SERVICE MANUAL

2004
LIBERTY

To order the special service tools used and

illustrated, please refer to the instructions on
inside back cover.

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.

DaimlerChrysler Corporation reserves the right to make changes in design or

to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.

Litho in U.S.A. Copyright © 2003 DaimlerChrysler Corporation

0603

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 CAUTION
ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE
APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE
ONLY. All test and repair procedures on components or assemblies in non-auto-
motive applications should be repaired in accordance with instructions supplied by
the manufacturer of the total product.

Proper service and repair is important to the safe, reliable, operation of all motor vehi-
cles. The service procedures recommended and described in this publication were
developed for professional service personnel and are effective methods for perform-
ing vehicle repair. Following these procedures will help assure efficient economical
vehicle performance and service reliability. Some of these service procedures require
the use of special tools designed for specific procedures. These special tools should
be used when recommended throughout this publication.

Special attention should be exercised when working with spring or tension loaded fas-
teners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal may
cause personal injury. Always wear safety goggles whenever working on vehicles or vehi-
cle components.

It is important to note that this publication contains various Cautions and Warnings.
These should be carefully read in order to minimize the risk of personal injury, or the
possibility that improper service methods may damage the vehicle or render it unsafe.
It is important to note that these Cautions and Warnings cover only the situations and
procedures DaimlerChrysler Corporation has encountered and recommended.
DaimlerChrysler Corporation could not possibly know, evaluate, and advise the
service trade of all conceivable ways that service may be performed, or of the possi-
ble hazards of each. Consequently, DaimlerChrysler Corporation has not undertaken
any such broad service review. Accordingly, anyone who uses a service procedure, or
tool, that is not recommended in this publication must assure oneself thoroughly that
neither personal safety, nor vehicle safety, be jeopardized by the service methods they
select.

For other Service and Owner Manuals for Chrysler, Plymouth,

Dodge, Dodge Truck, and JeepT vehicles, Call (800) 890-4038 or
FAX (440) 572-0815 to place an order. Or, visit our website at
techauthority.daimlerchrysler.com. Tech Authority Online at our
website offers you service information on a subscription basis.

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 FOREWORD

The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

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 GROUP TAB LOCATOR

Introduction

0 Lubrication & Maintenance

2 Suspension

3 Differential & Driveline

5 Brakes

6 Clutch

7 Cooling

8A Audio/Video

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8M Message Systems

8N Power Systems

8O Restraints

8P Speed Control

8Q Vehicle Theft Security

8R Wipers/Washers

8T Navigation/Telecommunication

8W Wiring

9 Engine

11 Exhaust System

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transmission and Transfer Case

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

Component and System Index

Service Manual Comment Forms (Rear of Manual)

KJ INTRODUCTION 1

INTRODUCTION
TABLE OF CONTENTS

page page

FASTENER IDENTIFICATION TORQUE REFERENCES

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...7
FASTENER USAGE VEHICLE EMISSION CONTROL INFORMATION
DESCRIPTION (VECI) LABEL
DESCRIPTION - FASTENER USAGE . . . . . ...4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...8
DESCRIPTION - THREADED HOLE REPAIR ..4 VEHICLE IDENTIFICATION NUMBER
INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...4 VEHICLE CERTIFICATION LABEL
METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...9
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...5

FASTENER IDENTIFICATION marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
DESCRIPTION
the head of the bolt. The higher the class number,
The SAE bolt strength grades range from grade 2
the greater the bolt strength. Some metric nuts are
to grade 8. The higher the grade number, the greater
imprinted with a single-digit strength class on the
the bolt strength. Identification is determined by the
nut face. Refer to the Fastener Identification and
line marks on the top of each bolt head. The actual
Fastener Strength Charts (Fig. 1) and (Fig. 2).
bolt strength grade corresponds to the number of line
2 INTRODUCTION KJ
FASTENER IDENTIFICATION (Continued)

Fig. 1 FASTENER IDENTIFICATION

KJ INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

Fig. 2 FASTENER STRENGTH

4 INTRODUCTION KJ

FASTENER USAGE DESCRIPTION - THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoilt recommen-
DESCRIPTION dations for application and repair procedures.

DESCRIPTION - FASTENER USAGE

INTERNATIONAL SYMBOLS
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER- DESCRIPTION
SONAL INJURY. The graphic symbols illustrated in the following
International Control and Display Symbols Chart
Fasteners and torque specifications references in (Fig. 3) are used to identify various instrument con-
this Service Manual are identified in metric and SAE trols. The symbols correspond to the controls and dis-
format. plays that are located on the instrument panel.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.

Fig. 3 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
KJ INTRODUCTION 5

METRIC SYSTEM The following chart will assist in converting metric

units to equivalent English and SAE units, or vise
versa.
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x 0.11298 = Newton Meters N·m x 8.851 = in-lbs
(N·m)
ft-lbs x 1.3558 = Newton Meters N·m x 0.7376 = ft-lbs
(N·m)
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. Km/h x 0.6214 = mph
(Km/h)
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert

torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.) (Fig. 4).
6 INTRODUCTION KJ
METRIC SYSTEM (Continued)

Fig. 4 METRIC CONVERSION CHART

KJ INTRODUCTION 7

TORQUE REFERENCES tions Chart for torque references not listed in the
individual torque charts (Fig. 5).
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-

Fig. 5 TORQUE SPECIFICATIONS

8 INTRODUCTION KJ

VEHICLE EMISSION CONTROL VEHICLE IDENTIFICATION

INFORMATION (VECI) LABEL NUMBER
DESCRIPTION DESCRIPTION
All models have a Vehicle Emission Control Infor- The Vehicle Identification Number (VIN) plate is
mation (VECI) Label. DaimlerChrysler permanently located on the lower left A-pillar and is visible
attaches the label in the engine compartment (Fig. through the windshield (Fig. 7). The VIN contains 17
6). The label cannot be removed without defacing characters that provide data concerning the vehicle.
label information and destroying label. Refer to the VIN decoding chart to determine the
The label contains the vehicle’s emission specifica- identification of a vehicle.
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
The label also contains an engine vacuum sche-
matic. There are unique labels for vehicles built for
sale in the state of California and the country of
Canada. Canadian labels are written in both the
English and French languages.
The VECI label contains the following:
• Engine family and displacement
• Evaporative family
• Emission control system schematic
• Certification application
• Engine timing specifications (if adjustable)
• Idle speeds (if adjustable)
• Spark plug and gap

Fig. 7 VIN NUMBER LOCATION

1 - A-PILLAR
2 - VIN CODE PLATE

The Vehicle Identification Number is also

imprinted on the:
• Vehicle Safety Certification Label.
• Frame rail.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
Fig. 6 VECI LABEL LOCATION manufacturer and government agencies to verify the
1 - RADIATOR SUPPORT
authenticity of the vehicle and official documenta-
2 - VECI LABEL tion. The formula to use the check digit is not
released to the general public.
KJ INTRODUCTION 9
VEHICLE IDENTIFICATION NUMBER (Continued)
VEHICLE IDENTIFICATION NUMBER DECODING CHART

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured by DaimlerChrysler
Corporation
2 Make J = Jeep
3 Vehicle Type 4 = MPV W/O Side Airbags.
8 = MPV With Side Airbags.
4 Gross Vehicle Weight Rating F = 4001 - 5000 lbs.
G = 5001 - 6000 lbs.
5 Vehicle Line K = Liberty 4X2 (LHD)
L = Liberty 4X4 (LHD) wihtout ABB
M = Cherokee 4X4 (RHD)
6 = Cherokee (LHD) with ABB
6 Series 3 = Liberty/Renegade
4 = Liberty Sport/Cherokee Sport
5 = Liberty Limited/Cherokee Limited
7 Body Style 8 = Sport Utility - 4 Door
8 Engine K = 3.7L 6 cyl MPI Gasoline
1 = 2.4L 4 cyl MPI Gasoline
7 = 2.5L 4 cyl Diesel
9 Check Digit 0 through 9 or X
10 Model Year 4=2004
11 Assembly Plant W = Toledo North Assembly Plant
12 thru 17 Vehicle Build Sequence

VEHICLE CERTIFICATION The label is located on the driver-side door

shut-face.
LABEL
DESCRIPTION
A vehicle certification label (Fig. 8) is attached to
every DaimlerChrysler Corporation vehicle. The label
certifies that the vehicle conforms to all applicable
Federal Motor Vehicle Standards. The label also lists:
• Month and year of vehicle manufacture.
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR’s) are
based on a minimum rim size and maximum cold tire
inflation pressure.
• Vehicle Identification Number (VIN).
• Type of vehicle.
• Type of rear wheels.
• Bar code.
• Month, Day and Hour (MDH) of final assembly.
• Paint and Trim codes. Fig. 8 VEHICLE CERTIFICATION LABEL - TYPICAL
• Country of origin.
KJ LUBRICATION & MAINTENANCE 0-1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

PARTS & LUBRICANT RECOMMENDATION FLUID CAPACITIES

DESCRIPTION SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 5
DESCRIPTION - FLUID TYPES . . . . . . . . . ...1 FLUID FILL/CHECK LOCATIONS
DESCRIPTION - LUBRICANT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RECOMMENDATIONS . . . . . . . . . . . . . . . . ...2 MAINTENANCE SCHEDULES
FLUID TYPES DESCRIPTION
DESCRIPTION DESCRIPTION – DOMESTIC SCHEDULES . . . 6
DESCRIPTION - FLUID TYPES . . . . . . . . . ...2 DESCRIPTION – GASOLINE ENGINES –
DESCRIPTION - AXLE . . . . . . . . . . . . . . . . ...3 EXPORT SCHEDULES . . . . . . . . . . . . . . . . . . 11
DESCRIPTION - MANUAL TRANSMISSION ...3 DESCRIPTION – DIESEL ENGINES –
DESCRIPTION - AUTOMATIC EXPORT SCHEDULES . . . . . . . . . . . . . . . . . . 16
TRANSMISSION FLUID . . . . . . . . . . . . . . . .. .3 HOISTING
DESCRIPTION - TRANSFER CASE - NV231 . .4 STANDARD PROCEDURE - HOISTING
DESCRIPTION - TRANSFER CASE - NV242 . .4 RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 19
DESCRIPTION - ENGINE COOLANT . . . . . .. .4 JUMP STARTING
DESCRIPTION - ENGINE OIL - DIESEL STANDARD PROCEDURE - JUMP STARTING
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . ...5 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION - POWER STEERING FLUID ..5 TOWING
OPERATION - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - TOWING . . . . . . . . 21
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5

PARTS & LUBRICANT DaimlerChrysler Corporation only recommends

multigrade engine oils.
RECOMMENDATION
API QUALITY CLASSIFICATION
This symbol (Fig. 1) on the front of an oil container
DESCRIPTION means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
DESCRIPTION - FLUID TYPES cation requirements specified by DaimlerChrysler
When service is required, DaimlerChrysler Corpo- Corporation.
ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopart provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used to service a
Chrysler Corporation vehicle.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API) (Fig. 1)
• National Lubricating Grease Institute (NLGI)
(Fig. 2)
Fig. 1 API Symbol
SAE VISCOSITY RATING GEAR LUBRICANTS
An SAE viscosity grade is used to specify the vis- SAE ratings also apply to multigrade gear lubri-
cosity of engine oil. These are specified with a dual cants. In addition, API classification defines the
SAE viscosity grade which indicates the cold-to-hot lubricants usage. Such as API GL-5 and SAE 75W-
temperature viscosity range. Example SAE 5W-30 = 90.
multigrade engine oil.
0-2 LUBRICATION & MAINTENANCE KJ
PARTS & LUBRICANT RECOMMENDATION (Continued)
LUBRICANTS AND GREASES Body
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI Component Fluid, Lubricant, and Genuine
symbol (Fig. 2) on the label. At the bottom NLGI Part
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter Hinges:
“G”. Chassis lubricant is identified by the latter “L”. Door & Hood MoparT Engine Oil
The letter following the usage letter indicates the Swing Gate MoparT Multi-Purpose Lube NLGI
quality of the lubricant. The following symbols indi- Grade 2 EP, GC-LB
cate the highest quality.
Latches: Door, MoparT Multi-Purpose Lube NLGI
Hood/Safety Grade 2 EP, GC-LB
Catch, Swing
Gate
Seat Regulator MoparT Multi-Purpose Lube NLGI
& Track Grade 2 EP, GC-LB
Lock Cylinders MoparT Lock Cylinder Lube

FLUID TYPES
Fig. 2 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION DESCRIPTION
3 - CHASSIS AND WHEEL BEARINGS
DESCRIPTION - FLUID TYPES
SPECIALIZED LUBRICANTS AND OILS When service is required, DaimlerChrysler Corpo-
Some maintenance or repair procedures may ration recommends that only Mopart brand parts,
require the use of specialized lubricants or oils. Con- lubricants and chemicals be used. Mopart provides
sult the appropriate sections in this manual for the the best engineered products for servicing
correct application of these lubricants. DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
DESCRIPTION - LUBRICANT the following organization should be used to service a
RECOMMENDATIONS Chrysler Corporation vehicle.
• Society of Automotive Engineers (SAE)
Chassis • American Petroleum Institute (API) (Fig. 3)
• National Lubricating Grease Institute (NLGI)
Component Fluid, Lubricant, or Genuine Part (Fig. 4)
Steering Gear MoparT Multi-Purpose Lubricant SAE VISCOSITY RATING
& Linkage, Ball NLGI Grade 2 EP, GC-LB An SAE viscosity grade is used to specify the vis-
Joints, Prop cosity of engine oil. These are specified with a dual
Shafts & SAE viscosity grade which indicates the cold-to-hot
Yokes, Wheel temperature viscosity range. Example SAE 5W-30 =
Bearings multigrade engine oil.
DaimlerChrysler Corporation only recommends
multigrade engine oils.
KJ LUBRICATION & MAINTENANCE 0-3
FLUID TYPES (Continued)
API QUALITY CLASSIFICATION DESCRIPTION - AXLE
This symbol (Fig. 3) on the front of an oil container
means that the oil has been certified by the Ameri- NOTE: DaimlerChrysler recommends using MoparT
can Petroleum Institute (API) to meet all the lubri- lubricants or lubricants of equal quality.
cation requirements specified by DaimlerChrysler
Corporation.
FRONT AXLE
• 186FIA (Model 30) - Mopart Synthentic Gear
Lubricant 75W-140

REAR AXLE
• 8 1/4 - Mopart Gear Lubricant 75W-90 (Trailer
Towing - Mopart Synthentic Gear Lubricant 75W-140

NOTE: Trac-lokT equipped axles require 118 ml (4

ounces) of Limited Slip Additive be added to the
lubricant.
Fig. 3 API Symbol
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubri- DESCRIPTION - MANUAL TRANSMISSION
cants. In addition, API classification defines the
NOTE: DaimlerChrysler recommends using MoparT
lubricants usage. Such as API GL-5 and SAE 75W-
lubricants or lubricants of equal quality.
90.
• NV1500 - Mopart Manual Transmission Lubri-
LUBRICANTS AND GREASES cant
Lubricating grease is rated for quality and usage • NV3550 - Mopart Manual Transmission Lubri-
by the NLGI. All approved products have the NLGI cant
symbol (Fig. 4) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
DESCRIPTION - AUTOMATIC TRANSMISSION
Wheel bearing lubricant is identified by the letter
“G”. Chassis lubricant is identified by the latter “L”. FLUID
The letter following the usage letter indicates the
NOTE: Refer to Service Procedures in this group for
quality of the lubricant. The following symbols indi-
fluid level checking procedures.
cate the highest quality.
Mopart ATF +4, Automatic Transmission Fluid is
the recommended fluid for DaimlerChrysler auto-
matic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopart ATF +4, Automatic Transmission Fluid
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
Fig. 4 NLGI Symbol permanent and is not an indicator of fluid condition.
1 - WHEEL BEARINGS As the vehicle is driven, the ATF will begin to look
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
darker in color and may eventually become brown.
This is normal. ATF+4 also has a unique odor that
SPECIALIZED LUBRICANTS AND OILS may change with age. Consequently, odor and color
Some maintenance or repair procedures may cannot be used to indicate the fluid condition or the
require the use of specialized lubricants or oils. Con- need for a fluid change.
sult the appropriate sections in this manual for the
correct application of these lubricants.
0-4 LUBRICATION & MAINTENANCE KJ
FLUID TYPES (Continued)
FLUID ADDITIVES engine block. Then coolant carries the heat to the
DaimlerChrysler strongly recommends against the radiator where the tube/fin radiator can transfer the
addition of any fluids to the transmission, other than heat to the air.
those automatic transmission fluids listed above. The use of aluminum cylinder blocks, cylinder
Exceptions to this policy are the use of special dyes heads, and water pumps requires special corrosion
to aid in detecting fluid leaks. protection. Mopart Antifreeze/Coolant, 5
Various “special” additives and supplements exist Year/100,000 Mile Formula (MS-9769), or the equiva-
that claim to improve shift feel and/or quality. These lent ethylene glycol base coolant with organic corro-
additives and others also claim to improve converter sion inhibitors (called HOAT, for Hybrid Organic
clutch operation and inhibit overheating, oxidation, Additive Technology) is recommended. This coolant
varnish, and sludge. These claims have not been sup- offers the best engine cooling without corrosion when
ported to the satisfaction of DaimlerChrysler and mixed with 50% Ethylene Glycol and 50% distilled
these additives must not be used. The use of trans- water to obtain a freeze point of -37°C (-35°F). If it
mission “sealers” should also be avoided, since they loses color or becomes contaminated, drain, flush,
may adversely affect the integrity of transmission and replace with fresh properly mixed coolant solu-
seals. tion.

DESCRIPTION - TRANSFER CASE - NV231 CAUTION: MoparT Antifreeze/Coolant, 5

Year/100,000 Mile Formula (MS-9769) may not be
Recommended lubricant for the NV231 transfer
mixed with any other type of antifreeze. Mixing of
case is Mopart ATF +4, Automatic Transmission
coolants other than specified (non-HOAT or other
Fluid.
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
DESCRIPTION - TRANSFER CASE - NV242
decreased corrosion protection.
Recommended lubricant for the NV242 transfer
case is Mopart ATF+4, Automatic Transmission
Fluid. COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
DESCRIPTION - ENGINE COOLANT mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
tures follows:
BASE COOLANT AND IS HARMFUL IF SWAL-
Pure Water-Water can absorb more heat than a
LOWED OR INHALED. IF SWALLOWED, DRINK
mixture of water and ethylene-glycol. This is for pur-
TWO GLASSES OF WATER AND INDUCE VOMIT-
pose of heat transfer only. Water also freezes at a
ING. IF INHALED, MOVE TO FRESH AIR AREA.
higher temperature and allows corrosion.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
100 percent Ethylene-Glycol-The corrosion
STORE IN OPEN OR UNMARKED CONTAINERS.
inhibiting additives in ethylene-glycol need the pres-
WASH SKIN AND CLOTHING THOROUGHLY AFTER
ence of water to dissolve. Without water, additives
COMING IN CONTACT WITH ETHYLENE GLYCOL.
form deposits in system. These act as insulation
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
causing temperature to rise to as high as 149°C
GLYCOL BASE COOLANT PROPERLY, CONTACT
(300°F). This temperature is hot enough to melt plas-
YOUR DEALER OR GOVERNMENT AGENCY FOR
tic and soften solder. The increased temperature can
LOCATION OF COLLECTION CENTER IN YOUR
result in engine detonation. In addition, 100 percent
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
ethylene-glycol freezes at -22°C (-8°F).
THE ENGINE IS AT OPERATING TEMPERATURE OR
50/50 Ethylene-Glycol and Water-Is the recom-
HOT UNDER PRESSURE, PERSONAL INJURY CAN
mended mixture, it provides protection against freez-
RESULT. AVOID RADIATOR COOLING FAN WHEN
ing to -37°C (-34°F). The antifreeze concentration
ENGINE COMPARTMENT RELATED SERVICE IS
must always be a minimum of 44 percent, year-
PERFORMED, PERSONAL INJURY CAN RESULT.
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
CAUTION: Use of Propylene Glycol based coolants tion against freezing is provided with a 68 percent
is not recommended, as they provide less freeze antifreeze concentration, which prevents freezing
protection and less corrosion protection. down to -67.7°C (-90°F). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
The cooling system is designed around the coolant. centage of antifreeze can cause the engine to over-
The coolant must accept heat from engine metal, in heat because specific heat of antifreeze is lower than
the cylinder head area near the exhaust valves and that of water.
KJ LUBRICATION & MAINTENANCE 0-5
FLUID TYPES (Continued)
CAUTION: Richer antifreeze mixtures cannot be transmission operation and shift feel will remain con-
measured with normal field equipment and can sistent. Transmission fluid must also be a good con-
cause problems associated with 100 percent ethyl- ductor of heat. The fluid must absorb heat from the
ene-glycol. internal transmission components and transfer that
heat to the transmission case.

CAUTION: Do not use coolant additives that are

claimed to improve engine cooling. FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
DESCRIPTION SPECIFICATION
Use only Diesel Engine Oil meeting standard MIL-
2104C or API Classification CD or higher or CCML FUEL TANK – Gasoline & 19.5 U.S. Gallons (74
D4, D5. Diesel Liters)****
ENGINE OIL
SAE VISCOSITY GRADE Engine Oil - with Filter - 4.7L (5.0 qts.)
2.4L
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation. Engine Oil - with Filter - 4.7L (5.0 qts.)
3.7L
To assure of properly formulated engine oils, it is
Engine Oil - With Filter - 6.0L (6.3 qts.)
recommended that SAE Grade 10W-40 engine oils
2.5L/2.8L Diesel
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification. ENGINE COOLANT
European Grade 10W-40 oils are also acceptable. Cooling System - 2.4L 9.5L (10.0 qts.)
Oils of the SAE 5W-40 grade number are preferred Cooling System - 3.7L 13.2L (14.0 qts.)
when minimum temperatures consistently fall below
-15°C. Cooling System - 12.5L (13.2 qts.)
2.5L/2.8L Diesel
DESCRIPTION - POWER STEERING FLUID POWER STEERING SYSTEM
Mopart ATF +4, Automatic Transmission Fluid is Power steering fluid capacities are dependent on
required in the power steering system. Substitute engine/chassis options as well as steering gear/cooler
fluids can induce power steering system failure. options. Depending on type and size of internal
Mopart ATF +4, Automatic Transmission Fluid cooler, length and inside diameter of cooler lines, or
when new is red in color. The ATF is dyed red so it use of an auxiliary cooler, these capacities may vary.
can be identified from other fluids used in the vehicle Refer to 19, Steering for proper fill and bleed
such as engine oil or antifreeze. The red color is not procedures.
permanent and is not an indicator of fluid condition.
AUTOMATIC TRANSMISSION
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown. Service Fill - 545RFE 4.73L (10.0 pts)
This is normal. ATF+4 also has a unique odor that O-haul Fill - 545RFE 13.33L (28.0 pts)
may change with age. Consequently, odor and color Service Fill - 42RLE 3.8L (8.0 pts)
cannot be used to indicate the fluid condition or the
need for a fluid change. O-haul Fill - 42RLE 8.3L (17.6 pts)
Dry fill capacity Depending on type and size of
OPERATION - AUTOMATIC TRANSMISSION internal cooler, length and inside diameter of cooler
FLUID lines, or use of an auxiliary cooler, these figures may
The automatic transmission fluid is selected based vary. (Refer to 21 - TRANSMISSION/AUTOMATIC/
upon several qualities. The fluid must provide a high FLUID - STANDARD PROCEDURE)
level of protection for the internal components by TRANSFER CASE
providing a lubricating film between adjacent metal NV231 1.4L (2.95 pts.)
components. The fluid must also be thermally stable
NV242 1.6L (3.4 pts.)
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con- MANUAL TRANSMISSION
stant through the temperature range of operation,
0-6 LUBRICATION & MAINTENANCE KJ
FLUID CAPACITIES (Continued)

DESCRIPTION SPECIFICATION Second is Schedule “A”. It is for vehicles that are

not operated under any of the conditions listed under
NV1500 (Approximate dry Schedule “B.”
fill or fill to bottom edge of 2.3L (4.8 pts.) Use the schedule that best describes your driving
the fill plug hole.) conditions. Where time and mileage are listed, follow
NV3550 (Approximate dry the interval that occurs first.
4X4 - 1.98L (4.2 pts.)
fill or fill to bottom edge of
4X2 - 2.28L (4.8 pts.)
fill plug hole.) CAUTION: Failure to perform the required mainte-
FRONT AXLE nance items may result in damage to the vehicle.
186 FIA (Model 30) 1.24L (2.6 pts.)
REAR AXLE At Each Stop for Fuel
• Check the engine oil level about 5 minutes after a
8 1/4 2.08L (4.4 pts.)*
fully warmed engine is shut off. Checking the oil level
* When equipped with Trac-lok, include 118 ml (4.0 while the vehicle is on level ground will improve the
ounces) of Limited Slip Additive. accuracy of the oil level reading. Add oil only when the
****Nominal refill capacities are shown. A variation level is at or below the ADD or MIN mark.
may be observed from vehicle to vehicle due to • Check the windshield washer solvent, add as
manufacturing tolerance and refill procedure. required.

