Jeep Liberty KJ. Manual — part 296
PINION GAUGE SET 6774
PINION BLOCK 8540
ARBOR DISCS 8541
3 - 88
REAR AXLE - 8 1/4
KJ
COVER-DIFFERENTIAL
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 bead of orange Mopar™ Axle RTV sealant
(1) or equivalent to the housing cover (2).
CAUTION: If cover is not installed within 3 to 5
minutes, the cover must be cleaned and new RTV
applied. Failure to follow these instructions will
cause a leak.
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.
KJ
REAR AXLE - 8 1/4
3 - 89
SHAFT-AXLE
REMOVAL
1. With vehicle in neutral, position vehicle on hoist.
2. Remove rear brake components.
3. Remove wheel speed sensor.
4. Remove differential housing cover and drain lubri-
cant.
5. Rotate differential case so pinion mate shaft (1)
lock screw (4) is accessible. Remove lock screw
and pinion mate shaft from differential case.
6. Push axle shaft inward and remove axle shaft
C-lock (1) from the axle shaft (2).
7. Remove axle shaft from side gear (3) and axle
tube.
INSTALLATION
1. Lubricate bearing bore and seal lip with gear lubri-
cant.
2. Install axle shaft (2) through seal, bearing and
engage into side gear (3) splines.
3. Install C-lock (1) in axle shaft end, then push axle
shaft outward to seat C-lock in side gear.
3 - 90
REAR AXLE - 8 1/4
KJ
4. Install pinion mate shaft (1) 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 (4) with Loctite
T
on the
threads. Tighten lock screw to 11 N·m (8 ft. lbs.).
6. Install differential cover.
7. Install wheel speed sensor.
8. Install rear brake components.
KJ
REAR AXLE - 8 1/4
3 - 91
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