79237446 2000 Jeep Wrangler Service Manual TJ

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GROUP TAB LOCATOR
IN
Introduction
INa
Introduction
0
Lubrication and Maintenance
2
Suspension
3
Differential and Driveline
5
Brakes
6
Clutch
7
Cooling System
8A
Battery
8B
Starting Systems
8C
Charging System
8D
Ignition System
8E
Instrument Panel Systems
8Ea
Instrument Panel Systems
8F
Audio Systems
8G
Horn Systems
8H
Speed Control System
8J
Turn Signal and Hazard Warning Systems
8K
Wiper and Washer Systems
8L
Lamps
8La
Lamps
8M
Passive Restraint Systems
8N
Electrically Heated System
8O
Power Distribution System
8Q
Vehicle Theft/Security Systems
8U
Chime/Buzzer Warning Systems
8W
Wiring Diagrams
9
Engine
11
Exhaust System
13
Frame and Bumpers
13a
Frame and Bumpers
14
Fuel System
14a
Fuel System
19
Steering
21
Transmission and Transfer Case
22
Tires and Wheels
23
Body
24
Heating and Air Conditioning
25
Emission Control Systems
25a
Emission Control Systems
Service Manual Comment Forms
INTRODUCTION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . . . 2
INTERNATIONAL SYMBOLS. . . . . . . . . . . . . . . . . 3
FASTENER IDENTIFICATION. . . . . . . . . . . . . . . . . 3
FASTENER USAGE . . . . . . . . . . . . . . . . . . . . . . . . 6
THREADED HOLE REPAIR . . . . . . . . . . . . . . . . . . 6
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 6
TORQUE REFERENCES. . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION
VEHICLE IDENTIFICATION NUMBER
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
l ocated on the l ower wi ndshi el d fence near the l eft
A-pi l l ar. The VI N contai ns 17 characters that provi de
data concerni ng the vehi cl e. Refer to the VI N decod-
i ng chart to determi ne the i denti fi cati on of a vehi cl e.
The Vehi cl e I denti fi cati on Number i s al so
i mpri nted on the:
• Vehi cl e Safety Certi fi cati on Label .
• Frame rai l .
To protect the consumer from theft and possi bl e
fraud the manufacturer i s requi red to i ncl ude a
Check Di gi t at the ni nth posi ti on of the Vehi cl e I den-
ti fi cati on Number. The check di gi t i s used by the
manufacturer and government agenci es to veri fy the
authenti ci ty of the vehi cl e and offi ci al documenta-
ti on. The formul a to use the check di gi t i s not
rel eased to the general publ i c.
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 E = 3001-4000 lbs.
F = 4001-5000 lbs.
5 Vehicle Line Y = Wrangler 4X4
6 Series 1 = Sport
2 = SE
4 = Sahara
7 Body Style 9 = Open Body
8 Engine P = 2.5L Unleaded-Gasoline
S = 4.0L Unleaded-Gasoline
9 Check Digit
10 Model Year Y=2000
11 Assembly Plant P = Toledo #2
12 thru 17 Vehicle Build Sequence
TJ INTRODUCTION 1
VEHICLE SAFETY CERTIFICATION LABEL
A vehi cl e safety certi fi cati on l abel (Fi g. 1) i s
attached to every Dai ml erChrysl er Corporati on vehi -
cl e. The l abel certi fi es that the vehi cl e conforms to al l
appl i cabl e Federal Motor Vehi cl e Safety Standards.
The l abel al so l i sts:
• Month and year of vehi cl e manufacture.
• Gross Vehi cl e Wei ght Rati ng (GVWR). The gross
front and rear axl e wei ght rati ngs (GAWR’s) are
based on a mi ni mum ri m si ze and maxi mum col d ti re
i nfl ati on pressure.
• Vehi cl e I denti fi cati on Number (VI N).
• Type of vehi cl e.
• Bar code.
• Month, Day and Hour (MDH) of fi nal assembl y.
• Pai nt and Tri m codes.
• Country of ori gi n.
The l abel i s l ocated above the door hi nge on the
dri ver-si de A-pi l l ar.
Fig. 1 Vehicle Safety Certification Label—Typical
2 INTRODUCTION TJ
DESCRIPTION AND OPERATION (Continued)
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphi c symbol s i l l ustrated i n the fol l owi ng
I nternati onal Control and Di spl ay Symbol s Chart are
used to i denti fy vari ous i nstrument control s. The
symbol s correspond to the control s and di spl ays that
are l ocated on the i nstrument panel .
FASTENER IDENTIFICATION
DESCRIPTION
GRADE/CLASS IDENTIFICATION
The SAE bol t strength grades range from grade 2
to grade 8. The hi gher the grade number, the greater
the bol t strength. I denti fi cati on i s determi ned by the
l i ne marks on the top of each bol t head. The actual
bol t strength grade corresponds to the number of l i ne
marks pl us 2. The most commonl y used metri c bol t
strength cl asses are 9.8 and 10.9. The metri c
strength cl ass i denti fi cati on number i s i mpri nted on
the head of the bol t. The hi gher the cl ass number,
the greater the bol t strength. Some metri c nuts are
i mpri nted wi th a si ngl e-di gi t strength cl ass on the
nut face. Refer to the Fastener I denti fi cati on and
Fastener Strength Charts.
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
TJ INTRODUCTION 3
DESCRIPTION AND OPERATION (Continued)
FASTENER IDENTIFICATION
4 INTRODUCTION TJ
DESCRIPTION AND OPERATION (Continued)
FASTENER STRENGTH
TJ INTRODUCTION 5
DESCRIPTION AND OPERATION (Continued)
FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fi gure art, speci fi cati ons and torque references i n
thi s Servi ce Manual are i denti fi ed i n metri c and SAE
format.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage al l fasteners (nuts, bol ts, etc.)
for reassembl y. I f the fastener i s not sal vageabl e, a
fastener of equi val ent speci fi cati on must be used.
THREADED HOLE REPAIR
Most stri pped threaded hol es can be repai red usi ng
a Hel i coi l ௡. Fol l ow the manufactures recommenda-
ti ons for appl i cati on and repai r procedures.
METRIC SYSTEM
The metri c system i s based on quanti ti es of one,
ten, one hundred, one thousand and one mi l l i on (Fi g.
2).
The fol l owi ng chart wi l l assi st i n converti ng metri c
uni ts to equi val ent Engl i sh and SAE uni ts, or vi se
versa.
Refer to the Conversi on Chart to convert torque
val ues l i sted i n metri c Newton- meters (N·m). Al so,
use the chart to convert between mi l l i meters (mm)
and i nches (i n.)
TORQUE REFERENCES
DESCRIPTION
I ndi vi dual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Speci fi -
cati ons Chart for torque references not l i sted i n the
i ndi vi dual torque charts.
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply By To Get Multiply By To Get
in-lbs x 0.11298 = Newton-Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton-Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg
(60°F)
x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
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) M x 1.0936 = Yards
Miles x 1.6093 = Kilometers (Km) Km x 0.6214 = Miles
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.
Kilometers/Hr. x 0.27778 = Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 = mph
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
Mega - (M) Million Deci - (D) Tenth
Kilo - (K) Thousand Centi - (C) Hundreth
Milli - (m) Thousandth
Fig. 2 Metric Prefixes
6 INTRODUCTION TJ
DESCRIPTION AND OPERATION (Continued)
METRIC CONVERSION CHART
TJ INTRODUCTION 7
DESCRIPTION AND OPERATION (Continued)
TORQUE SPECIFICATIONS
8 INTRODUCTION TJ
DESCRIPTION AND OPERATION (Continued)
INTRODUCTION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . . . 2
BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . . . 2
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
l ocated on the l ower wi ndshi el d fence near the l eft
A-pi l l ar. The VI N contai ns 17 characters that provi de
data concerni ng the vehi cl e. Refer to the VI N decod-
i ng chart to determi ne the i denti fi cati on of a vehi cl e.
The Vehi cl e I denti fi cati on Number i s al so
i mpri nted on the:
• Body Code Pl ate.
• Vehi cl e Safety Certi fi cati on Label .
• Frame rai l .
To protect the consumer from theft and possi bl e
fraud the manufacturer i s requi red to i ncl ude a
Check Di gi t at the ni nth posi ti on of the Vehi cl e I den-
ti fi cati on Number. The check di gi t i s used by the
manufacturer and government agenci es to veri fy the
authenti ci ty of the vehi cl e and offi ci al documenta-
ti on. The formul a to use the check di gi t i s not
rel eased to the general publ i c.
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 E = 3001-4000 lbs.
F = 4001-5000 lbs.
5 Vehicle Line A = Wrangler 4X4 Left Hand Drive
4 = Wrangler 4X4 Right Hand Drive
6 Series/Transmission 4 = Sport
5 = Sahara
N = 5 SPD. Manual - DDO
A = 3 SPD. Auto - DGA
7 Body Style 9 = Open Body
8 Engine P = 2.5L Gasoline
S = 4.0L Gasoline
9 Check Digit
10 Model Year Y = 2000
11 Assembly Plant P = Toledo #2
12 thru 17 Vehicle Build Sequence
TJ INTRODUCTION 1
2000 JEEP WRANGLER
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION
A vehi cl e safety certi fi cati on l abel (Fi g. 1) i s
attached to every Chrysl er Corporati on vehi cl e. The
l abel certi fi es that the vehi cl e conforms to al l appl i -
cabl e Federal Motor Vehi cl e Safety Standards. The
l abel al so l i sts:
• Month and year of vehi cl e manufacture.
• Gross Vehi cl e Wei ght Rati ng (GVWR). The gross
front and rear axl e wei ght rati ngs (GAWR’s) are
based on a mi ni mum ri m si ze and maxi mum col d ti re
i nfl ati on pressure.
• Vehi cl e I denti fi cati on Number (VI N).
• Type of vehi cl e.
• Bar code.
• Month, Day and Hour (MDH) of fi nal assembl y.
• Pai nt and Tri m codes.
• Country of ori gi n.
The l abel i s l ocated above the door hi nge on the
dri ver-si de A-pi l l ar.
BODY CODE PLATE
DESCRIPTION
A metal body code pl ate i s attached to the fl oor pan
under the dri vers seat (Fi g. 2). Di sengage the snaps
attachi ng the carpet to the fl oor pan to read the
i nformati on. There are seven l i nes of i nformati on on
the body code pl ate. Li nes 4, 5, 6, and 7 are not used
to defi ne servi ce i nformati on. I nformati on reads from
l eft to ri ght, starti ng wi th l i ne 3 i n the center of the
pl ate to l i ne 1 at the bottom of the pl ate (Fi g. 3).
The l ast code i mpri nted on a vehi cl e code pl ate wi l l
be fol l owed by the i mpri nted word END. When two
vehi cl e code pl ates are requi red, the l ast avai l abl e
spaces on the fi rst pl ate wi l l be i mpri nted wi th the
l etters CTD (for conti nued).
When a second vehi cl e code pl ate i s necessary, the
fi rst four spaces on each row wi l l not be used because
of the pl ate overl ap.
BODY CODE PLATE— LINE 3
DIGITS 1 THROUGH 12
Vehi cl e Order Number
DIGITS 13, 14, AND 15
Roof
• VJN = Soft Top Whi te
• VJU = Soft Top Spi ce
• VJX = Soft Top Bl ack
• VKN = Hard Top Whi te
• VKU = Hard Top Spi ce
• VKX = Hard Top Bl ack
DIGITS 16, 17, AND 18
Car Li ne Shel l
• TJJ = Wrangl er (LHD)
• TJU = Wrangl er (RHD)
Fig. 1 Vehicle Safety Certification Label—Typical
Fig. 2 Body Code Plate Location
1 – SNAP
2 – REAR CARPET
3 – BODY CODE PLATE
4 – SNAP
5 – FLOOR PAN
6 – FRONT CARPET
2 INTRODUCTION TJ
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
DIGIT 19
Pri ce Cl ass
• L = Wrangl er (Al l )
DIGITS 20 AND 21
Body Type
• 77 = Wheel Base (93.4 i n.)
BODY CODE PLATE— LINE 2
DIGITS 1, 2, AND 3
Pai nt Procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 8
Pri mary Pai nt
Refer to Group 23, Body for col or codes.
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Pai nt
DIGIT 14
Open Space
DIGITS 15 THROUGH 18
I nteri or Tri m Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engi ne Code
• EPE = 2.5 L 4 cyl . MPI Gasol i ne
• ERH = 4.0L 6 cyl . MPI Gasol i ne
BODY CODE PLATE— LINE 1
DIGITS 1, 2, AND 3
Transmi ssi on Codes
• DDQ = AX5 5–speed Manual
• DDO = AX15 5–speed Manual
• DGD = 30RH 3–speed Automati c
• DGG = 32RH 3–speed Automati c
DIGIT 4
Open Space
DIGIT 5
Market Code
• B = I nternati onal
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehi cl e I denti fi cati on Number (VI N)
Refer to Vehi cl e I denti fi cati on Number (VI N) para-
graph for proper breakdown of VI N code.
Fig. 3 Body Code Plate Decoding
1 – PRIMARY PAINT
2 – SECONDARY PAINT
3 – ROOF
4 – CAR LINE SHELL
5 – ENGINE
6 – TRIM
7 – VIN
8 – MARKET
9 – TRANSMISSION
10 – PAINT PROCEDURE
11 – VEHICLE ORDER NUMBER
TJ INTRODUCTION 3
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS
DESCRIPTION
The graphi c symbol s i l l ustrated i n the fol l owi ng
I nternati onal Control and Di spl ay Symbol s chart are
used to i denti fy vari ous i nstrument control s. The
symbol s correspond to the control s and di spl ays that
are l ocated on the i nstrument panel .
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
Fig. 4
4 INTRODUCTION TJ
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
LUBRICATION AND MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . 3
JUMP STARTING, HOISTING AND TOWING . . . . . 8
LUBRICANTS
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . . 1
CLASSIFICATION OF LUBRICANTS. . . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE PROCEDURES
PARTS AND LUBRICANT RECOMMENDATIONS
RECOMMENDATIONS
When servi ce i s requi red, Dai ml erChrysl er Corpo-
rati on recommends that onl y Mopar௡ brand parts,
l ubri cants and chemi cal s be used. Mopar provi des
the best engi neered products for servi ci ng Dai ml er-
Chrysl er Corporati on vehi cl es.
INTERNATIONAL SYMBOLS
Dai ml erChrysl er Corporati on uses i nternati onal
symbol s to i denti fy engi ne compartment l ubri cant
and fl ui d i nspecti on and fi l l l ocati ons (Fi g. 1).
CLASSIFICATION OF LUBRICANTS
Onl y l ubri cants beari ng desi gnati ons defi ned by
the fol l owi ng organi zati on shoul d be used to servi ce a
Dai ml erChrysl er Corporati on vehi cl e.
• Soci ety of Automoti ve Engi neers (SAE)
• Ameri can Petrol eum I nsti tute (API ) (Fi g. 2)
• Nati onal Lubri cati ng Grease I nsti tute (NLGI )
(Fi g. 3)
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 30 speci fi es a si ngl e vi scos-
i ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range.
• SAE 30 = si ngl e grade engi ne oi l .
• SAE 10W-30 = mul ti pl e grade engi ne oi l .
Dai ml erChrysl er Corporati on onl y recommends
mul ti pl e grade engi ne oi l s.
API QUALITY CLASSIFICATION
Thi s symbol (Fi g. 2) on the front of an oi l contai ner
means that the oi l has been certi fi ed by the Ameri -
can Petrol eum I nsti tute (API ) to meet al l the l ubri -
cati on requi rements speci fi ed by Dai l ml erChrysl er
Corporati on.
Refer to Group 9, Engi ne for gasol i ne engi ne oi l
speci fi cati on.
Fig. 1 International Symbols
TJ LUBRICATION AND MAINTENANCE 0 - 1
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti pl e grade gear
l ubri cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
“G”. Chassi s l ubri cant i s i denti fi ed by the l atter “L”.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
FLUID CAPACITIES
FUEL TANK
Standard . . . . . . . . . . . . . . . . . . . 71.9 L (19.0 gal .)
ENGINE OILW/FILTER CHANGE
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 L (4.0 qts.)
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qts.)
COOLING SYSTEM
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 L (9.0 qts.)
4.0L . . . . . . . . . . . . . . . . . . . . . . . . 9.9 L (10.5 qts.)
AUTOMATIC TRANSMISSION
Dry fi l l capaci ty*
32RH . . . . . . . . . . . . . . . . . . . . . . 6.31 L (13.33pts.)
30RH . . . . . . . . . . . . . . . . . . . . . . 4.67 L (9.86 pts.)
*Dependi ng on type and si ze of i nternal cool er,
l ength and i nsi de di ameter of cool er l i nes, or use of an
auxi l i ary cool er, these fi gures may vary. Refer to
Group 21, Transmi ssi on for proper fl ui d fi l l procedure.
MANUAL TRANSMISSION
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 L (3.5 qts.)
AX15 . . . . . . . . . . . . . . . . . . . . . . 3.15 L (3.32 qts.)
TRANSFER CASE
COMMAND-TRAC 231 . . . . . . . . . . 1.0 L (2.2 pts.)
FRONT AXLE
181–FBI . . . . . . . . . . . . . . . . . . . . . . 1.2 L (2.5 pts.)
REAR AXLE
194–RBI . . . . . . . . . . . . . . . . . . . . 1.66 L (3.5 pts.*)
216–RBI . . . . . . . . . . . . . . . . . . . . 1.89 L (4.0 pts.*)
* When equi pped wi th TRAC-LOK, i ncl ude 4
ounces of Fri cti on Modi fi er Addi ti ve.
POWER STEERING
Power steeri ng fl ui d capaci ti es are dependent on
engi ne/chassi s opti ons as wel l as steeri ng gear/cool er
opti ons. Dependi ng on type and si ze of i nternal
cool er, l ength and i nsi de di ameter of cool er l i nes, or
use of an auxi l i ary cool er, these capaci ti es may vary.
Refer to Secti on 19 of the servi ce manual for proper
fi l l and bl eed procedures.
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
1 – WHEEL BEARINGS
2 – CHASSIS LUBRICATION
3 – CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION AND MAINTENANCE TJ
SERVICE PROCEDURES (Continued)
MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page
SERVICE PROCEDURES
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
MAINTENANCE SCHEDULES
There are two mai ntenance schedul es that show
proper servi ce for the vehi cl e.
Fi rst i s Schedul e “A”. I t l i sts al l the schedul ed
mai ntenance to be performed under “normal ” operat-
i ng condi ti ons.
Second i s Schedul e “B”. I t i s a schedul e for vehi -
cl es that are operated under the condi ti ons l i sted at
the begi nni ng of that schedul e.
Use the schedul e that best descri bes the dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
At Each Stop For Fuel
• Check engi ne oi l l evel , add as requi red.
• Check wi ndshi el d washer sol vent and add i f
requi red.
Once A Month
• Check ti re pressure and l ook for unusual wear
or damage.
• I nspect battery and cl ean and ti ghten termi nal s
as requi red. Check el ectrol yte l evel and add water as
needed.
• Check fl ui d l evel s of cool ant reservoi r, power
steeri ng, brake master cyl i nder, and transmi ssi on
and add as needed.
• Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
At Each Oil Change
• I nspect exhaust system.
• I nspect brake hoses.
• Rotate the ti res at each oi l change i nterval
shown on Schedul e “A” (7,500 mi l es) or every other
i nterval shown on Schedul e “B” (6,000 mi l es).
• Check cool ant l evel , hoses, and cl amps.
• After compl eti on of off-road operati on, the
undersi de of the vehi cl e shoul d be thoroughl y
i nspected. Exami ne threaded fasteners for l ooseness.
Schedule “A”
7,500 Miles (12 000 km) or at 6 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
15,000 Miles (24 000 km) or at 12 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
22,500 Miles (36 000 km) or at 18 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• I nspect brake l i ni ngs.
• Lubri cate steeri ng l i nkage.
30,000 Miles (48 000 km) or at 24 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Replace engine air cleaner element.
• Replace spark plugs.
• I nspect dri ve bel t, adjust tensi on as necessary
(2.5L onl y).
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l transfer case fl ui d.
• Lubri cate steeri ng and suspensi on bal l joi nts.
37,500 Miles (60 000 km) or at 30 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage (4x4 onl y).
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter, and adjust bands.
45,000 Miles (72 000 km) or at 36 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Fl ush and repl ace engi ne cool ant at 36 months,
regardl ess of mi l eage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
TJ LUBRICATION AND MAINTENANCE 0 - 3
52,500 Miles (84 000 km) or at 42 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Fl ush and repl ace engi ne cool ant i f not done at
36 months.
• Lubri cate steeri ng l i nkage (4x4 onl y).
60,000 Miles (96 000 km) or at 48 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Replace engine air cleaner element.
• Replace ignition cables.
• Replace spark plugs.
• I nspect dri ve bel t, adjust tensi on as necessary
(2.5L onl y).
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l transfer case fl ui d.
• Lubri cate steeri ng and suspensi on bal l joi nts.
67,500 Miles (108 000 km) or at 54 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• I nspect brake l i ni ngs.
• Lubri cate steeri ng l i nkage (4x4 onl y).
75,000 Miles (120 000 km) or at 60 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
• Lubri cate steeri ng and suspensi on bal l joi nts.
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter, and adjust bands.
82,500 Miles (133 000 km) or at 66 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
• Lubri cate steeri ng l i nkage (4x4 onl y).
90,000 Miles (144 000 km) or at 72 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Replace engine air cleaner element.
• Replace spark plugs.
• I nspect dri ve bel t, adjust tensi on as necessary
(2.5L onl y).
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l transfer case fl ui d.
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
97,500 Miles (156 000 km) or at 78 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage (4x4 onl y).
105,000 Miles (168 000 km) or at 84 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
• Lubri cate steeri ng and suspensi on bal l joi nts.
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
112,500 Miles (180 000 km) or at 90 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• I nspect brake l i ni ngs.
• Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
• Lubri cate steeri ng l i nkage (4x4 onl y).
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter, and adjust bands.
120,000 Miles (192 000 km) or at 96 months
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Replace engine air cleaner element.
• Replace ignition cables.
• Replace spark plugs.
• I nspect dri ve bel t, adjust tensi on as necessary
(2.5L onl y).
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l transfer case fl ui d.
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
• Lubri cate steeri ng and suspensi on bal l joi nts.
Important: I nspecti on and servi ce shoul d al so be
performed any ti me a mal functi on i s observed or sus-
pected.
Schedule “B”
Fol l ow thi s schedul e i f the vehi cl e i s operated
under one or more of the fol l owi ng condi ti ons:
• Frequent short tri ps dri vi ng l ess than 5 mi l es (8 km)
• Frequent dri vi ng i n dusty condi ti ons
0 - 4 LUBRICATION AND MAINTENANCE TJ
SERVICE PROCEDURES (Continued)
• Frequent trai l er towi ng
• Extensi ve i dl i ng
• More than 50% of dri vi ng i s at sustai ned hi gh
speeds duri ng hot weather, above 90°F (32°C)
• Off-road dri vi ng
• Desert operati on
3,000 Miles (5 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
6,000 Miles (10 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
9,000 Miles (14 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
12,000 Miles (19 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
15,000 Miles (24 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Inspect engine air cleaner element, replace
if necessary.
• Lubri cate steeri ng l i nkage.
18,000 Miles (29 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
21,000 Miles (34 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
24,000 Miles (38 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l front and rear axl es.‡
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
27,000 Miles (43 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
30,000 Miles (48 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Inspect engine air cleaner element, replace
if necessary.
• Replace spark plugs.
• I nspect dri ve bel t, adjust tensi on as necessary
(2.5L onl y).
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l transfer case fl ui d.
• Lubri cate steeri ng and suspensi on bal l joi nts.
33,000 Miles (53 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
36,000 Miles (58 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
39,000 Miles (62 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
42,000 Miles (67 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
45,000 Miles (72 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Inspect engine air cleaner element, replace
if necessary.
• Lubri cate steeri ng l i nkage.
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
TJ LUBRICATION AND MAINTENANCE 0 - 5
SERVICE PROCEDURES (Continued)
48,000 Miles (77 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
51,000 Miles (82 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Fl ush and repl ace engi ne cool ant.
• Lubri cate steeri ng l i nkage.
54,000 Miles (86 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
57,000 Miles (91 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
60,000 Miles (96 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Inspect engine air cleaner element, replace
as necessary.
• Replace ignition cables.
• Replace spark plugs.
• I nspect dri ve bel t, adjust tensi on as necessary
(2.5L onl y).
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l transfer case fl ui d.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
63,000 Miles (101 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
66,000 Miles (106 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
69,000 Miles (110 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
72,000 Miles (115 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
75,000 Miles (120 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Inspect engine air cleaner element, replace
as necessary.
• Lubri cate steeri ng l i nkage.
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
78,000 Miles (125 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
81,000 Miles (134 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Fl ush and repl ace engi ne cool ant i f i t has been
3,000 mi l es (48 000 km) si nce l ast change.
• Lubri cate steeri ng l i nkage.
84,000 Miles (134 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
87,000 Miles (139 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
90,000 Miles (144 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Inspect engine air cleaner element, replace
as necessary.
0 - 6 LUBRICATION AND MAINTENANCE TJ
SERVICE PROCEDURES (Continued)
• Replace spark plugs.
• I nspect dri ve bel t, adjust tensi on as necessary
(2.5L onl y).
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l transfer case fl ui d.
• Lubri cate steeri ng and suspensi on bal l joi nts.
93,000 Miles (149 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
96,000 Miles (154 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
99,000 Miles (158 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
102,000 Miles (163 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
105,000 Miles (168 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Inspect engine air cleaner element, replace
as necessary.
• Lubri cate steeri ng l i nkage.
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
108,000 Miles (173 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
111,000 Miles (178 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Fl ush and repl ace engi ne cool ant i f i t has been
3,000 mi l es (48 000 km) si nce l ast change.
• Lubri cate steeri ng l i nkage.
114,000 Miles (182 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
• Lubri cate steeri ng and suspensi on bal l joi nts.
117,000 Miles (187 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Lubri cate steeri ng l i nkage.
120,000 Miles (192 000 km)
• Change engi ne oi l .
• Repl ace engi ne oi l fi l ter.
• Inspect engine air cleaner element, replace
as necessary.
• Replace ignition cables.
• Replace spark plugs.
• I nspect dri ve bel t, adjust tensi on as necessary
(2.5L onl y).
• I nspect dri ve bel t and repl ace as needed (4.0L
onl y).
• Lubri cate steeri ng l i nkage.
• Drai n and refi l l automati c transmi ssi on fl ui d,
change fi l ter and adjust bands.
• Drai n and refi l l transfer case fl ui d.
• Drai n and refi l l front and rear axl es.‡
• I nspect brake l i ni ngs.
• Lubri cate steeri ng and suspensi on bal l joi nts.
‡Off-hi ghway operati on, trai l er towi ng, taxi , l i mou-
si ne, bus, snow pl owi ng, or other types of commerci al
servi ce or prol onged operati on wi th heavy l oadi ng,
especi al l y i n hot weather, requi re front and rear axl e
servi ce i ndi cated wi th a ‡ i n Schedul e “B”. Perform
these servi ces i f the vehi cl e i s usual l y operated under
these condi ti ons.
TJ LUBRICATION AND MAINTENANCE 0 - 7
SERVICE PROCEDURES (Continued)
J UMP STARTING, HOISTING AND TOWING
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
JUMP STARTING PROCEDURE. . . . . . . . . . . . . . . 8
TOWING RECOMMENDATIONS. . . . . . . . . . . . . . . 8
VEHICLE TOWING. . . . . . . . . . . . . . . . . . . . . . . . 10
RECREATIONAL TOWING . . . . . . . . . . . . . . . . . . 10
EMERGENCY TOW HOOKS. . . . . . . . . . . . . . . . . 10
HOISTING RECOMMENDATIONS . . . . . . . . . . . . 10
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
DO NOT JUMP START A FROZEN BATTERY, PER-
SONAL INJURY CAN RESULT.
DO NOT JUMP START WHEN BATTERY INDICA-
TOR DOT IS YELLOW OR BRIGHT COLOR. BAT-
TERY CAN EXPLODE.
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL
ARCHING OF BATTERY CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW DISABLED VEHICLE’S
BATTERY TO EXCEED 16 VOLTS. PERSONAL
INJURY OR DAMAGE TO ELECTRICAL SYSTEM
CAN RESULT.
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) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
• Generator dri ve bel t condi ti on and tensi on.
• Fuel fumes or l eakage, correct i f necessary.
• Frozen battery.
• Yel l ow or bri ght col or test i ndi cator, i f equi pped.
• Low battery fl ui d l evel .
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, turn off al l accessori es, pl ace gear sel ector i n
park or neutral , set park brake or equi val ent and
operate engi ne at 1200 rpm.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake or equi val ent. Turn
OFF al l accessori es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t (Fi g.
1). Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to battery posi ti ve (+) termi nal . Connect
BLACK jumper cabl e cl amp to the engi ne as cl ose to
the ground cabl e connecti on as possi bl e (Fi g. 1).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
• Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
• When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
• Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
TOWING RECOMMENDATIONS
Dai ml erChrysl er Corporati on recommends that a
4WD vehi cl e be transported on a fl at-bed devi ce. A
Wheel -l i ft or front end attached Sl i ng-type devi ce can
be used provi ded al l the wheel s are l i fted off the
ground usi ng tow dol l i es (Fi g. 2) and (Fi g. 3).
0 - 8 LUBRICATION AND MAINTENANCE TJ
SAFETY PRECAUTIONS
• Secure l oose and protrudi ng parts.
• Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
• Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl e’s fuel tank.
• Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
• Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
• Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
• Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
• Do not attach tow chai ns, T-hooks, J-hooks, or a
tow sl i ng to a bumper, steeri ng l i nkage, dri ve shafts
or a non-rei nforced frame hol e.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehi cl e shoul d be rai sed unti l l i fted wheel s
are a mi ni mum 100 mm (4 i n) from the ground. Be
sure there i s adequate ground cl earance at the oppo-
si te end of the vehi cl e, especi al l y when towi ng over
rough terrai n or steep ri ses i n the road. I f necessary,
remove the wheel s from the l i fted end of the vehi cl e
and l ower the vehi cl e cl oser to the ground, to
i ncrease the ground cl earance at the opposi te end of
the vehi cl e. I nstal l l ug nuts on wheel attachi ng studs
to retai n brake drums.
FLAT-BED TOWING RAMP ANGLE
I f a vehi cl e wi th fl at-bed towi ng equi pment i s used,
the approach ramp angl e shoul d not exceed 15
degrees.
Fig. 1 Jumper Cable Clamp Connections
1 – BOOSTER BATTERY
2 – NEGATIVE JUMPER CABLE
3 – ENGINE GROUND
4 – DO NOT ALLOW VEHICLES TO TOUCH
5 – BATTERY NEGATIVE CABLE
6 – DISCHARGED BATTERY
7 – POSITIVE JUMPER CABLE
Fig. 2 Tow Vehicles With Approved Equipment
1 – SLING TYPE
2 – WHEEL LIFT
3 – FLAT BED
Fig. 3 Towing With Tow Dollies
1 – TOW DOLLY
TJ LUBRICATION AND MAINTENANCE 0 - 9
SERVICE PROCEDURES (Continued)
VEHICLE TOWING
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
DO NOT ATTACH SLING-TYPE TOWING EQUIP-
MENT TO THE REAR OF A TJ.
TOWING-FRONT END LIFTED (WHEEL LIFT)
(1) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(2) Attach the wheel l i ft to the front wheel s.
TOWING-REAR END LIFTED (WHEEL LIFT ONLY)
(1) Rai se the front of the vehi cl e off the ground
and i nstal l tow dol l i es under front wheel s.
(2) Attach the wheel l i ft to the rear wheel s.
TOWING-FRONT END LIFTED (SLING-TYPE)
(1) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(2) Attach T-hooks to the access hol es on the out-
board si de of the frame rai l s (Fi g. 4).
(3) Before ti ghteni ng the chai n, posi ti on a protec-
ti ve pad between the chai n and the bumper.
(4) Attach the safety chai ns to the vehi cl e (Fi g. 5).
(5) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
RECREATIONAL TOWING
Refer to the Owners Manual for towi ng procedures.
EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehi cl es are equi pped wi th front emer-
gency tow hooks. The tow hooks shoul d be used for
EMERGENCY purposes onl y.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
HOISTING RECOMMENDATIONS
Refer to the Owner’s Manual for emergency vehi cl e
l i fti ng procedures.
FLOOR JACK
When properl y posi ti oned, a fl oor jack can be used
to l i ft a Jeep vehi cl e (Fi g. 6). Support the vehi cl e i n
the rai sed posi ti on wi th jack stands at the front and
rear ends of the frame rai l s.
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
• An axl e tube.
• A body si de si l l .
• A steeri ng l i nkage component.
• A dri ve shaft.
• The engi ne or transmi ssi on oi l pan.
• The fuel tank.
• A front suspensi on arm.
• Transfer case.
Fig. 4 T-Hook Attachment
1 – PROTECTIVE PAD
2 – BUMPER
3 – CHAIN
4 – T-HOOK
5 – ACCESS HOLE
6 – FRAME
Fig. 5 Safety Chain Attachment
1 – SAFETY CHAIN
0 - 10 LUBRICATION AND MAINTENANCE TJ
SERVICE PROCEDURES (Continued)
NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
HOIST
A vehi cl e can be l i fted wi th:
• A si ngl e-post, frame-contact hoi st.
• A twi n-post, chassi s hoi st.
• A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
Fig. 6 Vehicle Lifting Locations
TJ LUBRICATION AND MAINTENANCE 0 - 11
SERVICE PROCEDURES (Continued)
SUSPENSION
TABLE OF CONTENTS
page page
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 6
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 14
ALIGNMENT
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
SUSPENSION AND STEERING SYSTEM. . . . . . . . 3
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . . 5
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT
DESCRIPTION
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe posi ti on (Fi g. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the 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.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
OPERATION
• CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e rearward provi des posi ti ve caster. Ti l ti ng the
top of the knuckl e forward provi des negati ve caster.
Caster i s a di recti onal stabi l i ty angl e. Thi s angl e
enabl es the front wheel s to return to a strai ght
ahead posi ti on after turns.
• CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re. The angl e i s not
adjustabl e, damaged component(s) must be repl aced
to correct the camber angl e.
• WHEEL TOE POSITION i s the di fference
between the l eadi ng i nsi de edges and trai l i ng i nsi de
edges of the front ti res. I ncorrect wheel toe posi ti on
i s the most common cause of unstabl e steeri ng and
uneven ti re wear. The wheel toe posi ti on i s the final
front wheel al i gnment adjustment.
TJ SUSPENSION 2 - 1
• STEERING AXIS INCLINATION ANGLE i s
measured i n degrees and i s the angl e that the steer-
i ng knuckl es are ti l ted. The i ncl i nati on angl e has a
fi xed rel ati onshi p wi th the camber angl e. I t wi l l not
change except when a spi ndl e or bal l stud i s dam-
aged or bent. The angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the steeri ng
axi s i ncl i nati on angl e.
• THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect thrust
angl e can cause off-center steeri ng and excessi ve ti re
wear. Thi s angl e i s not adjustabl e, damaged compo-
nent(s) must be repl aced to correct the thrust angl e.
Fig. 1 Wheel Alignment Measurements
1 – WHEEL CENTERLINE
2 – NEGATIVE CAMBER ANGLE
3 – PIVOT CENTERLINE
4 – SCRUB RADIUS
5 – TRUE VERTICAL
6 – KING PIN
7 – VERTICAL
8 – POSITIVE CASTER
2 - 2 SUSPENSION TJ
DESCRIPTION AND OPERATION (Continued)
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
suspension components.
2. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
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
suspension components.
2. Tighten or replace components as
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
suspension components.
2. Tighten or replace components as
necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
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
SIDE DURING BRAKING
1. Uneven tire pressure. 1. Adjust tire pressure.
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD
1. Radial tire lead. 1. Cross front tires.
2. Brakes dragging. 2. Repair brake as necessary.
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
suspension components.
6. Repair as necessary.
7. Cross caster out of spec. 7. Align vehicle.
TJ SUSPENSION 2 - 3
CONDITION POSSIBLE CAUSES CORRECTION
KNOCKING, RATTLING
OR SQUEAKING
1. Worn shock bushings. 1. Replace shock.
2. Loose, worn or bent steering/
suspension components.
2. Inspect, tighten or replace 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/
suspension components.
2. Inspect, tighten or replace components
as necessary.
SERVICE PROCEDURES
PRE-ALIGNMENT
Before starti ng wheel al i gnment, the fol l owi ng
i nspecti on and necessary correcti ons must be com-
pl eted. Refer to Suspensi on and Steeri ng System
Di agnosi s Chart for addi ti onal i nformati on.
(1) I nspect ti res for si ze and tread wear.
(2) Set ti re ai r pressure.
(3) I nspect front wheel beari ngs for wear.
(4) I nspect front wheel s for excessi ve radi al or l at-
eral runout and bal ance.
(5) I nspect bal l studs, l i nkage pi vot poi nts and
steeri ng gear for l ooseness, roughness or bi ndi ng.
(6) I nspect suspensi on components for wear and
noi se.
(7) Road test the vehi cl e.
WHEEL ALIGNMENT
Before each al i gnment readi ng the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down three ti mes. Al ways rel ease the bumper i n the
down posi ti on.
CAMBER
The wheel camber angl e i s preset. Thi s angl e i s not
adjustabl e and cannot be al tered.
CASTER
Check the caster of the front axl e for correct angl e.
Be sure the axl e i s not bent or twi sted. Road test the
vehi cl e and observe the steeri ng wheel return-to-cen-
ter posi ti on. Low caster wi l l cause poor steeri ng
wheel returnabi l i ty.
Duri ng the road test, turn the vehi cl e to both the
l eft and ri ght. I f the steeri ng wheel returns to the
center posi ti on unassi sted, the caster angl e i s correct.
However, i f steeri ng wheel does not return toward
the center posi ti on unassi sted, a l ow caster angl e i s
probabl e.
Caster can be adjusted by i nstal l i ng a cam bol ts
and rotati ng the cams on the l ower suspensi on arm
(Fi g. 2).
NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3, Dif-
ferential and Driveline for additional information.
TOE POSITION
NOTE: The wheel toe position adjustment is the
final adjustment. This adjustment must be per-
formed with the engine running, if the vehicle is
equipped with power steering.
Fig. 2 Cam Adjuster
1 – ADJUSTMENT CAM
2 – AXLE BRACKET
3 – BRACKET REINFORCEMENT
4 – LOWER SUSPENSION ARM
2 - 4 SUSPENSION TJ
DIAGNOSIS AND TESTING (Continued)
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the steeri ng wheel . Center and
secure the steeri ng wheel .
(2) Loosen the adjustment sl eeve cl amp bol ts (Fi g.
3).
(3) Adjust the ri ght wheel toe posi ti on wi th the
drag l i nk (Fi g. 4). Turn the sl eeve unti l the ri ght
wheel i s at the correct posi ti ve TOE-I N posi ti on. Posi -
ti on the cl amp bol ts as shown (Fi g. 3) and ti ghten to
49 N·m (36 ft. l bs.). Make sure the toe setting does
not change during clamp tightening.
(4) Adjust the l eft wheel toe posi ti on wi th the ti e
rod. Turn the sl eeve unti l the l eft wheel i s at the
same TOE-I N posi ti on as the ri ght wheel . Posi ti on
the cl amp bol ts as shown (Fi g. 3) and ti ghten to 27
N·m (20 ft. l bs.). Make sure the toe setting does
not change during clamp tightening.
(5) Veri fy the ri ght toe speci fi cati ons and turn off
the engi ne.
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
NOTE: Alignment specifications are in degrees.
ANGLE PREFERRED RANGE MAX RT/LT DIFFERENCE
CASTER + 7° Ϯ 1.0° 0.65°
CAMBER
(fixed angle)
− 0.25° Ϯ 0.63° 1.0°
TOE-IN
(each front wheel)
+ 0.15° Ϯ 0.07° 0.05°
REAR SPECIFICATION
REAR CAMBER − 0.25° Ϯ 0.25° NA
TOTAL TOE-IN + O.25° Ϯ 0.25° NA
THRUST ANGLE 0°Ϯ 0.25°
Fig. 3 Drag Link and Tie Rod Clamp
1 – TIE ROD CLAMP
2 – DRAG LINK CLAMPS
Fig. 4 Steering Linkage
1 – COTTER PIN
2 – DAMPENER
3 – PITMAN ARM
4 – WASHER
5 – TIE ROD
6 – DRAG LINK
7 – NUT
TJ SUSPENSION 2 - 5
SERVICE PROCEDURES (Continued)
FRONT SUSPENSION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 6
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . 6
JOUNCE BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . 6
COIL SPRINGS AND ISOLATORS . . . . . . . . . . . . . 6
LOWER SUSPENSION ARMS AND BUSHINGS . . . 7
UPPER SUSPENSION ARMS AND BUSHINGS . . . 7
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRACK BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HUB/BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL AND INSTALLATION
SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . . 8
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . 8
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . . 9
UPPER SUSPENSION ARM. . . . . . . . . . . . . . . . . . 9
FRONT AXLE BUSHING. . . . . . . . . . . . . . . . . . . . . 9
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . 10
TRACK BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HUB BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WHEEL MOUNTING STUDS. . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION AND OPERATION
FRONT SUSPENSION
The front suspensi on i s a l i nk/coi l desi gn com-
pri sed of:
• Shock absorbers
• Jounce Bumper
• Coi l spri ngs
• Upper and l ower suspensi on arms
• Stabi l i zer bar
• Track bar
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the 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/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bol ted to a
frame bracket. The bottom of the shocks are bol ted to
the axl e brackets.
OPERATION
The shock absorbers dampen jounce and rebound
moti on of the vehi cl e over vari ous road condi ti ons
and l i mi t suspensi on rebound travel .
JOUNCE BUMPER
DESCRIPTION
The jounce bumpers are mounted under the frame
rai l s i nsi de of the coi l spri ngs.
OPERATION
The jounce bumpers are used to l i mi t suspensi on
travel i n compressi on.
COIL SPRINGS AND ISOLATORS
DESCRIPTION
The coi l spri ngs mount up i n the wheel house whi ch
i s part of the uni ti zed body bracket. A rubber dough-
nut i sol ator i s l ocated between the top of the spri ng
and the bracket. The bottom of the spri ng seats on a
axl e pad.
2 - 6 SUSPENSION TJ
OPERATION
The coi l spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght. The i sol ators provi de road noi se
i sol ati on.
LOWER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The l ower suspensi on arms are steel and use bush-
i ngs at one end of the arm. The arms mount to the
frame rai l bracket and the axl e brackets.
OPERATION
The l ower suspensi on arm bushi ngs provi de i sol a-
ti on from the axl e. The arm and bushi ngs provi de
l ocati on and react to l oads from the axl e. The l ower
suspensi on arms can be used to adjust caster and
pi ni on angl e by i nstal l i ng a cam bol t servi ce package.
UPPER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The upper suspensi on arms are steel and use rub-
ber bushi ngs at each end of the arm. The arms
mount to the frame rai l bracket and the axl e brack-
ets.
OPERATION
The arm and bushi ngs provi de l ocati on and react
to l oads from the axl e. The bushi ngs provi de i sol ati on
from the axl e.
STABILIZER BAR
DESCRIPTION
The spri ng steel bar extends across the top of the
chassi s frame rai l s. Li nks are connected from the bar
to the axl e brackets. The stabi l i zer bar and l i nks are
i sol ated by rubber bushi ngs.
OPERATION
The stabi l i zer bar i s used to control vehi cl e body
rol l duri ng turns. The bar hel ps to control the vehi cl e
body i n rel ati onshi p to the suspensi on.
TRACK BAR
DESCRIPTION
The bar i s attached to a frame rai l bracket wi th a
bal l stud and an axl e bracket wi th a bushi ng. The
bar i s forged and has non repl aceabl e i sol ator bush-
i ng and bal l stud.
OPERATION
The track bar i s used to control front axl e l ateral
movement and provi des cross car l ocati on of the axl e
assembl y.
HUB/BEARING
DESCRIPTION
The beari ng used on the front hub of thi s vehi cl e i s
the combi ned hub and beari ng uni t type assembl y.
Thi s uni t assembl y combi nes the front wheel mount-
i ng hub (fl ange) and the front wheel beari ng i nto a
one pi ece uni t. The wheel mounti ng studs are the
onl y repl aceabl e component of the hub/beari ng
assembl y.
OPERATION
The hub/beari ng assembl y i s mounted to the steer-
i ng knuckl e and i s retai ned by three mounti ng bol ts
accessi bl e from the back of the steeri ng knuckl e. The
hub/beari ng uni t i s not servi ceabl e and must be
repl aced as an assembl y i f the beari ng or the hub i s
determi ned to be defecti ve.
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
TJ SUSPENSION 2 - 7
DESCRIPTION AND OPERATION (Continued)
SERVICE PROCEDURES
LUBRICATION
Peri odi c l ubri cati on of the suspensi on system i s
requi red. Refer to Group 0, Lubri cati on And Mai nte-
nance for the recommended mai ntenance schedul e.
The fol l owi ng component must be l ubri cated:
• Track bar
REMOVAL AND INSTALLATION
SHOCK ABSORBER
REMOVAL
(1) Remove the nut, retai ner and grommet from
the upper stud through engi ne compartment access
hol e (Fi g. 1).
(2) Remove the l ower nuts and bol ts from the axl e
bracket and remove the shock absorber.
INSTALLATION
(1) Posi ti on the l ower retai ner and grommet on the
upper stud. I nsert the shock absorber through the
shock bracket hol e.
(2) I nstal l the l ower bol ts and nuts. Ti ghten nuts
to 28 N·m (250 i n. l bs.).
(3) I nstal l the upper grommet and retai ner on the
stud and i nstal l the nut and ti ghten to 23 N·m (17 ft.
l bs.).
COIL SPRING
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support i t.
(2) Pai nt or scri be al i gnment marks on the cam
adjusters and axl e bracket for i nstal l ati on reference.
(3) Mark and di sconnect the front propel l er shaft
from the axl e.
(4) Remove the l ower suspensi on arm nut, cam
and cam bol t from the axl e.
(5) Di sconnect the stabi l i zer bar l i nks and shock
absorbers from the axl e.
(6) Di sconnect the track bar from the frame rai l
bracket.
(7) Di sconnect the drag l i nk from the pi tman arm.
(8) Lower the axl e unti l the spri ng i s free from the
upper mount and remove the spri ng.
NOTE: Left coil spring has a retainer and bolt
which must be removed from the axle pad.
(9) Remove the jounce bumper i f necessary from
the upper spri ng mount.
INSTALLATION
(1) Posi ti on the coi l spri ng on the axl e pad.
NOTE: Install retainer and bolt on the left spring
and tighten to 22 N·m (16 ft. lbs.).
(2) I nstal l the jounce bumper.
(3) Rai se the axl e i nto posi ti on unti l the spri ng
seats i n the upper mount, then rai se another 51 mm
(2 i n.).
(4) Connect the stabi l i zer bar l i nks and shock
absorbers to the axl e bracket. Connect the track bar
to the frame rai l bracket.
(5) I nstal l the l ower suspensi on arm to the axl e.
