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CORPORATION
SERVICE MANUAL
1995 JEEP
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owners Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components. To as-
sist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the
group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents
section that lists major topics within the group. If you are not sure which Group contains the information you
need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re-
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930.
GROUP TAB LOCATOR
Introduction
5 Brakes
6 Clutch
7 Cooling System
8 Electrical
9 Engines
14 Fuel System
16 Propeller Shafts
19 Steering
23 Body Components
Index
INTRODUCTION
CONTENTS
page page
INDEX
page page
Engine and Transmission/Transfer Case
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Vehicle Designations . . . . . . . . . . . . . . . . . . . . . . . . 1
International Vehicle Control and Display Symbols . . 5 Vehicle Dimension Data . . . . . . . . . . . . . . . . . . . . . 5
Major Component Identification . . . . . . . . . . . . . . . . 5 Vehicle Identification Number (VIN) Plate . . . . . . . . . 4
Trailer Towing Specifications . . . . . . . . . . . . . . . . . . 5 Vehicle Load Data . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vehicle Code Plate . . . . . . . . . . . . . . . . . . . . . . . . . 4 Vehicle Safety Certification Label . . . . . . . . . . . . . . . 4
VEHICLE SAFETY CERTIFICATION LABEL located on the lower windshield fence near the left
A vehicle safety certification label (Fig. 1) is at- A-pillar. The VIN contains 17 characters that provide
tached to every Jeep vehicle. The label certifies that data concerning the vehicle. Refer to the VIN decod-
the vehicle conforms to all applicable Federal Motor ing chart to determine the identification of a vehicle.
Vehicle Safety Standards. The label also lists: The Vehicle Identification Number is also imprinted
Gross vehicle weight rating (GVWR) and the gross on the:
front and rear axle weight ratings (GAWRs) based on Body Code Plate.
a minimum tire rim size and a maximum cold tire Vehicle Safety Certification Label.
inflation pressure. Frame rail.
Month and year of vehicle manufacture. To protect the consumer from theft and possible
Vehicle identification number (VIN). fraud the manufacturer is required to include a
Type of vehicle. Check Digit at the ninth position of the Vehicle Iden-
Month, day and hour (MDH) of final assembly. tification Number. The check digit is used by the
The label is located on the driver-side door shut- manufacturer and government agencies to verify the
face.
authenticity of the vehicle and official documentation.
The formula to use the check digit is not released to
the general public.
INDEX
page page
TORQUE SPECIFICATIONS
J INTRODUCTION 13
THREAD NOTATIONSAE AND METRIC imprinted with a single-digit strength class on the
nut face. Refer to the bolt identification and bolt
strength chart.
METRIC CONVERSION
Refer to the chart to convert torque values listed in
metric Newton-meters (Nzm). Also, use the chart to
convert between millimeters (mm) and inches (in.)
BOLT IDENTIFICATION
J INTRODUCTION 15
BOLT STRENGTH
16 INTRODUCTION J
METRIC CONVERSION
J LUBRICATION AND MAINTENANCE 0-1
CONTENTS
page page
GENERAL INFORMATION
INDEX
page page
INTRODUCTION
Lubrication and maintenance is divided into re-
quired and recommended service tasks. The required
service tasks must be completed to verify the emis-
sion controls function correctly. The recommended
service tasks should be completed to maintain safety
and durability.
This information will assist the service personnel
in providing maximum protection for each owners
vehicle.
Conditions can vary with individual driving habits.
It is necessary to schedule maintenance as a time in-
terval as well as a distance interval.
It is the owners responsibility to determine the ap-
plicable driving condition. Also to have the vehicle
serviced according to the maintenance schedule, and Fig. 1 International Symbols
to pay for the necessary parts and labor.
sensor. The fuel must have a minimum octane rating
Additional maintenance and lubrication informa-
of 87 based on the (R + M)/2 calculation method.
tion is listed in the Owners Manual.
