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Introduction

0 Lubrication & Maintenance

2 Suspension

3 Differential & Driveline

5 Brakes

7 Cooling

8A Audio

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8M Message Systems

8N Power Systems

8O Restraints

8P Speed Control

8Q Vehicle Theft Security

8R Wipers/Washers

8W Wiring

9 Engine

11 Exhaust System

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transmission and Transfer Case

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

30 New Vehicle Preparation

Component and System Index

Service Manual Comment Forms (Rear of Manual)


WJ INTRODUCTION 1

INTRODUCTION
TABLE OF CONTENTS

page page

BODY CODE PLATE TORQUE REFERENCES


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FASTENER IDENTIFICATION VECI LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FASTENER USAGE VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INTERNATIONAL VEHICLE CONTROL AND VEHICLE SAFETY CERTIFICATION LABEL
DISPLAY SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......4
METRIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......5

BODY CODE PLATE FASTENER IDENTIFICATION


DESCRIPTION DESCRIPTION
A metal Body Code plate is located in the engine The SAE bolt strength grades range from grade 2
compartment and attached to the top of the right to grade 8. The higher the grade number, the greater
frame rail. The information listed on the plate (Fig. the bolt strength. Identification is determined by the
1) is used for manufacturing and service purposes. line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.

Fig. 1 Body Code Plate


2 INTRODUCTION WJ
FASTENER IDENTIFICATION (Continued)

FASTENER IDENTIFICATION
WJ INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

FASTENER STRENGTH
4 INTRODUCTION WJ

FASTENER USAGE DESCRIPTION - THREADED HOLE REPAIR


Most stripped threaded holes can be repaired using
DESCRIPTION - FASTENER USAGE a Helicoilt. Follow the manufactures recommenda-
tions for application and repair procedures.
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY. INTERNATIONAL VEHICLE
CONTROL AND DISPLAY
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE SYMBOLS
format.
During any maintenance or repair procedures, it is DESCRIPTION - INTERNATIONAL SYMBOLS
important to salvage all fasteners (nuts, bolts, etc.) The graphic symbols illustrated in the following
for reassembly. If the fastener is not salvageable, a International Control and Display Symbols Chart are
fastener of equivalent specification must be used. used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.

INTERNATIONAL SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
WJ INTRODUCTION 5

METRIC SYSTEM The following chart will assist in converting metric


units to equivalent English and SAE units, or vise
versa.
DESCRIPTION - METRIC SYSTEM
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million .

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET


in-lbs x 0.11298 = Newton Meters (Nm) Nm x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (Nm) Nm x 0.7376 = ft-lbs
Inches Hg x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
(60 F)
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/ x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
Hr. (Km/h) (Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters


1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert


torque values listed in metric Newton- meters (Nm).
Also, use the chart to convert between millimeters
(mm) and inches (in.)
6 INTRODUCTION WJ
METRIC SYSTEM (Continued)

METRIC CONVERSION CHART


WJ INTRODUCTION 7

TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
cations Chart for torque references not listed in the
individual torque charts.
8 INTRODUCTION WJ
TORQUE REFERENCES (Continued)

TORQUE SPECIFICATIONS
WJ INTRODUCTION 9

VECI LABEL The VECI label(s) contain the following:


Engine family and displacement
Evaporative family
DESCRIPTION
Emission control system schematic
All vehicles are equipped with a combined VECI
Certification application
label(s). The label is located in the engine compart-
Spark plug and gap
ment on the vehicle hood (Fig. 2). Two labels are
The label also contains an engine vacuum sche-
used for vehicles built for sale in the country of Can-
matic. There are unique labels for vehicles built for
ada.
sale in the state of California and the country of
Canada. Canadian labels are written in both the
English and French languages. These labels are per-
manently attached and cannot be removed without
defacing information and destroying label.

VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.

Fig. 2 VECI Label Location


1 - VECI LABEL (CANADIAN)
2 - VECI LABEL
3 - HOOD
10 INTRODUCTION WJ
VEHICLE IDENTIFICATION NUMBER (Continued)
VEHICLE IDENTIFICATION NUMBER DECODING CHART

POSITION INTERPRETATION CODE = DESCRIPTION


1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line 2= Grand Cherokee 4X2 (LHD)
W = Grand Cherokee 4X4 (LHD)
6 Series 5 = Laredo
6 = Limited
7 Body Style 8 = 4dr Sport Utility
8 Engine S = 4.0 Liter
N = 4.7Liter
9 Check Digit
10 Model Year 1=2001
11 Assembly Plant C = Jefferson Assembly
12 thru 17 Vehicle Build Sequence

VEHICLE SAFETY Country of origin.


The label is located on the driver-side door
CERTIFICATION LABEL shut-face.

DESCRIPTION
A vehicle safety certification label (Fig. 3) is
attached to every Chrysler Corporation vehicle. The
label certifies that the vehicle conforms to all appli-
cable Federal Motor Vehicle Safety Standards. The
label also lists:
Month and year of vehicle manufacture.
Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWRs) are
based on a minimum rim size and maximum cold tire
inflation pressure.
Vehicle Identification Number (VIN).
Type of vehicle.
Type of rear wheels. Fig. 3 Vehicle Safety Certification Label
Bar code.
Month, Day and Hour (MDH) of final assembly.
Paint and Trim codes.
WJ LUBRICATION & MAINTENANCE 0-1

LUBRICATION & MAINTENANCE


TABLE OF CONTENTS

page page

INTERNATIONAL SYMBOLS MAINTENANCE SCHEDULES


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PARTS & LUBRICANT RECOMMENDATION LIFT POINTS
STANDARD PROCEDURE . . . . . . . . . . . . . ......1 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 12
FLUID TYPES HOISTING AND JACKING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......2 RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . ......4 JUMP STARTING
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . ......4 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 13
FLUID CAPACITIES EMERGENCY TOW HOOKS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . ......6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FLUID FILL/CHECK LOCATIONS TOWING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......6 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . ......6

INTERNATIONAL SYMBOLS PARTS & LUBRICANT


RECOMMENDATION
DESCRIPTION
DaimlerChrysler Corporation uses international STANDARD PROCEDURES
symbols to identify engine compartment lubricant
Lubricating grease is rated for quality and usage
and fluid inspection and fill locations (Fig. 1).
by the NLGI. All approved products have the NLGI
symbol (Fig. 2) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
G. Chassis lubricant is identified by the latter L.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.

Fig. 1 International Symbols


Fig. 2 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS

When service is required, DaimlerChrysler Corpo-


ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
0-2 LUBRICATION & MAINTENANCE WJ

FLUID TYPES components. Also, once ethylene-glycol and propy-


lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
DESCRIPTION
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
ETHYLENE-GLYCOL MIXTURES
lene glycol.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can ENGINE OIL
cause problems associated with 100 percent ethyl-
WARNING: NEW OR USED ENGINE OIL CAN BE
ene-glycol.
IRRITATING TO THE SKIN. AVOID PROLONGED OR
The required ethylene-glycol (antifreeze) and water REPEATED SKIN CONTACT WITH ENGINE OIL.
mixture depends upon the climate and vehicle oper- CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
ating conditions. The recommended mixture of 50/50 INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
ethylene-glycol and water will provide protection YOUR HEALTH. THOROUGHLY WASH EXPOSED
against freezing to -37 deg. C (-35 deg. F). The anti- SKIN WITH SOAP AND WATER. DO NOT WASH
freeze concentration must always be a minimum of SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
44 percent, year-round in all climates. If percentage SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
is lower than 44 percent, engine parts may be NOT POLLUTE, DISPOSE OF USED ENGINE OIL
eroded by cavitation, and cooling system com- PROPERLY. CONTACT YOUR DEALER OR GOVERN-
ponents may be severely damaged by corrosion. MENT AGENCY FOR LOCATION OF COLLECTION
Maximum protection against freezing is provided CENTER IN YOUR AREA.
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer tempera-
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
ture. Also, a higher percentage of antifreeze can
fied. MOPARt provides engine oils that conform to
cause the engine to overheat because the specific
this service grade.
heat of antifreeze is lower than that of water.
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
rosion inhibitive additives in ethylene-glycol require
cosity of engine oil. Use only engine oils with multi-
the presence of water to dissolve. The deposits act as
ple viscosities such as 5W-30 or 10W-30. These are
insulation, causing temperatures to rise to as high as
specified with a dual SAE viscosity grade which indi-
149 deg. C (300) deg. F). This temperature is hot
cates the cold-to-hot temperature viscosity range.
enough to melt plastic and soften solder. The
Select an engine oil that is best suited to your par-
increased temperature can result in engine detona-
ticular temperature range and variation (Fig. 3).
tion. In addition, 100 percent ethylene-glycol freezes
at 22 deg. C (-8 deg. F ).

PROPYLENE-GLYCOL MIXTURES
Its overall effective temperature range is smaller
than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32 deg. C (-26 deg. F).
5 deg. C higher than ethylene-glycols freeze point.
The boiling point (protection against summer boil-
over) of propylene-glycol is 125 deg. C (257 deg. F )
at 96.5 kPa (14 psi), compared to 128 deg. C (263
deg. F) for ethylene-glycol. Use of propylene-glycol
can result in boil-over or freeze-up on a cooling sys-
tem designed for ethylene-glycol. Propylene glycol
also has poorer heat transfer characteristics than Fig. 3 Temperature/Engine Oil Viscosity
ethylene glycol. This can increase cylinder head tem-
peratures under certain conditions. ENERGY CONSERVING OIL
Propylene-glycol/ethylene-glycol Mixtures can An Energy Conserving type oil is recommended for
cause the destabilization of various corrosion inhibi- gasoline engines. The designation of ENERGY CON-
tors, causing damage to the various cooling system SERVING is located on the label of an engine oil con-
tainer.
WJ LUBRICATION & MAINTENANCE 0-3
FLUID TYPES (Continued)
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 4).

Fig. 5 Temperature/Engine Oil Viscosity - 3.2/3.5L


Engine
CONTAINER IDENTIFICATION
Fig. 4 Engine Oil Container Standard Notations Standard engine oil identification notations have
DESCRIPTION - ENGINE OIL been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
WARNING: NEW OR USED ENGINE OIL CAN BE of engine oil plastic bottles and the top of engine oil
IRRITATING TO THE SKIN. AVOID PROLONGED OR cans (Fig. 6).
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA. Fig. 6 API Symbol

DESCRIPTION
API SERVICE GRADE CERTIFIED A multi-purpose, hypoid gear lubricant which con-
Use an engine oil that is API Service Grade Certi- forms to the following specifications should be used.
fied. MOPARt provides engine oils that conform to Mopar Hypoid Gear Lubricant conforms to all of
this service grade. these specifications.

SAE VISCOSITY FRONT AXLE


An SAE viscosity grade is used to specify the vis- The lubricant should have MIL-L-2105C and
cosity of engine oil. Use only engine oils with multi- API GL 5 quality specifications.
ple viscosities such as 5W-30 or 10W-30. These oils Lubricant is SAE 75W-140 SYNTHETIC gear
are specified with a dual SAE viscosity grade which lubricant.
indicates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par- REAR AXLE
ticular temperature range and variation (Fig. 5). The lubricant should have MIL-L-2105C and
API GL 5 quality specifications.
ENERGY CONSERVING OIL Lubricant is a thermally stable SAE 80W-90
An Energy Conserving type oil is recommended for gear lubricant.
gasoline engines. The designation of ENERGY CON- Lubricant for axles intended for heavy-duty or
SERVING is located on the label of an engine oil con- trailer tow use is SAE 75W-140 SYNTHETIC gear
tainer. lubricant.
0-4 LUBRICATION & MAINTENANCE WJ
FLUID TYPES (Continued)
NOTE: Trac-lokY and Vari-lokY equipped axles clutch operation and inhibit overheating, oxidation,
require a friction modifier be added to the lubricant. varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
CAUTION: If axle is submerged in water, lubricant these additives must not be used. The use of trans-
must be replaced immediately to avoid possible mission sealers should also be avoided, since they
premature axle failure. may adversely affect the integrity of transmission
seals.

DESCRIPTION - TRANSFER CASE - NV242 OPERATION - AUTOMATIC TRANSMISSION


Recommended lubricant for the NV242 transfer
case is Mopart ATF +4, type 9602 Automatic Trans-
FLUID
The automatic transmission fluid is selected based
mission Fluid.
upon several qualities. The fluid must provide a high
level of protection for the internal components by
DESCRIPTION - TRANSFER CASE - NV247
providing a lubricating film between adjacent metal
Mopart Transfer Case Lubricant (P/N 05016796) is
components. The fluid must also be thermally stable
the only lubricant recommended for the NV247
so that it can maintain a consistent viscosity through
transfer case.
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
DESCRIPTION - AUTOMATIC TRANSMISSION transmission operation and shift feel will remain con-
FLUID sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
NOTE: Refer to the maintenance schedules in this internal transmission components and transfer that
group for the recommended maintenance (fluid/filter heat to the transmission case.
change) intervals for this transmission.

