2003 JEEP GRAND CHEROKEE Prop

the shim thickness required on the pinion side of the
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 utilizing some items
from Adapter Set 6987, on the housing and spread
axle opening enough to receive differential case.
CAUTION: Never spread over 0.38 mm (0.015 in.). If
housing is over-spread, it could be distorted or
damaged.
(28) Place the bearing preload shims in the hous-
ing, against the axle tubes.
(29) Install differential case into the housing.
(30) Remove spreader from the housing.
(31) Install differential bearing caps in their origi-
nal locations.
(32) Install bearing cap bolts and tighten to 77
N´m (57 ft. lbs.).
(33) Rotate the differential case several times to
seat the side bearings.
(34) Position the indicator plunger against a ring
gear tooth (Fig. 22).
(35) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(36) Zero dial indicator face to pointer.
(37) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12-0.20 mm (0.005-0.008
in.). If backlash is not within specifications transfer
the necessary amount of shim thickness from one
side of the axle housing to the other (Fig. 23).
(38) 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.
Fig. 20 ZERO DIAL INDICATOR
1 - DIAL INDICATOR FACE
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 21 DIFFERENTIAL TO RING GEAR SIDE
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 22 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
3 - 62 REAR AXLE - 198RBIWJ
REAR AXLE - 198RBI (Continued)

(7) Press metal retaining ring onto axle shaft with
Installer 7913 and a press (Fig. 30).
(8) Install axle in vehicle.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake calipers and rotors.
(4) Mark propeller shaft and pinion yoke for
installation reference.
(5) Remove propeller shaft from the yoke.
(6) Rotate pinion gear a minimum of ten times and
verify pinion rotates smoothly.
(7) Record rotating torque of the pinion gear with
an inch pound dial-type torque wrench, for installa-
tion reference.
(8) Hold the pinion yoke with Spanner Wrench
6958 and remove the pinion nut and washer (Fig.
31).
(9) Remove pinion yoke with Remover C-452 and
Wrench C-3281 (Fig. 32).
(10) Remove pinion gear seal with Remover
7794-A and slide hammer (Fig. 33).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 34).
(2) Install yoke on pinion gear with Screw 8112,
Cup 8109 and Spanner Wrench 6958 (Fig. 35).
CAUTION: Do not exceed the minimum tightening
torque 271 N´m (200 ft. lbs.) when installing the pin-
ion yoke at this point. Damage to the collapsible
spacer or bearings may result.
(3) Install yoke washer and anewnut on the pin-
ion gear and tighten the nut until there is zero bear-
ing end-play.
Fig. 30 BEARING RETAINING RING
1 - PRESS
2 - AXLE
3 - AXLE BEARING
4 - INSTALLER
5 - METAL RETAINING RING
Fig. 31 PINION YOKE HOLDER
1 - PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
4 - LOWER CONTROL ARM
Fig. 32 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - YOKE PULLER
WJREAR AXLE - 198RBI 3 - 71
AXLE BEARINGS/SEALS (Continued)

(6) If the rotating torque is low, use Spanner
Wrench 6958 to hold the pinion yoke (Fig. 37), and
tighten the pinion nut in 6.8 N´m (5 ft. lbs.) incre-
ments until the proper rotating torque is achieved.
CAUTION: If maximum tightening torque is reached
prior to reaching required rotating torque, the col-
lapsible spacer may have been damaged. Replace
the collapsible spacer.
(7) Install the propeller shaft with reference marks
aligned.
(8) Add gear lubricant to the differential if neces-
sary.
(9) Install brake rotors and calipers.
(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 calipers and rotors.
(4) Mark propeller shaft and pinion yoke for
installation reference and remove propeller shaft.
(5) Rotate pinion gear a minimum of ten times and
verify pinion rotates smoothly.
(6) Record rotate torque of the pinion gear, with an
inch pound torque wrench.
(7) Hold pinion yoke with Spanner Wrench 6958
and remove pinion nut and washer (Fig. 38).
(8) Remove pinion yoke with Remover C-452 and
Wrench C-3281 (Fig. 39).(9) Remove pinion shaft seal with Remover 7794-A
and slide hammer (Fig. 40).
(10) Remove front pinion bearing using a pair of
pick tools to pull the bearing off the pinion gear
shaft.
NOTE: If the pinion bearing becomes bound on the
pinion shaft, lightly tap the end of the shaft with a
rawhide/rubber mallet.
(11) Remove the collapsible spacer.
INSTALLATION
(1) Install anewcollapsible spacer on pinion
shaft.
(2) Install pinion front bearing on the pinion shaft.
Fig. 37 PINION SHAFT NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
Fig. 38 PINION YOKE HOLDER
1 - 1 in. PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
4 - LOWER CONTROL ARM
Fig. 39 PINION YOKE PULLER
1 - WRENCH
2 - PINION YOKE
3 - PULLER
WJREAR AXLE - 198RBI 3 - 73
PINION SEAL (Continued)

