Jeep Cherokee (XJ): Service procedures. Removal and installation. Disassembly and assembly

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Differential and driveline > Propeller shafts > Service procedures. Removal and installation. Disassembly and assembly

Service procedures

Driveline angle measurement preparation

Before measuring universal joint angles, the following must be done;

  •  Inflate all tires to correct pressure.
  •  Check the angles in the same loaded or unloaded condition as when the vibration occurred. Propeller shaft angles change according to the amount of load in the vehicle.
  •  Check the condition of all suspension components and verify all fasteners are torqued to specifications.
  •  Check the condition of the engine and transmission mounts and verify all fasteners are torqued to specifications.

Propeller shaft angle measurement

To accurately check driveline alignment, raise and support the vehicle at the axles as level as possible.

Allow the wheels and propeller shaft to turn.

  1.  Remove any external bearing snap rings, if equipped, from universal joint so protractor base sits flat.
  2.  Rotate the shaft until transmission/transfer case output yoke bearing is facing downward. Always make measurements from front to rear. Also, be sure to take all measurements while working from the same side of the vehicle.
  3.  Place Inclinometer on yoke bearing (A) parallel to the shaft (Fig. 9). Center bubble in sight glass and record measurement. This measurement will give you the transmission or Output Yoke Angle (A).

Front (Output) Angle Measurement (A)
Fig. 9 Front (Output) Angle Measurement (A)

1 - SLIP YOKE BEARING CAP
2 - SPECIAL TOOL 7663 (J-23498A)

  1. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft (Fig. 10). Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the Propeller Shaft Angle (C).
  2.  Subtract smaller figure from larger (C minus A) to obtain Transmission Output Operating Angle.
  3.  Rotate propeller shaft 90 degrees and place Inclinometer on pinion yoke bearing parallel to the shaft (Fig. 11). Center bubble in sight glass and record measurement.

 Propeller Shaft Angle Measurement (C)
Fig. 10 Propeller Shaft Angle Measurement (C)

1 - SHAFT YOKE BEARING CAP
2 - SPECIAL TOOL 7663 (J23498-A)

This measurement will give you the pinion shaft or Input Yoke Angle (B).

(7) Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle.

Rear (Input) Angle Measurement (B)
Fig. 11 Rear (Input) Angle Measurement (B)

1 - PINION YOKE BEARING CAP
2 - SPECIAL TOOL 7663 (J-23498A)

Refer to rules given below and the example in (Fig. 12) for additional information.

Universal Joint Angle Example
Fig. 12 Universal Joint Angle Example

1 - 4.9 Angle (C)
2 - 3.2 Angle (B)
3 - Input Yoke
4 - 3.0 Angle (A)
5 - Output Yoke

  • Good cancellation of U-joint operating angles (within 1).
  •  Operating angles less than 3.
  •  At least 1/2 of one degree continuous operating (propeller shaft) angle.

Removal and installation

Front propeller shaft

REMOVAL

  1.  Hoist and support vehicle on safety stands.
  2.  Remove the crossmember/skid plate as necessary to gain access to the propeller shaft.
  3.  Shift the transmission and transfer case, if necessary, into the Neutral position.
  4.  Using a suitable marker, mark a line across the yoke at the transfer case, the link yoke, and propeller shaft yoke at the rear of the front propeller shaft for installation reference (Fig. 13).
  5.  Mark a line across the propeller shaft yoke and the pinion shaft yoke for installation reference.

 Reference Marks on Yokes
Fig. 13 Reference Marks on Yokes

1 - REFERENCE MARKS

  1. Remove the U-joint strap bolts at the pinion shaft yoke (Fig. 14).
  2.  Remove bolts holding rear universal joint to the transfer case yoke.
  3.  Separate the rear universal joint from the transfer case yoke.
  4.  Push rear of propeller shaft upward to clear transfer case yoke.
  5.  Separate front universal joint from front axle.
  6.  Separate propeller shaft from vehicle.

INSTALLATION

  1.  Position front propeller shaft under vehicle with rear universal joint over the transfer case yoke.

Front Propeller Shaft
Fig. 14 Front Propeller Shaft

1 - FRONT AXLE
2 - BOOT
3 - PROPELLER SHAFT
4 - CV-JOINT
5 - TRANSFER CASE
6 - BOOT
7 - SLINGER
8 - CLAMP
9 - YOKE

  1. Place front universal joint into the axle pinion yoke.
  2.  Align mark on the rear link yoke and universal joint to the mark on the transfer case yoke (Fig. 13).
  3.  Loosely install bolts to hold universal joint to transfer case yoke.
  4.  Align mark on front universal joint to the mark on the axle pinion yoke.
  5.  Tighten the U-joint strap/clamp bolts at the axle yoke to 19 N·m (14 ft. lbs.) torque.
  6.  Tighten the universal joint to transfer case bolts to 27 N·m (20 ft. lbs.) torque.
  7.  Lower the vehicle.

Rear propeller shaft

REMOVAL

  1.  Shift the transmission and transfer case into Neutral.
  2.  Hoist and support vehicle on safety stands.
  3.  Scribe alignment marks at the pinion shaft and at each end of the propeller shaft. These marks will be used for installation reference.
  4.  Remove the U-joint strap bolts at the pinion shaft yoke.
  5.  Pry open clamp holding the dust boot to propeller shaft yoke (Fig. 15).
  6.  Slide the slip yoke off of the transmission/ transfer case output shaft and remove the propeller shaft (Fig. 16).