Once a Month
FLUID FILL/CHECK • Check the tire pressure and look for unusual
LOCATIONS wear or damage.
• Inspect the battery, and clean and tighten the
terminals as required.
DESCRIPTION • Check the fluid levels of the coolant reservoir,
The fluid check/fill point locations are located in brake master cylinder, power steering, and transmis-
each applicable service manual section. sion, and add as needed.
• Check all lights and all other electrical items for
MAINTENANCE SCHEDULES correct operation.

At Each Oil Change

DESCRIPTION • Change the engine oil filter.
• Inspect the exhaust system.
DESCRIPTION – DOMESTIC SCHEDULES • Inspect brake hoses.
Maintenance Schedule Information not included in • Check the coolant level, hoses, and clamps.
this section, is located in the appropriate Owner’s • Rotate the tires.
Manual. • Inspect manual transmission fluid level — if
There are two maintenance schedules that show equipped.
the required service for your vehicle. • After completion of off-road operation, the
First is Schedule (B(. It is for vehicles that are underside of the vehicle should be thoroughly
operated under the conditions that are listed below inspected. Examine threaded fasteners for looseness.
and at the beginning of the schedule.
• Day or night temperatures are below 0°C (32°F).
Schedule “B”
• Stop and go driving. Follow schedule “B” if you usually operate your
• Extensive engine idling. vehicle under one or more of the following conditions.
• Driving in dusty conditions. • Day or night temperatures are below 0°C (32°F).
• Short trips of less than 16.2 km (10 miles). • Stop and go driving.
• More than 50% of your driving is at sustained • Extensive engine idling.
high speeds during hot weather, above 32°C (90°F). • Driving in dusty conditions.
• Trailer towing. • Short trips of less than 16.2 km (10 miles).
• Taxi, police, or delivery service (commercial ser- • More than 50% of your driving is at sustained
vice). high speeds during hot weather, above 32°C (90°F).
• Off-road or desert driving. • Trailer towing.
• Taxi, police, or delivery service (commercial ser-
NOTE: Most vehicles are operated under the condi- vice).
tions listed for Schedule “B.” • Off-road or desert driving.
KJ LUBRICATION & MAINTENANCE 0-7
MAINTENANCE SCHEDULES (Continued)

Kilometers 5 000 10 000 14 000 19 000 24 000

(Miles) (3,000) (6,000) (9,000) (12,000) (15,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X

Kilometers 29 000 34 000 38 000 43 000 48 000

(Miles) (18,000) (21,000) (24,000) (27,000) (30,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if X
necessary.L
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Drain and refill the automatic transmission X
fluid, and replace main sump filter.

Kilometers 53 000 58 000 62 000 67 000 72 000

(Miles) (33,000) (36,000) (39,000) (42,000) (45,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Inspect the brake linings. X
Drain and refill the front and rear axle X
fluid‡
Inspect the drive belt and replace as X
needed.

Kilometers 77 000 82 000 86 000 91 000 96 000

(Miles) (48,000) (51,000) (54,000) (57,000) (60,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if X
necessary.L
Replace the ignition cables (2.4L Only). X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid‡ X X
Drain and refill the automatic transmission X
fluid, and replace main sump filter.
0-8 LUBRICATION & MAINTENANCE KJ
MAINTENANCE SCHEDULES (Continued)

Kilometers 77 000 82 000 86 000 91 000 96 000

(Miles) (48,000) (51,000) (54,000) (57,000) (60,000)
Inspect the drive belt and replace as X
needed. Not required if belt was previously
Drain and refill the transfer case fluid. X

Kilometers 101 000 106 000 110 000 115 000 120 000
(Miles) (63,000) (66,000) (69,000) (72,000) (75,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as X
needed. Not required if belt was previously
replaced.

Kilometers 125 000 130 000 134 000 139 000 144 000
(Miles) (78,000) (81,000) (84,000) (87,000) (90,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if X
necessary.L
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Drain and refill the automatic transmission X
fluid, and replace transmission filter (s).
Inspect the drive belt and replace as X
needed. Not required if belt was previously
replaced.
Replace the timing belt (2.4L Only). X

Kilometers 149 000 154 000 158 000 163 000 168 000
(Miles) (93,000) (96,000) (99,000) (102,000) (105,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as X
needed. Not required if belt was previously
replaced.
Flush and replace the engine coolant. X
KJ LUBRICATION & MAINTENANCE 0-9
MAINTENANCE SCHEDULES (Continued)

Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if X
necessary.L
Replace the ignition cables (2.4L Only). X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid‡ X X
Drain and refill the automatic transmission X
fluid, and replace main sump filter.
Inspect the drive belt and replace as X
needed. Not required if belt was previously
replaced.
Drain and refill the transfer case fluid. X

‡Off-highway operation, trailer towing, taxi, limou-

Inspection and service should be performed any-
sine, bus, snow plowing, or other types of commercial
time a malfunction is observed or suspected.
service or prolonged operation with heavy loading,
L This maintenance is recommended by the man-
especially in hot weather, require front and rear axle
ufacturer to the owner, but it is not required to main-
service indicated with a ‡ in Schedule “B”. Perform
tain emissions warranty.
these services if the vehicle is usually operated under
these conditions.

Schedule “A”

Kilometers 10 000 19 000 29 000 38 000 48 000

(Miles) (6,000) (12,000) (18,000) (24,000) (30,000)
[Months] [6] [12] [18] [24] [30]
Change the engine oil and engine oil filter. X X X X X
Replace the engine air filter element. X
Replace the spark plugs. X
Inspect the brake linings. X
Inspect the transfer case fluid. X

Kilometers 58 000 67 000 77 000 86 000

(Miles) (36,000) (42,000) (48,000) (54,000)
[Months] [36] [42] [48] [54]
Change the engine oil and engine oil filter. X X X X
Inspect the brake linings. X X
0 - 10 LUBRICATION & MAINTENANCE KJ
MAINTENANCE SCHEDULES (Continued)

Kilometers 96 000 106 000 115 000 125 000

(Miles) (60,000) (66,000) (72,000) (78,000)
[Months] [60] [66] [72] [78]
Change the engine oil and engine oil filter. X X X X
Inspect the brake linings. X
Replace the engine air filter element. X
Replace the spark plugs. X
Replace the ignition cables (2.4L Only). X
Inspect and replace the PCV valve, if necessary.L X
Inspect the drive belt and replace, if needed. X
Inspect the drive belt and replace as needed. Not X
required if previously replaced.
Flush and replace the engine coolant at 60 months, X
regardless of mileage.
Inspect the transfer case fluid. X

Kilometers 134 000 144 000 154 000 163 000

(Miles) (84,000) (90,000) (96,000) (102,000)
[Months] [84] [90] [96] [102]
Change the engine oil and engine oil filter. X X X X
Inspect the brake linings. X
Replace the engine air filter element. X
Replace the spark plugs. X
Inspect and replace the PCV valve, if necessary.L X
Inspect the drive belt and replace as needed. Not X X
required if previously replaced.
Flush and replace the engine coolant if not done at 60 X
months.
Inspect the transfer case fluid. X

Kilometers 173 000 182 000 192 000

(Miles) (108,000) (114,000) (120,000)
[Months] [108] [114] [120]
Change the engine oil and engine oil filter. X X X
Inspect the brake linings. X
Replace the engine air filter element. X
Replace the spark plugs. X
Inspect and replace the PCV valve, if necessary.L X
Replace the ignition cables (2.4L Only). X
Inspect the drive belt and replace as needed. Not required if previously X X
replaced.
Flush and replace the engine coolant if not done at 163 000 km X
(102,000 miles).
Replace the timing belt (2.4L Only). X
Drain and refill the transfer case fluid. X
KJ LUBRICATION & MAINTENANCE 0 - 11
MAINTENANCE SCHEDULES (Continued)
improve the accuracy of the oil level reading. Add oil
Inspection and service should be performed any-
only when the level is at or below the ADD or MIN
time a malfunction is observed or suspected.
mark.
L This maintenance is recommended by the man-
• Check the windshield washer solvent, add as
ufacturer to the owner, but it is not required to main-
required.
tain emissions warranty.
Once a Month
DESCRIPTION – GASOLINE ENGINES – • Check the tire pressure and look for unusual
EXPORT SCHEDULES wear or damage.
There are two maintenance schedules that show • Inspect the battery, and clean and tighten the
the required service for your vehicle. terminals as required.
First is Schedule “A”. It is for vehicles that are not • Check the fluid levels of the coolant reservoir,
operated under any of the conditions listed under brake master cylinder, and transmission, and add as
Schedule “B.” needed.
Second is Schedule (B(. It is for vehicles that are • Check all lights and all other electrical items for
operated under the conditions that are listed below correct operation.
and at the beginning of the schedule.
• Day or night temperatures are below 0°C (32°F). At Each Oil Change
• Stop and go driving. • Change the engine oil filter.
• Extensive engine idling. • Inspect the exhaust system.
• Driving in dusty conditions. • Inspect brake hoses.
• Short trips of less than 16.2 km (10 miles). • Check the coolant level, hoses, and clamps.
• More than 50% of your driving is at sustained • Rotate the tires.
high speeds during hot weather, above 32°C (90°F). • Inspect manual transmission fluid level — if
• Trailer towing. equipped.
• Taxi, police, or delivery service (commercial ser- • After completion of off-road operation, the
vice). underside of the vehicle should be thoroughly
• Off-road or desert driving. inspected. Examine threaded fasteners for looseness.

NOTE: Most vehicles are operated under the condi- Schedule “A”
tions listed for Schedule “B.” Follow schedule “B” if you usually operate your
vehicle under one or more of the following conditions.
Use the schedule that best describes your driving • Day or night temperatures are below 0°C (32°F).
conditions. Where time and mileage are listed, follow • Stop and go driving.
the interval that occurs first. • Extensive engine idling.
• Driving in dusty conditions.
CAUTION: Failure to perform the required mainte-
• Short trips of less than 16.2 km (10 miles).
nance items may result in damage to the vehicle.
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32°C (90°F).
At Each Stop for Fuel • Trailer towing.
• Check the engine oil level about 5 minutes after • Taxi, police, or delivery service (commercial ser-
a fully warmed engine is shut off. Checking the oil vice).
level while the vehicle is on level ground will • Off-road or desert driving.
0 - 12 LUBRICATION & MAINTENANCE KJ
MAINTENANCE SCHEDULES (Continued)

Kilometers 12 000 24 000 36 000 48 000 60 000

(Miles) (7,500) (15,000) (22,500) (30,000) (37,500)
[Months] [6] [12] [18] [24] [30]
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect the brake linings. X
Inspect the transfer case fluid. X

Kilometers 72 000 84 000 96 000 108 000

(Miles) (45,000) (52,500) (60,000) (67,500)
[Months] [36] [42] [48] [54]
Change the engine oil and engine oil filter. X X X X
Inspect the engine air filter element, replace if X
necessary.
Inspect and replace the PCV valve, if necessaryL. X
Inspect the ignition cables, and replace if necessary X
(2.4L Only).
Replace the spark plugs. X
Inspect the brake linings. X X
Inspect and replace the Auto Tension Drive Belt, as X
needed.
Inspect the transfer case fluid. X

Kilometers 120 000 132 000 144 000 156 000

(Miles) (75,000) (82,500) (90,000) (97,500)
[Months] [60] [66] [72] [78]
Change the engine oil and engine oil filter. X X X X
Inspect the brake linings. X
Inspect the engine air filter element, replace if X
necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if necessary.L X
Inspect the drive belt and replace as needed. Not X X
required if previously replaced.
Flush and replace the engine coolant at 60 months, X
regardless of mileage.
Inspect the transfer case fluid. X
KJ LUBRICATION & MAINTENANCE 0 - 13
MAINTENANCE SCHEDULES (Continued)

Kilometers 160 000 168 000 180 000 192 000

(Miles) (100,000) (105,000) (112,500) (120,000)
[Months] [84] [90] [96]
Change the engine oil and engine oil filter. X X X
Inspect the brake linings. X
Inspect the engine air filter element, replace if X
necessary.
Replace the spark plugs. X
Inspect the ignition cables, replace if necessary (2.4L X
Only).
Inspect and replace the PCV valve, if necessary.L X
Inspect the drive belt and replace as needed. Not X X
required if previously replaced.
Flush and replace the engine coolant if not done at 60 X
months.
Replace the timing belt (2.4L Only). X
Drain the transfer case, and refill. X

Inspection and service should be performed any- Schedule “B”

time a malfunction is observed or suspected. Follow schedule “B” if you usually operate your
L This maintenance is recommended by the man- vehicle under one or more of the following conditions.
ufacturer to the owner, but it is not required to main- • Day or night temperatures are below 0°C (32°F).
tain emissions warranty. • Stop and go driving.
• Extensive engine idling.
• Driving in dusty conditions.
• Short trips of less than 16.2 km (10 miles).
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32°C (90°F).
• Trailer towing.
• Taxi, police, or delivery service (commercial ser-
vice).
• Off-road or desert driving.

Kilometers 5 000 10 000 14 000 19 000 24 000

(Miles) (3,000) (6,000) (9,000) (12,000) (15,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
0 - 14 LUBRICATION & MAINTENANCE KJ
MAINTENANCE SCHEDULES (Continued)

Kilometers 29 000 34 000 38 000 43 000 48 000

(Miles) (18,000) (21,000) (24,000) (27,000) (30,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if X
necessary.L
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the transfer case fluid, add if X
necessary.

Kilometers 53 000 58 000 62 000 67 000 72 000

(Miles) (33,000) (36,000) (39,000) (42,000) (45,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as X
needed.

Kilometers 77 000 82 000 86 000 91 000 96 000

(Miles) (48,000) (51,000) (54,000) (57,000) (60,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if X
necessary.L
Replace the ignition cables (2.4L Only). X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid‡ X X
Drain and refill the automatic transmission X
fluid, and replace main sump filter.
Inspect the drive belt and replace as X
needed. Not required if belt was previously
Drain and refill the transfer case fluid. X
KJ LUBRICATION & MAINTENANCE 0 - 15
MAINTENANCE SCHEDULES (Continued)

Kilometers 101 000 106 000 110 000 115 000 120 000
(Miles) (63,000) (66,000) (69,000) (72,000) (75,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as X
needed. Not required if belt was previously
replaced.

Kilometers 125 000 130 000 134 000 139 000 144 000
(Miles) (78,000) (81,000) (84,000) (87,000) (90,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if X
necessary.L
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as X
needed. Not required if belt was previously
replaced.
Replace the timing belt (2.4L Only). X
Inspect the transfer case fluid, add if X
necessary.

Kilometers 149 000 154 000 158 000 163 000 168 000
(Miles) (93,000) (96,000) (99,000) (102,000) (105,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as X
needed. Not required if belt was previously
replaced.
Flush and replace the engine coolant. X
0 - 16 LUBRICATION & MAINTENANCE KJ
MAINTENANCE SCHEDULES (Continued)

Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, X
replace if necessary.
Replace the spark plugs. X
Inspect and replace the PCV valve, if X
necessary.L
Replace the ignition cables (2.4L Only). X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid‡ X X
Drain and refill the automatic transmission X
fluid, and replace main sump filter.
Inspect the drive belt and replace as X
needed. Not required if belt was previously
replaced.
Drain and refill the transfer case fluid. X

Use the schedule that best describes your driving

Inspection and service should be performed any-
conditions. Where time and mileage are listed, follow
time a malfunction is observed or suspected.
the interval that occurs first.
L This maintenance is recommended by the man-
ufacturer to the owner, but it is not required to main- CAUTION: Failure to perform the required mainte-
tain emissions warranty. nance items may result in damage to the vehicle.
‡Off-highway operation, trailer towing, taxi, limou-
sine, bus, snow plowing, or other types of commercial
service or prolonged operation with heavy loading, At Each Stop for Fuel
especially in hot weather, require front and rear axle • Check the engine oil level about 5 minutes after
service indicated with a ‡ in Schedule “B”. Perform a fully warmed engine is shut off. Checking the oil
these services if the vehicle is usually operated under level while the vehicle is on level ground will
these conditions. improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
DESCRIPTION – DIESEL ENGINES – EXPORT mark.
SCHEDULES • Check the windshield washer solvent and add if
There are two maintenance schedules that show required.
the required service for your vehicle.
First is Schedule “A”. It is for vehicles that are not Once a Month
operated under any of the conditions listed under • Check the tire pressure and look for unusual
Schedule 9B9. wear or damage.
Second is Schedule “B”. It is for vehicles that are • Inspect the battery and clean and tighten the
operated under the conditions that are listed below terminals as required.
and at the beginning of the schedule. • Check the fluid levels of coolant reservoir, brake
• Extensive engine idling. master cylinder, power steering and transmission
• Driving in dusty conditions. and add as needed.
• More than 50% of your driving is at sustained • Check all lights and all other electrical items for
high speeds during hot weather, above 32° C (90° F). correct operation.
• Trailer towing.
• Taxi, police, or delivery service (commercial ser-
vice).
Most vehicles are operated under the conditions
listed for Schedule 9B9.
KJ LUBRICATION & MAINTENANCE 0 - 17
MAINTENANCE SCHEDULES (Continued)
At Each Oil Change • Inspect engine accessory drive belts. Replace as
• Change the engine oil filter. necessary.
• Inspect the exhaust system. • Inspect for the presence of water in the fuel fil-
• Inspect the brake hoses. ter/water separator unit.
• Check the manual transmission fluid level — if • Rotate the tires.
equipped.
• Check the coolant level, hoses, and clamps. Schedule “A”

Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000

km
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element. X X X
Replace as necessary.
Replace the engine air filter element. X X
Replace the fuel filter/water separator unit. X X X X X
Replace the engine timing belt, and idler X
pulleys.
Inspect timing belt tensioner, and replace if X
necessary.‡
Inspect the engine accessory drive belt. X X X X
Replace the engine accessory drive belt. X
Inspect the ball joints. X X X X X
Inspect the brake linings. X X
Inspect the transfer case fluid. X

Kilometers 120 000 140 000 160 000 180 000

km km km km
Change the engine oil and engine oil filter. X X X X
Inspect the engine accessory drive belts, and replace if X X X X
necessary.
Inspect the engine air filter element. Replace as X X
necessary.
Replace the engine air filter element. X X
Replace the fuel filter/water separator unit. X X X X
Flush and replace the engine coolant. X
Inspect the ball joints. X X X X
Inspect the brake linings. X X
Drain and refill the automatic transmission fluid, change X
sump filter, and cooler return filter (if equipped).
Inspect the transfer case fluid. X
Drain and refill the transfer case fluid. X

WARNING: You can be badly injured working on or

Inspection and service should also be performed
around a motor vehicle. Do only that service work
anytime a malfunction is observed or suspected.
for which you have the knowledge and the right
‡ Replace if there is superficial wear, bearing clear-
equipment. If you have any doubt about your ability
ance, or evident grease leak.
to perform a service job, take your vehicle to a
competent mechanic.
0 - 18 LUBRICATION & MAINTENANCE KJ
MAINTENANCE SCHEDULES (Continued)
Schedule “B” • More than 50% of your driving is at sustained
Follow schedule “B” if you usually operate your high speeds during hot weather, above 32° C (90° F).
vehicle under one or more of the following conditions. • Trailer towing.
• Extensive engine idling. • Taxi, police, or delivery service (commercial ser-
• Driving in dusty conditions. vice).

Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km

Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element. X X X
Replace as necessary.
Replace the engine air filter element. X X
Replace the fuel filter/water separator unit. X X
Inspect the engine accessory drive belt. X X X X
Replace the engine accessory drive belt. X
Replace the engine timing belt and idler X
pulleys.
Inspect the timing belt tensioner.‡ X
Inspect the ball joints. X X X X X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid. X X
Drain and refill the automatic transmission X
fluid, and replace sump filter.

Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000

km
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element. X X
Replace as necessary.
Replace the engine air filter element. X X X
Replace the fuel filter/water separator unit. X X X
Inspect the engine accessory drive belt. X X X X
Replace the engine accessory drive belt. X
Replace the engine timing belt, idler X
pulleys, and tensioner.
Inspect the ball joints. X X X X X
Inspect the brake linings. X X X
Drain and refill the front and rear axle fluid. X X X
Drain and refill the transfer case fluid. X
Drain and refill the automatic transmission X
fluid, and replace sump filter.
KJ LUBRICATION & MAINTENANCE 0 - 19
MAINTENANCE SCHEDULES (Continued)

Kilometers 110 000 120 000 130 000 140 000 150 000 160 000 km
km km km km km
Change the engine oil and X X X X X X
engine oil filter.
Inspect the engine air filter X X X
element. Replace as
necessary.
Replace the engine air filter X X X
element.
Inspect the engine accessory X X X X X
drive belts, and replace if
necessary.
Replace the engine X
accessory drive belt.
Inspect the timing belt X
tensioner.‡
Replace the engine timing X
belt and idler pulleys.
Replace the fuel filter/water X X X
separator unit.
Flush and replace the engine X
coolant.
Inspect the ball joints. X X X X X X
Inspect the brake linings. X X X
Drain and refill the front and X X X
rear axle fluid.
Drain and refill the automatic X
transmission fluid, and
replace sump filter.
Replace the transmission X
cooler return filter (if
equipped).

CAUTION: Do not attempt to lift a Jeep vehicle with

Inspection and service should also be performed
a floor jack positioned under:
anytime a malfunction is observed or suspected.
‡ Replace if there is superficial wear, bearing clear- • A body side sill.
ance, or evident grease leak. • A steering linkage component.
• A drive shaft.
• The engine or transmission oil pan.
HOISTING • The fuel tank.
• A front suspension arm.
STANDARD PROCEDURE - HOISTING • Transfer case.
RECOMMENDATIONS
Refer to the Owner’s Manual for emergency vehicle NOTE: Use the correct sub-frame rail or frame rail
lifting procedures. lifting locations only.
When properly positioned, a floor jack can be used
to lift a Jeep vehicle (Fig. 5). Support the vehicle in
the raised position with jack stands at the front and HOIST
rear ends of the frame rails. Refer to the Owner’s Manual for emergency vehicle
lifting procedures.
A vehicle can be lifted with:
0 - 20 LUBRICATION & MAINTENANCE KJ
HOISTING (Continued)
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
• DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
• IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
• DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
• DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
• DO NOT USE OPEN FLAME NEAR BATTERY.
• REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
• WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
Fig. 5 Correct Vehicle Lifting Locations RESULT IN PERSONAL INJURY.
1- Frame Contact Lift (Single Post)
Chassis Lift (Non-Axle Dual Post) CAUTION: When using another vehicle as a
Outboard Lift (Dual Post) booster, do not allow vehicles to touch. Electrical
Floor Jack
systems can be damaged on either vehicle.
2- Floor Jack

• A single-post, frame-contact hoist. TO JUMP START A DISABLED VEHICLE:

• A twin-post, chassis hoist. (1) Raise hood on disabled vehicle and visually
• A ramp-type, drive-on hoist. inspect engine compartment for:
• Generator drive belt condition and tension.
NOTE: When a frame-contact type hoist is used, • Fuel fumes or leakage, correct if necessary.
verify that the lifting pads are positioned properly. • Frozen battery.
• Yellow or bright color test indicator, if equipped.
WARNING: THE HOISTING AND JACK LIFTING • Low battery fluid level.
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CAUTION: If the cause of starting problem on dis-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
abled vehicle is severe, damage to booster vehicle
NENT IS REMOVED FROM A VEHICLE, THE
charging system can result.
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY (2) When using another vehicle as a booster
SUPPORT OR SECURE VEHICLE TO HOISTING source, turn off all accessories, place gear selector in
DEVICE WHEN THESE CONDITIONS EXIST. park or neutral, set park brake or equivalent and
operate engine at 1200 rpm.
(3) On disabled vehicle, place gear selector in park
JUMP STARTING or neutral and set park brake or equivalent. Turn
OFF all accessories.
(4) Connect jumper cables to booster battery. RED
STANDARD PROCEDURE - JUMP STARTING
clamp to positive terminal (+). BLACK clamp to neg-
PROCEDURE ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result (Fig.
WARNING: REVIEW ALL SAFETY PRECAUTIONS
6). Review all warnings in this procedure.
AND WARNINGS IN THE BATTERY SYSTEM SEC-
(5) On disabled vehicle, connect RED jumper cable
TION OF THE SERVICE MANUAL. (Refer to 8 -
clamp to battery positive (+) terminal. Connect
KJ LUBRICATION & MAINTENANCE 0 - 21
JUMP STARTING (Continued)
BLACK jumper cable clamp to the engine as close to
the ground cable connection as possible (Fig. 6).