(6) I nstal l the front propel l er shaft to the axl e.
(7) I nstal l drag l i nk to pi t man arm.
(8) Remove the supports and l ower the vehi cl e.
(9) Ti ghten al l suspensi on components to proper
torque.
STEERING KNUCKLE
For servi ce procedures on the steeri ng knuckl e and
bal l joi nts refer to Group 3 Di fferenti al s And Dri v-
el i ne.
Fig. 1 Coil Spring & Shock Absorber
1 – RETAINER
2 – GROMMET
3 – SHOCK
4 – FRONT AXLE
2 - 8 SUSPENSION TJ
LOWER SUSPENSION ARM
REMOVAL
(1) Rai se and support the vehi cl e.
(2) I f equi pped wi th ABS brakes remove sensor
wi re from the i nboard si de of the arm.
(3) I f the vehi cl e i s equi pped wi th a cam bol t ser-
vi ce package pai nt or scri be al i gnment marks on the
cam adjusters and suspensi on arm for i nstal l ati on
reference (Fi g. 2).
(4) Remove the l ower suspensi on arm nut and bol t
from the axl e (Fi g. 3).
(5) Remove the nut and bol t/cam bol t from the
frame rai l bracket and remove the l ower suspensi on
arm (Fi g. 3).
INSTALLATION
(1) Posi ti on the l ower suspensi on arm i n the axl e
bracket and frame rai l bracket.
NOTE: Small holes in the side of the arm face
inboard.
(2) I nstal l the rear bol t and nut fi nger ti ghten.
(3) I nstal l bol t/cam bol t and new nut fi nger ti ghten
i n the axl e and al i gn the reference marks.
(4) I f equi pped wi th ABS brakes i nstal l sensor
wi re to the i nboard si de of the arm wi th new cl i ps.
(5) Lower the vehi cl e.
(6) Ti ghten axl e bracket nut to 115 N·m (85 ft.
l bs.).
(7) Ti ghten frame bracket nut to 176 N·m (130 ft.
l bs.).
(8) Al i gn vehi cl e to speci fi cati ons.
UPPER SUSPENSION ARM
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the upper suspensi on arm nut and bol t
at the axl e bracket (Fi g. 3).
(3) Remove the nut and bol t at the frame rai l and
remove the upper suspensi on arm.
INSTALLATION
(1) Posi ti on the upper suspensi on arm at the axl e
and frame rai l .
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(3) Remove the supports and l ower the vehi cl e.
(4) Ti ghten the nut at the axl e and frame brackets
to 75 N·m (55 ft. l bs.).
FRONT AXLE BUSHING
REMOVAL
(1) Remove the upper suspensi on arm from axl e.
(2) Posi ti on Spacer 7932-3 over the axl e bushi ng
on a 4x2 vehi cl e and ri ght si de on a 4x4 vehi cl e.
(3) Pl ace Recei ver 7932-1 over fl anged end of the
bushi ng. (Fi g. 4).
(4) Pl ace smal l end of Remover/I nstal l 7932-2
agai nst other si de of the bushi ng.
Fig. 2 Cam Bolt Service Package
1 – ADJUSTMENT CAM
2 – AXLE BRACKET
3 – BRACKET REINFORCEMENT
4 – LOWER SUSPENSION ARM
Fig. 3 Upper & Lower Suspension Arms
1 – UPPER SUSPENSION ARM
2 – FRONT AXLE
3 – LOWER SUSPENSION ARM
TJ SUSPENSION 2 - 9
REMOVAL AND INSTALLATION (Continued)
(5) I nstal l bol t 7604 through remover, bushi ng and
recei ver.
(6) I nstal l Long Nut 7603 and ti ghten nut too pul l
bushi ng out of the axl e bracket.
(7) Remove nut, bol t, recei ver, remover and bush-
i ng.
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 7932-3 in position for bushing instal-
lation.
INSTALLATION
(1) Pl ace Recei ver 7932-1 on the other si de of the
axl e bracket.
(2) Posi ti on new bushi ng up to the axl e bracket.,
and l arge end of Remover/I nstal l 7932-2 agai nst the
bushi ng (Fi g. 5).
(3) I nstal l bol t 7604 through recei ver, bushi ng and
i nstal l er.
(4) I nstal l Long Nut 7603 and ti ghten nut to draw
the bushi ng i nto the axl e bracket.
(5) Remove tool s and i nstal l the upper suspensi on
arm.
STABILIZER BAR
REMOVAL
(1) Remove upper l i nk nuts (Fi g. 6) and separate
the l i nks from the stabi l i zer bar wi th Remove
MB-990635.
(2) Remove front bumper val ence, refer to Group
23 Body for procedure.
(3) Remove stabi l i zer retai ner bol ts (Fi g. 6) and
remove retai ners.
(4) Remove stabi l i zer bar.
(5) Remove l ower l i nk nuts and bol ts and remove
l i nks (Fi g. 6).
INSTALLATION
(1) Center stabi l i zer bar on top of the frame rai l s
and i nstal l retai ners and bol ts. Ti ghten bol ts to 54
N·m (40 ft. l bs.).
Fig. 4 Bushing Removal
1 – RECEIVER
2 – AXLE BRACKET
3 – BOLT
4 – REMOVER/INSTALLER
5 – LONG NUT
Fig. 5 Bushing Installation
1 – REMOVER/INSTALLER
2 – AXLE BRACKET
3 – BOLT
4 – RECEIVER
5 – LONG NUT
Fig. 6 Stabilizer Bar
1 – RETAINER
2 – STABILIZER BAR
3 – LINK
4 – BUSHING
2 - 10 SUSPENSION TJ
REMOVAL AND INSTALLATION (Continued)
(2) Posi ti on l i nks on axl e brackets and i nto the
stabi l i zer bar. I nstal l l ower l i nk bol ts and nuts and
ti ghten to 95 N·m (70 ft. l bs.).
(3) I nstal l upper l i nk nuts and ti ghten to 61 N·m
(45 ft. l bs.).
(4) I nstal l bumper val ence.
TRACK BAR
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the cotter pi n and nut from the bal l
stud end at the frame rai l bracket (Fi g. 7).
(3) Use a uni versal pul l er tool to separate the
track bar bal l stud from the frame rai l bracket.
(4) Remove the bol t and fl ag nut from the axl e
bracket (Fi g. 7). Remove the track bar.
INSTALLATION
(1) I nstal l the track bar at axl e tube bracket.
Loosel y i nstal l the retai ni ng bol t and fl ag nut.
(2) I t may be necessary to pry the axl e assembl y
over to i nstal l the track bar at the frame rai l . I nstal l
track bar at the frame rai l bracket. I nstal l the
retai ni ng nut on the stud.
(3) Ti ghten the bal l stud nut to 88 N·m (65 ft. l bs.)
and i nstal l a new cotter pi n.
(4) Remove the supports and l ower the vehi cl e.
(5) Ti ghten the bol t at the axl e bracket to 75 N·m
(55 ft. l bs.).
(6) Check al i gnment i f a new track bar was
i nstal l ed.
HUB BEARING
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per, rotor and ABS wheel
speed sensor, refer to Group 5 Brakes.
(4) Remove the cotter pi n, nut retai ner and axl e
hub nut (Fi g. 8).
(5) Remove the hub beari ng mounti ng bol ts from
the back of the steeri ng knuckl e. Remove hub bear-
i ng from the steeri ng knuckl e and off the axl e shaft.
INSTALLATION
(1) I nstal l the hub beari ng and brake dust shi el d
to the knuckl e.
(2) I nstal l the hub beari ng to knuckl e bol ts and
ti ghten to 102 N·m (75 ft. l bs.).
(3) I nstal l the hub washer and nut. Ti ghten the
hub nut to 237 N·m (175 ft. l bs.). I nstal l the nut
retai ner and a new cotter pi n.
(4) I nstal l the brake rotor, cal i per and ABS wheel
speed sensor, refer to Group 5 Brakes.
(5) I nstal l the wheel and ti re assembl y.
(6) Remove support and l ower the vehi cl e.
WHEEL MOUNTING STUDS
CAUTION: Do not use a hammer to remove wheel
studs.
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove brake cal i per, cal i per adapter and
rotor, refer to Group 5 Brakes for procedure.
(4) Remove stud from hub wi th Remover C-4150A
(Fi g. 9).
INSTALLATION
(1) I nstal l new stud i nto hub fl ange.
(2) I nstal l three washers onto stud, then i nstal l
l ug nut wi th the fl at si de of the nut agai nst the
washers.
(3) Ti ghten l ug nut unti l the stud i s pul l ed i nto
the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove l ug nut and washers.
(5) I nstal l the brake rotor, cal i per adapter, and cal -
i per, refer to Group 5 Brakes for procedure.
(6) I nstal l wheel and ti re assembl y, use new l ug
nut on stud or studs that were repl aced.
(7) Remove support and l ower vehi cl e.
Fig. 7 Track Bar
1 – TRACK BAR
2 – FRAME BRACKET
3 – FRONT AXLE
TJ SUSPENSION 2 - 11
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . 23 N·m (17 ft. l bs.)
Lower Nut . . . . . . . . . . . . . . 28 N·m (250 i n. l bs.)
Suspension ArmLower
Axl e Bracket Nut . . . . . . . . . 115 N·m (85 ft. l bs.)
Frame Bracket Nut . . . . . . 176 N·m (130 ft. l bs.)
Suspension ArmUpper
Axl e Bracket Nut . . . . . . . . . . 75 N·m (55 ft. l bs.)
Frame Bracket Bol t . . . . . . . . 75 N·m (55 ft. l bs.)
Stabilizer Bar
Retai ner Bol ts . . . . . . . . . . . . 54 N·m (40 ft. l bs.)
Li nk Upper Nut . . . . . . . . . . . 61 N·m (45 ft. l bs.)
Li nk Lower Bol t . . . . . . . . . . . 95 N·m (70 ft. l bs.)
Track Bar
Bal l Stud Nut . . . . . . . . . . . . 88 N·m (65 ft. l bs.)
Axl e Bracket Bol t . . . . . . . . . . 75 N·m (55 ft. l bs.)
Hub/Bearing
Bol ts . . . . . . . . . . . . . . . . . . 102 N·m (75 ft. l bs.)
Axl e Nut . . . . . . . . . . . . . . 237 N·m (175 ft. l bs.)
Fig. 8 Hub Bearing & Knuckle
1 – BRAKE SHIELD
2 – WASHER
3 – RETAINER
4 – COTTER PIN
5 – NUT
6 – HUB AND BEARING ASSEMBLY
7 – STEERING KNUCKLE
8 – BOLT
9 – TONE WHEEL (ABS)
Fig. 9 Wheel Stud Removal
1 – REMOVER
2 – WHEEL STUD
2 - 12 SUSPENSION TJ
REMOVAL AND INSTALLATION (Continued)
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
Nut, Long 7603
Bolt, Special 7604
Remover C-4150A
TJ SUSPENSION 2 - 13
REAR SUSPENSION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 14
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 14
COIL SPRINGS AND ISOLATORS . . . . . . . . . . . . 14
JOUNCE BUMPERS. . . . . . . . . . . . . . . . . . . . . . . 14
LOWER SUSPENSION ARMS AND BUSHINGS . . 14
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . 14
TRACK BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL AND INSTALLATION
SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . 15
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 16
UPPER SUSPENSION ARM. . . . . . . . . . . . . . . . . 16
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . 16
TRACK BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION AND OPERATION
REAR SUSPENSION
The rear suspensi on i s l i nk/coi l desi gn compri sed
of:
• Shock absorbers
• Coi l spri ngs
• Upper and l ower suspensi on arms
• Stabi l i zer bar
• Track bar
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle 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 ride comfort and prevent pre-
mature bushing wear.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bol ted to the
frame. The bottom of the shocks are bol ted to the
axl e brackets.
OPERATION
The shock absorbers dampen jounce and rebound
moti on of the vehi cl e over vari ous road condi ti ons
and l i mi t suspensi on rebound travel .
COIL SPRINGS AND ISOLATORS
DESCRIPTION
The coi l spri ngs mount between the bottom of the
frame rai l and the top of the axl e. A rubber doughnut
i sol ator i s l ocated between the top of the spri ng and
the frame rai l . A pl asti c i sol ator i s l ocated between
the bottom of the spri ng and the axl e.
OPERATION
The coi l spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght. The i sol ators are used to i sol ate
road noi se.
JOUNCE BUMPERS
DESCRIPTION
The jounce bumpers are mounted i nsi de the coi l
spri ng to the frame rai l .
OPERATION
The jounce bumpers are used to l i mi t suspensi on
travel i n compressi on.
LOWER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The l ower suspensi on arms are steel and use bush-
i ngs at each end of the arm. The arms are mounted
from the frame to the axl e brackets.
OPERATION
The bushi ngs i sol ati on axl e and road noi se. The
arm and bushi ngs provi de l ocati on and react to l oads
from the axl e.
STABILIZER BAR
DESCRIPTION
The spri ng steel bar extends across the axl e and
mounts to bracket on the axl e. Li nks are connected
2 - 14 SUSPENSION TJ
from the bar to the si de of the frame rai l . The stabi -
l i zer bar and l i nks are i sol ated by rubber bushi ngs.
OPERATION
The stabi l i zer bar i s used to control vehi cl e body
rol l duri ng turns. The bar hel ps to control the vehi cl e
body i n rel ati onshi p to the suspensi on.
TRACK BAR
DESCRIPTION
The bar i s attached to a frame rai l bracket and
axl e bracket. The bar has bushi ngs at both ends.
OPERATION
The track bar i s used to control rear axl e l ateral
movement.
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
REMOVAL AND INSTALLATION
SHOCK ABSORBER
REMOVAL
(1) Rai se and support the vehi cl e and the axl e.
(2) Remove the upper mounti ng bol ts (Fi g. 1).
(3) Remove the l ower nut and bol t from the axl e
bracket. Remove the shock absorber.
INSTALLATION
(1) I nstal l the shock absorber on the upper frame
rai l and i nstal l mounti ng bol ts.
(2) Ti ghten the upper bol ts to 31 N·m (23 ft. l bs.).
(3) I nstal l l ower bol t and nut fi nger ti ght.
(4) Remove the supports and l ower the vehi cl e.
(5) Ti ghten the l ower nut to 100 N·m (74 ft. l bs.).
COIL SPRING
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support i t.
(2) Di sconnect the stabi l i zer bar l i nks and shock
absorbers from the axl e brackets.
(3) Di sconnect the track bar from the frame rai l
bracket.
(4) Lower the axl e unti l the spri ng i s free from the
upper mount seat and remove the spri ng.
INSTALLATION
NOTE: Springs can be install with either end up.
(1) Posi ti on the coi l spri ng on the axl e pad i sol ator.
(2) Rai se the axl e i nto posi ti on unti l the spri ng
seats on the upper i sol ator.
(3) Connect the stabi l i zer bar l i nks and shock
absorbers to the axl e bracket. Connect the track bar
to the frame rai l bracket.
(4) Remove the supports and l ower the vehi cl e.
(5) Ti ghten the stabi l i zer bar l i nks, shock absorb-
ers and track bar to speci fi ed torque.
Fig. 1 Shock Absorber
1 – AXLE BRACKET
2 – SHOCK
TJ SUSPENSION 2 - 15
DESCRIPTION AND OPERATION (Continued)
LOWER SUSPENSION ARM
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the l ower suspensi on arm nut and bol t
at the axl e bracket (Fi g. 2).
(3) Remove the nut and bol t at the frame rai l
mount (Fi g. 3) and remove the l ower suspensi on arm.
INSTALLATION
(1) Posi ti on the l ower suspensi on arm i n the axl e
bracket and frame rai l mount.
(2) I nstal l the mounti ng bol ts and fi nger ti ghten
the nuts.
(3) Remove the supports and l ower the vehi cl e.
(4) Ti ghten the l ower suspensi on arm nuts to 177
N·m (130 ft. l bs.).
UPPER SUSPENSION ARM
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the parki ng brake cabl e/bracket and
ABS wi ri ng bracket from the arm i f equi pped (Fi g.
4).
(3) Remove the upper suspensi on arm nut and bol t
from the axl e bracket (Fi g. 2).
(4) Remove the nut and bol t from the frame rai l
bracket (Fi g. 3) and remove the upper suspensi on
arm.
INSTALLATION
(1) Posi ti on the upper suspensi on arm i n the axl e
bracket and frame rai l bracket.
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(3) I nstal l the parki ng brake cabl e/bracket and
ABS wi ri ng bracket on the arm i f equi pped.
(4) Remove the supports and l ower the vehi cl e.
(5) Ti ghten the upper suspensi on arm frame rai l
bracket bol t to 75 N·m (55 ft. l bs.).
(6) Ti ghten the upper suspensi on arm axl e bracket
nut to 75 N·m (55 ft. l bs.).
STABILIZER BAR
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the stabi l i zer bar l i nk bol ts from the
frame mounts (Fi g. 5).
Fig. 2 Upper & Lower Suspension Arms
1 – UPPER SUSPENSION ARM
2 – REAR AXLE
3 – LOWER SUSPENSION ARM
Fig. 3 Upper & Lower Suspension Arms
1 – FRAME MOUNT
2 – UPPER SUSPENSION ARM
3 – LOWER SUSPENSION ARM
Fig. 4 Parking Brake Cable/Bracket And Wiring
Bracket
1 – UPPER SUSPENSION ARM
2 – WIRING BRACKET
3 – PARKING BRAKE CABLE BRACKET
2 - 16 SUSPENSION TJ
REMOVAL AND INSTALLATION (Continued)
(3) Remove the l i nk bol ts from the stabi l i zer bar.
(4) Remove the stabi l i zer bar retai ner bol ts and
retai ners from the axl e mounts (Fi g. 6) and remove
the bar.
INSTALLATION
(1) I nstal l the stabi l i zer bar on the axl e mounts
and i nstal l the retai ners and bol ts.
NOTE: Ensure the bar is centered with equal spac-
ing on both sides and is positioned above the dif-
ferential housing (Fig. 6).
(2) Ti ghten the retai ner bol ts to 54 N·m (40 ft.
l bs.).
(3) I nstal l the l i nks onto the stabi l i zer bar and
frame mounts. I nstal l the bol ts and nuts fi nger ti ght.
(4) Remove support and l ower vehi cl e.
(5) Ti ghten the l i nk nuts/bol ts to 54 N·m (40 ft.
l bs.).
TRACK BAR
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the bol t and nut from the frame rai l
bracket (Fi g. 7).
(3) Remove the bol t from the axl e bracket (Fi g. 7)
and remove the track bar.
INSTALLATION
(1) I nstal l the track bar i n the axl e bracket and
i nstal l the bol t l oosel y.
(2) I nstal l the track bar i n the frame rai l bracket
and l oosel y i nstal l the bol t and nut.
NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar.
(3) Remove supports and l ower the vehi cl e.
(4) Ti ghten the track bar nut/bol t at both ends to
100 N·m (74 ft. l bs.).
Fig. 5 Stabilizer Bar Link
1 – FRAME MOUNT
2 – LINK
3 – STABILIZER BAR
Fig. 6 Stabilizer Bar
1 – LINK
2 – RETAINER
3 – STABILIZER BAR
4 – AXLE MOUNT
Fig. 7 Rear Track Bar
1 – TRACK BAR
2 – FRAME BRACKET
3 – REAR AXLE
TJ SUSPENSION 2 - 17
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Bol ts . . . . . . . . . . . . . . 31 N·m (23 ft. l bs.)
Lower Nut . . . . . . . . . . . . . . 100 N·m (74 ft. l bs.)
Suspension ArmLower
Axl e Bracket Nut . . . . . . . . 177 N·m (130 ft. l bs.)
Frame Bracket Nut . . . . . . 177 N·m (130 ft. l bs.)
Suspension ArmUpper
Axl e Bracket Nut . . . . . . . . . . 75 N·m (55 ft. l bs.)
Frame Bracket Bol t . . . . . . . . 75 N·m (55 ft. l bs.)
Stabilizer Bar
Retai ner Bol ts . . . . . . . . . . . . 54 N·m (40 ft. l bs.)
Li nk Nut/Bol t . . . . . . . . . . . . 54 N·m (40 ft. l bs.)
Track Bar
Frame Bracket Nut . . . . . . . 100 N·m (74 ft. l bs.)
Axl e Bracket Bol t . . . . . . . . . 100 N·m (74 ft. l bs.)
2 - 18 SUSPENSION TJ
DIFFERENTIAL AND DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . 1
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
194 RBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
216 RBI REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . 91
PROPELLER SHAFTS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1
PROPELLER SHAFT JOINTS. . . . . . . . . . . . . . . . . 3
PROPELLER SHAFT JOINT ANGLE. . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT ANGLE MEASUREMENT. . . . 6
REMOVAL AND INSTALLATION
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . . 8
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . . 8
DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . . . 9
DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . . . 10
CLEANING AND INSPECTION
SINGLE AND DOUBLE CARDAN JOINT. . . . . . . . 14
ADJUSTMENTS
AXLE PINION ANGLE ADJUSTMENT . . . . . . . . . . 15
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION AND OPERATION
PROPELLER SHAFT
DESCRIPTION
A propel l er shaft (Fi g. 2) i s the shaft whi ch con-
nects the transmi ssi on/transfer case to the axl e di f-
ferenti al . Thi s i s the l i nk through whi ch the engi ne
power i s transmi tted to the axl e.
The propel l er shaft i s desi gned and bui l t wi th the
yoke l ugs i n l i ne wi th each other whi ch i s cal l ed zero
phasi ng. Thi s desi gn produces the smoothest runni ng
condi ti on, an out-of-phase shaft can cause a vi bra-
ti on.
Tubul ar propel l er shafts are bal anced by the man-
ufacturer wi th wei ghts spot wel ded to the tube.
PRECAUTIONS
Use the exact repl acement parts when i nstal l i ng
the propel l er shafts. The use of the correct repl ace-
ment parts hel ps to ensure safe operati on. Al l fasten-
ers must be torqued to the speci fi ed val ues for safe
operati on.
Al so make al i gnment reference marks (Fi g. 1) on
the propel l er shaft yoke and axl e, or transmi ssi on,
yoke pri or to servi ci ng. Thi s hel ps to el i mi nate possi -
bl e vi brati on.
CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.
TJ DIFFERENTIAL AND DRIVELINE 3 - 1
OPERATION
The propel l er shaft must operate through con-
stantl y changi ng rel ati ve angl es between the trans-
mi ssi on and axl e when goi ng over vari ous road
surfaces. I t must al so be capabl e of changi ng l ength
whi l e transmi tti ng torque. The axl e ri des suspended
by spri ngs i n a fl oati ng moti on.Thi s i s accompl i shed
through uni versal joi nts, whi ch permi t the propel l er
shaft to operate at di fferent angl es. The sl i p joi nts (or
yokes) permi t contracti on or expansi on (Fi g. 2).
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered to pre-
vent an out-of-balance condition and driveline
vibration.
CAUTION: Use original equipment replacement
parts for attaching the propeller shafts. The speci-
fied torque must always be applied when tightening
the fasteners.
Fig. 2 Propeller Shafts
1 – FRONT AXLE
2 – FRONT PROPELLER SHAFT
3 – TRANSFER CASE
4 – BOOT
5 – REAR AXLE
6 – STRAP
7 – REAR PROPELLER SHAFT
8 – STRAP
Fig. 1 Reference Marks on Yokes
1 – REFERENCE MARKS
3 - 2 PROPELLER SHAFTS TJ
DESCRIPTION AND OPERATION (Continued)
PROPELLER SHAFT JOINTS
DESCRIPTION
Two di fferent types of propel l er shaft joi nts are
used i n TJ vehi cl es (Fi g. 3) and (Fi g. 4). None of the
joi nts are servi ceabl e. I f worn or damaged, they must
be repl aced as a compl ete assembl y.
LUBRICATION
The factory i nstal l ed uni versal joi nts are l ubri cated
for the l i fe of the vehi cl e and do not need l ubri cati on.
Al l uni versal joi nts shoul d be i nspected for l eakage
and damage each ti me the vehi cl e i s servi ced. I f seal
l eakage or damage exi sts, the uni versal joi nt shoul d
be repl aced.
PROPELLER SHAFT JOINT ANGLE
DESCRIPTION
When two shafts come together at a common joi nt,
the bend that i s formed i s cal l ed the operati ng angl e.
The l arger the angl e, the l arger the amount of angu-
l ar accel erati on and decel erati on of the joi nt. Thi s
speedi ng up and sl owi ng down of the joi nt must be
cancel l ed to produce a smooth power fl ow.
OPERATION
Thi s cancel l ati on i s done through the phasi ng of a
propel l er shaft and ensuri ng that the proper propel -
l er shaft joi nt worki ng angl es are mai ntai ned.
A propel l er shaft i s properl y phased when the yoke
ends are i n the same pl ane, or i n l i ne. A twi sted
shaft wi l l make the yokes out of phase and cause a
noti ceabl e vi brati on.
Fig. 3 Single Cardan U-Joint
1 – CROSS
2 – SEAL
3 – CAP AND NEEDLE BEARINGS
Fig. 4 Double Cardan U-Joint
TJ PROPELLER SHAFTS 3 - 3
DESCRIPTION AND OPERATION (Continued)
When taki ng propel l er shaft joi nt angl e measure-
ments, or checki ng the phasi ng, of two pi ece shafts,
consi der each shaft separatel y.
I deal l y the dri vel i ne system shoul d have;
• Angl es that are equal or opposi te wi thi n 1
degree of each other.
• Have a 3 degree maxi mum operati ng angl e.
• Have at l east a 1/2 degree conti nuous operati ng
(propel l er shaft) angl e.
Propel l er shaft speed (rpm) i s the mai n factor i n
determi ni ng the maxi mum al l owabl e operati ng angl e.
As a gui de to the maxi mum normal operati ng angl es
refer to (Fi g. 5).
DIAGNOSIS AND TESTING
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
Refer to Group 22, Ti res and Wheel s, for addi ti onal
i nformati on.
Brake drums that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on. Refer to Group 5,
Brakes, for addi ti onal i nformati on.
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts. Refer to Group 9, Engi nes,
for addi ti onal i nformati on.
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve uni versal
joi nts, or an i ncorrect propel l er shaft angl e, are usu-
al l y the cause of such a vi brati on.
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign material
on shaft.
1) Clean exterior of shaft and wash with
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 runout.
3) Install new yoke.
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
balance.
7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.
9) Re-index propeller shaft, test, and
evaluate.
10) Excessive drive pinion gear shaft
runout.
10) Re-index propeller shaft and evaluate.
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 as U-joints as necessary.
PROPELLER SHAFT MAX. NORMAL
R.P.M. OPERATING ANGLES
5000 3°
4500 3°
4000 4°
3500 5°
3000 5°
2500 7°
2000 8°
1500 11°
Fig. 5 Maximum Angles And Propeller Shaft Speed
3 - 4 PROPELLER SHAFTS TJ
DESCRIPTION AND OPERATION (Continued)
UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
vibrations.
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90° apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 6).
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 7) and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/4 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 8).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt, and undercoati ng
from the propel l er shaft surface where the di al i ndi -
cator wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
Fig. 6 Clamp Screw At Position 1
1 – CLAMP
2 – SCREWDRIVER
Fig. 7 Two Clamp Screws At The Same Position
Fig. 8 Clamp Screws Separated
1 –
1
⁄2 INCH
TJ PROPELLER SHAFTS 3 - 5
DIAGNOSIS AND TESTING (Continued)
that the effects of the wel d process wi l l not enter i nto
the measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) I f the propel l er shaft runout i s out of speci fi ca-
ti on, remove the propel l er shaft, i ndex the shaft 180°,
and re-i nstal l the propel l er shaft. Measure shaft
runout agai n.
(6) I f the propel l er shaft runout i s now wi thi n
speci fi cati ons, mark the shaft and yokes for proper
ori entati on.
(7) I f the propel l er shaft runout i s not wi thi n spec-
i fi cati ons, veri fy that the runout of the transmi ssi on/
transfer case and axl e are wi thi n speci fi cati ons.
Correct as necessary and re-measure propel l er shaft
runout.
(8) Repl ace the propel l er shaft i f the runout sti l l
exceeds the l i mi ts.
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION
Before measuri ng uni versal joi nt angl es, the fol -
l owi ng must be done;
• I nfl ate al l ti res to correct pressure.
• Check the angl es i n the same l oaded or
unl oaded condi ti on as when the vi brati on occurred.
Propel l er shaft angl es change accordi ng to the
amount of l oad i n the vehi cl e.
• Check the condi ti on of al l suspensi on compo-
nents and veri fy al l fasteners are torqued to speci fi -
cati ons.
• Check the condi ti on of the engi ne and transmi s-
si on mounts and veri fy al l fasteners are torqued to
speci fi cati ons.
PROPELLER SHAFT ANGLE MEASUREMENT
To accuratel y check dri vel i ne al i gnment, rai se and
support the vehi cl e at the axl es as l evel as possi bl e.
Al l ow the wheel s and propel l er shaft to turn.
(1) Remove any external beari ng snap ri ngs, i f
equi pped, from uni versal joi nt so protractor base si ts
fl at.
(2) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng i s faci ng downward.
Always make measurements from front to
rear. Also, be sure to take all measurements
while working from the same side of the vehi-
cle.
(3) Pl ace I ncl i nometer on yoke beari ng (A) paral l el
to the shaft (Fi g. 9). Center bubbl e i n si ght gl ass and
record measurement.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).
(4) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng paral l el to the shaft
(Fi g. 10). Center bubbl e i n si ght gl ass and record
measurement. Thi s measurement can al so be taken
at the rear end of the shaft.
This measurement will give you the Propeller
Shaft Angle (C).
(5) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n Transmi ssi on Output Operati ng Angl e.
(6) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng paral l el to the
shaft (Fi g. 11). Center bubbl e i n si ght gl ass and
record measurement.
This measurement will give you the pinion
shaft or Input Yoke Angle (B).
(7) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n (Fi g.
12) for addi ti onal i nformati on.
RUNOUT SPECIFICATIONS
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)
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.
Fig. 9 Front (Output) Angle Measurement (A)
1 – SLIP YOKE BEARING CAP
2 – SPECIAL TOOL 7663 (J-23498A)
3 - 6 PROPELLER SHAFTS TJ
DIAGNOSIS AND TESTING (Continued)
Fig. 12 Universal Joint Angle Example
1 – 4.9°Angle (C)
2 – 3.2°Angle (B)
3 – Input Yoke
4 – 3.0°Angle (A)
5 – Output Yoke
Fig. 10 Propeller Shaft Angle Measurement (C)
1 – SHAFT YOKE BEARING CAP
2 – SPECIAL TOOL 7663 (J23498–A)
Fig. 11 Rear (Input) Angle Measurement (B)
1 – PINION YOKE BEARING CAP
2 – SPECIAL TOOL 7663 (J-23498A)
TJ PROPELLER SHAFTS 3 - 7
SERVICE PROCEDURES (Continued)
• Good cancel l ati on of U–joi nt operati ng angl es
(wi thi n 1°).
• Operati ng angl es l ess than 3°.
• At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
REMOVAL AND INSTALLATION
FRONT PROPELLER SHAFT
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Remove the crossmember/ski d pl ate as neces-
sary to gai n access to the propel l er shaft.
(3) Shi ft the transmi ssi on and transfer case, i f nec-
essary, i nto the Neutral posi ti on.
(4) Usi ng a sui tabl e marker, mark a l i ne across
the yoke at the transfer case, the l i nk yoke, and pro-
pel l er shaft yoke at the rear of the front propel l er
shaft for i nstal l ati on reference (Fi g. 13).
(5) Mark a l i ne across the propel l er shaft yoke and
the pi ni on shaft yoke for i nstal l ati on reference.
(6) Remove the U-joi nt strap bol ts at the pi ni on
shaft yoke (Fi g. 14).
(7) Remove bol ts hol di ng rear uni versal joi nt to
the transfer case yoke.
(8) Separate the rear uni versal joi nt from the
transfer case yoke.
(9) Push rear of propel l er shaft upward to cl ear
transfer case yoke.
(10) Separate front uni versal joi nt from front axl e.
(11) Separate propel l er shaft from vehi cl e.
INSTALLATION
(1) Posi ti on front propel l er shaft under vehi cl e
wi th rear uni versal joi nt over the transfer case yoke.
(2) Pl ace front uni versal joi nt i nto the axl e pi ni on
yoke.
(3) Al i gn mark on the rear l i nk yoke and uni versal
joi nt to the mark on the transfer case yoke (Fi g. 13).
(4) Loosel y i nstal l bol ts to hol d uni versal joi nt to
transfer case yoke.
(5) Al i gn mark on front uni versal joi nt to the mark
on the axl e pi ni on yoke.
(6) Ti ghten the U-joi nt strap/cl amp bol ts at the
axl e yoke to 19 N·m (14 ft. l bs.) torque.
(7) Ti ghten the uni versal joi nt to transfer case
bol ts to 27 N·m (20 ft. l bs.) torque.
(8) Lower the vehi cl e.
REAR PROPELLER SHAFT
REMOVAL
(1) Shi ft the transmi ssi on and transfer case i nto
Neutral .
(2) Hoi st and support vehi cl e on safety stands.
(3) Scri be al i gnment marks at the pi ni on shaft and
at each end of the propel l er shaft. These marks wi l l
be used for i nstal l ati on reference.
(4) Remove the U-joi nt strap bol ts at the pi ni on
shaft yoke.
(5) Pry open cl amp hol di ng the dust boot to propel -
l er shaft yoke (Fi g. 15).
(6) Sl i de the sl i p yoke off of the transmi ssi on/
transfer case output shaft and remove the propel l er
shaft (Fi g. 16).
Fig. 13 Reference Marks on Yokes
1 – REFERENCE MARKS
Fig. 14 Front Propeller Shaft
1 – FRONT AXLE
2 – BOOT
3 – PROPELLER SHAFT
4 – CV-JOINT
5 – TRANSFER CASE
6 – BOOT
7 – SLINGER
8 – CLAMP
9 – YOKE
3 - 8 PROPELLER SHAFTS TJ
SERVICE PROCEDURES (Continued)
INSTALLATION
(1) Sl i de the sl i p yoke on the transmi ssi on/transfer
case output shaft. Al i gn the i nstal l ati on reference
marks at the axl e yoke and i nstal l the propel l er shaft
(Fi g. 16).
(2) Ti ghten the U-joi nt strap/cl amp bol ts at the
axl e yoke to 19 N·m (14 ft. l bs.) torque.
(3) Cri mp cl amp to hol d dust boot to propel l er
shaft yoke (Fi g. 17).
(4) Lower the vehi cl e.
DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT
DISASSEMBLY
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
repl aced as an assembl y.
(1) Remove the propel l er shaft.
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
(3) Remove snap ri ngs from both si des of yoke
(Fi g. 18).
(4) Set the yoke i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the yoke.
(5) Posi ti on the yoke wi th the grease fi tti ng, i f
equi pped, poi nti ng up.
(6) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and press the cap through the yoke to
rel ease the l ower beari ng cap (Fi g. 19).
(7) I f the beari ng cap wi l l not pul l out of the yoke
by hand after pressi ng, tap the yoke ear near the
beari ng cap to di sl odge the cap.
(8) To remove the opposi te beari ng cap, turn the
yoke over and strai ghten the cross i n the open hol e.
Then, careful l y press the end of the cross unti l the
remai ni ng beari ng cap can be removed (Fi g. 20).
Fig. 15 Dust Boot Clamp
1 – SLINGER
2 – BOOT
3 – AWL
4 – TRANSFER CASE
Fig. 16 Rear Propeller Shaft
1 – CLAMP
2 – YOKE
3 – PROPELLER SHAFT
4 – AXLE YOKE
5 – CLAMP
6 – OUTPUT SHAFT
7 – BOOT
Fig. 17 Crimping Dust Boot Clamp
1 – SPECIAL TOOL C-4975–A
2 – SLINGER
3 – BOOT
4 – CLAMP
TJ PROPELLER SHAFTS 3 - 9
REMOVAL AND INSTALLATION (Continued)
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) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Posi ti on the cross i n the yoke wi th i ts l ube fi t-
ti ng, i f equi pped, poi nti ng up (Fi g. 21).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 22). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4to i nstal l the opposi te
beari ng cap. I f the joi nt i s sti ff or bi ndi ng, stri ke the
yoke wi th a soft hammer to seat the needl e beari ngs.
(7) Add grease to l ube fi tti ng, i f equi pped.
(8) I nstal l the propel l er shaft.
DOUBLE CARDAN JOINT
DISASSEMBLY
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
repl aced as an assembl y.
(1) Remove the propel l er shaft.
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
Fig. 18 Remove Snap Ring
1 – SNAP RING
Fig. 19 Press Out Bearing
1 – PRESS
2 – SOCKET
Fig. 20 Press Out Remaining Bearing
1 – CROSS
2 – BEARING CAP
3 - 10 PROPELLER SHAFTS TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Remove al l the beari ng cap snap ri ngs (Fi g.
23).
(4) Set the joi nt i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the l i nk
yoke.
(5) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and parti al l y press one beari ng cap from
the outboard si de of the l i nk yoke enough to grasp
the beari ng cap wi th vi se jaws (Fi g. 24). Be sure to
remove grease fi tti ngs that i nterfere wi th removal .
(6) Grasp the protrudi ng beari ng by vi se jaws. Tap
the l i nk yoke wi th a mal l et and dri ft to di sl odge the
beari ng cap from the yoke (Fi g. 25).
Fig. 21 Install Cross In Yoke
1 – CROSS
2 – YOKE
Fig. 22 Install Bearing On Trunnion
1 – BEARING CAP
2 – TRUNNION
Fig. 23 Remove Snap Rings
Fig. 24 Press Out Bearing
TJ PROPELLER SHAFTS 3 - 11
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Fl i p assembl y and repeat Step 4, Step 5, and
Step 6 to remove the opposi te beari ng cap. Thi s wi l l
then al l ow removal of the cross centeri ng ki t assem-
bl y and spri ng (Fi g. 26).
(8) Press the remai ni ng beari ng caps out the other
end of the l i nk yoke as descri bed above to compl ete
the di sassembl y.
ASSEMBLY
During assembly, ensure that the alignment
marks on the link yoke and propeller shaft
yoke are aligned.
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Fi t a cross i nto the propel l er shaft yoke (Fi g.
27).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 28). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
Fig. 25 Remove Bearing From Yoke
Fig. 26 Remove Centering Kit
Fig. 27 Install Cross In Yoke
Fig. 28 Install Bearing Cap
3 - 12 PROPELLER SHAFTS TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng (Fi g. 29).
(5) I nstal l a snap ri ng.
(6) Fl i p the propel l er shaft yoke and i nstal l the
beari ng cap onto the opposi te trunni on. I nstal l a
snap ri ng (Fi g. 30).
(7) Fi t the l i nk yoke on the remai ni ng two trun-
ni ons and press both beari ng caps i nto pl ace (Fi g.
31).
(8) I nstal l snap ri ngs.
(9) I nstal l the centeri ng ki t assembl y i nsi de the
l i nk yoke maki ng sure the spri ng i s properl y posi -
ti oned (Fi g. 32).
Fig. 29 Press In Bearing Cap
Fig. 30 Press In Bearing Cap
Fig. 31 Install Link Yoke
Fig. 32 Install Centering Kit
TJ PROPELLER SHAFTS 3 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(10) Pl ace two beari ng caps on opposi te trunni ons
of the remai ni ng cross. Fi t the open trunni ons i nto
the l i nk yoke bores and the beari ng caps i nto the
centeri ng ki t (Fi g. 33).
(11) Press the remai ni ng two beari ng caps i nto
pl ace and i nstal l snap ri ngs (Fi g. 34).
(12) Tap the snap ri ngs to al l ow them to seat i nto
the grooves (Fi g. 35).
(13) Check for proper assembl y. Fl ex the joi nt
beyond center, i t shoul d snap over-center i n both
di recti ons when correctl y assembl ed (Fi g. 36).
(14) I nstal l the propel l er shaft.
CLEANING AND INSPECTION
SINGLE AND DOUBLE CARDAN JOINT
(1) Cl ean al l the uni versal joi nt yoke bores wi th
cl eani ng sol vent and a wi re brush.
(2) I nspect the yokes for di storti on, cracks, and
worn beari ng cap bores.
Fig. 33 Install Remaining Cross
Fig. 34 Press In Bearing Cap
Fig. 35 Seat Snap Rings In Groove
Fig. 36 Check Assembly
3 - 14 PROPELLER SHAFTS TJ
DISASSEMBLY AND ASSEMBLY (Continued)
ADJ USTMENTS
AXLE PINION ANGLE ADJUSTMENT
The pi ni on angl e of the front axl e can be adjusted
by the use of adjustment cams i n the l ower suspen-
si on arms (Fi g. 37). The pri mary functi on for the
cams i s to adjust the caster angl e for the al i gnment
of the front suspensi on. When usi ng the cams to
adjust the pi ni on angl e, make sure that both cams
are moved equal l y. After the pi ni on angl e i s adjusted,
the front suspensi on al i gnment shoul d be checked to
ensure that si de-to-si de caster angl es vari ance i s
wi th-i n the acceptabl e range. Havi ng the correct pi n-
i on angl e does have pri ori ty over havi ng the pre-
ferred caster angl e.
A cam ki t i s avai l abl e to be i nstal l ed i n the rear
axl e upper suspensi on arms i n order to provi de
adjustabl i ty of the pi ni on angl e. Fol l ow the proce-
dures suppl i ed wi th the ki t i n order to ensure a safe
i nstal l ati on.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Front Propeller Shaft
Bolts, Rear Yoke . . . . . . . . . . . 27 N·m (20 ft. l bs.)
Bolts, Front Yoke . . . . . . . . . . 41 N·m (30 ft. l bs.)
Rear Propeller Shaft
Bolts, Rear Yoke . . . . . . . . . . . 19 N·m (14 ft. l bs.)
SPECIAL TOOLS
PROPELLER SHAFT
Fig. 37 Adjustment Cam
1 – ADJUSTMENT CAM
2 – AXLE BRACKET
3 – BRACKET REINFORCEMENT
4 – LOWER SUSPENSION ARM
Inclinometer—7663
Boot Clamp Installer—C-4975-A
TJ PROPELLER SHAFTS 3 - 15
181 FBI AXLE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
181 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
STANDARD DIFFERENTIAL. . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 18
GEAR NOISE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 20
LOW SPEED KNOCK. . . . . . . . . . . . . . . . . . . . . . 20
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL AND INSTALLATION
FRONT AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AXLE SHAFT—CARDAN U-JOINT . . . . . . . . . . . . 22
PINION SHAFT SEAL. . . . . . . . . . . . . . . . . . . . . . 23
COLLAPSIBLE SPACER. . . . . . . . . . . . . . . . . . . . 25
HUB BEARING AND AXLE SHAFT . . . . . . . . . . . . 27
STEERING KNUCKLE AND BALL STUDS. . . . . . . 28
AXLE BUSHING REPLACEMENT. . . . . . . . . . . . . 30
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIFFERENTIAL SIDE BEARINGS. . . . . . . . . . . . . 33
AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . 33
PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL. . . . . . . . . . . . . . . . . 39
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 40
CLEANING AND INSPECTION
CARDAN U-JOINT . . . . . . . . . . . . . . . . . . . . . . . . 40
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . 40
ADJUSTMENTS
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . . 41
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . . 43
GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 47
SPECIFICATIONS
181 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SPECIAL TOOLS
181 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DESCRIPTION AND OPERATION
181 FBI AXLE
DESCRIPTION
The 181 Front Beam-desi gn I ron (FBI ) axl e con-
si sts of a cast i ron di fferenti al housi ng wi th axl e
shaft tubes extendi ng from ei ther si de. The tubes are
pressed i nto the di fferenti al housi ng and wel ded.
The i ntegral type housi ng, hypoi d gear desi gn has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear.
The axl e has a fi tti ng for a vent hose used to
rel i eve i nternal pressure caused by l ubri cant vapor-
i zati on and i nternal expansi on.
The axl es are equi pped wi th semi –fl oati ng axl e
shafts, meani ng that l oads are supported by the hub
beari ngs. The axl e shafts are retai ned by nuts at the
hub beari ngs. The hub beari ngs are bol ted to the
steeri ng knuckl e at the outboard end of the axl e tube
yoke. The hub beari ngs are servi ced as an assembl y.
For vehi cl es wi th ABS brakes, the ABS wheel
speed sensors are attached to the knuckl e assem-
bl i es. The tone ri ngs for the ABS system are pressed
onto the axl e shaft. Do not damage ABS tone
wheel or the sensor when removing axle shafts.
The stamped steel cover provi des a means for
i nspecti on and servi ci ng the di fferenti al .
The 181 FBI axl e has the assembl y part number
and gear rati o l i sted on a tag. The tag i s attached to
the housi ng cover by a cover bol t. Bui l d date i denti -
fi cati on codes are stamped on the cover si de of the
axl e shaft tube.
The di fferenti al case i s a one–pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a rol l
pi n. Di fferenti al beari ng prel oad and ri ng gear back-
l ash i s adjusted by the use of shi ms (sel ect thi ck-
ness). The shi ms are l ocated between the di fferenti al
beari ng cones and case. Pi ni on beari ng prel oad i s set
and mai ntai ned by the use of a col l apsi bl e spacer.
OPERATION
The axl e recei ves power from the transfer case
through the front propel l er shaft. The front propel l er
shaft i s connected to the pi ni on gear whi ch rotates
the di fferenti al through the gear mesh wi th the ri ng
gear bol ted to the di fferenti al case. The engi ne power
i s transmi tted to the axl e shafts through the pi ni on
mate and si de gears. The si de gears are spl i ned to
the axl e shafts.
3 - 16 181 FBI AXLE TJ
LUBRICANT
DESCRIPTION
A mul ti –purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar௡ Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
• The l ubri cant shoul d have MI L–L–2105C and
API GL 5 qual i ty speci fi cati ons.
• Lubri cant i s a thermal l y stabl e SAE 80W–90
gear l ubri cant.
• Lubri cant for axl es i ntended for heavy-duty or
trai l er tow use i s SAE 75W–140 SYNTHETI C gear
l ubri cant.
The 181 FBI axl e l ubri cant capaci ty i s 1.2 L (2.5
pts.).
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
STANDARD DIFFERENTIAL
DESCRIPTION
The di fferenti al gear system di vi des the torque
between the axl e shafts. I t al l ows the axl e shafts to
rotate at di fferent speeds when turni ng corners.
Each di fferenti al si de gear i s spl i ned to an axl e
shaft. The pi ni on gears are mounted on a pi ni on
mate shaft and are free to rotate on the shaft. The
pi ni on gear i s fi tted i n a bore i n the di fferenti al case
and i s posi ti oned at a ri ght angl e to the axl e shafts.
OPERATION
I n operati on, power fl ow occurs as fol l ows:
• The pi ni on gear rotates the ri ng gear
• The ri ng gear (bol ted to the di fferenti al case)
rotates the case
• The di fferenti al pi ni on gears (mounted on the
pi ni on mate shaft i n the case) rotate the si de gears
• The si de gears (spl i ned to the axl e shafts) rotate
the shafts
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
Fig. 1 Differential Operation—Straight Ahead Driving
1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 – PINION GEAR
3 – SIDE GEAR
4 – PINION GEARS ROTATE WITH CASE
Fig. 2 Differential Operation—On Turns
1 – PINION GEARS ROTATE ON PINION SHAFT
TJ 181 FBI AXLE 3 - 17
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Axl e beari ng probl em condi ti ons are usual l y caused
by:
• I nsuffi ci ent or i ncorrect l ubri cant.