CAUTION: UNLEADED FUEL ONLY must be used in
INTERNATIONAL SYMBOLS vehicles equipped with a catalyst emission control
Chrysler Corporation uses international symbols to system. All vehicles have reminders printed on the
identify engine compartment lubricant and fluid in- instrument panel below the fuel gauge and on the
spection and fill locations (Fig. 1). fuel filler door. The vehicles also have fuel filler
tubes that are specially designed to accept only the
FUEL REQUIREMENTS small-diameter dispensing nozzles. It is illegal to
All gasoline engines require the use of unleaded bypass the design of an unleaded fuel filler tube
gasoline to reduce the potentially harmful effects of and contaminate the fuel system.
lead to the environment. Also unleaded fuel is neces-
sary to prevent damage to the catalytic converter/O2
0-2 LUBRICATION AND MAINTENANCE J
MAINTENANCE SCHEDULES
37,500 MILES (60 000 KM) OR AT 30 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.
Lubricate steering linkage (4x4).
Drain and refill manual transmission. 90,000 MILES (145 000 KM) OR AT 72
MONTHS
45,000 MILES (72 500 KM) OR AT 36 MONTHS Replace air cleaner element.
Change engine oil. Replace spark plugs.
Replace engine oil filter. Adjust drive belts.
Lubricate steering linkage. Change engine oil.
Inspect brake linings. Replace engine oil filter.
Flush and replace engine coolant, regardless of Lubricate steering linkage.
mileage. Inspect brake linings.
Drain and refill automatic transmission.
52,500 MILES (84 500 KM) OR AT 42 MONTHS Drain and refill transfer case.
Change engine oil.
Replace engine oil filter. 97,500 MILES (157 000 KM) OR AT 78
Lubricate steering linkage (4x4). MONTHS
Flush and replace engine coolant if not done at 36 Change engine oil.
months. Replace engine oil filter.
Lubricate steering linkage (4x4).
60,000 MILES (96 500 KM) OR AT 48 MONTHS
Replace air cleaner element. 105,000 MILES (169 000 KM) OR AT 84
Replace distributor cap and rotor. MONTHS
Replace ignition wires. Change engine oil.
Replace spark plugs. Replace engine oil filter.
Adjust or replace drive belts. Lubricate steering linkage.
Change engine oil. Flush and replace engine coolant if it has been
Replace engine oil filter. 30,000 miles (48 000 km) or 24 months since last
Replace fuel filter. (See Note #1) change.
Lubricate steering linkage.
Drain and refill automatic transmission. 112,500 MILES (181 000 KM) OR AT 90
Drain and refill transfer case. MONTHS
Change engine oil.
67,500 MILES (108 500 KM) OR AT 54 Replace engine oil filter.
MONTHS Lubricate steering linkage (4x4).
Change engine oil. Inspect brake linings.
Replace engine oil filter. Drain and refill manual transmission.
Lubricate steering linkage (4x4). Flush and replace engine coolant if it has been
Inspect brake linings. 30,000 miles (48 000 km) or 24 months since last
change.
75,000 MILES (120 500 KM) OR AT 60
MONTHS 120,000 MILES (193 000 KM) OR AT 96
Change engine oil. MONTHS
Replace engine oil filter. Replace air cleaner element.
Lubricate steering linkage. Replace distributor cap and rotor.
Drain and refill manual transmission. Lubricate steering linkage.
Flush and replace engine coolant if it has been Drain and refill automatic transmission.
30,000 miles (48 000 km) or 24 months since last Drain and refill transfer case.
change. Replace ignition wires.
Replace spark plugs.
82,500 MILES (133 000 KM) OR AT 66 Adjust or replace drive belts.
MONTHS Change engine oil.
Change engine oil. Replace engine oil filter.
Replace engine oil filter. Replace fuel filter. (See note #1)
Lubricate steering linkage (4x4).
0-6 LUBRICATION AND MAINTENANCE J
Drain and refill automatic transmission fluid. 90,000 MILES (144 000KM)
Change front and rear axle fluid.* Change engine oil.
Replace air cleaner element. Replace engine oil filter.
Replace distributor cap and rotor. Lubricate steering linkage.
Replace ignition wires. Replace spark plugs.
Adjust or replace drive belts. Drain and refill Manual transmission fluid.
Replace fuel filter. See note #1. Replace air cleaner element.
Inspect brake linings. Adjust drive belts.
Drain and refill transfer case. Drain and refill transfer case fluid.
120,000 MILES (192 000KM) Drain and refill transfer case fluid.
Change engine oil. NOTE 1: Not required for California vehicles, rec-
Replace engine oil filter. ommended for proper vehicle performance.