SPECIFICATIONS
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
FUEL REQUIREMENTS
Mopart ATF Plus 4, Type 9602, automatic trans- Your engine is designed to meet all emissions reg-
mission fluid is the recommended fluid for Daimler- ulations and provide excellent fuel economy and per-
Chrysler automatic transmissions. formance when using high quality unleaded regular
Dexron II fluid IS NOT recommended. Clutch gasoline having an octane rating of 87. The routine
chatter can result from the use of improper use of premium gasoline is not recommended. Under
fluid. normal conditions the use of premium fuel will not
Mopart ATF Plus 4, Type 9602, automatic trans- provide a benefit over high quality regular gasolines
mission fluid when new is red in color. The ATF is and in some circumstances may result in poorer per-
dyed red so it can be identified from other fluids used formance.
in the vehicle such as engine oil or antifreeze. The Light spark knock at low engine speeds is not
red color is not permanent and is not an indicator of harmful to your engine. However, continued heavy
fluid condition. As the vehicle is driven, the ATF will spark knock at high speeds can cause damage and
begin to look darker in color and may eventually immediate service is required. Engine damage result-
become brown. This is normal. A dark brown/black ing from operation with a heavy spark knock may
fluid accompanied with a burnt odor and/or deterio- not be covered by the new vehicle warranty.
ration in shift quality may indicate fluid deteriora- Poor quality gasoline can cause problems such as
tion or transmission component failure. hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
FLUID ADDITIVES before considering service for the vehicle.
DaimlerChrysler strongly recommends against the Over 40 auto manufacturers world-wide have
addition of any fluids to the transmission, other than issued and endorsed consistent gasoline specifications
those automatic transmission fluids listed above. (the Worldwide Fuel Charter, WWFC) to define fuel
Exceptions to this policy are the use of special dyes properties necessary to deliver enhanced emissions,
to aid in detecting fluid leaks. performance and durability for your vehicle. We rec-
Various special additives and supplements exist ommend the use of gasolines that meet the WWFC
that claim to improve shift feel and/or quality. These specifications if they are available.
additives and others also claim to improve converter
WJ LUBRICATION & MAINTENANCE 0-5
SPECIFICATIONS (Continued)
REFORMULATED GASOLINE affect the performance of the vehicles catalytic con-
Many areas of the country require the use of verter. This may cause the Malfunction Indicator
cleaner burning gasoline referred to as reformulat- Lamp (MIL), Check Engine or Service Engine Soon
ed gasoline. Reformulated gasoline contain oxygen- light to illuminate. We recommend that you try a dif-
ates, and are specifically blended to reduce vehicle ferent brand of unleaded gasoline having lower sulfur
emissions and improve air quality. to determine if the problem is fuel related prior to
We strongly support the use of reformulated gaso- returning your vehicle to an authorized dealer for
line. Properly blended reformulated gasoline will pro- service.
vide excellent performance and durability for the
engine and fuel system components. CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
GASOLINE/OXYGENATE BLENDS ing, immediate service is required; see on-board
Some fuel suppliers blend unleaded gasoline with diagnostics system section.
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
MATERIALS ADDED TO FUEL
during the winter months to reduce carbon monoxide
All gasoline sold in the United States and Canada
emissions. Fuels blended with these oxygenates may
are required to contain effective detergent additives.
be used in your vehicle.
Use of additional detergents or other additives is not
CAUTION: DO NOT use gasoline containing METH- needed under normal conditions.
ANOL. Gasoline containing methanol may damage
critical fuel system components. FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
MMT IN GASOLINE vehicles performance:
MMT is a manganese-containing metallic additive
The use of leaded gas is prohibited by Federal
that is blended into some gasoline to increase octane.
law. Using leaded gasoline can impair engine perfor-
Gasoline blended with MMT provide no performance
mance, damage the emission control system, and
advantage beyond gasoline of the same octane num-
could result in loss of warranty coverage.
ber without MMT. Gasoline blended with MMT
An out-of-tune engine, or certain fuel or ignition
reduce spark plug life and reduce emission system
malfunctions, can cause the catalytic converter to
performance in some vehicles. We recommend that
overheat. If you notice a pungent burning odor or
gasolines free of MMT be used in your vehicle. The
some light smoke, your engine may be out of tune or
MMT content of gasoline may not be indicated on the
malfunctioning and may require immediate service.
gasoline pump; therefore, you should ask your gaso-
Contact your dealer for service assistance.
line retailer whether or not his/her gasoline contains
When pulling a heavy load or driving a fully
MMT.
loaded vehicle when the humidity is low and the tem-
It is even more important to look for gasoline with-
perature is high, use a premium unleaded fuel to
out MMT in Canada because MMT can be used at
help prevent spark knock. If spark knock persists,
levels higher than allowed in the United States.
lighten the load, or engine piston damage may result.
MMT is prohibited in Federal and California refor-
The use of fuel additives which are now being
mulated gasoline.
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
SULFUR IN GASOLINE
methanol. Fuel system damage or vehicle perfor-
If you live in the northeast United States, your
mance problems resulting from the use of such fuels
vehicle may have been designed to meet California
or additives is not the responsibility of Daimler-
low emission standards with Cleaner-Burning Cali-
Chrysler Corporation and may not be covered under
fornia reformulated gasoline with low sulfur. If such
the new vehicle warranty.
fuels are not available in states adopting California
emission standards, your vehicles will operate satis- NOTE: Intentional tampering with emissions control
factorily on fuels meeting federal specifications, but systems can result in civil penalties being assessed
emission control system performance may be against you.
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
0-6 LUBRICATION & MAINTENANCE WJ

FLUID CAPACITIES

SPECIFICATIONS
SPECIFICATIONS - FLUID CAPACITIES

DESCRIPTION SPECIFICATION
FUEL TANK 20 U.S. Gallons (76
Liters)****
Engine Oil - with Filter - 5.7L (6.0 qts.)
4.0L
Engine Oil - with Filter - 5.7L (6.0 qts.)
4.7L
Cooling System - 4.0L 14.1L (15 qts.)*** Fig. 7 Fill/Drain Plug
Cooling System - 4.7L 13.7L (14.5 qts.)*** 1 - I.D. TAG
Power Steering 2 - FILL PLUG
3 - DRAIN PLUG
AUTOMATIC TRANSMISSION
Service Fill - 42RE 3.8L (4.0 qts)
O-haul Fill - 42RE 9.1-9.5L (19-20 pts) INSPECTION
The fluid fill/check locations and lubrication points
O-haul Fill - 45RFE 13.33L (28.0 pts.) are located in each applicable group.
TRANSFER CASE
NV242 1.35L (2.85 pts.)
MAINTENANCE SCHEDULES
NV247 1.6L (3.4 pts.)
FRONT AXLE DESCRIPTION
Model 186 FBI 1.18L (2.5 pts.) There are two maintenance schedules that show
* When equipped with Vari-Lok, include 0.07L (0.15 proper service for the Grand Cherokee.
pts.) of Friction Modifier. First is Schedule A. It lists all the scheduled
maintenance to be performed under normal operat-
REAR AXLE ing conditions.
Model 194 RBI 1.66L (3.5 pts.)* Second is ScheduleB . It is a schedule for vehi-
Model 226 RBA 2.24L (4.75 pts.)** cles that are operated under the following conditions:
Frequent short trip driving less than 5 miles (8
* When equipped with Trac-lok, include 2.5 ounces of
km)
Friction Modifier.
Frequent driving in dusty conditions
** When equipped with Trac-lok or Vari-Lok, include Extensive idling
2.5 ounces of Friction Modifier. Trailer towing
*** Includes 0.9L (1.0 qts.) for coolant reservoir. Sustained high speed operation
****Nominal refill capacities are shown. A variation Off road driving
may be observed from vehicle to vehicle due to Desert operation
manufacturing tolerance and refill procedure. Frequent starting and stopping
Cold climate operation
Commercial service
FLUID FILL/CHECK Use the schedule that best describes the driving
conditions.
LOCATIONS Where time and mileage are listed, follow the
interval that occurs first.
DESCRIPTION - TRANSFER CASE
The fill and drain plugs are both in the rear case EMISSION CONTROL SYSTEM MAINTENANCE
(Fig. 7). Correct fill level is to the bottom edge of the The scheduled emission maintenance listed in bold
fill plug hole. Be sure the vehicle is level to ensure typeon the Maintenance Schedules, must be done at
an accurate fluid level check. the mileage specified to assure the continued proper
WJ LUBRICATION & MAINTENANCE 0-7
MAINTENANCE SCHEDULES (Continued)
functioning of the emission control system. These, 22,500 Miles (36 000 km) or at 18 months
and all other maintenance services included in this Change engine oil.
manual, should be done to provide the best vehicle Replace engine oil filter.
performance and reliability. More frequent mainte- Inspect engine coolant level, hoses, clamps.
nance may be needed for vehicles in severe operating Inspect brake linings.
conditions such as dusty areas and very short trip Clean and lubricate brake caliper pins.
driving. Inspect brake hoses.
Inspect exhaust system.
UNSCHEDULED INSPECTION
30,000 Miles (48 000 km) or at 24 months
AT EACH STOP FOR FUEL Change engine oil.
Check engine oil level, add as required. Replace engine oil filter.
Check windshield washer solvent and add if Replace engine air cleaner element.
required. Replace spark plugs.
Drain and refill transfer case fluid.
ONCE A MONTH Lubricate upper knuckle ball stud.
Check tire pressure (including spare) and look Inspect engine coolant level, hoses, clamps.
for unusual wear or damage. Inspect brake hoses.
Inspect battery and clean and tighten terminals Inspect exhaust system.
as required.
Check fluid levels of coolant reservoir, power 37,500 Miles (60 000 km) or at 30 months
steering and transmission and add as needed. Change engine oil.
Replace engine oil filter.
AT EACH OIL CHANGE Inspect engine coolant level, hoses, clamps.
Inspect exhaust system. Inspect brake hoses.
Inspect brake hoses. Inspect exhaust system.
Rotate the tires at each oil change interval
shown on ScheduleA (7,500 miles) or every other 45,000 Miles (72 000 km) or at 36 months
interval shown on ScheduleB (6,000 miles). Change engine oil.
Check coolant level, hoses and clamps. Replace engine oil filter.
Lubricate suspension ball joints. Inspect engine coolant level, hoses, clamps.
After completion of off-road (4WD) operation, the Inspect brake hoses.
underside of the vehicle should be thoroughly Inspect brake linings.
inspected. Examine threaded fasteners for looseness. Clean and lubricate brake caliper pins.
Flush and replace engine coolant at 36 months
MAINTENANCE SCHEDULES or 52,500 Miles (84 000 km).
Lubricate upper knuckle ball stud.
SCHEDULEA Inspect exhaust system.

NOTE: Where both time and mileage are indicated, 52,500 Miles (84 000 km) or at 42 months
follow the interval which occurs first. Change engine oil.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps.
7,500 miles (12 000 km) or at 6 months Inspect brake hoses.
Change engine oil. Inspect exhaust system.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. 60,000 Miles (96 000 km) or at 48 months
Inspect brake hoses. Change engine oil.
Inspect exhaust system. Replace engine oil filter.
Inspect engine coolant level, hoses, clamps.
15,000 Miles (24 000 km) or at 12 months Replace engine air cleaner element.
Change engine oil. Replace spark plugs.
Replace engine oil filter. Inspect PCV valve and replace if necessary
Inspect engine coolant level, hoses, clamps. (4.7L only).*
Inspect brake hoses. Inspect brake hoses.
Inspect exhaust system.
Lubricate upper knuckle ball stud.
0-8 LUBRICATION & MAINTENANCE WJ
MAINTENANCE SCHEDULES (Continued)
Inspect and replace drive belt if necessary 97,500 Miles (156 000 km) or at 78 months
(4.0L). Change engine oil.
Drain and replace brake fluid. Replace engine oil filter.
Drain and refill transfer case fluid. Inspect engine coolant level, hoses, clamps.
Lubricate upper knuckle ball stud. Inspect brake hoses.
Inspect exhaust system. Inspect exhaust system.

