2001 Jeep Grand Cherokee Service Repair Manual

(8) Slide the dial indicator probe across the gap between the pinion height block and the arbor bar with the scooter block againstthe pinionheight block (Fig.6). When the dial probe contacts the arbor bar , the dial pointer will turn clockwise. Continue moving the dial probe to the crest of the arbor bar and record the highest reading. If the dial indicator can not achieve the zero reading, the rear bearing cup or the pinion depth gauge set is not installed correctly . (9) Select a shim equal to the dialindicatorread- ing plus the drive pinion gear depth variance number etched in the face of the pinion (Fig.1). For example, if the depth variance is –2, add +0.002 in. to the dial indicatorreading. BEARING PRELOAD AND GEAR BACKLASH The following must be considered when adjusting bearing preload and gear backlash: • The maximum ring gear backlash variation is 0.003 inch (0.076 mm). • Mark the gears so the same teeth are meshed during all backlash measurements. • Maintain the torque while adjusting the bearing preload and ringgear backlash. • Excessive adjuster torque will introduce a high bearing load and cause premature bearing failure. Insufficient adjuster torque can result in excessive differential case free-play and ringgear noise. • Insufficient adjuster torque will not supportthe ringgear correctly and can causeexcessive differential case free-play and ringgear noise. NOTE: The differential bearing cups will not always immediately follow the threaded adjusters as they are moved during adjustment. To ensure accurate bearing cup responses to the adjustments: • Maintain the gear teeth engaged (meshed) as marked. • The bearings must be seated by rapidly rotating the pinion gear a half turn back and forth. • Do this five to ten times each time the threaded adjusters are adjusted. (1) Use Wrench C-4164 to adjust each threaded adjuster inward until the differential bearing free- play is eliminated (Fig. 7). Allow some ring gear backlash (approximately 0.01 inch/0.25 mm) between the ring andpinion gear . Seatthe bearing cups with the procedure described above. Fig. 4 Pinion Height Block 1 - PINION BLOCK 2 - PINION HEIGHT BLOCK Fig. 5 Gauge Tools In Housing 1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK Fig. 6 Pinion Gear Depth Measurement 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR XJ REAR AXLE - 81/4 3s - 25 REAR AXLE - 81/4 (Continued)

(2) Install dial indicator andposition the plunger againstthe drive side of a ring gear tooth (Fig. 8). Measure the backlash at 4 positions (90 degrees apart) around the ring gear . Locate and mark the area of minimum backlash. (3) Rotate the ringgear to the position of the least backlash. Mark the gear so that all future backlash measurements will be taken with the same gear teeth meshed. (4) Loosen the right-side, tighten the left-side threaded adjuster . Obtain backlash of 0.003 to 0.004 inch (0.076 to 0.102 mm) with each adjuster tight- ened to 14 N·m (10 ft. lbs.). Seatthe bearing cups with the procedure described above. (5) Tighten the differential bearing cap bolts 95 N·m (70 ft. lbs.). (6) Tighten the right-side threaded adjuster to 102 N·m (75 ft. lbs.). Seatthe bearing cups with the procedure described above. Continue to tighten the right-side adjuster and seat bearing cups until the torque remains constant at 102 N·m (75 ft. lbs.) (7) Measure the ring gear backlash. The range of backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm). (8) Continue increasing the torque at the right- side threaded adjuster until the specified backlash is obtained. NOTE: The left-side threaded adjuster torque should have approximately 102 N·m (75 ft. lbs.). If the torque is considerably less, the complete adjustment procedure must be repeated. (9) Tighten the left-side threaded adjuster until 102 N·m (75 ft. lbs.) torque is indicated. Seatthe bearing rollers with the procedure described above. Do this until the torque remains constant. (10) Install the threaded adjuster locks and tighten the lock screws to 10 N·m (90 in. lbs.). After the proper backlash is achieved, perform the Gear Contact Pattern procedure. GEAR CONTACT PATTERN The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing. It will also show if the ring gear backlashhas been adjusted correctly . The backlash can be adjusted within specifications to achieve desired tooth contact patterns. (1)Apply a thin coat of hydrated ferricoxide or equivalent, to the drive and coast side of the ring gear teeth. (2) Wrap, twist and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion. This will provide a more distinct contact pattern. (3) With a boxed end wrench on a ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel. The areas on the ringgear teeth with the greatest degree of contact againstthe pinion teeth will squee- gee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear T ooth Contact Patterns chart (Fig. 9)and adjust pinion depth and gear backlash as nec- essary . Fig. 7 Threaded Adjuster 1 - AXLE TUBE 2 - BACKING PLATE 3 - ADJUSTER WRENCH Fig. 8 Ring Gear Backlash 1 - DIAL INDICATOR 2 - RING GEAR 3 - EXCITER RING 3s - 26 REAR AXLE - 81/4 XJ REAR AXLE - 81/4 (Continued)