Lubricate steering linkage. * Off-highway operation, trailer towing, taxi, limou-
Replace spark plugs. sine, bus, snow plowing, or other types of commercial
Drain and refill automatic transmission fluid. service or prolonged operation with heavy loading,
Change front and rear axle fluid.* especially in hot weather, require front and rear axle
Inspect brake linings. service indicated with a * in ScheduleB. Perform
Replace air cleaner element. these services if you usually operate your vehicle un-
Replace distributor cap and rotor. der these conditions.
Replace ignition wires.
Inspection and service should also be performed
Adjust or replace drive belts.
anytime a malfunction is observed or suspected.
Replace fuel filter. See note #1.
J LUBRICATION AND MAINTENANCE 0-9
INDEX
page page
WARNING: DO NOT ATTEMPT TO PUSH OR TOW A CAUTION: If the cause of starting problem on dis-
VEHICLE TO START THE ENGINE. UNBURNED abled vehicle is severe, damage to booster vehicle
FUEL COULD ENTER THE EXHAUST CATALYTIC charging system can result.
CONVERTER AND IGNITE AFTER THE ENGINE IS
STARTED. THIS COULD CAUSE THE CONVERTER (2) When using another vehicle as a booster
TO OVERHEAT AND RUPTURE. source, turn off all accessories, place gear selector in
park or neutral, set park brake and operate engine at
1200 rpm.
WARNING: REVIEW ALL SAFETY PRECAUTIONS (3) On disabled vehicle, place gear selector in park
AND WARNINGS IN GROUP 8A, BATTERY/START- or neutral and set park brake. Turn off all accesso-
ING/CHARGING SYSTEMS DIAGNOSTICS. ries.
DO NOT JUMP START A FROZEN BATTERY, PER-
(4) Connect jumper cables to booster battery. RED
SONAL INJURY CAN RESULT.
clamp to positive terminal (+). BLACK clamp to neg-
DO NOT JUMP START WHEN MAINTENANCE
ative terminal (-). DO NOT allow clamps at opposite
FREE BATTERY INDICATOR DOT IS YELLOW OR
end of cables to touch, electrical arc will result. Re-
BRIGHT COLOR.
DO NOT JUMP START A VEHICLE WHEN THE view all warnings in this procedure.
BATTERY FLUID IS BELOW THE TOP OF LEAD (5) On disabled vehicle, connect RED jumper cable
PLATES. clamp to positive (+) terminal. Connect BLACK
DO NOT ALLOW JUMPER CABLE CLAMPS TO jumper cable clamp to engine ground as close to the
TOUCH EACH OTHER WHEN CONNECTED TO A ground cable attaching point as possible (Fig. 1).
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL
ARCING OF BATTERY CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING DE-
VICE, DO NOT ALLOW BATTERY VOLTAGE TO EX-
CEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
HOISTING RECOMMENDATIONS
Refer to the Owners Manual for emergency vehicle Fig. 2 Vehicle Lifting LocationsTypical
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
FLOOR JACK POINTS PROVIDED ARE FOR A COMPLETE VEHI-
When properly positioned, a floor jack can be used CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
to lift a Jeep vehicle (Fig. 2 and 3). Support the ve- NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
hicle in the raised position with jack stands at the
HOISTING CONDITIONS UNSTABLE. PROPERLY
front and rear ends of the frame rails.
SUPPORT OR SECURE VEHICLE TO HOISTING DE-
CAUTION: Do not attempt to lift a Jeep vehicle with VICE WHEN THESE CONDITIONS EXIST.
a floor jack positioned under:
An axle tube.
TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved sling-type
A body side sill.
towing equipment can be used to tow all Jeep vehi-
A steering linkage component.
cles. When towing a 4WD vehicle using a wheel-lift
A drive shaft.
towing device, use a tow dolly under the opposite end
The engine or transmission oil pan. of the vehicle. A vehicle with flat-bed device can also
The fuel tank. be used to transport a disabled vehicle (Fig. 4).
A front suspension arm. A wooden crossbeam may be required for proper
Use the correct sub-frame rail or frame rail connection when using the sling-type, front-end tow-
lifting locations only (Fig. 2 and 3). ing method.
HOIST SAFETY PRECAUTIONS
A vehicle can be lifted with: Secure loose and protruding parts.