67,500 Miles (108 000 km) or at 54 months 100,000 Miles (160 000 km)
Change engine oil. Drain and refill automatic transmission fluid
Replace engine oil filter. and change filter (except 45RFE & 545RFE applica-
Inspect engine coolant level, hoses, clamps. tions).
Inspect brake linings Adjust bands (except 45RFE & 545RFE applica-
Inspect brake hoses. tions).
Clean and lubricate brake caliper pins. Drain and refill automatic transmission fluid
Inspect exhaust system. and change main sump filter in 45RFE & 545RFE
applications.
75,000 Miles (120 000 km) or at 60 months Change spin-on cooler return filter in 45RFE &
Change engine oil. 545RFE appications.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. 105,000 Miles (168 000 km) or at 84 months
Flush and replace engine coolant if it has been Change engine oil.
30,000 miles (48 000 km) or 24 months since last Replace engine oil filter.
change. Inspect engine coolant level, hoses, clamps.
Inspect and replace drive belt if necessary Flush and replace engine coolant if it has been
(4.0L).** 30,000 miles (48 000 km) or 24 months since last
Inspect brake hoses. change.
Inspect exhaust system. Inspect and replace drive belt (4.0L and
Lubricate upper knuckle ball stud. 4.7L ).**
Inspect brake hoses.
82,500 Miles (132 000 km) or at 66 months Lubricate upper knuckle ball stud.
Change engine oil. Inspect exhaust system.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. 112,500 Miles (180 000 km) or at 90 months
Flush and replace engine coolant if it has been Change engine oil.
30,000 miles (48 000 km) or 24 months since last Replace engine oil filter.
change. Inspect engine coolant level, hoses, clamps.
Inspect brake hoses. Flush and replace engine coolant if it has been
Inspect exhaust system. 30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months Inspect brake hoses.
Change engine oil. Inspect brake linings.
Replace engine oil filter. Clean and lubricate brake caliper pins.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Replace engine air cleaner element.
Replace spark plugs. 120,000 Miles (192 000 km) or at 96 months
Inspect PCV valve and replace if necessary Change engine oil.
(4.7L only).* Replace engine oil filter.
Inspect and replace drive (4.0L and 4.7L).** Inspect engine coolant level, hoses, clamps.
Drain and refill transfer case fluid. Replace engine air cleaner element.
Inspect brake hoses. Replace spark plugs.
Inspect brake linings. Inspect PCV valve and replace if necessary
Clean and lubricate brake caliper pins. (4.7L only).*
Lubricate upper knuckle ball stud. Inspect and replace drive belt (4.0L and 4.7L).**
Inspect exhaust system. Inspect brake hoses.
Drain and replace brake fluid.
Drain and refill transfer case fluid.
WJ LUBRICATION & MAINTENANCE 0-9
MAINTENANCE SCHEDULES (Continued)
Lubricate upper knuckle ball stud. Inspect brake hoses.
Inspect exhaust system. Inspect exhaust system.

NOTE: Inspection and service should also be per- 18,000 Miles (29 000 km)
formed anytime a malfunction is observed or sus- Change engine oil.
pected. Replace engine oil filter.
Inspect engine coolant level, hoses, clamps.
*This maintenance is recommended, but is not Inspect brake hoses.
required to maintain warranty on the PCV valve. Inspect exhaust system.
**This maintenance is not required if the belt was Lubricate upper knuckle ball stud.
previously replaced.
21,000 Miles (34 000 km)
SCHEDULEB Change engine oil.
Replace engine oil filter.
NOTE: Where both time and mileage are indicated,
Inspect engine coolant level, hoses, clamps.
follow the interval which occurs first.
Inspect brake hoses.
Inspect exhaust system.
3,000 Miles (5 000 km)
24,000 Miles (38 000 km)
Change engine oil.
Replace engine oil filter. Change engine oil.
Inspect engine coolant level, hoses, clamps. Replace engine oil filter.
Inspect brake hoses. Inspect engine coolant level, hoses, clamps.
Inspect exhaust system. Drain and refill front and rear axles.
Inspect brake linings.
6,000 Miles (10 000 km) Clean and lubricate brake caliper pins.
Change engine oil. Inspect brake hoses.
Replace engine oil filter. Lubricate upper knuckle ball stud.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Inspect brake hoses.
27,000 Miles (43 000 km)
Lubricate upper knuckle ball stud.
Change engine oil.
Inspect exhaust system.
Replace engine oil filter.
9,000 Miles (14 000 km) Inspect engine coolant level, hoses, clamps.
Change engine oil. Inspect brake hoses.
Replace engine oil filter. Inspect exhaust system.
Inspect engine coolant level, hoses, clamps.
30,000 Miles (48 000 km)
Inspect brake hoses.
Change engine oil.
Inspect exhaust system.
Replace engine oil filter.
12,000 Miles (19 000 km) Inspect engine coolant level, hoses, clamps.
Change engine oil. Replace engine air cleaner element.
Replace engine oil filter. Replace spark plugs.
Inspect engine coolant level, hoses, clamps. Inspect PCV valve and replace if necessary
Drain and refill front and rear axles. (4.7L only).*
Inspect brake linings. Inspect brake hoses.
Clean and lubricate brake caliper pins. Drain and refill automatic transmission fluid
Inspect brake hoses. and change filter (except 45RFE & 545RFE applica-
Lubricate upper knuckle ball stud. tions).
Inspect exhaust system. Adjust bands (except 45RFE & 545RFE applica-
tions).
15,000 miles (24 000 km) Drain and refill automatic transmission fluid
Change engine oil. and change main sump filter in 45RFE & 545RFE
Replace engine oil filter. applications.
Inspect engine coolant level, hoses, clamps. Drain and refill transfer case fluid.
Inspect engine air cleaner element, replace Lubricate upper knuckle ball stud.
as necessary. Inspect exhaust system.
0 - 10 LUBRICATION & MAINTENANCE WJ
MAINTENANCE SCHEDULES (Continued)
33,000 Miles (53 000 km) 51,000 Miles (82 000 km)
Change engine oil. Change engine oil.
Replace engine oil filter. Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. Inspect engine coolant level, hoses, clamps.
Inspect brake hoses. Flush and replace engine coolant.
Inspect exhaust system. Inspect brake hoses.
Inspect exhaust system.
36,000 Miles (58 000 km)
Change engine oil. 54,000 Miles (86 000 km)
Replace engine oil filter. Change engine oil.
Inspect engine coolant level, hoses, clamps. Replace engine oil filter.
Drain and refill front and rear axles. Inspect engine coolant level, hoses, clamps.
Inspect brake linings. Inspect brake hoses.
Clean and lubricate brake caliper pins. Lubricate upper knuckle ball stud.
Inspect brake hoses. Inspect exhaust system.
Lubricate upper knuckle ball stud.
Inspect exhaust system. 57,000 Miles (91 000 km)
Change engine oil.
39,000 Miles (62 000 km) Replace engine oil filter.
Change engine oil. Inspect engine coolant level, hoses, clamps.
Replace engine oil filter. Inspect brake hoses.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Inspect brake hoses.
Inspect exhaust system. 60,000 Miles (96 000 km)
Change engine oil.
42,000 Miles (67 000 km) Replace engine oil filter.
Change engine oil. Inspect engine coolant level, hoses, clamps.
Replace engine oil filter. Replace engine air cleaner element.
Inspect engine coolant level, hoses, clamps. Inspect PCV valve and replace if necessary
Inspect brake hoses. (4.7L only).*
Lubricate upper knuckle ball stud. Replace spark plugs.
Inspect exhaust system. Inspect and replace drive belt (4.0L only).**
Drain and refill automatic transmission fluid
45,000 Miles (72 000 km) and change filter (except 45RFE & 545RFE applica-
Change engine oil. tions).
Replace engine oil filter. Adjust bands (except 45RFE & 545RFE applica-
Inspect engine coolant level, hoses, clamps. tions).
Inspect and replace drive belt if necessary (4.0L Drain and refill automatic transmission fluid
only). and change main sump filter in 45RFE & 545RFE
Inspect engine air cleaner element, replace applications.
as necessary. Drain and refill transfer case fluid.
Inspect brake hoses. Drain and refill front and rear axles.
Inspect exhaust system. Inspect brake hoses.
Inspect brake linings.
48,000 Miles (77 000 km) Drain and replace brake fluid.
Change engine oil. Clean and lubricate brake caliper pins.
Replace engine oil filter. Lubricate upper knuckle ball stud.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Drain and refill front and rear axles.
Inspect brake linings. 63,000 Miles (101 000 km)
Clean and lubricate brake caliper pins. Change engine oil.
Inspect brake hoses. Replace engine oil filter.
Lubricate upper knuckle ball stud. Inspect engine coolant level, hoses, clamps.
Inspect exhaust system. Inspect brake hoses.
Inspect exhaust system.
WJ LUBRICATION & MAINTENANCE 0 - 11
MAINTENANCE SCHEDULES (Continued)
66,000 Miles (106 000 km) Inspect brake linings.
Change engine oil. Clean and lubricate brake caliper pins.
Replace engine oil filter. Inspect brake hoses.
Inspect engine coolant level, hoses, clamps. Lubricate upper knuckle ball stud.
Inspect brake hoses. Inspect exhaust system.
Lubricate upper knuckle ball stud.
Inspect exhaust system. 87,000 Miles (139 000 km)
Change engine oil.
69,000 Miles (110 000 km) Replace engine oil filter.
Change engine oil. Inspect engine coolant level, hoses, clamps.
Replace engine oil filter. Inspect brake hoses.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Inspect brake hoses.
Inspect exhaust system. 90,000 Miles (144 000 km)
Change engine oil.
72,000 Miles (115 000 km) Replace engine oil filter.
Change engine oil. Inspect engine coolant level, hoses, clamps.
Replace engine oil filter. Replace engine air cleaner element.
Inspect engine coolant level, hoses, clamps. Replace spark plugs.
Drain and refill front and rear axles. Inspect PCV valve and replace if necessary
Inspect brake linings. (4.7L only).*
Clean and lubricate brake caliper pins. Inspect and replace drive (4.0L and 4.7L).**
Inspect brake hoses. Drain and refill automatic transmission fluid
Lubricate upper knuckle ball stud. and change filter (except 45RFE & 545RFE applica-
Inspect exhaust system. tions).
Adjust bands (except 45RFE & 545RFE applica-
75,000 Miles (120 000 km) tions).
Change engine oil. Drain and refill automatic transmission fluid
Replace engine oil filter. and change main sump filter in 45RFE & 545RFE
Inspect engine coolant level, hoses, clamps. applications.
Inspect and replace drive belt(4.0L and 4.7L).** Change spin-on cooler return filter in 45RFE &
Inspect engine air cleaner element, replace 545RFE appications.
as necessary. Inspect brake hoses.
Inspect brake hoses. Drain and refill transfer case fluid.
Inspect exhaust system. Lubricate upper knuckle ball stud.
Inspect exhaust system.
78,000 Miles (125 000 km)
Change engine oil. 93,000 Miles (149 000 km)
Replace engine oil filter. Change engine oil.
Inspect engine coolant level, hoses, clamps. Replace engine oil filter.
Inspect brake hoses. Inspect engine coolant level, hoses, clamps.
Lubricate upper knuckle ball stud. Inspect brake hoses.
Inspect exhaust system. Inspect exhaust system.

81,000 Miles (130 000 km) 96,000 Miles (154 000 km)
Change engine oil. Change engine oil.
Replace engine oil filter. Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. Inspect engine coolant level, hoses, clamps.
Flush and replace engine coolant. Drain and refill front and rear axles.
Inspect brake hoses. Inspect brake linings.
Inspect exhaust system. Clean and lubricate brake caliper pins.
Inspect brake hoses.
84,000 miles (134 000 km) Lubricate upper knuckle ball stud.
Change engine oil. Inspect exhaust system.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps.
Drain and refill front and rear axles.
0 - 12 LUBRICATION & MAINTENANCE WJ
MAINTENANCE SCHEDULES (Continued)
99,000 Miles (158 000 km) Inspect exhaust system.
Change engine oil.
Replace engine oil filter. 120,000 Miles (192 000 km)
Inspect engine coolant level, hoses, clamps. Change engine oil.
Inspect brake hoses. Replace engine oil filter.
Inspect exhaust system. Inspect engine coolant level, hoses, clamps.
Replace engine air cleaner element.
102,000 Miles (163 000 km) Inspect PCV valve and replace if necessary
Change engine oil. (4.7L only).*
Replace engine oil filter. Replace spark plugs.
Inspect engine coolant level, hoses, clamps. Inspect and replace drive belt (4.0L and 4.7L).**
Inspect brake hoses. Drain and refill automatic transmission fluid
Lubricate upper knuckle ball stud. and change filter (except 45RFE & 545RFE applica-
Inspect exhaust system. tions).
Adjust bands (except 45RFE & 545RFE applica-
105,000 Miles (168 000 km) tions).
Change engine oil. Drain and refill automatic transmission fluid
Replace engine oil filter. and change main sump filter in 45RFE & 545RFE
Inspect engine coolant level, hoses, clamps. applications.
Inspect engine air cleaner element, replace Drain and refill transfer case fluid.
as necessary. Drain and refill front and rear axles.
Inspect and replace drive belt (4.0L and 4.7L).** Inspect brake hoses.
Inspect brake hoses. Inspect brake linings.
Inspect exhaust system. Drain and replace brake fluid.
Clean and lubricate brake caliper pins.
108,000 Miles (173 000 km) Lubricate upper knuckle ball stud.
Change engine oil. Inspect exhaust system.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. NOTE: Inspection and service should also be per-
Drain and refill front and rear axles. formed anytime a malfunction is observed or sus-
Inspect brake linings. pected.
Clean and lubricate brake caliper pins.
Inspect brake hoses. *This maintenance is recommended, but is not
Lubricate upper knuckle ball stud. required to maintain warranty on the PCV valve.
Inspect exhaust system. **This maintenance is not required if the belt was
previously replaced.
111,000 Miles (178 000 km)
Change engine oil.
Replace engine oil filter.
LIFT POINTS
Inspect engine coolant level, hoses, clamps.
Flush and replace engine coolant. STANDARD PROCEDURES - HOISTING AND
Inspect brake hoses. JACKING RECOMMENDATIONS
Inspect exhaust system.
FLOOR JACK
114,000 Miles (182 000 km) When properly positioned, a floor jack can be used
Change engine oil. to lift a WJ vehicle (Fig. 8). Support the vehicle in
Replace engine oil filter. the raised position with jack stands at the front and
Inspect engine coolant level, hoses, clamps. rear ends of the frame rails.
Inspect brake hoses.
Lubricate upper knuckle ball stud. CAUTION: Do not attempt to lift a vehicle with a
Inspect exhaust system. floor jack positioned under:

117,000 Miles (187 000 km) An axle tube.