CAUTION: Do not crank starter motor on disabled

vehicle for more than 15 seconds, starter will over-
heat and could fail.

(6) Allow battery in disabled vehicle to charge to

at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.

Fig. 7 Tow Vehicles With Approved Equipment

SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:

• Secure loose and protruding parts.

• Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
• Do not allow towing equipment to contact the
disabled vehicle’s fuel tank.
• Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
Fig. 6 Jumper Cable Clamp Connections • Do not allow passengers to ride in a vehicle
1 - ENGINE GROUND being towed.
2 - NEGATIVE JUMPER CABLE
3 - BATTERY NEGATIVE CABLE • Always observe state and local laws regarding
4 - POSITIVE JUMPER CABLE towing regulations.
5 - BATTERY POSITIVE CABLE • Do not tow a vehicle in a manner that could
6 - BATTERY
7 - TEST INDICATOR (IF EQUIPPED) jeopardize the safety of the operator, pedestrians or
other motorists.
DISCONNECT CABLE CLAMPS AS FOLLOWS: • Do not attach tow chains, T-hooks, or J-hooks to
• Disconnect BLACK cable clamp from engine a bumper, steering linkage, drive shafts or a non-re-
ground on disabled vehicle. inforced frame hole.
• When using a Booster vehicle, disconnect • Do not tow a heavily loaded vehicle. Use a flat-
BLACK cable clamp from battery negative terminal. bed device to transport a loaded vehicle.
Disconnect RED cable clamp from battery positive
terminal. TWO-WHEEL-DRIVE VEHICLE TOWING
• Disconnect RED cable clamp from battery posi- DaimlerChrysler Corporation recommends that a
tive terminal on disabled vehicle. vehicle be towed with the rear end lifted, whenever
possible.

TOWING WARNING: WHEN TOWING A DISABLED VEHICLE

AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
STANDARD PROCEDURE - TOWING
TRANSMISSION IS IN THE PARK POSITION (AUTO-
A vehicle equipped with SAE approved wheel lift-
MATIC TRANSMISSION) OR A FORWARD DRIVE
type towing equipment can be used to tow Jeep vehi-
GEAR (MANUAL TRANSMISSION).
cles. When towing a 4WD vehicle using a wheel-lift
towing device, use tow dollies under the opposite end
of the vehicle. A vehicle with flatbed device can also
be used to transport a disabled vehicle (Fig. 7).
0 - 22 LUBRICATION & MAINTENANCE KJ
TOWING (Continued)
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR- WARNING: WHEN TOWING A DISABLED VEHICLE
FACE OR THE WHEELS ARE BLOCKED TO PRE- AND THE DRIVE WHEELS ARE SECURED IN A
VENT VEHICLE FROM ROLLING. WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION.

TWO WHEEL DRIVE TOWING-REAR END LIFTED

CAUTION: Many vehicles are equipped with air
CAUTION: Do not use steering column lock to dams, spoilers, and/or ground effect panels. To
secure steering wheel during towing operation. avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
2WD vehicles can be towed with the front wheels
on the surface for extended distances at speeds not
exceeding 48 km/h (30 mph). FOUR WHEEL DRIVE TOWING—REAR END LIFTED
(1) Attach wheel lift device to rear wheels.
(2) Place the transmission in neutral. WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
(3) Raise vehicle to towing position. FACE OR THE WHEELS ARE BLOCKED TO PRE-
(4) Attach safety chains. Route chains so not to VENT VEHICLE FROM ROLLING.
interfere with tail pipe when vehicle is lifted.
(5) Turn the ignition switch to the OFF position to (1) Attach wheel lift device to front wheels.
unlock the steering wheel. (2) Place the transmission in neutral.
(3) Raise the front of the vehicle off the ground
CAUTION: Do not use steering column lock to and install tow dollies under front wheels.
secure steering wheel during towing operation. (4) Attach wheel lift device to rear wheels and
raise vehicle to towing position.
(6) Secure steering wheel in straight ahead posi- (5) Attach safety chains. Route chains so not to
tion with a clamp device designed for towing. interfere with tail pipe when vehicle is lifted.
(7) Place transmission in park. (6) Turn the ignition switch to the OFF position to
unlock the steering wheel.
TWO WHEEL DRIVE TOWING-FRONT END LIFTED
CAUTION: Do not use steering column lock to
CAUTION: Many vehicles are equipped with air secure steering wheel during towing operation.
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi- (7) Secure steering wheel in straight ahead posi-
cle or a flat-bed hauling vehicle is recommended. tion with a clamp device designed for towing.
(8) Place transmission in park.
(1) Attach wheel lift device to rear wheels.
(2) Place the transmission in neutral. FOUR WHEEL DRIVE TOWING—FRONT END LIFTED
(3) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels. WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
(4) Attach wheel lift device to front wheels and FACE OR THE WHEELS ARE BLOCKED TO PRE-
raise vehicle to towing position. VENT VEHICLE FROM ROLLING.
(5) Attach the safety chains.
(1) Attach wheel lift device to rear wheels.
CAUTION: Do not use steering column lock to (2) Place the transmission in neutral.
secure steering wheel during towing operation. (3) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(6) Turn the ignition switch to the OFF position to (4) Attach wheel lift device to front wheels and
unlock the steering wheel. raise vehicle to towing position.
(7) Secure steering wheel in straight ahead posi- (5) Attach the safety chains.
tion with a clamp device designed for towing.
(8) Place transmission in park. CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
FOUR-WHEEL-DRIVE VEHICLE TOWING
DaimlerChrysler Corporation recommends that a (6) Turn the ignition switch to the OFF position to
4WD vehicle be transported on a flat-bed device. A unlock the steering wheel.
Wheel-lift device can be used provided the trailing (7) Secure steering wheel in straight ahead posi-
wheels are off the ground and positioned in tion with a clamp device designed for towing.
tow dollies. (8) Place transmission in park.
KJ SUSPENSION 2-1

SUSPENSION
TABLE OF CONTENTS

page page

SUSPENSION WHEEL ALIGNMENT ......................3

DIAGNOSIS AND TESTING - SUSPENSION FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AND STEERING SYSTEM . . . . . . . . . . . . . . . . 1 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION AND
STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.

EXCESSIVE PLAY IN 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

STEERING
2. Loose or worn steering or 2. Tighten or replace components as
suspension components. necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.

EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.

VEHICLE PULLS TO ONE 1. Uneven tire pressure. 1. Adjust tire pressure.

SIDE DURING BRAKING 2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
2-2 SUSPENSION KJ
SUSPENSION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE LEADS OR 1. Radial tire lead. 1. Cross front tires.

DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON 2. Brakes dragging. 2. Repair brake as necessary.
UNCROWNED ROAD 3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or 6. Repair as necessary.
suspension components.
7. Cross caster out of spec. 7. Align vehicle.

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.

OR SQUEAKING
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
3. Shock valve. 3. Replace shock.

IMPROPER TRACKING Loose, worn or bent steering/ Inspect, tighten or replace components as
suspension components. necessary.
KJ WHEEL ALIGNMENT 2-3

WHEEL ALIGNMENT

TABLE OF CONTENTS
page page

WHEEL ALIGNMENT STANDARD PROCEDURE - TOE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....3 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....3 STANDARD PROCEDURE - CAMBER,
STANDARD PROCEDURE CASTER AND TOE ADJUSTMENT . . . . . . . . . . 5
STANDARD PROCEDURE - HEIGHT SPECIFICATIONS
MEASUREMENT . . . . . . . . . . . . . . . . . . . ....4 ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT . . . . . . . . . . . . . . ....5

WHEEL ALIGNMENT
DESCRIPTION
NOTE: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If springs are not at their
normal ride position, vehicle ride comfort could be
affected and premature bushing wear may occur.

Wheel alignment involves the correct positioning of

the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
Fig. 1 Wheel Alignment Measurements
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important 1 - FRONT OF VEHICLE
2 - STEERING AXIS INCLINATION
measurements of an alignment are caster, camber 3 - PIVOT POINT
and toe (Fig. 1). 4 - TOE-IN

CAUTION: Never attempt to modify suspension or angle enables the front wheels to return to a straight
steering components by heating or bending. ahead position after turns (Fig. 1)
• CAMBER is the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting the
NOTE: Periodic lubrication of the front suspension/ top of the wheel inward provides negative camber.
steering system components may be required. Rub- Tilting the top of the wheel outward provides positive
ber bushings must never be lubricated. Refer to camber. Incorrect camber will cause wear on the
Lubrication And Maintenance for the recommended inside or outside edge of the tire (Fig. 1)
maintenance schedule. • TOE is the difference between the leading inside
edges and trailing inside edges of the front tires.
Wheel toe position out of specification cause’s unsta-
OPERATION ble steering, uneven tire wear and steering wheel off-
• CASTER is the forward or rearward tilt of the center. The wheel toe position is the final front
steering knuckle from vertical. Tilting the top of the wheel alignment adjustment (Fig. 1)
knuckle forward provides negative caster. Tilting the • THRUST ANGLE is the angle of the rear axle
top of the knuckle rearward provides positive caster. relative to the centerline of the vehicle. Incorrect
Positive caster promotes directional stability. This thrust angle can cause off-center steering and exces-
2-4 WHEEL ALIGNMENT KJ
WHEEL ALIGNMENT (Continued)
sive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle (Fig. 1)

STANDARD PROCEDURE
STANDARD PROCEDURE - HEIGHT
MEASUREMENT
RIDE HEIGHT
NOTE: The suspension is non-adjustable.

The vehicle suspension height should be measured

before performing wheel alignment procedure. Also
when front suspension components have been Fig. 2 FRONT RIDE HEIGHT MESUREMENT
replaced. This measure must be performed with the
1 - POINT - A
vehicle supporting it’s own weight and taken on both 2 - POINT - B
sides of the vehicle.
Front and rear ride heights are not adjustable. The
spring selections at assembly determine ride height
for acceptable appearance of the vehicle. Ride height
dimensions assume full fluids (including fuel) and
zero passengers. Refer to the table below for front
ride height dimensions.
Vehicle ride height audits should be performed uti-
lizing the following procedure:
(1) Drive the vehicle straight and forward on a
non-tacky surface for a minimum of 20 feet to neu-
tralize track width.
(2) Bounce the front of the vehicle five times.
(3) Measure and record the dimensions
FRONT RIDE HEIGHT Front ride height is
defined by the relative vertical distance between the
spindle center line and the rear pivot point of the
front lower control arm to cradle attachment. The Fig. 3 REAR RIDE HEIGHT MESUREMENT
spindle center line is to be measured at the outer 1 - POINT - C
wheel face (point A). The rear pivot point is to be 2 - POINT - D
measured at the center of the cam/pivot bolt (point
B) at its rearward most end (nut end). (Fig. 2)
REAR RIDE HEIGHT Rear ride height is defined
by the relative vertical distance between the top of
the lower spring seat strike surface and the bottom
of the jounce cup (true metal to metal jounce travel).
This is to be measured vertically inside the coil from
the point intersecting the inboard edge and the for/
aft center of the jounce cup (point C) down to the
strike surface (point D). (Fig. 3)
KJ WHEEL ALIGNMENT 2-5
WHEEL ALIGNMENT (Continued)

Measure- Target Minimum Maximum (2) Loosen the tie rod jam nuts.
ment
NOTE: Each front wheel should be adjusted for
Front Ride 66.5 mm 56.5 mm 76.5 mm one-half of the total toe position specification. This
Height Z=996.8 - will ensure the steering wheel will be centered
Distance 930.3 mm when the wheels are positioned straight-ahead.
AB
Front Cross 0.0 mm -10.0 mm 10.0 mm (3) Adjust the wheel toe position by turning the tie
Ride Height rod as necessary (Fig. 5).
Left - Right
Rear Ride 92.1 mm 82.1 mm 102.1 mm
Height
Distance
CD
Rear Cross 0.0 mm -10.0 mm 10.0 mm
Ride Height
Left - Right

STANDARD PROCEDURE - CAMBER AND

CASTER ADJUSTMENT
Camber and caster angle adjustments involve
changing the position of the lower control arm cam
bolts. (Fig. 4)

Fig. 5 TIE ROD END

1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER

(4) Tighten the tie rod jam nut to 75 N·m (55 ft.
lbs.).
(5) Verify the specifications
(6) Turn off engine.

STANDARD PROCEDURE - CAMBER, CASTER

AND TOE ADJUSTMENT
Camber and caster angle adjustments involve
changing the position of the lower suspension arm
cam bolts. (Fig. 4)
Fig. 4 LOWER CONTROL ARM
CASTER
1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
Moving the rear position of the cam bolt in or out,
3 - LOWER BALL JOINT NUT will change the caster angle significantly and camber
4 - LOWER CONTROL ARM angle only slightly. To maintain the camber angle
5 - REAR CAM BOLT
while adjusting caster, move the rear of the cam bolt
in or out. Then move the front of the cam bolt
STANDARD PROCEDURE - TOE ADJUSTMENT slightly in the opposite direction. (Fig. 4)
4X4 SUSPENSION HEIGHT MESUREMENT To increase positive caster angle, move the rear
MUST BE PERFORMED BEFORE AN ALIGN- position of the cam bolt outward (from the engine).
MENT. Move the front of cam bolt inward (toward the
The wheel toe position adjustment is the final engine) slightly until the original camber angle is
adjustment. obtained. (Fig. 4)
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
2-6 WHEEL ALIGNMENT KJ
WHEEL ALIGNMENT (Continued)
CAMBER SPECIFICATIONS
Move both of the cam bolts together in or out. This
will change the camber angle significantly and caster ALIGNMENT
angle slightly. (Fig. 4)
After adjustment is made tighten the cam bolt nuts NOTE: Specifications are in degrees.
to proper torque specification.

TOE ADJUSTMENT FRONT

The wheel toe position adjustment is the final SPECIFICATIONS
adjustment.
(1) Start the engine and turn wheels both ways DESCRIPTION SPECIFICATION
before straightening the wheels. Secure the steering
PREFERRED CASTER CAMBER TOTAL
wheel with the front wheels in the straight-ahead
3.9° ± -0.375° ± TOE-IN
position.
0.5° 0.375° .2° ±
(2) Loosen the tie rod jam nuts.
0.125°
NOTE: Each front wheel should be adjusted for RANGE 3.4° to + –0.750° +0.075° to
one-half of the total toe position specification. This 4.4° to 0° +0.325°
will ensure the steering wheel will be centered MAX RT/LT 0.5° 0.7° 0.13°
when the wheels are positioned straight-ahead. DIFFERENCE
(3) Adjust the wheel toe position by turning the tie
rod as necessary (Fig. 5). REAR
(4) Tighten the tie rod jam nut to 75 N·m (55 ft.
lbs.). SPECIFICATIONS
(5) Verify the specifications
(6) Turn off engine. DESCRIPTION SPECIFICATION
PREFERRED CAMBER THRUST TOTAL
–.25°± ANGLE TOE-IN
.375° 0° to ± .25° to ±
0.25° .41°
RANGE –.625° to –.25° to –.16° to
.125° +.25° .66°
KJ FRONT 2-7

FRONT

TABLE OF CONTENTS
page page

FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
WARNING .............................8 LOWER CONTROL ARM
SPECIFICATIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TORQUE CHART ......................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS SHOCK
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 9 REMOVAL
BUSHINGS REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . . 15
REMOVAL REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . . 15
REMOVAL - STABILIZER BAR BUSHINGS . . . 10 INSTALLATION
REMOVAL - LOWER CONTROL ARM INSTALLATION - LEFT SIDE . . . . . . . . . . . . . 16
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION - RIGHT SIDE . . . . . . . . . . . . 16
REMOVAL - CLEVIS BRACKET BUSHING . . . 10 SPRING
REMOVAL - UPPER CONTROL ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION CLEVIS BRACKET
INSTALLATION - STABILIZER BAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION - LOWER CONTROL ARM STABILIZER BAR
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION - CLEVIS BRACKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STABILIZER LINK
INSTALLATION - UPPER CONTROL ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
HUB / BEARING UPPER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . . 18
KNUCKLE REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION - RIGHT SIDE . . . . . . . . . . . . 19
LOWER BALL JOINT INSTALLATION - LEFT SIDE . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - LOWER BALL
JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

FRONT The front suspension is designed to allow each

wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub bearings on
DESCRIPTION
the steering knuckle spindles. The double-row hub
NOTE: Suspension components with rubber/ure- bearings are sealed and lubricated for life. The steer-
thane bushings should be tightened with the vehi- ing knuckles turn (pivot) on ball joints integral to the
cle at normal ride height. It is important to have the outboard portion of the upper control arms and
springs supporting the weight of the vehicle when pressed into the lower steering knuckle. The ball
the fasteners are torqued. If springs are not at their joints are lubricated for life. (Fig. 1)
normal ride position, vehicle ride comfort could be
affected and premature bushing wear may occur.
2-8 FRONT KJ
FRONT (Continued)

WARNING
WARNING: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.

Fig. 1 FRONT SUSPENSION

1 - SWAY BAR
2 - SWAY BAR BUSHING/BRACKET
3 - UPPER CONTROL ARM
4 - SPRING / SHOCK ASSEMBLY
5 - STEERING KNUCKLE
6 - OUTER TIE ROD END
7 - LOWER CONTROL ARM
8 - SWAY BAR LINK
9 - CLEVIS BRACKET

SPECIFICATIONS

TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Front Shock Absorber 136 100 —
Clevis Bracket Upper Nut
Front Shock Absorber 150 110 —
Clevis Bracket Lower Nut
Front Shock Absorber Top 108 80 —
(4) Mounting Nuts
Front Shock to Spring and 41 30 —
Insulator Nut
Upper Suspension Arm 122 90 —
Front Nut
Upper Suspension Arm 122 90 —
Rear Nut
Lower Suspension Arm 170 125 —
Front Nut
Lower Suspension Arm 170 125 —
Rear Nut
Stabilizer Bar Clamp Nut 149 110 —
KJ FRONT 2-9
FRONT (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Stabilizer Bar Link Upper 136 100 —
Nut
Stabilizer Bar Link Lower 115 85 —
Nut
Hub/Bearing 130 96 —
Bolt
Hub/Bearing 135 100 —
Halfshaft Nut
Upper Ball Joint Nut 81 60 —
Lower Ball Joint Nut 81 60 —
Wheel Speed Sensor 13.5 10 —

SPECIAL TOOLS
FRONT SUSPENSION

BALL JOINT PRESS - C-4212F

FRONT LOWER CONTROL ARM & CLEVIS
BUSHING REMOVER/INSTALLER - 8858

Remover C-4150A

FRONT LOWER CONTROL BUSHING REMOVER/

INSTALLER - 8830

REMOVER / INSTALLER FRONT LOWER BALL

JOINT - 8859
2 - 10 FRONT KJ

BUSHINGS NOTE: Extreme pressure lubrication must be used on

the threaded portions of the tool. This will increase
the longevity of the tool and insure proper operation
REMOVAL during the removal and installation process.

REMOVAL - STABILIZER BAR BUSHINGS (2) Press the bushing out using special tools
8858-1 (receiver), 8858-3 (driver) and 8839 with the
(1) Raise vehicle on hoist.
threaded rod 8839 and the bearing as shown (Fig. 3)
(2) Remove the stabilizer bushing clamps.
(3) Remove the stabilizer bushings from the stabi-
lizer bar.

REMOVAL - LOWER CONTROL ARM BUSHING

(1) Remove the lower control arm (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm in a vise.

NOTE: Extreme pressure lubrication must be used

on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.

(3) Press the bushing out using special tools

8858-5 (Receiver), 8858-6 (Driver) and 8839 with the Fig. 3 CLEVIS BRACKET BUSHING
threaded rod and the bearing as shown (Fig. 2) 1 - 8839 THREADED ROD
2 - 8858-1 RECEIVER
3 - 8858-3 DRIVER

REMOVAL - UPPER CONTROL ARM BUSHINGS

(1) Remove the upper control arm (Refer to 2 -
SUSPENSION/FRONT/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the control arm in a vise.

NOTE: Extreme pressure lubrication must be used

on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.

(3) Install bushing remover tools 8830-3 (Adapter),

8830-2 (Receiver) and 8830–4 (Driver) with the
Fig. 2 LOWER CONTROL ARM BUSHING - threaded rod 8838 and the bearing as shown (Fig. 4)
REMOVAL (4) Press out the bushing.
1 - 8858-5 RECEIVER
2 - 8858-6 DRIVER
3 - 8839 THREADED ROD INSTALLATION
REMOVAL - CLEVIS BRACKET BUSHING INSTALLATION - STABILIZER BAR BUSHINGS
(1) Remove the clevis bracket from the shock (1) Install the stabilizer bushings to the stabilizer
(Refer to 2 - SUSPENSION/FRONT/CLEVIS bar.
BRACKET - REMOVAL). (2) Install the stabilizer bushing clamps. Tighten
the nuts to 149 N·m (110 ft.lbs.).
(3) Lower the vehicle.
KJ FRONT 2 - 11
BUSHINGS (Continued)

Fig. 4 UPPER CONTROL ARM BUSHING REMOVAL Fig. 5 LOWER CONTROL ARM BUSHING -
1 - 8830-3 (ADAPTER) INSTALLATION
2 - 8830-2 (RECIEVER) 1 - 8858-5 DRIVER
3 - 8830-4 (DRIVER) 2 - 8858-6 RECEIVER
4 - 8838 (THREADED ROD) 3 - 8839 THREADED ROD

INSTALLATION - LOWER CONTROL ARM (1) Install the new clevis bracket bushing into the
BUSHING lower control arm using tools 8858-2 (driver), 8858-1
(receiver) and the bearing with the threaded rod
NOTE: Extreme pressure lubrication must be used 8839 (Fig. 6) making sure to properly orient the
on the threaded portions of the tool. This will bushing in the control.
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.

