Help with 02 Rear Axle Replacment

[J45p3r]

First and foremost I'm a backyard mechanic at best and I'm about to do something I've never done before so I come to you all for help. Most of my experience is in the GM world so working on a Jeep is a new experience for me. I have a friend who lost the rear end in her 2002 Liberty. Completely toast. We are going to buy a used unit for a local salvage yard and I (stupidly) told her I'd install it for her. Can you all tell me what I am in for? Is this a relatively straight forward job? Are there any resources I can use to help me through this? Any "gotchas" to be aware of? Thanks in advance for any advice.

 

[J-Thompson]

First and foremost I'm a backyard mechanic at best and I'm about to do something I've never done before so I come to you all for help. Most of my experience is in the GM world so working on a Jeep is a new experience for me. I have a friend who lost the rear end in her 2002 Liberty. Completely toast. We are going to buy a used unit for a local salvage yard and I (stupidly) told her I'd install it for her. Can you all tell me what I am in for? Is this a relatively straight forward job? Are there any resources I can use to help me through this? Any "gotchas" to be aware of? Thanks in advance for any advice.

if you are going to swap the entire rear then it is fairly easy
-LCA's
-brake lines
-upper link
-breather
-sway bar
-IIRC wiring harness

 

[Midgear]

should be a pretty straightforward unbolt the old and chuck it aside, and bolt the new one in..

take a 6 pack along and go to town lol

 

[tjkj2002]

If done right you can do the swap without having to bleed the brakes.

You must use a rear diff from a '02 KJ,and the same rear diff as the bad one(8.25 or D35).Mods will be needed for the driveshaft and brakes for a newer KJ rear axle even if it's the same kind due to differences between '02 and '03+ KJ's.

 

[JeepKj03]

Yea it’s pretty easy just a few bolts and the whole axle will just role right on out. It’s nothing special than from any other axle swap. Just check all the bushing and bearing, now would be a good time to replace them.

 

[J45p3r]

Thanks guys, are these known to fail or is it likely just poor maintenance or bad luck on her part?

 

[HoosierJeeper]

The 8.25 is pretty trouble free, so I'd say just bad luck on her part.

 

[J45p3r]

Also, how can I spot the differences between a Dana 35 and the Chrysler 8.25?

 

[HoosierJeeper]

The the 8.25 will have a flat bottom to it, the Dana 35 will be more rounded off.

 

[incommando]

If it is a Model 35, they are junk and she just got stuck. If it is an 8.25, there are ton's out there with more than 200,000 trouble free miles. But you can get a bad anything,.

 

[tjkj2002]

Thanks guys, are these known to fail or is it likely just poor maintenance or bad luck on her part?

In bold,the gear oil is supposed to be changed every 12,000-15,000 miles.

 

[J45p3r]

Well I picked up the Jeep and trailered it back up here and it does have the 8.25 rear end. When you move it sounds like someone tossed a few marbles in with the rear gears so it's definiately hosed. Local junk yard has a replacement with about 80,000 on it for $700 so it looks like that's the way we will be going.

Any trick for removing the rear coil springs or will I need a spring compressor tool?

 

[ptsb5a]

Unbolt the rear shocks, sway bar and push down on the axle, the spring will literally fall out.

$700 seems a bit steep for a used rear end unless it's complete disc to disc.

You might be able to replace the gears and carrier for the same price.

 

[JeepJeepster]

Removing the rear axle in the liberty is probably the easiest thing Ive ever done. Take the shocks off, take the vent off for the pumpkin, take the calipers off and tie them up with something, unplug the speed-o sensor, then support the Jeep by the frame and also support the axle. Take the four bolts out of the drive shaft and tie it up so it doesnt slide out of the tcase and tear that boot. Take the upper control arm off(the big boomerang) then unbolt the lower control arms from the axle. I found it easier to just unbolt the entire upper control arm than to try and unbolt it from the axle(unbolt it once the axle is removed), its whatever though.

 

[J45p3r]

Unbolt the rear shocks, sway bar and push down on the axle, the spring will literally fall out.

$700 seems a bit steep for a used rear end unless it's complete disc to disc.

You might be able to replace the gears and carrier for the same price.

$700 to replace the gears and carrier, is that the price for me to do it or to have a shop do it? I'm definitely not qualified to do that job.

 

[ThunderbirdJunkie]

Shop. You could definitely have new bearings and gears installed for $700

 

[ptsb5a]

Personally, I'd shop around. Unless there is a dire need for the KJ. I'd be inclined to have a shop replace the ring/pinion and bearings and have a relatively new rear end than purchase and install one with 80K miles use on it already.

 

[LibertyFever]

Besides the shocks & track bars and other suspension components you have to disconnect the E-brake cable, brake lines, vacuum line and the speedometer wiring to the diff. You are swapping identical 8.25 axles aren't you?

Take some pics for us would you? We can always use another write up

 

[J45p3r]

Thanks for all the advice guys. We talked the salvage yard down to $500 for the unit and hopefully I'll be doing the job next weekend. What gear oil and how much of it will I need?

 

[J45p3r]

Did a little digging and looks like I'll need synthetic 75w-90 and 2 bottles should do it.