Jeep Cherokee

 Service Manual

Differential and driveline » 194 RBI 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 axle shafts.

(5) Note the installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 23).

Fig. 23 Bearing Cap Identification

1 - INSTALLATION REFERENCE LETTERS
2 - INSTALLATION REFERENCE LETTERS

(6) Loosen the differential bearing cap bolts.

(7) Position Spreader W-129-B, utilizing some items from Adapter set 6987, with the tool dowel pins seated in the locating holes (Fig. 24). Install the holddown clamps and tighten the tool turnbuckle finger- tight.

Fig. 24 Install Axle Housing Spreader

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

(8) 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 (Fig. 25) and zero the indicator.

CAUTION: Do not spread over 0.38 mm (0.015 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. 26).

(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 from the housing.

Ensure that the differential bearing cups remain in position on the differential bearings (Fig. 27).

(13) Mark or tag the differential bearing cups to indicate which side of the differential they were removed from.

Fig. 25 Install Dial Indicator

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

Fig. 26 Spread Axle Housing

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

(14) Retrieve differential case preload shims from axle housing. Mark or tag the differential case preload shims to indicate which side of the differential they were removed from.

(15) Remove spreader from housing.

Fig. 27 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 set 6987, with the tool dowel pins seated in the locating holes (Fig. 28). 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 (Fig. 25) and zero the indicator.

CAUTION: Do not spread over 0.38 mm (0.015 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. 26).

(4) Remove the dial indicator.

(5) Install differential case in the housing. Ensure that the differential bearing cups remain in position on the differential bearings and that the preload shims remain between the face of the bearing cup and the housing. Tap the differential case to ensure the bearings cups and shims are fully seated in the housing.

(6) Install the bearing caps at their original locations (Fig. 29).

(7) Loosely install differential bearing cap bolts.

(8) Remove axle housing spreader.

Fig. 28 Install Axle Housing Spreader

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

Fig. 29 Differential Bearing Cap Reference Let

1 - INSTALLATION REFERENCE LETTERS
2 - INSTALLATION REFERENCE LETTERS

(9) Tighten the bearing cap bolts to 77 N·m (57 ft.

lbs.) torque.

(10) Install the axle shafts.

Rear axle

Pinion shaft seal

Collapsible spacer

Axle shaft

Axle shaft seal and bearing

Differential

Differential side bearings

Ring gear

Pinion gear

Final assembly