(1) Install the new lower control arm bushings into

the lower control arm using tools 8858-5 (driver),
8858-6 (receiver) and the bearing with the threaded
rod 8839 (Fig. 5) making sure to properly orient the
bushing in the control.
(2) Remove the control arm from the vise.
(3) Install the lower control arm (Refer to 2 - SUS-
PENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION).
(4) Reset the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
(5) Perform a wheel alignment (Refer to 2 - SUS-
Fig. 6 CLEVIS BRACKET BUSHING
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE). 1 - 8839 THREADED ROD
2 - 8858-2 DRIVER
3 - 8858-1 RECEIVER
INSTALLATION - CLEVIS BRACKET BUSHING
(2) Install the clevis bracket (Refer to 2 - SUS-
NOTE: Extreme pressure lubrication must be used PENSION/FRONT/CLEVIS BRACKET - INSTALLA-
on the threaded portions of the tool. This will TION).
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
2 - 12 FRONT KJ
BUSHINGS (Continued)

INSTALLATION - UPPER CONTROL ARM (3) Remove the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BUSHINGS
BRAKE CALIPERS - REMOVAL).
NOTE: Extreme pressure lubrication must be used
CAUTION: Never allow the disc brake caliper to
on the threaded portions of the tool. This will
hang from the brake hose. Damage to the brake
increase the longevity of the tool and insure proper
hose will result. Provide a suitable support to hang
operation during the removal and installation pro-
the caliper securely.
cess.
(4) Remove the disc brake rotor (Refer to 5 -
(1) Install the new upper control arm bushings
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
into the upper control arm using tools 8830-3
REMOVAL).
(Adapter), 8830-1 (Driver) and 8830-2 (Receiver) the
(5) Remove the wheel speed sensor (Refer to 5 -
bearing with the threaded rod 8838 (Fig. 7) making
BRAKES/ELECTRICAL/FRONT WHEEL SPEED
sure to properly orient the bushing in the control
SENSOR - REMOVAL).
arm.
(6) Remove the bracket securing the wheel speed
(2) Remove the control arm from the vise.
sensor wire.
(3) Install the upper control arm (Refer to 2 - SUS-
(7) Remove the axle shaft nut. (if equipped with
PENSION/FRONT/UPPER CONTROL ARM -
four wheel drive)
INSTALLATION).
(8) Remove the three mounting bolts for the hub/
(4) Reset the vehicle ride height (Refer to 2 - SUS-
bearing assembly.
PENSION/WHEEL ALIGNMENT - STANDARD
(9) Remove the hub/bearing.
PROCEDURE).
(5) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
INSTALLATION
(1) Install the hub/bearing assembly to the vehicle.
PROCEDURE).
(2) Install the three mounting bolts for the hub/
bearing. Tighten the bolt to 130 N·m (96 ft.lbs.).
(3) Install the axle shaft nut. Tighten the nut to
135 N·m (100 ft.lbs.). (if equipped with four wheel
drive)
(4) Install the bracket to the wheel speed sensor
wire.
(5) Install the wheel speed sensor to the hub.
Tighten the bolt to 13.5 N·m (10 ft.lbs.) (Refer to 5 -
BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - INSTALLATION).
(6) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(7) Install the disc brake caliper adapter. Tighten
the nut to 135 N·m (100 ft.lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
Fig. 7 UPPER CONTROL ARM BUSHING - INSTALLATION).
INSTALLATION (8) Install the tire and wheel assembly. (Refer to
1 - 8830-3 (ADAPTER) 22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
2 - 8830-1 (DRIVER) CEDURE).
3 - BUSHING
4 - 8830-2 (RECEIVER)
5 - 8838 (THREADED ROD)
KNUCKLE
HUB / BEARING
REMOVAL
REMOVAL (1) Raise and support the vehicle.
(1) Raise and support the vehicle. (2) Remove the tire and wheel assembly.
(2) Remove the tire and wheel assembly. (3) Remove the caliper adapter. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
KJ FRONT 2 - 13
KNUCKLE (Continued)
CAUTION: Never allow the disc brake caliper to LOWER BALL JOINT
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to hang
DIAGNOSIS AND TESTING - LOWER BALL
the caliper securely.
JOINT
(4) Remove the disc brake rotor. (Refer to 5 - (1) Raise the vehicle on a drive-on hoist.
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL). NOTE: If a drive-on hoist is not available, use
(5) Remove the wheel speed sensor. (Refer to 5 - wooden blocks with jack stands to support the
BRAKES/ELECTRICAL/FRONT WHEEL SPEED lower control arm in the ball joint area. Place the
SENSOR - REMOVAL). jack stands appropriately and lower the hoist plac-
(6) Remove the axle shaft nut. (if equipped with ing weight on the lower control arm. The lower con-
four wheel drive) trol arms should now be supporting the vehicle
(7) Remove the hub/bearing. (Refer to 2 - SUS- weight.
PENSION/FRONT/HUB / BEARING - REMOVAL).
(8) Seperate the outer tie rod end from the steer- (2) With the use of jack stands, lift the front end
ing knuckle. (Refer to 19 - STEERING/LINKAGE/ off the hoist and position wooden blocks underneath
TIE ROD END - REMOVAL). both lower control arms supporting the vehicles
(9) Remove the lower ball joint nut. weight.
(10) Seperate the lower ball joint from the suspen- (3) Remove the tire and wheel assembly.
sion arm using tool C–4150A. (4) Attach a dial indicator to the base of the lower
(11) Remove the upper ball joint nut. control arm and align the dial indicator’s contact
(12) Seperate the upper ball joint from the knuckle point with the direction of the stud axis, touch the
using tool C–4150A. machined flat on the knuckle and zero the dial indi-
(13) Remove the knuckle from the vehicle. cator. (Fig. 8)

NOTE: Use care when applying the load to the

INSTALLATION knuckle, so the parts are not damaged using care
(1) Install the knuckle to the vehicle. not to tear the boot.
(2) Install the upper ball joint nut. Tighten the nut
to 81 N·m (60 ft.lbs.). (5) From the front of the vehicle, insert a pry bar
(3) Install the lower ball joint nut. Tighten the nut to get it rested on the lower control arm and use
to 81 N·m (60 ft.lbs.). lever principle to push the knuckle up until the arm
(4) Install the outer tie rod end to the steering of the dial indicator no longer moves.
knuckle. (Refer to 19 - STEERING/LINKAGE/TIE (6) Record the ball joint movement on each side of
ROD END - INSTALLATION). the vehicle. The end play is acceptable with no more
(5) Install the hub/bearing. (Refer to 2 - SUSPEN- than 1.5mm of end play back to back.
SION/FRONT/HUB / BEARING - INSTALLATION).
(6) Install the axle shaft nut. Tighten the nut to REMOVAL
135 N·m (96 ft.lbs.).(if equipped with four wheel (1) Remove the tire and wheel assembly.
drive). (2) Remove the brake caliper and rotor (Refer to 5
(7) Install the wheel speed sensor. (Refer to 5 - - BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
BRAKES/ELECTRICAL/FRONT WHEEL SPEED REMOVAL).
SENSOR - INSTALLATION). (3) Disconnect the tie rod from the steering
(8) Install the disc brake rotor. (Refer to 5 - knuckle (Refer to 19 - STEERING/LINKAGE/TIE
BRAKES/HYDRAULIC/MECHANICAL/ROTORS - ROD END - REMOVAL).
INSTALLATION). (4) Remove the steering knuckle (Refer to 2 - SUS-
(9) Install the caliper adapter. (Refer to 5 - PENSION/FRONT/KNUCKLE - REMOVAL).
BRAKES/HYDRAULIC/MECHANICAL/DISC (5) Move the halfshaft to the side and support the
BRAKE CALIPER ADAPTER - INSTALLATION). halfshaft out of the way (If Equipped).
(10) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO- NOTE: Extreme pressure lubrication must be used
CEDURE). on the threaded portions of the tool. This will
(11) Perform the set toe procedure (Refer to 2 - increase the longevity of the tool and insure proper
SUSPENSION/WHEEL ALIGNMENT - STANDARD operation during the removal and installation pro-
PROCEDURE). cess.

(6) Secure the steering knuckle in a vise.

2 - 14 FRONT KJ
LOWER BALL JOINT (Continued)
(1) Install the ball joint into the steering knuckle
and press in using special tools C-4212–F (press),
8859-3 (driver) and 6761 (receiver) (Fig. 10).

Fig. 8 SUSPENSION IN THE CURB POSITION

1 - PRY BAR
2 - BALL JOINT
3 - DIAL INDICATOR
4 - WOODEN BLOCK OR SUPPORT Fig. 10 LOWER BALL JOINT
5 - CLAMP 1 - 6761 RECEIVER
2 - 8859-3 DRIVER
(7) Remove the ball joint boot. 3 - C-4212F PRESS
(8) Press the ball joint from the steering knuckle
using special tools C-4212–F (PRESS), 8859-2 (2) Install the ball joint boot.
(RECEIVER) and 8859-1 (DRIVER) (Fig. 9). (3) Remove the support for the halfshaft and
install into position (If Equipped).
(4) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(5) Install the tie rod end into the steering knuckle
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
INSTALLATION).
(6) Install and tighten the halfshaft nut to 136
N·m (100 ft. lbs.).
(7) Install the brake caliper and rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Check the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 9 LOWER BALL JOINT (10) Perform a wheel alignment (Refer to 2 - SUS-
1 - 8859-1 DRIVER PENSION/WHEEL ALIGNMENT - STANDARD
2 - C-4212F PRESS
3 - 8859-2 RECEIVER PROCEDURE).

INSTALLATION LOWER CONTROL ARM

NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will REMOVAL
increase the longevity of the tool and insure proper (1) Raise and support the vehicle.
operation during the removal and installation pro- (2) Remove the tire and wheel assembly.
cess. (3) Remove the lower clevis bracket bolt at the
lower control arm.
KJ FRONT 2 - 15
LOWER CONTROL ARM (Continued)
(4) Remove the stabilizer link bolt at the lower (9) Perform a full wheel alignment (Refer to 2 -
control arm. SUSPENSION/WHEEL ALIGNMENT - STANDARD
(5) Remove the lower ball joint nut. PROCEDURE).
(6) Separate the lower ball joint from the lower
control arm using tool C-4150A.
SHOCK
NOTE: Marking the lower control arm pivot bolts
front and rear will aid in the assembly procedure.
REMOVAL
(7) Mark the lower control arm pivot bolts front
and rear. REMOVAL - LEFT SIDE
(8) Remove the front cam/pivot bolt. (Fig. 11) (1) Disconnect the battery.
(9) Remove the rear cam/pivot bolt. (Fig. 11) (2) Remove the battery (Refer to 8 - ELECTRI-
(10) Remove the lower control arm from the vehi- CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
cle. (3) Unclip the power center and move it to the side
out of the way.
(4) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(5) Disconnect the battery temperature sensor
from the battery tray.
(6) Remove the four upper shock mounting nuts.
(7) Raise and support the vehicle.
(8) Remove the left tire and wheel assembly.
(9) Remove the lower bolt at the lower control
securing the clevis bracket.
(10) Remove the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - REMOVAL).
(11) Remove the lower ball joint nut.
(12) Seperate the lower ball joint from the lower
control arm using tool C-4150A.
(13) Rotate the lower control arm downward to
allow access.
Fig. 11 LOWER CONTROL ARM
(14) Remove the clevis bracket at the shock.
1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
(15) Remove the shock assembly from the vehicle.
3 - LOWER BALL JOINT NUT (Fig. 12)
4 - LOWER CONTROL ARM (16) Remove the spring from the shock (if needed).
5 - REAR CAM BOLT

REMOVAL - RIGHT SIDE

INSTALLATION (1) Remove the air box (Refer to 9 - ENGINE/AIR
(1) Install the lower control arm to the vehicle. INTAKE SYSTEM/AIR CLEANER ELEMENT -
(2) Install the rear cam/pivot bolt. REMOVAL).
(3) Install the front cam/pivot bolt. (2) Remove the two cruise control servo mounting
(4) Install the lower ball joint nut. Tighten the nut nuts.
to 81 N·m (60 ft.lbs.) (3) Remove the upper shock mounting nuts.
(5) Align the marks front and rear at the cam/ (4) Raise and support the vehicle.
pivot bolts and tighten the nuts. Tighten the nuts to (5) Remove the right side tire assembly.
170 N·m (125 ft.lbs.) (6) Remove the lower bolt at the lower control
(6) Install the stabilizer link bolt at the lower con- securing the clevis bracket.
trol arm. Tighten the nut to 136 N·m (100 ft.lbs.) (7) Remove the stabilizer link (Refer to 2 - SUS-
(7) Install the lower clevis bracket bolt at the PENSION/FRONT/STABILIZER LINK - REMOVAL).
lower control arm. Tighten the nut to 150 N·m (110 (8) Remove the lower ball joint nut.
ft.lbs.) (9) Seperate the lower ball joint from the lower
(8) Install the tire and wheel assembly. (Refer to control arm using tool C-4150A.
22 - TIRES/WHEELS/WHEELS - STANDARD PRO- (10) Rotate the lower control arm downward to
CEDURE). allow access.
(11) Remove the clevis bracket at the shock. (Fig.
13)
2 - 16 FRONT KJ
SHOCK (Continued)

INSTALLATION
INSTALLATION - LEFT SIDE
(1) Install the spring to the shock (if removed).
(2) Install the shock assembly to the vehicle.
(3) Install the four upper shock mounting nuts.
Tighten the nuts to 108 N·m (80 ft.lbs.).
(4) Install the clevis bracket at the shock. (Refer to
2 - SUSPENSION/FRONT/CLEVIS BRACKET -
INSTALLATION). Tighten the bolt to 88 N·m (65
ft.lbs.).
(5) Raise the lower control into place and recon-
nect the lower ball joint nut. Tighten the nut to 81
N·m (60 ft.lbs.).
(6) Install the clevis bracket at the lower control
arm. (Refer to 2 - SUSPENSION/FRONT/CLEVIS
Fig. 12 SHOCK ASSEMBLY BRACKET - INSTALLATION). Tighten the bolt to
1 - SPRING 150 N·m (110 ft.lbs.).
2 - JOUNCE BUMPER
3 - SHOCK
(7) Install the lower stabilizer link at the lower
4 - UPPER CONTROL ARM control arm. Tighten the bolt to 136 N·m (100 ft.lbs.)
(Refer to 2 - SUSPENSION/FRONT/STABILIZER
(12) Remove the shock assembly from the vehicle. LINK - INSTALLATION).
(Fig. 13) (8) Install the left tire and wheel assembly. (Refer
(13) Remove the spring from the shock (if needed). to 22 - TIRES/WHEELS/WHEELS - STANDARD
(Refer to 2 - SUSPENSION/FRONT/SPRING - PROCEDURE).
REMOVAL). (9) Lower the vehicle.
(10) Reconnect the battery temperature sensor.
(11) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(12) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(13) Reconnect the battery cables.

INSTALLATION - RIGHT SIDE

(1) Install the spring to the shock (if removed).
(Refer to 2 - SUSPENSION/FRONT/SPRING -
INSTALLATION).
(2) Install the shock assembly to the vehicle.
(3) Install the four upper shock mounting nuts.
Tighten the nuts to 108 N·m (80 ft.lbs.).
(4) Install the clevis bracket at the shock. (Refer to
2 - SUSPENSION/FRONT/CLEVIS BRACKET -
INSTALLATION). Tighten the bolt to 88 N·m (65
ft.lbs.).
(5) Raise the lower control into place and recon-
nect the lower ball joint nut. Tighten the nut to 81
Fig. 13 SHOCK & CLEVIS ASSEMBLY N·m (60 ft.lbs.).
(6) Install the clevis bracket at the lower control
1 - FRONT CRADLE
2 - SPRING & SHOCK ASSEMBLY arm. (Refer to 2 - SUSPENSION/FRONT/CLEVIS
3 - STEERING KNUCKLE BRACKET - INSTALLATION). Tighten the bolt to
4 - CLEVIS BRACKET 150 N·m (110 ft.lbs.).
5 - LOWER CONTROL ARM
(7) Install the lower stabilizer link at the lower
control arm. Tighten the bolt to 136 N·m (100 ft.lbs.)
KJ FRONT 2 - 17
SHOCK (Continued)
(Refer to 2 - SUSPENSION/FRONT/STABILIZER (2) Install the shock mounting nut. Tighten the
LINK - INSTALLATION). bolt to 41 N·m (30 ft.lbs.).
(8) Install the right tire and wheel assembly. (3) Loosen the compressed spring.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN- (4) Remove the shock assembly from the spring
DARD PROCEDURE). compressor.
(9) Lower the vehicle. (5) Install the shock to the vehicle. (Refer to 2 -
(10) Install the cruise control servo mounting nuts. SUSPENSION/FRONT/SHOCK - INSTALLATION).
(11) Install the airbox (Refer to 9 - ENGINE/AIR (6) Install the tire and wheel assembly. (Refer to
INTAKE SYSTEM/AIR CLEANER ELEMENT - 22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
INSTALLATION). CEDURE).
(7) Remove the support and lower the vehicle.

SPRING
CLEVIS BRACKET
REMOVAL
(1) Raise and support the vehicle. REMOVAL
(2) Remove the tire and wheel assembly. (1) Raise and support the vehicle.
(3) Remove the shock. Refer to the proper side (2) Remove the tire and wheel assembly.
shock removal procedure being worked on. (Refer to 2 (3) Remove the lower clevis bolt at the lower con-
- SUSPENSION/FRONT/SHOCK - REMOVAL). trol arm. (Fig. 15)
(4) Secure the shock assembly into a Pentastar (4) Remove the upper clevis bolt at the shock. (Fig.
Service Equipment W-7200 Spring compressor. (Fig. 15)
14)
(5) Compress the spring.

Fig. 15 CLEVIS BRACKET

1 - UPPER BOLT
Fig. 14 SPRING COMPRESSOR 2 - CLEVIS BRACKET
3 - LOWER BOLT
1 - SPRING COMPRESSOR
2 - SPRING
(5) Remove the lower stabilizer link bolt at the
(6) Remove the shock mount nut. lower control arm.
(7) Remove the shock from the spring compressor. (6) Remove the lower ball joint nut.
(8) Transfer the necessary parts to the type of (7) Seperate the lower ball joint from the lower
repair being done (Insulator, Spring, shock and control arm using tool C-4150A.
mount). (8) Swing the lower control arm downward to
allow clearence to remove the clevis braket.
INSTALLATION (9) Remove the clevis bracket from the vehicle.
(1) Install the shock to the spring and spring com-
pressor, After the transfer of the necessary parts to INSTALLATION
the type of repair being done (Insulator, Spring, (1) Install the clevis bracket to the shock Seat the
shock and mount). clevis against the stop on the shock. Tighten the
bolt to 136 N·m (100 ft.lbs.) (Fig. 15).
2 - 18 FRONT KJ
CLEVIS BRACKET (Continued)
(2) Raise the lower control arm to the lower ball STABILIZER LINK
joint.
(3) Install the nut to the lower ball joint. Tighten
REMOVAL
the nut to 81 N·m (60 ft.lbs.).
(1) Raise and support the vehicle.
(4) Install the clevis bracket to the lower control
(2) Remove the tire and wheel assembly.
arm. Tighten the bolt to 150 N·m (110 ft.lbs.).
(3) Remove the lower stabilizer link bolt at the
(5) Install the lower stabilizer link bolt at the
lower control arm.
lower control arm. Tighten the bolt to 115 N·m (85
(4) Remove the upper stabilizer link bolt at the
ft.lbs.).
stabilizer bar.
(6) Install the tire and wheel assembly. (Refer to
(5) Remove the stabilizer link. (Fig. 17)
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(7) Lower the vehicle.

STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the upper stabilizer link bolts at the
stabilizer bar.
(4) Remove the stabilizer bar bushing clamps from
the frame (Fig. 16).
(5) Remove the stabilizer bar from the vehicle.

Fig. 17 STABILIZER BAR LINK

1 - STABILIZER BAR
2 - STABILIZER BAR LINK

INSTALLATION
(1) Install the stabilizer link (Fig. 17).
(2) Install the upper stabilizer link bolt and
washer at the stabilizer bar. Tighten the bolt to 136
N·m (100 ft.lbs.).
(3) Install the lower stabilizer link bolt and
washer at the lower control arm. Tighten the nut to
115 N·m (85 ft.lbs.).
(4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
Fig. 16 SWAY BAR
1 - SWAY BAR
2 - SWAY BAR BUSHINGS
UPPER CONTROL ARM
REMOVAL
INSTALLATION
(1) Install the stabilizer bar to the vehicle. REMOVAL - RIGHT SIDE
(2) Install the stabilizer bar bushing clamps (Fig. (1) Raise and support the vehicle.
16). Tighten the nuts to 149 N·m (110 ft.lbs.). (2) Remove the right side tire and wheel assembly.
(3) Install the upper stabilizer link bolts and (3) Remove the upper ball joint nut.
washer at the stabilizer bar. Tighten the bolt to 136 (4) Separate the upper ball joint from the steering
N·m (100 ft.lbs.). knuckle using tool C-4150A.
(4) Install the tire and wheel assembly. (Refer to (5) Lower the vehicle.
22 - TIRES/WHEELS/WHEELS - STANDARD PRO- (6) Remove the air box (Refer to 9 - ENGINE/AIR
CEDURE). INTAKE SYSTEM/AIR CLEANER ELEMENT -
(5) Lower the vehicle. REMOVAL).
KJ FRONT 2 - 19
UPPER CONTROL ARM (Continued)
(7) Remove the cruise control servo mounting nuts. (5) Install the air box (Refer to 9 - ENGINE/AIR
(8) Remove the upper control arm rear bolt. INTAKE SYSTEM/AIR CLEANER ELEMENT -
(9) Remove the upper control arm front bolt. INSTALLATION).
(10) Remove the upper control arm from the vehicle. (6) Install the upper ball joint nut. Tighten the nut
to 81 N·m (60 ft.lbs.).
REMOVAL - LEFT SIDE (7) Install the right side tire and wheel assembly.
(1) Raise and support the vehicle. (Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
(2) Remove the left side tire and wheel assembly. DARD PROCEDURE).
(3) Remove the upper ball joint nut. (8) Lower the vehicle.
(4) Separate the upper ball joint from the steering (9) Set the toe and center the steering wheel
knuckle using tool C-4150A. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
(5) Lower the vehicle. STANDARD PROCEDURE).
(6) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL). INSTALLATION - LEFT SIDE
(7) Unclip the power center and move it to the side (1) Install the upper control arm to the vehicle.
out of the way. (2) Install the upper control arm front bolt (Fig.
(8) Remove the battery tray (Refer to 8 - ELEC- 19). Tighten the bolt to 122 N·m (90 ft.lbs.).
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL). (3) Install the upper control arm rear bolt (Fig.
(9) Disconnect the battery temperature sensor 19). Tighten the bolt to 122 N·m (90 ft.lbs.).
from the battery tray. (4) Reconnect the battery temperature sensor to
(10) Remove the upper control arm rear bolt by the battery tray.
using a ratchet and extension under the steering (5) Install the battery tray (Refer to 8 - ELECTRI-
shaft and positioned by the power steering reservoir. CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(Fig. 18) (6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(7) Reclip and mount the power center.
(8) Install the upper ball joint nut (Fig. 19).
Tighten the nut to 81 N·m (60 ft.lbs.).

Fig. 18 REAR BOLT

1 - STEERING SHAFT
2 - REAR BOLT
3 - RATCHET WITH AN EXTENSION

Fig. 19 UPPER CONTROL ARM

(11) Remove the upper control arm front bolt.
(12) Remove the upper control arm from the vehicle. 1 - FRONT PIVOT BOLT
2 - REAR PIVOT BOLT
3 - RATCHET TOOL
INSTALLATION 4 - STEERING KNUCKLE

INSTALLATION - RIGHT SIDE (9) Install the left side tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
(1) Install the upper control arm to the vehicle.
DARD PROCEDURE).
(2) Install the upper control arm front bolt.
(10) Lower the vehicle.
Tighten the bolt to 122 N·m (90 ft.lbs.).
(11) Set the toe and center the steering wheel
(3) Install the upper control arm rear bolt. Tighten
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
the bolt to 122 N·m (90 ft.lbs.).
STANDARD PROCEDURE).
(4) Install the cruise control servo mounting nuts.
2 - 20 REAR KJ

REAR

TABLE OF CONTENTS
page page

REAR UPPER CONTROL ARM

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20 DESCRIPTION - UPPER SUSPENSION ARM,
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 BUSHINGS, AND BALL JOINT . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - REAR OPERATION - UPPER SUSPENSION ARM,
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . 21 BUSHINGS, AND BALL JOINT . . . . . . . . . . . . 25
SPECIFICATIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIAL TOOLS LOWER CONTROL ARM
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . 22 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
SHOCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPRING BUSHINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 REMOVAL - LOWER SUSPENSION ARM
JOUNCE BUMPER BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 REMOVAL - UPPER SUSPENSION ARM
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STABILIZER BAR INSTALLATION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSTALLATION - LOWER SUSPENSION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24 ARM BUSHING . . . . . . . . . . . . . . . . . . . . . . . 27
UPPER BALL JOINT INSTALLATION - UPPER SUSPENSION ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25

REAR
DESCRIPTION
The rear suspension (Fig. 1) is comprised of :
• Drive axle
• Shock absorbers
• Coil springs
• Lower suspension arms
• Upper suspension arm
• Stabilizer bar

CAUTION: Suspension components with rubber/ure-

thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle
ride comfort and prevent premature bushing wear. Fig. 1 REAR SUSPENSION
1 - COIL SPRING
2 - UPPER SUSPENSION ARM
3 - STABILIZER BAR
4 - LOWER SUSPENSION ARM
5 - SHOCK
KJ REAR 2 - 21
REAR (Continued)

WARNING supporting the weight of the vehicle when the fas-

teners are torqued. If springs are not at their normal
WARNING: Suspension components with rubber ride position, vehicle ride comfort will be affected
bushings must be tightened with the vehicle at nor- and cause premature bushing wear.
mal ride height. It is important to have the springs

DIAGNOSIS AND TESTING - REAR SUSPENSION

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose, worn or bent suspension 2. Inspect, tighten or replace components

components. as necessary.
3. Tire pressure. 3. Adjust tire pressure.

VEHICLE PULLS TO ONE 1. Weak or broken spring. 1. Replace spring.

SIDE
2. Alignment. 2. Align vehicle to specifications.
3.Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.

OR SQUEAKING
2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
5. Loose, worn or bent suspension 5. Inspect, tighten or replace components
components. as necessary.

IMPROPER TRACKING 1. Loose, worn or bent suspension 1. Inspect, tighten or replace components
components. as necessary.
2. Bent axle. 2.Replace axle.

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Shock Absorber Upper 108 80 —
Nut
Shock Absorber Lower 115 85 —
Nut
Suspension Arm Upper 95 70 —
Ball Joint Nut
Suspension Arm Upper 100 74 —
Frame Bolts
Control Arm Frame Bolts 100 74 —
Rear Upper Ball Joint 136 100 —
Bracket Bolts
2 - 22 REAR KJ
REAR (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Suspension Arms Lower 163 120 —
Body/Axle Bracket Nut
Control Arms to Control 101 75 —
Arm Bracket
Suspension Arms Lower 163 120 —
Frame Bracket Nut
Control Arm Bracket to 135 100 —
Rear Differential
Rear Differential Damper 61 45 —
to Rear Differential
Stabilizer Bar Bolts 99 73 —

SPECIAL TOOLS
REAR SUSPENSION

BALL JOINT PRESS - C-4212F

REMOVAL / INSTALLATION REAR UPPER
CONTROL ARM BUSHINGS - 8860

REMOVER / INSTALLER REAR UPPER BALL JOINT

- 8861
REAR LOWER CONTROL ARM BUSHING
SHOCK REMOVER/INSTALLER - 8862
(3) Remove the lower nut and bolt from the axle
REMOVAL bracket. Remove the shock absorber.
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle. INSTALLATION
(1) Install the shock absorber in the frame bracket
CAUTION: Do not allow the axle to hang from the and install the bolt and nut (Fig. 2).
upper suspension arm ball joint. (2) Install the shock absorber in the axle bracket
and install the bolt and nut (Fig. 2).
(2) Remove the upper nut and bolt from the frame (3) Remove the supports and lower the vehicle.
bracket (Fig. 2).
KJ REAR 2 - 23
SHOCK (Continued)

INSTALLATION
(1) Install the upper isolator (Fig. 3).
(2) Install the lower isolator (Fig. 3).
(3) Pull down on the axle and position the coil
spring in the lower isolator.

