Jeep Cherokee

 Service Manual

Differential and driveline » 8 1/4 Rear axle » Removal and installation
Pinion gear

The ring gear and pinion are serviced in a matched set. Do not replace the pinion without replacing the ring gear.

REMOVAL

(1) Remove differential from the axle housing.

(2) Mark pinion yoke and propeller shaft for installation alignment.

(3) Disconnect propeller shaft from pinion yoke.

Using suitable wire, tie propeller shaft to underbody.

(4) Using Yoke Holder 6719 to hold yoke and remove the pinion yoke nut and washer.

(5) Using Remover C-452, remove the pinion yoke from pinion shaft (Fig. 24).

(6) Partially install pinion nut onto pinion to protect the threads.

(7) Remove the pinion from housing (Fig. 25).

Catch the pinion with your hand to prevent it from falling and being damaged.

(8) Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw.

(9) Remove oil slinger, if equipped, and front pinion bearing.

(10) Remove the front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 26).

(11) Remove the rear bearing cup from housing (Fig. 27). Use Remover C-4307 and Handle C-4171.

Fig. 24 Pinion Yoke Removal

1 - PINION YOKE
2 - TOOL C452

Fig. 25 Remove Pinion Gear

1 - RAWHIDE HAMMER

(12) Remove the collapsible preload spacer (Fig. 28).

(13) Remove the rear bearing from the pinion (Fig.

29) with Puller/Press C-293-PA and Adapters C-293-47.

Place 4 adapter blocks so they do not damage the bearing cage.

(14) Remove the depth shims from the pinion shaft. Record the thickness of the depth shims.

INSTALLATION

(1) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.

(2) Install the pinion rear bearing cup (Fig. 30) with Installer C-4308 and Driver Handle C-4171.

Fig. 26 Front Bearing Cup Removal

1 - REMOVER
2 - HANDLE

Fig. 27 Rear Bearing Cup Removal

1 - DRIVER
2 - HANDLE

(2) Ensure cup is correctly seated.

(3) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.

(4) Install the pinion front bearing cup (Fig. 31) with Installer D-130 and Handle C-4171.

(5) Install pinion front bearing, and oil slinger, if equipped.

Fig. 28 Collapsible Spacer

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING

Fig. 29 Rear Bearing Removal

1 - SPECIAL TOOL C-293-PA
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT

(6) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 32).

Fig. 30 Pinion Rear Bearing Cup Installation

1 - INSTALLER
2 - HANDLE

Fig. 31 Pinion Front Bearing Cup Installation

1 - INSTALLER
2 - HANDLE

NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion head to achieve proper ring and pinion gear mesh. If the factory installed ring gear and pinion are reused, the pinion depth shim should not require replacement.

If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing.

(7) Place the proper thickness depth shim on the pinion.

Fig. 32 Pinion Seal Installation

1 - SPECIAL TOOL C-4735
2 - DIFFERENTIAL HOUSING
3 - SPECIAL TOOL C-4076-A

(8) Install the rear bearing and slinger, if equipped, on the pinion (Fig. 33) with Installer 6448.

Fig. 33 Shaft Rear Bearing Installation

1 - PRESS
2 - INSTALLATION TOOL
3 - DRIVE PINION
4 - DRIVE PINION SHAFT REAR BEARING

(9) Install a new collapsible preload spacer on pinion shaft and install pinion in housing (Fig. 34).

(10) Install pinion in housing.

(11) Install yoke with Installer C-3718 and Yoke Holder 6719.

(12) Install the yoke washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing end-play if a new collapsible spacer was installed.

Fig. 34 Collapsible Preload Spacer

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING

(13) Tighten the nut to 285 N·m (210 ft. lbs.).

CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated.

(14) Using Yoke Holder 6719, crush collapsible spacer until bearing end play is taken up.

(15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 35).

(16) Check bearing rotating torque with an inch pound torque wrench (Fig. 35). The torque necessary to rotate the pinion gear should be:

•  Original Bearings - 1 to 2 N·m (10 to 20 in. lbs.).
•  New Bearings - 1 to 5 N·m (10 to 30 in. lbs.).

(17) Install propeller shaft.

(18) Install differential in housing.

Fig. 35 Check Pinion Rotating Torque

1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH

Rear axle

Axle shaft

Axle seal and bearing

Pinion seal

Differential

Differential side bearings

Ring gear

Pinion gear