• Forei gn matter/water contami nati on.
• I ncorrect beari ng prel oad torque adjustment.
• I ncorrect backl ash.
Axl e gear probl em condi ti ons are usual l y the resul t
of:
• I nsuffi ci ent l ubri cati on.
• I ncorrect or contami nated l ubri cant.
• Overl oadi ng (excessi ve engi ne torque) or exceed-
i ng vehi cl e wei ght capaci ty.
• I ncorrect cl earance or backl ash adjustment.
Axl e component breakage i s most often the resul t
of:
• Severe overl oadi ng.
• I nsuffi ci ent l ubri cant.
• I ncorrect l ubri cant.
• I mproperl y ti ghtened components.
• Di fferenti al housi ng bores not square to each
other.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load information
and correct as necessary.
4. Excessive gear backlash between the
ring gear and pinion.
4. Check adjustment of the ring gear and
pinion backlash. Correct as necessary.
5. Improper adjustment of pinion gear
bearings.
5. Adjust the pinion bearings pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact surfaces. 7. Inspect and replace as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or
correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect and
repair clutch as necessary.
3 - 18 181 FBI AXLE TJ
Condition Possible Causes Correction
Differential Cracked 1. Improper adjustment of the differential
bearings.
1. Replace case and inspect gears and
bearings for further damage. Set
differential bearing pre-load properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring
gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid
excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid erratic
use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential
with the correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential
with the correct fluid type and quantity.
3. Excessive spinning of one wheel/tire. 3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid
type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears
and bearings for possible damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid erratic
clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine remaining
parts for damage.
4. Improper adjustments. 4. Replace gears and examine remaining
parts for damage. Ensure ring gear
backlash is correct.
TJ 181 FBI AXLE 3 - 19
DIAGNOSIS AND TESTING (Continued)
Condition Possible Causes Correction
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid
type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion contact
pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring
gear and pinion.
4. Worn teeth on ring gear and/or pinion. 4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap bolts. 8. Inspect differential components and
replace as necessary. Ensure that the
bearing caps are torqued tot he proper
specification.
9. Housing not machined properly. 9. Replace housing.
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears, or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak–noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght–ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant–pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U–joi nt or by worn si de–gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out–of–bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U–joi nt(s).
• Loose/broken spri ngs.
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
3 - 20 181 FBI AXLE TJ
DIAGNOSIS AND TESTING (Continued)
Check for l oose or damaged front–end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear–end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
Refer to Group 22, Wheel s and Ti res, for addi ti onal
vi brati on i nformati on.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U–joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
SERVICE PROCEDURES
LUBRICANT CHANGE
(1) Rai se and support the vehi cl e.
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
drai n the l ubri cant from the housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the seal ant from the housi ng and cover
surfaces. Use sol vent to cl ean the mati ng surfaces.
(6) Appl y a bead of Mopar௡ Si l i cone Rubber Seal -
ant, or equi val ent, to the housi ng cover (Fi g. 3).
Install the housing cover within 5 minutes
after applying the sealant.
(7) I nstal l the cover and any i denti fi cati on tag.
Ti ghten the cover bol ts i n a cri ss–cross pattern to 41
N·m (30 ft. l bs.) torque.
(8) Refi l l the di fferenti al wi th Mopar௡ Hypoi d
Gear Lubri cant, or equi val ent, to bottom of the fi l l
pl ug hol e. Refer to the Lubri cant Speci fi cati ons i n
thi s group for the quanti ty necessary.
(9) I nstal l the fi l l hol e pl ug and l ower the vehi cl e.
Ti ghten fi l l pl ug to 34 N·m (25 ft. l bs.).
REMOVAL AND INSTALLATION
FRONT AXLE
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove the wheel s and ti res.
(5) Remove the brake rotors and cal i pers from the
axl e. Refer to Group 5, Brakes, for proper procedures.
(6) Di sconnect the wheel sensor wi ri ng harness
from the vehi cl e wi ri ng harness, i f necessary.
(7) Di sconnect the vent hose from the axl e shaft
tube.
(8) Mark the propel l er shaft and yoke for i nstal l a-
ti on al i gnment reference.
(9) Remove propel l er shaft.
(10) Di sconnect stabi l i zer bar l i nks at the axl e.
(11) Di sconnect shock absorbers from axl e brack-
ets.
(12) Di sconnect track bar.
(13) Di sconnect the ti e rod and drag l i nk from the
steeri ng knuckl e. Refer to Group 2, Suspensi on, for
proper procedures.
(14) Di sconnect the steeri ng damper from the axl e
bracket.
Fig. 3 Typical Housing Cover With Sealant
1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35MM (1/4”)
TJ 181 FBI AXLE 3 - 21
DIAGNOSIS AND TESTING (Continued)
(15) Di sconnect the upper and l ower suspensi on
arms from the axl e brackets.
(16) Lower the l i fti ng devi ce enough to remove the
axl e. The coi l spri ngs wi l l drop wi th the axl e.
(17) Remove the coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, ride height and
handling could be affected.
(1) I nstal l the spri ngs and retai ner cl i ps. Ti ghten
the retai ner bol ts to 21 N·m (16 ft. l bs.) torque.
(2) Support the axl e on a sui tabl e l i fti ng devi ce
and posi ti on axl e under the vehi cl e.
(3) Rai se the axl e and al i gn i t wi th the spri ng
pads.
(4) Posi ti on the upper and l ower suspensi on arms
i n the axl e brackets. Loosel y i nstal l bol ts and nuts to
hol d suspensi on arms to the axl e brackets.
(5) Connect the vent hose to the axl e shaft tube.
(6) Connect the track bar to the axl e bracket.
Loosel y i nstal l the bol t to hol d the track bar to the
axl e bracket.
(7) I nstal l the shock absorbers and ti ghten the
bol ts to 23 N·m (17 ft. l bs.) torque.
(8) I nstal l the stabi l i zer bar l i nks to the axl e
brackets. Ti ghten the nut to 95 N·m (70 ft. l bs.)
torque.
(9) I nstal l the drag l i nk and ti e rod to the steeri ng
knuckl es. Refer to Group 2, Suspensi on, for proper
procedures.
(10) I nstal l the steeri ng damper to the axl e
bracket and ti ghten the nut to 75 N·m (55 ft. l bs.)
torque.
(11) I nstal l the brake rotors and cal i pers. Refer to
Group 5, Brakes, for the proper procedures.
(12) Connect the wheel speed sensor wi ri ng har-
ness to the vehi cl e wi ri ng harness, i f necessary.
(13) Al i gn the previ ousl y made marks on the pro-
pel l er shaft and the yoke.
(14) I nstal l the straps and bol ts to hol d the propel -
l er shaft to the yoke.
(15) Check and fi l l axl e l ubri cant. Refer to the
Lubri cant Speci fi cati ons i n thi s group for the quan-
ti ty necessary.
(16) I nstal l the wheel and ti re assembl i es.
(17) Remove the l i fti ng devi ce from the axl e and
l ower the vehi cl e.
(18) Ti ghten the upper suspensi on arm nuts to 75
N·m (55 ft. l bs.) torque. Ti ghten the l ower suspensi on
arm nuts to 115 N·m (85 ft. l bs.) torque.
(19) Ti ghten the track bar bol t at the axl e bracket
to 100 N·m (74 ft. l bs.) torque.
(20) Check the front wheel al i gnment.
AXLE SHAFT— CARDAN U-JOINT
Si ngl e cardan U–joi nt components are not servi ce-
abl e. I f defecti ve, they must be repl aced as a uni t. I f
the beari ngs, seal s, spi der, or beari ng caps are dam-
aged or worn, repl ace the compl ete U–joi nt.
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Also, to avoid distorting the
yoke, do not over tighten the vise jaws.
(1) Remove axl e shaft.
(2) Remove the beari ng cap retai ni ng snap ri ngs
(Fi g. 4).
It can be helpful to saturate the bearing caps
with penetrating oil prior to removal.
(3) Locate a socket where the i nsi de di ameter i s
l arger i n di ameter than the beari ng cap. Pl ace the
socket (recei ver) agai nst the yoke and around the
peri meter of the beari ng cap to be removed.
(4) Locate a socket where the outsi de di ameter i s
smal l er i n di ameter than the beari ng cap. Pl ace the
socket (dri ver) agai nst the opposi te beari ng cap.
Fig. 4 Axle Shaft Outer U–Joint
1 – SHAFT YOKE
2 – BEARING CAP
3 – SNAP RINGS
4 – BEARING CAP
5 – SPINDLE YOKE
6 – BEARING
7 – BEARING CAP
8 – SNAP RINGS
9 – BEARING CAP
3 - 22 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(5) Posi ti on the yoke wi th the sockets i n a vi se
(Fi g. 5).
(6) Compress the vi se jaws to force the beari ng cap
i nto the l arger socket (recei ver).
(7) Rel ease the vi se jaws. Remove the sockets and
beari ng cap that was parti al l y forced out of the yoke.
(8) Repeat the above procedure for the remai ni ng
beari ng cap.
(9) Remove the remai ni ng beari ng cap, beari ngs,
seal s and spi der from the propel l er shaft yoke.
INSTALLATION
(1) Pack the beari ng caps 1/3 ful l of wheel beari ng
l ubri cant. Appl y extreme pressure (EP), l i thi um–base
l ubri cant to ai d i n i nstal l ati on.
(2) Posi ti on the spi der i n the yoke. I nsert the seal s
and beari ngs. Tap the beari ng caps i nto the yoke
bores far enough to hol d the spi der i n posi ti on.
(3) Pl ace the socket (dri ver) agai nst one beari ng
cap. Posi ti on the yoke wi th the socket wrench i n a
vi se.
(4) Compress the vi se to force the beari ng caps
i nto the yoke. Force the caps enough to i nstal l the
retai ni ng cl i ps.
(5) I nstal l the beari ng cap retai ni ng cl i ps.
(6) I nstal l axl e shaft.
PINION SHAFT SEAL
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove brake rotors and cal i pers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Usi ng Hol der 6958 to hol d the pi ni on yoke,
remove the pi ni on nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pi ni on yoke (Fi g. 6).
(10) Use a sui tabl e pry tool or a sl i de hammer
mounted screw to remove the pi ni on seal .
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C-4171 (Fi g. 7).
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
W-162–D, Cup 8109, and Hol der 6958 (Fi g. 8).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bear-
ings may result.
Fig. 5 Yoke Bearing Cap Removal
1 – LARGE-DIAMETER SOCKET WRENCH
2 – VISE
3 – SMALL-DIAMETER SOCKET WRENCH
Fig. 6 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
TJ 181 FBI AXLE 3 - 23
REMOVAL AND INSTALLATION (Continued)
(3) I nstal l the pi ni on washer and a new nut on the
pi ni on gear. Tighten the nut only enough to
remove the shaft end play.
(4) Rotate the pi ni on shaft usi ng a (i n. l bs.) torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal , pl us an addi ti onal 0.56
N·m (5 i n. l bs.) (Fi g. 9).
(5) I f the rotati ng torque i s l ow, use Hol der 6958 to
hol d the pi ni on yoke (Fi g. 10), and ti ghten the pi ni on
shaft nut i n 6.8 N·m (5 ft. l bs.) i ncrements unti l
proper rotati ng torque i s achi eved.
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
(6) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and yoke and i nstal l the propel l er
shaft.
(7) Check and fi l l the gear l ubri cant. Refer to the
Lubri cant Speci fi cati ons for gear l ubri cant requi re-
ments.
Fig. 7 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 8 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
Fig. 9 Check Pinion Rotation Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
Fig. 10 Tightening Pinion Shaft Nut—Typical
1 – PINION FLANGE
2 – FRONT AXLE
3 – TOOL 6958
3 - 24 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(8) I nstal l the brake rotors and cal i pers. Refer to
Group 5, Brakes, for proper procedures.
(9) I nstal l wheel and ti re assembl i es.
(10) Lower the vehi cl e.
COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove brake rotors and cal i pers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Usi ng Hol der 6958 to hol d the pi ni on yoke,
remove the pi ni on nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pi ni on yoke (Fi g. 11).
(10) Use a sui tabl e pry tool or a sl i de hammer
mounted screw, remove the pi ni on seal .
(11) Remove the front pi ni on beari ng usi ng a pai r
of sui tabl e pi ck tool s to pul l the beari ng strai ght off
the pi ni on gear shaft. I t may be necessary to l i ghtl y
tap the end of the pi ni on gear wi th a rawhi de or rub-
ber mal l et i f the beari ng becomes bound on the pi n-
i on shaft.
(12) Remove the col l apsi bl e spacer.
REMOVAL W/PINION REMOVED
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove brake rotors and cal i pers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Remove di fferenti al assembl y from axl e hous-
i ng.
(9) Usi ng Hol der 6958 to hol d yoke, remove the
pi ni on nut and washer.
(10) Usi ng Remover C-452 and Wrench C-3281,
remove the pi ni on yoke from pi ni on shaft (Fi g. 11).
(11) Remove the pi ni on gear from housi ng (Fi g.
12). Catch the pi ni on wi th your hand to prevent i t
from fal l i ng and bei ng damaged.
(12) Remove col l apsi bl e spacer from pi ni on shaft.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft (Fi g. 13).
(2) I f pi ni on gear was removed, i nstal l pi ni on gear
i n housi ng.
(3) I nstal l pi ni on front beari ng, i f necessary.
Fig. 11 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 12 Remove Pinion Gear
1 – RAWHIDE HAMMER
TJ 181 FBI AXLE 3 - 25
REMOVAL AND INSTALLATION (Continued)
(4) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C-4171 (Fi g. 14), i f necessary.
(5) I nstal l yoke wi th I nstal l er W-162-D, Cup 8109,
and hol der 6958 (Fi g. 15).
(6) I f the ori gi nal pi ni on beari ngs are bei ng used,
i nstal l di fferenti al assembl y and axl e shafts, i f neces-
sary.
NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
(7) I nstal l the pi ni on washer and a new nut on the
pi ni on gear. Ti ghten the nut to 217 N·m (160 ft. l bs.)
mi ni mum. Do not over-tighten. Maxi mum torque i s
353 N·m (260 ft. l bs.).
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded, a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
(8) Usi ng yoke hol der 6958 and a torque wrench
set at 353 N·m (260 ft. l bs.), crush col l apsi bl e spacer
unti l beari ng end pl ay i s taken up (Fi g. 16). I f more
than 353 N·m (260 ft. l bs.) i s needed to begi n to col -
l apse the spacer, the spacer i s defecti ve and must be
repl aced.
(9) Sl owl y ti ghten the nut i n 6.8 N·m (5 ft. l bs.)
i ncrements unti l the rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over
crushi ng the col l apsi bl e spacer (Fi g. 17).
(10) Check rotati ng torque wi th an i nch pound
torque wrench (Fi g. 17). The torque necessary to
rotate the pi ni on gear shoul d be:
• Ori gi nal Beari ngs — The readi ng recorded dur-
i ng removal , pl us an addi ti onal 0.56 N·m (5 i n. l bs.).
• New Beari ngs — 1.5 to 4 N·m (15 to 35 i n. l bs.).
(11) I nstal l di fferenti al assembl y and axl e shafts, i f
necessary.
(12) Al i gn marks made previ ousl y on yoke and
propel l er shaft and i nstal l propel l er shaft.
Fig. 13 Collapsible Preload Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING
Fig. 14 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 15 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
3 - 26 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(13) I nstal l brake rotors and cal i pers. Refer to
Group 5, Brakes, for proper procedures.
(14) Add gear l ubri cant, i f necessary. Refer to
Lubri cant Speci fi cati ons of thi s secti on for l ubri cant
requi rements.
(15) I nstal l wheel and ti re assembl i es.
(16) Lower vehi cl e.
HUB BEARING AND AXLE SHAFT
I f the axl e shaft and hub beari ng are bei ng
removed i n order to servi ce another component, the
axl e shaft and hub beari ng can be removed as an
assembl y.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per and rotor. Refer to
Group 5, Brakes, for proper procedures.
(4) Remove ABS wheel speed sensor, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(5) Remove the cotter pi n, nut retai ner, and axl e
hub nut (Fi g. 18), i f necessary.
(6) Remove the hub to knuckl e bol ts (Fi g. 19).
(7) Remove the hub from the steeri ng knuckl e and
axl e shaft, i f necessary.
(8) Remove hub beari ng and axl e shaft assembl y
(Fi g. 20), or axl e shaft from axl e. Avoid damaging
the axle shaft oil seals in the axle housing.
(9) Remove the brake rotor shi el d from the hub
beari ng or knuckl e (Fi g. 18).
INSTALLATION
(1) Thoroughl y cl ean the axl e shaft (Fi g. 18) and
appl y a thi n fi l m of Mopar௡ Wheel Beari ng Grease,
or equi val ent, to the shaft spl i nes, seal contact sur-
face, and hub bore.
(2) I nstal l the brake rotor shi el d to the knuckl e.
(3) I nstal l the hub beari ng and axl e shaft assem-
bl y, or axl e shaft, i nto the housi ng and di fferenti al
si de gears. Avoi d damagi ng the axl e shaft oi l seal s i n
the axl e housi ng.
(4) I nstal l the hub beari ng, i f necessary.
(5) I nstal l the hub to knuckl e bol ts and ti ghten to
102 N·m (75 ft. l bs.) torque.
(6) I nstal l the hub washer and nut, i f necessary.
Ti ghten the hub nut to 237 N·m (175 ft. l bs.) torque.
I nstal l the nut retai ner and a new cotter pi n (Fi g.
18).
(7) I nstal l ABS wheel speed sensor, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(8) I nstal l the brake rotor and cal i per. Refer to
Group 5, Brakes, for proper procedures.
(9) I nstal l the wheel and ti re assembl y.
(10) Remove support and l ower the vehi cl e.
Fig. 16 Tightening Pinion Nut
1 – PINION FLANGE
2 – FRONT AXLE
3 – TOOL 6958
Fig. 17 Check Pinion Gear Rotation Torque—Typical
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
TJ 181 FBI AXLE 3 - 27
REMOVAL AND INSTALLATION (Continued)
STEERING KNUCKLE AND BALL STUDS
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. Removal and
i nstal l ati on of upper and l ower bal l studs requi re the
use of Tool Ki t 6289.
Fig. 18 Hub, Knuckle and Axle Shaft
1 – BRAKE SHIELD
2 – WASHER
3 – RETAINER
4 – COTTER PIN
5 – NUT
6 – HUB AND BEARING ASSEMBLY
7 – STEERING KNUCKLE
8 – BOLT
9 – TONE WHEEL (ABS)
Fig. 19 Hub Bearing Bolts
1 – AXLE SHAFT
2 – AXLE
3 – KNUCKLE
4 – HUB BEARING
Fig. 20 Hub Bearing and Axle Assembly
1 – AXLE
2 – KNUCKLE
3 – HUB BEARING
4 – AXLE SHAFT
3 - 28 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
KNUCKLE REMOVAL
(1) Remove hub beari ng and axl e shaft.
(2) Di sconnect the ti e-rod or drag l i nk from the
steeri ng knuckl e arm. Refer to Group 2, Suspensi on,
for proper procedures.
(3) Remove the cotter pi ns from the upper and
l ower bal l studs.
(4) Remove the upper and l ower bal l stud nuts.
(5) Stri ke the steeri ng knuckl e wi th a brass ham-
mer to l oosen knuckl e from the bal l studs. Remove
knuckl e from bal l studs (Fi g. 21).
UPPER BALL STUD REPLACEMENT
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 22).
LOWER BALL STUD REPLACEMENT
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 23).
KNUCKLE INSTALLATION
(1) Posi ti on the steeri ng knuckl e on the bal l studs.
(2) I nstal l and ti ghten the bottom retai ni ng nut to
109 N·m (80 ft. l bs.) torque. I nstal l new cotter pi n.
(3) I nstal l and ti ghten the top retai ni ng nut to 101
N·m (75 ft. l bs.) torque. I nstal l new cotter pi n.
(4) I nstal l the hub beari ng and axl e shaft.
Fig. 22 Upper Ball Stud Remove/Install
Fig. 21 Steering Knuckle Removal/Installation
1 – AXLE YOKE
2 – UPPER BALL STUD
3 – LOWER BALL STUD
4 – STEERING KNUCKLE
TJ 181 FBI AXLE 3 - 29
REMOVAL AND INSTALLATION (Continued)
(5) Connect the ti e-rod or drag l i nk end to the
steeri ng knuckl e arm. Refer to Group 2, Suspensi on,
for proper procedures.
AXLE BUSHING REPLACEMENT
Refer to Group 2, Suspensi on, for the proper axl e
bushi ng procedures.
DIFFERENTIAL
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
al l ow fl ui d to drai n.
(4) Remove hub beari ngs and axl e shafts.
(5) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 24).
(6) Loosen the di fferenti al beari ng cap bol ts.
(7) Posi ti on Spreader W–129–B, uti l i zi ng some
i tems from Adapter Ki t 6987, wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 25). I nstal l the
hol ddown cl amps and ti ghten the tool turnbuckl e fi n-
ger–ti ght.
Fig. 23 Lower Ball Stud Remove/Install
1 – SPECIAL TOOL 6289–12
2 – SPECIAL TOOL 6289–4
3 – SPECIAL TOOL 4212F
4 – SPECIAL TOOL 4212F
5 – SPECIAL TOOL 6289–1
6 – SPECIAL TOOL 6289–3
Fig. 24 Bearing Cap Identification
1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
3 - 30 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(8) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to gui de pi n. Load the l ever adapter agai nst the
opposi te si de of the housi ng (Fi g. 26) and zero the
i ndi cator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(9) Spread the housi ng enough to remove the di f-
ferenti al case from the housi ng. Measure the di s-
tance wi th the di al i ndi cator (Fi g. 27).
(10) Remove the di al i ndi cator.
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
(12) Remove the di fferenti al from the housi ng.
Ensure that the di fferenti al beari ng cups remai n i n
posi ti on on the di fferenti al beari ngs (Fi g. 28).
(13) Mark or tag the di fferenti al beari ng cups to
i ndi cate whi ch si de of the di fferenti al they were
removed from.
(14) Remove spreader from housi ng.
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are bei ng i nstal l ed, di fferenti al si de beari ng
shi m requi rements may change. Refer to the Di ffer-
enti al Beari ng Prel oad and Gear Backl ash proce-
Fig. 25 Install Axle Housing Spreader
1 – AXLE HOUSING
2 – DOWEL
3 – SAFETY HOLD DOWN
4 – SPECIAL TOOL
W-129–B
5 – TURNBUCKLE
Fig. 26 Install Dial Indicator
1 – SPECIAL TOOL
C-3339
2 – DIAL INDICATOR
3 – LEVER ADAPTER
4 – SPECIAL TOOL
W-129–B
5 – SPECIAL TOOL
C-3288–B
Fig. 27 Spread Axle Housing
1 – SPECIAL TOOL
C-3339
2 – SPECIAL TOOL
W-129–B
TJ 181 FBI AXLE 3 - 31
REMOVAL AND INSTALLATION (Continued)
dures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) Posi ti on Spreader W-129-B, uti l i zi ng some
i tems from Adapter Ki t 6987, wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 29). I nstal l the
hol ddown cl amps and ti ghten the tool turnbuckl e fi n-
ger–ti ght.
(2) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to gui de pi n. Load the l ever adapter agai nst the
opposi te si de of the housi ng (Fi g. 26) and zero the
i ndi cator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 27).
(4) Remove the di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs. Tap the di fferenti al case
to ensure the beari ngs cups are ful l y seated i n the
housi ng.
(6) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 30).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 61 N·m (45 ft.
l bs.) torque.
(10) I nstal l the hub beari ngs and axl e shafts.
Fig. 28 Differential Case Removal
1 – AXLE HOUSING
2 – DIFFERENTIAL CASE
3 – BEARING CUPS
Fig. 29 Install Axle Housing Spreader
1 – AXLE HOUSING
2 – DOWEL
3 – SAFETY HOLD DOWN
4 – SPECIAL TOOL
W-129–B
5 – TURNBUCKLE
Fig. 30 Differential Bearing Cap Reference Letters
1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
3 - 32 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
DIFFERENTIAL SIDE BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove the beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, C-293-39 Adapter
Bl ocks, and Pl ug SP-3289 (Fi g. 31).
INSTALLATION
I f repl acement di fferenti al si de beari ngs or di ffer-
enti al case are bei ng i nstal l ed, di fferenti al si de bear-
i ng shi m requi rements may change. Refer to the
Di fferenti al Beari ng Prel oad and Gear Backl ash pro-
cedures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) I nstal l di fferenti al si de beari ng shi ms onto di f-
ferenti al case hubs.
(2) Usi ng I nstal l er C-3716-A and Handl e C-4171,
i nstal l di fferenti al si de beari ngs (Fi g. 32).
(3) I nstal l di fferenti al i n axl e housi ng.
AXLE SHAFT OIL SEAL
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove di fferenti al assembl y.
(3) Remove the i nner axl e shaft seal s wi th a pry
bay.
INSTALLATION
(1) Remove any seal er remai ni ng from ori gi nal
seal s.
(2) Remove seal er from axl e tube to housi ng junc-
ti on, i f necessary.
(3) I nstal l oi l seal s wi th Di scs 8110 and Turn-
buckl e 6797 (Fi g. 33). Ti ghten tool unti l di sc bottoms
i n housi ng.
(4) I nstal l di fferenti al assembl y.
PINION
The ri ng gear and pi ni on are servi ced as a matched
set. Do not repl ace the pi ni on wi thout repl aci ng the
ri ng gear.
REMOVAL
(1) Remove di fferenti al assembl y from axl e hous-
i ng.
(2) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from pi ni on yoke.
Usi ng sui tabl e wi re, ti e propel l er shaft to underbody.
Fig. 31 Differential Bearing Removal
1 – SPECIAL TOOL C–293–39
2 – BEARING
3 – DIFFERENTIAL
4 – SPECIAL TOOL SP–3289
5 – SPECIAL TOOL C–293–PA
Fig. 32 Differential Side Bearing Installation
1 – SPECIAL TOOL C-3716–A
2 – SPECIAL TOOL C-4171
TJ 181 FBI AXLE 3 - 33
REMOVAL AND INSTALLATION (Continued)
(4) Usi ng Hol der 6958 to the hol d yoke, remove
the pi ni on nut and washer (Fi g. 34).
(5) Usi ng Remover C–452 and Hol der C-3281,
remove the pi ni on yoke from pi ni on shaft (Fi g. 35).
(6) Remove the pi ni on and col l apsi bl e spacer from
housi ng (Fi g. 36). Catch the pi ni on wi th your hand to
prevent i t from fal l i ng and bei ng damaged.
Fig. 33 Axle Seal Installation
1 – TURNBUCKLE 6797
2 – DISCS 8110
Fig. 34 Pinion Yoke Holder—Typical
1 – 1 in. PIPE
2 – PINION YOKE
3 – SPECIAL TOOL
6958
4 – LOWER CONTROL ARM
Fig. 35 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 36 Remove Pinion
1 – RAWHIDE HAMMER
3 - 34 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(7) Remove the front pi ni on beari ng cup, beari ng,
oi l sl i nger, i f equi pped, and pi ni on seal wi th Remover
C-4345 and Handl e C–4171 (Fi g. 37).
(8) Remove the rear pi ni on beari ng cup from axl e
housi ng (Fi g. 38). Use Remover D-149 and Handl e
C–4171.
(9) Remove the col l apsi bl e prel oad spacer from
pi ni on gear (Fi g. 39).
(10) Remove the rear pi ni on beari ng from the pi n-
i on wi th Pul l er/Press C–293-PA and Adapters
C–293–39 (Fi g. 40).
Place 4 adapter blocks so they do not damage
the bearing cage.
(11) Remove the depth shi m/oi l sl i nger from the
pi ni on shaft. Record the thi ckness of the depth shi m/
oi l sl i nger.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If the factory installed ring gear and pinion
are reused, the pinion depth shim/oil slinger should
not require replacement. Refer to Pinion Gear Depth
to select the proper thickness shim/oil slinger
before installing pinion.
(1) Appl y Mopar௡ Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of rear pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-146 and
Dri ver Handl e C–4171 (Fi g. 41). Veri fy cup i s cor-
rectl y seated.
Fig. 37 Front Bearing Cup Removal
1 – REMOVER
2 – HANDLE
Fig. 38 Rear Bearing Cup Removal
1 – DRIVER
2 – HANDLE
Fig. 39 Collapsible Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION
4 – PINION DEPTH SHIM
5 – REAR BEARING
TJ 181 FBI AXLE 3 - 35
REMOVAL AND INSTALLATION (Continued)
(2) Appl y Mopar௡ Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of front pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-130 and
Handl e C–4171 (Fi g. 42).
(3) I nstal l front pi ni on beari ng, and oi l sl i nger, i f
equi pped.
(4) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C–4171 (Fi g. 43).
Fig. 40 Inner Bearing Removal
1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT
Fig. 41 Rear Pinion Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 42 Pinion Outer Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 43 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
3 - 36 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(5) I nstal l the rear pi ni on beari ng and the pi ni on
depth shi m/oi l sl i nger onto the pi ni on wi th I nstal l er
W-262 and a shop press (Fi g. 44).
(6) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft and i nstal l pi ni on i n housi ng (Fi g. 45).
(7) I nstal l yoke wi th I nstal l er W-162-B, Cup 8109,
and Hol der 6958 (Fi g. 46).
(8) I nstal l the pi ni on washer and a new nut onto
the pi ni on. Ti ghten the nut to 216 N·m (160 ft. l bs.)
mi ni mum. Do not over–tighten. Maxi mum torque
i s 352 N·m (260 ft. l bs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque is exceeded a
new collapsible spacer must be installed. The
torque sequence will then have to be repeated.
(9) Usi ng Hol der 6958 and torque wrench (set at
352 N·m (260 ft. l bs.)), crush col l apsi bl e spacer unti l
beari ng end pl ay i s taken up (Fi g. 47). I f more than
353 N⅐m (260 ft. l bs.) i s needed to begi n to col l apse
the spacer, the spacer i s defecti ve and must be
repl aced.
(10) Sl owl y ti ghten the nut i n 6.8 N·m (5 ft. l b.)
i ncrements unti l the rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over
crushi ng the col l apsi bl e spacer (Fi g. 48).
(11) Check beari ng rotati ng torque wi th an i nch
pound torque wrench (Fi g. 48). The torque necessary
to rotate the pi ni on shoul d be:
• Ori gi nal Beari ngs — 1 to 2 N·m (10 to 20 i n.
l bs.).
• New Beari ngs — 1.5 to 4 N·m (15 to 35 i n. l bs.).
(12) I nstal l di fferenti al assembl y.
Fig. 45 Collapsible Preload Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING
Fig. 46 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
Fig. 44 Rear Pinion Bearing Installation
1 – PRESS
2 – INSTALLATION TOOL
3 – PINION DEPTH SHIM/OIL BAFFLE
4 – DRIVE PINION
5 – DRIVE PINION SHAFT REAR BEARING
TJ 181 FBI AXLE 3 - 37
REMOVAL AND INSTALLATION (Continued)
RING GEAR
NOTE: The ring gear and pinion are serviced as a
matched set. Do not replace the ring gear without
replacing the pinion.
REMOVAL
(1) Remove di fferenti al from axl e housi ng.
(2) Pl ace di fferenti al case i n a sui tabl e vi se wi th
soft metal jaw protectors. (Fi g. 49)
(3) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(4) Usi ng a soft hammer, dri ve ri ng gear from di f-
ferenti al case (Fi g. 49).
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(1) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(2) I nvert the di fferenti al case i n the vi se.
(3) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 95–122 N·m (70–90 ft. l bs.) torque (Fi g.
50).
(4) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern.
Fig. 47 Tightening Pinion Nut—Typical
1 – PINION FLANGE
2 – FRONT AXLE
3 – TOOL 6958
Fig. 48 Check Pinion Rotation Torque
1 – in. lbs. TORQUE WRENCH
2 – PINION YOKE
Fig. 49 Ring Gear Removal
1 – CASE
2 – RING GEAR
3 – RAWHIDE HAMMER
3 - 38 181 FBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLY
(1) Remove the ri ng gear.
(2) Usi ng a sui tabl e rol l pi n punch, dri ve out the
rol l pi n hol di ng pi ni on gear mate shaft i n the di ffer-
enti al case (Fi g. 51).
(3) Remove the pi ni on gear mate shaft from the
di fferenti al case and the pi ni on mate gears.
(4) Rotate di fferenti al si de gears and remove the
pi ni on mate gears and thrust washers (Fi g. 52).
(5) Remove the di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l the di fferenti al si de gears and thrust
washers.
(2) I nstal l the pi ni on mate gears and thrust wash-
ers.
(3) I nstal l the pi ni on gear mate shaft. Al i gn the
rol l pi n hol es i n shaft and the di fferenti al case.
(4) I nstal l the rol l pi n to hol d the pi ni on mate
shaft i n the di fferenti al case (Fi g. 53).
(5) I nstal l the ri ng gear.
(6) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
Fig. 50 Ring Gear Bolt Installation
1 – TORQUE WRENCH
2 – RING GEAR BOLT
3 – RING GEAR
4 – CASE
Fig. 51 Mate Shaft Roll Pin Removal
1 – DRIFT
2 – LOCKPIN
3 – MATE SHAFT
Fig. 52 Pinion Mate Gear Removal
1 – THRUST WASHER
2 – SIDE GEAR
3 – PINION MATE GEAR
TJ 181 FBI AXLE 3 - 39
REMOVAL AND INSTALLATION (Continued)
FINAL ASSEMBLY
(1) Scrape the resi dual seal ant from the housi ng
and cover mati ng surfaces. Cl ean the mati ng surfaces
wi th mi neral spi ri ts. Appl y a bead of Mopar௡ Si l i cone
Rubber Seal ant, or equi val ent, on the housi ng cover
(Fi g. 54).
Install the housing cover within 5 minutes
after applying the sealant.
(2) I nstal l the cover on the di fferenti al wi th the
attachi ng bol ts. I nstal l the i denti fi cati on tag. Ti ghten
the cover bol ts to 41 N·m (30 ft. l bs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(3) Refi l l the di fferenti al housi ng wi th gear l ubri -
cant. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the gear l ubri cant requi rements.
(4) I nstal l the fi l l hol e pl ug.
CLEANING AND INSPECTION
CARDAN U-JOINT
Cl ean al l the U–joi nt yoke bores wi th cl eani ng sol -
vent and a wi re brush. Ensure that al l the rust and
forei gn matter are removed from the bores.
I nspect the yokes for di storti on, cracks and worn
beari ng cap bores.
Repl ace the compl ete U–joi nt i f any of the compo-
nents are defecti ve.
AXLE COMPONENTS
Wash di fferenti al components wi th cl eani ng sol vent
and dry wi th compressed ai r. Do not steam clean
the differential components.
Wash beari ngs wi th sol vent and towel dry, or dry
wi th compressed ai r. DO NOT spi n beari ngs wi th
compressed ai r. Cup and bearing must be
replaced as matched sets only.
Cl ean axl e shaft tubes and oi l channel s i n housi ng.
I nspect for;
• Smooth appearance wi th no broken/dented sur-
faces on the beari ng rol l ers or the rol l er contact sur-
faces.
• Beari ng cups must not be di storted or cracked.
• Machi ned surfaces shoul d be smooth and wi th-
out any rai sed edges.
• Rai sed metal on shoul ders of cup bores shoul d
be removed wi th a hand stone.
• Wear and damage to pi ni on gear mate shaft,
pi ni on gears, si de gears and thrust washers. Repl ace
as a matched set onl y.
• Ri ng and pi ni on gear for worn and chi pped
teeth.
• Ri ng gear for damaged bol t threads. Repl aced as
a matched set onl y.
Fig. 53 Mate Shaft Roll Pin Installation
1 – PUNCH
2 – PINION MATE SHAFT
3 – MATE SHAFT LOCKPIN
Fig. 54 Typical Housing Cover With Sealant
1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35MM (1/4”)
3 - 40 181 FBI AXLE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
• Pi ni on yoke for cracks, worn spl i nes, pi tted
areas, and a rough/corroded seal contact surface.
Repai r or repl ace as necessary.
• Prel oad shi ms for damage and di storti on. I nstal l
new shi ms, i f necessary.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng gear and pi ni on are suppl i ed as matched sets
onl y. The i denti fyi ng numbers for the ri ng gear and
pi ni on are etched i nto the face of each gear (Fi g. 55).
A pl us (+) number, mi nus (–) number or zero (0) i s
etched i nto the face of the pi ni on gear head. Thi s
number i s the amount (i n thousandths of an i nch)
the depth vari es from the standard depth setti ng of a
pi ni on etched wi th a (0). The standard setti ng from
the center l i ne of the ri ng gear to the back face of the
pi ni on i s 92.08 mm (3.625 i n.). The standard depth
provi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s paragraph i n
thi s secti on for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th a sel ect shi m/oi l sl i nger. The shi m/oi l
sl i nger i s pl aced between the rear pi ni on beari ng and
the pi ni on gear head (Fi g. 56).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on. Add or subtract the thi ckness of the
ori gi nal depth shi ms to compensate for the di fference
i n the depth vari ances. Refer to the Depth Vari ance
chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the dri ve
pi ni on (–1, –2, 0, +1, +2, etc.). The numbers repre-
sent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi m/oi l sl i nger. I f
the number i s posi ti ve, subtract that val ue from the
thi ckness of the depth shi m/oi l sl i nger. I f the number
i s 0 no change i s necessary.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the axl e housi ng.
Take measurements wi th Pi ni on Gauge Set 6774 and
Di al I ndi cator C-3339 (Fi g. 57).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6733, and rear pi ni on beari ng onto Screw 6741
(Fi g. 57).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto axl e housi ng through
pi ni on beari ng cups (Fi g. 58).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
hand ti ght (Fi g. 57).
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n axl e housi ng si de beari ng cradl es (Fi g. 59).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 N·m (30 ft. l bs.).
Fig. 55 Pinion Gear ID Numbers
1 – PRODUCTION NUMBERS
2 – DRIVE PINION GEAR DEPTH VARIANCE
3 – GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 56 Shim Locations
1 – COLLAPSIBLE SPACER
2 – DRIVE PINION GEAR DEPTH SHIM
3 – DIFFERENTIAL BEARING SHIM
TJ 181 FBI AXLE 3 - 41
CLEANING AND INSPECTION (Continued)
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock (Fi g. 57). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator face to the poi nter. Ti ghten
di al i ndi cator face l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 60). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
−4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008
Fig. 57 Pinion Gear Depth Gauge Tools—Typical
1 – DIAL INDICATOR
2 – ARBOR
3 – PINION HEIGHT BLOCK
4 – CONE
5 – SCREW
6 – PINION BLOCK
7 – SCOOTER BLOCK
8 – ARBOR DISC
Fig. 58 Pinion Height Block—Typical
1 – PINION BLOCK
2 – PINION HEIGHT BLOCK
3 - 42 181 FBI AXLE TJ
ADJ USTMENTS (Continued)
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a shi m/oi l sl i nger equal to the di al i ndi -
cator readi ng pl us the dri ve pi ni on depth vari ance
number etched i n the face of the pi ni on (Fi g. 55). For
exampl e, i f the depth vari ance i s –2, add +0.002 i n.
to the di al i ndi cator readi ng.
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
INTRODUCTION
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms posi ti oned behi nd the
di fferenti al si de beari ng cones. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs D-348 i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on i s i nstal l ed, and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng and the prel oad speci fi cati on added together.
The gear backl ash measurement determi nes the
thi ckness of the shi m used on the ri ng gear si de of
the di fferenti al case. Subtract the gear backl ash shi m
thi ckness from the total overal l shi m thi ckness and
sel ect that amount for the pi ni on gear si de of the di f-
ferenti al (Fi g. 61). Di fferenti al shi m measurements
are performed wi th axl e spreader W-129-B removed.
Fig. 59 Gauge Tools In Housing—Typical
1 – ARBOR DISC
2 – PINION BLOCK
3 – ARBOR
4 – PINION HEIGHT BLOCK
Fig. 60 Pinion Gear Depth Measurement—Typical
1 – ARBOR
2 – SCOOTER BLOCK
3 – DIAL INDICATOR
Fig. 61 Axle Adjustment Shim Locations
1 – COLLAPSIBLE SPACER
2 – DRIVE PINION GEAR DEPTH SHIM
3 – DIFFERENTIAL BEARING SHIM
TJ 181 FBI AXLE 3 - 43
ADJ USTMENTS (Continued)
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(4) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(5) I nstal l di fferenti al case i n axl e housi ng.
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts (Fi g. 62).
(7) Usi ng a dead-bl ow type mal l et, seat the di ffer-
enti al dummy beari ngs to each si de of the axl e hous-
i ng (Fi g. 63) and (Fi g. 64).
(8) Thread gui de stud C-3288-B i nto rear cover
bol t hol e bel ow ri ng gear (Fi g. 65).
(9) Attach a di al i ndi cator C-3339 to gui de stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
between the ri ng gear bol t heads (Fi g. 65).
(10) Push and hol d di fferenti al case to pi ni on gear
si de of axl e housi ng (Fi g. 66).
(11) Zero di al i ndi cator face to poi nter (Fi g. 66).
(12) Push and hol d di fferenti al case to ri ng gear
si de of the axl e housi ng (Fi g. 67).
(13) Record di al i ndi cator readi ng (Fi g. 67).
(14) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(15) Rotate di al i ndi cator out of the way on the
gui de stud.
(16) Remove di fferenti al case and dummy beari ngs
from axl e housi ng.
(17) I nstal l the pi ni on i n the axl e housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
(18) I nstal l di fferenti al case and dummy beari ngs
D-348 i n axl e housi ng (wi thout shi ms), i nstal l bear-
i ng caps and ti ghten bol ts snug.
(19) Seat ri ng gear si de dummy beari ng (Fi g. 64).
Fig. 62 Tighten Bolts Holding Bearing Caps
1 – BEARING CAP
2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
Fig. 63 Seat Pinion Gear Side Differential Dummy
Side Bearing
1 – MALLET
2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
Fig. 64 Seat Ring Gear Side Differential Dummy
Side Bearing
1 – AXLE HOUSING
2 – MALLET
3 – DIFFERENTIAL CASE
3 - 44 181 FBI AXLE TJ
ADJ USTMENTS (Continued)
(20) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads. (Fi g. 65).
(21) Push and hol d di fferenti al case toward pi ni on
gear (Fi g. 68).
(22) Zero di al i ndi cator face to poi nter (Fi g. 68).
(23) Push and hol d di fferenti al case to ri ng gear
si de of the axl e housi ng (Fi g. 69).
(24) Record di al i ndi cator readi ng (Fi g. 69).
(25) Subtract 0.002 i n. (0.05 mm) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(26) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
Fig. 65 Differential Side play Measurement
1 – DIFFERENTIAL CASE
2 – AXLE HOUSING
3 – SPECIAL TOOL C-3288–B
4 – SPECIAL TOOL C-3339
Fig. 66 Hold Differential Case and Zero Dial
Indicator
1 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 – SPECIAL TOOL C-3288–B
3 – SPECIAL TOOL C-3339
4 – ZERO DIAL INDICATOR FACE
Fig. 67 Hold Differential Case and Read Dial
Indicator
1 – READ DIAL INDICATOR
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 – AXLE HOUSING
Fig. 68 Hold Differential Case and Zero Dial
Indicator
1 – ZERO DIAL INDICATOR FACE
2 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 – PINION GEAR
4 – AXLE HOUSING
5 – DIFFERENTIAL CASE
TJ 181 FBI AXLE 3 - 45
ADJ USTMENTS (Continued)
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(27) Rotate di al i ndi cator out of the way on gui de
stud.
(28) Remove di fferenti al case and dummy beari ngs
from axl e housi ng.
(29) I nstal l si de beari ng shi ms on di fferenti al case
hubs.
(30) I nstal l si de beari ngs and cups on di fferenti al
case.
(31) I nstal l spreader W-129-B, uti l i zi ng some i tems
from Adapter Set 6987, on axl e housi ng and spread
axl e openi ng enough to recei ve di fferenti al case.
(32) I nstal l di fferenti al case i n axl e housi ng.
(33) Remove spreader from axl e housi ng.
(34) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(35) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 70).
(36) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(37) Zero di al i ndi cator face to poi nter.
(38) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the axl e housi ng to the other
(Fi g. 71).
(39) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
Fig. 69 Hold Differential Case and Read Dial
Indicator
1 – READ DIAL INDICATOR
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 – PINION GEAR
4 – AXLE HOUSING
5 – DIFFERENTIAL CASE
Fig. 70 Ring Gear Backlash Measurement
1 – DIAL INDICATOR
Fig. 71 Backlash Shim Adjustment
3 - 46 181 FBI AXLE TJ
ADJ USTMENTS (Continued)
GEAR CONTACT PATTERN ANALYSIS
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the axl e
housi ng. I t wi l l al so show i f the ri ng gear backl ash
has been adjusted correctl y. The backl ash can be
adjusted wi thi n speci fi cati ons to achi eve desi red
tooth contact patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de, or
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Usi ng a boxed end wrench on a ri ng gear bol t,
Rotate the di fferenti al case one compl ete revol uti on
i n both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
72) and adjust pi ni on depth and gear backl ash as
necessary.
TJ 181 FBI AXLE 3 - 47
ADJ USTMENTS (Continued)
Fig. 72 Gear Tooth Contact Patterns
3 - 48 181 FBI AXLE TJ
ADJ USTMENTS (Continued)
SPECIFICATIONS
181 FBI AXLE
Axl e Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hypoi d
Lubri cant . . . . . . . . SAE Thermal l y Stabl e 80W–90
Lube Capaci ty . . . . . . . . . . . . . . . . . 1.2 L (2.5 pts.)
Axl e Rati o . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.10
Di fferenti al Si de Gear Cl earance . . . 0.12–0.20 mm
(0.005–0.008 i n.)
Ri ng Gear Di ameter . . . . . . . . . 18.09 cm (7.125 i n.)
Backl ash . . . . . . . . . . . 0–0.15 mm (0.005–0.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . . 92.1 mm (3.625 i n.)
Pi ni on Beari ng Rotati ng Torque . . . . . . . . . . . . . . .
Ori gi nal Beari ngs . . . . . . . 1–2 N·m (10–20 i n. l bs.)
New Beari ngs . . . . . . . . . 1.5–4 N·m (15–35 i n. l bs.)
TORQUE
DESCRIPTION TORQUE
Fi l l Hol e Pl ug . . . . . . . . . . . . . . 34 N·m (25 ft. l bs.)
Di ff. Cover Bol t . . . . . . . . . . . . . 41 N·m (30 ft. l bs.)
Beari ng Cap Bol t . . . . . . . . . . . . 61 N·m (45 ft. l bs.)
Ri ng Gear Bol t . . . . . . . 95–122 N·m (70–90 ft. l bs.)
Axl e Nut . . . . . . . . . . . . . . . . 237 N·m (175 ft. l bs.)
Hub Brg. Bol t . . . . . . . . . . . . . 102 N·m (75 ft. l bs.)
