 198RBI 3 - 77
DIFFERENTIAL - TRAC-LOK (Continued)