CAUTION: Ensure the spring is positioned on the

lower isolator.

(4) Raise the axle with the hydraulic jack.

(5) Install the shock absorber to the axle bracket
and tighten to 115 N·m (85 ft. lbs.).
(6) Remove the supports and lower the vehicle.
(7) Tighten the stabilizer bar links to 99 N·m (73
ft. lbs.).

Fig. 2 SHOCK ABSORBER

1 - UPPER MOUNTING BOLT
JOUNCE BUMPER
2 - LOWER MOUNTING BOLT
REMOVAL
(4) Tighten the upper mounting nuts to 108 N·m (1) Remove the shock (Refer to 2 - SUSPENSION/
(80 ft. lbs.). Tighten the lower mounting nuts to 115 REAR/SHOCK - REMOVAL).
N·m (85 ft. lbs.). (2) Remove the coil spring (Refer to 2 - SUSPEN-
SION/REAR/SPRING - REMOVAL).
(3) Pull the jounce bumper downwards to remove.
SPRING (Fig. 4)

REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
(2) Remove the shock absorber lower bolt from the
axle bracket.
(3) Lower the hydraulic jack and tilt the axle and
remove the coil spring (Fig. 3).
(4) Remove and inspect the upper and lower
spring isolators (Fig. 3).

Fig. 4 JOUNCE BUMPER

INSTALLATION
(1) Install the jounce bumper into the mount by
twisting the bumper into place (Fig. 4).
(2) Install the coil spring (Refer to 2 - SUSPEN-
SION/REAR/SPRING - INSTALLATION).
(3) Install the shock (Refer to 2 - SUSPENSION/
REAR/SHOCK - INSTALLATION).

Fig. 3 COIL SPRING

1 - UPPER INSULATOR
2 - JOUNCE BUMPER
3 - COIL SPRING
2 - 24 REAR KJ

STABILIZER BAR UPPER BALL JOINT

REMOVAL REMOVAL
(1) Raise and support the vehicle. (1) Raise and support the vehicle.
(2) Remove the stabilizer bar bolts from the lower (2) Support the rear axle with a hydraulic jack.
suspension arm. (Fig. 5). (3) Remove the ball joint pinch bolt from the top of
(3) Remove the stabilizer bar. the axle. (Fig. 7)
(4) Separate the ball joint arm assembly from the
differential housing by prying upwards.

Fig. 5 REAR STABILIZER BAR

1 - MOUNTING HOLES
2 - STABILIZER BAR
Fig. 7 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
INSTALLATION
(1) Position the stabilizer bar over the axle and (5) Remove the upper suspension arm from the
install the bolts to the lower suspension arm (Fig. 6). vehicle (Refer to 2 - SUSPENSION/REAR/UPPER
Ensure the bar is centered with equal spacing on CONTROL ARM - REMOVAL).
both sides. Tighten the bolts to 99 N·m (73 ft. lbs.). (6) Secure the suspension arm in a vise.
(2) Remove support and lower the vehicle. (7) Install special tools C-4212F (press), 8861-3
(driver) and 8861-2 (receiver) (Fig. 8)

Fig. 6 STABILIZER BAR MOUNTS

1 - STABILIZER BAR MOUNTING BOLTS
Fig. 8 UPPER BALL JOINT - REMOVAL
2 - LOWER SUSPENSION ARM 1 - C-4212F PRESS
2 - 8861-3 DRIVER
3 - 8861-2 RECEIVER

(8) Press out the old ball joint.

KJ REAR 2 - 25
UPPER BALL JOINT (Continued)

INSTALLATION OPERATION - UPPER SUSPENSION ARM,

(1) Install special tools C-4212F (press), 8861-1 BUSHINGS, AND BALL JOINT
(receiver) and 8861-2 (driver) with the ball joint in The upper suspension arm provides fore/aft and
place (Fig. 9). lateral location of the rear axle. The suspension arm
travel is limited through the use of jounce bumpers
in compression and shock absorbers in rebound.

REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint pinch bolt from the top of
the differential housing bracket (Fig. 7).
(4) Remove partial nuts from the heat shield in
order to lower the shield down enough to get the
proper clearence to remove the right side bolt from
the body.
(5) Remove the upper suspension arm mounting
bolts from the body and remove the arm (Fig. 10).

Fig. 9 UPPER BALL JOINT - INSTALLATION

1 - C-4212F PRESS
2 - 8861-1 RECEIVER
3 - 8861-2 DRIVER

(2) Press the ball joint in the upper suspension

arm.
(3) Remove the upper suspension arm from the
vise.
(4) Reinstall the upper suspension arm (Refer to 2
- SUSPENSION/REAR/UPPER CONTROL ARM -
INSTALLATION).
(5) Raise the rear axle with a hydraulic jack to
align the ball joint with the differential housing
bracket.
(6) Insert the ball joint into the differential hous- Fig. 10 UPPER CONTROL ARM
ing bracket. 1 - BODY MOUNTS
(7) Install the ball joint pinch bolt and tighten to 2 - UPPER BALL JOINT
3 - STABILIZER BAR
95 N·m (70 ft. lbs.). (Fig. 7). 4 - UPPER CONTROL ARM
(8) Remove the supports and lower the vehicle. 5 - LOWER CONTROL ARM

(6) Remove the support bracket mounting bolts if

UPPER CONTROL ARM needed. (Fig. 11)

DESCRIPTION - UPPER SUSPENSION ARM, INSTALLATION

BUSHINGS, AND BALL JOINT (1) Position the upper suspension arm in the
The suspension arm uses vertical spool bushings to frame rail brackets (Fig. 10).
isolate road noise. The suspension arm is bolted (2) Install the mounting bolts and tighten to 100
through bushings to cage nuts in the body and a ball N·m (74 ft. lbs.).
joint to the top of the differential housing. (3) Retighten the heat shield back into place.
(4) Pull the arm down on the differential housing
bracket and install the pinch bolt and nut. Tighten
the nut to 95 N·m (70 ft. lbs.) (Fig. 7).
2 - 26 REAR KJ
UPPER CONTROL ARM (Continued)

Fig. 11 BALL JOINT BRACKET Fig. 12 LOWER SUSPENSION ARM

1 - UPPER BALL JOINT 1 - AXLE BRACKET BOLT
2 - SUPPORT BRACKET BOLTS 2 - LOWER CONTROL ARM
3 - BODY BRACKET BOLT
(5) Remove the supports and lower the vehicle.
(2) Install the axle bracket bolt and nut finger
tight (Fig. 12).
LOWER CONTROL ARM
NOTE: When installing the right side suspension
DESCRIPTION arm to the frame rail it will be necessary to pry the
exhaust over slightly to allow enough clearance to
The lower suspension arms are stamped steel and
install the bolt.
welded and use voided round bushings at the axle
end and solid rubber at the body end of the arm. (3) Install the frame rail bracket bolt and nut fin-
ger tight.
OPERATION (4) Install the stabilizer bar retaining bolts to the
The bushings provide isolation from the axle. The suspension arm.
arms mount to the unibody frame rail bracket and (5) Remove the supports and lower the vehicle.
the axle brackets. The arm and bushings provide (6) With the vehicle on the ground tighten the nut
location and react to loads. at the frame to 163 N·m (120 ft. lbs.). Tighten the
nut at the axle bracket to 163 N·m (120 ft. lbs.).
REMOVAL
(1) Raise the vehicle and support the rear axle.
(2) Remove the stabilizer bar retaining bolts from BUSHINGS
the suspension arm.
(3) Remove the lower suspension arm nut and bolt
from the axle bracket (Fig. 12). REMOVAL
NOTE: When removing the right side suspension REMOVAL - LOWER SUSPENSION ARM
arm from the frame rail it will be necessary to pry BUSHING
the exhaust over slightly to allow enough clearance (1) Remove the lower suspension arm (Refer to 2 -
to remove the bolt. SUSPENSION/REAR/LOWER CONTROL ARM -
REMOVAL).
(4) Remove the nut and bolt (Fig. 12) from the
(2) Secure the suspension arm in a vise.
frame rail and remove the lower suspension arm.
NOTE: Extreme pressure lubrication must be used
INSTALLATION on the threaded portions of the tool. This will
(1) Position the lower suspension arm in the axle increase the longevity of the tool and insure proper
bracket and frame rail bracket. operation during the removal and installation pro-
cess.
NOTE: The end of the arm with the voided round
bushing attaches to the axle bracket.
KJ REAR 2 - 27
BUSHINGS (Continued)
(3) Install special tools 8862-4 (receiver), 8862-5
(spacer) and 8862-1 or 8862- 2 (driver) with the
threaded rod 8839 and the bearing as shown (Fig. 13)

Fig. 14 UPPER SUSPENSION ARM BUSHING -

REMOVAL
1 - 8853-3 DRIVER
2 - 8860-1 RECEIVER
Fig. 13 LOWER SUSPENSION ARM BUSHING 3 - 8838 THREADED ROD
REMOVAL
1 - 8839 THREADED ROD (1) Install the new lower suspension arm bushings
2 - 8862-4 RECEIVER into the lower suspension arm using tools 8862-3
3 - 8862-5 SPACER
4 - 8862-1 OR 8862-2 DRIVERS (driver), 8862-4 (receiver), 8862-5 (spacer) and the
bearing with the threaded rod 8839 (Fig. 15) making
(4) Press out the bushing. sure to properly orient the bushing in the suspension
arm.
REMOVAL - UPPER SUSPENSION ARM
BUSHING
(1) Remove the upper suspension arm (Refer to 2 -
SUSPENSION/REAR/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the suspension arm in a vise.

NOTE: Extreme pressure lubrication must be used

on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.

(3) Install special tools 8853-3 (driver), 8860-1

(receiver) and with the threaded rod 8838 and the
bearing as shown (Fig. 14)
(4) Press out the bushing. Fig. 15 LOWER SUSPENSION ARM BUSHING
INSTALLATION
INSTALLATION 1
2
-
-
8862-3 DRIVER
8862-5 SPACER
3 - 8862-4 RECEIVER
INSTALLATION - LOWER SUSPENSION ARM 4 - 8839 THREADED ROD

BUSHING (2) Remove the suspension arm from the vise.

(3) Install the lower suspension arm (Refer to 2 -
NOTE: Extreme pressure lubrication must be used
SUSPENSION/REAR/LOWER CONTROL ARM -
on the threaded portions of the tool. This will
INSTALLATION).
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
2 - 28 REAR KJ
BUSHINGS (Continued)

INSTALLATION - UPPER SUSPENSION ARM

BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.

(1) Install the new upper suspension arm bushings

into the upper suspension arm using tools 8835-3
(receiver), 8860-2 (driver) and the bearing with the
threaded rod 8838 (Fig. 16) making sure to properly
orient the bushing in the suspension arm.
(2) Remove the suspension arm from the vise.
(3) Install the upper suspension arm (Refer to 2 -
SUSPENSION/REAR/UPPER CONTROL ARM - Fig. 16 UPPER SUSPENSION ARM BUSHING -
INSTALLATION). INSTALLATION
1 - 8838 THREADED ROD
2 - 8835-3 RECEIVER
3 - 8860-2 DRIVER
KJ DIFFERENTIAL & DRIVELINE 3-1

DIFFERENTIAL & DRIVELINE

TABLE OF CONTENTS

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PROPELLER SHAFT ......................1 DIFFERENTIAL & DRIVELINE . . . . . . . . . . . . . . . 18

HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REAR AXLE - 8 1/4 . . . . . . . . . . . . . . . . . . . . . . . 49

PROPELLER SHAFT

TABLE OF CONTENTS
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PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . .........6

DIAGNOSIS AND TESTING ................1 PROPELLER SHAFT - REAR
STANDARD PROCEDURE . ................3 REMOVAL .................... .........6
SPECIFICATIONS INSTALLATION . . . . . . . . . . . . . . . . . .........7
PROPELLER SHAFT . . . . ................5 SINGLE CARDAN UNIVERSAL JOINTS
SPECIAL TOOLS ........ ................5 DISASSEMBLY . . . . . . . . . . . . . . . . . .........7
PROPELLER SHAFT - FRONT ASSEMBLY . . . . . . . . . . . . . . . . . . . . .........8
REMOVAL ............. ................6

PROPELLER SHAFT Driveline vibration can be caused by loose or dam-

aged engine mounts.
Propeller shaft vibration increases with vehicle
DIAGNOSIS AND TESTING
speed. A vibration that occurs at a specific speed is
not usually caused by a out of balance propeller
VIBRATION
shaft. Worn universal joints or an incorrect propeller
Out-of-round tire or wheels that are out of balance,
shaft angle, can cause such a vibration.
will cause a low frequency vibration.
Brake rotors that are unbalanced will cause a
harsh, low frequency vibration.
3-2 PROPELLER SHAFT KJ
PROPELLER SHAFT (Continued)
DRIVELINE VIBRATION

Drive Condition Possible Cause Correction

Propeller Shaft Noise 1. Undercoating or other foreign 1. Clean exterior of shaft and wash
material on shaft. with solvent.

2. Loose U-joint clamp screws. 2. Install new clamps and screws

and tighten to proper torque.
3. Loose or bent U-joint yoke or 3. Install new yoke.
excessive runout.
4. Incorrect driveline angularity. 4. Measure and correct driveline
angles.
5. Worn joint. 5. Install new joint.
6. Propeller shaft damaged or out 6. Installl new propeller shaft.
of balance.
7. Broken rear spring. 7. Install new rear spring.
8. Excessive runout or unbalanced 8. Re-index propeller shaft, test, and
condition. evaluate.
9. Excessive drive pinion gear shaft 9. Re-index propeller shaft and
runout. evaluate.
10. Excessive axle yoke deflection. 10. Inspect and replace yoke if
necessary.
11. Excessive transfer case runout. 11. Inspect and repair as necessary.

U-Joint Noise 1. Loose U-joint clamp screws. 1. Install new clamps and screws
and tighten to proper torque.
2. Lack of lubrication. 2. Replace joints as necessary.

BALANCE (8) Install a screw clamp at position 1 (Fig. 1).

If propeller shaft is suspected of being out of bal-
ance, verify with the following procedure:

NOTE: Indexing the propeller shaft 180° relative to

the yoke may eliminate some vibrations.

(1) Raise the vehicle.

(2) Clean all the foreign material from the propel-
ler shaft and universal joints.
(3) Inspect propeller shaft for missing balance
weights, broken welds, and bent areas.

NOTE: If the propeller shaft is bent, it must be

replaced.

(4) Inspect universal joints for wear, properly

installation and correct alignment with the shaft.
(5) Remove wheels and tires and install wheel lug Fig. 1 CLAMP AT POSITION 1
nuts to retain brake drums/rotors. 1 - CLAMP
(6) Mark and number the shaft six inches from the 2 - SCREWDRIVER
pinion yoke end at four positions 90° apart.
(7) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.
KJ PROPELLER SHAFT 3-3
PROPELLER SHAFT (Continued)
(9) Start the engine and check for vibration. If RUNOUT
there is little or no change in vibration, move the (1) Clean propeller shaft surface where the dial
clamp to the next positions. Repeat the vibration indicator will contact the shaft.
test. (2) The dial indicator must be installed perpendic-
ular to the shaft surface.
NOTE: If there is no difference in vibration at the (3) Measure runout at the center and ends of the
other positions, the source of the vibration may not shaft away from weld areas to ensure an accurate
be propeller shaft. measurements.
(4) Refer to Runout Specifications chart.
(10) If vibration decreased, install a second clamp
(5) If propeller shaft runout is out of specification,
(Fig. 2) and repeat the test.
remove propeller shaft. Index the shaft 180° and
measure shaft runout again.
(6) If propeller shaft runout is now within specifi-
cations, mark the shaft and yokes for proper orienta-
tion.
(7) If propeller shaft runout is not within specifica-
tions, check runout of the transmission/transfer case
and axle. Correct as necessary and repeat propeller
shaft runout measurement.
(8) Replace propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS

Front of Shaft 0.020 in. (0.50 mm)

Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
Fig. 2 TWO CLAMPS AT SAME POSITION
note:
(11) If the additional clamp causes an additional Measure front/rear runout approximately 3 inches (76
vibration, separate the clamps (1/4 inch above and mm) from the weld seam at each end of the shaft
below the mark). Repeat the vibration test (Fig. 3). tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.

STANDARD PROCEDURE
This procedure applies to the front and rear propel-
ler shaft. To obtain front (output) angle on the C/V
front propeller shaft, place Inclinometer 7663 on the
machined ring of the pinion flange. To obtain propel-
ler shaft angle measurement on the C/V front propel-
ler shaft, place inclinometer on the propeller shaft
tube.

PROPELLER SHAFT ANGLE

(1) Raise and support the vehicle at the axles as
level as possible. Allow the wheels and propeller
Fig. 3 CLAMPS SEPARATED shaft to turn.
1 - 1⁄2 INCH (2) Remove universal joint snap rings if equipped,
so inclinometer base sits flat.
(12) Increase distance between the clamps and (3) Rotate shaft until transmission/transfer case
repeat the test until the amount of vibration is at the output yoke bearing cap is facing downward.
lowest level. Bend the slack end of the clamps so the
screws will not loosen. NOTE: Always make measurements from front to
(13) If vibration remains unacceptable, repeat the rear and from the same side of the vehicle.
procedure to the front end of the propeller shaft.
(14) Install wheel and tires, and lower vehicle.
3-4 PROPELLER SHAFT KJ
PROPELLER SHAFT (Continued)
(4) Place inclinometer on yoke bearing cap or pin-
ion flange ring (A) parallel to the shaft (Fig. 4). Cen-
ter bubble in sight glass and record measurement.

NOTE: This measurement will give you the trans-

mission or Output Yoke Angle (A).

Fig. 5 PROPELLER SHAFT ANGLE (C)

1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER

Fig. 4 OUTPUT YOKE ANGLE (A)

1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER

(5) Rotate propeller shaft 90 degrees and place

inclinometer on yoke bearing cap or propeller shaft
tube on C/V propeller shaft, parallel to the shaft (Fig.
5). Center bubble in sight glass and record measure-
ment. This measurement can also be taken at the
rear end of the shaft.

NOTE: This measurement will give you the propeller

shaft angle (C).

(6) Subtract smaller figure from larger (C minus

A) to obtain transmission output operating angle.
(7) Rotate propeller shaft 90 degrees and place
inclinometer on pinion yoke bearing cap parallel to Fig. 6 INPUT YOKE ANGLE (B)
the shaft (Fig. 6). Center bubble in sight glass and
1 - PINION YOKE BEARING CAP
record measurement. 2 - INCLINOMETER

NOTE: This measurement will give you the pinion RULES

shaft or input yoke angle (B). • Good cancellation of U-joint operating angles is
within 1degree.
(8) Subtract smaller figure from larger (C minus
• Operating angles less than 3 degrees.
B) to obtain axle Input Operating Angle.
• Operating angles less than 10 degrees for double
Refer to rules and example in (Fig. 7) for addi-
cardan U-joint.
tional information.
• At least 1/2 of one degree continuous operating
(propeller shaft) angle.
KJ PROPELLER SHAFT 3-5
PROPELLER SHAFT (Continued)

Fig. 7 UNIVERSAL JOINT ANGLE EXAMPLE

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

SPECIFICATIONS
PROPELLER SHAFT
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Front Shaft - Companion Flange Bolts 30 22 -
Rear Shaft - Companion Flange Bolts 115 85 -

SPECIAL TOOLS

INCLINOMETER 7663
3-6 PROPELLER SHAFT KJ

PROPELLER SHAFT - FRONT

REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Mark companion flanges and C/V joints at the
front and rear of the propeller shaft for installation
reference.
(3) Remove bolts from the front and rear C/V
joints.
(4) Push propeller shaft forward to clear transfer
case companion flange (Fig. 8).

Fig. 9 COMPANION FLANGE

1 - PROPELLER SHAFT
2 - PINION COMPANION FLANGE
3 - REFERENCE MARK
4 - PROPELLER SHAFT COMPANION FLANGE

(3) Pry open clamp holding the dust boot to propel-

ler shaft yoke (Fig. 10), if equipped.
Fig. 8 TRANSFER CASE COMPANION FLANGE
1 - FLANGE BOLT
2 - COMPANION FLANGE

(5) Remove shaft from the front axle companion

flange.
(6) Tilt the front of the shaft down and pull shaft
forward and remove from the vehicle.

INSTALLATION
(1) Install propeller shaft between companion
flanges.
(2) Align marks on the companion flanges with the
marks on the C/V joints.
(3) Install front C/V joint bolts and tighten to 30
N·m (22 ft. lbs.).
(4) Install rear C/V joint bolts and tighten to 30
N·m (22 ft. lbs.). Fig. 10 DUST BOOT CLAMP
1 - SLINGER
2 - BOOT
PROPELLER SHAFT - REAR 3 - AWL
4 - TRANSFER CASE

REMOVAL (4) Remove companion flange bolts.

(1) With vehicle in neutral, position vehicle on (5) Slide slip yoke off of the transmission/transfer
hoist. case output shaft and remove propeller shaft.
(2) Mark a reference line across companion flange
and propeller shaft for installation (Fig. 9).
KJ PROPELLER SHAFT 3-7
PROPELLER SHAFT - REAR (Continued)

INSTALLATION
(1) Slide slip yoke on the transmission/transfer
case output shaft.
(2) Align reference marks on companion flange and
propeller shaft (Fig. 11).

Fig. 12 CRIMPING BOOT CLAMP

1 - CLAMP TOOL
2 - SLINGER
3 - BOOT
4 - CLAMPS

(3) Remove snap rings from both sides of yoke

(Fig. 13).

Fig. 11 COMPANION FLANGE

1 - PROPELLER SHAFT
2 - PINION COMPANION FLANGE
3 - REFERENCE MARK
4 - PROPELLER SHAFT COMPANION FLANGE

(3) Install companion flange bolts and tighten to

115 N·m (85 ft. lbs.).
(4) Tighten dust boot clamp if equipped with
Clamp C-4975A (Fig. 12).

SINGLE CARDAN UNIVERSAL

JOINTS
Fig. 13 REMOVE SNAP RING
DISASSEMBLY
1 - SNAP RING
NOTE: Individual components of cardan universal
joints are not serviceable. If worn or leaking, they (4) Set yoke in an arbor press or vise with a socket
must be replaced as an assembly. with an inside diameter large enough to receive the
bearing cap positioned beneath the yoke.
(1) Remove propeller shaft. (5) Position yoke with the grease fitting, if
(2) Tap outside of the bearing cap assembly with a equipped, pointing up.
drift to loosen snap ring.
3-8 PROPELLER SHAFT KJ
SINGLE CARDAN UNIVERSAL JOINTS (Continued)
(6) 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. 14).

Fig. 15 PRESS OUT REMAINING BEARING

1 - CROSS
2 - BEARING CAP

Fig. 14 PRESS OUT BEARING

1 - PRESS
2 - SOCKET

(7) 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.
(8) 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. 15).

ASSEMBLY
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to inside of yoke bores.
(2) Position cross in the yoke with its lube fitting,
if equipped, pointing up (Fig. 16).

Fig. 16 CROSS IN YOKE

1 - CROSS
2 - YOKE
KJ PROPELLER SHAFT 3-9
SINGLE CARDAN UNIVERSAL JOINTS (Continued)
(3) Place a bearing cap over the cross and align
the cap with the yoke bore (Fig. 17).
(4) Press bearing cap into the yoke bore enough to
clear snap ring groove.
(5) Install a snap ring.
(6) Repeat Step 3 and Step 4 to install the oppo-
site bearing cap.

NOTE: If the joint is stiff or binding, strike the yoke

with a soft hammer to seat the needle bearings.

(7) Add grease to lube fitting, if equipped.

