Jeep Cherokee

 Service Manual

Differential and driveline » Tube, 181, and 186 FBI axle » Removal and installation
Differential

REMOVAL

1.  Raise and support vehicle.
2.  Remove the lubricant fill hole plug from the differential housing cover.
3.  Remove the differential housing cover and allow fluid to drain.
4.  Remove hub bearings and axle shafts.
5.  Note the installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 28).
6.  Loosen the differential bearing cap bolts.
7.  Position Spreader W-129-B, utilizing some items from Adapter Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 29). Install the holddown clamps and tighten the tool turnbuckle finger- tight.

Fig. 28 Bearing Cap Identification

1 - INSTALLATION REFERENCE LETTERS
2 - INSTALLATION REFERENCE LETTERS

Fig. 29 Install Axle Housing Spreader

1 - AXLE HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPECIAL TOOL W-129-B
5 - TURNBUCKLE

8. Install a Guide Pin C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to guide pin. Load the lever adapter against the opposite side of the housing (Fig. 30) and zero the indicator. CAUTION: Do not spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged.
9.  Spread the housing enough to remove the differential case from the housing. Measure the distance with the dial indicator (Fig. 31).
10.  Remove the dial indicator.
11.  While holding the differential case in position, remove the differential bearing cap bolts and caps.
12.  Remove the differential, and the differential preload shims for the 181FBI axles, from the housing. Ensure that the differential bearing cups remain in position on the differential bearings (Fig. 32).
13.  Mark or tag the differential bearing cups, and the differential preload shims for the 181FBI axles, to indicate which side of the differential they were removed from.
14.  Remove spreader from housing.

Fig. 30 Install Dial Indicator

1 - SPECIAL TOOL C-3339
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPECIAL TOOL W-129-B
5 - SPECIAL TOOL C-3288-B

Fig. 31 Spread Axle Housing

1 - SPECIAL TOOL C-3339
2 - SPECIAL TOOL W-129-B

Fig. 32 Differential Case Removal

1 - AXLE HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS

INSTALLATION

If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to the Differential Bearing Preload and Gear Backlash procedures in this section to determine the proper shim selection.

(1) Position Spreader W-129-B, utilizing some items from Adapter Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 33). Install the holddown clamps and tighten the tool turnbuckle finger- tight.

(2) Install a Guide Pin C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to guide pin. Load the lever adapter against the opposite side of the housing (Fig. 30) and zero the indicator.

CAUTION: Do not spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged.

(3) Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator (Fig. 31).

(4) Remove the dial indicator.

(5) Install differential case, and the differential preload shims for the 181FBI axles, in the housing.

Ensure that the differential bearing cups remain in position on the differential bearings. Tap the differential case to ensure the bearings cups are fully seated in the housing.

(6) Install the bearing caps at their original locations (Fig. 34).

(7) Loosely install differential bearing cap bolts.

Fig. 33 Install Axle Housing Spreader

1 - AXLE HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPECIAL TOOL W-129-B
5 - TURNBUCKLE

Fig. 34 Differential Bearing Cap Reference Letters

1 - INSTALLATION REFERENCE LETTERS
2 - INSTALLATION REFERENCE LETTERS

(8) Remove axle housing spreader.

(9) Tighten the bearing cap bolts to 61 N·m (45 ft.

lbs.) torque.

(10) Install the hub bearings and axle shafts.

Drive axle assembly

Tube axle assembly

Axle shaft-cardan U-joint

181 FBI pinion shaft seal

186 FBI pinion shaft seal

Collapsible spacer

Hub bearing and axle shaft

Steering knuckle and ball studs

Differential

Differential side bearings

Axle shaft oil seal

181 FBI pinion

186 FBI pinion

Ring gear