Change engine oil. Aluminum differential.
Replace engine oil filter. A body side sill.
Inspect engine coolant level, hoses, clamps. A steering linkage component.
Inspect brake hoses. A drive shaft.
WJ LUBRICATION & MAINTENANCE 0 - 13
LIFT POINTS (Continued)
The engine or transmission oil pan. JUMP STARTING
The fuel tank.
A front suspension arm.
STANDARD PROCEDURE - JUMP STARTING
HOIST PROCEDURE
A vehicle can be lifted with:
A single-post, frame-contact hoist. WARNING: REVIEW ALL SAFETY PRECAUTIONS
A twin-post, chassis hoist. AND WARNINGS IN GROUP 8A, BATTERY/START-
A ramp-type, drive-on hoist. ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
NOTE: When a frame-contact type hoist is used, INJURY CAN RESULT. DO NOT JUMP START WHEN
verify that the lifting pads are positioned properly MAINTENANCE FREE BATTERY INDICATOR DOT IS
(Fig. 8). YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
WARNING: THE HOISTING AND JACK LIFTING ALLOW JUMPER CABLE CLAMPS TO TOUCH
POINTS PROVIDED ARE FOR A COMPLETE VEHI- EACH OTHER WHEN CONNECTED TO A BOOSTER
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO- SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
NENT IS REMOVED FROM A VEHICLE, THE TERY. REMOVE METALLIC JEWELRY WORN ON
CENTER OF GRAVITY IS ALTERED MAKING SOME HANDS OR WRISTS TO AVOID INJURY BY ACCI-
HOISTING CONDITIONS UNSTABLE. PROPERLY DENTAL ARCING OF BATTERY CURRENT. WHEN
SUPPORT OR SECURE VEHICLE TO HOISTING USING A HIGH OUTPUT BOOSTING DEVICE, DO
DEVICE WHEN THESE CONDITIONS EXIST. NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.

CAUTION: When using another vehicle as a


booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE:


(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
Battery cable clamp condition, clean if necessary.
Frozen battery.
Yellow or bright color test indicator, if equipped.
Low battery fluid level.
Generator drive belt condition and tension.
Fuel fumes or leakage, correct if necessary.

CAUTION: If the cause of starting problem on dis-


abled vehicle is severe, damage to booster vehicle
charging system can result.

(2) When using another vehicle as a booster


source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
Fig. 8 Correct Vehicle Lifting Locations the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
0 - 14 LUBRICATION & MAINTENANCE WJ
JUMP STARTING (Continued)
(3) On disabled vehicle, place gear selector in park When using a Booster vehicle, disconnect
or neutral and set park brake. Turn off all accesso- BLACK cable clamp from battery negative terminal.
ries. Disconnect RED cable clamp from battery positive
(4) Connect jumper cables to booster battery. RED terminal.
clamp to positive terminal (+). BLACK clamp to neg- Disconnect RED cable clamp from battery posi-
ative terminal (-). DO NOT allow clamps at opposite tive terminal on disabled vehicle.
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable EMERGENCY TOW HOOKS
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the DESCRIPTION
ground cable attaching point as possible (Fig. 9).
(6) Start the engine in the vehicle which has the WARNING: REMAIN AT A SAFE DISTANCE FROM A
booster battery, let the engine idle a few minutes, VEHICLE THAT IS BEING TOWED VIA ITS TOW
then start the engine in the vehicle with the dis- HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
charged battery. AND CAUSE SERIOUS INJURY.

Some Jeep vehicles are equipped with front emer-


gency tow hooks (Fig. 10). The tow hooks should be
used for EMERGENCYpurposes only.

CAUTION: DO NOT use emergency tow hooks for


tow truck hook-up or highway towing.

Fig. 9 Jumper Cable Clamp Connections


1 - ENGINE GROUND
2 - NEGATIVE JUMPER CABLE
3 - BATTERY NEGATIVE CABLE
4 - POSITIVE JUMPER CABLE
5 - BATTERY POSITIVE CABLE
6 - BATTERY
7 - TEST INDICATOR
Fig. 10 Emergency Tow Hooks
1 - TOW HOOK

CAUTION: Do not crank starter motor on disabled


vehicle for more than 15 seconds, starter will over- TOWING
heat and could fail.

(7) Allow battery in disabled vehicle to charge to STANDARD PROCEDURES


at least 12.4 volts (75% charge) before attempting to A vehicle equipped with SAE approved wheel lift-
start engine. If engine does not start within 15 sec- type towing equipment can be used to tow WJ vehi-
onds, stop cranking engine and allow starter to cool cles. When towing a 4WD vehicle using a wheel-lift
(15 min.), before cranking again. towing device, use tow dollies under the opposite end
of the vehicle. A vehicle with flatbed device can also
DISCONNECT CABLE CLAMPS AS FOLLOWS: be used to transport a disabled vehicle (Fig. 11).
Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
WJ LUBRICATION & MAINTENANCE 0 - 15
TOWING (Continued)
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.

TWO WHEEL DRIVE TOWING-REAR END LIFTED


CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.

2WD vehicles can be towed with the front wheels


on the surface for extended distances at speeds not
exceeding 48 km/h (30 mph).
(1) Attach wheel lift device to rear wheels.
(2) Place the transmission in neutral.
(3) Raise vehicle to towing position.
(4) Attach safety chains. Route chains so not to
Fig. 11 Tow Vehicles With Approved Equipment
interfere with tail pipe when vehicle is lifted.
SAFETY PRECAUTIONS (5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
CAUTION: The following safety precautions must be
observed when towing a vehicle: CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
Secure loose and protruding parts.
Always use a safety chain system that is inde- (6) Secure steering wheel in straight ahead posi-
pendent of the lifting and towing equipment. tion with a clamp device designed for towing.
Do not allow towing equipment to contact the (7) Place transmission in park.
disabled vehicles fuel tank.
Do not allow anyone under the disabled vehicle TWO WHEEL DRIVE TOWING-FRONT END LIFTED
while it is lifted by the towing device.
Do not allow passengers to ride in a vehicle CAUTION: Many vehicles are equipped with air
being towed. dams, spoilers, and/or ground effect panels. To
Always observe state and local laws regarding avoid component damage, a wheel-lift towing vehi-
towing regulations. cle or a flat-bed hauling vehicle is recommended.
Do not tow a vehicle in a manner that could
(1) Attach wheel lift device to rear wheels.
jeopardize the safety of the operator, pedestrians or
(2) Place the transmission in neutral.
other motorists.
(3) Raise the rear of the vehicle off the ground and
Do not attach tow chains, T-hooks, or J-hooks to
install tow dollies under rear wheels.
a bumper, steering linkage, drive shafts or a non-re-
(4) Attach wheel lift device to front wheels and
inforced frame hole.
raise vehicle to towing position.
Do not tow a heavily loaded vehicle. Use a flat-
(5) Attach the safety chains.
bed device to transport a loaded vehicle.
CAUTION: Do not use steering column lock to
TWO-WHEEL-DRIVE VEHICLE TOWING secure steering wheel during towing operation.
DaimlerChrysler Corporation recommends that a
vehicle be towed with the rear end lifted, whenever (6) Turn the ignition switch to the OFF position to
possible. unlock the steering wheel.
(7) Secure steering wheel in straight ahead posi-
WARNING: WHEN TOWING A DISABLED VEHICLE tion with a clamp device designed for towing.
AND THE DRIVE WHEELS ARE SECURED IN A (8) Place transmission in park.
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO- FOUR-WHEEL-DRIVE VEHICLE TOWING
MATIC TRANSMISSION) OR A FORWARD DRIVE DaimlerChrysler Corporation recommends that a
GEAR (MANUAL TRANSMISSION). 4WD vehicle be transported on a flat-bed device. A
Wheel-lift device can be used provided the trailing
wheels are off the ground and positioned in
tow dollies.
0 - 16 LUBRICATION & MAINTENANCE WJ
TOWING (Continued)
WARNING: WHEN TOWING A DISABLED VEHICLE (7) Secure steering wheel in straight ahead posi-
AND THE DRIVE WHEELS ARE SECURED IN A tion with a clamp device designed for towing.
WHEEL LIFT OR TOW DOLLIES, ENSURE THE (8) Place transmission in park.
TRANSMISSION IS IN THE PARK POSITION.
FOUR WHEEL DRIVE TOWINGFRONT END
LIFTED
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
avoid component damage, a wheel-lift towing vehi- FACE OR THE WHEELS ARE BLOCKED TO PRE-
cle or a flat-bed hauling vehicle is recommended. VENT VEHICLE FROM ROLLING.

(1) Attach wheel lift device to rear wheels.


FOUR WHEEL DRIVE TOWINGREAR END LIFTED (2) Place the transmission in neutral.
(3) Raise the rear of the vehicle off the ground and
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
install tow dollies under rear wheels.
FACE OR THE WHEELS ARE BLOCKED TO PRE-
(4) Attach wheel lift device to front wheels and
VENT VEHICLE FROM ROLLING.
raise vehicle to towing position.
(1) Attach wheel lift device to front wheels. (5) Attach the safety chains.
(2) Place the transmission in neutral.
CAUTION: Do not use steering column lock to
(3) Raise the front of the vehicle off the ground
secure steering wheel during towing operation.
and install tow dollies under front wheels.
(4) Attach wheel lift device to rear wheels and (6) Turn the ignition switch to the OFF position to
raise vehicle to towing position. unlock the steering wheel.
(5) Attach safety chains. Route chains so not to (7) Secure steering wheel in straight ahead posi-
interfere with tail pipe when vehicle is lifted. tion with a clamp device designed for towing.
(6) Turn the ignition switch to the OFF position to (8) Place transmission in park.
unlock the steering wheel.

CAUTION: Do not use steering column lock to


secure steering wheel during towing operation.
WJ SUSPENSION 2-1

SUSPENSION
TABLE OF CONTENTS

page page

SUSPENSION INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2 STABILIZER BAR
SUSPENSION AND STEERING SYSTEM . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WHEEL ALIGNMENT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 4 TRACK BAR
CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TOE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FRONT SUSPENSION UPPER BALL JOINT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 6 UPPER CONTROL ARM
SERVICE WARNINGS AND PRECAUTIONS . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BUSHINGS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REAR SUSPENSION
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HUB / BEARING WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 17
JOUNCE BUMPER JOUNCE BUMPER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
KNUCKLE LOWER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LOWER BALL JOINT SHOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LOWER CONTROL ARM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPRING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SHOCK OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STABILIZER BAR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPRING OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-2 SUSPENSION WJ

UPPER BALL JOINT UPPER CONTROL ARM


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION AND
STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.

EXCESSIVE PLAY IN 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
STEERING
2. Loose or worn steering or 2. Tighten or replace components as
suspension components. necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.

EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.

VEHICLE PULLS TO ONE 1. Uneven tire pressure. 1. Adjust tire pressure.


SIDE DURING BRAKING 2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
WJ SUSPENSION 2-3
SUSPENSION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE LEADS OR 1. Radial tire lead. 1. Cross front tires.


DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON 2. Brakes dragging. 2. Repair brake as necessary.
UNCROWNED ROAD 3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or 6. Repair as necessary.
suspension components.
7. Cross caster out of spec. 7. Align vehicle.

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.


OR SQUEAKING
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
3. Shock valve. 3. Replace shock.

IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.