A single-post, frame-contact hoist. Always use a safety chain system that is indepen-
A twin-post, chassis hoist. dent of the lifting and towing equipment.
A ramp-type, drive-on hoist. Do not allow towing equipment to contact the dis-
When a frame-contact type hoist is used, ver- abled vehicles fuel tank.
ify that the lifting pads are positioned properly Do not allow anyone under the disabled vehicle
(Fig. 2 and 3). while it is lifted by the towing device.
J LUBRICATION AND MAINTENANCE 0 - 11
4WD XJ VEHICLES
(1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(2) Attach a J-hook to the disabled vehicle at the
left side of front the axle.
(3) Position the sling crossbar close to the J-hook
and below the front bumper (Fig. 6).
(4) Secure a chain to the right side of vehicle by
placing it over the axle shaft tube and attaching it to
a structural member
(4) Attach the safety chains to the vehicle.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
Fig. 5 Sling-Type, Front-End Towing (XJ Rear View) (6) Shift transfer case to NEUTRAL.
2WD-AUTOMATIC TRANSMISSION
Provided the transmission is operable, tow only in
NEUTRAL at speeds not to exceed 30 mph (50
km/h) and distances less than 15 miles (25km/h).
If the vehicle is to be towed more than 15 miles,
the propeller shaft should be disconnected or place
tow dollies under rear wheels.
2WD-MANUAL TRANSMISSION
To reduce the possible damage of transmission com-
ponents, the propeller shaft must be removed or
place tow dollies under the rear wheels before tow-
ing. Refer to Propeller Shafts, Group 16 for proper
removal procedure.
4WD YJ VEHICLES
(1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(3) Cover the open end of the transmission exten- (3) Shift transmission to Neutral.
sion housing. (4) Turn off engine with the ignition key in the un-
locked OFF position.
4WD VEHICLESXJ (5) Shift transfer case lever from 2H to N (NEU-
(1) Shift transfer case lever to NEUTRAL. TRAL) position.
(2) Place ignition switch in the unlocked position. (6) Shift manual transmission into gear or auto-
matic transmission into P (PARK).
4WD VEHICLESYJ
WARNING: WITH THE TRANSFER CASE IN NEU-
CAUTION: Follow these steps to be certain that the TRAL POSITION, THE VEHICLE COULD ROLL UN-
transfer case is fully in N (NEUTRAL) and that the
EXPECTEDLY. THE PARKING BRAKE SHOULD
axle is completely disengaged before flat towing to
ALWAYS BE APPLIED BEFORE THE TOW BAR IS
prevent damage to internal parts.
ATTACHED.
(1) Shift transfer case into 2H and check that the
(7) Attach vehicle to the tow vehicle with tow bar.
4WD light goes out.
(2) Start engine and drive the vehicle 3 mm (10 ft.)
CAUTION: Do not use a bumper mounted clamp-on
rearward and then 3 mm (10 ft.) forward to make
tow bar, damage to bumper face bar may occur.
sure the axle is disengaged.
J LUBRICATION AND MAINTENANCE 0 - 15
ENGINE MAINTENANCE
INDEX
page page
CAUTION: Wide open throttle operation in low CAUTION: Do not use non-detergent or straight
gears, before engine break-in period is complete, mineral oil when adding or changing crankcase lu-
can damage engine. bricant. Engine failure can result.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IR-
RITATING TO THE SKIN. AVOID PROLONGED OR
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 PROB- Fig. 1 Temperature/Engine Oil Viscosity
LEMS CAN RESULT. ENERGY CONSERVING OIL
DO NOT POLLUTE, DISPOSE OF USED ENGINE An Energy Conserving type oil is recommeded for
OIL PROPERLY. CONTACT YOUR DEALER OR GOV- gasoline engines. They are designated as either EN-
ERNMENT AGENCY FOR LOCATION OF COLLEC- ERGY CONSERVING or ENERGY CONSERVING
TION CENTER IN YOUR AREA. II.
0 - 16 LUBRICATION AND MAINTENANCE J
Fig. 5 Engine Oil Dipstick 4.0L Engine Fig. 6 Oil Filter2.5L Engine
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
USED ENGINE OIL DISPOSAL be at least above the ADD mark and preferably at
Care should be exercised when disposing used en- the FULL mark. Add coolant to the coolant recovery
gine oil after it has been drained from a vehicle en- bottle only, if necessary.
gine. Refer to the WARNING listed above. Cooling system freeze protection should be tested
at the onset of the winter season or every 12 months.