8Wa-10 POWER DISTRIBUTION Component Page A/CCompressor Clutch ................. 8Wa-10-23, 33 A/CCompressor Clutch Relay ........... 8Wa-10-20, 23, 33 Automatic Shut Down Relay ........... 8Wa-10-20, 24, 35 Battery ........................... 8Wa-10-12, 14 Blower Motor ......................... 8Wa-10-22 Blower Motor Relay ................. 8Wa-10-12, 22, 27 Brake Lamp Switch ................... 8Wa-10-33, 34 Brake Warning Pressure Switch ........... 8Wa-10-16, 17 Cargo Lamp/Switch ................... 8Wa-10-28, 31 Center High Mounted Stop Lamp ........... 8Wa-10-33, 34 Cigar Lighter ....................... 8Wa-10-21, 27 Cigar Lighter Relay ............... 8Wa-10-16, 17, 21, 27 Circuit Breaker 28 (JB) ................. 8Wa-10-16, 17 Circuit Breaker 29 (JB) ................. 8Wa-10-21, 27 Circuit Breaker 30 (JB) ................. 8Wa-10-16, 17 Coil Capacitor ......................... 8Wa-10-24 Coil Rail ............................ 8Wa-10-24 Combination Flasher .................. 8Wa-10-32, 36 Controller Antilock Brake ........... 8Wa-10-26, 27, 33, 34 Data Link Connector .................. 8Wa-10-29, 30 Daytime Running Lamp Module .............. 8Wa-10-23 Dome Lamp ................... 8Wa-10-28, 29, 30, 31 Dome Lamps Switch ................ 8Wa-10-29, 30, 31 Driver Door Ajar Switch ................... 8Wa-10-18 EGR Solenoid ......................... 8Wa-10-35 Engine Control Module ................. 8Wa-10-20, 33 Engine Starter Motor ............. 8Wa-10-12, 14, 25, 26 Engine Starter Motor Relay .............. 8Wa-10-25, 26 Fog Lamp Relay ........................ 8Wa-10-36 Fog Lamp Relay No.2 .................... 8Wa-10-34 Fuel Heater .......................... 8Wa-10-25 Fuel Heater Relay ...................... 8Wa-10-25 Fuel Injection Pump ................... 8Wa-10-20, 35 Fuel Injector No.1 ...................... 8Wa-10-24 Fuel Injector No.2 ...................... 8Wa-10-24 Fuel Injector No.3 ...................... 8Wa-10-24 Fuel Injector No.4 ...................... 8Wa-10-24 Fuel Injector No.5 ...................... 8Wa-10-24 Fuel Injector No.6 ...................... 8Wa-10-24 Fuel Pump Module ...................... 8Wa-10-32 Fuel Pump Relay ....................... 8Wa-10-32 Fuse 1 (JB) ........................ 8Wa-10-21, 27 Fuse 2 (JB) ........................ 8Wa-10-21, 27 Fuse 2 (PDC)(Diesel) .................. 8Wa-10-14, 20 Fuse 2 (PDC)(Gas) .................... 8Wa-10-12, 16 Fuse 3 (PDC)(Diesel) .................. 8Wa-10-14, 20 Fuse 3 (PDC)(Gas) .................... 8Wa-10-12, 16 Fuse 4 (PDC)(Diesel) .................. 8Wa-10-14, 20 Fuse 4 (PDC)(Gas) .................... 8Wa-10-12, 21 Fuse 5 (PDC)(Diesel) .................. 8Wa-10-14, 17 Fuse 5 (PDC)(Gas) .................... 8Wa-10-12, 22 Fuse 6 (PDC)(Diesel) .................. 8Wa-10-14, 25 Fuse 6 (PDC)(Gas) .................... 8Wa-10-12, 22 Fuse 7 (PDC) ................... 8Wa-10-12, 14, 23, 25 Fuse 8 (JB) ........................... 8Wa-10-18 Fuse 8 (PDC)(Diesel) .................. 8Wa-10-14, 25 Fuse 8 (PDC)(Gas) .................... 8Wa-10-12, 24 Fuse 9 (JB) ........................... 8Wa-10-18 Fuse 9 (PDC)(Diesel) .................. 8Wa-10-14, 27 Fuse 9 (PDC)(Gas) .................... 8Wa-10-12, 23 Fuse 10 (JB) .......................... 8Wa-10-18 Fuse 10 (PDC)(Diesel) .................. 8Wa-10-14, 17 Fuse 10 (PDC)(Gas) ................... 8Wa-10-12, 26 Fuse 11 (JB) .......................... 8Wa-10-18 Fuse 11 (PDC)(Diesel) .................. 8Wa-10-14, 27 Fuse 11 (PDC)(Gas) ................. 8Wa-10-12, 13, 26 Fuse 12 (JB) .......................... 8Wa-10-19 Fuse 12 (PDC)(Diesel) ............... 8Wa-10-14, 15, 27 Fuse 12 (PDC)(Gas) ................. 8Wa-10-12, 13, 26 Fuse 13 (JB) ........................ 8Wa-10-25, 26 Fuse 13 (PDC)(Diesel) ............... 8Wa-10-14, 15, 27 Fuse 13 (PDC)(Gas) ................... 8Wa-10-13, 26 Fuse 14 (JB) ........................ 