2003 JEEP GRAND CHEROKEE stall

(8) Install anewcollapsible preload spacer on pin-
ion shaft and install pinion gear in the housing (Fig.
84).
(9) Install yoke with Installer C-3718 and Spanner
Wrench 6958 (Fig. 85).
(10) Install the yoke washer and a new nut on the
pinion gear and tighten the pinion nut until there is
zero bearing end-play.
(11) Tighten the nut to 271 N´m (200 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be
installed.
(12) Using Spanner Wrench 6958 and a torque
wrench set at 474 N´m (350 ft. lbs.), (Fig. 86) slowly
tighten the nut in 6.8 N´m (5 ft. lbs.) increments
until the rotating torque is achieved. Measure the
rotating torque frequently to avoid over crushing the
collapsible spacer (Fig. 87).
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.(13) Check bearing rotating torque with a inch
pound torque wrench (Fig. 87). The pinion gear rotat-
ing torque should be:
²Original Bearings: 1 to 2.25 N´m (10 to 20 in.
lbs.).
²New Bearings: 1.7 to 3.9 N´m (15 to 35 in. lbs.).
(14) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
Fig. 84 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
Fig. 85 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
Fig. 86 PINION NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
3 - 88 REAR AXLE - 198RBIWJ
PINION GEAR/RING GEAR (Continued)

(15) Invert the differential case in the vise.
(16) Installnewring gear bolts and alternately
tighten to 136 N´m (100 ft. lbs.) (Fig. 88).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(17) Install differential in housing and verify dif-
ferential bearing preload, gear mesh and contact pat-
tern. Refer to Ajustments for procedure.
CAUTION: When installing a Vari-lokTdifferential
(Fig. 89), the oil feed tube must point to the bottom
of the housing. If differential is installed with the oil
feed tube pointed toward the top, the anti-rotation
tabs will be damaged.
(18) Install differential cover and fill with gear
lubricant.
(19) Install the propeller shaft with the reference
marks aligned.
(20) Remove supports and lower vehicle.
Fig. 87 PINION ROTATING TORQUE
1 - PINION YOKE/COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
Fig. 88 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
Fig. 89 VARI-LOK
1 - ANTI-ROTATION TAB
2 - OIL FEED TUBE
WJREAR AXLE - 198RBI 3 - 89
PINION GEAR/RING GEAR (Continued)

REAR AXLE - 226RBA
TABLE OF CONTENTS
page page
REAR AXLE - 226RBA
DESCRIPTION.........................90
OPERATION...........................90
DIAGNOSIS AND TESTING................92
REMOVAL.............................95
INSTALLATION.........................96
ADJUSTMENTS........................97
SPECIFICATIONS......................105
SPECIAL TOOLS.......................106
AXLE SHAFTS
REMOVAL............................109
INSTALLATION........................109
AXLE BEARINGS/SEALS
REMOVAL............................109
INSTALLATION........................110
PINION SEAL
REMOVAL............................111
INSTALLATION........................112
COLLAPSIBLE SPACER
REMOVAL............................113INSTALLATION........................114
DIFFERENTIAL
REMOVAL............................115
DISASSEMBLY........................117
ASSEMBLY...........................117
INSTALLATION........................117
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING...............119
DISASSEMBLY........................119
CLEANING...........................121
INSPECTION.........................121
ASSEMBLY...........................121
DIFFERENTIAL CASE BEARINGS
REMOVAL............................123
INSTALLATION........................123
PINION GEAR/RING GEAR
REMOVAL............................124
INSTALLATION........................126
REAR AXLE - 226RBA
DESCRIPTION
The Rear Beam-design Aluminum (RBA) axle hous-
ing has an aluminum center casting (differential
housing) with axle shaft tubes extending from either
side. The tubes are pressed into the differential hous-
ing to form a one-piece axle housing. The axle has
semi-floating axle shafts, meaning that vehicle load
is supported by the axle shaft and bearings.
The differential case is a one-piece design. Differen-
tial bearing preload and ring gear backlash is adjusted
with selective shims. Pinion bearing preload is set and
maintained by the use of a collapsible spacer. The cover
provides a means for inspection and service.
Optional Trac-Loktdifferential differential has a
one-piece differential case, and the same internal
components as a standard differential, plus two
clutch disc packs.
Optional Vari-Loktdifferential has a one-piece dif-
ferential case which contains the gerotor pump
assembly and the clutch mechinism. The unit is ser-
viced only as an assembly.
OPERATION
The axle receives power from the transfer case
through the front propeller shaft. The front propellershaft is connected to the pinion gear which rotates
the differential through the gear mesh with the ring
gear bolted to the differential case. The engine power
is transmitted to the axle shafts through the pinion
mate and side gears. The side gears are splined to
the axle shafts.
STANDARD DIFFERENTIAL
During straight-ahead driving the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must travel
a greater distance than the inside wheel to complete a
turn. The difference must be compensated for to prevent
the tires from scuffing and skidding through turns. To
accomplish this, the differential allows the axle shafts
to turn at unequal speeds (Fig. 2). In this instance, the
input torque applied to the pinion gears is not divided
equally. The pinion gears now rotate around the pinion
mate shaft in opposite directions. This allows the side
gear and axle shaft attached to the outside wheel to
rotate at a faster speed.
3 - 90 REAR AXLE - 226RBAWJ