(3) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 41).
(4) Install yoke with Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fig. 42).
(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 rotating torque and never exceed specified
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be
installed.
(6) Using yoke with Spanner Wrench 6958 and a
torque wrench set at 474 N´m (350 ft. lbs.), (Fig. 43)
slowly tighten the nut in 6.8 N´m (5 ft. lbs.) incre-
ments until the rotating torque is achieved. Measurethe rotating torque frequently to avoid over crushing
the collapsible spacer (Fig. 44).
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.
Fig. 40 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 41 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 42 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 43 PINION NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
3 - 74 REAR AXLE - 198RBIWJ
COLLAPSIBLE SPACER (Continued)

(7) Check rotating torque with an inch pound
torque wrench (Fig. 44). 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
align.
(9) Install rear brake calipers and rotors (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS
- INSTALLATION).
(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 fill hole plug from the differential
housing cover.
(3) Remove differential housing cover and drain
fluid.
(4) 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.
(5) Remove axle shafts.(6)
Note the reference letters stamped on the bearing
caps and housing machined sealing surface (Fig. 45).
(7) Loosen the differential bearing cap bolts.
(8) Position Spreader W-129-B with Adapter Kit
6987B on differential locating holes (Fig. 46). Install
holddown clamps and tighten the turnbuckle finger-
tight.
Fig. 44 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 45 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 46 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
WJREAR AXLE - 198RBI 3 - 75
COLLAPSIBLE SPACER (Continued)

DISASSEMBLY
(1) Remove pinion shaft lock screw (Fig. 50).
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove dif-
ferential pinions and thrust washers (Fig. 51).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion gears and thrust
washers.
(3) Install the pinion mate shaft.
(4) Align hole in the pinion mate shaft with the
hole in the differential case and install the pinion
mate shaft lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Position Spreader W-129-B with Adapter set
6987 on differential housing locating holes. Install
the holddown 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.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). If housing is over-spread, it could be dis-
torted or damaged.
(3) Spread housing enough to install the case in
the housing.
(4) Remove the dial indicator.
(5) Install differential case in housing (Fig. 52).
Verify differential bearing cups remain in position on
the bearings and preload shims are between the face
of the bearing cup and the housing. Tap the differen-
tial case to ensure bearings cups and shims are
seated in the housing.
CAUTION: On a Vari-lokTdifferential the oil feed
tube must be pointed at the bottom of the housing
(Fig. 53). If differential is installed with the oil feed
tube pointed at the top, the anti-rotation tabs will be
damaged.
(6) Install bearing caps in their original locations
(Fig. 54).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten bearing cap bolts in a criss-cross pat-
tern to 77 N´m (57 ft. lbs.).
(10) Install the axle shafts.
Fig. 50 SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 51 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
WJREAR AXLE - 198RBI 3 - 77
DIFFERENTIAL (Continued)

INSTALLATION
NOTE: If differential side bearings or differential
case are replaced, differential side bearing shim
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.
(1) Install differential side bearings with Installer
C-3716-A and Handle C-4171 (Fig. 70).
(2) Install differential in axle housing.
(3) Remove support and lower vehicle.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without the
other gear.
(1) Raise and support vehicle.
(2) Mark pinion yoke and propeller shaft for
installation reference.
(3) Disconnect propeller shaft from pinion yoke
and tie shaft to underbody.
(4) Remove differential from the housing.
(5) Place differential case in a vise with soft metal
jaw.(6) Remove bolts holding ring gear to differential
case.
(7) Drive ring gear from differential case with a
rawhide hammer (Fig. 71).
(8) Hold the pinion yoke with Spanner Wrench
6958 and remove the pinion yoke nut and washer
(Fig. 72).
Fig. 70 Differential Side Bearing
1 - INSTALLER
2 - HANDLE
Fig. 71 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 72 PINION YOKE HOLDER
1 - 1 in. PIPE
2 - PINION YOKE
3 - HOLDER
4 - LOWER CONTROL ARM
3 - 84 REAR AXLE - 198RBIWJ
DIFFERENTIAL CASE BEARINGS (Continued)

(14) Remove rear bearing cup (Fig. 77) with
Remover D-149 and Handle C-4171.
(15) Remove collapsible preload spacer (Fig. 78).
(16) Remove rear bearing from the pinion with
Puller/Press C-293-PA and Adapters C-293-40 (Fig.
79).
(17) Remove depth shims from the pinion gear
shaft and record shim thickness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
Fig. 77 REAR PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 78 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - SHIM
5 - REAR BEARING
Fig. 79 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
3 - 86 REAR AXLE - 198RBIWJ
PINION GEAR/RING GEAR (Continued)