8Wa-10-25, 26 Fuse 14 (PDC) ...................... 8Wa-10-15, 27 Component Page Fuse 15 (JB) ........................ 8Wa-10-21, 27 Fuse 15 (PDC) ...................... 8Wa-10-15, 25 Fuse 16 (PDC) .................. 8Wa-10-13, 15, 28, 31 Fuse 17 (JB) ........................ 8Wa-10-16, 17 Fuse 17 (PDC) ...................... 8Wa-10-13, 28 Fuse 18 (JB) ........................ 8Wa-10-16, 17 Fuse 18 (PDC) ......................... 8Wa-10-24 Fuse 19 (JB) .......................... 8Wa-10-19 Fuse 19 (PDC)(Diesel) .................. 8Wa-10-15, 33 Fuse 19 (PDC)(Gas) ................. 8Wa-10-13, 29, 30 Fuse 20 (JB) ........................ 8Wa-10-21, 27 Fuse 20 (PDC)(Diesel) .................. 8Wa-10-15, 33 Fuse 20 (PDC)(Gas) ................... 8Wa-10-13, 32 Fuse 21 (JB) ........................ 8Wa-10-21, 27 Fuse 21 (PDC)(Diesel) .................. 8Wa-10-20, 35 Fuse 21 (PDC)(Gas) ..................... 8Wa-10-24 Fuse 22 (JB) .......................... 8Wa-10-19 Fuse 22 (PDC)(Diesel) .................. 8Wa-10-15, 35 Fuse 22 (PDC)(Gas) ................... 8Wa-10-13, 32 Fuse 23 (PDC)(Diesel) .................. 8Wa-10-15, 36 Fuse 23 (PDC)(Gas) ................... 8Wa-10-13, 34 Fuse 24 (JB) .......................... 8Wa-10-19 Fuse 24 (PDC)(Diesel) .................... 8Wa-10-20 Fuse 25 (JB) .......................... 8Wa-10-19 Fuse 25 (PDC)(Diesel) .................. 8Wa-10-15, 36 Fuse 25 (PDC)(Gas) ................... 8Wa-10-13, 34 Fuse 26 (JB) .......................... 8Wa-10-19 Fuse 26 (PDC)(Diesel) .................. 8Wa-10-15, 30 Fuse 26 (PDC)(Gas) ................... 8Wa-10-13, 34 Fuse 27 (JB) .......................... 8Wa-10-18 Fuse 27 (PDC) ...................... 8Wa-10-23, 33 G108 ............................ 8Wa-10-16, 17 Generator ......................... 8Wa-10-12, 14 Glow Plug Assembly ..................... 8Wa-10-20 Glow Plug Relay ..................... 8Wa-10-20, 35 Headlamp Delay Module ................ 8Wa-10-23, 25 Headlamp Switch ......... 8Wa-10-16, 17, 18, 23, 25, 29, 30 High Note Horn ..................... 8Wa-10-21, 27 Horn Relay ........................ 8Wa-10-21, 27 Ignition Switch ................. 8Wa-10-16, 17, 18, 19 Instrument Cluster ................. 8Wa-10-18, 28, 31 Junction Block ................. 8Wa-10-16, 17, 18, 19, 21, 25, 26, 27, 28, 29, 30, 31 Left Courtesy Lamp ................... 8Wa-10-28, 31 Left Fog Lamp ...................... 8Wa-10-34, 36 Left Tail/Stop Lamp ................... 8Wa-10-33, 34 Left Visor/V anity Lamp ............... 8Wa-10-29, 30, 31 Low Note Horn ...................... 8Wa-10-21, 27 Overhead Console .................. 8Wa-10-29, 30, 31 Oxygen Sensor Downstream Relay ............ 8Wa-10-28 Oxygen Sensor Upstream Relay .............. 8Wa-10-28 Park Brake Switch .................... 8Wa-10-16, 17 Passenger Door Module ................... 8Wa-10-18 Power Amplifier ..................... 8Wa-10-34, 35 Power Antenna Relay .................... 8Wa-10-30 Power Distribution Center .. 8Wa-10-12, 13, 14, 15, 16, 17, 2, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 8 Powertrain Control Module ............ 8Wa-10-20, 24, 32 Radiator Fan Motor ................... 8Wa-10-22, 27 Radiator Fan Relay ................. 8Wa-10-20, 22, 27 Radio ............................ 8Wa-10-28, 31 Rear WindowDefogger ................. 8Wa-10-25, 26 Rear WindowDefogger Relay ........... 8Wa-10-19, 25, 26 Remote Keyless Entry Module .......... 8Wa-10-29, 30, 31 Right Courtesy Lamp .................. 8Wa-10-28, 31 Right Fog Lamp ..................... 8Wa-10-34, 36 Right Tail/Stop Lamp .................. 8Wa-10-33, 34 Right Visor/V anity Lamp .............. 8Wa-10-29, 30, 31 Sentry Key Immobilizer Module ............ 8Wa-10-23, 33 Transmission Control Module ............... 8Wa-10-28 Underhood Lamp/Switch ................ 8Wa-10-28, 31 XJ 8Wa-10 POWERDISTRIBUTION 8Wa - 10 - 1

