2003 JEEP GRAND CHEROKEE transfer box

(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the housing to the other (Fig.
20).
(36) 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.
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 inboth 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 squee-
gee 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.
21)and adjust pinion depth and gear backlash as nec-
essary.
Fig. 20 BACKLASH SHIM ADJUSTMENT
3 - 28 FRONT AXLE - 186FBIWJ
FRONT AXLE - 186FBI (Continued)

(32) Position the indicator plunger against a ring
gear tooth (Fig. 22).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.076 mm (0.003 in.) and
0.15 mm (0.006 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the housing to the other (Fig.
23).
(36) 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 procedure.
GEAR CONTACT PATTERN
The ring gear and pinion teeth contact patterns
will show if the pinion depth is correct in the axle
housing. It will also show if the ring gear backlashhas 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 squee-
gee 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
WJREAR AXLE - 226RBA 3 - 103
REAR AXLE - 226RBA (Continued)

INSTALLATION
(1) Position and install the power steering cooler
to the vehicle.
(2) Install the three mounting bracket bolts (Fig.
6).
(3) Reconnect the upper hose at cooler (Fig. 6).
(4) Reconnect the lower hose at cooler (Fig. 6).
(5) Connect negative battery cable to battery.
(6) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(7) Start engine and check for leaks.
(8) Install the grille opening reinforcement panel
(9) Install the front fascia grille,(Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- INSTALLATION).
HOSES - 4.0L
DESCRIPTION
DESCRIPTION - PRESSURE LINE
The hose consists of two metal ends and rubber
center section that contains a tuning cable. The
pump end uses a quick connect fitting. Lubircation
must be used on the quick connect nut and o-ring
when installing.
DESCRIPTION - RETURN LINE
Power steering return line is a hose which is
clamped at the pump and the gear.
OPERATION
OPERATION - PRESSURE LINE
Power steering pressure line, is used to transfer
high pressure power steering fluid, from the power
steering pump to the power steering gear on the
4.0L. The 4.7L power steering pressure line, is used
to transfer high pressure power steering fluid, from
the power steering pump to the engine cooling fan
and the steering gear.
OPERATION - RETURN LINE
Power steering return line, is used to transfer low
pressure power steering fluid, from the power steer-
ing gear to the power steering pump.
REMOVAL
(1) Drain the power steering fluid from the reser-
voir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the power steering pressure hose
from the power steering pump and then the power
steering gear (Fig. 7).
(4) Disconnect the power steering return hose from
the power steering cooler and the reservoir.
(5) Remove the hoses from the vehicle.
INSTALLATION
(1) Install the hoses to the vehicle.
(2) Reconnect the power steering return hose to
the power steering cooler and the reservoir.
(3) Reconnect the power steering pressure hose to
the power steering pump and then the power steer-
ing gear.
(4) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(5) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
Fig. 7 POWER STEERING HOSES
1 - RETURN HOSE
2 - HIGH PRESSURE HOSE
3 - STEERING GEAR
WJPUMP 19 - 37
FLUID COOLER (Continued)

(22) Remove the front bin from the floor console.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL).
(23) Reach through the front bin opening of the
floor console to access and remove the two screws
that secure the center floor tunnel bracket to the
instrument panel.
(24) Reach through the front bin opening of the
floor console to access and loosen the two nuts that
secure the center floor tunnel bracket to the studs on
the floor panel transmission tunnel.
(25) Slide the center floor tunnel bracket rearward
in the vehicle far enough to disengage the locating
hole in the lower flange of the top pad from the locat-
ing pin on the instrument panel structural duct (Fig.
25).
(26) Remove the instrument panel top pad from
the instrument panel structural duct.INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
If the top pad is being replaced with a new unit, be
certain to transfer or install the panel outlets and
the passenger side trim bezel to the new unit before
it is installed on the instrument panel structural
duct. (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/AIR OUTLETS - REMOVAL)
and (Refer to 23 - BODY/INSTRUMENT PANEL/IP
TRIM BEZEL - PASSENGER - REMOVAL).
(1) Position the instrument panel top pad over the
instrument panel structural duct and the studs on
the dash panel near the windshield fence line.
(2) Route the instrument panel wire harness take
out for the glove box lamp and switch unit to the
switch mounting hole in the upper glove box opening
reinforcement.
(3) Reach through the front bin opening of the
floor console to engage the locating hole in the lower
flange of the top pad with the locating pin on the
instrument panel structural duct (Fig. 25).
(4) Reach through the front bin opening of the
floor console to slide the center floor tunnel bracket
forward in the vehicle far enough to capture the
lower flange of the top pad between the bracket and
the structural duct.
(5) Reach through the front bin opening of the
floor console to install and tighten the two screws
that secure the center floor tunnel bracket to the
instrument panel. Tighten the screws to 11.8 N´m
(105 in. lbs.).
Fig. 25 Instrument Panel Top Pad Remove/Install
1 - STRUCTURAL DUCT
2 - LOCATING PIN
3 - INSTRUMENT PANEL TOP PAD
4 - LOWER FLANGE
5 - CENTER FLOOR TUNNEL BRACKET
23 - 54 INSTRUMENT PANEL SYSTEMWJ
INSTRUMENT PANEL TOP PAD (Continued)