Jeep Cherokee 2000 Service Manual - page 161
slightly tighten the forcing screw in order to install
the pinions.
(12) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinions and align washers with a small screw driver.
Insert mate shaft into each pinion to verify align-
ment.
(14) Remove Forcing Screw 6960-4, Step Plate
8140–2, and Threaded Adapter 8140-1.
(15) Install pinion mate shaft and align holes in
shaft and case.
(16) Install the pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.
CLEANING AND INSPECTION
8 1/4 AXLE
Wash differential components with cleaning solvent
and dry with dry 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
and
bearing
must
be
replaced as matched sets only.
Be sure that the axle tubes and oil channels are
thoroughly cleaned in the 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 mate shaft, pinions,
side gears and thrust washers. Replace as a matched
set only.
• Ring gear and pinion 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.
• Pinion depth shims for damage and distortion.
Install new shims if necessary.
• The differential case. Replace the case if cracked
or damaged.
• The axle shaft C-locks for cracks and excessive
wear. Replace them if necessary.
• Each threaded adjuster to determine if it rotates
freely. If an adjuster binds, repair the damaged
threads or replace the adjuster.
Polish each axle shaft sealing surface with No. 600
crocus cloth. This can remove slight surface damage.
Do not reduce the diameter of the axle shaft seal con-
tact surface. When polishing, the crocus cloth should
be moved around the circumference of the shaft (not
in-line with the shaft).
TRAC-LOK
Y
Clean all components in cleaning solvent. Dry com-
ponents with compressed air. Inspect clutch pack
plates for wear, scoring or damage. Replace both
clutch packs if any one component in either pack is
damaged. Inspect side gears and pinions. Replace
any gear that is worn, cracked, chipped or damaged.
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.
Fig. 50 Upper Side Gear & Clutch Disc Pack
Installation
1 – UPPER SIDE GEAR AND CLUTCH DISC PACK
2 – DIFFERENTIAL CASE
3 – SPECIAL TOOL 8140–2
XJ
8 1/4 REAR AXLE
3 - 125
DISASSEMBLY AND ASSEMBLY (Continued)