WHEEL ALIGNMENT OPERATION


CASTER is the forward or rearward tilt of the
DESCRIPTION steering knuckle from vertical. Tilting the top of the
Wheel alignment involves the correct positioning of knuckle rearward provides positive caster. Tilting the
the wheels in relation to the vehicle. The positioning top of the knuckle forward provides negative caster.
is accomplished through suspension and steering Caster is a directional stability angle. This angle
linkage adjustments. An alignment is considered enables the front wheels to return to a straight
essential for efficient steering, good directional stabil- ahead position after turns.
ity and to minimize tire wear. The most important CAMBER is the inward or outward tilt of the
measurements of an alignment are caster, camber wheel relative to the center of the vehicle. Tilting the
and toe position (Fig. 1). top of the wheel inward provides negative camber.
Tilting the top of the wheel outward provides positive
CAUTION: Never attempt to modify suspension or camber. Incorrect camber will cause wear on the
steering components by heating or bending. inside or outside edge of the tire. The angle is not
adjustable, damaged component(s) must be replaced
to correct the camber angle.
CAUTION: Components attached with a nut and cot- WHEEL TOE POSITION is the difference
ter pin must be torqued to specification. Then if the between the leading inside edges and trailing inside
slot in the nut does not line up with the cotter pin edges of the front tires. Incorrect wheel toe position
hole, tighten nut until it is aligned. Never loosen the is the most common cause of unstable steering and
nut to align the cotter pin hole. uneven tire wear. The wheel toe position is the final
front wheel alignment adjustment.
NOTE: Periodic lubrication of the front suspension/ STEERING AXIS INCLINATION ANGLE is
steering system components may be required. Rub- measured in degrees and is the angle that the steer-
ber bushings must never be lubricated. Refer to ing knuckles are tilted. The inclination angle has a
Lubrication And Maintenance for the recommended fixed relationship with the camber angle. It will not
maintenance schedule. change except when a spindle or ball stud is dam-
aged or bent. The angle is not adjustable, damaged
component(s) must be replaced to correct the steering
axis inclination angle.
2-4 SUSPENSION WJ
WHEEL ALIGNMENT (Continued)

Fig. 1 Wheel Alignment Measurements


1 - WHEEL CENTERLINE 6 - KING PIN
2 - NEGATIVE CAMBER ANGLE 7 - VERTICAL
3 - PIVOT CENTERLINE 8 - POSITIVE CASTER
4 - SCRUB RADIUS
5 - TRUE VERTICAL

THRUST ANGLE is the angle of the rear axle STANDARD PROCEDURE - CASTER
relative to the centerline of the vehicle. Incorrect
Before each alignment reading the vehicle should
thrust angle can cause off-center steering and exces-
be jounced (rear first, then front). Grasp each
sive tire wear. This angle is not adjustable, damaged
bumper at the center and jounce the vehicle up and
component(s) must be replaced to correct the thrust
down three times. Always release the bumper in the
angle.
down position.
To obtain an accurate alignment, a 4 wheel align-
STANDARD PROCEDURE - CAMBER ment machine must be used and the equipment cali-
Before each alignment reading the vehicle should bration verified.
be jounced (rear first, then front). Grasp each The wheel caster angle is preset. This angle is not
bumper at the center and jounce the vehicle up and adjustable and cannot be altered.
down three times. Always release the bumper in the
down position. STANDARD PROCEDURE - TOE POSITION
To obtain an accurate alignment, a 4 wheel align-
Before each alignment reading the vehicle should
ment machine must be used and the equipment cali-
be jounced (rear first, then front). Grasp each
bration verified.
bumper at the center and jounce the vehicle up and
The wheel camber angle is preset. This angle is not
down three times. Always release the bumper in the
adjustable and cannot be altered.
down position.
WJ SUSPENSION 2-5
WHEEL ALIGNMENT (Continued)
To obtain an accurate alignment, a 4 wheel align- SPECIFICATIONS
ment machine must be used and the equipment cali-
bration verified. ALIGNMENT
NOTE: For an accurate wheel toe position adjust- NOTE: Specifications are in degrees.
ment the engine must be engine running.

(1) Apply parking brakes. FRONT WHEELS - STANDARD SUSPENSION


(2) Start the engine and turn wheels both ways SPECIFICATIONS
before straightening the steering wheel. Center and
secure the steering wheel.
(3) Loosen the tie rod adjustment sleeve clamp DESCRIPTION SPECIFICATION
bolts (Fig. 2) . PREFERRED CASTER CAMBER TOTAL
(4) Turn the sleeve to obtain the preferred positive + 6.75 0.37 TOE-IN
TOE-IN specification. Position the clamp bolts as + 0.20
shown (Fig. 2) for proper clearance. RANGE + 6.0 to 0.75 to N/A
(5) Tighten the clamp bolts to 68 Nm (50 ft. lbs.). + 7.5 + 0.5
NOTE: Make sure the toe setting does not change MAX RT/LT 0.5 0.5 0.5
during clamp tightening. DIFFERENCE

(6) Verify alignment specifications, then turn the FRONT WHEELS - UP-COUNTRY SUSPENSION
engine off. SPECIFICATIONS

DESCRIPTION SPECIFICATION
PREFERRED CASTER CAMBER TOTAL
+ 6.5 0.37 TOE-IN
+ 0.20
RANGE + 5.7 to 0.75 to N/A
+ 7.2 + 0
MAX RT/LT 0.5 0.5 0.05
DIFFERENCE

REAR AXLE
SPECIFICATIONS

DESCRIPTION SPECIFICATION
Fig. 2 Steering Linkage
PREFERRED CASTER THRUST TOTAL
1 - DRAG LINK ADJUSTMENT SLEEVE
ANGLE TOE-IN
2 - TIE ROD ADJUSTMENT SLEEVE
RANGE 0 to 6 0.25 0 to
0.5 +0.5
STEERING WHEEL CENTERING
NOTE: The steering wheel can be centered without FRONT SUSPENSION
affecting the toe position.

(1) Loosen the drag link adjustment sleeve clamp


DESCRIPTION
The front suspension (Fig. 3) is a link/coil design
bolts.
comprised of :
(2) Turn the adjustment sleeve to center the
Drive axle
wheel.
Shock absorbers
(3) Position the clamp bolts as shown (Fig. 2)for
Coil springs
proper clearance.
Upper and lower suspension arms
(4) Tighten the clamp bolts to 68 Nm (50 ft. lbs.).
Stabilizer bar
(5) Road test the vehicle to verify the wheel is cen-
Track bar
tered.
Jounce bumpers
2-6 SUSPENSION WJ
FRONT SUSPENSION (Continued)
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.

CAUTION: Suspension components with rubber


bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.

STANDARD PROCEDURES - SERVICE


WARNINGS AND CAUTIONS
Fig. 3 Front
1 - SHOCK CAUTION: Suspension components with rubber
2 - COIL SPRING bushings must be tightened with the vehicle at nor-
3 - UPPER SUSPENSION ARM mal ride height. It is important to have the springs
4 - STABILIZER BAR supporting the weight of the vehicle when the fas-
5 - LOWER SUSPENSION ARM teners are torqued. If springs are not at their normal
6 - TRACK BAR ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the

SPECIFICATIONS

TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION Nm Ft. Lbs. In. Lbs.


Shock Absorber Upper Nut 35 26
Shock Absorber Lower Nut 28 250
Suspension Arm Upper Axle 61 45
Bracket Nut
Suspension Arm Upper Frame 61 45
Bracket Bolt
Suspension Arm Lower Axle 163 120
Bracket Nut
Suspension Arm Lower Frame 156 115
Bracket Bolt
Stabilizer Bar Retainer Bolts 92 68
Stabilizer Bar Link Upper Nut 106 78
Stabilizer Bar Link Lower Nut 106 78
Track Bar Frame Bracket Nut 108 80
Track Bar Axle Bracket Bolt 100 74
Hub Bearing Knuckle Bolts 102 75
WJ SUSPENSION 2-7

SPECIAL TOOLS
FRONT SUSPENSION

Remover C-4150A

Remover/Installer Suspension Bushing 7932

Remover/Installer 6289

Spacer 8279

Reciever 6761

Nut, Long 7603

Installer 6752
Bolt, Special 7604
2-8 SUSPENSION WJ

BUSHINGS
REMOVAL
(1) Remove the upper suspension arm from axle.
(2) Position Spacer 8279 over the axle bushing on
a 4x2 vehicle and right side on a 4x4 vehicle.
(3) Place Receiver 7932-1 over flanged end of the
bushing. (Fig. 4).
(4) Place small end of Remover/Install 7932-2
against other side of the bushing.
(5) Install bolt 7604 through remover, bushing and
receiver.
(6) Install Long Nut 7603 and tighten nut too pull
bushing out of the axle bracket.

Fig. 5 Bushing Installation


1 - REMOVER/INSTALLER
2 - AXLE BRACKET
3 - BOLT
4 - RECEIVER
5 - LONG NUT

(5) Remove tools and install the upper suspension


arm.

HUB / BEARING
DESCRIPTION
The bearing used on the front hub of this vehicle is
Fig. 4 Bushing Removal
the combined hub and bearing unit type assembly.
1 - RECEIVER This unit assembly combines the front wheel mount-
2 - AXLE BRACKET
ing hub (flange) and the front wheel bearing into a
3 - BOLT
one piece unit. The wheel mounting studs are the
4 - REMOVER/INSTALLER
5 - LONG NUT
only replaceable component of the hub/bearing
assembly.

(7) Remove nut, bolt, receiver, remover and bush- OPERATION


ing. The hub/bearing assembly is mounted to the steer-
ing knuckle and is retained by three mounting bolts
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
accessible from the back of the steering knuckle. The
leave Spacer 8279 in position for bushing installa-
hub/bearing unit is not serviceable and must be
tion.
replaced as an assembly if the bearing or the hub is
determined to be defective.
INSTALLATION
(1) Place Receiver 7932-1on the other side of the REMOVAL
axle bracket. (1) Raise and support the vehicle.
(2) Position new bushing up to the axle bracket., (2) Remove the wheel and tire assembly.
and large end of Remover/Install 7932-2 against the (3) Remove the brake caliper, caliper anchor, rotor
bushing (Fig. 5). and ABS wheel speed sensor,(Refer to 5 - BRAKES/
(3) Install bolt 7604 through receiver, bushing and ELECTRICAL/FRONT WHEEL SPEED SENSOR -
installer. REMOVAL).
(4) Install Long Nut 7603 and tighten nut to draw (4) Remove the cotter pin, nut retainer and axle
the bushing into the axle bracket. hub nut.
WJ SUSPENSION 2-9
HUB / BEARING (Continued)
(5) Remove the hub bearing mounting bolts from KNUCKLE
the back of the steering knuckle. Remove hub bear-
ing (Fig. 6) from the steering knuckle and off the
DESCRIPTION
axle shaft.
The knuckle is a single casting with legs machined
for the upper and lower ball joints. The knuckle also
has machined mounting locations for the front brake
calipers and hub bearing.

OPERATION
The steering knuckle pivot between the upper and
lower ball joint. Steering linkage attached to the
knuckle allows the vehicle to be steered.

REMOVAL - STEERING KNUCKLE


Ball stud service procedures below require removal
of the hub bearing and axle shaft. Removal and
installation of upper and lower ball studs require the
use of Tool Kit 6289.
(1) Remove hub bearing and axle shaft.
(2) Disconnect the tie-rod or drag link from the
Fig. 6 Hub Bearing & Knuckle
steering knuckle arm. Refer to Group 2, Suspension,
1 - HUB BEARING
for proper procedures.
2 - KNUCKLE
(3) Remove the cotter pins from the upper and
lower ball studs.
INSTALLATION (4) Remove the upper and lower ball stud nuts.
(1) Install the hub bearing to the knuckle. (5) Strike the steering knuckle with a brass ham-
(2) Install the hub bearing to knuckle bolts and mer to loosen knuckle from the ball studs. Remove
tighten to 102 Nm (75 ft. lbs.). knuckle from ball studs (Fig. 7).
(3) Install the hub washer and nut. Tighten the
hub nut to 237 Nm (175 ft. lbs.). Install the nut
retainer and a new cotter pin.
(4) Install the brake rotor, caliper anchor, caliper
and ABS wheel speed sensor,(Refer to 5 - BRAKES/
ELECTRICAL/FRONT WHEEL SPEED SENSOR -
INSTALLATION).
(5) Install the wheel and tire assembly.
(6) Remove the support and lower the vehicle.

JOUNCE BUMPER
DESCRIPTION
They are mounted under the unibody rails to min-
imize transmission of noise to the passenger com-
partment.

OPERATION
The jounce bumpers are used to limit suspension
travel in compression.
Fig. 7 Steering Knuckle Removal/Installation
1 - AXLE YOKE
2 - UPPER BALL STUD
3 - LOWER BALL STUD
4 - STEERING KNUCKLE
2 - 10 SUSPENSION WJ
KNUCKLE (Continued)

INSTALLATION LOWER CONTROL ARM


(1) Position the steering knuckle on the ball studs.
(2) Install and tighten the bottom retaining nut to DESCRIPTION
109 Nm (80 ft. lbs.) torque. Install new cotter pin. The lower suspension arms are hydroformed steel
(3) Install and tighten the top retaining nut to 101 and use voided oval bushings at one end of the arm.
Nm (75 ft. lbs.) torque. Install new cotter pin.
(4) Install the hub bearing and axle shaft. OPERATION
(5) Connect the tie-rod or drag link end to the The bushings provide isolation from the axle. The
steering knuckle arm. Refer to Group 2, Suspension, arms mount to the unibody frame rail bracket and
for proper procedures. the axle brackets. The arm and bushings provide
location and react to loads from the axle.
LOWER BALL JOINT REMOVAL
(1) Raise the vehicle and support the front axle.
REMOVAL (2) Remove the lower suspension arm nut and bolt
Ball stud service procedures below require removal
from the axle bracket (Fig. 9).
of the hub bearing and axle shaft. Removal and
(3) Remove the nut and bolt from the frame rail
installation of upper and lower ball studs require the
bracket and remove the lower suspension arm (Fig.
use of Tool Kit 6289.
9).
(1) Position tools as shown to remove and install
ball stud (Fig. 8).

