Jeep 1996 Grand Cherokee Service Manual page 141

3 - 96 DIFFERENTIAL AND DRIVELINE
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install lubricated Step Plate C–4487–1 on first
clutch pack (Fig. 53).
Fig. 53 Upper Side Gear & Clutch Disc Pack
Installation
(6) Install the upper side gear and clutch disc pack
(Fig. 53).
(7) Hold assembly in position. Insert Threaded
Adapter C–4487–3 into top side gear, insert forcing
Screw C–4487–2.
(8) Tighten forcing screw tool to slightly compress
clutch discs.
(9) Place pinion gears in position in side gears and
verify that mate shaft hole line up.
(10) Rotate case with Turning Bar C–4487–4 until
mate shaft holes in pinion gears align with holes in
case.
(11) Tighten forcing screw to 122 N·m (90 ft. lbs.)
to compress the Belleville springs. Lubricate and
install thrust washers behind pinion gears and align
washers with a small screw driver. Insert mate shaft
into each pinion gear to verify alignment.
(12) Remove forcing screw, threaded adapter and
step plate. Install pinion gear mate shaft, align holes
in shaft and case.
(13) Install the pinion mate shaft lock screw finger
tight to hold shaft during installation.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
(14) Lubricate all differential components with
hypoid gear lubricant.
CLEANING AND INSPECTION
AXLE COMPONENTS
Wash differential components with cleaning solvent
and dry with compressed air. Do not steam clean
the differential components.
Wash bearings with solvent and towel dry, or dry
with compressed air. DO NOT spin bearings with
compressed air. Cup
replaced as matched sets only.
Clean axle shaft tubes and oil channels in housing.
Inspect for;
• Smooth appearance with no broken/dented sur-
faces on the bearing rollers or the roller contact sur-
faces
• Bearing cups must not be distorted or cracked
• Machined surfaces should be smooth and with-
out any raised edges
• Raised metal on shoulders of cup bores should
be removed with a hand stone
• Wear and damage to pinion gear mate shaft,
pinion gears, side gears and thrust washers. Replace
as a matched set only.
• Ring and pinion gear for worn and chipped teeth
• Ring gear for damaged bolt threads. Replaced as
a matched set only.
• Pinion yoke for cracks, worn splines, pitted
areas, and a rough/corroded seal contact surface.
Repair or replace as necessary.
• Preload shims for damage and distortion. Install
new shims if necessary.
TRAC-LOK
(1) Clean all components in cleaning solvent. Dry
components with compressed air.
(2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo-
nent in either pack is damaged.
(3) Inspect side and pinion gears. Replace any gear
that is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft.
Replace if worn or damaged.
PRESOAK PLATES AND DISC
Plates and discs with fiber coating (no grooves or
lines) must be presoaked in Friction Modifier before
assembly. Soak plates and discs for a minimum of 20
minutes. Add remaining Friction Modifier to differen-
tial after assembly.
and bearing must
ZJ
be