Jeep Grand Cherokee WK. Manual — part 76
2. Rotate remaining pinion gear (3) with thrust washer
(2) to the differential window (1). Remove gear and
washer.
3. Remove differential side gears (1) (2) and thrust
washers.
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REAR AXLE - C213R
WK
ASSEMBLY
NOTE: If same gears and thrust washers are being
used, install them into their original locations.
1. Lubricate all differential components with axle lubri-
cant.
2. Install
differential
side
gears
(2)
and
thrust
washers.
3. Install first pinion gear (3) with thrust washer into
differential window (1) and side gears (2). Rotate
pinion gear into the case.
4. Install remaining pinion gear and thrust washer.
Rotate gears to align hole in the pinion gears with
hole in the differential case.
5. Slide pinion shaft into the case and through the
pinion gears to align the gears.
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REAR AXLE - C213R
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INSTALLATION
1. Apply a coat of hypoid gear lubricant to differential
bearings, bearing cups and threaded adjusters.
NOTE: Grease can be used to keep the adjusters
in position.
2. Install differential assembly into the housing.
3. Install differential bearing caps in their original loca-
tions.
4. Install bearing cap bolts and tighten upper bolts to
14 N·m (10 ft. lbs.). Tighten lower bolts finger-tight
until the bolt head is seated.
5. Perform differential bearing preload and adjustment
procedure.
6. Tighten bearing cap bolts (2) to 135 N·m (100 ft.
lbs).
7. Install adjuster locks (3) on bearing caps and
tighten bolts to 11 N·m (8 ft. lbs.).
8. Install axle shafts.
9. Install differential cover.
DIFFERENTIAL-VARI-LOK
OPERATION
A gerotor pump and clutch pack are used to provide
the torque transfer capability. One axle shaft is splined
to the gerotor pump and one differential side gears,
this provides input to the pump. Anti-rotation tabs (1)
on the pump hold the oil feed tube (2) down in the dif-
ferential lubricant. As a wheel begins to lose traction,
the speed differential is transmitted from one side of
the differential to the other through the side gears. The
motion of one side gear relative to the other turns the
inner rotor of the pump. Since the outer rotor of the
pump is grounded to the differential case, the inner
and outer rotors are moving relative to each other,
which creates pressure in the pump. The tuning of the
front and rear axle orifices and valves inside the gero-
tor pump are unique. Each system has a torque-limit-
ing pressure relief valve to protect the clutch pack,
which also facilitates vehicle control under extreme
side-to-side traction variations. The resulting pressure
is applied to the clutch pack and the transfer of torque
is completed. Vari-lok
T
system is less subject to wear,
remaining more consistent over time in its ability to
transfer torque.
DIAGNOSIS AND TESTING-VARI-LOK
1. Park the vehicle on a level surface or raise vehicle on hoist so that the vehicle is level.
2. Remove the axle fill plug.
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REAR AXLE - C213R
WK
3. Verify that the axle fluid level is correct. The fluid level is correct if the fluid is level with the bottom of the fill hole.
4. Shift the transfer case into the 4WD full-time position.
5. Drive the vehicle in a tight circle for 2 minutes at 5mph to fully prime the pump.
6. Block the tires opposite the axle to be tested to prevent the vehicle from moving.
7. Shift the transfer case into the 4WD Low position and the transmission into the Park position.
8. Raise both the wheels of the axle to be tested off of the ground.
9. Rotate the left wheel by hand at a minimum of one revolution per second while an assistant rotates the right
wheel in the opposite direction.
10. The left wheel should spin freely at first and then increase in resistance within 5 revolutions until the wheels
cannot be continuously rotated in opposite directions.
11. The Vari-lok
T
differential has engaged properly if the wheels cannot be rotated in opposite directions for a
moment. After the wheels stop rotating for a moment, the fluid pressure will drop in the differential and the
wheels begin to rotate once again.
12. If the system does not operate properly, replace the Vari-lok
T
differential.
BEARINGS-VARI-LOK DIFFERENTIAL CASE
REMOVAL
1. Install Plug SP 3298 (3) Into the differential axle
shaft hole.
2. Remove differential case bearings with Puller 6444
(1), Puller Rods 6444-4 (2) and Puller Flange
6444-1(4). Position puller on the differential.
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REAR AXLE - C213R
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