(3) Remove the wheels and tires.
(4) Remove brake calipers and rotors.
(5) Disconnect parking brake cables from brackets
and lever.
(6) Remove wheel speed sensors.
(7) Remove brake hose at the axle junction block.
Do not disconnect the brake hydraulic lines at the
calipers.
(8) Disconnect the vent hose from the axle shaft
tube.
(9) Mark propeller shaft and yokes for installation
reference.
(10) Remove propeller shaft.
(11) Disconnect stabilizer bar links.
(12) Remove upper suspension arm rear axle ball
joint nut.
(13) Separate rear axle ball joint from the upper
suspension arm with Remover 8278 (Fig. 4).
(14) Disconnect shock absorbers from axle.
(15) Disconnect track bar.
(16) Disconnect lower suspension arms from the
axle brackets.
(17) Separate the axle from the vehicle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners are tightened. If springs are notat their normal ride position, vehicle ride height and
handling could be affected.
(1) Raise axle with lift and align coil springs.
(2) Install lower suspension arms in axle brackets.
Install nuts and bolts, do not tighten bolts at this
time.
(3) Install upper suspension arm on rear axle ball
joint.
(4) Install rear axle ball joint nut and tighten to
122 N´m (90 ft.lbs.) (Fig. 5).
(5) Install track bar and attachment bolts, do not
tighten bolts at this time.
(6) Install shock absorbers and tighten nuts to 60
N´m (44 ft. lbs.).
(7) Install stabilizer bar links and tighten nuts to
36 N´m (27 ft. lbs.).
(8) Install wheel speed sensors.
(9) Connect parking brake cable to brackets and
lever.
(10) Install brake rotors and calipers.
(11) Install the brake hose to the axle junction
block.
(12) Install axle vent hose.
(13) Align propeller shaft and pinion yoke refer-
ence marks. Install U-joint straps and nuts tighten to
19 N´m (14 ft. lbs.).
(14) Install the wheels and tires.
(15) Add gear lubricant, if necessary.
(16) Remove support and lower the vehicle.
(17) Tighten lower suspension arm bolts to 177
N´m (130 ft. lbs.).
(18) Tighten track bar bolts to 100 N´m (74 ft.
lbs.).
Fig. 4 REAR BALL JOINT
1 - REMOVER
2 - UPPER SUSPENSION ARM
3 - BALL JOINT STUD
Fig. 5 REAR BALL JOINT NUT
1 - UPPER SUSPENSION ARM
2 - REAR AXLE BALL JOINT
3 - REAR AXLE
3 - 96 REAR AXLE - 226RBAWJ
REAR AXLE - 226RBA (Continued)

ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
6). A plus (+) number, minus (±) number or zero (0) is
etched into the face of the pinion gear. This number
is the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched with a (0). The standard setting from the cen-
ter line of the ring gear to the back face of the pinion
is 109.52 mm (4.312 in.). The standard depth pro-
vides the best gear tooth contact pattern. Refer to
Backlash and Contact Pattern in this section for
additional information.
Compensation for pinion depth variance is
achieved with a select shim/oil baffle. The shims areplaced between the rear pinion bearing and the pin-
ion gear head (Fig. 7).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Pinion Gear Depth Variance chart.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.
Note the etched number on the face of the pinion
gear head (±1, ±2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 6 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 7 ADJUSTMENT SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
WJREAR AXLE - 226RBA 3 - 97
REAR AXLE - 226RBA (Continued)

PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set 6775 and Dial
Indicator C-3339 (Fig. 8).(1) Assemble Pinion Height Block 6739, Pinion
Block 8144 and rear pinion bearing onto Screw 6741
(Fig. 8).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 9).
(3) Install front pinion bearing and Cone-nut 6740
hand tight (Fig. 8).
(4) Place Arbor Disc 6927A on Arbor D-115-3 in
position in the housing side bearing cradles (Fig. 10).
Install differential bearing caps in their original posi-
tions on arbor discs and tighten cap bolts to 85 N´m
(63 ft. lbs.).
Fig. 8 PINION GEAR DEPTH GAUGE
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 9 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 98 REAR AXLE - 226RBAWJ
REAR AXLE - 226RBA (Continued)

NOTE: Arbor Discs 6927A has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position
in axle housing so dial probe and scooter block are
flush against the rearward surface of the pinion
height block (Fig. 8). Hold scooter block in place and
zero the dial indicator face to the pointer. Tighten
dial indicator face lock screw.
(7) With scooter block still in position against the
pinion height block, slowly slide the dial indicator
probe over the edge of the pinion height block.
(8) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 11). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
turn dial face. Continue moving the dial probe to the
crest of the arbor bar and record the highest reading.
If the dial indicator can not achieve the zero reading,
the rear bearing cup or the pinion depth gauge set is
not installed correctly.
(9) Select a depth shim equal to the dial indicator
reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 6). For example,
if the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL BEARING PRELOAD & GEAR
BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims positioned behind the
differential side bearing cones. The proper shim
thickness can be determined using slip-fit Dummy
Bearings 6929-A in place of the differential side bear-
ings and a Dial Indicator C-3339. Before proceeding
with the differential bearing preload and gear back-
lash measurements, measure the pinion gear depth
and prepare the pinion for installation. Establishing
proper pinion gear depth is essential to establishing
gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential side
play is measured, the pinion is installed, and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 12). Differential shim measurements
are performed with the spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove differential side bearings from differ-
ential case.
Fig. 10 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 11 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
WJREAR AXLE - 226RBA 3 - 99
REAR AXLE - 226RBA (Continued)

(2) Install ring gear on differential case and
tighten bolts to specification.
(3)
Install Dummy Bearings 6929-A on differential case.
(4) Install differential case in the housing.
(5) Record the thickness of Dummy Shims 8107,
then insert the shims between the dummy bearings
and the differential housing (Fig. 13).(6) Install the bearing caps in their original posi-
tions and snug the bolts (Fig. 14).
(7) With a dead-blow hammer, seat the differential
dummy bearings to each side of the housing (Fig. 15)
and (Fig. 16).
Fig. 12 ADJUSTMENT SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
Fig. 13 DUMMY SHIM POINT
1 - DUMMY SHIMS
2 - HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
Fig. 14 TIGHTEN BEARING CAP BOLTS
1 - BEARING CAPS
2 - HOUSING
3 - DIFFERENTIAL CASE
Fig. 15 SEAT DUMMY BEARING
1 - HAMMER
2 - HOUSING
3 - DIFFERENTIAL CASE
3 - 100 REAR AXLE - 226RBAWJ
REAR AXLE - 226RBA (Continued)