Fig. 17 BEARING ON CROSS

1 - BEARING CAP
2 - CROSS
3 - 10 HALF SHAFT KJ

HALF SHAFT

TABLE OF CONTENTS
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HALF SHAFT SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 11

CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CV JOINT/BOOT-OUTER
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 CV JOINT/BOOT-INNER
SPECIFICATIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16

HALF SHAFT VIBRATION AT HIGHWAY SPEEDS

This problem could be a result of out of balance
CAUTION front tires or tire/wheel runout. Foreign material
(mud, etc.) packed on the backside of the wheel(s)
CAUTION:: Never grasp half shaft assembly by the will also cause a vibration.
boots. This may cause the boot to pucker or crease
and reduce the service life of the boot. REMOVAL
Avoid over angulating or stroking the C/V joints (1) With vehicle in neutral, position vehicle on
when handling the half shaft. hoist.
Half shafts exposed to battery acid, transmission (2) Remove half shaft hub nut.
fluid, brake fluid, differential fluid or gasoline may (3) Remove stabilizer link (Fig. 1).
cause the boots to deteriorate. Failure to heed cau-
tion may result in damage.

DIAGNOSIS AND TESTING

Check inboard and outboard C/V joint for leaking
grease. This is a sign of boot or boot clamp damage.

NOISE/VIBRATION IN TURNS
A clicking noise or vibration in turns could be
caused by a damaged outer C/V or inner tripod joint
seal boot or seal boot clamps. This will result in the
loss/contamination of the joint grease, resulting in
inadequate lubrication of the joint. Noise could also
be caused by another component of the vehicle com-
ing in contact with the half shafts.

CLUNKING NOISE DURING ACCELERATION Fig. 1 STABILIZER BAR LINK

This noise may be a damaged or worn C/V joint. A 1 - STABILIZER BAR
2 - STABILIZER BAR LINK
torn boot or loose/missing clamp on the inner/outer
joint which has allowed the grease to be lost will (4) Remove lower clevis bolt (Fig. 2).
damage the C/V joint. (5) Separate lower ball joint from the lower control
arm (Fig. 3).
SHUDDER/VIBRATION DURING ACCELERATION (6) Pull out on the steering knuckle and push the
This could be a worn/damaged inner tripod joint or half shaft out of the knuckle.
a sticking tripod joint. Improper wheel alignment (7) With a pry bar remove the half shaft from the
may also cause a shudder or vibration. axle.
KJ HALF SHAFT 3 - 11
HALF SHAFT (Continued)

Fig. 2 CLEVIS BRACKET

1 - UPPER BOLT Fig. 3 LOWER CONTROL ARM
2 - CLEVIS BRACKET 1 - FRONT CAM BOLT
3 - LOWER BOLT 2 - OUTER TIE ROD END
3 - LOWER BALL JOINT NUT
NOTE: Right side half shaft has an axle shaft that 4 - LOWER CONTROL ARM
may come out of the axle. 5 - REAR CAM BOLT

(3) Clean hub bearing bore and apply a light coat

INSTALLATION of wheel bearing grease.
(4) Pull out on the steering knuckle and push the
NOTE: Seperate right half shaft from axle shaft in a half shaft through the knuckle.
vise if necessary and install axle shaft in the axle. (5) Install lower ball joint into the lower control
arm and tighten pinch bolt.
(1) Apply a light coat of wheel bearing grease on (6) Align clevis with knuckle. Install and tighten
the female splines of the inner C/V joint. lower clevis bolt.
(2) Install half shaft on the axle shaft spline and (7) Install stabilizer link.
push firmly to engage the snap ring. Pull on the half (8) Install half shaft hub nut.
shaft to verify snap has engaged.

SPECIFICATIONS

HALF SHAFT
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Half Shaft Nut 136 100 -

SPECIAL TOOLS

CLAMP INSTALLER C-4975A

3 - 12 HALF SHAFT KJ

CV JOINT/BOOT-OUTER (7) Mark alignment marks on the inner race/hub,

bearing cage and housing with dabs of paint (Fig. 6).
REMOVAL
(1) Clamp shaft in a vise (with soft jaws) and sup-
port C/V joint.
(2) Remove clamps with a cut-off wheel or grinder
(Fig. 4).

Fig. 6 BEARING ACCESS

1 - ALIGNMENT MARKS
2 - BEARING HUB
3 - BEARING CAGE
4 - HOUSING

Fig. 4 BOOT CLAMP LOCATIONS

(8) Clamp C/V joint in a vertical position in a soft
1 - C/V HOUSING jawed vise.
2 - CLAMP
3 - HALF SHAFT (9) Press down one side of the bearing cage to gain
4 - CLAMP access to the ball at the opposite side.
5 - C/V BOOT
NOTE: If joint is tight, use a hammer and brass drift
(3) Slide boot down the shaft. to loosen the bearing hub. Do not contact the bear-
(4) Remove lubricant to expose the C/V joint snap ing cage with the drift.
ring.
(5) Spread snap ring and slide the joint off the (10) Remove ball from the bearing cage (Fig. 7).
shaft (Fig. 5).

Fig. 7 BEARING
Fig. 5 OUTER C/V JOINT 1 - HOUSING
2 - INNER RACE/HUB
1 - SNAP RING 3 - BEARING CAGE
2 - SNAP RING GROVE 4 - BALL
3 - SNAP RING PLIERS
(11) Repeat step above until all six balls are
(6) Slide boot off the shaft and discard old boot. removed from the bearing cage.
KJ HALF SHAFT 3 - 13
CV JOINT/BOOT-OUTER (Continued)
(12) Lift cage and inner race upward and out from
the housing (Fig. 8).

Fig. 10 INNER RACE/HUB

1 - INNER RACE/HUB
2 - BEARING CAGE

Fig. 8 CAGE AND INNER RACE/HUB

1 - HOUSING
2 - INNER RACE
3 - CAGE WINDOW

(13) Turn inner race 90° in the cage and rotate the
inner race/hub out of the cage (Fig. 9).

Fig. 11 CAGE AND INNER RACE/HUB

1 - CAGE WINDOWS
2 - SNAP RING

Fig. 9 INNER RACE/HUB

INSTALLATION
(1) Apply a light coat of grease to the C/V joint
components before assembling them.
(2) Align inner race, cage and housing according to
the alignment reference marks.
(3) Insert inner race (1) into the cage (2) (Fig. 10)
and rotate race into the cage.
(4) Rotate inner race/hub in the cage (1) (Fig. 11).
(5) Insert cage into the housing (3) (Fig. 12).
Fig. 12 BEARING CAGE AND HOUSING
1 - OUTER RACE
2 - BEARING CAGE WINDOW
3 - CV JOINT HOUSING
3 - 14 HALF SHAFT KJ
CV JOINT/BOOT-OUTER (Continued)
(9) Place new clamps onto new boot and slide boot
onto the shaft to it’s original position.
(10) Apply the rest of lubricant to the C/V joint
and boot.

Fig. 13 CAGE AND INNER RACE/HUB

1 - C/V HOUSING
2 - BEARING HUB LARGE COUNTERBORE OUTWARD
3 - BOOT RETAINING SHOULDER
4 - BEARING HUB SMALL COUNTERBORE INWARD
5 - SLINGER
Fig. 15 OUTER C/V JOINT
(6) Rotate cage 90° into the housing (1) (Fig. 13). 1 - SNAP RING
(7) Apply lubricant included with replacement 2 - SHAFT TAPER
3 - SNAP RING GROVE
boot/joint to the ball races. Spread lubricant equally 4 - BEARING HUB
between all the races.
(11) Push the joint onto the shaft until the snap
ring (1) seats in the groove (3) (Fig. 15). Pull on the
joint to verify the span ring has engaged.
(12) Position boot on the joint in it’s original posi-
tion. Ensure boot is not twisted and remove any
excess air.

Fig. 14 BALL BEARING

1 - C/V HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BEARING

(8) Tilt inner race/hub (2) and cage (3) and install Fig. 16 BOOT CLAMP LOCATIONS
the balls (4) (Fig. 14). 1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT

(13) Secure both boot clamps (2) (4) (Fig. 16) with
Clamp Installer C-4975A. Place tool on clamp bridge
and tighten tool until the jaws of the tool are closed.
KJ HALF SHAFT 3 - 15

CV JOINT/BOOT-INNER (5) Remove bearings from the cage (Fig. 19).

REMOVAL
(1) Clamp shaft in a vise (with soft jaws) and sup-
port C/V joint.
(2) Remove clamps with a cut-off wheel or grinder.
(3) Slide boot down the shaft (Fig. 17).

Fig. 19 C/V BEARINGS

1 - CAGE
2 - INNER RACE
3 - SHAFT
4 - BEARING

Fig. 17 INNER C/V BOOT (6) Rotate cage 30° and slide cage off the inner
race and down the shaft.
1 - HOUSING
2 - BOOT (7) Remove spread inner race snap ring (Fig. 20)
3 - HOUSING SNAP RING and remove race from the shaft.

(4) Remove lubricant to expose the C/V housing

snap ring and remove snap ring (Fig. 18).

Fig. 20 INNER RACE

1 - INNER RACE
2 - PLIERS
Fig. 18 HOUSING SNAP RING 3 - SHAFT
4 - SNAP RING ACCESS
1 - HOUSING
2 - SNAP RING
3 - CAGE/INNER RACE (8) Remove boot from the shaft and discard.
3 - 16 HALF SHAFT KJ
CV JOINT/BOOT-INNER (Continued)
(9) Clean and inspect all components for wear or
damage (Fig. 21).

Fig. 22 BEARING CAGE

1 - SHAFT
2 - CAGE
Fig. 21 INNER C/V JOINT 3 - SMALL DIAMETER
1 - HOUSING 4 - SNAP RING GROOVE
2 - CAGE
3 - BEARINGS
4 - HOUSING SNAP RING
5 - INNER RACE SNAP RING
6 - INNER RACE

INSTALLATION
(1) Apply a coat of grease supplied with the joint/
boot to the C/V joint components before assembling
them.
(2) Place new clamps on the new boot and slide
boot down the shaft.
(3) Slide cage onto the shaft (Fig. 22) with the
small diameter end towards the boot.
(4) Install the inner race onto the shaft (Fig. 23).
Pull on the race to verify snap ring has engaged.
(5) Align cage with the inner race and slide over
the race.

Fig. 23 INNER RACE

1 - INNER RACE
2 - CAGE
3 - SHAFT
KJ HALF SHAFT 3 - 17
CV JOINT/BOOT-INNER (Continued)
(6) Turn the cage 30° to align the cage windows
with the race (Fig. 24).

Fig. 25 C/V COMPONENTS

1 - HOUSING
2 - BEARING ASSEMBLY
Fig. 24 CAGE/INNER RACE 3 - HOUSING SNAP RING
1 - CAGE 4 - HOUSING BORE
2 - INNER RACE
3 - SHAFT (10) Fill the housing and boot with the remaining
4 - CAGE WINDOW
grease.
(7) Apply grease to the inner race and bearings (11) Slide the boot onto the C/V housing into it’s
and install the bearings. original position. Ensure boot is not twisted and
(8) Apply grease to the housing bore (Fig. 25) then remove any excess air.
install the bearing assmbly into the housing. (12) Secure both boot clamps with Clamp Installer
(9) Install the housing snap ring and verify it is C-4975A. Place tool on clamp bridge and tighten tool
seated in the groove. until the jaws of the tool are closed.
3 - 18 DIFFERENTIAL & DRIVELINE KJ

DIFFERENTIAL & DRIVELINE

TABLE OF CONTENTS
page page

DIFFERENTIAL & DRIVELINE AXLE BEARINGS

DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24 PINION SEAL
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIFICATIONS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
FRONT AXLE ........ . . . . . . . . . . . . . . . . 32 DIFFERENTIAL
SPECIAL TOOLS ....... . . . . . . . . . . . . . . . . 33 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIFFERENTIAL COVER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
AXLE SHAFTS DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
AXLE SHAFT SEALS PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46

DIFFERENTIAL & DRIVELINE BEARING NOISE

Bearing noise can be either a whining or a growl-
DIAGNOSIS AND TESTING ing sound.
Pinion bearings have a constant high pitch noise,
GEAR NOISE because it rotates at a faster rate. This noise changes
Axle gear noise can be caused by insufficient lubri- with vehicle speed. If noise is heard under a load, the
cant, incorrect backlash, tooth contact, worn/damaged rear pinion bearing is the source. If noise is heard
gears or the carrier housing not having the proper during a coast, the front pinion bearing is the source.
offset and squareness. Differential bearings usually produce a low pitch
Gear noise usually happens at a specific speed noise. The differential bearing noise is constant and
range. The noise can also occur during a specific type varies only with vehicle speed.
of driving condition. These conditions are accelera- Axle shaft bearing noise generally changes when
tion, deceleration, coast, or constant load. the bearings are loaded. Turn vehicle sharply to the
When road testing, first warm-up the axle fluid by left and the right during a road test. This will load
driving the vehicle at least 5 miles and then acceler- and unload the bearings and change the noise level.
ate the vehicle to the speed range where the noise is If axle bearing damage is slight, the noise is usually
the greatest. Shift out-of-gear and coast through the not noticeable at speeds above 30 m.p.h.
peak-noise range. If the noise stops or changes
greatly check for: LOW SPEED KNOCK
• Insufficient lubricant. Low speed knock is generally caused by:
• Incorrect ring gear backlash. • Worn U-joints/CV joint.
• Gear damage. • Worn side-gear thrust washers.
Differential side and pinions gears, usually do not • Worn pinion shaft bore.
cause noise during straight-ahead driving, when the
gears are unloaded. The side gears are loaded during
turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise.
KJ DIFFERENTIAL & DRIVELINE 3 - 19
DIFFERENTIAL & DRIVELINE (Continued)
VIBRATION DRIVELINE SNAP
Vibration at the rear of the vehicle is usually A snap or clunk noise when the vehicle is shifted
caused by: into gear or the clutch engaged, can be caused by:
• Damaged drive shaft. • High engine idle speed.
• Missing drive shaft balance weight(s). • Transmission shift operation.
• Worn or out-of-balance wheels. • Loose engine/transmission/transfer case mounts.
• Loose wheel lug nuts. • Worn U-joints/CV joint.
• Worn U-joints/CV joint. • Loose spring mounts.
• Loose/broken springs. • Loose pinion gear nut and yoke.
• Damaged axle shaft bearing(s). • Excessive ring gear backlash.
• Loose pinion gear nut. • Excessive side gear to case clearance.
• Excessive pinion yoke run out. To determined the source of a snap/clunk noise,
• Bent axle shaft(s). raise vehicle on a hoist with the wheels free to
Check for loose or damaged front-end components rotate. Have a helper shift the transmission into gear
or engine/transmission mounts. These components and listen for the noise.
can contribute to what appears to be an axle vibra-
tion. Also look at engine accessories, brackets and
drive belts.

NOTE: All driveline components should be exam-

ined before starting any repair.

DIAGNOSTIC CHART

Condition Possible Causes Correction

Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing. 2. Replace bearing.

Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.

2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.

3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash 4. Check adjustment of the ring
between the ring gear and pinion. gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion 5. Adjust the pinion bearings
gear bearings. pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact 7. Inspect and replace as
surfaces. necessary.

Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.

2 Vehicle overloaded. 2. Replace broken shaft and avoid

excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
3 - 20 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL & DRIVELINE (Continued)

Condition Possible Causes Correction

Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears
differential bearings. and bearings for further damage.
Set differential bearing pre-load
properly.

2. Excessive ring gear backlash. 2. Replace case and inspect gears

and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.

Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill

differential with the correct fluid type
and quantity.

2. Improper grade of lubricant. 2. Replace scored gears. Fill

differential with the correct fluid type
and quantity.
3. Excessive spinning of one 3. Replace scored gears. Inspect all
wheel/tire. gears, pinion bores, and shaft for
damage. Service as necessary.

Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.

2. Worn axle shaft seals. 2. Replace seals.

3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.

Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.

2. Improper grade of lubricant. 2. Fill differential with the correct

fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
KJ DIFFERENTIAL & DRIVELINE 3 - 21
DIFFERENTIAL & DRIVELINE (Continued)

Condition Possible Causes Correction

Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other

gears and bearings for possible
damage.

2. Erratic clutch operation. 2. Replace gears and examine the

remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct

fluid type and quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion
adjustment. contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or 4. Replace ring gear and pinion.
pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap 8. Inspect differential components
bolts. and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
3 - 22 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL & DRIVELINE (Continued)

REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove skid plate.
(3) Remove differential drain plug (Fig. 1) and
drain fluid.

Fig. 2 LOWER CONTROL ARM

1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
3 - LOWER BALL JOINT NUT
4 - LOWER CONTROL ARM
5 - REAR CAM BOLT

Fig. 1 DRAIN PLUG

1 - LEFT FRONT AXLE BRACKET
2 - DRAIN PLUG
3 - DIFFERENTIAL HOUSING

(4) Mark front propeller shaft and pinion flange.

Remove propeller shaft from pinion flange.
(5) Remove half shaft hub nuts.
(6) Remove stabilizer bar links from the lower con-
trol arms.
(7) Remove tie rod end nuts and separate ends Fig. 3 CLEVIS BRACKET
from the knuckles. 1 - UPPER BOLT
(8) Remove lower ball joint nuts (Fig. 2) and sepa- 2 - CLEVIS BRACKET
rate ball joints from the lower control arms. 3 - LOWER BOLT
(9) Remove lower shock clevis bolts (Fig. 3).
(10) Pull out on the steering knuckles and push
the half shaft out of the knuckles.
(11) With a pry bar remove the half shafts from
the axle.

NOTE: Right half shaft has a splined axle that may

come out with the half shaft.
KJ DIFFERENTIAL & DRIVELINE 3 - 23
DIFFERENTIAL & DRIVELINE (Continued)

(12) Remove differential vent hose from cover and

remove drain trough (Fig. 4).

Fig. 6 RIGHT AXLE BRACKET

1 - RIGHT AXLE BRACKET
2 - FRONT BRACKET BOLT
Fig. 4 DRAIN TROUGH 3 - REAR BRACKET BOLT

1 - TROUGH
2 - MOUNTING NUT (18) Remove bolt from left rear axle bracket frame
mount (Fig. 7).
(13) Support axle with a lift/jack.
(14) Remove bolts from left front axle bracket (Fig.
5).

Fig. 5 LEFT FRONT AXLE BRACKET

1 - LEFT FRONT AXLE BRACKET
2 - CRADLE BRACKET BOLT
Fig. 7 LEFT REAR AXLE BRACKET
(15) Remove oil filter drip tray. 1 - LEFT REAR AXLE BRACKET
(16) Mark and remove right control arm cam bolt. 2 - BRACKET BOLT
(17) Remove bolts from right axle bracket frame
mounts (Fig. 6). (19) Lower axle and from vehicle.
3 - 24 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL & DRIVELINE (Continued)

INSTALLATION
NOTE: Seperate right axle shaft from the half shaft
if necessary and install axle shaft in the axle.

(1) Install left rear bracket to axle and tighten to

61 N·m (45 ft. lbs.).
(2) Install right bracket to axle and tighten to 88
N·m (65 ft. lbs.).
(3) Install left front bracket to axle and tighten to
61 N·m (45 ft. lbs.).
(4) Raise axle up and align brackets with frame
mounts.
(5) Install frame mount bolts and tighten to 88
N·m (65 ft. lbs.) (Fig. 8), (Fig. 9) and (Fig. 10).

Fig. 9 LEFT AXLE BRACKET

1 - LEFT REAR AXLE BRACKET
2 - BRACKET BOLT

Fig. 8 RIGHT AXLE BRACKET

1 - RIGHT AXLE BRACKET
2 - FRONT BRACKET BOLT
3 - REAR BRACKET BOLT

(6) Install half shafts. Fig. 10 FRONT AXLE BRACKET

(7) Install right front control arm cam bolt with 1 - LEFT FRONT AXLE BRACKET
marks aligned. 2 - CRADLE BRACKET BOLT
(8) Install lower ball joint into lower control arms
and tighten pinch bolts. (15) Fill differential with gear lubricant.
(9) Align clevis with knuckles and install clevis (16) Install skid plate.
bolts. (17) Tighten clevis and stabilizer links bolts to
(10) Install stabilizer links to lower control arms specifications.
and install bolts. (18) Check vehicle alignment.
(11) Install oil filter trough.
(12) Install new half shaft hub nuts and tighten to ADJUSTMENTS
136 N·m (100 ft. lbs.). Ring and pinion gears are supplied as matched
(13) Install propeller shaft. sets. Identifying numbers for the ring and pinion
(14) Install axle vent hose. gear are etched onto each gear (Fig. 11). A plus (+)
KJ DIFFERENTIAL & DRIVELINE 3 - 25
DIFFERENTIAL & DRIVELINE (Continued)
number, minus (–) number or zero (0) is etched into
the face of the pinion gear. This number is the
amount (in thousandths of an inch) the depth varies
from the standard depth setting of a pinion etched
with a (0).

Fig. 12 SHIM LOCATIONS

1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
Fig. 11 PINION GEAR ID NUMBERS
the depth variances. The numbers represent thou-
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE sands of an inch deviation from the standard. If the
3 - GEAR MATCHING NUMBER number is negative, add that value to the required
thickness of the depth shims. If the number is posi-
Compensation for pinion depth variance is tive, subtract that value from the thickness of the
achieved with a select shim/oil slinger. The shims are depth shim.
placed between the rear pinion bearing and the pin- Pinion Gear Depth Variance Chart: Note where
ion gear head (Fig. 12). Old and New Pinion Marking columns intersect.
If installing a new gear, note the depth variance Intersecting figure represents plus or minus the
number of the original and replacement pinion. Add amount needed.
or subtract this number from the original depth
shim/oil slinger to compensate for the difference in

PINION GEAR DEPTH VARIANCE

Original Pinion
Gear Depth Replacement Pinion Gear Depth Variance
Variance
24 23 22 21 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002 20.003
0 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002 20.003 20.004
21 +0.003 +0.002 +0.001 0 20.001 20.002 20.003 20.004 20.005
22 +0.002 +0.001 0 20.001 20.002 20.003 20.004 20.005 20.006
23 +0.001 0 20.001 20.002 20.003 20.004 20.005 20.006 20.007
24 0 20.001 20.002 20.003 20.004 20.005 20.006 20.007 20.008
3 - 26 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL & DRIVELINE (Continued)
PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 13).

Fig. 14 DEPTH TOOLS IN HOUSING

1 - PINION HEIGHT BLOCK
2 - ARBOR DISC
3 - ARBOR
4 - PINION BLOCK

(7) Slowly slide the scooter block across the pinion

Fig. 13 PINION GEAR DEPTH TOOLS height block over to the arbor (Fig. 15). Move the
1 - DIAL INDICATOR scooter block till the dial indicator probe crests the
2 - ARBOR
3 - PINION HEIGHT BLOCK arbor and record the highest reading.
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC

(1) Assemble Pinion Height Block 6739, Pinion

Block 8804 and rear pinion bearing onto Screw 6741
(Fig. 13).
(2) Insert height gauge components into the hous-
ing through pinion bearing cups.
(3) Install front pinion bearing and Cone-nut 6740
onto the screw. Tighen Cone-Nut until Torque To
Rotate screw is 1.7 N·m (15 in. lbs.).
(4) Position Arbor Disc 6732 and Arbor D-115-3
into the housing bearing cradles. Install differential
bearing caps on Arbor Discs and tighten bolts to 41
N·m (30 ft. lbs.) (Fig. 14).

NOTE: Arbor Discs 6732 has different step diame-

ters to fit other axles. Choose proper step for axle
being serviced.

(5) Assemble Dial Indicator C-3339 into Scooter

Block D-115-2 and secure set screw. Fig. 15 PINION DEPTH MEASUREMENT
(6) Position Scooter Block/Dial Indicator flush on 1 - SCOOTER BLOCK
the pinion height block. Hold the scooter block and 2 - ARBOR
3 - DIAL INDICATOR
zero the dial indicator.
KJ DIFFERENTIAL & DRIVELINE 3 - 27
DIFFERENTIAL & DRIVELINE (Continued)
(8) Select a shim/oil slinger equal to the dial indi- PRELOAD SHIM SELECTION
cator reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 11). For exam- NOTE: It is difficult to salvage the differential side
ple, if the depth variance is –2, add +0.002 in. to the bearings during the removal procedure. Install
dial indicator reading. replacement bearings if necessary.

DIFFERENTIAL SIDE BEARING PRELOAD AND (1) Remove differential side bearings from differ-
GEAR BACKLASH ential case.
Differential bearing preload and gear backlash is (2) Install ring gear on differential case and
achieved with selective shims located between the tighten bolts to specification.
differential bearing cups and differential housing. (3) Install Dummy Bearings D-348 on differential
The proper shim thickness can be determined using case.
slip-fit Dummy Bearings D-348 in place of the differ- (4) Install differential case in the housing.
ential side bearings and a Dial Indicator C-3339. (5) Record the thickness of Dummy Shims 8107.
Before measuring differential bearing preload and Insert the shims between the dummy bearings and
gear backlash, measure pinion gear depth and pre- the differential housing (Fig. 17).
pare pinion for installation. Pinion gear depth is
essential to establishing gear backlash and tooth con-
tact patterns. After measuring shim thickness to take
up differential side play, install pinion and measure
gear backlash shim thickness. Overall shim thickness
is the dial indicator reading and preload specification
added together. The gear backlash measurement
determines the shim thickness used on the ring gear
side of the differential case. Subtract gear backlash
shim thickness from overall shim thickness to deter-
mine shim thickness for pinion gear side of the dif-
ferential (Fig. 16). Differential shim measurements
are performed with spreader W-129-B removed.

