2002 JEEP LIBERTY torque

lbs.) increments until proper rotating torque is
achieved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, it indicates a binding
condition.
(9) The seal replacement is unacceptable if the
final pinion nut torque is less than 285 N´m (210 ft.
lbs.).
(10) Install the propeller shaft with the installa-
tion reference marks aligned.
(11) Install the brake drums.
(12) Check the differential housing lubricant level.
(13) Install wheel and tire assemblies and lower
the vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove fill hole plug from the differential
housing cover.
(3) Remove differential housing cover and drain
housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.(5) Remove the axle shafts.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark the differential housing and bearing caps
for installation reference (Fig. 28).
(7) Remove bearing threaded adjuster locks from
each bearing cap.
(8) Loosen bearing cap bolts, them loosen the
threaded adjusters with Wrench C-4164 (Fig. 29).
Fig. 27 Pinion Rotation Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH
Fig. 28 Reference Mark
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP
Fig. 29 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
3 - 104 REAR AXLE-81/4KJ
PINION SEAL (Continued)

(6) Install adjuster locks on the bearing caps.
(7) Install axle shafts.
(8) Apply a bead of red Mopar silicone rubber axle
sealant or equivalent to the housing cover (Fig. 33).
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.
(9) Install cover and tighten bolts in a criss-cross
pattern to 41 N´m (30 ft. lbs.).
(10) Fill differential with gear lubricant to bottom
of the fill plug hole.
(11) Install the fill hole plug.
(12) Install wheel and tire assemblies.
(13) Remove support and lower vehicle.
(14) Trac-loktdifferential equipped vehicles should
be road tested by making 10 to 12 slow figure-eight
turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
ter noise complaint.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. 34).
(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. 33 Differential Cover Sealant
1 - SEALANT
2 - DIFFERNTIAL COVER
Fig. 34 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 106 REAR AXLE-81/4KJ
DIFFERENTIAL (Continued)

(8) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress Belleville springs in clutch
packs (Fig. 38).
(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 39).
(10) Insert Turning Bar 6960-2 into the pinion
mate shaft hole in the case (Fig. 40).(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 and discs.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in order during removal
(Fig. 41).
Fig. 38 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 39 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 40 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 41 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
3 - 108 REAR AXLE-81/4KJ
DIFFERENTIAL - TRAC-LOK (Continued)

(11) Install yoke washer and a new nut on the pin-
ion. The convex side of the washer must face out-
ward.
(12) Tighten the nut to 285 N´m (210 ft. lbs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
(13) Holding the yoke with Holder 6719A slowly
tighten the nut in 6.8 N´m (5 ft. lbs.) increments
until the desired rotating torque is achieved. Mea-
sure the rotating torque frequently to avoid over
crushing the spacer (Fig. 59).
(14) Check bearing rotating torque with an inch
pound torque wrench (Fig. 59). The pinion gear rotat-
ing torque should be:
²Original Bearings: 1 to 2 N´m (10 to 20 in. lbs.).
²New Bearings: 1 to 5 N´m (10 to 30 in. lbs.).
Fig. 57 Rear Pinion Bearing
1 - PRESS
2 - INSTALLATION
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 58 Collapsible Preload Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 59 Pinion Rotating Torque
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 114 REAR AXLE-81/4KJ
PINION GEAR/RING GEAR/TONE RING (Continued)

(15) Invert the differential case.
(16) Install ring gear on the differential case and
start two ring gear bolts. This will provide case-to-
ring gear bolt hole alignment.
(17) Invert the differential case in the vise.
(18) Installnewring gear bolts and alternately
tighten to 102 N´m (75 ft. lbs.) (Fig. 60).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(19) Install differential in axle housing and verify
gear mesh refer to Adjustments (Gear Contact Pat-
tern).
(20) Install differential cover fill with gear lubri-
cant.
(21) Install the propeller shaft with reference
marks aligned.
(22) Install wheel and tire assemblies and lower
the vehicle.
Fig. 60 Ring Gear
1 - TORQUE WRENCH
2 - BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
KJREAR AXLE - 8 1/4 3 - 115
PINION GEAR/RING GEAR/TONE RING (Continued)