ENGINE COOLING SYSTEM Service is required if coolant is low, contaminated,
rusty or freeze protection is inadequate. To properly
WARNINGS AND PRECAUTIONS test cooling system, see Group 7, Cooling System.
The cooling system factory fill is a mixture of 50%
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
Ethylene Glycol based antifreeze and 50% water. Us-
BASE COOLANT AND IS HARMFUL IF SWAL-
ing a suitable hydrometer, measure antifreeze con-
LOWED OR INHALED. IF SWALLOWED, DRINK
centration in the radiator when the engine is cool. If
TWO GLASSES OF WATER AND INDUCE VOMIT-
the cooling system has recently been serviced, allow
ING. IF INHALED, MOVE TO FRESH AIR AREA.
coolant to circulate for at least 20 minutes before
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
taking hydrometer reading. Properly mixed coolant
STORE IN OPEN OR UNMARKED CONTAINERS.
will protect the cooling system to -37C (-35F). If the
WASH SKIN AND CLOTHING THOROUGHLY AFTER
freeze protection is above -28C (-20F), drain enough
COMING IN CONTACT WITH ETHYLENE GLYCOL.
coolant from the cooling system to allow room to add
KEEP OUT OF REACH OF CHILDREN. antifreeze to achieve adequate protection. A mix table
DISPOSE OF GLYCOL BASE COOLANT PROP- on the coolant container indicates the amount of an-
ERLY, CONTACT YOUR DEALER OR GOVERNMENT tifreeze required to winterize the cooling system
AGENCY FOR LOCATION OF COLLECTION CENTER based on the capacity, see Capacity Chart in General
IN YOUR AREA. Information section of this group.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE, PER- ANTIFREEZE SPECIFICATION
SONAL INJURY CAN RESULT. Chrysler Corporation recommends the use of Mo-
AVOID RADIATOR COOLING FAN WHEN ENGINE par Antifreeze/Coolant or a high quality, ethylene
COMPARTMENT RELATED SERVICE IS PER- glycol base antifreeze/coolant, with a silicate inhibi-
FORMED, PERSONAL INJURY CAN RESULT. tor.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag-
nostic and service procedures refer to Group 14, Fuel
System.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
and ETBE. The type and amount of oxygenate used
in the blend is important. The following are generally
used in gasoline blends:
ETHANOL
Ethanol (Ethyl or Grain Alcohol) properly blended,
is used as a mixture of 10 percent ethanol and 90
percent gasoline. Gasoline with ethanol may be
used in your vehicle.
METHANOL
line. You may encounter fuels containing 3 percent or DLING/SERVICING A BATTERY. THE BATTERY
more methanol along with other alcohols called cosol- ELECTROLYTE CONTAINS SULFURIC ACID AND
vents. WILL CAUSE HARM IF IT CONTACTS SKIN, EYES
Problems that are the result of using methanol/gas- OR CLOTHING. IT WILL ALSO DAMAGE PAINTED
oline blends are not the responsibility of Chrysler (AS WELL AS UN-PAINTED) SURFACES OF A VEHI-
Corporation. They may not be covered by the vehicle CLE. IF SULFURIC ACID CONTACTS ANY OF
warranty. THESE, FLUSH IMMEDIATELY WITH LARGE
AMOUNTS OF WATER. IF SULFURIC ACID CON-
MTBE/ETBE TACTS SKIN OR EYES, GET IMMEDIATE MEDICAL
Gasoline and MTBE (Methyl Tertiary Butyl Ether) ATTENTION. DO NOT SMOKE IN THE VICINITY OF A
blends are a mixture of unleaded gasoline and up to BATTERY. KEEP OPEN FLAMES AND SPARKS
15 percent MTBE. Gasoline and ETBE (Ethyl Ter- AWAY FROM BATTERY FILLER CAPS BECAUSE
tiary Butyl Ether) are blends of gasoline and up to EXPLOSIVE GAS IS ALWAYS PRESENT.
17 percent ETBE. Gasoline blended with MTBE or
ETBE may be used. Inspect battery tray, hold down and terminal con-
nections when other under hood service is performed.