Lower Bal l Stud . . . . . . . . . . . 108 N·m (80 ft. l bs.)
Upper Bal l Stud . . . . . . . . . . . 101 N·m (75 ft. l bs.)
SPECIAL TOOLS
181 FBI AXLE
Puller—C-293-PA
Plug—SP-3289
Adapter—C-293-39
Puller—C-452
Wrench—C-3281
Dial Indicator—C-3339
Driver—C-3716-A
TJ 181 FBI AXLE 3 - 49
Handle—C-4171
Installer—D-146
Remover—D-149
Installer—W-162-D
Cup—8109
Remover/Installer—6289
Installer—6761
Installer—6752
Installer Discs—8110
Turnbuckle—6797
3 - 50 181 FBI AXLE TJ
SPECIAL TOOLS (Continued)
Tool Set, Pinion Depth—6774
Gauge Block—6733
Spanner—6958
Installer—C-3972-A
Spreader—W-129-B
Adapter Kit—6987
Pilot Stud—C-3288-B
Remover—C-4345
Installer—D-130
Installer—W-262
TJ 181 FBI AXLE 3 - 51
SPECIAL TOOLS (Continued)
194 RBI AXLE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
STANDARD DIFFERENTIAL. . . . . . . . . . . . . . . . . 53
TRAC-LOKி DIFFERENTIAL . . . . . . . . . . . . . . . . 54
DIAGNOSIS AND TESTING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 54
GEAR NOISE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 57
LOW SPEED KNOCK. . . . . . . . . . . . . . . . . . . . . . 57
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 58
TRAC–LOKி DIFFERENTIAL NOISE . . . . . . . . . . 58
TRAC–LOKி TEST . . . . . . . . . . . . . . . . . . . . . . . 58
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL AND INSTALLATION
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
PINION SHAFT SEAL. . . . . . . . . . . . . . . . . . . . . . 60
COLLAPSIBLE SPACER. . . . . . . . . . . . . . . . . . . . 61
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
AXLE SHAFT SEAL AND BEARING . . . . . . . . . . . 65
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DIFFERENTIAL SIDE BEARINGS. . . . . . . . . . . . . 68
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
RING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 73
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL. . . . . . . . . . . . . . . . . 74
TRAC-LOKி DIFFERENTIAL . . . . . . . . . . . . . . . . 75
CLEANING AND INSPECTION
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . 79
TRAC-LOKி . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
ADJUSTMENTS
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . . 80
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . . 82
GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 85
SPECIFICATIONS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SPECIAL TOOLS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DESCRIPTION AND OPERATION
194 RBI AXLE
DESCRIPTION
The 194 Rear Beam-desi gn I ron (RBI ) axl e housi ng
has an i ron center casti ng (di fferenti al housi ng) wi th
axl e shaft tubes extendi ng from ei ther si de. The
tubes are pressed i nto and wel ded to the di fferenti al
housi ng to form a one-pi ece axl e housi ng.
The i ntegral type, hypoi d gear desi gn, housi ng has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear.
The axl e has a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
The axl es are equi pped wi th semi –fl oati ng axl e
shafts, meani ng that l oads are supported by the axl e
shaft and beari ngs. The axl e shafts are retai ned by
C–cl i ps i n the di fferenti al si de gears.
The cover provi des a means for servi ci ng the di ffer-
enti al wi thout removi ng the axl e.
For vehi cl es equi pped wi th ABS brakes, the axl es
have a tone ri ng pressed onto the axl e shaft. Use
care when removi ng axl e shafts to ensure that the
tone wheel or the wheel speed sensor are not dam-
aged.
The 194 RBI axl e has the assembl y part number
and gear rati o l i sted on a tag. The tag i s attached to
the di fferenti al housi ng by a cover bol t. Bui l d date
i denti fi cati on codes are stamped on the cover si de of
an axl e shaft tube.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash i s adjusted by the use of sel ecti ve
spacer shi ms. Pi ni on beari ng prel oad i s set and
mai ntai ned by the use of a col l apsi bl e spacer (Fi g. 1).
Axl es equi pped wi th a Trac-Lok௢ di fferenti al are
opti onal . A Trac-Lok di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
3 - 52 194 RBI AXLE TJ
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
LUBRICANT
DESCRIPTION
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar௡ Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
• The l ubri cant shoul d have MI L–L–2105C and
API GL 5 qual i ty speci fi cati ons.
• Lubri cant i s a thermal l y stabl e SAE 80W–90
gear l ubri cant.
• Lubri cant for axl es i ntended for heavy-duty or
trai l er tow use i s SAE 75W–140 SYNTHETI C gear
l ubri cant.
Trac-l ok di fferenti al s requi re the addi ti on of 4 oz.
of fri cti on modi fi er to the axl e l ubri cant. The 194 RBI
axl e l ubri cant capaci ty i s 1.66L (3.50 pts.) total ,
i ncl udi ng the fri cti on modi fi er i f necessary.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
STANDARD DIFFERENTIAL
DESCRIPTION
The di fferenti al gear system di vi des the torque
between the axl e shafts. I t al l ows the axl e shafts to
rotate at di fferent speeds when turni ng corners.
Each di fferenti al si de gear i s spl i ned to an axl e
shaft. The pi ni on gears are mounted on a pi ni on
mate shaft and are free to rotate on the shaft. The
pi ni on gear i s fi tted i n a bore i n the di fferenti al case
and i s posi ti oned at a ri ght angl e to the axl e shafts.
OPERATION
I n operati on, power fl ow occurs as fol l ows:
• The pi ni on gear rotates the ri ng gear
• The ri ng gear (bol ted to the di fferenti al case)
rotates the case
• The di fferenti al pi ni on gears (mounted on the
pi ni on mate shaft i n the case) rotate the si de gears
• The si de gears (spl i ned to the axl e shafts) rotate
the shafts
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 2).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
3). I n thi s i nstance, the i nput torque appl i ed to the
Fig. 1 Shim Locations
1 – PINION GEAR DEPTH SHIM
2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 – RING GEAR
4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 – COLLAPSIBLE SPACER
Fig. 2 Differential Operation—Straight Ahead Driving
1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 – PINION GEAR
3 – SIDE GEAR
4 – PINION GEARS ROTATE WITH CASE
TJ 194 RBI AXLE 3 - 53
DESCRIPTION AND OPERATION (Continued)
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
TRAC-LOKி DIFFERENTIAL
DESCRIPTION
I n a standard di fferenti al , i f one wheel spi ns, the
opposi te wheel wi l l generate onl y as much torque as
the spi nni ng wheel .
I n the Trac-l ok௢ di fferenti al , part of the ri ng gear
torque i s transmi tted through cl utch packs whi ch
contai n mul ti pl e di scs. The cl utches wi l l have radi al
grooves on the pl ates, and concentri c grooves on the
di scs or bonded fi ber materi al that i s smooth i n
appearance.
OPERATION
I n operati on, the Trac-l ok௢ cl utches are engaged
by two concurrent forces. The fi rst bei ng the prel oad
force exerted through Bel l evi l l e spri ng washers
wi thi n the cl utch packs. The second i s the separati ng
forces generated by the si de gears as torque i s
appl i ed through the ri ng gear (Fi g. 4).
The Trac-l ok௢ desi gn provi des the di fferenti al
acti on needed for turni ng corners and for dri vi ng
strai ght ahead duri ng peri ods of unequal tracti on.
When one wheel l ooses tracti on, the cl utch packs
transfer addi ti onal torque to the wheel havi ng the
most tracti on. Trac-l ok௢ di fferenti al s resi st wheel
spi n on bumpy roads and provi de more pul l i ng power
when one wheel l ooses tracti on. Pul l i ng power i s pro-
vi ded conti nuousl y unti l both wheel s l oose tracti on. I f
both wheel s sl i p due to unequal tracti on, Trac-l ok௢
operati on i s normal . I n extreme cases of di fferences
of tracti on, the wheel wi th the l east tracti on may
spi n.
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Axl e beari ng probl em condi ti ons are usual l y caused
by:
• I nsuffi ci ent or i ncorrect l ubri cant.
• Forei gn matter/water contami nati on.
• I ncorrect beari ng prel oad torque adjustment.
• I ncorrect backl ash.
Axl e gear probl em condi ti ons are usual l y the resul t
of:
• I nsuffi ci ent l ubri cati on.
• I ncorrect or contami nated l ubri cant.
• Overl oadi ng (excessi ve engi ne torque) or exceed-
i ng vehi cl e wei ght capaci ty.
Fig. 3 Differential Operation—On Turns
1 – PINION GEARS ROTATE ON PINION SHAFT
Fig. 4 Trac-lokி Limited Slip Differential Operation
1 – CASE
2 – RING GEAR
3 – DRIVE PINION
4 – PINION GEAR
5 – MATE SHAFT
6 – CLUTCH PACK
7 – SIDE GEAR
8 – CLUTCH PACK
3 - 54 194 RBI AXLE TJ
DESCRIPTION AND OPERATION (Continued)
• I ncorrect cl earance or backl ash adjustment.
Axl e component breakage i s most often the resul t
of:
• Severe overl oadi ng.
• I nsuffi ci ent l ubri cant.
• I ncorrect l ubri cant.
• I mproperl y ti ghtened components.
• Di fferenti al housi ng bores not square to each
other.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
TJ 194 RBI AXLE 3 - 55
DIAGNOSIS AND TESTING (Continued)
Condition Possible Causes Correction
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
3 - 56 194 RBI AXLE TJ
DIAGNOSIS AND TESTING (Continued)
Condition Possible Causes Correction
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears, or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak–noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght–ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant–pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U–joi nt or by worn si de–gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out–of–bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U–joi nt(s).
• Loose/broken spri ngs.
TJ 194 RBI AXLE 3 - 57
DIAGNOSIS AND TESTING (Continued)
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front–end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear–end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
Refer to Group 22, Wheel s and Ti res, for addi ti onal
vi brati on i nformati on.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U–joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
TRAC–LOKி DIFFERENTIAL NOISE
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok௢ uni t
for repai r, drai n, fl ush and refi l l the axl e wi th the
speci fi ed l ubri cant. Refer to Lubri cant change i n thi s
Group.
A contai ner of Mopar௡ Trac-l ok௢ Lubri cant (fri c-
ti on modi fi er) shoul d be added after repai r servi ce or
duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
TRAC–LOKி TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOKி DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRAC–LOKி AXLE CAN
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON-
TACT WITH A SURFACE TO CAUSE THE VEHICLE
TO MOVE.
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 to
studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 5).
(6) I f rotati ng torque i s l ess than 22 N·m (30 ft.
l bs.) or more than 271 N·m (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
SERVICE PROCEDURES
LUBRICANT CHANGE
(1) Rai se and support the vehi cl e.
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
drai n the l ubri cant from the housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l , or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(5) Remove the ori gi nal seal ant from the housi ng
and cover surfaces.
Fig. 5 Trac-lokி Test —Typical
1 – SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 – TORQUE WRENCH
3 - 58 194 RBI AXLE TJ
DIAGNOSIS AND TESTING (Continued)
(6) Appl y a bead of Mopar௡ Si l i cone Rubber Seal -
ant, or equi val ent, to the housi ng cover (Fi g. 6).
Install the housing cover within 5 minutes
after applying the sealant.
(7) I nstal l the cover and any i denti fi cati on tag.
Ti ghten the cover bol ts to 41 N·m (30 ft. l bs.) torque.
(8) For Trac–l ok௢ di fferenti al s, a quanti ty of
Mopar௡ Trac–l ok௢ l ubri cant (fri cti on modi fi er), or
equi val ent, must be added after repai r servi ce or a
l ubri cant change. Refer to the Lubri cant Speci fi ca-
ti ons secti on of thi s group for the quanti ty necessary.
(9) Fi l l di fferenti al wi th Mopar௡ Hypoi d Gear
Lubri cant, or equi val ent, to bottom of the fi l l pl ug
hol e. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the quanti ty necessary.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(10) I nstal l the fi l l hol e pl ug and l ower the vehi cl e.
(11) Trac–l ok௢ di fferenti al equi pped vehi cl es
shoul d be road tested by maki ng 10 to 12 sl ow fi gure-
ei ght turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
REMOVAL AND INSTALLATION
REAR AXLE
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove the wheel s and ti res.
(5) Remove the brake drums from the axl e. Refer
to Group 5, Brakes, for proper procedures.
(6) Di sconnect parki ng brake cabl es from brackets
and l ever.
(7) Remove wheel speed sensors, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(8) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the wheel cyl i nders. Refer to Group 5, Brakes, for
proper procedures.
(9) Di sconnect the vent hose from the axl e shaft
tube.
(10) Mark the propel l er shaft and yokes for i nstal -
l ati on al i gnment reference.
(11) Remove propel l er shaft.
(12) Di sconnect stabi l i zer bar l i nks.
(13) Di sconnect shock absorbers from axl e.
(14) Di sconnect track bar.
(15) Di sconnect upper and l ower suspensi on arms
from the axl e brackets.
(16) Separate the axl e from the vehi cl e.
INSTALLATION
NOTE: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, vehicle ride
height and handling could be affected.
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn coi l
spri ngs.
(2) Posi ti on the upper and l ower suspensi on arms
on the axl e brackets. I nstal l nuts and bol ts, do not
ti ghten bol ts at thi s ti me.
(3) I nstal l track bar and attachment bol ts, do not
ti ghten bol ts at thi s ti me.
(4) I nstal l shock absorbers and ti ghten nuts to 100
N·m (74 ft. l bs.) torque.
(5) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
54 N·m (40 ft. l bs.) torque.
(6) I nstal l the wheel speed sensors, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(7) Connect parki ng brake cabl e to brackets and
l ever.
(8) I nstal l the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(9) Connect the brake hose to the axl e juncti on
bl ock. Refer to Group 5, Brakes, for proper proce-
dures.
(10) I nstal l axl e vent hose.
(11) Al i gn propel l er shaft and pi ni on yoke refer-
ence marks. I nstal l U-joi nt straps and bol ts. Ti ghten
to 19 N·m (14 ft. l bs.) torque.
(12) I nstal l the wheel s and ti res.
Fig. 6 Apply Sealant
1 – SEALANT
2 – AXLE HOUSING COVER
TJ 194 RBI AXLE 3 - 59
SERVICE PROCEDURES (Continued)
(13) Add gear l ubri cant, i f necessary. Refer to
Lubri cant Speci fi cati ons i n thi s secti on for l ubri cant
requi rements.
(14) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(15) Ti ghten l ower suspensi on arm bol ts to 177
N·m (130 ft. l bs.) torque.
(16) Ti ghten upper suspensi on arm bol ts to 75 N·m
(55 ft. l bs.) torque.
(17) Ti ghten track bar bol ts to 100 N·m (74 ft. l bs.)
torque.
PINION SHAFT SEAL
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on al i gnment reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Usi ng Hol der 6958 to hol d the pi ni on yoke,
remove the pi ni on nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pi ni on yoke (Fi g. 7).
(10) Use a sui tabl e pry tool or sl i de hammer
mounted screw to remove the pi ni on gear seal .
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C-4171 (Fi g. 8).
(2) I nstal l yoke on the pi ni on gear wi th Screw
8112, Cup 8109, and Hol der 6958 (Fi g. 9).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.
(3) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
(4) Ti ghten the nut to 271 N·m (200 ft. l bs.).
Fig. 7 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 8 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 9 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
3 - 60 194 RBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
(5) Rotate the pi ni on shaft usi ng a (i n. l bs.) torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal pl us an addi ti onal 0.56
N·m (5 i n. l bs.) (Fi g. 10).
(6) I f the rotati ng torque i s l ow, use Hol der 6958 to
hol d the pi ni on yoke (Fi g. 11), and ti ghten the pi ni on
shaft nut i n 6.8 N·m (5 ft. l bs.) i ncrements unti l the
proper rotati ng torque i s achi eved.
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
(7) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and yoke and i nstal l the propel l er
shaft.
(8) Add gear l ubri cant to the di fferenti al housi ng,
i f necessary. Refer to the Lubri cant Speci fi cati ons for
gear l ubri cant requi rements.
(9) I nstal l the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(10) I nstal l wheel and ti re assembl i es.
(11) Lower the vehi cl e.
COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove rear brake drums. Refer to Group 5,
Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Usi ng Hol der 6958 to hol d the pi ni on yoke,
remove the pi ni on nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pi ni on yoke (Fi g. 12).
(10) Use a sui tabl e pry tool or a sl i de hammer
mounted screw to remove the pi ni on shaft seal .
(11) Remove the front pi ni on beari ng usi ng a pai r
of sui tabl e pi ck tool s to pul l the beari ng strai ght off
the pi ni on gear shaft. I t may be necessary to l i ghtl y
tap the end of the pi ni on gear wi th a rawhi de or rub-
ber mal l et i f the beari ng becomes bound on the pi n-
i on shaft.
(12) Remove the col l apsi bl e spacer.
Fig. 10 Check Pinion Rotation Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
Fig. 11 Tightening Pinion Shaft Nut
1 – SPECIAL TOOL
6958
2 – 1 in. PIPE
3 – 3/4 DRIVE TORQUE WRENCH
TJ 194 RBI AXLE 3 - 61
REMOVAL AND INSTALLATION (Continued)
REMOVAL W/PINION REMOVED
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove rear brake drums. Refer to Group 5,
Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Remove di fferenti al assembl y from axl e hous-
i ng.
(9) Usi ng Hol der 6958 to hol d yoke, remove the
pi ni on yoke nut and washer.
(10) Usi ng Remover C–452 and Wrench C–3281,
remove the pi ni on yoke from pi ni on shaft (Fi g. 12).
(11) Remove the pi ni on gear from housi ng (Fi g.
13). Catch the pi ni on wi th your hand to prevent i t
from fal l i ng and bei ng damaged.
(12) Remove col l apsi bl e spacer from pi ni on shaft.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft (Fi g. 14).
(2) I f pi ni on gear was removed, i nstal l pi ni on gear
i n housi ng.
(3) I nstal l pi ni on front beari ng, i f necessary.
(4) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C–4171 (Fi g. 15).
(5) I nstal l yoke wi th Screw 8112, Cup 8109, and
Hol der 6958 (Fi g. 16).
Fig. 12 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 13 Remove Pinion Gear
1 – RAWHIDE HAMMER
Fig. 14 Collapsible Preload Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING
3 - 62 194 RBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(6) I f the ori gi nal pi ni on beari ngs are bei ng used,
i nstal l di fferenti al assembl y and axl e shafts, i f neces-
sary.
NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
(7) I nstal l the yoke washer and a new nut on the
pi ni on gear. Ti ghten the pi ni on nut unti l there i s zero
beari ng end-pl ay.
(8) Ti ghten the nut to 271 N·m (200 ft. l bs.).
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
(9) Usi ng yoke hol der 6958 and a torque wrench
set at 474 N·m (350 ft. l bs.), crush col l apsi bl e spacer
unti l beari ng end pl ay i s taken up (Fi g. 17).
NOTE: If more than 474 N·m (350 ft. lbs.) of torque
is necessary to remove the bearing end play, the
collapsible spacer is defective and must be
replaced.
(10) Sl owl y ti ghten the nut i n 6.8 N·m (5 ft. l bs.)
i ncrements unti l the rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over
crushi ng the col l apsi bl e spacer (Fi g. 18).
(11) Check rotati ng torque wi th a (i n. l bs.) torque
wrench (Fi g. 18). The torque necessary to rotate the
pi ni on gear shoul d be:
• Ori gi nal Beari ngs — The readi ng recorded dur-
i ng removal , pl us an addi ti onal 0.56 N·m (5 i n. l bs.).
• New Beari ngs — 1.5 to 4 N·m (15 to 35 i n. l bs.).
(12) I nstal l di fferenti al assembl y and axl e shafts,
i f necessary.
(13) Al i gn marks made previ ousl y on yoke and
propel l er shaft and i nstal l propel l er shaft.
(14) I nstal l rear brake drums. Refer to Group 5,
Brakes, for proper procedures.
(15) Add gear l ubri cant, i f necessary. Refer to
Lubri cant Speci fi cati ons of thi s secti on for l ubri cant
requi rements.
(16) I nstal l wheel and ti re assembl i es.
(17) Lower vehi cl e.
Fig. 15 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 16 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
Fig. 17 Tightening Pinion Nut
1 – SPECIAL TOOL
6958
2 – 1 in. PIPE
3 – 3/4 DRIVE TORQUE WRENCH
TJ 194 RBI AXLE 3 - 63
REMOVAL AND INSTALLATION (Continued)
AXLE SHAFT
REMOVAL
(1) Rai se and support vehi cl e. Ensure that the
transmi ssi on i s i n neutral .
(2) Remove wheel and ti re assembl y.
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure.
(4) Cl ean al l forei gn materi al from housi ng cover
area.
(5) Loosen housi ng cover bol ts. Drai n l ubri cant
from the housi ng and axl e shaft tubes. Remove hous-
i ng cover.
(6) Rotate di fferenti al case so that pi ni on mate
gear shaft l ock screw i s accessi bl e. Remove l ock
screw and pi ni on mate gear shaft from di fferenti al
case (Fi g. 19).
(7) Push axl e shaft i nward and remove axl e shaft
C–cl i p l ock from the axl e shaft (Fi g. 20).
(8) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal , whi ch wi l l remai n i n
axl e shaft tube. Al so, exerci se care not to damage the
wheel speed sensor on vehi cl es equi pped wi th ABS
brakes.
(9) I nspect axl e shaft seal for l eakage or damage.
(10) I nspect rol l er beari ng contact surface on axl e
shaft for si gns of bri nel l i ng, gal l i ng and pi tti ng. I f
any of these condi ti ons exi st, the axl e shaft and/or
beari ng and seal must be repl aced.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip. Also, exercise care not to
damage the wheel speed sensor on vehicles
equipped with ABS brakes
(2) I nsert C–cl i p l ock i n end of axl e shaft. Push
axl e shaft outward to seat C–cl i p l ock i n si de gear.
(3) I nsert pi ni on mate shaft i nto di fferenti al case
and through thrust washers and pi ni on gears.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te௡ on the
Fig. 18 Check Pinion Gear Rotation Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
Fig. 19 Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION GEAR MATE SHAFT
Fig. 20 Axle Shaft C–Clip Lock
1 – C-CLIP LOCK
2 – AXLE SHAFT
3 – SIDE GEAR
3 - 64 194 RBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
threads. Ti ghten l ock screw to 19 N·m (14 ft. l bs.)
torque.
(5) I nstal l cover and add fl ui d. Refer to Lubri cant
Change procedure i n thi s secti on for procedure and
l ubri cant requi rements.
(6) I nstal l brake drum. Refer to Group 5, Brakes,
for proper procedures.
(7) I nstal l wheel and ti re.
(8) Lower vehi cl e.
AXLE SHAFT SEAL AND BEARING
REMOVAL
(1) Remove the axl e shaft.
(2) Remove the axl e shaft seal from the end of the
axl e shaft tube wi th a smal l pry bar.
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove the axl e shaft beari ng from the axl e
tube wi th Beari ng Removal Tool Set 6310 usi ng
Adapter Foot 6310-5 (Fi g. 21).
(4) I nspect the axl e shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
Do not install the original axle shaft seal.
Always install a new seal.
(1) Wi pe the axl e shaft tube bore cl ean.
(2) I nstal l axl e shaft beari ng wi th I nstal l er 6436
and Handl e C–4171. Ensure that the part number on
the beari ng i s agai nst the i nstal l er.
(3) I nstal l the new axl e shaft seal wi th I nstal l er
6437 and Handl e C–4171 (Fi g. 22).
(4) I nstal l the axl e shaft.
DIFFERENTIAL
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
al l ow fl ui d to drai n.
(4) Remove axl e shafts.
(5) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 23).
(6) Loosen the di fferenti al beari ng cap bol ts.
(7) Posi ti on Spreader W–129–B, uti l i zi ng some
i tems from Adapter set 6987, wi th the tool dowel pi ns
seated i n the l ocati ng hol es (Fi g. 24). I nstal l the hol d-
down cl amps and ti ghten the tool turnbuckl e fi nger–
ti ght.
(8) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng (Fi g. 25) and zero the
i ndi cator.
Fig. 21 Axle Shaft Bearing Removal
1 – AXLE SHAFT TUBE
2 – NUT
3 – GUIDE PLATE
4 – GUIDE
5 – THREADED ROD
6 – ADAPTER
7 – FOOT
Fig. 22 Axle Shaft Seal Installation
1 – SPECIAL TOOL 6437
2 – SEAL
3 – AXLE SHAFT TUBE
4 – SPECIAL TOOL C-4171
TJ 194 RBI AXLE 3 - 65
REMOVAL AND INSTALLATION (Continued)
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.
(9) Spread the housi ng enough to remove the di f-
ferenti al case from the housi ng. Measure the di s-
tance wi th the di al i ndi cator (Fi g. 26).
(10) Remove the di al i ndi cator.
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
(12) Remove the di fferenti al from the housi ng.
Ensure that the di fferenti al beari ng cups remai n i n
posi ti on on the di fferenti al beari ngs (Fi g. 27).
Fig. 23 Bearing Cap Identification
1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
Fig. 24 Install Axle Housing Spreader
1 – AXLE HOUSING
2 – DOWEL
3 – SAFETY HOLD DOWN
4 – SPECIAL TOOL W-129–B
5 – TURNBUCKLE
Fig. 25 Install Dial Indicator
1 – SPECIAL TOOL C-3339
2 – DIAL INDICATOR
3 – LEVER ADAPTER
4 – SPECIAL TOOL W-129–B
5 – SPECIAL TOOL C-3288–B
Fig. 26 Spread Axle Housing
1 – SPECIAL TOOL C-3339
2 – SPECIAL TOOL W-129–B
3 - 66 194 RBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(13) Mark or tag the di fferenti al beari ng cups to
i ndi cate whi ch si de of the di fferenti al they were
removed from.
(14) Retri eve di fferenti al case prel oad shi ms from
axl e housi ng. Mark or tag the di fferenti al case pre-
l oad shi ms to i ndi cate whi ch si de of the di fferenti al
they were removed from.
(15) Remove spreader from housi ng.
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are bei ng i nstal l ed, di fferenti al si de beari ng
shi m requi rements may change. Refer to the Di ffer-
enti al Beari ng Prel oad and Gear Backl ash proce-
dures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) Posi ti on Spreader W–129–B, uti l i zi ng some
i tems from Adapter set 6987, wi th the tool dowel pi ns
seated i n the l ocati ng hol es (Fi g. 28). I nstal l the hol d-
down cl amps and ti ghten the tool turnbuckl e fi nger–
ti ght.
(2) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng (Fi g. 25) and zero the
i ndi cator.
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 26).
(4) Remove the di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs and that the prel oad
shi ms remai n between the face of the beari ng cup
and the housi ng. Tap the di fferenti al case to ensure
the beari ngs cups and shi ms are ful l y seated i n the
housi ng.
(6) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 29).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 77 N·m (57 ft.
l bs.) torque.
(10) I nstal l the axl e shafts.
Fig. 27 Differential Case Removal
1 – AXLE HOUSING
2 – DIFFERENTIAL CASE
3 – BEARING CUPS
Fig. 28 Install Axle Housing Spreader
1 – AXLE HOUSING
2 – DOWEL
3 – SAFETY HOLD DOWN
4 – SPECIAL TOOL W-129–B
5 – TURNBUCKLE
TJ 194 RBI AXLE 3 - 67
REMOVAL AND INSTALLATION (Continued)
DIFFERENTIAL SIDE BEARINGS
REMOVAL
(1) Remove di fferenti al from axl e housi ng.
(2) Remove the beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, C-293-39 Bl ocks, and
Pl ug SP-3289 (Fi g. 30).
INSTALLATION
(1) Usi ng tool C-3716-A wi th handl e C-4171,
i nstal l di fferenti al si de beari ngs (Fi g. 31).
(2) I nstal l di fferenti al i n axl e housi ng.
PINION GEAR
The ri ng and pi ni on gears are servi ced i n a
matched set. Do not repl ace the pi ni on gear wi thout
repl aci ng the ri ng gear.
REMOVAL
(1) Remove di fferenti al from the axl e housi ng.
(2) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from pi ni on yoke.
Usi ng sui tabl e wi re, ti e propel l er shaft to underbody.
(4) Usi ng Hol der 6958 to hol d yoke, remove the
pi ni on yoke nut and washer.
(5) Usi ng Remover C–452 and Wrench C–3281,
remove the pi ni on yoke from pi ni on shaft (Fi g. 32).
(6) Remove the pi ni on gear from housi ng (Fi g. 33).
Catch the pi ni on wi th your hand to prevent i t from
fal l i ng and bei ng damaged.
(7) Use a sui tabl e pry tool or a sl i de hammer
mounted screw to remove the pi ni on shaft seal .
(8) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(9) Remove the front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C–4171 (Fi g. 34).
(10) Remove the rear beari ng cup from housi ng
(Fi g. 35). Use Remover D-149 and Handl e C–4171.
(11) Remove the col l apsi bl e prel oad spacer (Fi g.
36).
(12) Remove the rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-40 (Fi g.
37).
Place 4 adapter blocks so they do not damage
the bearing cage.
(13) Remove the depth shi ms from the pi ni on gear
shaft. Record the thi ckness of the depth shi ms.
Fig. 29 Differential Bearing Cap Reference Letters
1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
Fig. 30 Differential Bearing Removal
1 – SPECIAL TOOL C–293–39
2 – BEARING
3 – DIFFERENTIAL
4 – SPECIAL TOOL SP–3289
5 – SPECIAL TOOL C–293–PA
3 - 68 194 RBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
Fig. 31 Install Differential Side Bearings
1 – HANDLE C-4171
2 – DIFFERENTIAL
3 – BEARING
4 – TOOL C-3716–A
Fig. 32 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 33 Remove Pinion Gear
1 – RAWHIDE HAMMER
Fig. 34 Front Bearing Cup Removal
1 – REMOVER
2 – HANDLE
TJ 194 RBI AXLE 3 - 69
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Appl y Mopar௡ Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of beari ng cup.
(2) I nstal l the pi ni on rear beari ng cup wi th
I nstal l er D-146 and Dri ver Handl e C–4171 (Fi g. 38).
Ensure cup i s correctl y seated.
(3) Appl y Mopar௡ Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of beari ng cup.
(4) I nstal l the pi ni on front beari ng cup wi th
I nstal l er D–130 and Handl e C–4171 (Fi g. 39).
(5) I nstal l pi ni on front beari ng, and oi l sl i nger, i f
equi pped.
(6) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C–4171 (Fi g. 40).
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin-
ion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
bearing.
(7) Pl ace the proper thi ckness depth shi m on the
pi ni on gear.
Fig. 35 Rear Bearing Cup Removal
1 – DRIVER
2 – HANDLE
Fig. 36 Collapsible Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING
Fig. 37 Rear Bearing Removal
1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT
3 - 70 194 RBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(8) I nstal l the rear beari ng and sl i nger, i f
equi pped, on the pi ni on gear wi th I nstal l er W-262
(Fi g. 41).
Fig. 38 Pinion Rear Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 39 Pinion Front Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 40 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 41 Shaft Rear Bearing Installation
1 – PRESS
2 – INSTALLATION TOOL
3 – DRIVE PINION GEAR
4 – DRIVE PINION GEAR SHAFT REAR BEARING
TJ 194 RBI AXLE 3 - 71
REMOVAL AND INSTALLATION (Continued)
(9) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft and i nstal l pi ni on gear i n housi ng (Fi g. 42).
(10) I nstal l pi ni on gear i n housi ng.
(11) I nstal l yoke wi th I nstal l er Screw 8112, Cup
8109, and hol der 6958 (Fi g. 43).
(12) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
(13) Ti ghten the nut to 271 N·m (200 ft. l bs.).
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
(14) Usi ng yoke hol der 6958 and a torque wrench
set at 474 N·m (350 ft. l bs.), crush col l apsi bl e spacer
unti l beari ng end pl ay i s taken up (Fi g. 44).
NOTE: If the spacer requires more than 474 N·m
(350 ft. lbs.) torque to crush, the collapsible spacer
is defective and must be replaced.
(15) Sl owl y ti ghten the nut i n 6.8 N·m (5 ft. l bs.)
i ncrements unti l the rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over
crushi ng the col l apsi bl e spacer (Fi g. 45).
(16) Check beari ng rotati ng torque wi th a (i n. l bs.)
torque wrench (Fi g. 45). The torque necessary to
rotate the pi ni on gear shoul d be:
• Ori gi nal Beari ngs — 1 to 2 N·m (10 to 20 i n.
l bs.).
• New Beari ngs — 1.5 to 4 N·m (15 to 35 i n. l bs.).
(17) I nstal l di fferenti al i n housi ng.
Fig. 42 Collapsible Preload Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING
Fig. 43 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
Fig. 44 Tightening Pinion Nut
1 – SPECIAL TOOL
6958
2 – 1 in. PIPE
3 – 3/4 DRIVE TORQUE WRENCH
3 - 72 194 RBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
RING GEAR
NOTE: The ring gear and pinion are serviced as a
matched set. Do not replace the ring gear without
replacing the pinion.
REMOVAL
(1) Remove di fferenti al from axl e housi ng.
(2) Pl ace di fferenti al case i n a sui tabl e vi se wi th
soft metal jaw protectors. (Fi g. 46)
(3) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(4) Usi ng a soft hammer, dri ve ri ng gear from di f-
ferenti al case (Fi g. 46).
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(1) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(2) I nvert the di fferenti al case i n the vi se.
(3) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 95–122 N·m (70–90 ft. l bs.) torque (Fi g.
47).
(4) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern.
FINAL ASSEMBLY
(1) Scrape the resi dual seal ant from the housi ng
and cover mati ng surfaces. Cl ean the mati ng surfaces
wi th mi neral spi ri ts. Appl y a bead of Mopar௡ Si l i cone
Fig. 45 Check Pinion Gear Rotating Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
Fig. 46 Ring Gear Removal
1 – CASE
2 – RING GEAR
3 – RAWHIDE HAMMER
Fig. 47 Ring Gear Bolt Installation
1 – TORQUE WRENCH
2 – RING GEAR BOLT
3 – RING GEAR
4 – CASE
TJ 194 RBI AXLE 3 - 73
REMOVAL AND INSTALLATION (Continued)
Rubber Seal ant, or equi val ent, on the housi ng cover
(Fi g. 48).
Install the housing cover within 5 minutes
after applying the sealant.
(2) I nstal l the cover on the di fferenti al wi th the
attachi ng bol ts. I nstal l the i denti fi cati on tag. Ti ghten
the cover bol ts to 41 N·m (30 ft. l bs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(3) Refi l l the di fferenti al housi ng wi th gear l ubri -
cant. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the gear l ubri cant requi rements.
(4) I nstal l the fi l l hol e pl ug.
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLY
(1) Remove pi ni on mate shaft l ock screw (Fi g. 49).
(2) Remove pi ni on mate shaft.
(3) Rotate the di fferenti al si de gears and remove
the di fferenti al pi ni on gears and thrust washers (Fi g.
50).
(4) Remove the di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l the di fferenti al si de gears and thrust
washers.
(2) I nstal l the di fferenti al pi ni on gears and thrust
washers.
(3) I nstal l the pi ni on mate shaft.
(4) Al i gn the hol e i n the pi ni on mate shaft wi th
the hol e i n the di fferenti al case and i nstal l the pi ni on
mate shaft l ock screw.
Fig. 48 Typical Housing Cover With Sealant
1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35MM (1/4”)
Fig. 49 Pinion Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION MATE SHAFT
Fig. 50 Pinion Mate Gear Removal
1 – THRUST WASHER
2 – SIDE GEAR
3 – PINION MATE GEAR
3 - 74 194 RBI AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(5) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
TRAC-LOKி DIFFERENTIAL
The Trac–l ok௢ di fferenti al components are i l l us-
trated i n (Fi g. 51). Refer to thi s i l l ustrati on duri ng
repai r servi ce.
Fig. 51 Trac–lokி Differential Components
1 – THRUST WASHER
2 – PINION
3 – SHAFT LOCK SCREW
4 – PINION MATE SHAFT
5 – SIDE GEAR
6 – RETAINER
7 – DISC
8 – CLUTCH PACK
9 – DIFFERENTIAL CASE
10 – RETAINER
TJ 194 RBI AXLE 3 - 75
DISASSEMBLY AND ASSEMBLY (Continued)
DISASSEMBLY
(1) Cl amp Si de Gear Hol di ng Tool 6965 i n a vi se.
(2) Posi ti on the di fferenti al case on Si de Gear
Hol di ng Tool 6965 (Fi g. 52).
(3) Remove ri ng gear, i f necessary. Ri ng gear
removal i s necessary onl y i f the ri ng gear i s to be
repl aced. The Trac-l ok௢ di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(4) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 53).
(5) Remove the pi ni on gear mate shaft. I f neces-
sary, use a dri ft and hammer (Fi g. 54).
(6) I nstal l and l ubri cate Step Pl ate C-6960-3 (Fi g.
55).
(7) Assembl e Threaded Adapter C-6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(8) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter C-6960-1 (Fi g. 56) to prevent
adapter from turni ng.
(9) Ti ghten forci ng screw tool 122 N·m (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 57).
(10) Usi ng an appropri ate si ze feel er gauge,
remove thrust washers from behi nd the pi ni on gears
(Fi g. 58).
(11) I nsert Turni ng Bar C-6960-2 i n case (Fi g. 59).
(12) Loosen the Forci ng Screw C-6960-4 i n smal l
i ncrements unti l the cl utch pack tensi on i s rel i eved
and the di fferenti al case can be turned usi ng Turni ng
Bar C-6960-2.
(13) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(14) Remove pi ni on gears from di fferenti al case.
(15) Remove Forci ng Screw C-6960-4, Step Pl ate
C-6960-3, and Threaded Adapter C-6960-1.
Fig. 52 Differential Case Holding Tool
1 – SPECIAL TOOL 6965
2 – VISE
3 – DIFFERENTIAL
Fig. 53 Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION GEAR MATE SHAFT
Fig. 54 Mate Shaft Removal
1 – PINION MATE SHAFT
2 – SIDE GEAR
3 – DRIFT
4 – PINION MATE GEAR
3 - 76 194 RBI AXLE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(16) Remove top si de gear, cl utch pack retai ner,
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 60).
(17) Remove di fferenti al case from Si de Gear Hol d-
i ng Tool 6965. Remove si de gear, cl utch pack retai ner,
and cl utch pack. Keep pl ates i n correct order duri ng
removal .
Fig. 55 Step Plate Tool Installation
1 – LOWER SIDE GEAR
2 – DIFFERENTIAL CASE
3 – SPECIAL TOOL C-6960–3
Fig. 56 Threaded Adapter Installation
1 – SOCKET
2 – SLOT IN ADAPTER
3 – SCREWDRIVER
4 – DISC C-6960–3
5 – THREADED ROD C-6960–4
6 – THREADED ADAPTER DISC C–6960–1
Fig. 57 Tighten Belleville Spring Compressor Tool
1 – TORQUE WRENCH
2 – TOOL ASSEMBLED
3 – DIFFERENTIAL CASE
Fig. 58 Remove Pinion Gear Thrust Washer
1 – THRUST WASHER
2 – FEELER GAUGE
TJ 194 RBI AXLE 3 - 77
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 61).
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 62). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
Fig. 59 Pinion Gear Removal
1 – PINION GEARS
2 – TOOL
Fig. 60 Side Gear & Clutch Disc Removal
1 – DIFFERENTIAL CASE
2 – RETAINER
3 – SIDE GEAR AND CLUTCH DISC PACK
Fig. 61 Clutch Disc Pack
1 – CLUTCH PACK
2 – RETAINER
3 – SIDE GEAR
4 – RETAINER
Fig. 62 Clutch Discs & Lower Side Gear Installation
1 – DIFFERENTIAL CASE
2 – LOWER SIDE GEAR AND CLUTCH DISC PACK
3 - 78 194 RBI AXLE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Posi ti on the di fferenti al case on Si de Gear
Hol di ng Tool 6965.
(5) I nstal l l ubri cated Step Pl ate C-6960-3 i n l ower
si de gear (Fi g. 63).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 63).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C-6960-1 i nto top si de gear.
(8) I nsert Forci ng Screw C-6960-4.
(9) Ti ghten forci ng screw tool to sl i ghtl y compress
cl utch di scs.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar C-6960-2 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(12) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw C-6960-4, Step Pl ate
C-6960-3, and Threaded Adapter C-6960-1.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l the pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
(17) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
CLEANING AND INSPECTION
AXLE COMPONENTS
Wash di fferenti al components wi th cl eani ng sol vent
and dry wi th compressed ai r. Do not steam clean
the differential components.
Wash beari ngs wi th sol vent and towel dry, or dry
wi th compressed ai r. DO NOT spi n beari ngs wi th
compressed ai r. Cup and bearing must be
replaced as matched sets only.
Cl ean axl e shaft tubes and oi l channel s i n housi ng.
I nspect for;
• Smooth appearance wi th no broken/dented sur-
faces on the beari ng rol l ers or the rol l er contact sur-
faces.
• Beari ng cups must not be di storted or cracked.
• Machi ned surfaces shoul d be smooth and wi th-
out any rai sed edges.
• Rai sed metal on shoul ders of cup bores shoul d
be removed wi th a hand stone.
• Wear and damage to pi ni on gear mate shaft,
pi ni on gears, si de gears and thrust washers. Repl ace
as a matched set onl y.
• Ri ng and pi ni on gear for worn and chi pped
teeth.
• Ri ng gear for damaged bol t threads. Repl aced as
a matched set onl y.
• Pi ni on yoke for cracks, worn spl i nes, pi tted
areas, and a rough/corroded seal contact surface.
Repai r or repl ace as necessary.
• Prel oad shi ms for damage and di storti on. I nstal l
new shi ms, i f necessary.
TRAC-LOKி
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de gears and pi ni ons. Repl ace
any gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
PRESOAK PLATES AND DISC
Pl ates and di scs wi th fi ber coati ng (no grooves or
l i nes) must be presoaked i n Fri cti on Modi fi er before
Fig. 63 Upper Side Gear & Clutch Disc Pack
Installation
1 – UPPER SIDE GEAR AND CLUTCH DISC PACK
2 – DIFFERENTIAL CASE
3 – SPECIAL TOOL C-6960–3
TJ 194 RBI AXLE 3 - 79
DISASSEMBLY AND ASSEMBLY (Continued)
assembl y. Soak pl ates and di scs for a mi ni mum of 20
mi nutes.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
64). A pl us (+) number, mi nus (–) number or zero (0)
i s etched i nto the face of the pi ni on gear. Thi s num-
ber i s the amount (i n thousandths of an i nch) the
depth vari es from the standard depth setti ng of a
pi ni on etched wi th a (0). The standard setti ng from
the center l i ne of the ri ng gear to the back face of the
pi ni on i s 96.850 mm (3.813 i n.). The standard depth
provi des the best teeth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s Paragraph i n
thi s secti on for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
under the i nner pi ni on beari ng cone (Fi g. 65).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance charts.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 6735,
Arbor Di scs 6732, and Di al I ndi cator C-3339 (Fi g.
66).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6735, and rear pi ni on beari ng onto Screw 6741
(Fi g. 66).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto axl e housi ng through
pi ni on beari ng cups (Fi g. 67).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght (Fi g. 66).
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n axl e housi ng si de beari ng cradl es (Fi g. 68).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons
i n thi s secti on.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
Fig. 64 Pinion Gear ID Numbers
1 – PRODUCTION NUMBERS
2 – DRIVE PINION GEAR DEPTH VARIANCE
3 – GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 65 Shim Locations
1 – PINION GEAR DEPTH SHIM
2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 – RING GEAR
4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 – COLLAPSIBLE SPACER
3 - 80 194 RBI AXLE TJ
CLEANING AND INSPECTION (Continued)
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the surface of the pi ni on hei ght bl ock.
Hol d scooter bl ock i n pl ace and zero the di al i ndi ca-
tor face to the poi nter. Ti ghten di al i ndi cator face
l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
Observe how many revol uti ons countercl ockwi se the
di al poi nter travel s (approxi matel y 0.125 i n.) to the
out-stop of the di al i ndi cator.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 69). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
−4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008
Fig. 66 Pinion Gear Depth Gauge Tools—Typical
1 – DIAL INDICATOR
2 – ARBOR
3 – PINION HEIGHT BLOCK
4 – CONE
5 – SCREW
6 – PINION BLOCK
7 – SCOOTER BLOCK
8 – ARBOR DISC
Fig. 67 Pinion Height Block—Typical
1 – PINION BLOCK
2 – PINION HEIGHT BLOCK
TJ 194 RBI AXLE 3 - 81
ADJ USTMENTS (Continued)
etched i n the face of the pi ni on gear (Fi g. 64) usi ng
the opposi te si gn on the vari ance number. For exam-
pl e, i f the depth vari ance i s –2, add +0.002 i n. to the
di al i ndi cator readi ng.
(10) Remove the pi ni on depth gauge components
from the axl e housi ng
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the axl e housi ng. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs D-348 i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on gear for i nstal l ati on. Estab-
l i shi ng proper pi ni on gear depth i s essenti al to estab-
l i shi ng gear backl ash and tooth contact patterns.
After the overal l shi m thi ckness to take up di fferen-
ti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of
the di al i ndi cator readi ng, starti ng poi nt shi m thi ck-
ness, and the prel oad speci fi cati on added together.
The gear backl ash measurement determi nes the
thi ckness of the shi m used on the ri ng gear si de of
the di fferenti al case. Subtract the gear backl ash shi m
thi ckness from the total overal l shi m thi ckness and
sel ect that amount for the pi ni on gear si de of the di f-
ferenti al (Fi g. 70).
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear, i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
(3) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(4) I nstal l di fferenti al case i n axl e housi ng.
Fig. 68 Gauge Tools In Housing—Typical
1 – ARBOR DISC
2 – PINION BLOCK
3 – ARBOR
4 – PINION HEIGHT BLOCK
Fig. 69 Pinion Gear Depth Measurement—Typical
1 – ARBOR
2 – SCOOTER BLOCK
3 – DIAL INDICATOR
Fig. 70 Axle Adjustment Shim Locations
1 – PINION GEAR DEPTH SHIM
2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 – RING GEAR
4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 – COLLAPSIBLE SPACER
3 - 82 194 RBI AXLE TJ
ADJ USTMENTS (Continued)
(5) I nsert Dummy Shi ms 8107 (0.118 i n. (3.0 mm))
starti ng poi nt shi ms between the dummy beari ng
and the axl e housi ng (Fi g. 71).
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts.
(7) Usi ng a dead-bl ow type mal l et, seat the di ffer-
enti al dummy beari ngs to each si de of the axl e hous-
i ng (Fi g. 72) and (Fi g. 73).
(8) Thread gui de stud C-3288-B i nto rear cover
bol t hol e bel ow ri ng gear (Fi g. 74).
(9) Attach di al i ndi cator C-3339 to gui de stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
on a ri ng gear bol t head (Fi g. 74).
(10) Push fi rml y and hol d di fferenti al case to pi n-
i on gear si de of axl e housi ng (Fi g. 75).
(11) Zero di al i ndi cator face to poi nter.
(12) Push fi rml y and hol d di fferenti al case to ri ng
gear si de of the axl e housi ng (Fi g. 76).