Fig. 17 DUMMY SHIMS

1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS

Fig. 16 SHIM LOCATIONS

1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
3 - 28 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL & DRIVELINE (Continued)
(6) Install the bearing caps in their correct posi-
tions and snug the bolts (Fig. 18).

Fig. 20 SEAT DUMMY BEARING RING GEAR SIDE

1 - DIFFERENTAIL HOUSING
2 - HAMMER
Fig. 18 BEARING CAP BOLTS 3 - RING GEAR
(7) With a dead-blow hammer, seat the differential
dummy bearings to each side of the axle housing
(Fig. 19) and (Fig. 20).

Fig. 19 SEAT DUMMY BEARINGS PINION SIDE

1 - HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL
Fig. 21 DIFFERENTIAL PINION GEAR SIDE
(8) Thread Pilot Stud C-3288-B into rear cover bolt 1 - PINION SIDE
hole below ring gear. 2 - PILOT STUD
3 - DIAL INDICATOR
(9) Attach a Dial Indicator C-3339 to the Pilot
Stud. Position the dial indicator plunger on flat sur-
face between the ring gear bolts.
(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 21).
KJ DIFFERENTIAL & DRIVELINE 3 - 29
DIFFERENTIAL & DRIVELINE (Continued)
(11) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 22).

Fig. 23 DIFFERENTIAL PINION GEAR SIDE

1 - DIAL INDICATOR
2 - PINION GEAR
3 - RING GEAR
Fig. 22 DIFFERENTIAL RING GEAR SIDE
1 - DIAL INDICATOR
2 - DIFFERENTIAL HOUSING

(12) Add 0.152 mm (0.006 in.) to the zero end play

total. This new total represents the thickness of
shims to compress or preload the new bearings when
the differential is installed.
(13) Rotate dial indicator out of the way on the
pilot stud.
(14) Remove differential case and dummy bearings
from the housing.
(15) Install the pinion gear in the housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(16) Install differential case and Dummy Bearings
D-348 in the housing.
(17) Install a single dummy shim in the ring gear Fig. 24 DIFFERENTIAL RING GEAR SIDE
side. Install bearing caps and tighten bolts snug.
1 - DIAL INDICATOR
(18) Seat ring gear side dummy bearing (Fig. 20). 2 - PINION GEAR
(19) Position the dial indicator plunger on a flat 3 - RING GEAR
surface between the ring gear bolt heads.
(20) Push and hold differential case toward pinion (24) Rotate dial indicator out of the way on pilot
gear and zero dial indicator (Fig. 23). stud.
(21) Push and hold differential case to ring gear (25) Remove differential case and dummy bearings
side of the housing and record dial indicator reading from the housing.
(Fig. 24). Add dummy shim thickness to this reading. (26) Install side bearings and cups on differential
This will be the total shim thickness to achieve zero case.
backlash. (27) Install spreader W-129-B with Adapter Set
(22) Subtract 0.076 mm (0.003 in.) from the dial 6987 on the housing and spread axle opening enough
indicator reading to compensate for backlash between to receive differential case.
ring and pinion gears. This total is the thickness
shim required to achieve proper backlash. CAUTION: Never spread the differential housing
(23) Subtract the backlash shim thickness from over 0.34 mm (0.013 in.). If the housing is over-
the total preload shim thickness. The remainder is spread, it could be distorted or damaged.
the shim thickness required on the pinion side of the
(28) Place the bearing preload shims in the axle
axle housing.
housing, against the axle tubes.
3 - 30 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL & DRIVELINE (Continued)
(29) Install differential case into the housing.
(30) Remove spreader from the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 25).

Fig. 25 RING GEAR BACKLASH Fig. 26 BACKLASH SHIMS

1 - DIAL INDICATOR ter. The HEEL of the gear is the portion of the tooth
2 - RING GEAR at the outer-end. The ROOT of the gear tooth is the
lowest portion of the tooth (Fig. 27).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate. NOTE: If the PROFILE across the tooth is the same
(34) Zero dial indicator face to pointer. it is a 3 Axis cut gear. If the PROFILE across the
(35) Push and hold ring gear downward while not tooth is tapered it is a 2 Axis cut gear.
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the housing to the other (Fig.
26).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform
Gear Contact Pattern Analysis procedure.

GEAR CONTACT PATTERN

The ring gear and pinion teeth contact patterns
will show if the pinion depth is correct in the hous- Fig. 27 GEAR DESCRIPTION
ing. It will also show if the ring gear backlash has 1 - TOP LAND
2 - PROFILE
been adjusted correctly. The backlash can be adjusted 3 - TOE
within specifications to achieve desired tooth contact 4 - HEEL
patterns. 5 - ROOT
The TOP LAND of the gear tooth is the top surface
of the tooth. The PROFILE of the gear tooth is the (1) Apply a thin coat of hydrated ferric oxide or
depth of the tooth. The TOE of the gear is the por- equivalent to the drive and coast side of the ring gear
tion of the tooth surface at the end towards the cen- teeth.
KJ DIFFERENTIAL & DRIVELINE 3 - 31
DIFFERENTIAL & DRIVELINE (Continued)
(2) Wrap, twist and hold a shop towel around the DIFFERENTIAL BEARING PRELOAD CHECK
pinion yoke to increase the turning resistance of the The final check on the differential assembly before
pinion. This will provide a more distinct contact pat- installing the axles, is torque to rotate pinion and
tern. differential combined. This will verify the correct dif-
(3) With a boxed end wrench on a ring gear bolt, ferential bearing preload.
rotate the differential case one complete revolution in Torque to rotate the differential and pinion is the
both directions while a load is being applied from torque to rotate the pinion plus:
shop towel. • Gear Ratio 3.73 - 0.45-0.75 N·m (3.9-6.6 in. lbs.)
The areas on the ring gear teeth with the greatest • Gear Ratio 4.10 - 0.41-0.69 N·m (3.6-6.0 in. lbs.)
degree of contact against the pinion teeth will squee-
gee the compound to the areas with the least amount
of contact. Note and compare patterns on the ring
gear teeth to Gear Tooth Contact Patterns chart (Fig.
28) and adjust pinion depth and gear backlash as
necessary.

Fig. 28 PATTERN INTERPRETATION (GEAR CUT 2 AXIS)

3 - 32 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL & DRIVELINE (Continued)

SPECIFICATIONS
FRONT AXLE
AXLE SPECIFICATIONS

DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 4.10
Ring Gear Diameter 186 mm (7.33 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Bearing Preload 1.69-2.82 N·m (15-25 in. lbs.)
Differential Bearing Preload
Added To Pinion Torque To Rotate
Gear Ratio 3.73 0.45-0.75 N·m (3.9-6.6 in. lbs.)
Gear Ratio 4.10 0.41-0.69 N·m (3.6-6.0 in. lbs.)

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Ring Gear Bolts 95-122 70-90 -
Differential Bearing Cap
54-67 39-50 -
Bolts
Differential Cover Bolts 19-26 14-19 -
Pinion Nut 217-352 160-260 -
Left Axle Bracket Bolts 61 45 -
Front Axle Bracket Bolts 61 45 -
Right Axle Bracket Bolts 88 65 -
Axle Brackets To Frame
88 65 -
Bolts
KJ DIFFERENTIAL & DRIVELINE 3 - 33
DIFFERENTIAL & DRIVELINE (Continued)

SPECIAL TOOLS

INSTALLER C-3716-A

PULLER C-293-PA

ADAPTER C-293-39

HANDLE C-4171

ADAPTER C-293-42

REMOVER C-4307

PILOT STUD C-3288-B

INSTALLER C-4308

DIAL INDICATOR C-3339

PULLER C-452
3 - 34 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL & DRIVELINE (Continued)

INSTALLER D-146
INSTALLER W-162-D

REMOVER D-149

INSTALLER 6448

DUMMY BEARINGS D-348

PINION DEPTH SET 6774

PLUG SP-3289

SPANNER WRENCH 6958

SPREADER W-129-B

ADAPTER KIT 6987B

KJ DIFFERENTIAL & DRIVELINE 3 - 35
DIFFERENTIAL & DRIVELINE (Continued)

INSTALLER 8681

REMOVER 7794-A

PINION BLOCK 8804

DUMMY SHIMS 8107

CUP 8109

INSTALLER 8805

REMOVER 8420A

INSTALLER 8806
3 - 36 DIFFERENTIAL & DRIVELINE KJ

DIFFERENTIAL COVER
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove skid plate.
(3) Remove drain plug and drain fluid (Fig. 29).

Fig. 30 DRAIN TROUGH

1 - TROUGH
2 - MOUNTING NUT

Fig. 29 DRAIN PLUG

1 - LEFT FRONT AXLE BRACKET
2 - DRAIN PLUG
3 - DIFFERENTIAL HOUSING

(4) Remove oil trough bolt from axle bracket.

(5) Remove oil trough nut from differential cover
(Fig. 30).
(6) Loosen left front axle bracket bolt at cradle
(Fig. 31).
(7) Remove left front axle bracket bolts from the
axle and let bracket hang forward of the axle.
(8) Remove vent hose from cover and remove oil Fig. 31 LEFT FRONT AXLE BRACKET
trough. 1 - LEFT FRONT AXLE BRACKET
(9) Remove differential cover bolts and remove 2 - CRADLE BRACKET BOLT
cover.
KJ DIFFERENTIAL & DRIVELINE 3 - 37
DIFFERENTIAL COVER (Continued)

INSTALLATION
(1) Clean cover and mating surface.
(2) Apply a bead of Mopar Axle RTV sealant or
equivalent to the housing cover (Fig. 32).

CAUTION: If cover is not installed within 3 to 5 min-

utes, the cover must be cleaned and new RTV
applied. Failure to heed caution may result in dam-
age.

Fig. 33 AXLE SHAFT PULLER

1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR

NOTE: Use care to prevent damage to axle shaft

bearing and seal, which will remain in axle shaft
tube.
Fig. 32 APPLY SEALANT
1 - SEALANT INSTALLATION
2 - DIFFERNTIAL COVER
(1) Lubricate bearing bore and seal lip with gear
lubricant. Insert axle shaft through seal, bearing
(3) Install differential housing cover and tighten
(Fig. 34) and engage it into side gear splines.
bolts in a criss-cross pattern to 19-26 N·m (14-19 ft.
lbs.).
(4) Install drain trough and tighten nut to 23 N·m
(200 in. lbs.).
(5) Install vent hose on differential cover with new
clamp.
(6) Install axle bracket to axle and tighten to 61
N·m (45 ft. lbs.).
(7) Install drain trough bolt to axle bracket and
tighten to 12 N·m (110 in. lbs.).
(8) Tighten left front axle bracket cradle nut to 61
N·m (45 ft. lbs.).
(9) Install skid plate.

AXLE SHAFTS
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove right half shaft from vehicle.
(3) Remove snap ring from axle shaft.
(4) Assemble Remover 8420A onto the shaft (Fig.
33). Thread slid hammer into remover and remove Fig. 34 AXLE SHAFT SEAL
shaft. 1 - BEARING
(5) Slide axle shaft out of the axle tube. 2 - SEAL
3 - 38 DIFFERENTIAL & DRIVELINE KJ
AXLE SHAFTS (Continued)
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal.

(2) Push the axle shaft until the axle shaft snap-
ring passes through the side gear.
(3) Install right half shaft.
(4) Install right wheel and tire assembly.
(5) Check differential fluid level.
(6) Lower vehicle.

AXLE SHAFT SEALS

REMOVAL
(1) Remove half shaft.
(2) Remove axle shaft for right side seal removal.
(3) Remove shaft seal with Remover 7794-A and a Fig. 36 SEAL INSTALLER
slide hammer (Fig. 35).
1 - SEAL BORE
2 - INSTALLER

AXLE BEARINGS
REMOVAL
(1) Remove half shaft.
(2) Remove axle shaft for right side seal removal.
(3) Remove shaft seal with Remover 7794-A and a
slide hammer.
(4) Remove shaft bearing with Remover 7794-A
and a slide hammer (Fig. 37).

Fig. 35 SHAFT SEAL REMOVER

1 - SHAFT SEAL
2 - REMOVER

INSTALLATION
(1) Apply a light coat of lubricant on the lip of the
shaft seal.
(2) Install new shaft seal with Installer 8806 and
Handle C-4171 (Fig. 36).
(3) Install right axle shaft if removed.
(4) Install half shaft.
Fig. 37 SHAFT BEARING REMOVER
1 - SHAFT BEARING
2 - REMOVER
KJ DIFFERENTIAL & DRIVELINE 3 - 39
AXLE BEARINGS (Continued)

INSTALLATION
(1) Install new shaft bearing with Installer 8805
and Handle C-4171.
(2) Apply a light coat of lubricant on the lip of the
shaft seal.
(3) Install new shaft seal with Installer 8806 (Fig.
38).

Fig. 39 PINION ROTATING TORQUE

1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH

Fig. 38 SEAL INSTALLER

1 - SEAL BORE
2 - INSTALLER

(4) Install right axle shaft if removed.

(5) Install half shaft.

PINION SEAL
REMOVAL
(1) With vehicle in neutral, position vehicle on hoist. Fig. 40 PINION FLANGE NUT
(2) Remove brake calipers and rotors. 1 - SPANNER WRENCH
(3) Remove propeller shaft. 2 - PINION COMPANION FLANGE
(4) Rotate pinion gear a minimum of ten times and
verify the pinion rotates smoothly.
(5) Record the torque to rotate the pinion gear
(Fig. 39) with a inch pound torque wrench.
(6) Using a short piece of pipe and Spanner
Wrench 6958 to hold the pinion companion flange
(Fig. 40) and remove the pinion nut.
(7) Remove pinion companion flange (Fig. 41) with
Remover C-452 and Spanner Wrench 6958.
(8) Remove pinion seal with Remover 7794-A and
a slide hammer (Fig. 42).

INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer 8681.
(2) Install pinion companion flange on the pinion Fig. 41 PINION FLANGE REMOVER
gear with Installer W-162-D, Cup 8109 and Wrench 1 - SPANNER WRENCH
6958. 2 - REMOVER
3 - 40 DIFFERENTIAL & DRIVELINE KJ
PINION SEAL (Continued)

Fig. 42 PINION SEAL

1 - REMOVER Fig. 43 PINION ROTATING TORQUE
2 - SLIDE HAMMER 1 - PINION COMPANION FLANGE
3 - PINION SEAL 2 - TORQUE WRENCH

CAUTION: Do not exceed the minimum tightening

torque 216 N·m (160 ft. lbs.) while installing pinion
nut at this point. Failure to heed caution may result
in damage.

(3) Install a new nut on the pinion gear. Tighten

the nut only enough to remove the shaft end
play.

CAUTION: Never loosen pinion nut to decrease pin-

ion rotating torque and never exceed specified pre-
load torque. Failure to heed caution may result in
damage.

(4) Rotate pinion a minimum of ten time and ver-

ify pinion rotates smoothly. Rotate the pinion shaft
with an inch pound torque wrench. Rotating torque
should be equal to the reading recorded during
removal plus 0.56 N·m (5 in. lbs.) (Fig. 43).
(5) If rotating torque is low, use Spanner Wrench
6958 to hold the pinion companion flange and tighten
the pinion nut in 6.8 N·m (5 ft. lbs.) increments until
proper rotating torque is achieved.
Fig. 44 DIFFERENTIAL COVER
CAUTION: If maximum tightening torque is reached 1 - COVER
prior to reaching the required rotating torque, the 2 - VENT TUBE
collapsible spacer may have been damaged. Failure
to heed caution may result in damage. (2) Push right axle shaft out of side gear (Fig. 45)
and remove shaft.
(6) Install propeller shaft. (3) Mark differential bearing caps for installation
(7) Fill differential with gear lubricant. reference.
(8) Install brake rotors and calipers. (4) Loosen bearing cap bolts.

DIFFERENTIAL
REMOVAL
(1) Remove differential housing cover (Fig. 44).
KJ DIFFERENTIAL & DRIVELINE 3 - 41
DIFFERENTIAL (Continued)
(6) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing and zero the indicator.
(7) Spread differential case while measuring the
distance with the dial indicator (Fig. 47).

CAUTION: Never spread the differential housing

over 0.34 mm (0.013 in). Failure to heed caution
may result in damage.

Fig. 45 RIGHT SHAFT IN SIDE GEAR

1 - AXLE SHAFT
2 - SCREWDRIVER
3 - SIDE GEAR

(5) Position Spreader W-129-B onto differential

locating holes and install the safety hold-down
clamps (Fig. 46). Tighten tool turnbuckle finger-tight.

Fig. 47 SPREAD DIFFERENTIAL CASE

1 - PILOT STUD
2 - DIAL INDICATOR
3 - SPREADER

Fig. 46 DIFFERENTIAL SPREADER

1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
3 - 42 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL (Continued)
(8) Remove dial indicator.
(9) Hold differential case and remove bearing caps.
(10) Remove differential from the housing (Fig.
48).

Fig. 49 PINION MATE GEAR

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

Fig. 48 DIFFERENTIAL CASE

1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - DIFFERENTIAL BEARINGS

(11) Tag differential bearing cups and shims to

indicate location.
(12) Remove spreader from housing.

DISASSEMBLY
(1) Remove ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft.
(4) Rotate differential side gears and remove the
pinion mate gears and thrust washers (Fig. 49).
(5) Remove differential side gears and thrust
washers.

ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft. Fig. 50 PINION MATE SHAFT ROLL-PIN
(4) Align hole in the pinion gear mate shaft with 1 - PUNCH
the hole in the differential case. 2 - PINION MATE SHAFT
(5) Install the roll-pin in the differential case with 3 - MATE SHAFT LOCKPIN
a hammer and punch (Fig. 50). Peen the edge of the
roll-pin hole in the differential case in two places (6) Lubricate all differential components with
180° apart. hypoid gear lubricant.
(7) Install ring gear.
KJ DIFFERENTIAL & DRIVELINE 3 - 43
DIFFERENTIAL (Continued)

INSTALLATION (8) Tighten bearing cap bolts in a criss-cross pat-

tern to 54-68 N·m (39-50 ft. lbs.).
NOTE: If differential bearings or differential case are (9) Install right axle shaft.
replaced, Refer to adjustments fore Differential (10) Apply a bead of orange Mopar Axle RTV seal-
Bearing Preload and Gear Backlash procedures. ant or equivalent to the housing cover.

(1) Position Spreader W-129-B on differential loca- CAUTION: If cover is not installed within 3 to 5 min-
tion holes and install safety holddown clamps. utes, the cover must be cleaned and new RTV
Tighten spreader turnbuckle finger-tight. applied. Failure to heed caution may result in dam-
(2) Install Pilot Stud C-3288-B to the left side of age.
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the (11) Install differential housing cover and tighten
opposite side of the housing and zero the indicator. bolts in a criss-cross pattern to 19-26 N·m (14-19 ft.
(3) Spread housing while measuring the distance lbs.).
with the dial indicator.

CAUTION: Never spread the differential housing DIFFERENTIAL CASE

over 0.34 mm (0.013 in). Failure to heed caution BEARINGS
may result in damage.
REMOVAL
(4) Remove dial indicator.
(1) Remove differential from the housing.
(5) Install differential case in the housing. Tap dif-
(2) Remove bearings from the differential case
ferential case to seat bearings cups and preload
with Puller/Press C-293-PA, Adapters C-293-39 and
shims in housing.
Plug SP-3289 (Fig. 52).
(6) Install bearing caps and loosely install bolts.
(7) Remove differential housing spreader (Fig. 51).

Fig. 52 DIFFERENTIAL BEARING PULLER

Fig. 51 DIFFERENTIAL SPREADER 1 - PULLER
2 - ADAPTERS
1 - DIFFERENTIAL HOUSING 3 - BEARING
2 - SAFETY CLAMPS 4 - DIFFERENTIAL
3 - SPREADER 5 - PLUG
4 - TURNBUCKLE
3 - 44 DIFFERENTIAL & DRIVELINE KJ
DIFFERENTIAL CASE BEARINGS (Continued)

INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 53).

Fig. 54 RING GEAR

1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER

Fig. 53 DIFFERENTIAL CASE BEARINGS

1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER

(2) Install differential into the housing.

PINION GEAR/RING GEAR Fig. 55 PINION COMPANION FLANGE

1 - SPANNER WRENCH
REMOVAL 2 - PINION COMPANION FLANGE

NOTE: The ring gear and pinion are serviced as a

matched set. Never replace ring gear without
replacing the matched pinion gear.

(1) Remove differential from axle housing.

(2) Place differential case in a vise with soft metal
jaw (Fig. 54).
(3) Remove bolts holding ring gear to differential
case.
(4) Driver ring gear off the differential case with a
rawhide hammer (Fig. 54).
(5) With Spanner Wrench 6958 and a short length
of 1 in. pipe, hold pinion companion flange and
remove pinion nut (Fig. 55).
(6) Remove pinion companion flange from pinion
shaft with Remover C-452 (Fig. 56). Fig. 56 PINION FLANGE REMOVER
1 - SPANNER WRENCH
2 - REMOVER
KJ DIFFERENTIAL & DRIVELINE 3 - 45
PINION GEAR/RING GEAR (Continued)
(7) Remove pinion gear and collapsible spacer from (9) Remove rear pinion bearing cup (Fig. 59) with
housing (Fig. 57). Remover C-4307 and Handle C-4171.

Fig. 59 REAR PINION BEARING CUP

Fig. 57 PINION GEAR 1 - REMOVER
2 - HANDLE
1 - RAWHIDE HAMMER
(10) Remove collapsible preload spacer from pinion
(8) Remove front pinion bearing cup, bearing, oil gear (Fig. 60).
slinger and pinion seal with Remover C-149 and
Handle C-4171 (Fig. 58).

Fig. 60 COLLAPSIBLE PRELOAD SPACER

1 - COLLAPSIBLE SPACER
Fig. 58 FRONT BPINION BEARING CUP 2 - SHOULDER
1 - REMOVER 3 - PINION GEAR
2 - HANDLE 4 - OIL SLINGER
5 - REAR BEARING
3 - 46 DIFFERENTIAL & DRIVELINE KJ
PINION GEAR/RING GEAR (Continued)
(11) Remove rear pinion bearing from the pinion
with Puller/Press C-293-PA and Adapters C-293-42
(Fig. 61). Remove oil slinger/pinion depth shim from
the pinion shaft and record thickness.

Fig. 62 FRONT PINION BEARING CUP

1 - INSTALLER
2 - HANDLE

Fig. 61 REAR PINION BEARING

1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT

INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing and the pinion gear head to
achieve proper ring and pinion gear mesh. If ring
and pinion gears are reused, the pinion oil slinger/
depth shim should not require replacement. Refer
to Adujstments (Pinion Gear Depth) to select the
proper thickness shim before installing pinion gear.

(1) Apply Mopar Door Ease or equivalent lubricant

to outside surface of pinion bearing cups.
Fig. 63 REAR PINION BEARING
(2) Install rear bearing cup with Installer C-4308
and Handle C-4171 and verify cup is seated. 1 - INSTALLER
2 - OIL SLINGER
(3) Install front bearing cup with Installer D-146 3 - PINION GEAR
and Handle C-4171 (Fig. 62) and verify cup is seated. 4 - REAR PINION BEARING
(4) Install front pinion bearing, and oil slinger if 5 - PRESS
equipped.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal and intall seal with Installer 8681.
(6) Install rear pinion bearing and oil slinger/depth
shim onto the pinion shaft with Installer 6448 and a
press (Fig. 63).
KJ DIFFERENTIAL & DRIVELINE 3 - 47
PINION GEAR/RING GEAR (Continued)
(7) Install a new collapsible spacer on pinion shaft (10) Use Spanner Wrench 6958, a length of 1 in.
and install the pinion into the housing (Fig. 64). pipe and a torque wrench set at 678 N·m (500 ft. lbs.)
and crush collapsible spacer until bearing end play is
taken up (Fig. 65).
(11) Slowly tighten the nut in 6.8 N·m (5 ft. lb.)
increments until the required rotating torque is
achieved. Measure rotating torque frequently to
avoid over crushing the collapsible spacer (Fig. 66).