CLEAN AIR GASOLINE For proper diagnostic procedures refer to Group 8A,
Many gasolines are now being blended that con- Battery/Starting/Charging System Diagnostics. For
tribute to cleaner air, especially in those areas of the service and cleaning procedures refer to Group 8B,
country where air pollution levels are high. These Battery/Starter Service.
new blends provide a cleaner burning fuel and some Care should be taken when disposing a bat-
are referred to as Reformulated Gasoline. tery after removal from a vehicle. Lead-acid
In areas of the country where carbon monoxide lev- batteries are highly poisonous and, when indis-
els are high, gasolines are being treated with oxygen- criminately disposed, could create a problem
ated materials such as MTBE, ETBE and ethanol. for the environment. Contact the applicable lo-
Chrysler Corporation supports these efforts toward cal city or county government agency to deter-
cleaner air and recommends the use of these gaso- mine where automobile (lead-acid) batteries
lines as they become available. can be properly disposed in the local area.
IGNITION CABLES, DISTRIBUTOR CAP AND RUBBER AND PLASTIC COMPONENT INSPECTION
ROTOR
Inspect and test ignition cables, distributor cap and CAUTION: Plastic hoses or wire harness covers will
rotor when the spark plugs are replaced. Oil and melt or deform when exposed to heat from exhaust
grime should be cleaned from the ignition cables and system or engine manifolds.
distributor cap to avoid possible spark plug fouling. Position plastic or rubber components away from
Mopar Foamy Engine Degreaser or equivalent is rec- moving parts in engine compartment or under vehi-
ommended for cleaning the engine compartment. For cle, or damage will result.
proper service and diagnostic procedures refer to Do not allow rubber engine mounts or other com-
Group 8D, Ignition System.
ponents to become oil contaminated, repair cause
IGNITION TIMING of oil contamination and clean area.
The ignition timing for 2.5L and 4.0L engines is All rubber and plastic components should be in-
not adjustable. Refer to the specifications listed on spected when engine compartment or under vehicle
the engine Emission Control Information Label. Re- service is performed. When evidence of deterioration
fer to Group 25, Emission Control Systems for addi- exists, replacement is required. To reduce deteriora-
tional information.
tion of rubber components, Chrysler Corporation rec-
ommends Mopar Foamy Engine Degreaser or
SPARK PLUGS
equivalent be used to clean engine compartment of
Ignition spark plugs should be replaced at the
oil and road grime.
mileage interval described in the Lubrication and
Maintenance Schedules. Refer to the General Infor-
mation section of this group. For proper service pro-
EMISSION CONTROL SYSTEM
cedures refer to Group 8D, Ignition Systems. Inspect all emission control components and hoses
when other under hood service is performed. Refer to
BATTERY emission system Vacuum Hose Label located on the
inside of the hood in the engine compartment and
WARNING: WEAR SAFETY GLASSES, RUBBER Group 25, Emission Control Systems for proper ser-
GLOVES AND PROTECTIVE CLOTHING WHEN HAN- vice procedures.
J LUBRICATION AND MAINTENANCE 0 - 21
ENGINE SUPPORTS (2) Inspect the rubber in the engine support cush-
The general condition of the engine supports ions for softening and swelling. Slight surface deteri-
should be inspected when engine compartment or un- oration and wear at the ends will not affect the
functioning of an engine support.
der vehicle service is performed.
EXHAUST SYSTEM
The exhaust system should be inspected when un-
der vehicle service is performed or as specified in the
Lubrication and Maintenance Schedules.
INSPECTION
When inspecting an exhaust system, inspect for
cracked or loose joints, stripped screw/bolt threads,
corrosion damage, and worn or broken hangers
(Slight cracking in rubber isolator or hanger is ac-
ceptable). Replace all components that are corroded
or damaged. Do not attempt repair. Also, inspect for
the following obvious conditions and correct as neces-
sary:
Exhaust system leaks, damage, misalignment.
Fig. 11 Front Engine SupportTypical
Contact with body panels metal or the frame.
Catalytic converter bulging or excessive heat dam-
age.