Fig. 8 Lower
1 - SPECIAL TOOL 628912 5 - SPECIAL TOOL 62891
2 - SPECIAL TOOL 62894 6 - SPECIAL TOOL 62893
3 - SPECIAL TOOL 4212F
4 - SPECIAL TOOL 4212F
WJ SUSPENSION 2 - 11
LOWER CONTROL ARM (Continued)

REMOVAL
(1) Remove the nut, retainer and grommet from
the shock stud in the engine compartment (Fig. 10).

Fig. 9 Lower Suspension Arm


1 - LOWER SUSPENSION ARM
2 - FRAME RAIL BRACKET
3 - AXLE BRACKET
Fig. 10 Upper Shock Mounting
1 - RETAINER
INSTALLATION 2 - STUD
3 - NUT
(1) Position the lower suspension arm in the axle
4 - GROMMET
bracket and frame rail bracket.

NOTE: The end of the arm with the oval bushing (2) Raise and support the front axle.
attaches to the axle bracket. (3) Remove the lower mounting nuts from the axle
bracket (Fig. 11). Remove the shock absorber.
(2) Install the axle bracket bolt and nut finger
tight.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
(4) Remove support and lower the vehicle.
(5) With the vehicle on the ground tighten the
frame bracket bolt to 156 Nm (115 ft. lbs.). Tighten
the axle bracket nut to 163 Nm (120 ft. lbs.).
(6) Check the alignment if new parts were
installed.

SHOCK
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle Fig. 11 Lower Shock Mounting
brackets. The standard shocks have conventional 1 - SHOCK ABSORBER
twin tube construction and are low pressure gas 2 - MOUNTING NUTS
charged. Gas charging prevents cavitation during
rough road operation. Up-Country shocks are mono
tube design and are high pressure gas charged. INSTALLATION
(1) Position the lower retainer and grommet on the
OPERATION shock stud. Insert the shock absorber through the
The shock absorbers dampen jounce and rebound shock tower hole.
motion of the vehicle over various road conditions (2) Install the lower shock studs into the axle
and limit suspension rebound travel. bracket.
2 - 12 SUSPENSION WJ
SHOCK (Continued)
(3) Install the mounting nuts and tighten to 28
Nm (250 in. lbs.).
(4) Remove support and lower the vehicle.
(5) Install the upper grommet, retainer and nut on
the stud in the engine compartment. Hold the shock
stud with a 8 mm wrench and tighten the nut to 35
Nm (26 ft. lbs.).

SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert.

OPERATION Fig. 12 Front Coil Spring


The coil springs control ride quality and maintain 1 - UPPER ISOLATOR
proper ride height. The isolators provide road noise 2 - COIL SPRING
isolation. 3 - LOWER ISOLATOR
4 - STABILIZER LINK
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support it.
(2) Remove the wheel and tire assemblies.
(3) Remove stabilizer bar links mounting nuts and
bolts from the axle brackets.
(4) Remove shock absorbers lower mounting nuts
from the axle brackets.
(5) Remove the track bar mounting bolt from the
axle bracket.
(6) Lower the axle until the spring is free from the
upper mount and isolator (Fig. 12).
(7) Remove the spring from the vehicle.
(8) Remove and inspect the upper and lower
spring isolators.

INSTALLATION
(1) Install the upper isolator.
(2) Install the lower isolator with the isolator loca-
tor nub in the axle pad hole (Fig. 13).
(3) Position the coil spring on the axle spring pad. Fig. 13 Lower Isolator
1 - LOCATING NUB
CAUTION: Ensure the spring is positioned on the 2 - LOWER ISOLATOR
lower isolator with the end of the spring coil 3 - AXLE SPRING PAD
against the isolator spring locator (Fig. 14). 4 - LOCATING HOLE

(4) Raise the axle and guide the springs onto the
(7) Install the track bar to the axle bracket and
spring upper mounts and lower shock studs into the
install the mounting bolt.
axle brackets.
(5) Install the shock absorbers lower mounting NOTE: It may be necessary to pry the axle assem-
nuts. bly over to install the track bar bolt.
(6) Install the stabilizer bar link to the axle
bracket and install the mounting bolts and nuts.
WJ SUSPENSION 2 - 13
SPRING (Continued)

Fig. 15 Stabilizer Bar


Fig. 14 Isolator Spring Locator 1 - LINK
1 - COIL SPRING 2 - STABILIZER BAR
2 - SPRING LOCATOR 3 - BUSHING
3 - LOWER ISOLATOR 4 - RETAINER

(8) Tighten all suspension components to proper (2) Install the links onto the stabilizer bar and
torque. axle brackets and install the bolts and nuts finger
(9) Install the wheel and tire assemblies. tight.
(10) Remove support and lower vehicle. (3) Remove the supports and lower the vehicle.
(4) With the vehicle on the ground tighten the sta-
bilizer bar link nuts to 106 Nm (78 ft. lbs.).
STABILIZER BAR
DESCRIPTION TRACK BAR
The bar extends across the front underside of the
chassis and is mounted to the frame rails. Links are DESCRIPTION
connected from the bar to the axle brackets. The sta- The bar is attached to a frame rail bracket and
bilizer bar and links are isolated by rubber bushings. axle bracket. The bar is forged and has non replace-
able isolator bushings at both ends.
OPERATION
The stabilizer bar is used to control vehicle body OPERATION
roll during turns. The spring steel bar helps to con- The track bar is used to control front axle lateral
trol the vehicle body in relationship to the suspen- movement and provides cross car location of the axle
sion. assembly.

REMOVAL REMOVAL
(1) Raise and support the vehicle. (1) Raise and support the vehicle.
(2) Remove link nuts and bolts (Fig. 15) and (2) Remove the nut and bolt from the frame rail
remove the links. bracket (Fig. 16).
(3) Remove the stabilizer bar retainer bolts (Fig. (3) Remove the bolt from the axle shaft tube
15)from the frame rails and remove the stabilizer bracket (Fig. 17). Remove the track bar.
bar.
INSTALLATION
INSTALLATION (1) Install the track bar to the axle tube bracket.
(1) Position the stabilizer bar on the frame rail Install the retaining bolt finger tight.
and install the retainers and bolts. Ensure the bar is (2) Install track bar to the frame rail bracket.
centered with equal spacing on both sides. Tighten Install the bolt and nut finger tight.
the bolts to 92 Nm (68 ft. lbs.).
2 - 14 SUSPENSION WJ
TRACK BAR (Continued)

Fig. 17 Track Bar Axle Bracket


Fig. 16 Track Bar Frame Rail Bracket
1 - AXLE BRACKET
1 - FRAME RAIL 2 - TRACK BAR
2 - TRACK BAR

NOTE: It may be necessary to pry the axle assem- UPPER BALL JOINT
bly over to install the track bar to the frame rail
bracket. REMOVAL
Ball stud service procedures below require removal
(3) Remove the supports and lower the vehicle. of the hub bearing and axle shaft. Removal and
(4) With the vehicle on the ground tighten the nut installation of upper and lower ball studs require the
at the frame rail bracket and to the bolt at the axle use of Tool Kit 6289.
bracket to 100 Nm (74 ft. lbs.). (1) Position tools as shown to remove and install
(5) Check alignment specifications if a new track ball stud (Fig. 18).
bar was installed.
WJ SUSPENSION 2 - 15
UPPER BALL JOINT (Continued)

Fig. 18 Upper

UPPER CONTROL ARM


DESCRIPTION
The upper suspension arms are hydroformed steel
and use rubber bushings at each end of the arm.

OPERATION
The arms mount to the unibody frame rail bracket
and the axle brackets. The arm and bushings provide
location and react to loads from the axle. The bush-
ings provide isolation from the axle.

REMOVAL
(1) Raise vehicle and support the axle.
(2) Remove the upper suspension arm mounting Fig. 19 Upper Suspension Arm
nut and bolt (Fig. 19) from the axle bracket. 1 - UPPER SUSPENSION ARM
(3) Remove the nut and bolt (Fig. 19) at the frame 2 - FRAME BOLT
rail and remove the upper suspension arm. 3 - AXLE BOLT

INSTALLATION (4) With the vehicle on the ground tighten the axle
(1) Position the upper suspension arm at the axle bracket nut and the frame bracket bolt to 61 Nm (45
and frame rail. ft. lbs.).
(2) Install the bolts and finger tighten the nuts. (5) Check the alignment if new parts were
(3) Remove the supports and lower the vehicle. installed.
2 - 16 SUSPENSION WJ

REAR SUSPENSION
DESCRIPTION
The rear suspension (Fig. 20) is comprised of :
Drive axle
Shock absorbers
Coil springs
Lower suspension arms
Upper suspension arm
Stabilizer bar

CAUTION: Suspension components with rubber/ure-


thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle Fig. 20 Rear Suspension
ride comfort and prevent premature bushing wear.
1 - SHOCK
2 - UPPER SUSPENSION ARM
3 - COIL SPRING
WARNING 4 - STABILIZER BAR
5 - LOWER SUSPENSION ARM
WARNING: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.

DIAGNOSIS AND TESTING - REAR SUSPENSION

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose, worn or bent suspension 2. Inspect, tighten or replace components


components. as necessary.
3. Tire pressure. 3. Adjust tire pressure.

VEHICLE PULLS TO ONE 1. Weak or broken spring. 1. Replace spring.


SIDE
2. Alignment. 2. Align vehicle to specifications.
3.Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.


OR SQUEAKING 2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
5. Loose, worn or bent suspension 5. Inspect, tighten or replace components
components. as necessary.
WJ SUSPENSION 2 - 17
REAR SUSPENSION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

IMPROPER TRACKING 1. Loose, worn or bent suspension 1. Inspect, tighten or replace components
components. as necessary.
2. Bent axle. 2.Replace axle.

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION Nm Ft. Lbs. In. Lbs.


Shock Absorber Upper 108 80
Nut
Shock Absorber Lower 115 85
Nut
Suspension Arm Upper 142 105
Ball Joint Nut
Suspension Arm Upper 100 74
Frame Bolts
Ball Joint Plate Bolts 136 100
Suspension Arms Lower 163 120
Axle Bracket Nut
Suspension Arms Lower 156 115
Frame Bracket Nut
Stabilizer Bar Retainer 54 40
Bolts
Stabilizer Bar Bar Link Nut 54 40
Stabilizer Bar Bracket Link 92 68
Nut

SPECIAL TOOLS JOUNCE BUMPER


REAR SUSPENSION DESCRIPTION
The jounce bumpers are mounted inside the coil
spring, between the axle and the frame rail, to min-
imize transmission of noise to the passenger com-
partment.

OPERATION
The jounce bumpers are used to limit suspension
travel in compression.

LOWER CONTROL ARM


Remover 8278
DESCRIPTION
The lower suspension arms are hydroformed steel
and use voided oval bushings at each end of the arm.
2 - 18 SUSPENSION WJ
LOWER CONTROL ARM (Continued)

OPERATION brackets. The standard shocks have conventional


The bushings provide isolation from the axle. The twin tube construction and are low pressure gas
arms mount to the unibody frame rail bracket and charged. Gas charging prevents cavitation during
the axle brackets. The arm and bushings provide rough road operation. Up-Country shocks are mono
location and react to loads. tube design and are high pressure gas charged.

REMOVAL OPERATION
(1) Raise the vehicle and support the rear axle. The shock absorbers dampen jounce and rebound
(2) Remove the lower suspension arm nut and bolt motion of the vehicle over various road conditions
from the axle bracket (Fig. 21). and limit suspension rebound travel.
(3) Remove the nut and bolt (Fig. 21) from the
frame rail and remove the lower suspension arm. REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.

CAUTION: Do not allow the axle to hang from the


upper suspension arm ball joint.

(2) Remove the upper nut and bolt from the frame
bracket (Fig. 22).
(3) Remove the lower nut and bolt from the axle
bracket. Remove the shock absorber.

Fig. 21 Lower Suspension Arm


1 - LOWER SUSPENSION ARM
2 - AXLE BRACKET
3 - FRAME BRACKET

INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.
Fig. 22 Shock Absorber
NOTE: The end of the arm with the oval bushing
1 - SHOCK
attaches to the axle bracket.