(13) Record di al i ndi cator readi ng.
(14) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
(15) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(16) Rotate di al i ndi cator out of the way on gui de
stud.
(17) Remove di fferenti al case, dummy beari ngs,
and starti ng poi nt shi ms from axl e housi ng.
(18) I nstal l pi ni on gear i n axl e housi ng. I nstal l the
yoke and establ i sh the correct pi ni on rotati ng torque.
(19) I nstal l di fferenti al case and dummy beari ngs
i n axl e housi ng (wi thout shi ms) and ti ghten retai ni ng
cap bol ts.
(20) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 74).
(21) Push and hol d di fferenti al case toward pi ni on
gear.
(22) Zero di al i ndi cator face to poi nter.
(23) Push and hol d di fferenti al case to ri ng gear
si de of the axl e housi ng.
Fig. 71 Insert Starting Point Shims
1 – SPECIAL TOOL 8107
2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
4 – SPECIAL TOOL D-348
Fig. 72 Seat Pinion Gear Dummy Side Bearing
1 – MALLET
2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
Fig. 73 Seat Ring Gear Side Dummy Bearing
1 – AXLE HOUSING
2 – MALLET
3 – DIFFERENTIAL CASE
TJ 194 RBI AXLE 3 - 83
ADJ USTMENTS (Continued)
(24) Record di al i ndi cator readi ng.
(25) Subtract 0.002 i n. (0.05 mm) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness of
shi m requi red to achi eve proper backl ash.
(26) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(27) Rotate di al i ndi cator out of the way on gui de
stud.
(28) Remove di fferenti al case and dummy beari ngs
from axl e housi ng.
(29) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(30) I nstal l spreader W-129-B, uti l i zi ng some com-
ponents of Adapter Set 6987, on axl e housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(31) Pl ace si de beari ng shi ms i n axl e housi ng
agai nst axl e tubes.
(32) I nstal l di fferenti al case i n axl e housi ng.
(33) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(34) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 77).
(35) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(36) Zero di al i ndi cator face to poi nter.
(37) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the di fferenti al housi ng to the
other (Fi g. 78).
(38) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
Fig. 74 Differential Side play Measurement
1 – DIFFERENTIAL CASE
2 – AXLE HOUSING
3 – SPECIAL TOOL C-3288–B
4 – SPECIAL TOOL C-3339
Fig. 75 Hold Differential Case and Zero Dial
Indicator
1 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 – SPECIAL TOOL C-3288–B
3 – SPECIAL TOOL C-3339
4 – ZERO DIAL INDICATOR FACE
Fig. 76 Hold Differential Case and Read Dial
Indicator
1 – READ DIAL INDICATOR
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 – AXLE HOUSING
3 - 84 194 RBI AXLE TJ
ADJ USTMENTS (Continued)
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN ANALYSIS
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the axl e
housi ng. I t wi l l al so show i f the ri ng gear backl ash
has been adjusted correctl y. The backl ash can be
adjusted wi thi n speci fi cati ons to achi eve desi red
tooth contact patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de, or
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Usi ng a boxed end wrench on a ri ng gear bol t,
Rotate the di fferenti al case one compl ete revol uti on
i n both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
79) and adjust pi ni on depth and gear backl ash as
necessary.
SPECIFICATIONS
194 RBI AXLE
DESCRIPTION SPECIFICATION
Axl e Type . . . . . . . . . . . . . . . Semi –Fl oati ng Hypoi d
Lubri cant . . . . . . . . SAE Thermal l y Stabl e 80W–90
Lubri cant Trai l er Tow . . . . . . . Syntheti c 75W–140
Lube Capaci ty . . . . . . . . . . . . . . . 1.66 L (3.50 pts.)
Axl e Rati os . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.10
Di fferenti al Beari ng Prel oad . . . 0.1 mm (0.004 i n.)
Di fferenti al Si de Gear Cl earance . . . . . . 0–0.15 mm
(0–0.006 i n.)
Ri ng Gear Di ameter . . . . . . . . . 19.2 cm (7.562 i n.)
Ri ng Gear Backl ash . . 0–0.15 mm (0.005–0.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . 92.08 mm (3.625 i n.)
Pi ni on Beari ng Prel oad-Ori gi nal
Beari ngs . . . . . . . . . . . . 1–2 N·m (10–20 i n. l bs.)
Pi ni on Beari ng Prel oad-New Beari ngs . . 1.5–4 N·m
(15–35 i n. l bs.)
Maxi mum Carri er Spread . . . . 0.51 mm (0.020 i n.)
TORQUE
DESCRIPTION TORQUE
Bol t, Di ff. Cover . . . . . . . . . . . . 41 N·m (30 ft. l bs.)
Bol t, Beari ng Cap . . . . . . . . . . . 77 N·m (57 ft. l bs.)
Nut, Pi ni on . . . . . . . 271–474 N·m (200–350 ft. l bs.)
Screw, Pi ni on Mate Shaft Lock . . . . . . . . 16.25 N·m
(12 ft. l bs.)
Bol t, Ri ng Gear . . . . . . 95–122 N·m (70–90 ft. l bs.)
Bol t, ABS Sensor . . . . . . . . . . . . 8 N·m (70 i n. l bs.)
Fig. 77 Ring Gear Backlash Measurement
1 – DIAL INDICATOR
Fig. 78 Backlash Shim Adjustment
TJ 194 RBI AXLE 3 - 85
ADJ USTMENTS (Continued)
Fig. 79 Gear Tooth Contact Patterns
3 - 86 194 RBI AXLE TJ
SPECIFICATIONS (Continued)
SPECIAL TOOLS
194 RBI AXLE
Puller—C-293-PA
Adapter—C-293-39
Adapter—C-293-40
Plug—SP-3289
Puller—C-452
Wrench—C-3281
Installer—C-3972-A
Spanner—6958
Installer Screw—8112
Cup—8109
TJ 194 RBI AXLE 3 - 87
Handle—C-4171
Driver—C-3716-A
Installer—D-130
Installer—D-146
Remover—C-4345
Remover—D-149
Installer—W-262
Installer—6436
Installer—6437
3 - 88 194 RBI AXLE TJ
SPECIAL TOOLS (Continued)
Disc, Axle Arbor—6732
Gauge Block—6735
Tool Set, Pinion Depth—6774
Trac-lok Tool Set—6960
Holder—6965
Starting Point Shim—8107
Spreader—W-129-B
Adapter Kit—6987
Guide Pin—C-3288-B
Bearing Remover Tool Set—6310
TJ 194 RBI AXLE 3 - 89
SPECIAL TOOLS (Continued)
Hub Puller—6790
Dial Indicator—C-3339
3 - 90 194 RBI AXLE TJ
SPECIAL TOOLS (Continued)
216 RBI REAR AXLE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
STANDARD DIFFERENTIAL. . . . . . . . . . . . . . . . . 92
TRAC-LOKி DIFFERENTIAL . . . . . . . . . . . . . . . . 93
DIAGNOSIS AND TESTING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 93
GEAR NOISE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 96
LOW SPEED KNOCK. . . . . . . . . . . . . . . . . . . . . . 96
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 97
TRAC–LOKி DIFFERENTIAL NOISE . . . . . . . . . . 97
TRAC–LOKி TEST . . . . . . . . . . . . . . . . . . . . . . . 97
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 97
REMOVAL AND INSTALLATION
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
PINION SHAFT SEAL. . . . . . . . . . . . . . . . . . . . . . 99
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
AXLE BEARING AND SEAL . . . . . . . . . . . . . . . . 100
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 102
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . 104
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 110
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 110
TRAC-LOKி DIFFERENTIAL . . . . . . . . . . . . . . . 111
CLEANING AND INSPECTION
AXLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . 116
TRAC-LOKி. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
ADJUSTMENTS
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . 116
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . 118
GEAR CONTACT PATTERN ANALYSIS. . . . . . . . 122
SPECIFICATIONS
216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 125
216 RBI TORQUE. . . . . . . . . . . . . . . . . . . . . . . . 125
SPECIAL TOOLS
216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 125
DESCRIPTION AND OPERATION
216 RBI AXLE
DESCRIPTION
The 216 Rear Beam-desi gn I ron (RBI ) axl e housi ng
has an i ron center casti ng (di fferenti al housi ng) wi th
axl e shaft tubes extendi ng from ei ther si de. The
tubes are pressed and wel ded i nto the di fferenti al
housi ng to form a one-pi ece axl e housi ng.
The i ntegral type housi ng, hypoi d gear desi gn has
the center l i ne of the pi ni on set bel ow the center l i ne
of the ri ng gear.
The axl e has a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
The axl es are equi pped wi th semi -fl oati ng axl e
shafts. The vehi cl e wei ght i s supported by the axl e
shaft and beari ngs. The axl e shafts are retai ned by
pl ates bol ted to the end fl anges of the axl e tubes.
The cover provi des a means for servi ci ng the di ffer-
enti al wi thout removi ng the axl e housi ng.
For vehi cl es equi pped wi th ABS brakes, the axl es
have a tone ri ng pressed onto the axl e shaft. Use
care when removi ng axl e shafts to ensure that the
tone ri ng or the wheel speed sensor are not damaged.
The 216 RBI axl e has the assembl y part number
and gear rati o l i sted on a tag. The tag i s attached to
the di fferenti al housi ng by a cover bol t. Bui l d date
i denti fi cati on codes are stamped on the cover si de of
an axl e shaft tube.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a rol l -
pi n. Di fferenti al si de beari ng prel oad and ri ng gear
backl ash i s adjusted by shi ms posi ti oned between the
si de beari ng cone and di fferenti al case. Pi ni on gear
depth i s adjusted by shi ms posi ti oned between the
axl e housi ng and the i nner pi ni on beari ng cup. Pi n-
i on beari ng prel oad i s mai ntai ned by shi ms posi -
ti oned between the pi ni on gear shaft shoul der and
the outer beari ng cone. (Fi g. 1)
Axl es equi pped wi th a Trac-Lok௢ di fferenti al are
opti onal . A Trac-Lok di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
TJ 216 RBI REAR AXLE 3 - 91
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
LUBRICANT
DESCRIPTION
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar௡ Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
• The l ubri cant shoul d have MI L–L–2105C and
API GL 5 qual i ty speci fi cati ons.
• Lubri cant i s a thermal l y stabl e SAE 80W–90
gear l ubri cant.
• Lubri cant for axl es i ntended for heavy-duty or
trai l er tow use i s SAE 75W–140 SYNTHETI C gear
l ubri cant.
Trac-l ok di fferenti al s requi re the addi ti on of 4 oz.
of fri cti on modi fi er to the axl e l ubri cant. The 216 RBI
axl e l ubri cant capaci ty i s 1.89 L (4.0 pts.) total ,
i ncl udi ng the fri cti on modi fi er i f necessary.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
STANDARD DIFFERENTIAL
DESCRIPTION
The di fferenti al gear system di vi des the torque
between the axl e shafts. I t al l ows the axl e shafts to
rotate at di fferent speeds when turni ng corners.
Each di fferenti al si de gear i s spl i ned to an axl e
shaft. The pi ni on gears are mounted on a pi ni on
mate shaft and are free to rotate on the shaft. The
pi ni on gear i s fi tted i n a bore i n the di fferenti al case
and i s posi ti oned at a ri ght angl e to the axl e shafts.
OPERATION
I n operati on, power fl ow occurs as fol l ows:
• The pi ni on gear rotates the ri ng gear
• The ri ng gear (bol ted to the di fferenti al case)
rotates the case
• The di fferenti al pi ni on gears (mounted on the
pi ni on mate shaft i n the case) rotate the si de gears
• The si de gears (spl i ned to the axl e shafts) rotate
the shafts
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 2).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
3). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
Fig. 1 Axle Adjustment Shims
1 – PINION BEARING PRELOAD SHIM
2 – PINION GEAR DEPTH SHIM
3 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
4 – RING GEAR
5 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
Fig. 2 Differential Operation—Straight Ahead Driving
1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 – PINION GEAR
3 – SIDE GEAR
4 – PINION GEARS ROTATE WITH CASE
3 - 92 216 RBI REAR AXLE TJ
DESCRIPTION AND OPERATION (Continued)
TRAC-LOKி DIFFERENTIAL
DESCRIPTION
I n a standard di fferenti al , i f one wheel spi ns, the
opposi te wheel wi l l generate onl y as much torque as
the spi nni ng wheel .
I n the Trac-l ok௢ di fferenti al , part of the ri ng gear
torque i s transmi tted through cl utch packs whi ch
contai n mul ti pl e di scs. The cl utches wi l l have radi al
grooves on the pl ates, and concentri c grooves on the
di scs or bonded fi ber materi al that i s smooth i n
appearance.
OPERATION
I n operati on, the Trac-l ok௢ cl utches are engaged
by two concurrent forces. The fi rst bei ng the prel oad
force exerted through Bel l evi l l e spri ng washers
wi thi n the cl utch packs. The second i s the separati ng
forces generated by the si de gears as torque i s
appl i ed through the ri ng gear (Fi g. 4).
The Trac-l ok௢ desi gn provi des the di fferenti al
acti on needed for turni ng corners and for dri vi ng
strai ght ahead duri ng peri ods of unequal tracti on.
When one wheel l ooses tracti on, the cl utch packs
transfer addi ti onal torque to the wheel havi ng the
most tracti on. Trac-l ok௢ di fferenti al s resi st wheel
spi n on bumpy roads and provi de more pul l i ng power
when one wheel l ooses tracti on. Pul l i ng power i s pro-
vi ded conti nuousl y unti l both wheel s l oose tracti on. I f
both wheel s sl i p due to unequal tracti on, Trac-l ok௢
operati on i s normal . I n extreme cases of di fferences
of tracti on, the wheel wi th the l east tracti on may
spi n.
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Axl e beari ng probl em condi ti ons are usual l y caused
by:
• I nsuffi ci ent or i ncorrect l ubri cant.
• Forei gn matter/water contami nati on.
• I ncorrect beari ng prel oad torque adjustment.
• I ncorrect backl ash.
Axl e gear probl em condi ti ons are usual l y the resul t
of:
• I nsuffi ci ent l ubri cati on.
• I ncorrect or contami nated l ubri cant.
• Overl oadi ng (excessi ve engi ne torque) or exceed-
i ng vehi cl e wei ght capaci ty.
• I ncorrect cl earance or backl ash adjustment.
Axl e component breakage i s most often the resul t
of:
Fig. 3 Differential Operation—On Turns
1 – PINION GEARS ROTATE ON PINION SHAFT
Fig. 4 Trac-lokி Limited Slip Differential Operation
1 – CASE
2 – RING GEAR
3 – DRIVE PINION
4 – PINION GEAR
5 – MATE SHAFT
6 – CLUTCH PACK
7 – SIDE GEAR
8 – CLUTCH PACK
TJ 216 RBI REAR AXLE 3 - 93
DESCRIPTION AND OPERATION (Continued)
• Severe overl oadi ng.
• I nsuffi ci ent l ubri cant.
• I ncorrect l ubri cant.
• I mproperl y ti ghtened components.
• Di fferenti al housi ng bores not square to each
other.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
3 - 94 216 RBI REAR AXLE TJ
DIAGNOSIS AND TESTING (Continued)
Condition Possible Causes Correction
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
TJ 216 RBI REAR AXLE 3 - 95
DIAGNOSIS AND TESTING (Continued)
Condition Possible Causes Correction
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears, or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak–noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght–ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant–pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U–joi nt or by worn si de–gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out–of–bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U–joi nt(s).
• Loose/broken spri ngs.
3 - 96 216 RBI REAR AXLE TJ
DIAGNOSIS AND TESTING (Continued)
2000 JEEP WRANGLER 2000 JEEP WRANGLER 2000 JEEP WRANGLER 2000 JEEP WRANGLER
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front–end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear–end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
Refer to Group 22, Wheel s and Ti res, for addi ti onal
vi brati on i nformati on.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U–joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
TRAC–LOKி DIFFERENTIAL NOISE
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok௢ uni t
for repai r, drai n, fl ush and refi l l the axl e wi th the
speci fi ed l ubri cant. Refer to Lubri cant change i n thi s
Group.
A contai ner of Mopar௡ Trac-l ok௢ Lubri cant (fri c-
ti on modi fi er) shoul d be added after repai r servi ce or
duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
TRAC–LOKி TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOKி DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRAC–LOKி AXLE CAN
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON-
TACT WITH A SURFACE TO CAUSE THE VEHICLE
TO MOVE.
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 to
studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 5).
(6) I f rotati ng torque i s l ess than 22 N·m (30 ft.
l bs.) or more than 271 N·m (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
SERVICE PROCEDURES
LUBRICANT CHANGE
(1) Rai se and support the vehi cl e.
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
drai n the l ubri cant from the housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l , or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(5) Remove the ori gi nal seal ant from the housi ng
and cover surfaces.
Fig. 5 Trac-lokி Test —Typical
1 – SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 – TORQUE WRENCH
TJ 216 RBI REAR AXLE 3 - 97
DIAGNOSIS AND TESTING (Continued)
2000 JEEP WRANGLER 2000 JEEP WRANGLER 2000 JEEP WRANGLER 2000 JEEP WRANGLER
(6) Appl y a bead of Mopar௡ Si l i cone Rubber Seal -
ant, or equi val ent, to the housi ng cover (Fi g. 6).
Install the housing cover within 5 minutes
after applying the sealant.
(7) I nstal l the cover and any i denti fi cati on tag.
Ti ghten the cover bol ts to 41 N·m (30 ft. l bs.) torque.
(8) For Trac–l ok௢ di fferenti al s, a quanti ty of
Mopar௡ Trac–l ok௢ l ubri cant (fri cti on modi fi er), or
equi val ent, must be added after repai r servi ce or a
l ubri cant change. Refer to the Lubri cant Speci fi ca-
ti ons secti on of thi s group for the quanti ty necessary.
(9) Fi l l di fferenti al wi th Mopar௡ Hypoi d Gear
Lubri cant, or equi val ent, to bottom of the fi l l pl ug
hol e. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the quanti ty necessary.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(10) I nstal l the fi l l hol e pl ug and l ower the vehi cl e.
(11) Trac–l ok௢ di fferenti al equi pped vehi cl es
shoul d be road tested by maki ng 10 to 12 sl ow fi gure-
ei ght turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
REMOVAL AND INSTALLATION
REAR AXLE
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove the wheel s and ti res.
(5) Remove the brake drums from the axl e. Refer
to Group 5, Brakes, for proper procedures.
(6) Di sconnect parki ng brake cabl es from brackets
and l ever.
(7) Remove wheel speed sensors, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(8) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the wheel cyl i nders. Refer to Group 5, Brakes, for
proper procedures.
(9) Di sconnect the vent hose from the axl e shaft
tube.
(10) Mark the propel l er shaft and yokes for i nstal -
l ati on al i gnment reference.
(11) Remove propel l er shaft.
(12) Di sconnect stabi l i zer bar l i nks.
(13) Di sconnect shock absorbers from axl e.
(14) Di sconnect track bar.
(15) Di sconnect upper and l ower suspensi on arms
from the axl e brackets.
(16) Separate the axl e from the vehi cl e.
INSTALLATION
NOTE: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, vehicle ride
height and handling could be affected.
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn coi l
spri ngs.
(2) Posi ti on the upper and l ower suspensi on arms
on the axl e brackets. I nstal l nuts and bol ts, do not
ti ghten bol ts at thi s ti me.
(3) I nstal l track bar and attachment bol ts, do not
ti ghten bol ts at thi s ti me.
(4) I nstal l shock absorbers and ti ghten nuts to 100
N·m (74 ft. l bs.) torque.
(5) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
54 N·m (40 ft. l bs.) torque.
(6) I nstal l the wheel speed sensors, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(7) Connect parki ng brake cabl e to brackets and
l ever.
(8) I nstal l the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(9) Connect the brake hose to the axl e juncti on
bl ock. Refer to Group 5, Brakes, for proper proce-
dures.
(10) I nstal l axl e vent hose.
(11) Al i gn propel l er shaft and pi ni on yoke refer-
ence marks. I nstal l U-joi nt straps and bol ts. Ti ghten
to 19 N·m (14 ft. l bs.) torque.
(12) I nstal l the wheel s and ti res.
Fig. 6 Apply Sealant
1 – SEALANT
2 – AXLE HOUSING COVER
3 - 98 216 RBI REAR AXLE TJ
SERVICE PROCEDURES (Continued)
(13) Add gear l ubri cant, i f necessary. Refer to
Lubri cant Speci fi cati ons i n thi s secti on for l ubri cant
requi rements.
(14) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(15) Ti ghten l ower suspensi on arm bol ts to 177
N·m (130 ft. l bs.) torque.
(16) Ti ghten upper suspensi on arm bol ts to 75 N·m
(55 ft. l bs.) torque.
(17) Ti ghten track bar bol ts to 100 N·m (74 ft. l bs.)
torque.
PINION SHAFT SEAL
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove brake drums. Refer to Group 5,
Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Usi ng Hol der 6958 to hol d the pi ni on yoke,
remove the pi ni on nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pi ni on yoke (Fi g. 7).
(10) Use a sui tabl e pry tool or a sl i de hammer
mounted screw to remove the pi ni on shaft seal .
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C-4171 (Fi g. 8).
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
W-162–D, Cup 8109, and Hol der 6958 (Fi g. 9).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to the pinion bearings may
result.
(3) I nstal l the pi ni on washer and a new nut on the
pi ni on gear. Tighten the nut only enough to
remove the shaft end play.
(4) Ti ghten pi ni on nut to 217 N·m (160 ft. l bs.).
(5) Rotate the pi ni on shaft usi ng a (i n. l bs.) torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal , pl us an addi ti onal 0.56
N·m (5 i n. l bs.) (Fi g. 10).
Fig. 7 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 8 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 9 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
TJ 216 RBI REAR AXLE 3 - 99
REMOVAL AND INSTALLATION (Continued)
(6) I f the rotati ng torque i s l ow, use Hol der 6958 to
hol d the pi ni on yoke, and ti ghten the pi ni on shaft
nut i n 6.8 N·m (5 ft. l bs.) i ncrements unti l proper
rotati ng torque i s achi eved.
(7) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and yoke, and i nstal l the propel l er
shaft.
(8) Check and fi l l the gear l ubri cant. Refer to the
Lubri cant Speci fi cati ons for gear l ubri cant requi re-
ments.
(9) I nstal l the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(10) I nstal l wheel and ti re assembl i es.
(11) Lower the vehi cl e.
AXLE SHAFT
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Remove wheel from vehi cl e.
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure.
(4) Through access hol e i n axl e fl ange, remove
nuts hol di ng axl e retai ner pl ate to axl e tube.
(5) Usi ng Sl i de Hammer 7420, Adapter 6790, and
sui tabl e l ug nuts, pul l axl e shaft from vehi cl e (Fi g.
11).
INSTALLATION
WARNING: Do not reuse the bolts and nuts that
retained the axle shaft to axle tube flange. Used
prevailing torque nuts can loosen, causing a dan-
gerous condition.
(1) I nsert axl e i nto openi ng at end of axl e tube.
(2) Al i gn fl at area on axl e shaft retai ni ng pl ate
upward.
(3) I nsert the retai ni ng bol ts i nto the axl e tube
fl ange and through the hol es i n the brake backi ng
and axl e shaft retai ni ng pl ates.
(4) I nstal l nuts to hol d axl e retai ni ng pl ate to axl e
tube.
(5) Through access hol e i n axl e fl ange, ti ghten
nuts to 61 N·m (45 ft. l bs.).
(6) I nstal l brake drum.
(7) I nstal l wheel and ti re assembl y.
(8) Check and fi l l the gear l ubri cant. Refer to the
Lubri cant Speci fi cati ons for gear l ubri cant requi re-
ments.
(9) Lower vehi cl e and road test to veri fy repai r.
AXLE BEARING AND SEAL
REMOVAL
(1) Remove axl e shaft from vehi cl e.
(2) Usi ng a 3/8 i n. di a. dri l l bi t, dri l l a shal l ow hol e
i nto soft steel axl e beari ng retai ni ng ri ng (Fi g. 12). I f
possi bl e, use a dri l l depth stop to avoi d marki ng axl e.
(3) Usi ng a sui tabl e col d chi sel , cut retai ni ng ri ng
across dri l l ed hol e. (Fi g. 13)
(4) Sl i de retai ni ng ri ng from axl e shaft.
Fig. 10 Check Pinion Rotation Torque
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
Fig. 11 Axle Shaft, Remove
1 – SPECIAL TOOL 6790
2 – SPECIAL TOOL 7420
3 – LUGNUT
4 – ACCESS HOLE
5 – AXLE SHAFT
3 - 100 216 RBI REAR AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(5) Usi ng Spl i tter 1130 pl aced between the seal
and beari ng and a sui tabl e Arbor Press, press uni t
beari ng from axl e shaft (Fi g. 14).
(6) Sl i de seal from axl e.
(7) Sl i de retai ni ng pl ate from axl e shaft.
INSTALLATION
(1) Usi ng a sui tabl e strai ght edge, veri fy fl atness
of axl e shaft retai ni ng pl ate. Repl ace pl ate i f warped.
(2) I nstal l retai ni ng pl ate on axl e (Fi g. 15).
(3) Appl y a coat of mul ti -purpose grease on seal i ng
surface of axl e seal .
(4) I nstal l seal on axl e wi th cavi ty away from
retai ni ng pl ate (Fi g. 15).
(5) Lubri cate beari ng wi th Mopar௡ Wheel Beari ng
Grease, or equi val ent. Wi pe excess grease from out-
si de of beari ng.
(6) Sl i de beari ng onto axl e shaft wi th groove i n
outer surface toward seal (Fi g. 15).
(7) Usi ng I nstal l er 7913 and shop press, press
beari ng onto axl e shaft (Fi g. 16).
(8) Usi ng I nstal l er 7913 and shop press, press soft
metal retai ni ng ri ng onto axl e shaft (Fi g. 17).
(9) I nstal l axl e i n vehi cl e.
Fig. 12 Drill Retaining Ring
1 – 3/8 in. DIA. DRILL BIT
2 – AXLE
3 – RETAINING PLATE
4 – SOFT METAL RETAINING RING
Fig. 13 Cut Retaining Ring
1 – COLD CHISEL
2 – VISE
3 – RETAINING RING
4 – AXLE
Fig. 14 Axle Bearing and Seal Remove
1 – AXLE
2 – UNIT BEARING
3 – PRESS PLATES
4 – BLOCKS
5 – SPECIAL TOOL 1130
TJ 216 RBI REAR AXLE 3 - 101
REMOVAL AND INSTALLATION (Continued)
DIFFERENTIAL
REMOVAL
(1) Remove axl e shafts.
(2) Note the ori entati on of the i nstal l ati on refer-
ence l etters stamped on the beari ng caps and hous-
i ng machi ned seal i ng surface (Fi g. 18).
(3) Remove the di fferenti al beari ng caps.
(4) Posi ti on Spreader W–129–B wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 19).
(5) I nstal l the hol d down cl amps and ti ghten the
tool turnbuckl e fi nger–ti ght.
(6) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach di al i ndi cator to
housi ng pi l ot stud. Load the i ndi cator pl unger
agai nst the opposi te si de of the housi ng (Fi g. 19) and
zero the i ndi cator.
(7) Spread the housi ng enough to remove the case
from the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 19).
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(8) Remove the di al i ndi cator.
Fig. 15 Axle Bearing and Seal Components
1 – RETAINING RING
2 – SEAL
3 – AXLE
4 – RETAINING PLATE
5 – UNIT BEARING
Fig. 16 Press Bearing On Axle
1 – PRESS RAM
2 – SPECIAL TOOL
7913
3 – UNIT BEARING
4 – SEAL
5 – RETAINING PLATE
6 – AXLE
Fig. 17 Press Bearing Retaining Ring On Axle
1 – PRESS RAM
2 – UNIT BEARING
3 – SPECIAL TOOL
7913
4 – SOFT METAL RETAINING RING
5 – AXLE
3 - 102 216 RBI REAR AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(9) Pry the di fferenti al case l oose from the hous-
i ng. To prevent damage, pi vot on housi ng wi th the
end of the pry bar agai nst spreader (Fi g. 20).
(10) Remove the case from housi ng. Mark or tag
beari ng cups to i ndi cate whi ch si de they were
removed from.
INSTALLATION
(1) Posi ti on Spreader W–129–B wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 19). I nstal l the
hol d down cl amps and ti ghten the tool turnbuckl e
fi nger–ti ght.
(2) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach di al i ndi cator to
housi ng pi l ot stud. Load the i ndi cator pl unger
agai nst the opposi te si de of the housi ng (Fi g. 19) and
zero the i ndi cator.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 19).
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(4) Remove the di al i ndi cator.
(5) I nstal l di fferenti al i n housi ng.
(6) I nstal l case i n the housi ng. Tap the di fferenti al
case wi th a rawhi de or rubber mal l et to ensure the
beari ngs are ful l y seated i n the di fferenti al housi ng
(Fi g. 21).
(7) Remove the spreader.
(8) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 22). Ti ghten the beari ng cap bol ts to 109
N·m (80 ft. l bs.) torque.
(9) I nstal l axl e shafts.
Fig. 18 Bearing Cap Identification
1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
Fig. 19 Spread Differential Housing
1 – HOUSING SPREADER W-129B
2 – DIAL INDICATOR C-3339
3 – DIFFERENTIAL
4 – AXLE HOUSING
5 – GUIDE PIN C-3288–B
Fig. 20 Differential Removal
1 – DIFFERENTIAL
2 – PRY BAR
TJ 216 RBI REAR AXLE 3 - 103
REMOVAL AND INSTALLATION (Continued)
DIFFERENTIAL SIDE BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove the beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, Adapters C-293-18, and
Adapter C-293-3 (Fi g. 23).
(3) Remove di fferenti al prel oad shi ms from di ffer-
enti al case hubs. Tag the shi ms to i denti fy whi ch si de
of the di fferenti al they came from.
INSTALLATION
I f ri ng and pi ni on gears have been repl aced, veri fy
di fferenti al si de beari ng prel oad and gear mesh back-
l ash.
(1) I nstal l di fferenti al prel oad shi ms on di fferenti al
case hubs.
(2) Usi ng tool D-156 wi th handl e C-4171, i nstal l
di fferenti al si de beari ngs (Fi g. 24).
(3) I nstal l di fferenti al i n axl e housi ng.
PINION GEAR
The ri ng and pi ni on gears are servi ced as a
matched set. Do not repl ace the pi ni on gear wi thout
repl aci ng the ri ng gear.
REMOVAL
(1) Remove di fferenti al assembl y from axl e hous-
i ng.
(2) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from pi ni on yoke.
Usi ng sui tabl e wi re, ti e propel l er shaft to underbody.
Fig. 21 Differential Installation
1 – RAWHIDE HAMMER
Fig. 22 Differential Bearing Cap Reference Letters
1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
Fig. 23 Differential Bearing Removal
1 – SPECIAL TOOL C-293–18
2 – BEARING
3 – DIFFERENTIAL
4 – SPECIAL TOOL C-293–3
5 – SPECIAL TOOL C-293–PA
3 - 104 216 RBI REAR AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(4) Usi ng Hol der 6958 to hol d yoke, remove the
pi ni on nut and washer (Fi g. 25).
(5) Usi ng Remover C-452 and Hol der C-3281,
remove the pi ni on yoke from pi ni on shaft (Fi g. 26).
(6) Remove the pi ni on gear and prel oad shi ms
from housi ng (Fi g. 27). Catch the pi ni on wi th your
hand to prevent i t from fal l i ng and bei ng damaged.
(7) Remove the front pi ni on beari ng cup, beari ng,
oi l sl i nger, i f equi pped, and pi ni on seal wi th Remover
D-147 and Handl e C–4171 (Fi g. 28).
(8) Remove the rear pi ni on beari ng cup from axl e
housi ng (Fi g. 29). Use Remover D-148 and Handl e
C–4171.
(9) Remove the depth shi ms from rear pi ni on bear-
i ng cup bore i n axl e housi ng. Record the thi ckness of
the depth shi ms.
Fig. 24 Install Differential Side Bearings
1 – HANDLE C-4171
2 – DIFFERENTIAL
3 – BEARING
4 – TOOL D-156
Fig. 25 Pinion Yoke Holder—Typical
1 – 1 in. PIPE
2 – PINION YOKE
3 – SPECIAL TOOL
6958
4 – LOWER CONTROL ARM
Fig. 26 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 27 Remove Pinion Gear
1 – RAWHIDE HAMMER
TJ 216 RBI REAR AXLE 3 - 105
REMOVAL AND INSTALLATION (Continued)
NOTE: The pinion depth shims can be very thin.
Verify that all shims have been removed before pro-
ceeding.
(10) Remove the rear pi ni on beari ng from the pi n-
i on wi th Pul l er/Press C–293-PA and Adapters
C-293-48 (Fi g. 30).
Place 4 adapter blocks so they do not damage
the bearing cage.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing cup and axle housing to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin-
ion depth shim should not require replacement.
Refer to Pinion Gear Depth to select the proper
thickness shim before installing pinion gear.
(1) Pl ace proper thi ckness depth shi m i n rear pi n-
i on beari ng cup bore i n the axl e housi ng.
(2) Appl y Mopar௡ Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of rear pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-145 and
Handl e C–4171 (Fi g. 31). Veri fy cup i s correctl y
seated.
(3) Appl y Mopar௡ Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of front pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-144 and
Handl e C–4171 (Fi g. 32).
(4) I nstal l front pi ni on beari ng, and oi l sl i nger, i f
equi pped.
Fig. 28 Front Bearing Cup Removal
1 – REMOVER
2 – HANDLE
Fig. 29 Rear Bearing Cup Removal
1 – DRIVER
2 – HANDLE
Fig. 30 Inner Bearing Removal
1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT
3 - 106 216 RBI REAR AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(5) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C–4171 (Fi g. 33).
(6) I nstal l the rear pi ni on beari ng and oi l sl i nger,
i f equi pped, on the pi ni on gear wi th I nstal l er W-262
and a shop press (Fi g. 34).
(7) I nstal l pi ni on beari ng prel oad shi ms onto the
pi ni on gear (Fi g. 35).
(8) I nstal l pi ni on gear i n housi ng.
(9) I nstal l yoke wi th I nstal l er W-162-B, Cup 8109,
and Hol der 6958 (Fi g. 36).
(10) I nstal l the pi ni on washer and a new nut on
the pi ni on gear. Ti ghten the nut to 217 N·m (160 ft.
l bs.) (Fi g. 37).
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload rotating torque.
Fig. 31 Rear Pinion Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 32 Pinion Outer Bearing Cup Installation
1 – INSTALLER
2 – HANDLE
Fig. 33 Pinion Seal Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
Fig. 34 Rear Pinion Bearing Installation
1 – INSTALLATION TOOL
2 – OIL SLINGER
3 – DRIVE PINION GEAR
4 – DRIVE PINION GEAR SHAFT REAR BEARING
5 – PRESS
TJ 216 RBI REAR AXLE 3 - 107
REMOVAL AND INSTALLATION (Continued)
(11) Check beari ng prel oad torque wi th an i nch
pound torque wrench (Fi g. 38). The torque necessary
to rotate the pi ni on gear shoul d be:
• Ori gi nal Beari ngs—1 to 2.26 N·m (10 to 20 i n.
l bs.).
• New Beari ngs—2.26 to 4.52 N·m (20 to 40 i n.
l bs.).
(12) I f rotati ng torque i s above the desi red
amount, remove the pi ni on yoke and i ncrease the
prel oad shi m pack thi ckness. I ncreasi ng the shi m
pack thi ckness 0.025 mm (0.001 i n.) wi l l decrease the
rotati ng torque approxi matel y 0.9 N·m (8 i n. l bs.).
(13) Ti ghten pi ni on shaft nut i n 6.8 N·m (5 ft. l bs.)
i ncrements unti l the maxi mum ti ghteni ng or desi red
rotati ng torque i s reached.
(14) I f the maxi mum ti ghteni ng torque i s reached
pri or to achi evi ng the desi red rotati ng torque, remove
the pi ni on yoke and decrease the thi ckness of the
prel oad shi m pack. Decreasi ng the shi m pack thi ck-
ness 0.025 mm (0.001 i n.) wi l l i ncrease the rotati ng
torque approxi matel y 0.9 N·m (8 i n. l bs.).
Fig. 35 Pinion Preload Shims–Typical
1 – PINION PRELOAD SHIMS
2 – FRONT BEARING CUP
3 – SLINGER
4 – PINION YOKE
5 – WASHER
6 – PINION NUT
7 – PINION OIL SEAL
8 – FRONT BEARING CONE
Fig. 36 Pinion Yoke Installation
1 – PINION YOKE
2 – AXLE HOUSING
3 - 108 216 RBI REAR AXLE TJ
REMOVAL AND INSTALLATION (Continued)
(15) I nstal l di fferenti al assembl y.
RING GEAR
NOTE: The ring gear and pinion are serviced as a
matched set. Do not replace the ring gear without
replacing the pinion.
REMOVAL
(1) Remove di fferenti al from axl e housi ng.
(2) Pl ace di fferenti al case i n a sui tabl e vi se wi th
soft metal jaw protectors. (Fi g. 39)
(3) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(4) Usi ng a soft hammer, dri ve ri ng gear from di f-
ferenti al case (Fi g. 39).
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(1) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(2) I nvert the di fferenti al case i n the vi se.
(3) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 95–122 N·m (70–90 ft. l bs.) torque (Fi g.
40).
(4) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern.
Fig. 37 Tightening Pinion Nut
1 – PINION FLANGE
2 – FRONT AXLE
3 – TOOL 6958
Fig. 38 Check Pinion Gear Rotating Torque
1 – in. lbs. TORQUE WRENCH
2 – PINION YOKE
Fig. 39 Ring Gear Removal
1 – CASE
2 – RING GEAR
3 – RAWHIDE HAMMER
TJ 216 RBI REAR AXLE 3 - 109
REMOVAL AND INSTALLATION (Continued)
FINAL ASSEMBLY
(1) Scrape the resi dual seal ant from the housi ng
and cover mati ng surfaces. Cl ean the mati ng surfaces
wi th mi neral spi ri ts. Appl y a bead of Mopar௡ Si l i cone
Rubber Seal ant, or equi val ent, on the housi ng cover
(Fi g. 41).
Install the housing cover within 5 minutes
after applying the sealant.
(2) I nstal l the cover on the di fferenti al wi th the
attachi ng bol ts. I nstal l the i denti fi cati on tag. Ti ghten
the cover bol ts to 41 N·m (30 ft. l bs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(3) Refi l l the di fferenti al housi ng wi th gear l ubri -
cant. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the gear l ubri cant requi rements.
(4) I nstal l the fi l l hol e pl ug.
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLY
(1) Remove pi ni on mate shaft l ock screw (Fi g. 42).
(2) Remove pi ni on mate shaft.
(3) Rotate the di fferenti al si de gears and remove
the di fferenti al pi ni on gears and thrust washers (Fi g.
43).
(4) Remove the di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l the di fferenti al si de gears and thrust
washers.
(2) I nstal l the di fferenti al pi ni on gears and thrust
washers.
(3) I nstal l the pi ni on mate shaft.
(4) Al i gn the hol e i n the pi ni on mate shaft wi th
the hol e i n the di fferenti al case and i nstal l the pi ni on
mate shaft l ock screw.
(5) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
Fig. 40 Ring Gear Bolt Installation
1 – TORQUE WRENCH
2 – RING GEAR BOLT
3 – RING GEAR
4 – CASE
Fig. 41 Typical Housing Cover With Sealant
1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35MM (1/4”)
3 - 110 216 RBI REAR AXLE TJ
REMOVAL AND INSTALLATION (Continued)
TRAC-LOKி DIFFERENTIAL
The Trac–Lok௢ di fferenti al components are i l l us-
trated i n (Fi g. 44). Refer to thi s i l l ustrati on duri ng
repai r servi ce.
DISASSEMBLY
(1) Cl amp Si de Gear Hol di ng Tool 6963–A i n a
vi se.
(2) Posi ti on the di fferenti al case on Si de Gear
Hol di ng Tool 6963-A (Fi g. 45).
(3) Remove ri ng gear, i f necessary. Ri ng gear
removal i s necessary onl y i f the ri ng gear i s to be
repl aced. The Trac-Lok௢ di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(4) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 46).
(5) Remove the pi ni on gear mate shaft. I f neces-
sary, use a dri ft and hammer (Fi g. 47).
(6) I nstal l and l ubri cate Step Pl ate C–4487–1 (Fi g.
48).
(7) Assembl e Threaded Adapter C–4487–3 i nto top
si de gear. Thread Forci ng Screw C–4487–2 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(8) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter C–4487–3 (Fi g. 49) to prevent
adapter from turni ng.
(9) Ti ghten forci ng screw tool 122 N·m (90 ft. l bs.)
(maxi mum) to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 50).
(10) Usi ng an appropri ate si ze feel er gauge,
remove thrust washers from behi nd the pi ni on gears
(Fi g. 51).
(11) I nsert Turni ng Bar C–4487–4 i n case (Fi g.
52).
(12) Loosen the Forci ng Screw C-4487-2 i n smal l
i ncrements unti l the cl utch pack tensi on i s rel i eved
and the di fferenti al case can be turned usi ng Turni ng
Bar C-4487-4.
(13) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(14) Remove pi ni on gears from di fferenti al case.
(15) Remove Forci ng Screw C–4487-2, Step Pl ate
C-4487-1, and Threaded Adapter C-4487-3.
(16) Remove top si de gear, cl utch pack retai ner,
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 53).
(17) Remove di fferenti al case from Si de Gear Hol d-
i ng Tool 6963-A. Remove si de gear, cl utch pack
retai ner, and cl utch pack. Keep pl ates i n correct
order duri ng removal .
Fig. 42 Pinion Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION MATE SHAFT
Fig. 43 Pinion Mate Gear Removal
1 – THRUST WASHER
2 – SIDE GEAR
3 – PINION MATE GEAR
TJ 216 RBI REAR AXLE 3 - 111
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 44 Trac–Lokி Differential Components
1 – THRUST WASHER
2 – PINION
3 – SHAFT LOCK SCREW
4 – PINION MATE SHAFT
5 – SIDE GEAR
6 – RETAINER
7 – DISC
8 – CLUTCH PACK
9 – DIFFERENTIAL CASE
10 – RETAINER
3 - 112 216 RBI REAR AXLE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 45 Differential Case Holding Tool
1 – SPECIAL TOOL
6963–A
2 – VISE
3 – TRAC-LOK DIFFERENTIAL
Fig. 46 Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION GEAR MATE SHAFT
Fig. 47 Mate Shaft Removal
1 – PINION MATE SHAFT
2 – SIDE GEAR
3 – DRIFT
4 – PINION MATE GEAR
Fig. 48 Step Plate Tool Installation
1 – SPECIAL TOOL C-4487–1
2 – LOWER SIDE GEAR
3 – DIFFERENTIAL CASE
TJ 216 RBI REAR AXLE 3 - 113
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 49 Threaded Adapter Installation
1 – SOCKET
2 – SLOT IN ADAPTER
3 – SCREWDRIVER
4 – DISC C-4487–1
5 – THREADED ROD C-4487–2
6 – THREADED ADAPTER DISC C-4487–3
Fig. 50 Tighten Belleville Spring Compressor Tool
1 – TORQUE WRENCH
2 – TOOL ASSEMBLED
3 – DIFFERENTIAL CASE
Fig. 51 Remove Pinion Gear Thrust Washer
1 – THRUST WASHER
2 – FEELER GAUGE
Fig. 52 Pinion Gear Removal
1 – PINION GEARS
2 – TOOL
3 - 114 216 RBI REAR AXLE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 54).
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 55). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
(4) Posi ti on the di fferenti al case on Si de Gear
Hol di ng Tool 6963-A.
(5) I nstal l l ubri cated Step Pl ate C–4487–1 on si de
gear (Fi g. 56).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 56).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C–4487–3 i nto top si de gear.
(8) I nsert Forci ng Screw C–4487–2.
(9) Ti ghten forci ng screw tool to sl i ghtl y compress
cl utch di scs.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar C–4487–4 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
Fig. 53 Side Gear & Clutch Disc Removal
1 – DIFFERENTIAL CASE
2 – SPECIAL TOOL C-4487–1
3 – RETAINER
4 – SIDE GEAR AND CLUTCH DISC PACK
Fig. 54 Clutch Disc Pack
1 – CLUTCH PACK
2 – RETAINER
3 – SIDE GEAR
4 – RETAINER
Fig. 55 Clutch Discs & Lower Side Gear Installation
1 – DIFFERENTIAL CASE
2 – LOWER SIDE GEAR AND CLUTCH DISC PACK
TJ 216 RBI REAR AXLE 3 - 115
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove forci ng screw, threaded adapter, and
step pl ate.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l the pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
If replacement side and/or pinion gears and
thrust washers were installed, it is not neces-
sary to measure the side gear backlash. Correct
fit is due to close machining tolerances during
manufacture.
(17) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
CLEANING AND INSPECTION
AXLE COMPONENTS
Wash di fferenti al components wi th cl eani ng sol vent
and dry wi th compressed ai r. Do not steam clean
the differential components.
Wash beari ngs wi th sol vent and towel dry, or dry
wi th compressed ai r. DO NOT spi n beari ngs wi th
compressed ai r. Cup and bearing must be
replaced as matched sets only.
Cl ean axl e shaft tubes and oi l channel s i n housi ng.
I nspect for;
• Smooth appearance wi th no broken/dented sur-
faces on the beari ng rol l ers or the rol l er contact sur-
faces.
• Beari ng cups must not be di storted or cracked.
• Machi ned surfaces shoul d be smooth and wi th-
out any rai sed edges.
• Rai sed metal on shoul ders of cup bores shoul d
be removed wi th a hand stone.
• Wear and damage to pi ni on gear mate shaft,
pi ni on gears, si de gears and thrust washers. Repl ace
as a matched set onl y.
• Ri ng and pi ni on gear for worn and chi pped
teeth.
• Ri ng gear for damaged bol t threads. Repl aced as
a matched set onl y.
• Pi ni on yoke for cracks, worn spl i nes, pi tted
areas, and a rough/corroded seal contact surface.
Repai r or repl ace as necessary.
• Prel oad shi ms for damage and di storti on. I nstal l
new shi ms, i f necessary.
TRAC-LOKி
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de gears and pi ni ons. Repl ace
any gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
PRESOAK PLATES AND DISC
Pl ates and di scs wi th fi ber coati ng (no grooves or
l i nes) must be presoaked i n Fri cti on Modi fi er before
assembl y. Soak pl ates and di scs for a mi ni mum of 20
mi nutes.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
57). A pl us (+) number, mi nus (–) number or zero (0)
i s etched i nto the face of the pi ni on gear. Thi s num-
ber i s the amount (i n thousandths of an i nch) the
depth vari es from the standard depth setti ng of a
pi ni on etched wi th a (0). The standard setti ng from
the center l i ne of the ri ng gear to the back face of the
pi ni on i s 109.52 mm (4.312 i n.). The standard depth
provi des the best teeth contact pattern. Refer to
Fig. 56 Upper Side Gear & Clutch Disc Pack
Installation
1 – UPPER SIDE GEAR AND CLUTCH DISC PACK
2 – DIFFERENTIAL CASE
3 – SPECIAL TOOL C-4487–1
3 - 116 216 RBI REAR AXLE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
Backl ash and Contact Pattern Anal ysi s Paragraph i n
thi s secti on for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
under the i nner pi ni on beari ng cup i n the axl e hous-
i ng bore (Fi g. 58).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance charts.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. The i ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th Pi ni on Gauge Set 6730 and Di al
I ndi cator C-3339 (Fi g. 59).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6734, and rear pi ni on beari ng onto Screw 6741
(Fi g. 59).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto axl e housi ng through
pi ni on beari ng cups (Fi g. 60).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght.