 Dust Boot Clamp
Fig. 15 Dust Boot Clamp

1 - SLINGER
2 - BOOT
3 - AWL
4 - TRANSFER CASE

Rear Propeller Shaft
Fig. 16 Rear Propeller Shaft

1 - CLAMP
2 - YOKE
3 - PROPELLER SHAFT
4 - AXLE YOKE
5 - CLAMP
6 - OUTPUT SHAFT
7 - BOOT

INSTALLATION

  1.  Slide the slip yoke on the transmission/transfer case output shaft. Align the installation reference marks at the axle yoke and install the propeller shaft (Fig. 16).
  2.  Tighten the U-joint strap/clamp bolts at the axle yoke to 19 N·m (14 ft. lbs.) torque.
  3.  Crimp clamp to hold dust boot to propeller shaft yoke (Fig. 17).
  4. Lower the vehicle.

Crimping Dust Boot Clamp
Fig. 17 Crimping Dust Boot Clamp

1 - SPECIAL TOOL C-4975-A
2 - SLINGER
3 - BOOT
4 - CLAMP

Disassembly and assembly

Single cardan universal joint

DISASSEMBLY

Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly.

  1.  Remove the propeller shaft.
  2.  Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring.
  3.  Remove snap rings from both sides of yoke (Fig. 18).

 Remove Snap Ring
Fig. 18 Remove Snap Ring

1 - SNAP RING

  1. Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke.
  2.  Position the yoke with the grease fitting, if equipped, pointing up.
  3.  Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap (Fig. 19).

Press Out Bearing
Fig. 19 Press Out Bearing

1 - PRESS
2 - SOCKET

  1. If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap.
  2.  To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed (Fig. 20).

CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur.

ASSEMBLY

  1.  Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation.
  2.  Position the cross in the yoke with its lube fitting, if equipped, pointing up (Fig. 21).

Press Out Remaining Bearing
Fig. 20 Press Out Remaining Bearing

1 - CROSS
2 - BEARING CAP

Install Cross In Yoke
Fig. 21 Install Cross In Yoke

1 - CROSS
2 - YOKE

  1. Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 22). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly.

Install Bearing On Trunnion
Fig. 22 Install Bearing On Trunnion

1 - BEARING CAP
2 - TRUNNION

  1. Press the bearing cap into the yoke bore enough to install a snap ring.
  2.  Install a snap ring.
  3.  Repeat Step 3 and Step 4to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings.
  4.  Add grease to lube fitting, if equipped.
  5.  Install the propeller shaft.

Double cardan joint

DISASSEMBLY

Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly.

  1.  Remove the propeller shaft.
  2.  Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring.
  3.  Remove all the bearing cap snap rings (Fig. 23).
  4.  Set the joint in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the link yoke.
  5.  Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and partially press one bearing cap from the outboard side of the link yoke enough to grasp the bearing cap with vise jaws (Fig. 24). Be sure to remove grease fittings that interfere with removal.

Remove Snap Rings
Fig. 23 Remove Snap Rings

Press Out Bearing
Fig. 24 Press Out Bearing

  1. Grasp the protruding bearing by vise jaws. Tap the link yoke with a mallet and drift to dislodge the bearing cap from the yoke (Fig. 25).
  2.  Flip assembly and repeat Step 4, Step 5, and Step 6 to remove the opposite bearing cap. This will then allow removal of the cross centering kit assembly and spring (Fig. 26).
  3.  Press the remaining bearing caps out the other end of the link yoke as described above to complete the disassembly.

Remove Bearing From Yoke
Fig. 25 Remove Bearing From Yoke

Remove Centering Kit
Fig. 26 Remove Centering Kit

ASSEMBLY

During assembly, ensure that the alignment marks on the link yoke and propeller shaft yoke are aligned.

  1.  Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation.
  2.  Fit a cross into the propeller shaft yoke (Fig. 27).

Install Cross In Yoke
Fig. 27 Install Cross In Yoke

  1. Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 28). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly.

Install Bearing Cap
Fig. 28 Install Bearing Cap

  1. Press the bearing cap into the yoke bore enough to install a snap ring (Fig. 29).
  2.  Install a snap ring.

 Press In Bearing Cap
Fig. 29 Press In Bearing Cap

  1. Flip the propeller shaft yoke and install the bearing cap onto the opposite trunnion. Install a snap ring (Fig. 30).

 Press In Bearing Cap
Fig. 30 Press In Bearing Cap

  1. Fit the link yoke on the remaining two trunnions and press both bearing caps into place (Fig. 31).
  2.  Install snap rings.

 Install Link Yoke

Fig. 31 Install Link Yoke

  1. Install the centering kit assembly inside the link yoke making sure the spring is properly positioned (Fig. 32).

Install Centering Kit
Fig. 32 Install Centering Kit

  1. Place two bearing caps on opposite trunnions of the remaining cross. Fit the open trunnions into the link yoke bores and the bearing caps into the centering kit (Fig. 33).

 Install Remaining Cross
Fig. 33 Install Remaining Cross

  1. Press the remaining two bearing caps into place and install snap rings (Fig. 34).

Press In Bearing Cap
Fig. 34 Press In Bearing Cap

  1. Tap the snap rings to allow them to seat into the grooves (Fig. 35).
  2.  Check for proper assembly. Flex the joint beyond center, it should snap over-center in both directions when correctly assembled (Fig. 36).
  3.  Install the propeller shaft.

Seat Snap Rings In Groove
Fig. 35 Seat Snap Rings In Groove

Check Assembly
Fig. 36 Check Assembly

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