(2) Install the axle bracket bolt and nut finger


INSTALLATION
tight.
(1) Install the shock absorber in the frame bracket
(3) Install the frame rail bracket bolt and nut fin-
and install the bolt and nut.
ger tight.
(2) Install the shock absorber in the axle bracket
(4) Remove the supports and lower the vehicle.
and install the bolt and nut.
(5) With the vehicle on the ground tighten the nut
(3) Tighten the upper mounting nuts to 108 Nm
at the frame to 156 Nm (115 ft. lbs.). Tighten the
(80 ft. lbs.). Tighten the lower mounting nuts to 115
nut at the axle bracket to 163 Nm (120 ft. lbs.).
Nm (85 ft. lbs.).
(4) Remove the supports and lower the vehicle.
SHOCK
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle
WJ SUSPENSION 2 - 19

SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert. The
isolators provide road noise isolation

OPERATION
The coil springs control ride quality and maintain
proper ride height.

REMOVAL
(1) Raise and support the vehicle. Position a
Fig. 24 Isolator Locator Nub
hydraulic jack under the axle to support the axle.
1 - LOWER ISOLATOR
(2) Remove the wheel and tire assemblies.
2 - LOCATOR NUB
(3) Remove the stabilizer bar link from the stabi-
3 - AXLE SPRING PAD
lizer bar (Fig. 23).
(4) Remove the shock absorber lower bolt from the
axle bracket. CAUTION: Ensure the spring is positioned on the
(5) Lower the hydraulic jack and tilt the axle and lower isolator with the end of the spring coil
remove the coil spring (Fig. 23). against the isolator spring locator (Fig. 25).

Fig. 23 Coil Spring Fig. 25 Isolator Spring Locator - Typical


1 - COIL SPRING 1 - LOWER ISOLATOR
2 - ISOLATOR 2 - SPRING LOCATOR
3 - STABILIZER LINK 3 - COIL SPRING
4 - ISOLATOR

(4) Raise the axle with the hydraulic jack.


(6) Remove and inspect the upper and lower (5) Install the shock absorber to the axle bracket
spring isolators (Fig. 23). and tighten to specification.
(6) Install the stabilizer bar link to the stabilizer
INSTALLATION bar.
(1) Install the upper isolator. (7) Install the wheel and tire assemblies.
(2) Install the lower isolator with the isolator loca- (8) Remove the supports and lower the vehicle.
tor nub in the axle pad hole (Fig. 24). (9) Tighten the stabilizer bar links to specification.
(3) Pull down on the axle and position the coil
spring in the lower isolator.
2 - 20 SUSPENSION WJ

STABILIZER BAR UPPER BALL JOINT


DESCRIPTION DESCRIPTION - UPPER SUSPENSION ARM,
The stabilizer bar extends across the back side of BUSHINGS, AND BALL JOINT
the rear axle. Links are connected between the bar The suspension arm uses vertical spool bushings to
and frame rail brackets. The stabilizer bar and links isolate road noise. The suspension arm is bolted
are isolated by rubber bushings. through bushings to cage nuts in the body and a ball
joint plate to the top of the differential housing.
OPERATION
The stabilizer bar is used to control vehicle body OPERATION - UPPER SUSPENSION ARM,
roll, during turns. The bar helps control the vehicle
BUSHINGS, AND BALL JOINT
body in relationship to the suspension.
The upper suspension arm provides fore/aft and
lateral location of the rear axle. The suspension arm
REMOVAL travel is limited through the use of jounce bumpers
(1) Raise and support the vehicle.
in compression and shock absorbers in rebound.
(2) Remove the stabilizer bar links from stabilizer
bar and frame mount. (Fig. 26).
REMOVAL
(3) Remove the stabilizer bar retainer bolts.
(1) Raise and support the vehicle.
(4) Remove the stabilizer bar.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint nut from the top of the
upper suspension arm (Fig. 27).

Fig. 26 Rear Stabilizer Bar


1 - LINK
2 - RETAINER
3 - BUSHING Fig. 27 Ball Joint Nut
4 - STABILIZER BAR
1 - BALL JOINT NUT
2 - UPPER SUSPENSION ARM

INSTALLATION
(1) Position the stabilizer bar on the axle and (4) Separate ball joint from the arm with Remover
install the retainers and bolts. Ensure the bar is cen- 8278 (Fig. 28).
tered with equal spacing on both sides. Tighten the
bolts to 54 Nm (40 ft. lbs.). NOTE: It may be necessary to strike the upper con-
(2) Install the links to the stabilizer bar and frame trol arm with a hammer to separate the ball joint
brackets. from the arm.
(3) Tighten the nuts at the stabilizer bar to 54
(5) Remove the ball joint mounting bolts (Fig.
Nm (40 ft. lbs.).
29)from the differential housing.
(4) Tighten the nuts at the frame brackets to 92
(6) Remove the ball joint from the differential
Nm (68 ft. lbs.).
housing.
(5) Remove support and lower the vehicle.
WJ SUSPENSION 2 - 21
UPPER BALL JOINT (Continued)
(2) Install the ball joint mounting bolts and
tighten to 136 Nm (100 ft. lbs.).
(3) Raise the rear axle with a hydraulic jack to
align the upper arm with the ball joint.
(4) Pull the arm down on the ball joint stud and
install a new nut. Tighten the nut to 142 Nm (105
ft. lbs.).
(5) Remove the supports and lower the vehicle.

UPPER CONTROL ARM


DESCRIPTION
The suspension arm uses vertical spool bushings to
isolate road noise. The suspension arm is bolted
through bushings to cage nuts in the body and a ball
joint plate to the top of the differential housing.

OPERATION
The upper suspension arm provides fore/aft and
lateral location of the rear axle. The suspension arm
travel is limited through the use of jounce bumpers
Fig. 28 Separate Ball Joint
in compression and shock absorbers in rebound.
1 - REMOVER - 8278
2 - UPPER SUSPENSION ARM
3 - BALL JOINT STUD
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the park brake cables and brake hose
from the arm (Fig. 30).

Fig. 30 Park Brake Cables And Brake Hose


Fig. 29 Ball Joint Mounting Bolts 1 - UPPER SUSPENSION ARM
1 - BALL JOINT 2 - REAR BRAKE HOSE
2 - MOUNTING BOLTS 3 - PARK BRAKE CABLES

(4) Remove the ball joint nut from the top of the
INSTALLATION upper suspension arm (Fig. 31).
(1) Install the ball joint on the differential hous- (5) Separate ball joint from the arm with Remover
ing. 8278 (Fig. 32).
2 - 22 SUSPENSION WJ
UPPER CONTROL ARM (Continued)

Fig. 31 Ball Joint Nut


1 - BALL JOINT NUT
2 - UPPER SUSPENSION ARM

NOTE: It may be necessary to strike the upper con-


trol arm with a hammer to separate the ball joint Fig. 32 Separate Ball Joint
from the arm. 1 - REMOVER - 8278
2 - UPPER SUSPENSION ARM
(6) Remove the upper suspension arm mounting 3 - BALL JOINT STUD
bolts and remove the arm (Fig. 33).

INSTALLATION
(1) Position the upper suspension arm in the
frame rail brackets.
(2) Install the mounting bolts and tighten to 100
Nm (74 ft. lbs.).
(3) Pull the arm down on the ball joint stud and
install a new nut. Tighten the nut to 142 Nm (105
ft. lbs.).
(4) Install the park brake cables and brake hose to
the arm.
(5) Remove the supports and lower the vehicle.

Fig. 33 Upper Suspension Arm Mounting Bolt


1 - UPPER SUSPENSION ARM
2 - MOUNTING BOLT
WJ DIFFERENTIAL & DRIVELINE 3-1

DIFFERENTIAL & DRIVELINE


TABLE OF CONTENTS

page page

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1 REAR AXLE - 198RBI . . . . . . . . . . . . . . . . . . . . . 49


FRONT TUBE AXLE . . . . . . . . . . . . . . . . . . . . . . 15 REAR AXLE - 226RBA . . . . . . . . . . . . . . . . . . . . . 87
FRONT AXLE - 186FBI . . . . . . . . . . . . . . . . . . . . 16

PROPELLER SHAFT

TABLE OF CONTENTS
page page

PROPELLER SHAFT PROPELLER SHAFT - FRONT 4.7L


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .2 PROPELLER SHAFT - REAR
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . .2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . .4 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . .4 SINGLE CARDAN UNIVERSAL JOINTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . .6 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . .7 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PROPELLER SHAFT - FRONT DOUBLE CARDAN UNIVERSAL JOINTS
REMOVAL . . . . . . . . . . . . . . . ................7 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . ................7 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PROPELLER SHAFT essary to accommodate the variations in length nec-


essary due to suspension travel. The C/V joint at the
transfer case end of the propeller shaft is fixed. The
DESCRIPTION
two C/V joints are connected by a hollow tube shaft.
A propeller shaft (Fig. 1) is the shaft which con-
The shaft length is not adjustable and does vary
nects the transmission/transfer case to the axle dif-
according to application.
ferential. This is the link through which the engine
power is transmitted to the axle.
The propeller shaft is designed and built with the
OPERATION
yoke lugs in line with each other which is called zero The propeller shaft must operate through con-
stantly changing relative angles between the trans-
phasing. This design produces the smoothest running
mission and axle when going over various road
condition, an out-of-phase shaft can cause a vibra-
surfaces. It must also be capable of changing length
tion.
Tubular propeller shafts are balanced by the man- while transmitting torque. The axle rides suspended
by springs in a floating motion. This is accomplished
ufacturer with weights spot welded to the tube.
Two styles of front propeller shafts are used on this through universal joints, which permit the propeller
vehicle. The 4.7L engine propeller shaft uses a single shaft to operate at different angles. The slip joints (or
yokes) permit contraction or expansion.
cardan U-joint at the axle end and a double cardan
Before undercoating a vehicle, the propeller
U-joint at the transfer case end. The rest uses a Con-
stant Velocity (C/V) joint at both the axle and trans- shaft and the U-joints should be covered to pre-
vent an out-of-balance condition and driveline
fer case end of the propeller shaft. The C/V joint at
the axle end contracts and extends (plunges) as nec- vibration.
3-2 PROPELLER SHAFT WJ
PROPELLER SHAFT (Continued)

Fig. 1 Propeller Shafts - Except 4.7L


1 - REAR AXLE 6 - PINION FLANGE
2 - STRAP 7 - FRONT AXLE
3 - BOLT 8 - BOLT
4 - SLIP YOKE 9 - FRONT PROPELLER SHAFT
5 - REAR PROPELLER SHAFT 10 - TRANSFER CASE

CAUTION: Use original equipment replacement Brake rotors that are unbalanced will cause a
parts for attaching the propeller shafts. The speci- harsh, low frequency vibration. (Refer to 5 - BRAKES
fied torque must always be applied when tightening - DIAGNOSIS AND TESTING)
the fasteners. Driveline vibration can also result from loose or
damaged engine mounts.
Propeller shaft vibration increases as the vehicle
DIAGNOSIS AND TESTING - PROPELLER speed is increased. A vibration that occurs within a
SHAFT specific speed range is not usually caused by a pro-
peller shaft being unbalanced. Defective universal
VIBRATION joints, or an incorrect propeller shaft angle, are usu-
Tires that are out-of-round, or wheels that are ally the cause of such a vibration.
unbalanced, will cause a low frequency vibration.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
WJ PROPELLER SHAFT 3-3
PROPELLER SHAFT (Continued)
DRIVELINE VIBRATION

Drive Condition Possible Cause Correction

Propeller Shaft Noise 1) Undercoating or other foreign material 1) Clean exterior of shaft and wash with
on shaft. solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws and
tighten to proper torque.
3) Loose or bent U-joint yoke or excessive 3) Install new yoke.
runout.
4) Incorrect driveline angularity. 4) Measure and correct driveline angles.
5) Rear spring center bolt not in seat. 5) Loosen spring u-bolts and seat center
bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out of 7) Installl new propeller shaft.
balance.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced 9) Re-index propeller shaft, test, and
condition. evaluate.
10) Excessive drive pinion gear shaft 10) Re-index propeller shaft and evaluate.
runout.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.

Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws and
tighten to proper torque.
2) Lack of lubrication. 2) Replace U-joints as necessary.

BALANCE (9) Install a screw clamp at position 1 (Fig. 2).