Fig. 32 ENGINE COMPARTMENT AUXILIARY VIEWS DIESEL ENGINE XJ 8Wa-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 41 CONNECTOR/GROUND LOCATIONS (Continued)

Fig. 6 ENGINE COMPARTMENT SPLICES, DIESEL RHD 8Wa - 95 - 12 8Wa-95 SPLICE LOCATIONS XJ SPLICE LOCATIONS (Continued)

(7) Pull front output shaft upward and out of front output shaft bearing (Fig. 14). (8) Remove front output shaft and chain. SHIFT FORKS ANDMAINSHAFT (1) Remove detent plug, O-ring, detent spring and detent plunger (Fig. 15). (2) Remove mainshaft frommode sleeve and input gear pilot bearing. Fig. 12 Oil Pickup Tube Removal 1 - CONNECTING HOSE 2 - PICKUP SCREEN 3 - PICKUP TUBE Fig. 13 Mode Fork Spring Removal 1 - MODE SPRING Fig. 14 Remove Front Output Shaft And Chain 1 - DRIVE CHAIN 2 - FRONT OUTPUT SHAFT 3 - SHAFT FRONT BEARING Fig. 15 Detent Plug, Spring And Plunger Removal 1 - POPPET 2 - SPRING 3 - SCREW 4 - POPPET BORE (IN CASE) XJ TRANSFER CASE NV-231 21s - 45 TRANSFER CASE NV-231 (Continued)

2001 Jeep Grand Cherokee Service Repair Manual

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