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

TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Brake Pedal Pivot Bolt/Nut 35 26 Ð
Brake Booster Mounting Nuts 39 29 Ð
Brake Pedal to the Column
Nut22.6 Ð 200
Master Cylinder Mounting
Nuts25 Ð 220
Master Cylinder Brake Lines 20 15 180
Combination Valve Mounting
Nuts17.5 Ð 155
Combination Valve Brake
Lines20 15 180
Caliper Mounting Bolts 15 11 Ð
Caliper Brake Hose Bolt 31 23 Ð
Wheel Cylinder Mounting
Bolts10 7 Ð
Wheel Cylinder Brake Line 14 Ð 124
Parking Brake Lever Screws 10-14 7-10 Ð
Parking Brake Lever Bracket
Screws10-14 7-10 Ð
SPECIAL TOOLS
BASE BRAKES
Installer Caliper Dust Boot 8280
Handle C-4171
Adapter Pressure Bleeder 6921
KJBRAKES - BASE 5 - 7
BRAKES - BASE (Continued)

BRAKE LINES
DESCRIPTION
Flexible rubber hose is used at both front brakes
and at the rear axle junction block. Double walled
steel tubing is used to connect the master cylinder to
the major hydraulic braking components and then to
the flexible rubber hoses. Double inverted style and
ISO style flares are used on the brake lines.
DIAGNOSIS AND TESTING - BRAKE LINE AND
HOSES
Flexible rubber hose is used at both front brakes
and at the rear axle junction block. Inspect the hoses
whenever the brake system is serviced, at every
engine oil change, or whenever the vehicle is in for
service.
Inspect the hoses for surface cracking, scuffing, or
worn spots. Replace any brake hose immediately if
the fabric casing of the hose is exposed due to cracks
or abrasions.
Also check brake hose installation. Faulty installa-
tion can result in kinked, twisted hoses, or contact
with the wheels and tires or other chassis compo-
nents. All of these conditions can lead to scuffing,
cracking and eventual failure.
The steel brake lines should be inspected periodi-
cally for evidence of corrosion, twists, kinks, leaks, or
other damage. Heavily corroded lines will eventually
rust through causing leaks. In any case, corroded or
damaged brake lines should be replaced.
Factory replacement brake lines and hoses are rec-
ommended to ensure quality, correct length and supe-
rior fatigue life. Care should be taken to make sure
that brake line and hose mating surfaces are clean
and free from nicks and burrs. Also remember that
right and left brake hoses are not interchangeable.
Use new copper seal washers at all caliper connec-
tions. Be sure brake line connections are properly
made (not cross threaded) and tightened to recom-
mended torque.
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE INVERTED
FLARING
A preformed metal brake tube is recommended and
preferred for all repairs. However, double-wall steel
tube can be used for emergency repair when factory
replacement parts are not readily available.
Special bending tools are needed to avoid kinking
or twisting of metal brake tubes. Special flaring tools
are needed to make a double inverted flare or ISO
flare.(1) Cut off damaged tube with Tubing Cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on the tube.
(4) Insert tube in flaring tool.
(5) Place gauge form over the end of the tube.
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch in gauge that matches
tube diameter.
(7) Tighten the tool bar on the tube
(8) Insert plug on gauge in the tube. Then swing
compression disc over gauge and center tapered flar-
ing screw in recess of compression disc (Fig. 2).
(9) Tighten tool handle until plug gauge is
squarely seated on jaws of flaring tool. This will start
the inverted flare.
(10) Remove the plug gauge and complete the
inverted flare.
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube is recommended and
preferred for all repairs. However, double-wall steel
tube can be used for emergency repair when factory
replacement parts are not readily available.
Special bending tools are needed to avoid kinking
or twisting of metal brake tubes. Special flaring tools
are needed to make a double inverted flare or ISO
flare.
To make a ISO flare use a ISO brake flaring tool or
equivalent.
(1) Cut off damaged tube with Tubing Cutter.
(2) Remove any burrs from the inside of the tube.
(3) Install tube nut on the tube.
Fig. 2 Inverted
5 - 8 BRAKES - BASEKJ