NOTE: Removing and re-indexing the propeller


shaft 180 relative to the yoke may eliminate some
vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, are properly installed, and are cor-
rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque.
(6) Remove the wheels and tires. Install the wheel Fig. 2 Clamp Screw At Position 1
lug nuts to retain the brake drums or rotors. 1 - CLAMP
(7) Mark and number the shaft six inches from the 2 - SCREWDRIVER
yoke end at four positions 90 apart.
(8) Run and accelerate the vehicle until vibration
(10) Start the engine and re-check for vibration. If
occurs. Note the intensity and speed the vibration
there is little or no change in vibration, move the
occurred. Stop the engine.
3-4 PROPELLER SHAFT WJ
PROPELLER SHAFT (Continued)
clamp to one of the other three positions. Repeat the RUNOUT
vibration test. (1) Remove dirt, rust, paint, and undercoating
(11) If there is no difference in vibration at the from the propeller shaft surface where the dial indi-
other positions, the source of the vibration may not cator will contact the shaft.
be propeller shaft. (2) The dial indicator must be installed perpendic-
(12) If the vibration decreased, install a second ular to the shaft surface.
clamp (Fig. 3) and repeat the test. (3) Measure runout at the center and ends of the
shaft sufficiently far away from weld areas to ensure
that the effects of the weld process will not enter into
the measurements.
(4) Refer to Runout Specifications chart.
(5) If the propeller shaft runout is out of specifica-
tion, remove the propeller shaft, index the shaft 180,
and re-install the propeller shaft. Measure shaft
runout again.
(6) If the propeller shaft runout is now within
specifications, mark the shaft and yokes for proper
orientation.
(7) If the propeller shaft runout is not within spec-
ifications, verify that the runout of the transmission/
transfer case and axle are within specifications.
Correct as necessary and re-measure propeller shaft
runout.
Fig. 3 Two Clamp Screws At The Same Position (8) Replace the propeller shaft if the runout still
(13) If the additional clamp causes an additional exceeds the limits.
vibration, separate the clamps (1/4 inch above and RUNOUT SPECIFICATIONS
below the mark). Repeat the vibration test (Fig. 4).
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches
(76 mm) from the weld seam at each end of the
shaft tube for tube lengths over 30 inches. For
tube lengths under 30 inches, the maximum
allowed runout is 0.020 in. (0.50 mm) for the full
length of the tube.

STANDARD PROCEDURES - PROPELLER


SHAFT ANGLE
The procedure applies to both the front propeller
shafts and the rear propeller shaft. To obtain the
Fig. 4 Clamp Screws Separated front (output) angle on the C/V front propeller shaft,
1 - 12 INCH the inclinometer is placed on the machined ring of
the pinion flange. To obtain the propeller shaft angle
(14) Increase distance between the clamp screws measurement on the C/V front propeller shaft, the
and repeat the test until the amount of vibration is inclinometer is placed on the propeller shaft tube.
at the lowest level. Bend the slack end of the clamps (1) Raise and support the vehicle at the axles as
so the screws will not loosen. level as possible. Allow the wheels and propeller
(15) If the vibration remains unacceptable, apply shaft to turn.
the same steps to the front end of the propeller shaft. (2) Remove any external bearing snap rings from
(16) Install the wheel and tires. Lower the vehicle. universal joint if equipped, so the inclinometer base
will sits flat.
WJ PROPELLER SHAFT 3-5
PROPELLER SHAFT (Continued)
(3) Rotate the shaft until transmission/transfer
case output yoke bearing cap is facing downward, if
necessary.
Always make measurements from front to
rear.
(4) Place Inclinometer on yoke bearing cap, or the
pinion flange ring, (A) parallel to the shaft (Fig. 5).
Center bubble in sight glass and record measure-
ment.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).

Fig. 6 Propeller Shaft Angle Measurement (C)


1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER

Fig. 5 Front (Output) Angle Measurement (A)


1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER

(5) Rotate propeller shaft 90 degrees and place


Inclinometer on yoke bearing cap, or propeller shaft
tube on C/V propeller shaft, parallel to the shaft (Fig.
6). Center bubble in sight glass and record measure-
ment. This measurement can also be taken at the
rear end of the shaft.
This measurement will give you the propeller
shaft angle (C).
(6) Subtract smaller figure from larger (C minus Fig. 7 Rear (Input) Angle Measurement (B)
A) to obtain transmission output operating angle. 1 - PINION YOKE BEARING CAP
(7) Rotate propeller shaft 90 degrees and place 2 - INCLINOMETER
Inclinometer on pinion yoke bearing cap parallel to
the shaft (Fig. 7). Center bubble in sight glass and Good cancellation of U-joint operating angles
record measurement. (within 1).
This measurement will give you the pinion Operating angles less than 3.
shaft or input yoke angle (B). Operating angles less than 10 for double cardan
(8) Subtract smaller figure from larger (C minus U-joint.
B) to obtain axle Input Operating Angle. At least 1/2 of one degree continuous operating
Refer to rules given below and the example in (Fig. (propeller shaft) angle.
8) for additional information.
3-6 PROPELLER SHAFT WJ
SPECIFICATIONS (Continued)

Fig. 8 Universal Joint Angle Example


1 - 4.9 Angle (C) 4 - 3.0 Angle (A)
2 - 3.2 Angle (B) 5 - Output Yoke
3 - Input Yoke

SPECIFICATIONS
PROPELLER SHAFT
TORQUE SPECIFICATIONS

DESCRIPTION Nm Ft. Lbs. In. Lbs.


Front Shaft - Companion
32 24
Flange Bolts
Rear Shaft - Yoke Nuts 19 14
WJ PROPELLER SHAFT 3-7

SPECIAL TOOLS (5) Mark a line across the companion flange at the
transfer case and C/V joint at the rear of the front
SPECIAL TOOLS propeller shaft for installation reference.
(6) Mark a line across the C/V joints and the pin-
ion companion flanges for installation reference.
(7) Remove bolts from the front C/V joint to the
pinion companion flange.
(8) Remove bolts from the rear C/V joint to the
transfer case companion flange.
(9) Push the propeller shaft forward to clear trans-
fer case companion flange and remove the shaft.

Inclinometer 7663 INSTALLATION


PROPELLER SHAFT - FRONT NOTE: Different length propeller shafts are used for
different drivetrain applications. Ensure that the
REMOVAL correct propeller shaft is used.

NOTE: Different length propeller shafts are used for (1) Install the shaft between companion flanges.
different drivetrain applications. Ensure that the (2) The shaft should rotate freely in the pinion
correct propeller shaft is used. flange.
(3) Align marks on the companion flanges with the
(1) Place vehicle on floor or drive-on hoist with full marks on the C/V joints.
weight of vehicle on suspension. (4) Install bolts to the front C/V joint and tighten
(2) Shift the transmission and transfer case, if nec- bolts to 32 Nm (24 ft. lbs.).
essary, into the Neutral position. (5) Install the bolts to the rear C/V joint and
(3) Measure the distance from the face of the C/V tighten bolts to 32 Nm (24 ft. lbs.).
joint cup to the end of the C/V joint boot (Fig. 9). (6) Verify propeller shaft length.
(7) Lower vehicle.

PROPELLER SHAFT - FRONT


4.7L
REMOVAL
(1) Raise and support vehicle.
(2) Remove crossmember/skid plate as necessary to
gain access to the propeller shaft.
(3) Shift transmission and transfer case, if neces-
sary into Neutral.
(4) Mark a line across the yoke at the transfer
case, link yoke and propeller shaft yoke at the rear of
the front propeller shaft for installation reference
(Fig. 10).
Fig. 9 Measurement
(5) Mark a line across the propeller shaft yoke and
1 - C/V JOINT CUP pinion shaft yoke for installation reference.
2 - C/V BOOT END
(6) Remove the U-joint strap bolts at the pinion
3 - MEASUREMENT
shaft yoke (Fig. 11).
(7) Remove bolts holding rear universal joint to
(4) The correct length is 142.7 mm (5.61 in.). the transfer case yoke.
(8) Separate the rear universal joint from the
NOTE: If the measurement is not correct, the wrong transfer case yoke.
shaft may have been installed or a mating compo-
nent (front axle or transfer case) may be installed
incorrectly. Investigate and correct as necessary.
3-8 PROPELLER SHAFT WJ
PROPELLER SHAFT - FRONT 4.7L (Continued)
(3) Align mark on the rear link yoke and universal
joint to the mark on the transfer case yoke.
(4) Loosely install bolts to hold universal joint to
transfer case yoke.
(5) Align mark on front universal joint to the mark
on the axle pinion yoke.
(6) Tighten the U-joint strap/clamp bolts at the
axle yoke to 19 Nm (14 ft. lbs.).
(7) Tighten the universal joint to transfer case
bolts to 27 Nm (20 ft. lbs.).
(8) Lower the vehicle.

PROPELLER SHAFT - REAR


REMOVAL
Fig. 10 Reference Marks on Yokes (1) Raise and support vehicle on safety stands.
1 - REFERENCE MARKS (2) Shift the transmission and transfer case if nec-
essary, to their neutral positions.
(3) Mark a line across the axle pinion yoke and the
(9) Push rear of propeller shaft upward to clear propeller shaft yoke for installation reference.
transfer case yoke. (4) Remove the bolts holding the universal joint
(10) Separate front universal joint from front axle. clamps to the pinion yoke.
(11) Separate propeller shaft from vehicle. (5) Slide the slip yoke off of the transmission, or
transfer case, output shaft and remove the propeller
shaft (Fig. 12).

Fig. 11 Front Propeller Shaft - 4.7L


1 - FRONT AXLE
2 - BOOT
3 - PROPELLER SHAFT
4 - DOUBLE CARDAN U-JOINT
5 - TRANSFER CASE
6 - BOOT
7 - SLINGER
8 - CLAMP
9 - YOKE
Fig. 12 Rear Propeller Shaft
1 - SLIDING YOKE
INSTALLATION 2 - PROPELLER SHAFT
(1) Position front propeller shaft under vehicle 3 - PINION YOKE
with rear universal joint over the transfer case yoke. 4 - CLAMP/STRAP
(2) Place front universal joint into the axle pinion 5 - BOLT
yoke. 6 - OUTPUT SHAFT
WJ PROPELLER SHAFT 3-9
PROPELLER SHAFT - REAR (Continued)

INSTALLATION
(1) Slide the slip yoke on the transmission, or
transfer case, output shaft.
(2) Align the installation reference marks made on
the propeller shaft and pinion yoke.
(3) Position universal joint into pinion yoke.
(4) Install the universal joint clamp and clamp
bolts to the pinion yoke. Tighten bolts to 19 Nm (14
ft. lbs.).
(5) Lower the vehicle.

SINGLE CARDAN UNIVERSAL


JOINTS
DISASSEMBLY
Individual components of cardan universal joints
are not serviceable. If worn or leaking, they must be
replaced as an assembly.
(1) Remove the propeller shaft.
(2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring. Fig. 14 Press Out Bearing
(3) Remove snap rings from both sides of yoke 1 - PRESS
(Fig. 13). 2 - SOCKET

(7) If the bearing cap will not pull out of the yoke
by hand after pressing, tap the yoke ear near the
bearing cap to dislodge the cap.
(8) To remove the opposite bearing cap, turn the
yoke over and straighten the cross in the open hole.
Then, carefully press the end of the cross until the
remaining bearing cap can be removed (Fig. 15).

CAUTION: If the cross or bearing cap are not


straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.

ASSEMBLY
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to inside of yoke bores to aid in installa-
Fig. 13 Remove Snap Ring tion.
1 - SNAP RING (2) Position the cross in the yoke with its lube fit-
ting, if equipped, pointing up (Fig. 16).
(3) Place a bearing cap over the trunnion and
(4) Set the yoke in an arbor press or vise with a align the cap with the yoke bore (Fig. 17). Keep the
socket whose inside diameter is large enough to needle bearings upright in the bearing assembly. A
receive the bearing cap positioned beneath the yoke. needle bearing lying at the bottom of the cap will
(5) Position the yoke with the grease fitting, if prevent proper assembly.
equipped, pointing up. (4) Press the bearing cap into the yoke bore
(6) Place a socket with an outside diameter enough to install a snap ring.
smaller than the upper bearing cap on the upper (5) Install a snap ring.
bearing cap and press the cap through the yoke to
release the lower bearing cap (Fig. 14).
3 - 10 PROPELLER SHAFT WJ
SINGLE CARDAN UNIVERSAL JOINTS (Continued)

Fig. 17 Install Bearing On Trunnion


Fig. 15 Press Out Remaining Bearing 1 - BEARING CAP
1 - CROSS 2 - TRUNNION
2 - BEARING CAP

(6) Repeat Step 3 and Step 4to install the opposite


bearing cap. If the joint is stiff or binding, strike the
yoke with a soft hammer to seat the needle bearings.
(7) Add grease to lube fitting, if equipped.
(8) Install the propeller shaft.

DOUBLE CARDAN UNIVERSAL


JOINTS
DISASSEMBLY
Individual components of cardan universal joints
are not serviceable. If worn or leaking, they must be
replaced as an assembly.
(1) Remove the propeller shaft.
(2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring.
(3) Remove all the bearing cap snap rings (Fig.
18).
(4) Set the joint in an arbor press or vise with a
socket whose inside diameter is large enough to
receive the bearing cap positioned beneath the link
Fig. 16 Cross In Yoke yoke.
1 - CROSS
(5) Place a socket with an outside diameter
2 - YOKE smaller than the upper bearing cap on the upper
bearing cap and partially press one bearing cap from
the outboard side of the link yoke enough to grasp
the bearing cap with vise jaws (Fig. 19). Be sure to
remove grease fittings that interfere with removal.
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