Fig. 64 COLLAPSIBLE PRELOAD SPACER Fig. 65 PINION FLANGE NUT

1 - COLLAPSIBLE SPACER 1 - SPANNER WRENCH
2 - SHOULDER 2 - PINION COMPANION FLANGE
3 - PINION GEAR
4 - OIL SLINGER (12) Rotate the pinion a minimum of ten times.
5 - REAR BEARING
Verify pinion rotates smoothly and check rotating
(8) Install pinion companion flange, with Installer torque with an inch pound torque wrench (Fig. 66).
W-162-D, Cup 8109 and Spanner Wrench 6958. Pinion gear rotating torque is:
(9) Install pinion a new nut onto the pinion gear • Original Bearings: 1 to 2.25 N·m (10 to 20 in.
and tighten the nut to 216 N·m (160 ft. lbs.). Do not lbs.).
over-tighten. • New Bearings: 1.69 to 2.82 N·m (15 to 25 in. lbs.).

CAUTION: Never loosen pinion gear nut to decrease

pinion rotating torque and never exceed specified
preload torque. Failure to heed caution may result
in damage.

Fig. 66 PINION ROTATING TORQUE

1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
3 - 48 DIFFERENTIAL & DRIVELINE KJ
PINION GEAR/RING GEAR (Continued)
(13) Invert differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(14) Invert differential case in the vise. Install
new ring gear bolts and alternately tighten to 108
N·m (80 ft. lbs.) (Fig. 67).

CAUTION: Never reuse the ring gear bolts. Failure

to heed caution may result in damage.

(15) Install differential in housing and verify dif-

ferential bearing preload, gear mesh and contact pat-
tern. Refer to Adjustment for procedure.

Fig. 67 RING GEAR BOLTS

1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
KJ REAR AXLE - 8 1/4 3 - 49

REAR AXLE - 8 1/4

TABLE OF CONTENTS
page page

REAR AXLE - 8 1/4 PINION SEAL

DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 49 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVAL . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 53 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . .. . . . . . . . . . . . . . . . 54 DIFFERENTIAL
ADJUSTMENTS . . . . . . . .. . . . . . . . . . . . . . . . 54 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SPECIFICATIONS DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 70
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SPECIAL TOOLS ...... . . . . . . . . . . . . . . . . . 61 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
DIFFERENTIAL COVER DIFFERENTIAL - TRAC-LOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
AXLE SHAFTS DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
AXLE SHAFT SEALS DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
AXLE BEARINGS PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79

REAR AXLE - 8 1/4 BEARING NOISE

Bearing noise can be either a whining or a growl-
DIAGNOSIS AND TESTING ing sound.
Pinion bearings have a constant high pitch noise,
GEAR NOISE because it rotates at a faster rate. This noise changes
Axle gear noise can be caused by insufficient lubri- with vehicle speed. If noise is heard under a load, the
cant, incorrect backlash, incorrect pinion depth, tooth rear pinion bearing is the source. If noise is heard
contact, worn/damaged gears, or the carrier housing during a coast, the front pinion bearing is the source.
not having the proper offset and squareness. Differential bearings usually produce a low pitch
Gear noise usually happens at a specific speed noise. The differential bearing noise is constant and
range. The noise can also occur during a specific type varies only with vehicle speed.
of driving condition. These conditions are accelera- Axle shaft bearing noise generally changes when
tion, deceleration, coast, or constant load. the bearings are loaded. Turn vehicle sharply to the
When road testing, first warm-up the axle fluid by left and the right during a road test. This will load
driving the vehicle at least 5 miles and then acceler- and unload the bearings and change the noise level.
ate the vehicle to the speed range where the noise is If axle bearing damage is slight, the noise is usually
the greatest. Shift out-of-gear and coast through the not noticeable at speeds above 30 m.p.h.
peak-noise range. If the noise stops or changes
greatly check for: LOW SPEED KNOCK
• Insufficient lubricant. Low speed knock is generally caused by:
• Incorrect ring gear backlash. • Worn U-joints/CV joint.
• Gear damage. • Worn side-gear thrust washers.
Differential side and pinions gears, usually do not • Worn pinion shaft bore.
cause noise during straight-ahead driving, when the
gears are unloaded. The side gears are loaded during
turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise.
3 - 50 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
VIBRATION DRIVELINE SNAP
Vibration at the rear of the vehicle is usually A snap or clunk noise when the vehicle is shifted
caused by: into gear or the clutch engaged, can be caused by:
• Damaged drive shaft. • High engine idle speed.
• Missing drive shaft balance weight(s). • Transmission shift operation.
• Worn or out-of-balance wheels. • Loose engine/transmission/transfer case mounts.
• Loose wheel lug nuts. • Worn U-joints/CV joint.
• Worn U-joints/CV joint. • Loose spring mounts.
• Loose/broken springs. • Loose pinion gear nut and yoke.
• Damaged axle shaft bearing(s). • Excessive ring gear backlash.
• Loose pinion gear nut. • Excessive side gear to case clearance.
• Excessive pinion yoke run out. To determined the source of a snap/clunk noise,
• Bent axle shaft(s). raise vehicle on a hoist with the wheels free to
Check for loose or damaged front-end components rotate. Have a helper shift the transmission into gear
or engine/transmission mounts. These components and listen for the noise.
can contribute to what appears to be an axle vibra-
tion. Also look at engine accessories, brackets and
drive belts.

NOTE: All driveline components should be exam-

ined before starting any repair.

DIAGNOSTIC CHART

Condition Possible Causes Correction

Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing. 2. Replace bearing.

Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.

2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.

Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.

2 Vehicle overloaded. 2. Replace broken shaft and avoid

excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
KJ REAR AXLE - 8 1/4 3 - 51
REAR AXLE - 8 1/4 (Continued)

Condition Possible Causes Correction

Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears
differential bearings. and bearings for further damage.
Set differential bearing pre-load
properly.

2. Excessive ring gear backlash. 2. Replace case and inspect gears

and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.

Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill

differential with the correct fluid type
and quantity.

2. Improper grade of lubricant. 2. Replace scored gears. Fill

differential with the correct fluid type
and quantity.
3. Excessive spinning of one 3. Replace scored gears. Inspect all
wheel/tire. gears, pinion bores, and shaft for
damage. Service as necessary.

Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.

2. Worn axle shaft seals. 2. Replace seals.

3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.

Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.

2. Improper grade of lubricant. 2. Fill differential with the correct

fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
3 - 52 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)

Condition Possible Causes Correction

Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other

gears and bearings for possible
damage.

2. Erratic clutch operation. 2. Replace gears and examine the

remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct

fluid type and quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion
adjustment. contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or 4. Replace ring gear and pinion.
pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap 8. Inspect differential components
bolts. and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
KJ REAR AXLE - 8 1/4 3 - 53
REAR AXLE - 8 1/4 (Continued)

REMOVAL (9) Remove shock absorbers from axle brackets

(1) With vehicle in neutral, position vehicle on (Fig. 3).
hoist.
(2) Position a lift/jack under the axle and secure
axle to device.
(3) Mark propeller shaft and pinion yoke for
installation reference.
(4) Remove propeller shaft and suspend under the
vehicle.
(5) Remove brake components.
(6) Remove vent hose from the axle shaft tube.
(7) Remove the stabilizer bar (Fig. 1).

Fig. 3 SHOCK ABSORBER

1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT

(10) Loosen all lower control arms mounting bolts

(Fig. 4).

Fig. 1 STABILIZER BAR MOUNTS

1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM

(8) Remove upper control arm ball joint pinch bolt

from bracket (Fig. 2).

Fig. 4 LOWER SUSPENSION ARM

1 - AXLE BRACKET BOLT
2 - LOWER CONTROL ARM
3 - BODY BRACKET BOLT

(11) Lower axle enough to remove coil springs and

spring insulators.
(12) Remove lower control arm bolts from the axle
brackets.
(13) Lower and remove the axle.

Fig. 2 BALL JOINT PINCH BOLT

1 - UPPER BALL JOINT
2 - PINCH BOLT
3 - 54 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)

INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.

(1) Raise the axle under the vehicle.

(2) Install lower control arms onto the axle brack-
ets and loosely install the mounting bolts.
(3) Install coil spring isolators and spring.
(4) Raise axle up until springs are seated.
(5) Install upper control arm ball joint into axle
bracket and tighten pinch bolt to torque specification.
(6) Install shock absorbers and tighten nuts to
Fig. 5 PINION ID NUMBERS
torque specification.
1 - VARIANCE NUMBER
(7) Install stabilizer bar and tighten nuts to torque 2 - SEQUENCE NUMBER
specification.
(8) Install brake components.
(9) Install axle vent hose.
(10) Install propeller shaft with reference marks.
(11) Install the wheels and tires.
(12) Remove lifting device from axle and lower the
vehicle.
(13) Tighten the lower control arm bolts to torque
specification.

ADJUSTMENTS
Ring gear and pinion are supplied as matched sets.
Identifying numbers for the ring gear and pinion are
painted onto the pinion gear shaft (Fig. 5) and the
side of the ring gear. A plus (+) number, minus (–)
number or zero (0) along with the gear set sequence
number (01 to 99) is on each gear. This first number
is the amount (in thousandths of an inch) the depth Fig. 6 ADJUSTMENT SHIM LOCATIONS
varies from the standard depth setting of a pinion 1 - AXLE HOUSING
marked with a (0). The next two numbers are the 2 - COLLAPSIBLE SPACER
3 - PINION BEARING
sequence number of the gear set. The standard depth 4 - PINION DEPTH SHIM
provides the best teeth contact pattern. 5 - PINION GEAR
Compensation for pinion depth variance is 6 - BEARING CUP
achieved with select shims. The shims are placed
thickness of the depth shims. If the number is posi-
behind the rear pinion bearing (Fig. 6).
tive, subtract that value from the thickness of the
If installing a new gear, note the depth variance
depth shim.
number of the original and replacement pinion. Add
Pinion Gear Depth Variance Chart: Note where
or subtract this number from the original depth
Old and New Pinion Marking columns intersect.
shim/oil slinger to compensate for the difference in
Intersecting figure represents plus or minus the
the depth variances. The numbers represent thou-
amount needed.
sands of an inch deviation from the standard. If the
number is negative, add that value to the required
KJ REAR AXLE - 8 1/4 3 - 55
REAR AXLE - 8 1/4 (Continued)
PINION GEAR DEPTH VARIANCE

Original Pinion
Gear Depth Replacement Pinion Gear Depth Variance
Variance
24 23 22 21 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002 20.003
0 +0.004 +0.003 +0.002 +0.001 0 20.001 20.002 20.003 20.004
21 +0.003 +0.002 +0.001 0 20.001 20.002 20.003 20.004 20.005
22 +0.002 +0.001 0 20.001 20.002 20.003 20.004 20.005 20.006
23 +0.001 0 20.001 20.002 20.003 20.004 20.005 20.006 20.007
24 0 20.001 20.002 20.003 20.004 20.005 20.006 20.007 20.008

PINION DEPTH MEASUREMENT (1) Assemble Pinion Height Block 6739, Pinion
Measurements are taken with pinion bearing cups Block 8540 and rear pinion bearing onto Screw 6741
and pinion bearings installed in the housing. Take (Fig. 7).
measurements with Pinion Gauge Set and Dial Indi- (2) Insert assembled height gauge components,
cator C-3339 (Fig. 7). rear bearing and screw into housing through pinion
bearing cups (Fig. 8).
(3) Install front pinion bearing and Cone-Nut 6740
on the screw. Tighten Cone-Nut until Torque To
Rotate screw is 1.7 N·m (15 in. lbs.) (Fig. 7).

Fig. 8 PINION HEIGHT BLOCK

Fig. 7 PINION DEPTH GAUGE 1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK (4) Place Arbor Disc 8541 on Arbor D-115-3 in posi-
4 - CONE tion in the housing side bearing cradles (Fig. 9).
5 - SCREW Install differential bearing caps on arbor discs and
6 - PINION BLOCK
7 - SCOOTER BLOCK tighten cap bolts to 41 N·m (30 ft. lbs.).
8 - ARBOR DISC
3 - 56 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.

Fig. 10 PINION GEAR DEPTH

1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 9 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC • Mark the gears so the same teeth are meshed
2 - PINION BLOCK
3 - ARBOR during all backlash measurements.
4 - PINION HEIGHT BLOCK • Maintain the torque while adjusting the bearing
preload and ring gear backlash.
(5) Assemble Dial Indicator C-3339 into Scooter • Excessive adjuster torque will introduce a high
Block D-115-2 and secure set screw. bearing load and cause premature bearing failure.
(6) Place Scooter Block/Dial Indicator in position Insufficient adjuster torque can result in excessive
in axle housing so dial probe and scooter block are differential case free-play and ring gear noise.
flush against the rearward surface of the pinion • Insufficient adjuster torque will not support the
height block (Fig. 7). Hold scooter block in place and ring gear correctly and can cause excessive differen-
zero the dial indicator. Tighten dial indicator face tial case free-play and ring gear noise.
lock screw.
(7) Slowly slide the dial indicator probe over the NOTE: The differential bearing cups will not always
edge of the pinion height block. immediately follow the threaded adjusters as they
(8) Slide the dial indicator probe across the gap are moved during adjustment. To ensure accurate
between the pinion height block and the arbor bar bearing cup responses to the adjustments:
with the scooter block against the pinion height block • Maintain the gear teeth engaged (meshed) as
(Fig. 10). When dial probe contacts the arbor bar, the marked.
dial pointer will turn clockwise. Continue moving the • The bearings must be seated by rapidly rotat-
dial probe to the crest of the arbor bar and record the ing the pinion gear a half turn back and forth.
highest reading. If the dial indicator can not achieve • Do this five to ten times each time the threaded
a zero reading, the rear bearing cup or the pinion adjusters are adjusted.
depth gauge set is not installed correctly.
(9) Select a shim equal to the dial indicator read- (1) Use Wrench C-4164 to adjust each threaded
ing plus the drive pinion gear depth variance number adjuster inward until the differential bearing free-
marked on the shaft of the pinion. For example, if play is eliminated. Allow some ring gear backlash
the depth variance is –2, add +0.002 in. to the dial (approximately 0.01 inch/0.25 mm) between the ring
indicator reading. and pinion gear. Seat the bearing cups with the pro-
cedure described above.
DIFFERENTIAL BEARING PRELOAD AND GEAR (2) Install dial indicator and position the plunger
BACKLASH against the drive side of a ring gear tooth (Fig. 11).
The following must be considered when adjusting Measure the backlash at 4 positions (90 degrees
bearing preload and gear backlash: apart) around the ring gear. Locate and mark the
• The maximum ring gear backlash variation is area of minimum backlash.
0.003 inch (0.076 mm). (3) Rotate the ring gear to the position of the least
backlash. Mark the gear so that all future backlash
KJ REAR AXLE - 8 1/4 3 - 57
REAR AXLE - 8 1/4 (Continued)
measurements will be taken with the same gear GEAR CONTACT PATTERN
teeth meshed. Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N·m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern.
• Gear contact pattern is correct (Fig. 12). Back-
lash and pinion depth is correct.
Fig. 11 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING

(4) Loosen the right-side, tighten the left-side

threaded adjuster. Obtain backlash of 0.003 to 0.004
inch (0.076 to 0.102 mm) with each adjuster tight-
ened to 14 N·m (10 ft. lbs.). Seat the bearing cups
with the procedure described above.
(5) Tighten the differential bearing cap bolts to 95
N·m (70 ft. lbs.).
(6) Tighten the right-side threaded adjuster to 102
N·m (75 ft. lbs.). Seat the bearing cups with the pro-
cedure described above. Continue to tighten the Fig. 12 CORRECT CONTACT PATTERN
right-side adjuster and seat bearing cups until the • Ring gear is too far away from the pinion gear
torque remains constant at 102 N·m (75 ft. lbs.) (Fig. 13). Decrease the backlash, by moving the ring
(7) Measure the ring gear backlash. The range of closer to the pinion gear using the adjusters.
backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm).
(8) Continue increasing the torque at the right-
side threaded adjuster until the specified backlash is
obtained.

NOTE: The left-side threaded adjuster torque

should have approximately 102 N·m (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.

(9) Tighten the left-side threaded adjuster until

102 N·m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
(10) Install the threaded adjuster locks and Fig. 13 INCORRECT BACKLASH
tighten the lock screws to 10 N·m (90 in. lbs.). 1 - COAST SIDE TOE
After the proper backlash is achieved, perform the 2 - DRIVE SIDE HEEL
Gear Contact procedure.
3 - 58 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
• Ring gear is too close to the pinion gear (Fig.
14). Increase the backlash, by moving the ring away
from the pinion gear using the adjusters.

Fig. 16 INCORRECT BACKLASH

1 - DRIVE SIDE TOE
2 - COAST SIDE TOE

Fig. 14 INCORRECT BACKLASH

1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL

• Ring gear is too far away from the pinion gear

(Fig. 15). Decrease the backlash, by moving the ring
closer to the pinion gear using the adjusters.

Fig. 17 LOW PINION HEIGHT

Fig. 15 INCORRECT BACKLASH

1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL

• Ring gear is too close to the pinion gear (Fig.

16). Increase the backlash, by moving the ring away
from the pinion gear using the adjusters.
• Pinion gear is set too low (Fig. 17). Increase the
pinion gear height, by increasing the pinion depth Fig. 18 HIGH PINION HEIGHT
shim thickness.
• Pinion gear is set too high (Fig. 18). Decrease
the pinion depth, by decreasing the pinion depth
shim thickness.
KJ REAR AXLE - 8 1/4 3 - 59
REAR AXLE - 8 1/4 (Continued)
SIDE GEAR CLEARANCE (4) If clearance is more than 0.005 inch (axle shaft
When measuring side gear clearance, check each not contacting mate shaft), record the side gear clear-
gear independently. If it necessary to replace a side ance. Remove the thrust washer and measure its
gear, replace both gears as a matched set. thickness with a micrometer. Add the washer thick-
(1) Install the axle shafts and C-locks and pinion ness to the recorded side gear clearance. The sum of
mate shaft. gear clearance and washer thickness will determine
(2) Measure each side gear clearance. Insert a required thickness of replacement thrust washer
matched pair of feeler gauge blades between the gear (Fig. 20).
and differential housing on opposite sides of the hub
(Fig. 19).

Fig. 20 SIDE GEAR CALCULATIONS

In some cases, the end of the axle shaft will move
and contact the mate shaft when the feeler gauge is
inserted. The C-lock is preventing the side gear from
sliding on the axle shaft.
(5) If there is no side gear clearance, remove the
C-lock from the axle shaft. Use a micrometer to mea-
sure the thrust washer thickness. Record the thick-
ness and re-install the thrust washer. Assemble the
differential case without the C-lock installed and re-
measure the side gear clearance.
Fig. 19 SIDE GEAR CLEARANCE
(6) Compare both clearance measurements. If the
1 - FEELER GAUGE
2 - SIDE GEARS
difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-lock was installed to
(3) If side gear clearances is no more than 0.005 thrust washer thickness measured. The sum will
inch. Determine if the axle shaft is contacting the determine the required thickness of the replacement
pinion mate shaft. Do not remove the feeler thrust washer.
gauges, inspect the axle shaft with the feeler (7) If clearance is 0.012 inch (0.305 mm) or
gauge inserted behind the side gear. If the end of greater, both side gears must be replaced (matched
the axle shaft is not contacting the pinion mate set) and the clearance measurements repeated.
shaft, the side gear clearance is acceptable. (8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
3 - 60 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)

SPECIFICATIONS
REAR AXLE
AXLE SPECIFICATIONS

DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 4.10
Differential Case Flange Runout 0.076 mm (0.003 in.)
Differential Case Clearance 0.12 mm (0.005 in.)
Ring Gear Diameter 209.5 mm (8.25 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Pinion Bearing Preload - Original Bearings 1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 1-3.4 N·m (10-30 in. lbs.)

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Differential Cover Bolts 41 30 -
Bearing Cap Bolts 136 100 -
Ring Gear Bolts 95 70 -
Pinion Nut Minimum 285 210 -
Pinion Mate Shaft Screw 16.25 12 -
Axle Damper 61 45 -
KJ REAR AXLE - 8 1/4 3 - 61
REAR AXLE - 8 1/4 (Continued)

SPECIAL TOOLS

PULLER/PRESS C-293-PA
INSTALLER C-4076-B

ADAPTERS C-293-47
ADJUSTMENT WRENCH C-4164

ADAPTERS C-293-48

HANDLE C-4171

INSTALLER C-3718

INSTALLER C-4198
DIAL INDICATOR C-3339
3 - 62 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)

REMOVER C-4307 HANDLE C-4735

INSTALLER C-4308 INSTALLER D-130

INSTALLER C-4340 ADAPTER PLUG SP-3289

REMOVER 6310
REMOVER C-4345

PULLER C-452 INSTALLER 6448

KJ REAR AXLE - 8 1/4 3 - 63
REAR AXLE - 8 1/4 (Continued)

HOLDER 6719A
TRAC-LOK DISCS 8140

PINION GAUGE SET 6774

PINION BLOCK 8540

TRAC-LOK TOOLS 6960

ARBOR DISCS 8541

FIXTURE 8138
3 - 64 REAR AXLE - 8 1/4 KJ

DIFFERENTIAL COVER
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove drain plug.
(3) Remove cover bolts.
(4) Remove cover and drain lubricant.

INSTALLATION
(1) Apply a 6.35mm (1/4 in.) bead of Mopar Sili-
cone Rubber Sealant or equivalent to the housing
cover (Fig. 21).

Fig. 22 LOCK SCREW

1 - PINION MATE SHAFT
2 - BEARING CAP BOLT
3 - ADJUSTER LOCK BOLT
4 - LOCK SCREW

(4) Push axle shaft inward and remove axle shaft

C-lock from the axle shaft (Fig. 23).

Fig. 21 COVER SEALANT

1 - SEALANT
2 - DIFFERENTIAL COVER

CAUTION: If housing cover is not installed within 3

to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.

(2) Install cover and identification tag. Tighten

cover bolts in a criss-cross pattern to 41 N·m (30 ft.
lbs.).
(3) Fill differential to specifications.
(4) Install fill plug.
Fig. 23 AXLE SHAFT C-LOCK
1 - C-LOCK
2 - AXLE SHAFT
AXLE SHAFTS 3 - SIDE GEAR

REMOVAL (5) Remove axle shaft.

(1) With vehicle in neutral, position vehicle on
hoist. INSTALLATION
(2) Remove differential housing cover and drain (1) Lubricate bearing bore and seal lip with gear
lubricant. lubricant.
(3) Rotate differential case so pinion mate shaft (2) Install axle shaft through seal, bearing and
lock screw is accessible. Remove lock screw and pin- engage into side gear splines.
ion mate shaft from differential case (Fig. 22). (3) Install C-lock in axle shaft end, then push axle
shaft outward to seat C-lock in side gear.
KJ REAR AXLE - 8 1/4 3 - 65
AXLE SHAFTS (Continued)
(4) Install pinion shaft into differential case and
through thrust washers and differential pinions.
(5) Align hole in shaft with hole in the differential
case and install lock screw (Fig. 24) with Loctitet on
the threads. Tighten lock screw to 11 N·m (8 ft. lbs.).

Fig. 25 AXLE SHAFT SEAL

1 - SEAL
2 - AXLE TUBE

Fig. 24 LOCK SCREW

1 - PINION MATE SHAFT
2 - BEARING CAP BOLT
3 - ADJUSTER LOCK BOLT
4 - LOCK SCREW

(6) Install differential cover.

(7) Install rear brake componants.

AXLE SHAFT SEALS

REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal (Fig. 25) from the end
of the axle tube with a pry bar.

INSTALLATION
(1) Remove any old sealer/burrs from axle tube. Fig. 26 SEAL INSTALLER
(2) Coat new seal lip with axle lubricant and 1 - INSTALLER
install seal with Installer C-4198 and Handle C-4171 2 - HANDLE
(Fig. 26).
(3) Install axle shaft.
3 - 66 REAR AXLE - 8 1/4 KJ

AXLE BEARINGS (5) Tighten remove nut to pull bearing into the
receiver (Fig. 29).
REMOVAL
NOTE: Remove bearing with Bearing Remover 6310
and Foot 6310-9.

(1) Remove axle shaft.

(2) Remove axle seal with pry bar.
(3) Position bearing receiver on axle tube (Fig. 27).

Fig. 29 BEARING REMOVER ASSEMBLY

1 - NUT
2 - BEARING
3 - RECEIVER
4 - SHAFT

INSTALLATION
(1) Remove any old sealer/burrs from axle tube.
(2) Install axle shaft bearing with Installer C-4198
Fig. 27 BEARING RECEIVER and Handle C-4171 (Fig. 30). Drive bearing in until
1 - RECEIVER tool contacts the axle tube.
2 - AXLE BEARING
NOTE: Bearing is installed with the bearing part
(4) Insert bearing remover foot through receiver number against the installer.
and bearing (Fig. 28).

Fig. 28 BEARING REMOVER FOOT

Fig. 30 BEARING INSTALLER
1 - BEARING
2 - RECEIVER 1 - INSTALLER
3 - FOOT 2 - HANDLE
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