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n axl e housi ng si de beari ng cradl es (Fi g. 61).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 N·m (30 ft. l bs.).
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock. Hol d scooter bl ock i n pl ace and zero the
di al i ndi cator face to the poi nter. Ti ghten di al i ndi ca-
tor face l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
Observe how many revol uti ons countercl ockwi se the
di al poi nter travel s (approxi matel y 0.125 i n.) to the
out-stop of the di al i ndi cator.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 62). When the di al probe contacts the arbor bar,
Fig. 57 Pinion Gear ID Numbers
1 – PRODUCTION NUMBERS
2 – DRIVE PINION GEAR DEPTH VARIANCE
3 – GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 58 Shim Locations
1 – DRIVE PINION BEARING PRELOAD SPACER/SHIM
2 – DRIVE PINION GEAR DEPTH SHIM
3 – DIFFERENTIAL BEARING SHIM
TJ 216 RBI REAR AXLE 3 - 117
ADJ USTMENTS (Continued)
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a shi m equal to the thi ckest di al i ndi ca-
tor readi ng pl us or mi nus the dri ve pi ni on gear depth
vari ance number etched i n the face of the pi ni on gear
(Fi g. 57).
(10) Remove the pi ni on depth gauge components
from the axl e housi ng.
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the axl e housi ng. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs D-345 i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on gear for i nstal l ati on. Estab-
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
−4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008
Fig. 59 Pinion Gear Depth Gauge Tools—Typical
1 – DIAL INDICATOR
2 – ARBOR
3 – PINION HEIGHT BLOCK
4 – CONE
5 – SCREW
6 – PINION BLOCK
7 – SCOOTER BLOCK
8 – ARBOR DISC
Fig. 60 Pinion Height Block—Typical
1 – PINION BLOCK
2 – PINION HEIGHT BLOCK
3 - 118 216 RBI REAR AXLE TJ
ADJ USTMENTS (Continued)
l i shi ng proper pi ni on gear depth i s essenti al to estab-
l i shi ng gear backl ash and tooth contact patterns.
After the overal l shi m thi ckness to take up di fferen-
ti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of
the di al i ndi cator readi ng and the prel oad speci fi ca-
ti on added together. The gear backl ash measurement
determi nes the thi ckness of the shi m used on the
ri ng gear si de of the di fferenti al case. Subtract the
gear backl ash shi m thi ckness from the total overal l
shi m thi ckness and sel ect that amount for the pi ni on
gear si de of the di fferenti al (Fi g. 63).
DIFFERENTIAL PRELOAD AND GEAR BACHLASH
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(4) I nstal l dummy si de beari ngs D-345 on di fferen-
ti al case.
(5) I nstal l di fferenti al case i n axl e housi ng (Fi g.
64).
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts (Fi g. 65).
(7) Usi ng a dead-bl ow type mal l et, seat the di ffer-
enti al dummy beari ngs to each si de of the axl e hous-
i ng (Fi g. 66) and (Fi g. 67).
(8) Thread gui de stud C-3288-B i nto rear cover
bol t hol e bel ow ri ng gear (Fi g. 68).
(9) Attach a di al i ndi cator C-3339 to Gui de Stud
C-3288-B. Posi ti on the di al i ndi cator pl unger on a
fl at surface between the ri ng gear bol t heads (Fi g.
68).
(10) Push and hol d di fferenti al case to pi ni on gear
si de of axl e housi ng (Fi g. 69).
(11) Zero di al i ndi cator face to poi nter (Fi g. 69).
(12) Push and hol d di fferenti al case to ri ng gear
si de of the axl e housi ng (Fi g. 70).
(13) Record di al i ndi cator readi ng (Fi g. 70).
Fig. 61 Gauge Tools In Housing—Typical
1 – ARBOR DISC
2 – PINION BLOCK
3 – ARBOR
4 – PINION HEIGHT BLOCK
Fig. 62 Pinion Gear Depth Measurement—Typical
1 – ARBOR
2 – SCOOTER BLOCK
3 – DIAL INDICATOR
Fig. 63 Axle Adjustment Shim Locations
1 – PINION BEARING PRELOAD SHIM
2 – PINION GEAR DEPTH SHIM
3 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
4 – RING GEAR
5 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
TJ 216 RBI REAR AXLE 3 - 119
ADJ USTMENTS (Continued)
Fig. 64 Install Differential Case W/Dummy Bearings
1 – SPECIAL TOOL D-345
2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
Fig. 65 Tighten Bolts Holding Bearing Caps
1 – BEARING CAP
2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
Fig. 66 Seat Pinion Gear Side Differential Dummy
Bearing
1 – MALLET
2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
Fig. 67 Seat Ring Gear Side Differential Dummy
Bearing
1 – AXLE HOUSING
2 – MALLET
3 – DIFFERENTIAL CASE
3 - 120 216 RBI REAR AXLE TJ
ADJ USTMENTS (Continued)
(14) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
(15) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(16) Rotate di al i ndi cator out of the way on gui de
stud.
(17) Remove di fferenti al case and dummy beari ngs
from axl e housi ng.
(18) I nstal l pi ni on gear i n axl e housi ng. I nstal l the
pi ni on yoke and establ i sh the correct pi ni on rotati ng
torque.
(19) I nstal l di fferenti al case and dummy beari ngs
D-345 i n axl e housi ng (wi thout shi ms), i nstal l bear-
i ng caps and ti ghten bol ts snug.
(20) Seat ri ng gear si de dummy beari ng (Fi g. 67).
(21) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads. (Fi g. 68).
(22) Push and hol d di fferenti al case toward pi ni on
gear (Fi g. 71).
(23) Zero di al i ndi cator face to poi nter (Fi g. 71).
(24) Push and hol d di fferenti al case to ri ng gear
si de of the axl e housi ng (Fi g. 72).
(25) Record di al i ndi cator readi ng (Fi g. 72).
(26) Subtract 0.002 i n. (0.05 mm) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(27) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(28) Rotate di al i ndi cator out of the way on gui de
stud.
(29) Remove di fferenti al case and dummy beari ngs
from axl e housi ng.
Fig. 68 Differential Side Play Measurement
1 – DIFFERENTIAL CASE
2 – AXLE HOUSING
3 – SPECIAL TOOL C-3288–B
4 – SPECIAL TOOL C-3339
Fig. 69 Hold Differential Case and Zero Dial
Indicator
1 – ZERO DIAL INDICATOR FACE
2 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 – SPECIAL TOOL C-3288
4 – SPECIAL TOOL C-3339
Fig. 70 Hold Differential Case and Read Dial
Indicator
1 – READ DIAL INDICATOR
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 – AXLE HOUSING
TJ 216 RBI REAR AXLE 3 - 121
ADJ USTMENTS (Continued)
(30) I nstal l si de beari ng shi ms on di fferenti al case
hubs.
(31) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(32) I nstal l spreader W-129-B on axl e housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(33) I nstal l di fferenti al case i n axl e housi ng. Refer
to Di fferenti al Removal and I nstal l ati on paragraph.
(34) Remove spreader from axl e housi ng.
(35) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(36) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 73).
(37) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(38) Zero di al i ndi cator face to poi nter.
(39) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the axl e housi ng to the other
(Fi g. 74).
(40) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN ANALYSIS
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the axl e
housi ng. I t wi l l al so show i f the ri ng gear backl ash
has been adjusted correctl y. The backl ash can be
adjusted wi thi n speci fi cati ons to achi eve desi red
tooth contact patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de, or
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
Fig. 71 Hold Differential Case and Zero Dial
Indicator
1 – ZERO DIAL INDICATOR FACE
2 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 – PINION GEAR
4 – AXLE HOUSING
5 – DIFFERENTIAL CASE
Fig. 72 Hold Differential Case and Read Dial
Indicator
1 – READ DIAL INDICATOR
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 – PINION GEAR
4 – AXLE HOUSING
5 – DIFFERENTIAL CASE
Fig. 73 Ring Gear Backlash Measurement
1 – DIAL INDICATOR
3 - 122 216 RBI REAR AXLE TJ
ADJ USTMENTS (Continued)
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Usi ng a boxed end wrench on a ri ng gear bol t,
Rotate the di fferenti al case one compl ete revol uti on
i n both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
75) and adjust pi ni on depth and gear backl ash as
necessary.
Fig. 74 Backlash Shim Adjustment
TJ 216 RBI REAR AXLE 3 - 123
ADJ USTMENTS (Continued)
Fig. 75 Gear Tooth Contact Patterns
3 - 124 216 RBI REAR AXLE TJ
ADJ USTMENTS (Continued)
SPECIFICATIONS
216 RBI AXLE
DESCRIPTION SPECIFICATION
Axl e Type . . . . . . . . . . . . . . . . Semi -fl oati ng Hypoi d
Lubri cant . . . . . . . . SAE Thermal l y Stabl e 80W–90
Lubri cant–Trai l er Tow . . . . . . . Syntheti c 75W–140
Lubri cant Capaci ty . . . . . . . . . . . . 1.89 L (4.0 pts.)
Axl e Rati os . . . . . . . . . . . . . . . . . . . 3.07, 3.55, 4.10
Di fferenti al Beari ng Prel oad . . . 0.1 mm (0.004 i n.)
Di fferenti al Si de Gear Cl earance . . . . . . 0–0.15 mm
(0–0.006 i n.)
Ri ng Gear Di ameter . . . . . . . . . . . 216 mm (8.5 i n.)
Ri ng Gear Backl ash . . . . . . . . . . . . . 0.13–0.20 mm
(0.005–0.008 i n.)
Pi ni on Depth . . . . . . . . . . . . 109.52 mm (4.312 i n.)
Brg. Prel oad, Pi ni on (New) . . . . . . . 2.26–4.52 N·m
(20–40 i n. l bs.)
Brg. Prel oad, Pi ni on (Ori gi nal ) . . . . . . . . . 1–3 N·m
(10–20 i n. l bs.)
216 RBI TORQUE
DESCRIPTION TORQUE
Pl ug, Fi l l . . . . . . . . . . . . . . . . . . 34 N·m (25 ft. l bs.)
Bol ts, Di ff. Cover . . . . . . . . . . . . 41 N·m (30 ft. l bs.)
Bol ts, Di ff. Beari ng Cap . . . . . 108 N·m (80 ft. l bs.)
Bol ts, Ri ng Gear . . . . . . . . . . . 108 N·m (80 ft. l bs.)
Nuts, Brake Backi ng Pl ate . . . . 61 N·m (45 ft. l bs.)
Nut, Pi ni on Gear—Mi ni mum . . . . . . . . . . 217 N·m
(160 ft. l bs.)
SPECIAL TOOLS
216 RBI AXLE
Puller Set—C-293-M
Adapters—C-293-18
Adapters—C-293-48
Extension—C-293-3
Remover—C-452
TJ 216 RBI REAR AXLE 3 - 125
Handle—C-4171
Installer—D-156
Pilot—C-3288-B
Dial Indicator—C-3339
Trac-lok Tool Set—C-4487
Installer—C-3972-A
Installer—D-144
Installer—D-145
Remover—D-147
Remover—D-148
3 - 126 216 RBI REAR AXLE TJ
SPECIAL TOOLS (Continued)
Spreader—W-129-B
Installer—W-162–D
Cup—8109
Splitter—1130
Installer—W-262
Pinion Depth Set—6730
Adapter—6790
Adapter Set—6956
Holder—6958
Holder—6963-A
TJ 216 RBI REAR AXLE 3 - 127
SPECIAL TOOLS (Continued)
Adapter Set—6987
Slide Hammer—7420
Adapter—7420-8
Installer—7913-A
3 - 128 216 RBI REAR AXLE TJ
SPECIAL TOOLS (Continued)
BRAKES
TABLE OF CONTENTS
page page
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . . 33
BASE BRAKE SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . . 2
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2
RED BRAKE WARNING LAMP. . . . . . . . . . . . . . . . 3
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . 3
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 3
COMBINATION VALVE. . . . . . . . . . . . . . . . . . . . . . 3
FRONT DISC BRAKES. . . . . . . . . . . . . . . . . . . . . . 5
REAR DRUM BRAKE. . . . . . . . . . . . . . . . . . . . . . . 5
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE HOSES AND LINES. . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 7
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 9
RED BRAKE WARNING LAMP. . . . . . . . . . . . . . . . 9
MASTER CYLINDER/POWER BOOSTER. . . . . . . 10
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 11
DISC BRAKE ROTOR. . . . . . . . . . . . . . . . . . . . . . 11
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . 12
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . . 12
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 12
SERVICE PROCEDURES
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 13
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 13
BASE BRAKE BLEEDING. . . . . . . . . . . . . . . . . . . 13
DISC ROTOR MACHINING. . . . . . . . . . . . . . . . . . 14
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 14
BRAKE TUBE FLARING. . . . . . . . . . . . . . . . . . . . 14
REMOVAL AND INSTALLATION
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 15
BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 16
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 17
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 18
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 18
DISC BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . . 19
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 21
DRUM BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . 21
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 22
PARKING BRAKE HAND LEVER . . . . . . . . . . . . . 23
REAR PARKING BRAKE CABLE . . . . . . . . . . . . . 24
DISASSEMBLY AND ASSEMBLY
MASTER CYLINDER RESERVOIR . . . . . . . . . . . . 24
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 25
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 27
CLEANING AND INSPECTION
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REAR DRUM BRAKE. . . . . . . . . . . . . . . . . . . . . . 29
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 29
ADJUSTMENTS
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 29
PARKING BRAKE CABLE TENSIONER . . . . . . . . 29
REAR DRUM BRAKE. . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . . . 32
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 32
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TJ BRAKES 5 - 1
DESCRIPTION AND OPERATION
BRAKE SYSTEM
DESCRIPTION
Power assi st front di sc and rear drum brakes are
standard equi pment. Di sc brake components consi st
of si ngl e pi ston cal i pers and venti l ated rotors. Rear
drum brakes are dual shoe uni ts wi th cast brake
drums.
The parki ng brake mechani sm i s l ever and cabl e
operated. The cabl es are attached to l evers on the
rear drum brake secondary shoes. The parki ng
brakes are operated by a hand l ever.
A dual di aphragm vacuum power brake booster i s
used for al l appl i cati ons. Al l model s have an al umi -
num master cyl i nder wi th pl asti c reservoi r.
Al l model s are equi pped wi th a combi nati on val ve.
The val ve contai ns a pressure di fferenti al val ve and
swi tch and a fi xed rate rear proporti oni ng val ve.
Factory brake l i ni ng on al l model s consi sts of an
organi c base materi al combi ned wi th metal l i c parti -
cl es. The ori gi nal equi pment l i ni ngs do not contai n
asbestos.
SERVICE WARNINGS & CAUTIONS
DESCRIPTION
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET LININGS. BREATHING EXCESSIVE
CONCENTRATIONS OF ASBESTOS FIBERS CAN
CAUSE SERIOUS BODILY HARM. EXERCISE CARE
WHEN SERVICING BRAKE PARTS. DO NOT CLEAN
BRAKE PARTS WITH COMPRESSED AIR OR BY
DRY BRUSHING. USE A VACUUM CLEANER SPE-
CIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS.
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL-
ABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR
GRIND BRAKE LINING UNLESS EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
ERS. FOLLOW PRACTICES PRESCRIBED BY THE
OCCUPATIONAL SAFETY AND HEALTH ADMINIS-
TRATION AND THE ENVIRONMENTAL PROTECTION
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if con-
tamination is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
BRAKE PEDAL
DESCRIPTION
A suspended-type brake pedal i s used, the pedal
pi vots on a shaft mounted i n the pedal support
bracket. The bracket i s attached to the dash panel .
The brake pedal assembl y and pedal pad are the
onl y servi ceabl e component.
OPERATION
The brake pedal i s attached to the booster push
rod. When the pedal i s depressed, the pri mary
booster push rod i s depressed whi ch moves the
booster secondary rod. The booster secondary rod
depresses the master cyl i nder pi ston.
BRAKE LAMP SWITCH
DESCRIPTION
The pl unger type brake l amp swi tch i s mounted on
a bracket attached to the brake pedal support. The
swi tch can be adjusted when necessary.
OPERATION
The brake l amp swi tch i s used to for the brake
l amp, speed control and brake sensor ci rcui ts.
5 - 2 BRAKES TJ
RED BRAKE WARNING LAMP
DESCRIPTION
A red warni ng l amp i s used for the servi ce brake
porti on of the hydraul i c system. The l amp i s l ocated
i n the i nstrument cl uster.
OPERATION
The red warni ng l i ght al erts the dri ver i f a pres-
sure di fferenti al exi sts between the front and rear
hydraul i c systems, the parki ng brakes are appl i ed or
i f the brake swi tch i s not functi oni ng properl y. The
l amp i s turned on momentari l y when the i gni ti on
swi tch i s turn to the on posi ti on. Thi s i s a sel f test to
veri fy the l amp i s operati onal .
POWER BRAKE BOOSTER
DESCRIPTION
The booster assembl y consi sts of a housi ng di vi ded
i nto separate chambers by two i nternal di aphragms.
The outer edge of each di aphragm i s attached to the
booster housi ng.
Two push rods are used i n the booster. The pri -
mary push rod connects the booster to the brake
pedal . The secondary push rod connects the booster
to the master cyl i nder to stroke the cyl i nder pi stons.
OPERATION
The atmospheri c i nl et val ve i s opened and cl osed
by the pri mary push rod. Booster vacuum suppl y i s
through a hose attached to an i ntake mani fol d fi tti ng
at one end and to the booster check val ve at the
other. The vacuum check val ve i n the booster housi ng
i s a one-way devi ce that prevents vacuum l eak back.
Power assi st i s generated by uti l i zi ng the pressure
di fferenti al between normal atmospheri c pressure
and a vacuum. The vacuum needed for booster oper-
ati on i s taken di rectl y from the engi ne i ntake mani -
fol d. The entry poi nt for atmospheri c pressure i s
through a fi l ter and i nl et val ve at the rear of the
housi ng (Fi g. 1).
The chamber areas forward of the booster di a-
phragms are exposed to vacuum from the i ntake
mani fol d. The chamber areas to the rear of the di a-
phragms, are exposed to normal atmospheri c pres-
sure of 101.3 ki l opascal s (14.7 pounds/square i n.).
Brake pedal appl i cati on causes the pri mary push
rod to open the atmospheri c i nl et val ve. Thi s exposes
the area behi nd the di aphragms to atmospheri c pres-
sure. The resul ti ng pressure di fferenti al provi des the
extra appl y force for power assi st.
The booster check val ve, check val ve grommet and
booster seal s are servi ceabl e.
MASTER CYLINDER
DESCRIPTION
The master cyl i nder has a removabl e nyl on reser-
voi r. The cyl i nder body i s made of al umi num and
contai ns a pri mary and secondary pi ston assembl y.
The cyl i nder body i ncl udi ng the pi ston assembl i es
are not servi ceabl e. I f di agnosi s i ndi cates an i nternal
probl em wi th the cyl i nder body, i t must be repl aced
as an assembl y. The reservoi r and grommets are the
onl y repl aceabl e parts on the master cyl i nder.
OPERATION
The master cyl i nder bore contai ns a pri mary and
secondary pi ston. The pri mary pi ston suppl i es
hydraul i c pressure to the front brakes. The secondary
pi ston suppl i es hydraul i c pressure to the rear brakes.
The master cyl i nder reservoi r stores reserve brake
fl ui d for the hydraul i c brake ci rcui ts.
COMBINATION VALVE
DESCRIPTION
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e and must be
repl aced as an assembl y i f di agnosi s i ndi cates thi s i s
necessary.
OPERATION
PRESSURE DIFFERENTIAL VALVE
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs to the
brake system are made.
PROPORTIONING VALVE
The proporti oni ng val ve i s used to bal ance front-
rear brake acti on at hi gh decel erati ons. The val ve
al l ows normal fl ui d fl ow duri ng moderate braki ng.
The val ve onl y control s fl ui d fl ow duri ng hi gh decel -
erati ons brake stops.
TJ BRAKES 5 - 3
DESCRIPTION AND OPERATION (Continued)
Fig. 1 Power Brake Booster–Typical
1 – VACUUM CHECK VALVE
2 – FRONT DIAPHRAGM
3 – REAR DIAPHRAGM
4 – HOUSING
5 – SEAL
6 – AIR FILTER
7 – PRIMARY PUSH ROD (TO BRAKE PEDAL)
8 – ATMOSPHERIC INLET VALVE ASSEMBLY
9 – BOOSTER MOUNTING STUDS (4)
10 – SECONDARY PUSH ROD (TO MASTER CYLINDER)
11 – MASTER CYLINDER MOUNTING STUD (2)
12 – SPRING
5 - 4 BRAKES TJ
DESCRIPTION AND OPERATION (Continued)
FRONT DISC BRAKES
DESCRIPTION
The cal i pers are a si ngl e pi ston type. The cal i pers
are free to sl i de l ateral l y, thi s al l ows conti nuous com-
pensati on for l i ni ng wear.
OPERATION
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi ston. The fl ui d pressure
i s exerted equal l y and i n al l di recti ons. Thi s means
pressure exerted agai nst the cal i per pi ston and
wi thi n the cal i per bore wi l l be equal (Fi g. 2).
Fl ui d pressure appl i ed to the pi ston i s transmi tted
di rectl y to the i nboard brake shoe. Thi s forces the
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bore forces the cal i per to sl i de i nward on
the mounti ng bol ts. Thi s acti on bri ngs the outboard
brake shoe l i ni ng i nto contact wi th the outer surface
of the di sc brake rotor.
I n summary, fl ui d pressure acti ng si mul taneousl y
on both pi ston and cal i per, produces a strong cl amp-
i ng acti on. When suffi ci ent force i s appl i ed, fri cti on
wi l l attempt to stop the rotors from turni ng and
bri ng the vehi cl e to a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi ston. Upon rel ease of the pedal , the cal i per and pi s-
ton return to a rest posi ti on. The brake shoes do not
retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal control s the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal i s defl ected out-
ward by fl ui d pressure and pi ston movement (Fi g. 3).
When the brakes (and fl ui d pressure) are rel eased,
the seal rel axes and retracts the pi ston.
The amount of pi ston retracti on i s determi ned by
the amount of seal defl ecti on. General l y the amount
i s just enough to mai ntai n contact between the pi s-
ton and i nboard brake shoe.
REAR DRUM BRAKE
DESCRIPTION
The brake systems use a l eadi ng shoe (pri mary)
and trai l i ng shoe (secondary). The mounti ng hard-
ware i s si mi l ar but not i nterchangeabl e (Fi g. 4).
OPERATION
When the brake pedal i s depressed hydraul i c pres-
sure pushes the rear brake wheel cyl i nder pi stons
outward. The wheel cyl i nder push rods then push the
brake shoes outward agai nst the brake drum. When
the brake pedal i s rel eased return spri ngs attached
to the brake shoes pul l the shoes back to there ori g-
i nal posi ti on.
Fig. 2 Brake Caliper Operation
1 – CALIPER
2 – PISTON
3 – PISTON BORE
4 – SEAL
5 – INBOARD SHOE
6 – OUTBOARD SHOE
Fig. 3 Lining Wear Compensation By Piston Seal
1 – PISTON
2 – CYLINDER BORE
3 – PISTON SEAL BRAKE PRESSURE OFF
4 – CALIPER HOUSING
5 – DUST BOOT
6 – PISTON SEAL BRAKE PRESSURE ON
TJ BRAKES 5 - 5
DESCRIPTION AND OPERATION (Continued)
PARKING BRAKE
DESCRIPTION
The parki ng bake i s a hand l ever and cabl e oper-
ated system used to appl y the rear brakes.
OPERATION
A hand operated l ever i n the passenger compart-
ment i s the mai n appl i cati on devi ce. The front cabl e
i s connected between the hand l ever and the ten-
si oner. The tensi oner rod i s attached to the equal i zer
whi ch i s the connecti ng poi nt for the rear cabl es (Fi g.
5).
The rear cabl es are connected to the actuati ng
l ever on each secondary brake shoe. The l evers are
attached to the brake shoes by a pi n ei ther pressed
i nto, or wel ded to the l ever. A cl i p i s used to secure
the pi n i n the brake shoe. The pi n al l ows each l ever
to pi vot i ndependentl y of the brake shoe.
To appl y the parki ng brakes, the hand l ever i s
pul l ed upward. Thi s pul l s the rear brake shoe actu-
ati ng l evers forward, by means tensi oner and cabl es.
Fig. 4 Brake Components
1 – ADJUSTER LEVER
2 – ADJUSTER CABLE
3 – HOLDDOWN SPRING AND RETAINERS
4 – ADJUSTER LEVER SPRING
5 – TRAILING SHOE
6 – CYLINDER-TO-SUPPORT SEAL
7 – HOLDDOWN PINS
8 – ACCESS PLUGS
9 – SUPPORT PLATE
10 – CABLE HOLE PLUG
11 – PARK BRAKE STRUT AND SPRING
12 – ADJUSTER SCREW ASSEMBLY
13 – HOLDDOWN SPRING AND RETAINERS
14 – LEADING SHOE
15 – CABLE GUIDE
16 – SHOE RETURN SPRINGS
17 – SHOE GUIDE PLATE
18 – PIN
19 – SHOE SPRING
20 – PARK BRAKE LEVER
Fig. 5 Parking Brake Components
1 – FRONT CABLE
2 – L. R. CABLE
3 – R. R. CABLE
4 – EQUALIZER
5 – TENSIONER ROD
5 - 6 BRAKES TJ
DESCRIPTION AND OPERATION (Continued)
As the actuati ng l ever i s pul l ed forward, the parki ng
brake strut (whi ch i s connected to both shoes), exerts
a l i near force agai nst the pri mary brake shoe. Thi s
acti on presses the pri mary shoe i nto contact wi th the
drum. Once the pri mary shoe contacts the drum,
force i s exerted through the strut. Thi s force i s trans-
ferred through the strut to the secondary brake shoe
causi ng i t to pi vot i nto the drum as wel l .
A gear type ratcheti ng mechani sm i s used to hol d
the l ever i n an appl i ed posi ti on. Parki ng brake
rel ease i s accompl i shed by the hand l ever rel ease
button.
A parki ng brake swi tch i s mounted on the parki ng
brake l ever and i s actuated by movement of the
l ever. The swi tch, whi ch i s i n ci rcui t wi th the red
warni ng l i ght i n the dash, wi l l i l l umi nate the warn-
i ng l i ght whenever the parki ng brakes are appl i ed.
Parki ng brake adjustment i s control l ed by a cabl e
tensi oner mechani sm. The cabl e tensi oner, once
adjusted at the factory, shoul d not need further
adjustment under normal ci rcumstances. Adjustment
may be requi red i f a new tensi oner, or cabl es are
i nstal l ed, or di sconnected.
BRAKE HOSES AND LINES
DESCRIPTION
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. Doubl e wal l ed
steel tubi ng i s used to connect the master cyl i nder to
the major hydraul i c braki ng components and then to
the fl exi bl e rubber hoses. Doubl e i nverted styl e and
I SO styl e fl ares are used on the brake l i nes.
OPERATION
The hoses and l i nes transmi t the brake fl ui d
hydraul i c pressure to the cal i pers and or wheel cyl -
i nders.
DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM
Base brake components consi st of the brake shoes,
cal i pers, wheel cyl i nders, brake drums, rotors, brake
l i nes, master cyl i nder, booster, and parki ng brake
components.
Brake di agnosi s i nvol ves determi ni ng i f the prob-
l em i s rel ated to a mechani cal , hydraul i c, or vacuum
operated component.
The fi rst di agnosi s step i s the prel i mi nary check.
PRELIMINARY BRAKE CHECK
(1) Check condi ti on of ti res and wheel s. Damaged
wheel s and worn, damaged, or underi nfl ated ti res
can cause pul l , shudder, vi brati on, and a condi ti on
si mi l ar to grab.
(2) I f compl ai nt was based on noi se when braki ng,
check suspensi on components. Jounce front and rear
of vehi cl e and l i sten for noi se that mi ght be caused
by l oose, worn or damaged suspensi on or steeri ng
components.
(3) I nspect brake fl ui d l evel and condi ti on. Note
that the front di sc brake reservoi r fl ui d l evel wi l l
decrease i n proporti on to normal l i ni ng wear. Also
note that brake fluid tends to darken over time.
This is normal and should not be mistaken for
contamination.
(a) I f fl ui d l evel i s abnormal l y l ow, l ook for evi -
dence of l eaks at cal i pers, wheel cyl i nders, brake
l i nes, and master cyl i nder.
(b) I f fl ui d appears contami nated, drai n out a
sampl e. System wi l l have to be fl ushed i f fl ui d i s
separated i nto l ayers, or contai ns a substance
other than brake fl ui d. The system seal s and cups
wi l l al so have to be repl aced after fl ushi ng. Use
cl ean brake fl ui d to fl ush the system.
(4) Check parki ng brake operati on. Veri fy free
movement and ful l rel ease of cabl es and pedal . Al so
note i f vehi cl e was bei ng operated wi th parki ng
brake parti al l y appl i ed.
(5) Check brake pedal operati on. Veri fy that pedal
does not bi nd and has adequate free pl ay. I f pedal
l acks free pl ay, check pedal and power booster for
bei ng l oose or for bi nd condi ti on. Do not road test
unti l condi ti on i s corrected.
(6) I f components checked appear OK, road test
the vehi cl e.
ROAD TESTING
(1) I f compl ai nt i nvol ved l ow brake pedal , pump
pedal and note i f i t comes back up to normal hei ght.
(2) Check brake pedal response wi th transmi ssi on
i n Neutral and engi ne runni ng. Pedal shoul d remai n
fi rm under constant foot pressure.
(3) Duri ng road test, make normal and fi rm brake
stops i n 25-40 mph range. Note faul ty brake opera-
ti on such as l ow pedal , hard pedal , fade, pedal pul sa-
ti on, pul l , grab, drag, noi se, etc.
PEDAL FALLS AWAY
A brake pedal that fal l s away under steady foot
pressure i s general l y the resul t of a system l eak. The
l eak poi nt coul d be at a brake l i ne, fi tti ng, hose, or
cal i per/wheel cyl i nder. I nternal l eakage i n the master
cyl i nder caused by worn or damaged pi ston cups,
may al so be the probl em cause.
I f l eakage i s severe, fl ui d wi l l be evi dent at or
around the l eaki ng component. However, i nternal
l eakage i n the master cyl i nder may not be physi cal l y
evi dent.
TJ BRAKES 5 - 7
DESCRIPTION AND OPERATION (Continued)
LOW PEDAL
I f a l ow pedal i s experi enced, pump the pedal sev-
eral ti mes. I f the pedal comes back up, worn l i ni ng,
rotors, or drums are the most l i kel y causes.
SPONGY PEDAL
A spongy pedal i s most often caused by ai r i n the
system. However, thi n brake drums or substandard
brake l i nes and hoses can al so cause a spongy pedal .
The proper course of acti on i s to bl eed the system, or
repl ace thi n drums and suspect qual i ty brake l i nes
and hoses.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or hi gh pedal effort may be due to
l i ni ng that i s water soaked, contami nated, gl azed, or
badl y worn. The power booster or check val ve coul d
al so be faul ty.
PEDAL PULSATION
Pedal pul sati on i s caused by components that are
l oose, or beyond tol erance l i mi ts.
The pri mary cause of pul sati on are di sc brake
rotors wi th excessi ve l ateral runout or thi ckness vari -
ati on, or out of round brake drums. Other causes are
l oose wheel beari ngs or cal i pers and worn, damaged
ti res.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the l i ni ng i s i n constant
contact wi th the rotor or drum. Drag can occur at one
wheel , al l wheel s, fronts onl y, or rears onl y.
Drag i s a product of i ncompl ete brake shoe rel ease.
Drag can be mi nor or severe enough to overheat the
l i ni ngs, rotors and drums.
Mi nor drag wi l l usual l y cause sl i ght surface char-
ri ng of the l i ni ng. I t can al so generate hard spots i n
rotors and drums from the overheat-cool down pro-
cess. I n most cases, the rotors, drums, wheel s and
ti res are qui te warm to the touch after the vehi cl e i s
stopped.
Severe drag can char the brake l i ni ng al l the way
through. I t can al so di stort and score rotors and
drums to the poi nt of repl acement. The wheel s, ti res
and brake components wi l l be extremel y hot. I n
severe cases, the l i ni ng may generate smoke as i t
chars from overheati ng.
Possi bl e causes for brake drag condi ti on are:
• Sei zed or i mproperl y adjusted parki ng brake
cabl es.
• Loose/worn wheel beari ng.
• Sei zed cal i per or wheel cyl i nder pi ston.
• Cal i per bi ndi ng on corroded bushi ngs or rusted
sl i de surfaces.
• Loose cal i per mounti ng bracket.
• Drum brake shoes bi ndi ng on worn/damaged
support pl ates.
• Mi s-assembl ed components.
I f brake drag occurs at al l wheel s, the probl em
may be rel ated to a bl ocked master cyl i nder return
port, or faul ty power booster (bi nds-does not rel ease).
BRAKE FADE
Brake fade i s usual l y a product of overheati ng
caused by brake drag. However, brake overheati ng
and resul ti ng fade can al so be caused by ri di ng the
brake pedal , maki ng repeated hi gh decel erati on stops
i n a short ti me span, or constant braki ng on steep
mountai n roads. Refer to the Brake Drag i nformati on
i n thi s secti on for causes.
BRAKE PULL
Possi bl e causes for front brake pul l condi ti on are:
• Contami nated l i ni ng i n one cal i per.
• Sei zed cal i per pi ston.
• Bi ndi ng cal i per.
• Loose cal i per.
• Rusty adapter/cal i per sl i de surfaces.
• I mproper brake shoes.
• Damaged rotor.
A worn, damaged wheel beari ng or suspensi on
component are further causes of pul l . A damaged
front ti re (brui sed, pl y separati on) can al so cause
pul l .
A common and frequentl y mi sdi agnosed pul l condi -
ti on i s where di recti on of pul l changes after a few
stops. The cause i s a combi nati on of brake drag fol -
l owed by fade at one of the brake uni ts.
As the draggi ng brake overheats, effi ci ency i s so
reduced that fade occurs. Si nce the opposi te brake
uni t i s sti l l functi oni ng normal l y, i ts braki ng effect i s
magni fi ed. Thi s causes pul l to swi tch di recti on i n
favor of the normal l y functi oni ng brake uni t.
An addi ti onal poi nt when di agnosi ng a change i n
pul l condi ti on concerns brake cool down. Remember
that pul l wi l l return to the ori gi nal di recti on, i f the
draggi ng brake uni t i s al l owed to cool down (and i s
not seri ousl y damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pul l i s usual l y caused by i mproperl y
adjusted or sei zed parki ng brake cabl es, contami -
nated l i ni ng, bent or bi ndi ng shoes and support
pl ates, or i mproperl y assembl ed components. Thi s i s
parti cul arl y true when onl y one rear wheel i s
i nvol ved. However, when both rear wheel s are
affected, the master cyl i nder or proporti oni ng val ve
coul d be at faul t.
5 - 8 BRAKES TJ
DIAGNOSIS AND TESTING (Continued)
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Thi s condi ti on i s general l y caused by water soaked
l i ni ng. I f the l i ni ng i s onl y wet, i t can be dri ed by
dri vi ng wi th the brakes very l i ghtl y appl i ed for a
mi l e or two. However, i f the l i ni ng i s both soaked and
di rt contami nated, cl eani ng and/or repl acement wi l l
be necessary.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to l i ni ngs that
are wet or contami nated wi th brake fl ui d, grease, or
oi l . Gl azed l i ni ngs and rotors wi th hard spots can
al so contri bute to squeak. Di rt and forei gn materi al
embedded i n the brake l i ni ng wi l l al so cause squeak/
squeal .
A very l oud squeak or squeal i s frequentl y a si gn of
severel y worn brake l i ni ng. I f the l i ni ng has worn
through to the brake shoes i n spots, metal -to-metal
contact occurs. I f the condi ti on i s al l owed to conti nue,
rotors and drums can become so scored that repl ace-
ment i s necessary.
BRAKE CHATTER
Brake chatter i s usual l y caused by l oose or worn
components, or gl azed/burnt l i ni ng. Rotors wi th hard
spots can al so contri bute to chatter. Addi ti onal causes
of chatter are out-of-tol erance rotors, brake l i ni ng not
securel y attached to the shoes, l oose wheel beari ngs
and contami nated brake l i ni ng.
THUMP/CLUNK NOISE
Thumpi ng or cl unk noi ses duri ng braki ng are fre-
quentl y not caused by brake components. I n many
cases, such noi ses are caused by l oose or damaged
steeri ng, suspensi on, or engi ne components. However,
cal i pers that bi nd on the sl i de surfaces can generate
a thump or cl unk noi se. I n addi ti on, worn out,
i mproperl y adjusted, or i mproperl y assembl ed rear
brake shoes can al so produce a thump noi se.
BRAKE LINING CONTAMINATION
Brake l i ni ng contami nati on i s mostl y a product of
l eaki ng cal i pers or wheel cyl i nders, worn seal s, dri v-
i ng through deep water puddl es, or l i ni ng that has
become covered wi th grease and gri t duri ng repai r.
Contami nated l i ni ng shoul d be repl aced to avoi d fur-
ther brake probl ems.
WHEEL AND TIRE PROBLEMS
Some condi ti ons attri buted to brake components
may actual l y be caused by a wheel or ti re probl em.
A damaged wheel can cause shudder, vi brati on and
pul l . A worn or damaged ti re can al so cause pul l .
Severel y worn ti res wi th very l i ttl e tread l eft can
produce a grab-l i ke condi ti on as the ti re l oses and
recovers tracti on. Fl at-spotted ti res can cause vi bra-
ti on and generate shudder duri ng brake operati on. A
ti re wi th i nternal damage such as a severe brui se,
cut, or pl y separati on can cause pul l and vi brati on.
BRAKE LAMP SWITCH
The brake l amp swi tch operati on can be tested
wi th an ohmmeter. The ohmmeter i s used to check
conti nui ty between the pi n termi nal s (Fi g. 6).
SWITCH CIRCUIT IDENTIFICATION
• Termi nal s 1 and 2: brake sensor ci rcui t
• Termi nal s 3 and 4: speed control ci rcui t i f
equi pped
• Termi nal s 5 and 6: brake l amp ci rcui t
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
switch continuity.
Wi th the swi tch pl unger retracted, attach test
l eads to termi nal pi ns 1 and 2. Repl ace swi tch i f
meter i ndi cates no conti nui ty.
Wi th the swi tch pl unger retracted, attach test
l eads to termi nal pi ns 3 and 4. Repl ace swi tch i f
meter i ndi cates no conti nui ty.
Wi th the swi tch pl unger extended, attach test
l eads to termi nal pi ns 5 and 6. Repl ace swi tch i f
meter i ndi cates no conti nui ty.
RED BRAKE WARNING LAMP
The red brake warni ng l amp wi l l i l l umi nate under
the fol l owi ng condi ti ons:
• Sel f test at start-up.
• Parki ng brakes are appl i ed.
• Leak i n front/rear brake hydraul i c ci rcui t.
Fig. 6 Brake Lamp Switch Terminal Identification
1 – TERMINAL PINS
2 – PLUNGER TEST POSITIONS
TJ BRAKES 5 - 9
DIAGNOSIS AND TESTING (Continued)
I f the red l i ght remai ns on after start-up, fi rst ver-
i fy that the parki ng brakes are ful l y rel eased. Then
check pedal acti on and fl ui d l evel . I f the l amp on and
the brake pedal i s l ow thi s i ndi cates the pressure di f-
ferenti al swi tch and val ve have been actuated due to
a l eak i n the hydraul i c system.
On model s wi th ABS brakes, the amber warni ng
l amp onl y i l l umi nates duri ng the sel f test and when
an ABS mal functi on has occurred. The ABS l amp
operates i ndependentl y of the red warni ng l amp.
For addi ti onal i nformati on refer to Group 8W.
MASTER CYLINDER/POWER BOOSTER
(1) Start engi ne and check booster vacuum hose
connecti ons. A hi ssi ng noi se i ndi cates vacuum l eak.
Correct any vacuum l eak before proceedi ng.
(2) Stop engi ne and shi ft transmi ssi on i nto Neu-
tral .
(3) Pump brake pedal unti l al l vacuum reserve i n
booster i s depl eted.
(4) Press and hol d brake pedal under l i ght foot
pressure. The pedal shoul d hol d fi rm, i f the pedal
fal l s away master cyl i nder i s faul ty (i nternal l eak-
age).
(5) Start engi ne and note pedal acti on. I t shoul d
fal l away sl i ghtl y under l i ght foot pressure then hol d
fi rm. I f no pedal acti on i s di scerni bl e, power booster,
vacuum suppl y, or vacuum check val ve i s faul ty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebui l d booster vacuum reserve as fol l ows:
Rel ease brake pedal . I ncrease engi ne speed to 1500
rpm, cl ose the throttl e and i mmedi atel y turn off i gni -
ti on to stop engi ne.
(7) Wai t a mi ni mum of 90 seconds and try brake
acti on agai n. Booster shoul d provi de two or more vac-
uum assi sted pedal appl i cati ons. I f vacuum assi st i s
not provi ded, booster i s faul ty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check val ve
wi th short l ength of hose and T-fi tti ng (Fi g. 7).
(2) Start and run engi ne at curb i dl e speed for one
mi nute.
(3) Observe the vacuum suppl y. I f vacuum suppl y
i s not adequate, repai r vacuum suppl y.
(4) Cl amp hose shut between vacuum source and
check val ve.
(5) Stop engi ne and observe vacuum gauge.
(6) I f vacuum drops more than one i nch HG (33
mi l l i bars) wi thi n 15 seconds, booster di aphragm or
check val ve i s faul ty.
POWER BOOSTER CHECK VALVE TEST
(1) Di sconnect vacuum hose from check val ve.
(2) Remove check val ve and val ve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Appl y 15-20 i nches vacuum at l arge end of
check val ve (Fi g. 8).
(5) Vacuum shoul d hol d steady. I f gauge on pump
i ndi cates vacuum l oss, check val ve i s faul ty and
shoul d be repl aced.
Fig. 7 Typical Booster Vacuum Test Connections
1 – TEE FITTING
2 – SHORT CONNECTING HOSE
3 – CHECK VALVE
4 – CHECK VALVE HOSE
5 – CLAMP TOOL
6 – INTAKE MANIFOLD
7 – VACUUM GAUGE
Fig. 8 Vacuum Check Valve And Seal
1 – BOOSTER CHECK VALVE
2 – APPLY TEST VACUUM HERE
3 – VALVE SEAL
5 - 10 BRAKES TJ
DIAGNOSIS AND TESTING (Continued)
COMBINATION VALVE
Pressure Differential Switch
(1) Have hel per si t i n dri vers seat to appl y brake
pedal and observe red brake warni ng l i ght.
(2) Rai se vehi cl e on hoi st.
(3) Connect bl eed hose to a rear wheel cyl i nder
and i mmerse hose end i n contai ner parti al l y fi l l ed
wi th brake fl ui d.
(4) Have hel per press and hol d brake pedal to fl oor
and observe warni ng l i ght.
(a) I f warni ng l i ght i l l umi nates, swi tch i s operat-
i ng correctl y.
(b) I f l i ght fai l s to i l l umi nate, check ci rcui t fuse,
bul b, and wi ri ng. The parki ng brake swi tch can be
used to ai d i n i denti fyi ng whether or not the brake
l i ght bul b and fuse i s functi onal . Repai r or repl ace
parts as necessary and test di fferenti al pressure
swi tch operati on agai n.
(5) I f warni ng l i ght sti l l does not i l l umi nate,
swi tch i s faul ty. Repl ace combi nati on val ve assembl y,
bl eed brake system and veri fy proper swi tch and
val ve operati on.
DISC BRAKE ROTOR
The rotor braki ng surfaces shoul d not be refi ni shed
unl ess necessary.
Li ght surface rust and scal e can be removed wi th a
l athe equi pped wi th dual sandi ng di scs. The rotor
surfaces can be restored by machi ni ng i n a di sc brake
l athe i f surface scori ng and wear are l i ght.
Repl ace the rotor under the fol l owi ng condi ti ons:
• Severel y Scored
• Tapered
• Hard Spots
• Cracked
• Bel ow Mi ni mum Thi ckness
ROTOR MINIMUM THICKNESS
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f machi ni ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
Rotor mi ni mum thi ckness i s usual l y speci fi ed on
the rotor hub. The speci fi cati on i s ei ther stamped or
cast i nto the hub surface.
ROTOR RUNOUT
Check rotor l ateral runout wi th di al i ndi cator
C-3339 (Fi g. 9). Excessi ve l ateral runout wi l l cause
brake pedal pul sati on and rapi d, uneven wear of the
brake shoes. Posi ti on the di al i ndi cator pl unger
approxi matel y 25.4 mm (1 i n.) i nward from the rotor
edge.
NOTE: Be sure wheel bearing has zero end play
before checking rotor runout.
Maxi mum al l owabl e rotor runout i s 0.102 mm
(0.004 i n.).
ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Measure rotor thi ckness at 6-to-12 poi nts around
the rotor face (Fi g. 10).
Posi ti on the mi crometer approxi matel y 25.4 mm ( 1
i n.) from the rotor outer ci rcumference for each mea-
surement.
Thi ckness shoul d not vary by more than 0.013 mm
(0.0005 i n.) from poi nt-to-poi nt on the rotor. Machi ne
or repl ace the rotor i f necessary.
BRAKE DRUM
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s i ndi cated on the drum outer edge.
General l y, a drum can be machi ned to a maxi mum of
1.52 mm (0.060 i n.) oversi ze. Al ways repl ace the
drum i f machi ni ng woul d cause drum di ameter to
exceed the si ze l i mi t i ndi cated on the drum.
BRAKE DRUM RUNOUT
Measure drum di ameter and runout wi th an accu-
rate gauge. The most accurate method of measure-
ment i nvol ves mounti ng the drum i n a brake l athe
and checki ng vari ati on and runout wi th a di al i ndi -
cator.
Vari ati ons i n drum di ameter shoul d not exceed
0.069 mm (0.0028 i n.). Drum runout shoul d not
exceed 0.18 mm (0.007 i n.) out of round. Machi ne the
Fig. 9 Checking Rotor Runout And Thickness
Variation
1 – DIAL INDICATOR
TJ BRAKES 5 - 11
DIAGNOSIS AND TESTING (Continued)
drum i f runout or vari ati on exceed these val ues.
Repl ace the drum i f machi ni ng causes the drum to
exceed the maxi mum al l owabl e di ameter.
PARKING BRAKE
NOTE: Parking brake adjustment is controlled by a
cable tensioner. Once the tensioner is adjusted at
the factory, it should not require further attention.
