Jeep XJ. Manual — part 661
(14) Remove rear pinion bearing with Puller/Press
C-293-PA and Adapters C-293-39 (Fig. 18).
Place 4 adapter blocks so they do not damage
the bearing cage.
(15) Remove pinion depth shim/oil slinger from the
pinion shaft and record thickness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer toAdjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Apply Mopar
t Door Ease or equivalent lubri-
cant to outside surface of rear pinion bearing cup.
Install bearing cup with Installer D-146 and Driver
Handle C-4171 (Fig. 19) and verify cup is seated.
(2) Apply Mopar
t Door Ease or equivalent lubri-
cant to outside surface of front pinion bearing cup.
Install bearing cup with Installer D-130 and Handle
C-4171 (Fig. 20) and verify cup is seated.
Fig. 17 Collapsible Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 18 Rear Pinion Bearing
1 - PULLER - C-293-PA
2 - VISE
3 - ADAPTERS - C-293-39
4 - PINION GEAR SHAFT
Fig. 19 Rear Pinion Bearing Cup
1 - INSTALLER - D-146
2 - HANDLE - C-4171
3s - 10
FRONT AXLE - 181FBI - 186FBI
XJ
PINION GEAR/RING GEAR (Continued)
2001 JEEP CHEROKEE
(3) Install front pinion bearing, and oil slinger, if
equipped.
(4) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with Installer
C-3972-A and Handle C-4171 (Fig. 21).
(5) Install rear pinion depth shim/oil slinger and
bearing on the pinion shaft with Installer W-262 and
a press (Fig. 22).
(6) Install new collapsible spacer on pinion shaft
and install pinion into the housing (Fig. 23).
(7) Install yoke with Installer W-162-B, Cup 8109
and Spanner Wrench 6958 (Fig. 24).
(8) Install pinion washer and a new nut onto the
pinion. Tighten the nut to 216 N·m (160 ft. lbs.).
CAUTION: Never loosen the pinion nut to decrease
pinion bearing rotating torque and never exceed
specified
preload
torque.
If
preload
torque
is
exceeded
a
new
collapsible
spacer
must
be
installed.
Fig. 20 Front Pinion Bearing Cup
1 - INSTALLER - D-130
2 - HANDLE - C-4171
Fig. 21 Pinion Seal
1 - HANDLE - C-4171
2 - INSTALLER - C-3972-A
Fig. 22 Rear Pinion Bearing
1 - PRESS
2 - INSTALLATION TOOL - W-262
3 - PINION DEPTH SHIM/OIL BAFFLE
4 - DRIVE PINION
5 - REAR PINION BEARING
XJ
FRONT AXLE - 181FBI - 186FBI
3s - 11
PINION GEAR/RING GEAR (Continued)
2001 JEEP CHEROKEE
(9) Using
Spanner
Wrench
6958
and
torque
wrench set at 352 N·m (260 ft. lbs.) (Fig. 25). Slowly
tighten the nut in 6.8 N·m (5 ft. lb.) increments until
the rotating torque is achieved. Measure rotating
torque frequently to avoid over crushing the collaps-
ible spacer (Fig. 26).
CAUTION: If more than 352 N·m (260 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced.
(10) Check bearing rotating torque with an inch
pound torque wrench (Fig. 26). The torque necessary
to rotate the pinion should be:
• Original Bearings: 1 to 2 N·m (10 to 20 in. lbs.).
• New Bearings: 1.7 to 3.4 N·m (15 to 30 in. lbs.).
(11) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(12) Invert the differential case in the vise and
install new ring gear bolts and alternately tighten to
108 N·m (80 ft. lbs.) (Fig. 27).
CAUTION: Do not reuse ring gear bolts, the bolts
can fracture causing extensive damage.
Fig. 23 Collapsible Preload Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 24 Pinion Yoke
1 - PINION YOKE
2 - DIFFERENTIAL HOUSING
Fig. 25 Tightening Pinion Nut - Typical
1 - PINION FLANGE
2 - DIFFERENTIAL HOUSING
3 - SPANNER WRENCH - 6958
3s - 12
FRONT AXLE - 181FBI - 186FBI
XJ
PINION GEAR/RING GEAR (Continued)
2001 JEEP CHEROKEE
(13) Install differential in the housing and verify
differential bearing preload, gear mesh and contact
pattern.
(14) Install differential cover and fill with gear
lubricate.
(15) Install propeller shaft with reference marks
aligned.
(16) Remove supports and lower vehicle.
Fig. 26 Check Pinion Rotation Torque
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 27 Ring Gear Bolt
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
XJ
FRONT AXLE - 181FBI - 186FBI
3s - 13
PINION GEAR/RING GEAR (Continued)
2001 JEEP CHEROKEE
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