Jeep Liberty KJ. Manual — part 291
9. Remove rear pinion bearing cup with Remover
C-4307 (1) and Handle C-4171 (2).
10. Remove collapsible spacer (1) from pinion gear
(3).
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11. Remove rear pinion bearing from the pinion (4)
with Puller/Press C-293-PA (1) and Adapters
C-293-42 (3). Remove oil slinger/pinion depth
shim from the pinion shaft and record thickness.
INSTALLATION
NOTE: Pinion depth shims are located under the
rear pinion bearing. If ring and pinion gears are
reused, the pinion oil slinger/depth shim should
not require replacement. Refer to Adjustments
(Pinion Gear Depth) to select the proper thickness
shim before installing pinion gear.
1. Install front pinion bearing, and oil slinger if
equipped.
2. Apply a light coating of gear lubricant on the lip of
pinion seal and install seal with Installer 8681.
3. Apply Mopar Door Ease or equivalent lubricant to
outside surface of pinion bearing cups.
4. Install rear bearing cup with Installer C-4308 and
Handle C-4171.
5. Install front bearing cup with Installer D-146 (1) and
Handle C-4171 (1).
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6. Install oil slinger/depth shim (2) and rear pinion
bearing (4) on pinion shaft (3) with Installer 6448A
(1) and a press (1).
7. Install a new collapsible spacer (1) on pinion shaft
(3) and install pinion into the housing.
8. Install
pinion
companion
flange,
with
Installer
W-162-D, Cup 8109 and Spanner Wrench 6958.
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9. Install pinion a new nut onto the pinion gear and
tighten the nut to 217 N·m (160 ft. lbs.). Do not
over-tighten.
CAUTION:
Never
loosen
pinion
gear
nut
to
decrease pinion rotating torque and never exceed
specified preload torque. Failure to follow these
instructions will result in damage.
10. Use Spanner Wrench 6958 (1), a length of 1 in.
pipe and a torque wrench set at 678 N·m (500 ft.
lbs.) and crush collapsible spacer until bearing
end play is taken up.
11. Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) incre-
ments
until
the
required
rotating
torque
is
achieved. Measure rotating torque frequently to
avoid over crushing the collapsible spacer.
12. Rotate the pinion a minimum of ten times. Verify
pinion (1) rotates smoothly and check rotating
torque with an inch pound torque wrench (2). Pin-
ion gear rotating torque is:
•
Original Bearings: 1 to 2.25 N·m (10 to 20 in.
lbs.).
•
New Bearings: 1.69 to 2.82 N·m (15 to 25 in.
lbs.).
13. Invert differential case and start two ring gear
bolts. This will provide case-to-ring gear bolt hole
alignment.
14. Invert differential case (4) in the vise. Install new
ring gear (3) bolts (2) and alternately tighten to
108 N·m (80 ft. lbs.).
CAUTION: Never reuse the ring gear bolts. Failure
to follow these instructions will result in damage.
15. Install differential in housing and verify differential
bearing preload, gear mesh and contact pattern.
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