Jeep Cherokee (XJ): Disassembly and assembly. Cleaning and inspection

Disassembly and assembly

Standard differential

DISASSEMBLY

(1) Remove the ring gear.

(2) Using a suitable roll pin punch, drive out the roll pin holding pinion gear mate shaft in the differential case (Fig. 67).

(3) Remove the pinion gear mate shaft from the differential case and the pinion mate gears.

(4) Rotate differential side gears and remove the pinion mate gears and thrust washers (Fig. 68).

(5) Remove the differential side gears and thrust washers.

ASSEMBLY

(1) Install the differential side gears and thrust washers.

Fig. 67 Mate Shaft Roll Pin Removal
Fig. 67 Mate Shaft Roll Pin Removal

1 - DRIFT
2 - LOCKPIN
3 - MATE SHAFT

Fig. 68 Pinion Mate Gear Removal
Fig. 68 Pinion Mate Gear Removal

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

(2) Install the pinion mate gears and thrust washers.

(3) Install the pinion gear mate shaft. Align the roll pin holes in shaft and the differential case.

(4) Install the roll pin to hold the pinion mate shaft in the differential case (Fig. 69).

Fig. 69 Mate Shaft Roll Pin Installation
Fig. 69 Mate Shaft Roll Pin Installation

1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN

(5) Install the ring gear.

(6) Lubricate all differential components with hypoid gear lubricant.

Final assembly

(1) Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating surfaces with mineral spirits. Apply a bead of Mopart Silicone Rubber Sealant, or equivalent, on the housing cover (Fig. 70).

Install the housing cover within 5 minutes after applying the sealant.

(2) Install the cover on the differential with the attaching bolts. Install the identification tag. Tighten the cover bolts to 41 N·m (30 ft. lbs.) torque.

CAUTION: Overfilling the differential can result in lubricant foaming and overheating.

(3) Refill the differential housing with gear lubricant.

Refer to the Lubricant Specifications section of this group for the gear lubricant requirements.

(4) Install the fill hole plug.

Fig. 70 Typical Housing Cover With Sealant
Fig. 70 Typical Housing Cover With Sealant

1 - SEALING SURFACE
2 - CONTOUR OF BEAD
3 - BEAD THICKNESS 6.35mm (1/4")

Cleaning and inspection

Cardan U-joint

Clean all the U-joint yoke bores with cleaning solvent and a wire brush. Ensure that all the rust and foreign matter are removed from the bores.

Inspect the yokes for distortion, cracks and worn bearing cap bores.

Replace the complete U-joint if any of the components are defective.

Axle components

Wash differential components with cleaning solvent and dry with compressed air. Do not steam clean the differential components.

Wash bearings with solvent and towel dry, or dry with compressed air. DO NOT spin bearings with compressed air. Cup and bearing must be replaced as matched sets only.

Clean axle shaft tubes and oil channels in housing.

Inspect for;

  •  Smooth appearance with no broken/dented surfaces on the bearing rollers or the roller contact surfaces.
  •  Bearing cups must not be distorted or cracked.
  •  Machined surfaces should be smooth and without any raised edges.
  •  Raised metal on shoulders of cup bores should be removed with a hand stone.
  • Wear and damage to pinion gear mate shaft, pinion gears, side gears and thrust washers. Replace as a matched set only.
  •  Ring and pinion gear for worn and chipped teeth.
  •  Ring gear for damaged bolt threads. Replaced as a matched set only.
  •  Pinion yoke for cracks, worn splines, pitted areas, and a rough/corroded seal contact surface. Repair or replace as necessary.
  •  Preload shims for damage and distortion. Install new shims, if necessary.

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