Cleaning And Inspection - Jeep Cherokee 1988 Quick Start Manual

perform overhaul.
1) Raise and support rear of vehicle. Remove rear cover and
drain lubricant. Remove wheels, brake drums, hubs and axle shafts.
2) Mark differential bearing caps for reassembly reference
and loosen them until a few threads remain engaged. Pry differential
loose and remove bearing caps and differential from housing.
3) Mark bearing caps, races and shims for reassembly
reference. Remove differential side bearings with a puller. Remove
differential and ring gear from case. Remove pinion shaft lock pin.
4) Using 2 feeler gauges, measure differential side gear
clearance. Insert an equal distance feeler gauge between each side
gear and case. Continue checking clearance until each feeler gauge is
a tight drag fit. Ensure side clearance does not exceed .007" (.18 mm)
on either side. If side gear clearance exceeds specification, replace
side gear thrust washers.
5) Remove pinion yoke and nut. Retain pinion nut for pinion
depth adjustment during reassembly. Tap pinion gear end with a soft
faced mallet to release it from front bearing. Remove pinion gear,
pinion bearings and preload collapsible spacer. Discard collapsible
spacer.
6) Remove pinion seal and pinion rear bearing cup. Remove and
retain pinion depth shim located under rear bearing cup. Remove pinion
front bearing cup. Using a press, remove pinion gear rear bearing.
CLEANING & INSPECTION
Clean all components in solvent and dry with compressed air.
Inspect all components for excessive wear or damage and replace as
necessary.
REASSEMBLY
NOTE: Ensure correct shims have been chosen to obtain proper
ring gear backlash and bearing preload before reassembly.
See ADJUSTMENTS in this article.
Drive Pinion
1) Press rear bearing on pinion stem with large diameter of
roller cage toward gear. Clean housing bearing bores. Place shim in
rear bearing bore and install rear bearing cup.
NOTE: When installing a new gear set, use original depth shim as a
starting point. Chamfered side of shim must be installed to
bottom side of rear bearing cup bore.
2) Install front bearing cup into housing. Install drive
pinion through rear bearing cup. Install front bearing, yoke and
original pinion nut. Tighten nut to remove bearing end play only.
NOTE: A new nut and collapsible spacer are not installed at this
time, as pinion will be removed after a depth measurement.
Differential Case
1) Assemble side gears and thrust washers and install into
differential case. Ensure side gear thrust washers were replaced in
clearance measured at disassembly was greater than .007" (.18 mm).
2) Install differential pinions and thrust washers in case.
Ensure pinions are aligned with shaft bores. Recheck side gear
clearance. If clearance exceeds .007" (.18 mm), side gears must be
replaced.
3) Install differential pinion shaft and lockpin. Using
Remover (J-22912-01), remove differential bearings. Install correct