Jeep Cherokee (XJ): Disassembly and assembly
DISASSEMBLY (1) Remove pinion mate shaft lock screw (Fig. 49).
(2) Remove pinion mate shaft.
(3) Rotate the differential side gears and remove
the differential pinion gears and thrust washers (Fig.
50).
(4) Remove the differential side gears and thrust
washers. ASSEMBLY (1) Install the differential side gears and thrust
washers.
(2) Install the differential pinion gears and thrust
washers.
(3) Install the pinion mate shaft.
(4) Align the 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.
1 - LOCK SCREW
1 - THRUST WASHER
1 - THRUST WASHER The Trac-loky differential components are illustrated
in (Fig. 51). Refer to this illustration during
repair service. DISASSEMBLY (1) Clamp Side Gear Holding Tool 6965 in a vise.
(2) Position the differential case on Side Gear
Holding Tool 6965 (Fig. 52).
(3) Remove ring gear, if necessary. Ring gear
removal is necessary only if the ring gear is to be
replaced. The Trac-loky differential can be serviced
with the ring gear installed.
(4) Remove the pinion gear mate shaft lock screw
(Fig. 53).
(5) Remove the pinion gear mate shaft. If necessary,
use a drift and hammer (Fig. 54).
(6) Install and lubricate Step Plate C-6960-3 (Fig.
55).
1 - SPECIAL TOOL 6965
1 - LOCK SCREW
1 - PINION MATE SHAFT (7) Assemble Threaded Adapter C-6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
(8) Position a small screw driver in slot of
Threaded Adapter C-6960-1 (Fig. 56) to prevent
adapter from turning.
(9) Tighten forcing screw tool 122 N·m (90 ft. lbs.)
maximum to compress Belleville springs in clutch
packs (Fig. 57).
1 - LOWER SIDE GEAR
1 - SOCKET
1 - TORQUE WRENCH (10) Using an appropriate size feeler gauge,
remove thrust washers from behind the pinion gears
(Fig. 58).
1 - THRUST WASHER (11) Insert Turning Bar C-6960-2 in case (Fig. 59).
(12) Loosen the Forcing Screw C-6960-4 in small
increments until the clutch pack tension is relieved
and the differential case can be turned using Turning
Bar C-6960-2 (13) Rotate differential case until the pinion gears
can be removed.
(14) Remove pinion gears from differential case.
1 - PINION GEARS (15) Remove Forcing Screw C-6960-4, Step Plate
C-6960-3, and Threaded Adapter C-6960-1.
(16) Remove top side gear, clutch pack retainer,
and clutch pack. Keep plates in correct order during
removal (Fig. 60).
1 - DIFFERENTIAL CASE (17) Remove differential case from Side Gear Holding
Tool 6965. Remove side gear, clutch pack retainer,
and clutch pack. Keep plates in correct order during
removal. ASSEMBLY NOTE: The clutch discs are replaceable as complete
sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubricate each component with gear lubricant
before assembly. (1) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 61).
1 - CLUTCH PACK (2) Position assembled clutch disc packs on the
side gear hubs.
(3) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 62). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
(4) Position the differential case on Side Gear
Holding Tool 6965.
(5) Install lubricated Step Plate C-6960-3 in lower
side gear (Fig. 63).
(6) Install the upper side gear and clutch disc pack
(Fig. 63).
(7) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
1 - DIFFERENTIAL CASE
1 - UPPER SIDE GEAR AND CLUTCH DISC PACK (8) Insert Forcing Screw C-6960-4.
(9) Tighten forcing screw tool to slightly compress
clutch discs.
(10) Place pinion gears in position in side gears
and verify that the pinion mate shaft hole is aligned. (11) Rotate case with Turning Bar C-6960-2 until
the pinion mate shaft holes in pinion gears align
with holes in case. It may be necessary to slightly
tighten the forcing screw in order to install the pinion
gears.
(12) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to verify
alignment.
(14) Remove Forcing Screw C-6960-4, Step Plate
C-6960-3, and Threaded Adapter C-6960-1.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install the pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
(17) Lubricate all differential components with
hypoid gear lubricant.Standard differential
Fig. 49 Pinion Mate Shaft Lock Screw
2 - PINION MATE SHAFT
Fig. 50 Pinion Mate Gear Removal
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 51 Trac-lokY Differential Components
2 - PINION
3 - SHAFT LOCK SCREW
4 - PINION MATE SHAFT
5 - SIDE GEAR
6 - RETAINER
7 - DISC
8 - CLUTCH PACK
9 - DIFFERENTIAL CASE
10 - RETAINERTrac-lok differential
Fig. 52 Differential Case Holding Tool
2 - VISE
3 - DIFFERENTIAL
Fig. 53 Mate Shaft Lock Screw
2 - PINION GEAR MATE SHAFT
Fig. 54 Mate Shaft Removal
2 - SIDE GEAR
3 - DRIFT
4 - PINION MATE GEAR
Fig. 55 Step Plate Tool Installation
2 - DIFFERENTIAL CASE
3 - SPECIAL TOOL C-6960-3
Fig. 56 Threaded Adapter Installation
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - DISC C-6960-3
5 - THREADED ROD C-6960-4
6 - THREADED ADAPTER DISC C-6960-1
Fig. 57 Tighten Belleville Spring Compressor Tool
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE
Fig. 58 Remove Pinion Gear Thrust Washer
2 - FEELER GAUGE
Fig. 59 Pinion Gear Removal
2 - TOOL
Fig. 60 Side Gear & Clutch Disc Removal
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 61 Clutch Disc Pack
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 62 Clutch Discs & Lower Side Gear Installation
2 - LOWER SIDE GEAR AND CLUTCH DISC PACK
Fig. 63 Upper Side Gear & Clutch Disc Pack Installation
2 - DIFFERENTIAL CASE
3 - SPECIAL TOOL C-6960-3
Cleaning and inspection. Adjustments. Specifications
Other materials:
Interior Lights
The interior lights come on when a door is opened.
To protect the battery, the interior lights will turn off
automatically 10 minutes after the ignition is moved to
the LOCK position. This will occur if the interior lights
were switched on manually or are on because a door is
open. This inclu ...