However, there are two instances when adjustment
will be required. The first is when a new tensioner,
or cables have been installed. And the second, is
when the tensioner and cables are disconnected for
access to other brake components.
The parki ng brake swi tch i s i n ci rcui t wi th the red
warni ng l amp i n the dash. The swi tch wi l l cause the
l amp to i l l umi nate onl y when the parki ng brakes are
appl i ed. I f the l amp remai ns on after parki ng brake
rel ease, the swi tch or wi res are faul ty, or cabl e ten-
si oner adjustment i s i ncorrect.
I n most cases, the actual cause of an i mproperl y
functi oni ng parki ng brake (too l oose/too ti ght/won’t
hol d), can be traced to a parki ng brake component.
The l eadi ng cause of i mproper parki ng brake oper-
ati on, i s excessi ve cl earance between the parki ng
brake shoes and the shoe braki ng surface. Excessi ve
cl earance i s a resul t of l i ni ng and/or drum wear,
drum surface machi ned oversi ze, or i noperati ve
adjuster components.
Excessi ve parki ng brake l ever travel (someti mes
descri bed as a l oose l ever or too l oose condi ti on), i s
the resul t of worn brake shoes, i mproper brake shoe
adjustment, or i mproperl y assembl ed brake parts.
A condi ti on where the parki ng brakes do not hol d,
wi l l most probabl y be due to a wheel brake compo-
nent.
I tems to l ook for when di agnosi ng a parki ng brake
probl em, are:
• Rear brake shoe wear.
• Drum surface machi ned oversi ze.
• Front cabl e not secured to l ever.
• Rear cabl e not attached to l ever.
• Rear cabl e sei zed.
• Brake shoes reversed.
• Parki ng brake strut not seated i n shoes.
• Parki ng brake l ever not seated.
• Parki ng brake l ever bi nd.
• Adjuster screws sei zed.
• Adjuster screws reversed.
Parki ng brake adjustment and parts repl acement
procedures are descri bed i n the Parki ng Brake sec-
ti on.
BRAKE LINE AND HOSES
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. I nspect the hoses
whenever the brake system i s servi ced, at every
engi ne oi l change, or whenever the vehi cl e i s i n for
servi ce.
I nspect the hoses for surface cracki ng, scuffi ng, or
worn spots. Repl ace any brake hose i mmedi atel y i f
the fabri c casi ng of the hose i s exposed due to cracks
or abrasi ons.
Al so check brake hose i nstal l ati on. Faul ty i nstal l a-
ti on can resul t i n ki nked, twi sted hoses, or contact
wi th the wheel s and ti res or other chassi s compo-
nents. Al l of these condi ti ons can l ead to scuffi ng,
cracki ng and eventual fai l ure.
The steel brake l i nes shoul d be i nspected peri odi -
cal l y for evi dence of corrosi on, twi sts, ki nks, l eaks, or
other damage. Heavi l y corroded l i nes wi l l eventual l y
rust through causi ng l eaks. I n any case, corroded or
damaged brake l i nes shoul d be repl aced.
Factory repl acement brake l i nes and hoses are rec-
ommended to ensure qual i ty, correct l ength and supe-
ri or fati gue l i fe. Care shoul d be taken to make sure
that brake l i ne and hose mati ng surfaces are cl ean
and free from ni cks and burrs. Al so remember that
ri ght and l eft brake hoses are not i nterchangeabl e.
Use new copper seal washers at al l cal i per connec-
ti ons. Be sure brake l i ne connecti ons are properl y
made (not cross threaded) and ti ghtened to recom-
mended torque.
BRAKE FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
Fig. 10 Measuring Rotor Thickness
1 – MICROMETER
2 – ROTOR
5 - 12 BRAKES TJ
DIAGNOSIS AND TESTING (Continued)
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
SERVICE PROCEDURES
BRAKE FLUID LEVEL
Al ways cl ean the master cyl i nder reservoi r and
caps before checki ng fl ui d l evel . I f not cl eaned, di rt
coul d enter the fl ui d.
The fl ui d fi l l l evel i s i ndi cated on the si de of the
master cyl i nder reservoi r (Fi g. 11).
The correct fl ui d l evel i s to the FULL i ndi cator on
the si de of the reservoi r. I f necessary, add fl ui d to the
proper l evel .
MASTER CYLINDER BLEEDING
A new master cyl i nder shoul d be bl ed before i nstal -
l ati on on the vehi cl e. Requi red bl eedi ng tool s i ncl ude
bl eed tubes and a wood dowel to stroke the pi stons.
Bl eed tubes can be fabri cated from brake l i ne.
BLEEDING PROCEDURE
(1) Mount master cyl i nder i n vi se.
(2) Attach bl eed tubes to cyl i nder outl et ports.
Then posi ti on each tube end i nto the reservoi r (Fi g.
12).
(3) Fi l l reservoi r wi th fresh brake fl ui d.
(4) Press cyl i nder pi stons i nward wi th wood dowel .
Then rel ease pi stons and al l ow them to return under
spri ng pressure. Conti nue bl eedi ng operati ons unti l
ai r bubbl es are no l onger vi si bl e i n fl ui d.
BASE BRAKE BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Do not pump the brake pedal at any ti me whi l e
bl eedi ng. Ai r i n the system wi l l be compressed i nto
smal l bubbl es that are di stri buted throughout the
hydraul i c system. Thi s wi l l make addi ti onal bl eedi ng
operati ons necessary.
Do not al l ow the master cyl i nder to run out of fl ui d
duri ng bl eed operati ons. An empty cyl i nder wi l l al l ow
addi ti onal ai r to be drawn i nto the system. Check the
cyl i nder fl ui d l evel frequentl y and add fl ui d as
needed.
Bl eed onl y one brake component at a ti me i n the
fol l owi ng sequence:
• Master Cyl i nder
• Combi nati on Val ve
• Ri ght Rear Wheel
• Left Rear Wheel
• Ri ght Front Wheel
• Left Front Wheel
MANUAL BLEEDING
(1) Remove reservoi r fi l l er caps and fi l l reservoi r.
(2) I f cal i pers, or wheel cyl i nders were overhaul ed,
open al l cal i per and wheel cyl i nder bl eed screws.
Then cl ose each bl eed screw as fl ui d starts to dri p
from i t. Top off master cyl i nder reservoi r once more
before proceedi ng.
(3) Attach one end of bl eed hose to bl eed screw
and i nsert opposi te end i n gl ass contai ner parti al l y
Fig. 11 Master Cylinder Fluid Level - Typical
1 – INDICATOR
2 – RESERVOIR
Fig. 12 Master Cylinder Bleeding
1 – BLEEDING TUBES
2 – RESERVOIR
TJ BRAKES 5 - 13
DIAGNOSIS AND TESTING (Continued)
fi l l ed wi th brake fl ui d (Fi g. 13). Be sure end of bl eed
hose i s i mmersed i n fl ui d.
(4) Open up bl eeder, then have a hel per press
down the brake pedal . Once the pedal i s down cl ose
the bl eeder. Repeat bl eedi ng unti l fl ui d stream i s
cl ear and free of bubbl es. Then move to the next
wheel .
PRESSURE BLEEDING
Fol l ow the manufacturers i nstructi ons careful l y
when usi ng pressure equi pment. Do not exceed the
tank manufacturers pressure recommendati ons. Gen-
eral l y, a tank pressure of 15-20 psi i s suffi ci ent for
bl eedi ng.
Fi l l the bl eeder tank wi th recommended fl ui d and
purge ai r from the tank l i nes before bl eedi ng.
Do not pressure bl eed wi thout a proper master cyl -
i nder adapter. The wrong adapter can l ead to l eak-
age, or drawi ng ai r back i nto the system. Use
adapter provi ded wi th the equi pment or Adapter
6921.
DISC ROTOR MACHINING
The di sc brake rotor can be machi ned i f scored or
worn. The l athe must machi ne both si des of the rotor
si mul taneousl y wi th dual cutter heads. The rotor
mounti ng surface must be cl ean before pl aci ng on the
l athe. Equi pment capabl e of machi ni ng onl y one si de
at a ti me may produce a tapered rotor.
NOTE: A hub mounted on-vehicle lathe is recom-
mended. This type of lathe trues the rotor to the
vehicles hub/bearing.
CAUTION: Brake rotors that do not meet minimum
thickness specifications before or after machining
must be replaced.
BRAKE DRUM MACHINING
The brake drums can be machi ned on a drum l athe
when necessary. I ni ti al machi ni ng cuts shoul d be l i m-
i ted to 0.12 - 0.20 mm (0.005 - 0.008 i n.) at a ti me as
heavi er feed rates can produce taper and surface
vari ati on. Fi nal fi ni sh cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 i n.) are recommended and wi l l gen-
eral l y provi de the best surface fi ni sh.
Be sure the drum i s securel y mounted i n the l athe
before machi ni ng operati ons. A damper strap shoul d
al ways be used around the drum to reduce vi brati on
and avoi d chatter marks.
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s stamped or cast i nto the drum
outer edge.
CAUTION: Replace the drum if machining will
cause the drum to exceed the maximum allowable
diameter.
BRAKE TUBE FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
Speci al bendi ng tool s are needed to avoi d ki nki ng
or twi sti ng of metal brake tubes. Speci al fl ari ng tool s
are needed to make a doubl e i nverted fl are or I SO
fl are (Fi g. 14).
DOUBLE INVERTED FLARING
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Ream cut edges of tubi ng to ensure proper
fl are.
(3) I nstal l repl acement tube nut on the tube.
(4) I nsert tube i n fl ari ng tool .
(5) Pl ace gauge form over the end of the tube.
(6) Push tubi ng through fl ari ng tool jaws unti l
tube contacts recessed notch i n gauge that matches
tube di ameter.
(7) Ti ghten the tool bar on the tube
(8) I nsert pl ug on gauge i n the tube. Then swi ng
compressi on di sc over gauge and center tapered fl ar-
i ng screw i n recess of compressi on di sc (Fi g. 15).
Fig. 13 Bleed Hose Setup
1 – BLEED HOSE
2 – FLUID CONTAINER PARTIALLY FILLED WITH FLUID
5 - 14 BRAKES TJ
SERVICE PROCEDURES (Continued)
(9) Ti ghten tool handl e unti l pl ug gauge i s
squarel y seated on jaws of fl ari ng tool . Thi s wi l l start
the i nverted fl are.
(10) Remove the pl ug gauge and compl ete the
i nverted fl are.
ISO FLARING
To make a I SO fl are use Snap-On௡ Fl ari ng Tool
TFM-428 or equi val ent.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Remove any burrs from the i nsi de of the tube.
(3) I nstal l tube nut on the tube.
(4) Posi ti on the tube i n the fl ari ng tool fl ush wi th
the top of the tool bar (Fi g. 16). Then ti ghten the tool
bar on the tube.
(5) I nstal l the correct si ze adaptor on the fl ari ng
tool yoke screw.
(6) Lubri cate the adaptor.
(7) Al i gn the adaptor and yoke screw over the tube
(Fi g. 16).
(8) Turn the yoke screw i n unti l the adaptor i s
squarel y seated on the tool bar.
REMOVAL AND INSTALLATION
BRAKE LAMP SWITCH
REMOVAL
(1) Remove steeri ng col umn cover and l ower tri m
panel for swi tch access (i f necessary).
(2) Press brake pedal downward to ful l y appl i ed
posi ti on.
(3) Rotate swi tch approxi matel y 30° i n counter-
cl ockwi se di recti on to unl ock swi tch retai ner. Then
pul l swi tch rearward and out of bracket.
(4) Di sconnect swi tch harness and remove swi tch
(Fi g. 17).
Fig. 14 Inverted Flare And ISO Flare
1 – ISO-STYLE FLARE
2 – DOUBLE INVERTED-STYLE FLARE
Fig. 15 Inverted Flare Tools
Fig. 16 ISO Flaring
1 – ADAPTER
2 – LUBRICATE HERE
3 – PILOT
4 – FLUSH WITH BAR
5 – TUBING
6 – BAR ASSEMBLY
TJ BRAKES 5 - 15
SERVICE PROCEDURES (Continued)
INSTALLATION
(1) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(2) Connect harness wi res to swi tch.
(3) Press and hol d brake pedal i n appl i ed posi ti on.
(4) I nstal l swi tch as fol l ows: Al i gn tab on swi tch
wi th notch i n swi tch bracket. Then i nsert swi tch i n
bracket and turn i t cl ockwi se about 30° to l ock i t i n
pl ace.
(5) Rel ease brake pedal , then pul l pedal ful l y rear-
ward. Pedal wi l l set pl unger to correct posi ti on as
pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make racheti ng sound as i t sel f adjusts.
BRAKE PEDAL
REMOVAL
(1) Remove negati ve battery cabl e.
(2) Remove brake l amp swi tch.
(3) Remove ABS control l er i f equi pped.
(4) Remove retai ner cl i p securi ng booster push rod
to pedal (Fi g. 18) and cl utch rod retai ner cl i p i f
equi pped.
(5) Remove bol ts from brake pedal support and
booster mounti ng nuts. Remove mounti ng stud pl ate
nuts or cl utch cyl i nder mounti ng nuts i f equi pped.
(6) Sl i d brake booster/master cyl i nder assembl y
forward.
(7) Remove mounti ng stud pl ate or sl i d cl utch cyl -
i nder forward i f equi pped.
(8) Ti l t the pedal support down to gai n shaft cl ear-
ance.
(9) Remove pedal shaft C–cl i p from passenger si de
of the shaft.
(10) Sl i de the pedal shaft toward the dri vers si de
and remove the remai ni ng C-cl i p.
(11) Sl i d the shaft out of the pedal bracket and
remove the pedal .
(12) Remove pedal bushi ngs i f they are to be
repl aced.
INSTALLATION
(1) I nstal l new bushi ngs i n pedal . Lubri cate bush-
i ngs and shaft wi th mul ti -purpose grease.
(2) Posi ti on pedal i n bracket and i nstal l shaft.
(3) I nstal l new pi vot pi n C-cl i p.
(4) Posi ti on pedal support and i nstal l support bol ts
and ti ghten to 28 N·m (21 ft. l bs.).
(5) Sl i d the booster/master cyl i nder assembl y i nto
pl ace, i nstal l mounti ng nuts and ti ghten to 39 N·m
(29 ft. l bs.).
(6) I nstal l stud pl ate or cl utch cyl i nder i f equi pped
and ti ghten mounti ng nut to 28 N·m (21 ft. l bs.).
I nstal l retai ner cl i p securi ng booster push rod to
pedal (Fi g. 18) and cl utch rod retai ner cl i p i f
equi pped.
(7) I nstal l ABS control l er i f equi pped.
(8) I nstal l and connect brake l amp swi tch.
(9) I nstal l negati ve battery cabl e.
COMBINATION VALVE
REMOVAL
(1) Remove brake l i nes that connect master cyl i n-
der to combi nati on val ve (Fi g. 19).
(2) Di sconnect brake l i nes that connect combi na-
ti on val ve to front and rear brakes.
(3) Di sconnect wi re from combi nati on val ve swi tch
termi nal . Be careful when separati ng wi re connector
as l ock tabs are easi l y damaged i f not ful l y di sen-
gaged.
Fig. 17 Brake Lamp Switch
1 – RETAINER
2 – TERMINALS
3 – SWITCH PLUNGER
Fig. 18 Push Rod Attachment
1 – BRAKE PEDAL
2 – BOOSTER ROD
5 - 16 BRAKES TJ
REMOVAL AND INSTALLATION (Continued)
(4) Remove nuts attachi ng combi nati on val ve
bracket to booster studs and remove val ve bracket off
booster studs (Fi g. 20).
INSTALLATION
(1) Posi ti on val ve bracket on booster studs and
ti ghten bracket attachi ng nuts to 20 N·m (15 ft. l bs.).
(2) Al i gn and start brake l i ne fi tti ngs i n combi na-
ti on val ve and master cyl i nder by hand to avoi d cross
threadi ng.
(3) Ti ghten brake l i ne fi tti ngs at combi nati on val ve
to 19 N·m (14 ft. l bs.).
(4) Ti ghten brake l i ne fi tti ngs at master cyl i nder
to 19 N·m (14 ft. l bs.).
(5) Connect wi re to di fferenti al pressure swi tch i n
combi nati on val ve.
(6) Bl eed base brake system.
MASTER CYLINDER
REMOVAL
(1) Remove evaporati ve cani ster, refer to Group 25
Emi ssi ons for servi ce procedure.
(2) Di sconnect brake l i nes to master cyl i nder and
combi nati on val ve (Fi g. 21).
(3) Remove combi nati on val ve bracket mounti ng
nuts and remove val ve.
(4) Remove master cyl i nder mounti ng nuts and
remove master cyl i nder.
(5) Remove cyl i nder cover and drai n fl ui d.
INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.
(1) Remove protecti ve sl eeve from pri mary pi ston
shank on new master cyl i nder.
(2) Check condi ti on of seal at rear of cyl i nder body.
Reposi ti on seal i f di sl odged. Repl ace seal i f cut, or
torn.
(3) I nstal l master cyl i nder onto brake booster
studs and ti ghten mounti ng nuts to 17 N·m (13 ft.
l bs.).
NOTE: Use only original or factory replacement
nuts.
(4) I nstal l combi nati on val ve onto brake booster
studs and ti ghten mounti ng nuts to 20 N·m (15 ft.
l bs.).
(5) I nstal l brake l i nes to master cyl i nder and com-
bi nati on val ve by hand to avoi d cross threadi ng.
(6) Ti ghten master cyl i nder brake l i nes to 19 N·m
(14 ft. l bs.).
Fig. 19 Combination Valve/Master Cylinder
1 – COMBINATION VALVE
2 – MASTER CYLINDER
Fig. 20 Combination Valve Bracket
1 – MASTER CYLINDER
2 – COMBINATION VALVE BRACKET
Fig. 21 Master Cylinder/Combination Valve
1 – COMBINATION VALVE
2 – MASTER CYLINDER
TJ BRAKES 5 - 17
REMOVAL AND INSTALLATION (Continued)
(7) Ti ghten combi nati on val ve brake l i nes to 19
N·m (14 ft. l bs.).
(8) I nstal l evaporati ve cani ster, refer to Group 25
Emi ssi ons for servi ce procedure.
(9) Bl eed base brake system.
POWER BRAKE BOOSTER
REMOVAL
(1) Remove combi nati on val ve and master cyl i nder.
(2) Di sconnect vacuum hose from booster check
val ve.
(3) Remove retai ni ng cl i p that secures booster
push rod to brake pedal (Fi g. 22) and sl i de the rod off
the pi n.
(4) Remove four nuts attachi ng booster to front
cowl panel (Fi g. 23).
(5) I n engi ne compartment, sl i de booster studs out
of cowl panel , and remove the booster from engi ne
compartment.
(6) Remove dash seal from booster.
INSTALLATION
(1) Cl ean the booster mounti ng surface.
(2) I nstal l dash seal on booster.
(3) Al i gn and posi ti on booster on the front cowl
panel .
(4) I n passenger compartment, i nstal l nuts that
attach booster to dash panel . Ti ghten nuts just
enough to hol d booster i n pl ace.
(5) Lubri cate the pedal pi n and bushi ng wi th
Mopar mul ti -mi l eage grease. Then sl i d the booster
push rod onto brake pedal pi n and secure wi th
retai ni ng cl i p.
(6) Ti ghten booster mounti ng nuts to 39 N·m (29
ft. l bs.).
(7) Connect vacuum hose to booster check val ve.
(8) I nstal l master cyl i nder and combi nati on val ve.
(9) Top off master cyl i nder fl ui d l evel and bl eed
base brakes.
DISC BRAKE CALIPER
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove front wheel and ti re assembl y.
(3) Drai n smal l amount of fl ui d from master cyl i n-
der brake reservoi r wi th sucti on gun.
(4) Bottom cal i per pi ston i n bore wi th C-cl amp.
Posi ti on cl amp screw on outboard brake shoe and
cl amp frame on rear of cal i per (Fi g. 24). Do not
allow clamp screw to bear directly on outboard
shoe retainer spring. Use wood or metal spacer
between shoe and clamp screw.
(5) Remove brake hose mounti ng bol t and di scard
washers (Fi g. 25).
(6) Remove cal i per mounti ng bol ts (Fi g. 26).
(7) Ti l t top of cal i per outward wi th pry tool i f nec-
essary (Fi g. 27) and remove cal i per.
(8) Remove cal i per from vehi cl e.
INSTALLATION
(1) Cl ean brake shoe mounti ng l edges wi th wi re
brush and appl y l i ght coat of Mopar mul ti -mi l eage
grease to surfaces (Fi g. 28).
(2) I nstal l cal i per by posi ti on notches at l ower end
of brake shoes on bottom mounti ng l edge. Then
rotate cal i per over rotor and seat notches at upper
end of shoes on top mounti ng l edge (Fi g. 29).
(3) Coat cal i per mounti ng bol ts wi th si l i cone
grease. Then i nstal l and ti ghten bol ts to 15 N·m (11
ft. l bs.).
Fig. 22 Push Rod & Clip
1 – BRAKE PEDAL
2 – BOOSTER ROD
Fig. 23 Booster Mounting Nuts
1 – BOOSTER
2 – BRAKE PEDAL
5 - 18 BRAKES TJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: If new caliper bolts are being installed,
or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. Bolts must not have a shank length greater
than 67.6 mm (2.66 in.) (Fig. 30).
(4) I nstal l brake hose to cal i per wi th new seal
washers and ti ghten fi tti ng bol t to 31 N·m (23 ft.
l bs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Bl eed base brake system.
(6) I nstal l wheel and ti re assembl i es.
(7) Remove supports and l ower vehi cl e.
(8) Veri fy fi rm pedal before movi ng vehi cl e.
DISC BRAKE SHOES
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove cal i per.
(4) Pressi ng one end of outboard shoe i nward to
di sengage shoe l ug. Then rotate shoe upward unti l
retai ner spri ng cl ears cal i per. Press opposi te end of
shoe i nward to di sengage shoe l ug and rotate shoe up
and out of cal i per (Fi g. 31).
Fig. 24 Bottoming Caliper Piston With C-Clamp
1 – CALIPER BOSS
2 – OUTBOARD BRAKESHOE
3 – C-CLAMP
Fig. 25 Brake Hose And Bolt
1 – FITTING WASHERS
2 – CALIPERS
Fig. 26 Caliper Mounting Bolts
1 – CALIPER MOUNTING BOLT (2)
2 – CALIPER
Fig. 27 Caliper Removal
1 – TILT CALIPER OUTBOARD TO REMOVE
TJ BRAKES 5 - 19
REMOVAL AND INSTALLATION (Continued)
(5) Grasp ends of i nboard shoe and ti l t shoe out-
ward to rel ease spri ngs from cal i per pi ston (Fi g. 32)
and remove shoe from cal i per.
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not inter-
changeable.
(6) Secure cal i per to nearby suspensi on part wi th
wi re. Do not allow brake hose to support caliper
weight.
(7) Wi pe cal i per off wi th shop rags or towel s.
CAUTION: Do not use compressed air, this can
unseat dust boot and force dirt into piston bore.
INSTALLATION
(1) I nstal l i nboard shoe i n cal i per and veri fy shoe
retai ni ng i s ful l y seated i nto the pi ston.
(2) Starti ng one end of outboard shoe i n cal i per
and rotati ng shoe downward i nto pl ace. Veri fy shoe
l ocati ng l ugs and shoe spri ng are seated.
Fig. 28 Caliper Lubrication Points
1 – BUSHINGS
2 – CALIPER MOUNTING BOLTS
3 – MOUNTING LEDGES
Fig. 29 Caliper Installation
1 – TOP LEDGE
2 – BRAKESHOE TAB ON LEDGE OUTER SURFACE
3 – LEDGE SEATED IN BRAKESHOE NOTCH
4 – BOTTOM LEDGE
Fig. 30 Mounting Bolt Dimensions
1 – 67 mm (Ϯ 0.6 mm) 2.637 in. (Ϯ 0.0236 in.)
2 – 22 mm (0.866 in.) THREAD LENGTH
3 – CALIPER BOLT
Fig. 31 Outboard Brake Shoe Removal
1 – OUTBOARD BRAKESHOE
2 – SHOE SPRING
3 – LOCATING LUG
4 – CALIPER
5 – LOCATING LUG
5 - 20 BRAKES TJ
REMOVAL AND INSTALLATION (Continued)
(3) I nstal l cal i per.
(4) I nstal l wheel and ti re assembl y.
(5) Remove support and l ower vehi cl e.
(6) Pump brake pedal unti l cal i per pi stons and
brake shoes are seated.
(7) Top off brake fl ui d l evel i f necessary.
DISC BRAKE ROTOR
REMOVAL
(1) Remove wheel and ti re assembl e.
(2) Remove cal i per.
(3) Remove retai ners securi ng rotor to hub studs
(Fi g. 33).
(4) Remove rotor from hub.
(5) I f rotor shi el d requi res servi ce, remove front
hub and beari ng assembl y.
INSTALLATION
(1) I f new rotor i s bei ng i nstal l ed, remove protec-
ti ve coati ng from rotor surfaces wi th carburetor
cl eaner.
(2) I nstal l rotor on hub.
(3) I nstal l cal i per.
(4) I nstal l wheel and ti re assembl y.
DRUM BRAKE SHOES
REMOVAL
(1) Rai se vehi cl e and remove rear wheel s.
(2) Remove and di scard spri ng nuts securi ng
drums to wheel studs.
(3) Remove brake drums.
NOTE: If drums are difficult to remove, back off
adjuster through support plate access hole with
brake tool and screwdriver.
(4) Remove U-cl i p and washer securi ng adjuster
cabl e to parki ng brake l ever (Fi g. 34).
(5) Remove pri mary and secondary return spri ngs
from anchor pi n wi th brake spri ng pl i ers.
(6) Remove hol d-down spri ngs, retai ners and pi ns
wi th standard retai ni ng spri ng tool .
(7) I nstal l spri ng cl amps on wheel cyl i nders to
hol d pi stons i n pl ace.
(8) Remove adjuster l ever, adjuster screw and
spri ng.
(9) Remove adjuster cabl e and cabl e gui de.
(10) Remove brake shoes and parki ng brake strut.
(11) Di sconnect cabl e from parki ng brake l ever and
remove l ever.
INSTALLATION
(1) Cl ean support pl ate wi th brake cl eaner.
(2) I f new drums are bei ng i nstal l ed, remove pro-
tecti ve coati ng wi th carburetor cl eaner or brake
cl eaner.
(3) Appl y mul ti -purpose grease to brake shoe con-
tact surfaces of support pl ate (Fi g. 35).
(4) Lubri cate adjuster screw threads and pi vot
wi th spray l ube.
(5) Attach parki ng brake l ever to secondary brake
shoe. Use new washer and U-cl i p to secure l ever.
(6) Remove wheel cyl i nder cl amps.
(7) Attach parki ng brake cabl e to l ever.
Fig. 32 Inboard Brake Shoe Removal
1 – CALIPER PISTON
2 – SHOE SPRINGS
3 – INBOARD BRAKESHOE
Fig. 33 Rotor & Hub
1 – ROTOR
2 – RETAINER
3 – BEARING NUT
4 – NUT LOCK
5 – COTTER PIN
6 – WASHER
TJ BRAKES 5 - 21
REMOVAL AND INSTALLATION (Continued)
(8) I nstal l brake shoes on support pl ate. Secure
shoes wi th new hol d-down spri ngs, pi ns and retai n-
ers.
(9) I nstal l parki ng brake strut and spri ng.
(10) I nstal l gui de pl ate and adjuster cabl e on
anchor pi n.
(11) I nstal l pri mary and secondary return spri ngs.
(12) I nstal l adjuster cabl e gui de on secondary
shoe.
(13) Lubri cate and assembl e adjuster screw.
(14) I nstal l adjuster screw, spri ng and l ever and
connect to adjuster cabl e.
(15) Adjust shoes to drum.
(16) I nstal l wheel /ti re assembl i es and l ower vehi cl e.
(17) Veri fy fi rm brake pedal before movi ng vehi cl e.
WHEEL CYLINDER
REMOVAL
(1) Remove wheel and ti re assembl y.
(2) Remove brake drum.
(3) Remove wheel cyl i nder brake l i ne.
(4) Remove brake shoe return spri ngs and move
shoes out of engagement wi th cyl i nder push rods.
(5) Remove cyl i nder attachi ng bol ts and remove
cyl i nder from support pl ate.
Fig. 34 Drum Brake Components—Typical
1 – ADJUSTER LEVER
2 – ADJUSTER CABLE
3 – HOLDDOWN SPRING AND RETAINERS
4 – ADJUSTER LEVER SPRING
5 – TRAILING SHOE
6 – CYLINDER-TO-SUPPORT SEAL
7 – HOLDDOWN PINS
8 – ACCESS PLUGS
9 – SUPPORT PLATE
10 – CABLE HOLE PLUG
11 – PARK BRAKE STRUT AND SPRING
12 – ADJUSTER SCREW ASSEMBLY
13 – HOLDDOWN SPRING AND RETAINERS
14 – LEADING SHOE
15 – CABLE GUIDE
16 – SHOE RETURN SPRINGS
17 – SHOE GUIDE PLATE
18 – PIN
19 – SHOE SPRING
20 – PARK BRAKE LEVER
Fig. 35 Shoe Contact Surfaces
1 – ANCHOR PIN
2 – SUPPORT PLATE
3 – SHOE CONTACT SURFACES
5 - 22 BRAKES TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Appl y bead of si l i cone seal er around cyl i nder
mounti ng surface of support pl ate.
(2) I nstal l cyl i nder mounti ng bol ts and ti ghten to
10 N·m (7 ft. l bs.).
(3) I nstal l brake l i ne to cyl i nder and ti ghten to 16
N·m (12 ft. l bs.).
(4) I nstal l brake shoe return spri ng.
(5) I nstal l brake drum.
(6) I nstal l wheel and ti re assembl y.
(7) Bl eed base brake system.
PARKING BRAKE HAND LEVER
REMOVAL
(1) Rel ease parki ng brakes.
(2) Rai se vehi cl e on hoi st.
(3) Remove front cabl e adjusti ng nut and di sen-
gage cabl e tensi oner from equal i zer. Then remove
front cabl e from tensi oner (Fi g. 36).
(4) Lower vehi cl e.
(5) Remove l ever cover or center consol e i f
equi pped. Refer to Group 23 Body for procedures.
(6) Di sconnect parki ng brake swi tch wi ri ng con-
nectors (Fi g. 37).
(7) Remove screws attachi ng parki ng brake l ever
to mount (Fi g. 38).
(8) Di sengage front cabl e from parki ng brake l ever
and remove l ever assembl y from vehi cl e.
INSTALLATION
(1) I nstal l front cabl e on l ever assembl y.
(2) I nstal l l ever assembl y on mounti ng bracket and
ti ghten mounti ng bol ts to 12 N·m (9 ft. l bs.).
(3) Connect parki ng brake swi tch wi re.
(4) I nstal l parki ng l ever cover.
(5) Rai se vehi cl e.
(6) Assembl e front cabl e, cabl e tensi oner and cabl e
bracket.
(7) Adjust parki ng brake front cabl e.
(8) Lower vehi cl e.
Fig. 36 Parking Brake Cable Attachment
1 – FRONT CABLE
2 – L. R. CABLE
3 – R. R. CABLE
4 – EQUALIZER
5 – TENSIONER
Fig. 37 Parking Brake Lamp Switch
1 – PARK BRAKE LEVER
2 – PARK BRAKE LAMP SWITCH
Fig. 38 Parking Brake Lever
1 – PARKING BRAKE LEVER
2 – FRONT CABLE
3 – LEVER MOUNTING BRACKET
4 – COVER
TJ BRAKES 5 - 23
REMOVAL AND INSTALLATION (Continued)
REAR PARKING BRAKE CABLE
REMOVAL
(1) Rai se vehi cl e and l oosen equal i zer nuts unti l
rear cabl es are sl ack.
(2) Di sengage cabl e from equal i zer and remove
cabl e (Fi g. 36).
(3) Remove cabl e bracket from upper suspensi on
arm (Fi g. 39).
(4) Remove rear wheel and brake drum.
(5) Remove secondary brake shoe and di sconnect
cabl e from l ever on brake shoe.
(6) Compress cabl e retai ner wi th worm dri ve hose
cl amp (Fi g. 40) and remove cabl e from backi ng pl ate.
INSTALLATION
(1) I nstal l new cabl e i n backi ng pl ate. Be sure
cabl e retai ner i s seated.
(2) Attach cabl e to l ever on brake shoe and i nstal l
brake shoe on backi ng pl ate.
(3) Adjust brake shoes to drum wi th brake gauge.
(4) I nstal l brake drum and wheel .
(5) I nstal l cabl e/bracket on upper suspensi on arm.
(6) Engage cabl e i n equal i zer and i nstal l equal i zer
nuts.
(7) Adjust parki ng brakes.
DISASSEMBLY AND ASSEMBLY
MASTER CYLINDER RESERVOIR
REMOVAL
(1) Remove reservoi r cap and empty fl ui d i nto
drai n contai ner.
(2) Remove pi ns that retai n reservoi r to master
cyl i nder. Use hammer and pi n punch to remove pi ns
(Fi g. 41).
(3) Cl amp cyl i nder body i n vi se wi th brass protec-
ti ve jaws.
(4) Loosen reservoi r from grommets wi th pry tool
(Fi g. 42).
(5) Remove reservoi r by rocki ng i t to one si de and
pul l i ng free of grommets (Fi g. 43).
Fig. 39 Parking Brake Cable Bracket
1 – UPPER SUSPENSION ARM
2 – WIRING BRACKET
3 – PARKING BRAKE CABLE BRACKET
Fig. 40 Cable Retainer
1 – CABLE RETAINER
2 – REAR CABLE
3 – WORM DRIVE HOSE CLAMP
Fig. 41 Reservoir Retaining Pins
1 – PIN PUNCH
2 – RESERVOIR
3 – BODY
4 – ROLL PINS
5 - 24 BRAKES TJ
REMOVAL AND INSTALLATION (Continued)
(6) Remove ol d grommets from cyl i nder body (Fi g.
44).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubri cate new grommets wi th cl ean brake fl ui d
and I nstal l new grommets i n cyl i nder body (Fi g. 45).
Use fi nger pressure to i nstal l and seat grommets.
(2) Start reservoi r i n grommets. Then rock reser-
voi r back and forth whi l e pressi ng downward to seat
i t i n grommets.
(3) I nstal l pi ns that retai n reservoi r to cyl i nder
body.
(4) Fi l l and bl eed master cyl i nder on bench before
i nstal l ati on i n vehi cl e.
DISC BRAKE CALIPER
DISASSEMBLY
(1) Remove brake shoes from cal i per.
(2) Drai n brake fl ui d out of cal i per.
(3) Take a pi ece of wood and pad i t wi th one-i nch
thi ckness of shop towel s. Pl ace thi s pi ece i n the out-
board shoe si de of the cal i per i n front of the pi ston.
Thi s wi l l cushi on and protect cal i per pi ston duri ng
removal (Fi g. 46).
(4) Remove cal i per pi ston wi th short bursts of
l ow pressure compressed ai r. Di rect ai r through fl ui d
i nl et port and ease pi ston out of bore (Fi g. 47).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.
Fig. 42 Loosening Reservoir
1 – PRY TOOL
2 – RESERVOIR
3 – GROMMET
4 – MASTER CYLINDER BODY
Fig. 43 Reservoir Removal
1 – RESERVOIR
2 – GROMMETS
Fig. 44 Grommet Removal
1 – MASTER CYLINDER BODY
2 – GROMMETS
Fig. 45 Grommet Installation
1 – WORK NEW GROMMETS INTO PLACE USING FINGER
PRESSURE ONLY
TJ BRAKES 5 - 25
DISASSEMBLY AND ASSEMBLY (Continued)
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.
(5) Remove cal i per pi ston dust boot wi th sui tabl e
pry tool (Fi g. 48).
(6) Remove cal i per pi ston seal wi th wood or pl asti c
tool (Fi g. 49). Do not use metal tool s as they wi l l
scratch pi ston bore.
(7) Remove cal i per mounti ng bol t bushi ngs and
boots (Fi g. 50).
Fig. 46 Padding Caliper Interior
1 – SHOP TOWELS OR CLOTHS
2 – CALIPER
Fig. 47 Caliper Piston Removal
1 – AIR GUN
2 – CALIPER PISTON
3 – PADDING MATERIAL
Fig. 48 Caliper Piston Dust Boot Removal
1 – COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER
2 – PISTON DUST BOOT
Fig. 49 Piston Seal Removal
1 – REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL
2 – PISTON SEAL
Fig. 50 Mounting Bolt Bushing And Boot
1 – CALIPER SLIDE BUSHING
2 – BOOT
5 - 26 BRAKES TJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubri cate cal i per pi ston bore, new pi ston seal
and pi ston wi th cl ean brake fl ui d.
(2) Lubri cate cal i per bushi ngs and i nteri or of
bushi ng boots wi th si l i cone grease.
(3) I nstal l bushi ng boots i n cal i per, then i nsert
bushi ng i nto boot and push bushi ng i nto pl ace (Fi g.
51).
(4) I nstal l new pi ston seal i nto seal groove wi th
fi nger (Fi g. 52).
(5) I nstal l new dust boot on cal i per pi ston and seat
boot i n pi ston groove (Fi g. 53).
(6) Press pi ston i nto cal i per bore by hand, use a
turn and push moti on to work pi ston i nto seal (Fi g.
54).
(7) Press cal i per pi ston to bottom of bore.
(8) Seat dust boot i n cal i per wi th I nstal l er Tool
C-4842 and Tool Handl e C-4171 (Fi g. 55).
(9) Repl ace cal i per bl eed screw i f removed.
WHEEL CYLINDER
DISASSEMBLY
(1) Remove push rods and boots (Fi g. 56).
(2) Press pi stons, cups and spri ng and expander
out of cyl i nder bore.
(3) Remove bl eed screw.
ASSEMBLY
(1) Lubri cate wheel cyl i nder bore, pi stons, pi ston
cups and spri ng and expander wi th cl ean brake fl ui d.
(2) I nstal l fi rst pi ston i n cyl i nder bore. Then
i nstal l fi rst cup i n bore and agai nst pi ston. Be sure
lip of piston cup is facing inward (toward
Fig. 51 Bushings And Boots Installation
1 – BUSHING
2 – BOOT
Fig. 52 Piston Seal Installation
1 – SEAL GROOVE
2 – PISTON SEAL
Fig. 53 Dust Boot On Piston
1 – PISTION
2 – DUST BOOT
Fig. 54 Caliper Piston Installation
1 – PISTON
2 – BOOT
TJ BRAKES 5 - 27
DISASSEMBLY AND ASSEMBLY (Continued)
spring and expander) and flat side is against
piston.
(3) I nstal l spri ng and expander fol l owed by
remai ni ng pi ston cup and pi ston.
(4) I nstal l boots on each end of cyl i nder and i nsert
push rods i n boots.
(5) I nstal l cyl i nder bl eed screw.
CLEANING AND INSPECTION
CALIPER
CLEANING
Cl ean the cal i per components wi th cl ean brake
fl ui d or brake cl ean onl y. Wi pe the cal i per and pi ston
dry wi th l i nt free towel s or use l ow pressure com-
pressed ai r.
CAUTION: Do not use gasoline, kerosene, paint
thinner, or similar solvents. These products may
leave a residue that could damage the piston and
seal.
INSPECTION
The pi ston i s made from a phenol i c resi n (pl asti c
materi al ) and shoul d be smooth and cl ean.
The pi ston must be repl aced i f cracked or scored.
Do not attempt to restore a scored pi ston surface by
sandi ng or pol i shi ng.
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can be lightly pol i shed wi th a brake
hone to remove very mi nor surface i mperfecti ons
(Fi g. 57). The cal i per shoul d be repl aced i f the bore i s
severel y corroded, rusted, scored, or i f pol i shi ng
woul d i ncrease bore di ameter more than 0.025 mm
(0.001 i nch).
Fig. 55 Piston Dust Boot Installation
1 – HANDLE C-4171
2 – INSTALLER C-4842
3 – DUST BOOT
Fig. 56 Wheel Cylinder Components–Typical
1 – SPRING
2 – CYLINDER
3 – PISTON CUP
4 – BOOT
5 – PUSH ROD
6 – PISTON
7 – BLEED SCREW
8 – CUP EXPANDERS
Fig. 57 Polishing Piston Bore
1 – SPECIAL HONE
2 – CALIPER
3 – PISTON BORE
5 - 28 BRAKES TJ
DISASSEMBLY AND ASSEMBLY (Continued)
REAR DRUM BRAKE
CLEANING
Cl ean the i ndi vi dual brake components, i ncl udi ng
the support pl ate and wheel cyl i nder exteri or, wi th a
water dampened cl oth or wi th brake cl eaner. Do not
use any other cl eani ng agents. Remove l i ght rust and
scal e from the brake shoe contact pads on the sup-
port pl ate wi th fi ne sandpaper.
INSPECTION
As a general rul e, ri veted brake shoes shoul d be
repl aced when worn to wi thi n 0.78 mm (1/32 i n.) of
the ri vet heads. Bonded l i ni ng shoul d be repl aced
when worn to a thi ckness of 1.6 mm (1/16 i n.).
Exami ne the l i ni ng contact pattern to determi ne i f
the shoes are bent or the drum i s tapered. The l i ni ng
shoul d exhi bi t contact across i ts enti re wi dth. Shoes
exhi bi ti ng contact onl y on one si de shoul d be
repl aced and the drum checked for runout or taper.
I nspect the adjuster screw assembl y. Repl ace the
assembl y i f the star wheel or threads are damaged,
or the components are severel y rusted or corroded.
Di scard the brake spri ngs and retai ner components
i f worn, di storted or col l apsed. Al so repl ace the
spri ngs i f a brake drag condi ti on had occurred. Over-
heati ng wi l l di stort and weaken the spri ngs.
I nspect the brake shoe contact pads on the support
pl ate, repl ace the support pl ate i f any of the pads are
worn or rusted through. Al so repl ace the pl ate i f i t i s
bent or di storted (Fi g. 58).
WHEEL CYLINDER
CLEANING
Cl ean the cyl i nder and pi stons wi th cl ean brake
fl ui d or brake cl eaner onl y. Do not use any other
cl eani ng agents.
Dry the cyl i nder and pi stons wi th compressed ai r.
Do not use rags or shop towel s to dry the cyl i nder
components. Li nt from cl oth materi al wi l l adhere to
the cyl i nder bores and pi stons.
INSPECTION
I nspect the cyl i nder bore. Li ght di scol orati on and
dark stai ns i n the bore are normal and wi l l not
i mpai r cyl i nder operati on.
The cyl i nder bore can be l i ghtl y pol i shed but onl y
wi th crocus cl oth. Repl ace the cyl i nder i f the bore i s
scored, pi tted or heavi l y corroded. Honi ng the bore to
restore the surface i s not recommended.
I nspect the cyl i nder pi stons. The pi ston surfaces
shoul d be smooth and free of scratches, scori ng and
corrosi on. Repl ace the pi stons i f worn, scored, or cor-
roded. Do attempt to restore the surface by sandi ng
or pol i shi ng.
Di scard the ol d pi ston cups and the spri ng and
expander. These parts are not reusabl e. The ori gi nal
dust boots may be reused but onl y i f they are i n good
condi ti on.
ADJ USTMENTS
BRAKE LAMP SWITCH
(1) Press and hol d brake pedal i n appl i ed posi ti on.
(2) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(3) Rel ease brake pedal . Then pul l pedal l i ghtl y
rearward. Pedal wi l l set pl unger to correct posi ti on
as pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make ratcheti ng sound as i t sel f adjusts.
CAUTION: Booster damage may occur if the pedal
pull exceeds 20 lbs..
PARKING BRAKE CABLE TENSIONER
NOTE: Parking brake adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
essary, perform the following procedure for proper
parking brake operation.
Fig. 58 Shoe Contact Surfaces
1 – ANCHOR PIN
2 – SUPPORT PLATE
3 – SHOE CONTACT SURFACES
TJ BRAKES 5 - 29
CLEANING AND INSPECTION (Continued)
ADJUSTMENT
(1) Rai se vehi cl e.
(2) Back off tensi oner adjusti ng nut to create sl ack
i n cabl es.
(3) Remove rear wheel /ti re assembl i es and remove
brake drums.
(4) Check rear brake shoe adjustment wi th stan-
dard brake gauge. Excessive shoe-to-drum clear-
ance, or worn brake components will result in
faulty parking brake adjustment and operation.
(5) Veri fy that parki ng brake cabl es operate freel y
and are not bi ndi ng, or sei zed. Repl ace faul ty cabl es,
before proceedi ng.
(6) Rei nstal l brake drums and wheel /ti re assem-
bl i es after brake shoe adjustment i s compl ete.
(7) Lower vehi cl e enough for access to parki ng
brake l ever. Then fully appl y parki ng brakes. Leave
brakes appl i ed unti l adjustment i s compl ete.
(8) Rai se vehi cl e and mark tensi oner rod 6.5 mm
(1/4 i n.) from tensi oner bracket (Fi g. 59).
(9) Ti ghten adjusti ng nut at equal i zer unti l mark
on tensi oner rod moves i nto al i gnment wi th tensi oner
bracket.
(10) Lower vehi cl e unti l rear wheel s are 15-20 cm
(6-8 i n.) off shop fl oor.
(11) Rel ease parki ng brake l ever and veri fy that
rear wheel s rotate freel y wi thout drag.
(12) Lower vehi cl e.
NOTE: Do not loosen/tighten equalizer adjusting
nut for any reason after completing adjustment.
REAR DRUM BRAKE
The rear drum brakes are equi pped wi th a sel f-ad-
justi ng mechani sm. Under normal ci rcumstances, the
onl y ti me adjustment i s requi red i s when the shoes
are repl aced, removed for access to other parts, or
when one or both drums are repl aced.
Adjustment can be made wi th a standard brake
gauge or wi th adjusti ng tool . Adjustment i s per-
formed wi th the compl ete brake assembl y i nstal l ed
on the backi ng pl ate.
ADJUSTMENT WITH BRAKE GAUGE
(1) Be sure parki ng brakes are ful l y rel eased.
(2) Rai se rear of vehi cl e and remove wheel s and
brake drums.
(3) Veri fy that l eft and ri ght automati c adjuster
l evers and cabl es are properl y connected.
(4) I nsert brake gauge i n drum. Expand gauge
unti l gauge i nner l egs contact drum braki ng surface.
Then l ock gauge i n posi ti on (Fi g. 60).
(5) Reverse gauge and i nstal l i t on brake shoes.
Posi ti on gauge l egs at shoe centers as shown (Fi g.
61). I f gauge does not fi t (too l oose/too ti ght), adjust
shoes.
(6) Pul l shoe adjuster l ever away from adjuster
screw star wheel .
(7) Turn adjuster screw star wheel (by hand) to
expand or retract brake shoes. Conti nue adjustment
unti l gauge outsi de l egs are l i ght drag-fi t on shoes.
(8) I nstal l brake drums and wheel s and l ower
vehi cl e.
Fig. 59 Tensioner Rod Measurement
1 – TENSIONER BRACKET
2 – 6.5 mm
(1/4 in.)
