Jeep Cherokee (XJ): Disassembly and assembly

Standard differential

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.

Fig. 49 Pinion Mate Shaft Lock Screw

1 - LOCK SCREW
2 - PINION MATE SHAFT

Fig. 50 Pinion Mate Gear Removal

1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR

Fig. 51 Trac-lokY Differential Components

1 - THRUST WASHER
2 - PINION
3 - SHAFT LOCK SCREW
4 - PINION MATE SHAFT
5 - SIDE GEAR
6 - RETAINER
7 - DISC
8 - CLUTCH PACK
9 - DIFFERENTIAL CASE
10 - RETAINER

Trac-lok differential

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).

Fig. 52 Differential Case Holding Tool

1 - SPECIAL TOOL 6965
2 - VISE
3 - DIFFERENTIAL

Fig. 53 Mate Shaft Lock Screw

1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT

Fig. 54 Mate Shaft Removal

1 - PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
4 - PINION MATE GEAR

(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).

Fig. 55 Step Plate Tool Installation

1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - SPECIAL TOOL C-6960-3

Fig. 56 Threaded Adapter Installation

1 - SOCKET
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

1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE

(10) Using an appropriate size feeler gauge, remove thrust washers from behind the pinion gears (Fig. 58).

Fig. 58 Remove Pinion Gear Thrust Washer

1 - THRUST WASHER
2 - FEELER GAUGE

(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.

Fig. 59 Pinion Gear Removal

1 - PINION GEARS
2 - TOOL

(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).

Fig. 60 Side Gear & Clutch Disc Removal

1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK

(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).

Fig. 61 Clutch Disc Pack

1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER

(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.

Fig. 62 Clutch Discs & Lower Side Gear Installation

1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH DISC PACK

Fig. 63 Upper Side Gear & Clutch Disc Pack Installation

1 - UPPER SIDE GEAR AND CLUTCH DISC PACK
2 - DIFFERENTIAL CASE
3 - SPECIAL TOOL C-6960-3

(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.