Liberty, Wrangler, 1997-2005

Pinion Seal

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Removal & Installation



C-Clip Type
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake drums
     
    Driveshaft
     

  4.  
  5. Check the bearing preload with an inch lb. torque wrench.
  6.  
  7. Remove the pinion flange and seal.
  8.  

To install:


NOTE
Use a new pinion nut for assembly.

  1. Install the new pinion seal and flange. Tighten the nut to 200 ft. lbs. (271 Nm).
  2.  
  3. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch lbs.
  4.  
  5. If the preload torque is low, tighten the pinion nut in 5 inch lb. increments until the torque value is reached. Do not exceed 350 ft. lbs. (474 Nm) pinion nut torque.
  6.  
  7. If the pinion bearing preload torque cannot be attained at maximum pinion nut torque, replace the collapsible spacer.
  8.  
  9. Install or connect the following:

    Driveshaft
     
    Brake drums
     
    Wheels
     

  10.  
  11. Fill the axle assembly with gear oil and check for leaks.

    Click image to see an enlarged view

    Fig. Companion shaft puller--C-Clip Type Axle C-Clip Type Axle



    Click image to see an enlarged view

    Fig. Tightening the pinion nut-C-Clip Type Axle



    Click image to see an enlarged view

    Fig. Pinion seal installer-C-Clip Type Axle



    Click image to see an enlarged view

    Fig. Measuring pinion rotating torque-C-Clip Type Axle

  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. With vehicle in neutral, position vehicle on hoist.
  4.  
  5. Mark a reference line across the axle companion flange and propeller shaft flange yoke.
  6.  
  7. Remove companion flange bolts and remove propeller shaft
  8.  
  9. Remove wheel and tire assemblies.
  10.  
  11. Remove brake calipers and rotors to prevent any drag.
  12.  
  13. Rotate companion flange three or four times and verify flange rotates smoothly.
  14.  
  15. Measure rotating torque of the pinion with a inch pound torque wrench and record reading for installation reference.
  16.  
  17. Install bolts into two of the threaded holes in the companion flange 180° apart.
  18.  
  19. Position Holder 6719, or equivalent, against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
  20.  
  21. Remove the pinion nut and washer.
  22.  
  23. Remove companion flange with Remover C-452, or equivalent.
  24.  
  25. Remove pinion seal with a seal pick.
  26.  

To install

  1. Apply a light coating of gear lubricant on the lip of pinion seal.
  2.  
  3. Install new pinion seal with Installer C-4076-B and Handle C-4735, or equivalent.
  4.  
  5. Install companion flange on the end of the shaft with the reference marks aligned.
  6.  
  7. Install bolts into two of the threaded holes in the companion flange 180° apart.
  8.  
  9. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so Holder 6719 is held to the flange.
  10.  
  11. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719.
  12.  
  13. Install the pinion washer and a new pinion nut. The convex side of the washer must face outward.
    NOTE
    Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Failure to heed caution may result in damage.

  14.  
  15. Hold companion flange with Holder 6719 and with a torque wrench tighten pinion nut to 210 ft. lbs. (285 Nm). Rotate pinion several revolutions to ensure the bearing rollers are seated.
  16.  
  17. Rotate pinion with an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 5 inch lbs. (0.56 Nm).
    WARNING
    Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.

  18.  
  19. If rotating torque is low use Holder 6719 to hold the companion flange and tighten pinion nut in 60 inch lbs. (6.8 Nm) increments until proper rotating torque is achieved.
    NOTE
    The seal replacement is unacceptable if final pinion nut torque is less than 210 ft. lbs. (285 Nm). The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition.

  20.  
  21. Install propeller shaft with installation reference marks aligned.
  22.  
  23. Tighten companion flange bolts to 85 ft. lbs. (115 Nm).
  24.  
  25. Install rear brake components.
  26.  

Non C-Clip Type
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake rotors or drums
     
    Driveshaft
     

  4.  
  5. Check the bearing preload with an inch lb. torque wrench.
  6.  
  7. Remove the pinion flange and seal.
  8.  

To install:


NOTE
Use a new pinion nut for assembly.

  1. Install the new pinion seal and flange. Tighten the nut to 160 ft. lbs. (217 Nm).
  2.  
  3. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch lbs.
  4.  
  5. If the preload torque is low, tighten the pinion nut in 5 inch lb. increments until the torque value is reached. Do not exceed 260 ft. lbs. (353 Nm) pinion nut torque.
  6.  
  7. If the pinion bearing preload torque can not be attained at maximum pinion nut torque, remove one or more pinion preload shims.
  8.  
  9. Install or connect the following:

    Driveshaft
     
    Brake rotors or drums
     
    Wheels
     

  10.  
  11. Fill the axle assembly with gear oil and check for leaks.
  12.  

 
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