Assemble a Grand Cherokee Open Front Axle
This article introduces the procedure to assemble a Jeep Grand Cherokee's open front axle. The guidelines are done to manufacturer specs insuring the optimum fit and finish.
Steps
- Grind down the outer diameter of one pinion head bearing cup. This is to allow a slip fit into the housing. This is necessary because the pinion depth shim may need changing.
- Grind down the inner diameter of one pinion tail bearing cone to allow a slip fit over the pinion. This is necessary because the pinion may have to be removed to allow the pinion depth shim to be changed.
- Do not install the following parts when the pinion is installed into the housing for the first time:
- Support ring - collapsible spacer
- Collapsible spacer
- Pinion seal
- Once the end play, gear lash and pattern are within the limits of the standard pinion head bearing cup, pinion tail bearing cone, support ring - collapsible spacer, collapsible spacer and the pinion seal can be installed.
- Install the pinion tail bearing cup into the housing with taper facing out. Ensure that the correct installation tool is used.
- Install the nominal thickness shim(dnom) first. Press in pinion head bearing cup with taper facing out. Ensure that the correct installation tool is used.
- Heat the pinion head cone to 100 degrees Celsius/212 degrees Fahrenheit.
- Install the heated cone onto the pinion head.
- Install the assembled pinion into housing.
- Assemble all the other parts in this order:
- support ring/collapsible spacer(taper facing inward)
- pinion tail bearing cone
- pinion seal
- companion flange
- pinion nut
- Tighten the pinion nut. Rotate the pinion five times. Measure the torque moment.
- Repeat this process until 3.5+/- 0.2 nm is achieved. If exceeded, a new collapsible spaces must be installed.
- Insert the pinion height measurement tool into the housing. Measure from the tool to the pinion head to determine pinion height.
- The correct pinion shim thickness is determined as follows:
- dshim=measurement-66mm+dnom-tool's deviation
- Install thrust washers onto side gears.
- Insert side gear into differential case.
- Place the spherical thrust washers onto the differential pinion gear.
- Insert the differential pinion gears in the differential case.
- Install the differential's pinion shaft.
- Install the roll pin into the case.
- Complete the assembly of the differential assembly case.
- Ring gear and bearing cones must be heated to 100 degrees Celsius/212 degrees Fahrenheit.
- Install heated ring gear to case and torque belts when gear has cooled.
- Install the heated differential bearing cones.
- Install the differential assembly case into the housing.
- Install the right and left side bearing cups.
- Install the master retaining ring shims, tube side first.
- Install the measurement tools of the axle.
- Measure the end play clearance to determine correct bearing preload.
- Retaining ring shim thickness must be adjusted. Change shims as needed to +0.11mm for correct preload.
- Measure the ring gear backlash(0.1mm-0.15mm).
- The total retaining ring shim thickness must remain the same.
- Check the tooth pattern. Rotate the pinion five times in both directions with load.
- If the pattern is not okay, adjust the shim thickness for case and pinion.