AIR-CONDITIONER COMPRESSOR
LUBRICANT AND REFRIGERANT
The lubricant level in the air-conditioner compres-
sor should be checked if there are indications that oil
was lost. Loss of lubricating oil usually accompanies
Fig. 12 Rear Engine SupportTypical a loss of refrigerant.
For additional information involving the A/C sys-
tem, refer to Group 24, Heater And Air Conditioning.
0 - 22 LUBRICATION AND MAINTENANCE J
DRIVETRAIN
INDEX
page page
MANUAL TRANSMISSION
The manual transmission should be inspected for
oil leaks and proper oil level when other under vehi-
cle service is performed.
LUBRICANT SPECIFICATION
When it becomes necessary to add to or change the
lube oil in a Jeep manual transmission, use SAE
Fig. 1 Clutch Reservoir LocationTypical 75W-90, API Quality Grade GL-5 gear lubricant.
The fluid level is determined by its height in rela-
tion to the level indicator ring (Fig. 2) located inside LUBRICANT LEVEL
the reservoir. Add fluid until the height is level with The fill-hole plug for all manual transmissions is
the indicator ring. located on the right side of the case (Fig. 3). Deter-
mine the lubricant level according to the following
FLUID SPECIFICATION procedure.
Use Mopar, Brake And Hydraulic Clutch Fluid or (1) Remove the fill-hole plug (Fig. 3) from the
equivalent. Use only brake fluid conforming to DOT transmission. The lube oil should be level with the
3, Federal, Department of Transportation specifica- bottom edge of the fill hole. The level can be slightly
tion. To avoid fluid contamination, use fluid from a below the bottom edge of the fill hole if the lube oil is
properly sealed container. cold.
J LUBRICATION AND MAINTENANCE 0 - 23
LUBRICANT SPECIFICATIONS
For normal vehicle operation, use SAE 75W-90,
API Quality Grade GL-5 gear lubricant in all Jeep
front (4WD only) and rear axles. Vehicles equipped
with a Trac-Lok rear axle also require a friction mod-
ifier additive included with the gear lubricant.
When involved in trailer towing applications
use SAE 80W-140, API Quality Grade GL-5 gear
Fig. 5 Transfer CaseTypical lubricant in the rear axle. XJ Vehicles equipped
Determine the transfer case fluid (ATF) level ac- with a class III trailer hitch require SAE 75W-
cording to the following procedure. 140 synthetic gear lubricant in the rear axle.
J LUBRICATION AND MAINTENANCE 0 - 25
LUBRICANT SPECIFICATION
Use Mopar, Multi-purpose Grease or any lubricate
that is identified as NLGI GC-LB lubricant.
HOSE/TUBING INSPECTION
(1) Inspect all hose and tubing fittings for loose-
ness and corrosion. Inspect the rubber hoses for brit-
tleness and cracks. Thoroughly inspect the hose ends
Fig. 9 Differential Housing Cover Installed (those that are slipped over nipple connectors) for
splits (Fig. 10, 11, 12, 13, 14, 15 and 16).
(11) Remove the support and lower the vehicle.
DRIVE SHAFTS
Lubricate at the intervals described in the Mainte-
nance Schedule section of this Group. Refer to Group
16, Propeller Shafts for proper service procedures.
Fig. 12 Front Axle Vacuum Shift Tubing Fig. 15 Rear Axle Vent HoseYJ Vehicles
Fig. 13 Transfer Case Vent Hose (4WD)Typical Fig. 16 Rear Axle Vent Hose At WheelhouseYJ
Vehicles
INDEX
page page
hose unless the caliper must also be removed (14) Tighten the spindle nut with 28 Nzm (21 ft.
for maintenance.Support the caliper with a lbs.) torque while rotating the disc brake rotor to
hanger to prevent brake fluid hose damage. seat the bearings.
(2) Remove the dust cap, the cotter pin, the nut re- (15) Loosen the spindle nut 1/2 turn. While rotat-
tainer, the adjustment nut, and the thrust washer ing the disc brake rotor, tighten the spindle nut with
from the spindle (Fig. 3). Discard the cotter pin. 2 Nzm (19 in. lbs.) torque.
(16) Install the nut retainer and a replacement cot-
ter pin.
(17) Clean the dust cap and apply wheel bearing
lubricant to the inside surface. Do not fill the dust
cap with lubricant.
(18) Install the dust cap.
(19) Install the disc brake caliper.