3 – TENSIONER ROD
4 – ROD TO EQUALIZER
Fig. 60 Adjusting Gauge On Drum
1 – BRAKE GAUGE
2 – BRAKE DRUM
5 - 30 BRAKES TJ
ADJ USTMENTS (Continued)
(9) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
ADJUSTMENT WITH ADJUSTING TOOL
(1) Be sure parki ng brake l ever i s ful l y rel eased.
(2) Rai se vehi cl e so rear wheel s can be rotated
freel y.
(3) Remove pl ug from each access hol e i n brake
support pl ates.
(4) Loosen parki ng brake cabl e adjustment nut
unti l there i s sl ack i n front cabl e.
(5) I nsert adjusti ng tool through support pl ate
access hol e and engage tool i n teeth of adjusti ng
screw star wheel (Fi g. 62).
(6) Rotate adjuster screw star wheel (move tool
handl e upward) unti l sl i ght drag can be fel t when
wheel i s rotated.
(7) Push and hol d adjuster l ever away from star
wheel wi th thi n screwdri ver.
(8) Back off adjuster screw star wheel unti l brake
drag i s el i mi nated.
(9) Repeat adjustment at opposi te wheel . Be sure
adjustment i s equal at both wheel s.
(10) I nstal l support pl ate access hol e pl ugs.
(11) Adjust parki ng brake cabl e and l ower vehi cl e.
(12) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid, etc.
Fig. 61 Adjusting Gauge On Brake Shoes
1 – BRAKE GAUGE
2 – BRAKE SHOES
Fig. 62 Brake Adjustment
1 – STAR WHEEL
2 – LEVER
3 – BRAKE SHOE WEB
4 – SCREWDRIVER
5 – ADJUSTING TOOL
6 – ADJUSTER SPRING
TJ BRAKES 5 - 31
ADJ USTMENTS (Continued)
BRAKE COMPONENTS
Disc Brake Caliper
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sl i di ng
Disc Brake Rotor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . Venti l ated
Si ze . . . . . . . . . 279.4 x 23.876 mm (11 x 0.94 i n.)
Max. Runout . . . . . . . . . . . . . 0.12 mm (0.005 i n.)
Max. Thi ckness Vari ati on . 0.013 mm (0.0005 i n.)
Mi n. Thi ckness . . . . . . . . . . 22.7 mm (0.8937 i n.)
Brake Drum
Si ze . . . . . . . . . . . . 228.6 x 63.5 mm (9 x 2.5 i n.)
Brake Booster
Type . . . . . . . . . . . . . . . . . . . Tandem Di aphragm
TORQUE CHART
DESCRIPTION TORQUE
Brake Pedal
Support Bol t . . . . . . . . . . . . . 28 N·m (21 ft. l bs.)
Brake Booster
Mounti ng Nuts . . . . . . . . . . . 39 N·m (29 ft. l bs.)
Master Cylinder
Mounti ng Nuts . . . . . . . . . . . 17 N·m (13 ft. l bs.)
Brake Li nes . . . . . . . . . . . . . . 19 N·m (14 ft. l bs.)
Combination Valve
Mounti ng Nuts . . . . . . . . . . . 20 N·m (15 ft. l bs.)
Brake Li nes . . . . . . . . . . . . . . 19 N·m (14 ft. l bs.)
Caliper
Mounti ng Bol ts . . . . . . . . . . . 15 N·m (11 ft. l bs.)
Brake Hose Bol t . . . . . . . . . . . 31 N·m (23 ft. l bs.)
Wheel Cylinder
Mounti ng Bol ts . . . . . . . . . . . . 10 N·m (7 ft. l bs.)
Brake Li ne . . . . . . . . . . . . . . . 16 N·m (12 ft. l bs.)
Parking Brake
Lever Bol ts . . . . . . . . . . . . . . . 12 N·m (9 ft. l bs.)
Lever Bracket Bol ts . . . . . . . . . 12 N·m (9 ft. l bs.)
Cabl e Retai ner Nut . . . . . . . 1.5 N·m (14 i n. l bs.)
SPECIAL TOOLS
BASE BRAKES
Installer Caliper Dust Boot C-4842
Handle C-4171
Adaptor Cap Pressure Bleeder 6921
5 - 32 BRAKES TJ
SPECIFICATIONS (Continued)
ANTILOCK BRAKES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . 33
CONTROLLER ANTILOCK BRAKES. . . . . . . . . . . 33
HYDRAULIC CONTROL UNIT. . . . . . . . . . . . . . . . 34
WHEEL SPEED SENSORS AND TONE WHEEL . . 35
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 35
G-SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . . . . . 36
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . . . 36
REMOVAL AND INSTALLATION
CONTROLLER ANTILOCK BRAKES. . . . . . . . . . . 36
HYDRAULIC CONTROL UNIT. . . . . . . . . . . . . . . . 36
FRONT WHEEL SENSOR. . . . . . . . . . . . . . . . . . . 37
REAR WHEEL SPEED SENSOR . . . . . . . . . . . . . 38
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 39
G-SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIFICATIONS
T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION AND OPERATION
ANTILOCK BRAKE SYSTEM
DESCRIPTION
The purpose of the anti l ock system i s to prevent
wheel l ockup duri ng peri ods of hi gh wheel sl i p. Pre-
venti ng l ockup hel ps mai ntai n vehi cl e braki ng acti on
and steeri ng control .
The anti l ock CAB acti vates the system whenever
sensor si gnal s i ndi cate peri ods of hi gh wheel sl i p.
Hi gh wheel sl i p can be descri bed as the poi nt where
wheel rotati on begi ns approachi ng 20 to 30 percent of
actual vehi cl e speed duri ng braki ng. Peri ods of hi gh
wheel sl i p occur when brake stops i nvol ve hi gh pedal
pressure and rate of vehi cl e decel erati on.
Battery vol tage i s suppl i ed to the CAB i gni ti on ter-
mi nal when the i gni ti on swi tch i s turned to Run posi -
ti on. The CAB performs a system i ni ti al i zati on
procedure at thi s poi nt. I ni ti al i zati on consi sts of a
stati c and dynami c sel f check of system el ectri cal
components.
The stati c check occurs after the i gni ti on swi tch i s
turned to Run posi ti on. The dynami c check occurs
when vehi cl e road speed reaches approxi matel y 30
kph (18 mph). Duri ng the dynami c check, the CAB
bri efl y cycl es the pump and sol enoi ds to veri fy oper-
ati on.
I f an ABS component exhi bi ts a faul t duri ng i ni -
ti al i zati on, the CAB i l l umi nates the amber warni ng
l i ght and regi sters a faul t code i n the mi croprocessor
memory.
OPERATION
Duri ng normal braki ng, the master cyl i nder, power
booster and wheel brake uni ts al l functi on as they
woul d i n a vehi cl e wi thout ABS. The HCU compo-
nents are not acti vated.
Duri ng anti l ock braki ng fl ui d pressure i s modu-
l ated accordi ng to wheel speed, degree of sl i p and
rate of decel erati on. A sensor at each wheel converts
wheel speed i nto el ectri cal si gnal s. These si gnal s are
transmi tted to the CAB for processi ng and determi -
nati on of wheel sl i p and decel erati on rate.
The ABS system has three fl ui d pressure control
channel s. The front brakes are control l ed separatel y
and the rear brakes i n tandem. A speed sensor i nput
si gnal i ndi cati ng a hi gh sl i p condi ti on acti vates the
CAB anti l ock program. Two sol enoi d val ves are used
i n each anti l ock control channel . The val ves are al l
l ocated wi thi n the HCU val ve body and work i n pai rs
to ei ther i ncrease, hol d, or decrease appl y pressure as
needed i n the i ndi vi dual control channel s. The sol e-
noi d val ves are not stati c duri ng anti l ock braki ng.
They are cycl ed conti nuousl y to modul ate pressure.
Sol enoi d cycl e ti me i n anti l ock mode can be mea-
sured i n mi l l i seconds.
CONTROLLER ANTILOCK BRAKES
DESCRIPTION
The CAB operates the ABS system (Fi g. 1) and i s
separate from other vehi cl e el ectri cal ci rcui ts. The
CAB i s l ocated under the i nstrument panel to the
ri ght si de of the steeri ng col umn. I t i s mounted to
bracket wi th one bol t. The bracket i s mounted to the
front upper cowl panel .
OPERATION
The CAB vol tage source i s through the i gni ti on
swi tch i n the RUN posi ti on. The CAB contai ns dual
mi croprocessors. A l ogi c bl ock i n each mi croprocessor
recei ves i denti cal sensor si gnal s. These si gnal s are
TJ BRAKES 5 - 33
processed and compared si mul taneousl y. The CAB
contai ns a sel f check program that i l l umi nates the
ABS warni ng l i ght when a system faul t i s detected.
Faul ts are stored i n a di agnosti c program memory
and are accessi bl e wi th the DRB scan tool . ABS
faul ts remai n i n memory unti l cl eared, or unti l after
the vehi cl e i s started approxi matel y 50 ti mes. Stored
faul ts are not erased i f the battery i s di sconnected.
HYDRAULIC CONTROL UNIT
DESCRIPTION
The hydraul i c control uni t (HCU) consi sts of a
val ve body, pump body, accumul ators, pump motor,
and wi re harnesses (Fi g. 2). The pump, motor, and
accumul ators are combi ned i nto an assembl y
attached to the val ve body.
OPERATION
The HCU accumul ators store the extra fl ui d
rel eased to the system for ABS mode operati on. The
pump provi des the fl ui d vol ume needed and i s oper-
ated by a DC type motor. The motor i s control l ed by
the CAB.
The val ve body contai ns the sol enoi d val ves. The
val ves modul ate brake pressure duri ng anti l ock brak-
i ng and are control l ed by the CAB.
The HCU provi des three channel pressure control
to the front and rear brakes. One channel control s
the rear wheel brakes i n tandem. The two remai ni ng
channel s control the front wheel brakes i ndi vi dual l y.
Duri ng anti l ock braki ng, the sol enoi d val ves are
opened and cl osed as needed. The val ves are not
stati c. They are cycl ed rapi dl y and conti nuousl y to
modul ate pressure and control wheel sl i p and decel -
erati on.
Duri ng normal braki ng, the HCU sol enoi d val ves
and pump are not acti vated. The master cyl i nder and
power booster operate the same as a vehi cl e wi thout
an ABS brake system.
Duri ng anti l ock braki ng, sol enoi d val ve pressure
modul ati on occurs i n three stages, pressure i ncrease,
pressure hol d, and pressure decrease. The val ves are
al l contai ned i n the val ve body porti on of the HCU.
PRESSURE DECREASE
The outl et val ve i s opened and the i nl et val ve i s
cl osed duri ng the pressure decrease cycl e.
A pressure decrease cycl e i s i ni ti ated when speed
sensor si gnal s i ndi cate hi gh wheel sl i p at one or
more wheel s. At thi s poi nt, the CAB opens the outl et
val ve, whi ch al so opens the return ci rcui t to the accu-
mul ators. Fl ui d pressure i s al l owed to bl eed off
(decrease) as needed to prevent wheel l ock.
Once the peri od of hi gh wheel sl i p has ended, the
CAB cl oses the outl et val ve and begi ns a pressure
i ncrease or hol d cycl e as needed.
PRESSURE HOLD
Both sol enoi d val ves are cl osed i n the pressure
hol d cycl e. Fl ui d appl y pressure i n the control chan-
nel i s mai ntai ned at a constant rate. The CAB mai n-
tai ns the hol d cycl e unti l sensor i nputs i ndi cate a
pressure change i s necessary.
PRESSURE INCREASE
The i nl et val ve i s open and the outl et val ve i s
cl osed duri ng the pressure i ncrease cycl e. The pres-
sure i ncrease cycl e i s used to counteract unequal
wheel speeds. Thi s cycl e control s re-appl i cati on of
fl ui d appl y pressure due to changi ng road surfaces or
wheel speed.
Fig. 1 Controller Antilock Brakes
1 – CAB
2 – MOUNTING HOLE
Fig. 2 Hydraulic Controller Unit
1 – SOLENOID BODY
2 – VALVE BODY
3 – PUMP MOTOR
5 - 34 BRAKES TJ
DESCRIPTION AND OPERATION (Continued)
WHEEL SPEED SENSORS AND TONE WHEEL
DESCRIPTION
A speed sensor i s used at each wheel . The front
sensors are mounted to the steeri ng knuckl es. The
rear sensors are mounted to the rear brake backi ng
pl ate.
OPERATION
The sensors convert wheel speed i nto a smal l AC
el ectri cal si gnal . Thi s si gnal i s transmi tted to the
CAB. The CAB convert the AC si gnal i nto a di gi tal
si gnal for each wheel . Thi s vol tage i s generated by
magneti c i nducti on when a tone wheel passes by the
stati onary magneti c of the wheel speed sensor.
A gear type tone ri ng serves as the tri gger mecha-
ni sm for each sensor. The tone ri ngs are mounted at
the outboard ends of the front and rear axl e shafts.
Di fferent sensors are used at the front and rear
wheel s (Fi g. 3). The front/rear sensors have the same
el ectri cal val ues but are not i nterchangeabl e. The
sensors have a resi stance between 900 and 1300
ohms.
FRONT SENSOR AIR GAP
Front sensor ai r gap i s fi xed and not adjustabl e.
Onl y rear sensor ai r gap i s adjustabl e.
Al though front ai r gap i s not adjustabl e, i t can be
checked i f di agnosi s i ndi cates thi s i s necessary. Front
ai r gap shoul d be 0.40 to 1.3 mm (0.0157 to 0.051
i n.). I f gap i s i ncorrect, the sensor i s ei ther l oose, or
damaged.
REAR SENSOR AIR GAP
A rear sensor ai r gap adjustment i s onl y needed
when rei nstal l i ng an ori gi nal sensor. Repl acement
sensors have an ai r gap spacer attached to the sensor
pi ckup face. The spacer establ i shes correct ai r gap
when pressed agai nst the tone ri ng duri ng i nstal l a-
ti on. As the tone ri ng rotates, i t peel s the spacer off
the sensor to create the requi red ai r gap. Rear sensor
ai r gap i s 0.28-1.5 mm (0.011-0.059 i n.).
Sensor ai r gap measurement, or adjustment proce-
dures are provi ded i n thi s secti on. Refer to the front,
or rear sensor removal and i nstal l ati on procedures as
requi red.
COMBINATION VALVE
DESCRIPTION
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e and must be
repl aced as an assembl y i f di agnosi s i ndi cates thi s i s
necessary.
OPERATION
PRESSURE DIFFERENTIAL VALVE
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs to the
brake system are made.
PROPORTIONING VALVE
The proporti oni ng val ve i s used to bal ance front-
rear brake acti on at hi gh decel erati ons. The val ve
al l ows normal fl ui d fl ow duri ng moderate braki ng.
The val ve onl y control s fl ui d fl ow duri ng hi gh decel -
erati ons brake stops.
G-SWITCH
DESCRIPTION
The G-swi tch i s l ocated i n front of the consol e/
shi fter mounted to a bracket on the fl oor pan. The
swi tch has di recti onal arrow and must be mounted
wi th the arrow poi nti ng towards the front of the
vehi cl e.
OPERATION
The swi tch (Fi g. 4), provi des an addi ti onal vehi cl e
decel erati on reference duri ng 4-wheel dri ve opera-
ti on. The swi tch i s moni tored by the CAB at al l
Fig. 3 Typical Wheel Speed Sensors
1 – FRONT SENSOR
2 – REAR SENSOR
3 – PICKUP FACE
TJ BRAKES 5 - 35
DESCRIPTION AND OPERATION (Continued)
ti mes. The swi tch reference si gnal i s uti l i zed by the
CAB when al l wheel s are decel erati ng at the same
speed.
ABS WARNING LAMP
DESCRIPTION
The amber ABS warni ng l amp i s l ocated i n the
i nstrument cl uster. The l amp i l l umi nates at start-up
to perform a sel f check. The l amp goes out when the
sel f check program determi nes the system i s operat-
i ng normal .
OPERATION
I f an ABS component exhi bi ts a faul t the CAB wi l l
i l l umi nate the l amp and regi ster a troubl e code i n
the mi croprocessor. The l amp i s control l ed by the
CAB. The l amp i s i l l umi nated when the CAB sends a
ground si gnal to the ABS rel ay. The ABS rel ay then
grounds the l amp ci rcui t and i l l umi nates the l amp.
DIAGNOSIS AND TESTING
ANTILOCK BRAKES
The ABS brake system performs several sel f-tests
every ti me the i gni ti on swi tch i s turned on and the
vehi cl e i s dri ven. The CAB moni tors the systems
i nput and output ci rcui ts to veri fy the system i s oper-
ati ng correctl y. I f the on board di agnosti c system
senses that a ci rcui t i s mal functi oni ng the system
wi l l set a troubl e code i n i ts memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag-
nostic Manual.
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM
ABS system bl eedi ng requi res conventi onal bl eed-
i ng methods pl us use of the DRB scan tool . The pro-
cedure i nvol ves performi ng a base brake bl eedi ng,
fol l owed by use of the scan tool to cycl e and bl eed the
HCU pump and sol enoi ds. A second base brake bl eed-
i ng procedure i s then requi red to remove any ai r
remai ni ng i n the system.
(1) Perform base brake bl eedi ng. Refer to base
brake secti on for procedure.
(2) Connect scan tool to the Data Li nk Connector.
(3) Sel ect ANTI LOCK BRAKES, fol l owed by MI S-
CELLANEOUS, then ABS BRAKES. Fol l ow the
i nstructi ons di spl ayed. When scan tool di spl ays TEST
COMPLETE, di sconnect scan tool and proceed.
(4) Perform base brake bl eedi ng a second ti me.
Refer to base brake secti on for procedure.
(5) Top off master cyl i nder fl ui d l evel and veri fy
proper brake operati on before movi ng vehi cl e.
REMOVAL AND INSTALLATION
CONTROLLER ANTILOCK BRAKES
REMOVAL
(1) Remove negati ve battery termi nal .
(2) Remove the harness connector from the CAB
l ocated underneath the i nstrument panel (Fi g. 5).
(3) Remove mounti ng bol t and remove the CAB.
INSTALLATION
(1) I nstal l the control l er and i nstal l the mounti ng
bol t.
(2) Ti ghten the mounti ng bol t to 7-9 N·m (60-80 i n.
l bs.).
(3) Pl ug i n the harness connector i nto the control -
l er.
(4) I nstal l negati ve battery cabl e.
HYDRAULIC CONTROL UNIT
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery ter-
mi nal .
(2) Di sconnect the HCU harness connectors.
Fig. 4 G-Switch
1 – SWITCH PART NUMBER
2 – ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
5 - 36 BRAKES TJ
DESCRIPTION AND OPERATION (Continued)
(3) Remove al l the brake l i nes from the HCU (Fi g.
6).
(4) Remove HCU mounti ng bol ts and remove HCU
(Fi g. 7).
(5) Remove bol ts from mount and remove mount
from HCU.
INSTALLATION
(1) I nstal l mounti ng bracket on HCU and ti ghten
to 6.5 N·m (57 i n. l bs.).
(2) I nstal l HCU and ti ghten mounti ng bol ts to 9-13
N·m (80-115 i n. l bs.).
(3) Al i gn and start brake l i ne fi tti ngs by hand to
avoi d cross threadi ng.
(4) Ti ghten brake l i nes to 15-18 N·m (130-160 i n.
l bs.).
(5) Connect HCU harness.
(6) Connect negati ve battery termi nal .
(7) Bl eed compl ete brake system.
FRONT WHEEL SENSOR
REMOVAL
(1) Rai se vehi cl e and turn wheel outward to access
the sensor.
(2) Di sconnect sensor wi re connector at harness
pl ug.
(3) Remove sensor wi re from mounti ng retai ners.
(4) Cl ean sensor and surroundi ng area wi th shop
towel before removal .
(5) Remove bol t attachi ng sensor to steeri ng
knuckl e and remove sensor (Fi g. 8).
INSTALLATION
(1) I f original sensor wi l l be i nstal l ed, wi pe al l
traces of ol d spacer materi al off sensor pi ckup face.
Use a dry shop towel for thi s purpose.
(2) Appl y Mopar Lock N’ Seal or Locti te ௡ 242 on
bol t that secures sensor i n steeri ng knuckl e. Use new
sensor bol t i f ori gi nal bol t i s worn or damaged.
(3) Posi ti on sensor on steeri ng knuckl e. Seat sen-
sor l ocati ng tab i n hol e i n knuckl e and i nstal l sensor
attachi ng bol t fi nger ti ght.
(4) Ti ghten sensor attachi ng bol t to 4-6 N·m (34-50
i n. l bs.).
(5) I f ori gi nal sensor has been i nstal l ed, check sen-
sor ai r gap. Ai r gap shoul d be 0.40 to 1.3 mm (0.0157
to 0.051 i n.). I f gap i s i ncorrect, sensor i s ei ther l oose,
or damaged.
Fig. 5 Controller Antilock Brakes
1 – CAB
2 – MOUNTING BOLT
Fig. 6 HCU Brake Lines
1 – MASTER CYLINDER
2 – COMBINATION VALVE
3 – HCU
Fig. 7 HCU Mount
1 – HCU
2 – HCU MOUNT
TJ BRAKES 5 - 37
REMOVAL AND INSTALLATION (Continued)
(6) Route sensor wi re and i nstal l i nto mounti ng
retai ners.
(7) Connect sensor wi re to harness.
REAR WHEEL SPEED SENSOR
REMOVAL
(1) Di sconnect sensors at rear harness connectors.
(2) Remove wheel and ti re assembl y.
(3) Remove brake drum.
(4) Remove cl i ps securi ng sensor wi res to brake
l i nes, rear axl e and, brake hose.
(5) Unseat sensor wi re support pl ate grommet.
(6) Remove bol t attachi ng sensor to bracket (Fi g.
9) and remove sensor.
INSTALLATION
(1) I f original sensor i s bei ng i nstal l ed, remove
any remai ni ng pi eces of cardboard spacer from sen-
sor pi ckup face. Use dry shop towel onl y to remove
ol d spacer materi al .
(2) I nsert sensor wi re through support pl ate hol e.
Then seat sensor grommet i n support pl ate.
(3) Appl y Mopar Lock N’ Seal or Locti te ௡ 242 to
ori gi nal sensor bol t. Use new bol t i f ori gi nal i s worn
or damaged.
(4) I nstal l sensor bol t fi nger ti ght onl y at thi s
ti me.
(5) I f original rear sensor was i nstal l ed, adjust
sensor ai r gap to 0.28-1.5 mm (0.011-0.059 i n.). Use
feel er gauge to measure ai r gap (Fi g. 10). Ti ghten
sensor bol t to 12-14 N·m (106-124 i n. l bs.).
(6) I f new sensor was i nstal l ed, push cardboard
spacer on sensor face agai nst tone ri ng (Fi g. 11).
Then ti ghten sensor bol t to 12-14 N·m (106-124 i n.
l bs.). Correct ai r gap wi l l be establ i shed as tone ri ng
rotates and peel s spacer off sensor face.
(7) Secure the rear sensor wi res to the retai ner
cl i ps. Veri fy that wi re i s cl ear of rotati ng components.
(8) Connect sensor wi re to harness connector.
(9) I nstal l brake drum and wheel and ti re assem-
bl y.
(10) Lower vehi cl e.
(11) Connect sensor wi re to harness connector.
Fig. 8 Front Wheel Speed Sensor
1 – WHEEL SPEED SENSOR PIGTAIL
2 – STEERING KNUCKLE
3 – TONE WHEEL
4 – FRONT WHEEL SPEED SENSOR
Fig. 9 Wheel Speed Sensor
1 – TONE WHEEL
2 – WHEEL SPEED SENSOR
Fig. 10 Setting Air Gap On Original Rear Sensor
1 – WHEEL SPEED SENSOR
2 – BRASS FEELER GAUGE
3 – TONE RING
5 - 38 BRAKES TJ
REMOVAL AND INSTALLATION (Continued)
COMBINATION VALVE
REMOVAL
(1) Remove brake l i nes that connect master cyl i n-
der to combi nati on val ve (Fi g. 12).
(2) Di sconnect brake l i nes that connect combi na-
ti on val ve to HCU.
(3) Di sconnect wi re from combi nati on val ve swi tch
termi nal . Be careful when separati ng wi re connector
as l ock tabs are easi l y damaged i f not ful l y di sen-
gaged.
(4) Remove nuts attachi ng combi nati on val ve
bracket to booster studs and val ve bracket off booster
studs (Fi g. 13).
INSTALLATION
(1) Posi ti on val ve bracket on booster studs and
ti ghten bracket attachi ng nuts to 17 N·m (13 ft. l bs.).
(2) Al i gn and start brake l i ne fi tti ngs i n combi na-
ti on val ve, master cyl i nder and HCU by hand to
avoi d cross threadi ng.
(3) Ti ghten brake l i ne fi tti ngs at combi nati on val ve
to 21 N·m (15 ft. l bs.).
(4) Ti ghten brake l i ne fi tti ngs at master cyl i nder
to 15 N·m (11 ft. l bs.).
(5) Ti ghten brake l i ne fi tti ngs at HCU to 16 N·m
(12 ft. l bs.).
(6) Connect wi re to di fferenti al pressure swi tch i n
combi nati on val ve.
(7) Bl eed base brake system.
G-SWITCH
REMOVAL
(1) From the dri vers si de l i ft carpet back i n front
of the consol e/shi fter.
(2) Di sconnect harness for swi tch.
(3) Remove mounti ng bol ts and remove swi tch
(Fi g. 14).
INSTALLATION
CAUTION: The mercury switch (inside the
G-switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig.
15).
(1) Posi ti on swi tch on mounti ng bracket.
(2) I nstal l mounti ng bol ts and ti ghten to 4-5 N·m
(35-45 i n. l bs.)
Fig. 11 New Rear Sensor
1 – REAR SENSOR
2 – AIR GAP SPACER ATTACHED TO SENSOR FACE
Fig. 12 Combination Valve Brake Lines
1 – MASTER CYLINDER
2 – COMBINATION VALVE
3 – HCU
Fig. 13 Combination Valve Bracket
1 – MASTER CYLINDER
2 – COMBINATION VALVE BRACKET
TJ BRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)
(3) Connect harness to swi tch.
(4) Pl ace carpet back i nto posi ti on.
SPECIFICATIONS
T0RQUE CHART
DESCRIPTION TORQUE
G-Sensor
Sensor Bol t . . . . . . . . . . . 4-5 N·m (35-45 i n. l bs.)
Bracket Bol t . . . . . . . . . . . . . . . . . . . . . 8-13 N·m
(75-115 i n. l bs.)
Hydraulic Control Unit
Bracket to HCU Bol ts . . . . . 6.5 N·m (57 i n. l bs.)
Body Bracket Bol ts . . . . . . . . . . . . . . . 16-24 N·m
(142-212 i n. l bs.)
HCU to Body Bracket Bol ts . . . . . . . . . 9-13 N·m
(80-115 i n. l bs.)
Brake Li nes . . . . . . . 15-18 N·m (130-160 i n. l bs.)
Controller Anitlock Brakes
Mounti ng Bol t . . . . . . . . . 7-9 N·m (60-80 i n. l bs.)
Wheel Speed Sensors
Front Mounti ng Bol t . . . . . . . . 4-6 (34-50 i n. l bs.)
Rear Mounti ng Bol t . . . . . . . . . . . . . . 12-14 N·m
(106-124 i n. l bs.)
Fig. 14 G-Switch
1 – ACCELERATION SWITCH
2 – MOUNTING BRACKET
Fig. 15 G-Switch Position Indicator
1 – SWITCH PART NUMBER
2 – ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
5 - 40 BRAKES TJ
REMOVAL AND INSTALLATION (Continued)
CLUTCH
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLUTCH DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLUTCH PRESSURE PLATE. . . . . . . . . . . . . . . . . 2
CLUTCH RELEASE BEARING . . . . . . . . . . . . . . . . 3
HYDRAULIC CLUTCH LINKAGE . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION METHODS AND PARTS
USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLUTCH DIAGNOSTIC INFORMATION. . . . . . . . . 4
CLUTCH CONTAMINATION. . . . . . . . . . . . . . . . . . 6
IMPROPER CLUTCH RELEASE OR
ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLUTCH MISALIGNMENT. . . . . . . . . . . . . . . . . . . 6
CLUTCH HOUSING MISALIGNMENT . . . . . . . . . . 6
CLUTCH FLYWHEEL RUNOUT . . . . . . . . . . . . . . . 6
CLUTCH COVER AND DISC RUNOUT . . . . . . . . . 7
CLUTCH DIAGNOSIS CHARTS . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
CLUTCH COMPONENT LUBRICATION . . . . . . . . . 9
CLUTCH LINKAGE FLUID. . . . . . . . . . . . . . . . . . . 9
CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 10
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL AND INSTALLATION
CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . 11
RELEASE BEARING . . . . . . . . . . . . . . . . . . . . . . 12
PILOT BEARING. . . . . . . . . . . . . . . . . . . . . . . . . 12
CLUTCH HOUSING. . . . . . . . . . . . . . . . . . . . . . . 12
CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . . 13
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION AND OPERATION
CLUTCH
DESCRIPTION
The cl utch mechani sm consi sts of a fl ywheel , a si n-
gl e, dry-type di sc, and a di aphragm styl e cl utch cover
(Fi g. 1). A hydraul i c l i nkage i s used to operate the
cl utch rel ease beari ng and fork. The fl ywheel i s
bol ted to the rear fl ange of the crankshaft. The
cl utch pressure pl ate i s bol ted to the fl ywheel wi th
the cl utch di sc l ocated between these two compo-
nents. The cl utch system provi des the mechani cal ,
but sti l l easi l y detachabl e, l i nk between the engi ne
and the transmi ssi on. The system i s desi gned to
ensure that the ful l torque output of the engi ne i s
transfered to the transmi ssi on whi l e i sol ati ng the
transmi ssi on from the engi ne fi ri ng pul ses to mi ni -
mi ze concerns such as gear rattl e.
OPERATION
Leverage, cl ampi ng force, and fri cti on are what
make the cl utch work. The di sc serves as the fri cti on
el ement and a di aphragm spri ng and pressure pl ate
provi de the cl ampi ng force. The cl utch pedal , hydrau-
l i c l i nkage, rel ease l ever and beari ng provi de the
l everage.
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal . When the cl utch pedal i s
depressed, the sl ave cyl i nder i s operated by the
Fig. 1 Engine Powerflow
TJ CLUTCH 6 - 1
cl utch master cyl i nder mounted on the dash panel .
The rel ease fork i s actuated by the hydraul i c sl ave
cyl i nder mounted on the transmi ssi on housi ng. The
rel ease beari ng i s operated by a rel ease fork pi voti ng
on a bal l stud mounted i n the transmi ssi on housi ng.
The rel ease beari ng then depresses the pressure
pl ate spri ng fi ngers, thereby rel easi ng pressure on
the cl utch di sc and al l owi ng the engi ne crankshaft to
spi n i ndependentl y of the transmi ssi on i nput shaft
(Fi g. 2).
FLYWHEEL
DESCRIPTION
The fl ywheel (Fi g. 3) i s a heavy pl ate bol ted to the
rear of the crankshaft. The fl ywheel i ncorporates the
ri ng gear around the outer ci rcumference to mesh
wi th the starter to permi t engi ne cranki ng. The rear
face of the fl ywheel serves as the dri vi ng member to
the cl utch di sc.
OPERATION
The fl ywheel serves to dampen the engi ne fi ri ng
pul ses. The heavy wei ght of the fl ywheel rel ati ve to
the rotati ng mass of the engi ne components serves to
stabi l i ze the fl ow of power to the remai nder of the
dri vetrai n. The crankshaft has the tendency to
attempt to speed up and sl ow down i n response to
the cyl i nder fi ri ng pul ses. The fl ywheel dampens
these i mpul ses by absorbi ng energy when the crank-
shaft speeds and rel easi ng the energy back i nto the
system when the crankshaft sl ows down.
CLUTCH DISC
DESCRIPTION
The cl utch di sc fri cti on materi al i s ri veted to the di sc
hub (Fi g. 4). The hub bore i s spl i ned for i nstal l ati on on
the transmi ssi on i nput shaft. The cl utch di sc has cush-
i on spri ngs i n the di sc hub to dampen di sc vi brati ons
duri ng appl i cati on and rel ease of the cl utch.
OPERATION
The cl utch di sc i s hel d onto the surface of the fl y-
wheel by the force exerted by the pressure pl ate’s
di aphragm spri ng. The fri cti on materi al of the cl utch
di sc then transfers the engi ne torque from the fl y-
wheel and pressure pl ate to the i nput shaft of the
transmi ssi on.
CLUTCH PRESSURE PLATE
DESCRIPTION
The cl utch pressure pl ate assembl y i s a di aphragm
type wi th a one-pi ece spri ng and mul ti pl e rel ease fi n-
gers (Fi g. 5). The pressure pl ate rel ease fi ngers are
preset duri ng manufacture and are not adjustabl e.
The assembl y al so contai ns the cover, pressure pl ate,
and ful crum components.
OPERATION
The cl utch pressure pl ate assembl y cl amps the
cl utch di sc agai nst the fl ywheel . When the rel ease
Fig. 2 Clutch Operation
1 – FLYWHEEL
2 – PRESSURE PLATE FINGERS
3 – PIVOT POINT
4 – RELEASE BEARING PUSHED IN
5 – CLUTCH DISC ENGAGED
6 – CLUTCH DISC ENGAGED
7 – RELEASE BEARING
Fig. 3 Flywheel
1 – CRANKSHAFT
2 – RING GEAR
3 – FLYWHEEL
6 - 2 CLUTCH TJ
DESCRIPTION AND OPERATION (Continued)
beari ng i s depressed by the shi ft fork, the pressure
exerted on the cl utch di sc by the pressure pl ate
spri ng i s decreased. As addi ti onal force i s appl i ed,
the beari ng presses the di aphragm spri ng fi ngers
i nward on the ful crums. Thi s acti on moves the pres-
sure pl ate rearward rel i evi ng cl amp force on the di sc.
The cl utch di sc i s di sengaged and freewheel i ng at
thi s poi nt.
CLUTCH RELEASE BEARING
DESCRIPTION
A conventi onal rel ease beari ng (Fi g. 6) i s used to
engage and di sengage the cl utch pressure pl ate
assembl y. The cl utch rel ease beari ng i s mounted on
the transmi ssi on front beari ng retai ner. The beari ng
i s attached to the rel ease fork, whi ch moves the bear-
i ng i nto contact wi th the cl utch cover di aphragm
spri ng.
OPERATION
The rel ease beari ng i s operated by a rel ease fork i n
the cl utch housi ng. Sl ave cyl i nder force causes the
rel ease l ever to move the rel ease beari ng i nto contact
wi th the di aphragm spri ng. As addi ti onal force i s
appl i ed, the beari ng presses the di aphragm spri ng
fi ngers i nward on the ful crums. Thi s acti on moves
the pressure pl ate rearward rel i evi ng cl amp force on
the di sc. Rel easi ng pedal pressure removes cl utch
hydraul i c pressure. The rel ease beari ng then moves
away from the di aphragm spri ng whi ch al l ows the
pressure pl ate to exert cl ampi ng force on the cl utch
di sc.
HYDRAULIC CLUTCH LINKAGE
DESCRIPTION
The hydraul i c l i nkage consi sts of a cl utch master
cyl i nder wi th i ntegral reservoi r, a cl utch sl ave cyl i n-
der and an i nterconnecti ng fl ui d l i ne (Fi g. 7).
Fig. 4 Clutch Disc-Typical
1 – FACING MATERIAL
2 – DAMPER SPRINGS
3 – HUB
Fig. 5 Clutch Pressure Plate-Typical
1 – COVER
2 – RELEASE FINGERS
3 – PRESSURE PLATE
Fig. 6 Clutch Release Bearing
1 – RELEASE BEARING
2 – RELEASE FORK
TJ CLUTCH 6 - 3
DESCRIPTION AND OPERATION (Continued)
The cl utch master cyl i nder push rod i s connected to
the cl utch pedal . The sl ave cyl i nder push rod i s con-
nected to the cl utch rel ease fork. The master cyl i nder i s
mounted on the dri ver si de of the dash panel adjacent
to the brake master cyl i nder and booster assembl y.
OPERATION
The cl utch l i nkage uses hydraul i c pressure to oper-
ate the cl utch. Depressi ng the cl utch pedal devel ops
fl ui d pressure i n the cl utch master cyl i nder. Thi s
pressure i s transmi tted to the sl ave cyl i nder through
a connecti ng l i ne. I n turn, the sl ave cyl i nder operates
the cl utch rel ease l ever.
Sl ave cyl i nder force causes the rel ease l ever to
move the rel ease beari ng i nto contact wi th the di a-
phragm spri ng. As addi ti onal force i s appl i ed, the
beari ng presses the di aphragm spri ng fi ngers i nward
on the ful crums. Thi s acti on moves the pressure
pl ate rearward rel i evi ng cl amp force on the di sc.
DIAGNOSIS AND TESTING
SAFETY PRECAUTIONS
WARNING: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS OF THESE FIBERS CAN CAUSE
SERIOUS BODILY HARM. WEAR A RESPIRATOR
DURING SERVICE AND NEVER CLEAN CLUTCH
COMPONENTS WITH COMPRESSED AIR OR WITH
A DRY BRUSH. EITHER CLEAN THE COMPONENTS
WITH A WATER DAMPENED RAGS OR USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
OTHERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
INSTALLATION METHODS AND PARTS USAGE
Di storti on of cl utch components duri ng i nstal l ati on
and the use of non-standard components are common
causes of cl utch mal functi on.
I mproper cl utch cover bol t ti ghteni ng can di stort
the cover. The usual resul t i s cl utch grab, chatter
and rapi d wear. Ti ghten the cover bol ts as descri bed
i n Removal and I nstal l ati on secti on.
An i mproperl y seated fl ywheel and/or cl utch hous-
i ng are addi ti onal causes of cl utch fai l ure. I mproper
seati ng wi l l produce mi sal i gnment and addi ti onal
cl utch probl ems.
The use of non-standard or l ow qual i ty parts wi l l
al so l ead to probl ems and wear. Use recommended
factory qual i ty parts to avoi d comebacks.
A cocked pi l ot beari ng i s another cause of cl utch
noi se, drag, hard shi fti ng, and rapi d beari ng wear.
Al ways use an al i gnment tool to i nstal l a new bear-
i ng. Thi s practi ce hel ps avoi d cocki ng the beari ng
duri ng i nstal l ati on.
CLUTCH DIAGNOSTIC INFORMATION
Unl ess the cause of a cl utch probl em i s obvi ous,
accurate probl em di agnosi s wi l l usual l y requi re a
road test to confi rm a probl em. Component i nspecti on
(Fi g. 8) wi l l then be requi red to determi ne the actual
probl em cause.
Duri ng a road test, dri ve the vehi cl e at normal
speeds. Shi ft the transmi ssi on through al l gear
ranges and observe cl utch acti on. I f chatter, grab,
sl i p, or i mproper rel ease i s experi enced, remove and
i nspect the cl utch components. However, i f the prob-
l em i s noi se or hard shi fti ng, further di agnosi s may
be needed as the transmi ssi on or another dri vel i ne
component may be at faul t. Careful observati on dur-
i ng the test wi l l hel p narrow the probl em area.
Fig. 7 Clutch Master Cylinder
1 – CAP
2 – FILL LINE
3 – CLUTCH MASTER CYLINDER
4 – RESERVOIR
6 - 4 CLUTCH TJ
DESCRIPTION AND OPERATION (Continued)
Fig. 8 Clutch Components And Inspection
TJ CLUTCH 6 - 5
DIAGNOSIS AND TESTING (Continued)
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , water, or cl utch fl ui d on the cl utch
di sc and pressure pl ate surfaces wi l l cause chatter,
sl i p and grab.
Duri ng i nspecti on, note i f any components are con-
tami nated wi th oi l , hydraul i c fl ui d, or water/road
spl ash.
Oi l contami nati on i ndi cates a l eak at ei ther the
rear mai n seal or transmi ssi on i nput shaft. Oi l l eak-
age produces a resi due of oi l on the housi ng i nteri or
and on the cl utch cover and fl ywheel . Heat bui l dup
caused by sl i ppage between the cover, di sc and fl y-
wheel , can someti mes bake the oi l resi due onto the
components. The gl aze-l i ke resi due ranges i n col or
from amber to bl ack.
Road spl ash contami nati on means di rt/water i s
enteri ng the cl utch housi ng due to l oose bol ts, hous-
i ng cracks, or through hydraul i c l i ne openi ngs. Dri v-
i ng through deep water puddl es can force water/road
spl ash i nto the housi ng through such openi ngs.
Cl utch fl ui d l eaks are usual l y from damaged sl ave
cyl i nder push rod seal s. Thi s type of l eak can onl y be
confi rmed by vi sual i nspecti on.
IMPROPER CLUTCH RELEASE OR
ENGAGEMENT
Cl utch rel ease or engagement probl ems are caused
by wear, or damage to one or more cl utch compo-
nents. A vi sual i nspecti on of the rel ease components
wi l l usual l y reveal the probl em part.
Rel ease probl ems can resul t i n hard shi fti ng and
noi se. I tems to l ook for are: l eaks at the cl utch cyl i n-
ders and i nterconnecti ng l i ne; l oose sl ave cyl i nder
bol ts; worn/l oose rel ease fork and pi vot stud; dam-
aged rel ease beari ng; and a worn cl utch di sc, or pres-
sure pl ate.
Normal condensati on i n vehi cl es that are stored or
out of servi ce for l ong peri ods of ti me can generate
enough corrosi on to make the di sc sti ck to the fl y-
wheel , or pressure pl ate. I f thi s condi ti on i s experi -
enced, correcti on onl y requi res that the di sc be
l oosened manual l y through the i nspecti on pl ate open-
i ng.
Engagement probl ems usual l y resul t i n sl i p, chat-
ter/shudder, and noi sy operati on. The pri mary causes
are cl utch di sc contami nati on; cl utch di sc wear; mi s-
al i gnment, or di storti on; fl ywheel damage; or a com-
bi nati on of the foregoi ng. A vi sual i nspecti on i s
requi red to determi ne the part actual l y causi ng the
probl em.
CLUTCH MISALIGNMENT
Cl utch components must be i n proper al i gnment
wi th the crankshaft and transmi ssi on i nput shaft.
Mi sal i gnment caused by excessi ve runout or warpage
of any cl utch component wi l l cause grab, chatter and
i mproper cl utch rel ease.
CLUTCH HOUSING MISALIGNMENT
Cl utch housi ng al i gnment i s i mportant to proper
cl utch operati on. The housi ng mai ntai ns al i gnment
between the crankshaft and transmi ssi on i nput
shaft. Mi sal i gnment can cause cl utch noi se, hard
shi fti ng, i ncompl ete rel ease and chatter. I t can al so
resul t i n premature wear of the pi l ot beari ng, cover
rel ease fi ngers and cl utch di sc. I n severe cases, mi s-
al i gnment can al so cause premature wear of the
transmi ssi on i nput shaft and front beari ng.
Housi ng mi sal i gnment i s general l y caused by
i ncorrect seati ng on the engi ne or transmi ssi on, l oose
housi ng bol ts, mi ssi ng al i gnment dowel s, or housi ng
damage. I nfrequentl y, mi sal i gnment may al so be
caused by housi ng mounti ng surfaces that are not
compl etel y paral l el . Mi sal i gnment can be corrected
wi th shi ms.
CLUTCH FLYWHEEL RUNOUT
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Common causes of runout are:
• heat warpage
• i mproper machi ni ng
• i ncorrect bol t ti ghteni ng
• i mproper seati ng on crankshaft fl ange shoul der
• forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. However,
mi nor fl ywheel scori ng can be cl eaned up by hand
wi th 180 gri t emery, or wi th surface gri ndi ng equi p-
ment. Remove onl y enough materi al to reduce scor-
i ng (approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar௡ Lock And Seal . Ti ghten fl ywheel
bol ts to speci fi ed torque onl y. Overti ghteni ng can di s-
tort the fl ywheel hub causi ng runout.
6 - 6 CLUTCH TJ
DIAGNOSIS AND TESTING (Continued)
CLUTCH COVER AND DISC RUNOUT
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.50
mm (0.020 i n.). Measure runout about 6 mm (1/4 i n.)
from the outer edge of the di sc faci ng. Obtai n
another di sc i f runout i s excessi ve.
Check condi ti on of the cl utch before i nstal l ati on. A
warped cover or di aphragm spri ng wi l l cause grab
and i ncompl ete rel ease or engagement. Be careful
when handl i ng the cover and di sc. I mpact can di stort
the cover, di aphragm spri ng, rel ease fi ngers and the
hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on (and
consequent mi sal i gnment) i s i mproper bol t ti ghten-
i ng.
CLUTCH DIAGNOSIS CHARTS
The cl utch i nspecti on chart (Fi g. 8) outl i nes i tems
to be checked before and duri ng cl utch i nstal l ati on.
Use the chart as a check l i st to hel p avoi d overl ook-
i ng potenti al probl em sources duri ng servi ce opera-
ti ons.
The di agnosi s charts descri be common cl utch prob-
l ems, causes and correcti on. Faul t condi ti ons are
l i sted at the top of each chart. Condi ti ons, causes and
correcti ve acti on are outl i ned i n the i ndi cated col -
umns.
The charts are provi ded as a conveni ent reference
when di agnosi ng faul ty cl utch operati on.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.
3. Replace cover and disc.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
1. Leak at rear main engine seal or
transmission input shaft seal.
1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.
2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.
1. Release bearing sticking or
binding and does not return to the
normal running position.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
1. Rough handling. Impact bent
cover, spring, or disc.
1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.
2. Tighten clutch cover using proper
procedure.
TJ CLUTCH 6 - 7
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Facing on flywheel side of disc torn,
gouged, or worn.
1. Flywheel surface scored or
nicked.
2. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.
2. Inspect components and
correct/replace as necessary.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
6 - 8 CLUTCH TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
Clutch master or slave cylinder
plunger dragging andør binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy. 1. Release bearing defective or
damaged.
1. Replace release bearing.
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.
2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.
SERVICE PROCEDURES
CLUTCH COMPONENT LUBRICATION
Proper cl utch component l ubri cati on i s i mportant
to sati sfactory operati on. Usi ng the correct l ubri cant
and not over l ubri cati ng are equal l y i mportant. Appl y
recommended l ubri cant spari ngl y to avoi d di sc and
pressure pl ate contami nati on.
Cl utch and transmi ssi on components requi ri ng
l ubri cati on are:
• Pi l ot beari ng.
• Rel ease l ever pi vot bal l stud.
• Rel ease l ever contact surfaces.
• Rel ease beari ng bore.
• Cl utch di sc hub spl i nes.
• Cl utch pedal pi vot shaft bore.
• Cl utch pedal bushi ngs.
• I nput shaft spl i nes.
• I nput shaft pi l ot hub.
• Transmi ssi on front beari ng retai ner sl i de sur-
face.
NOTE: Never apply grease to any part of the clutch
cover, or disc.
RECOMMENDED LUBRICANTS
Use Mopar௡ mul ti -purpose grease for the cl utch
pedal bushi ngs and pi vot shaft. Use Mopar௡ hi gh
temperature grease (or equi val ent) for al l other l ubri -
cati on requi rements. Appl y recommended amounts
and do not over l ubri cate.
CLUTCH LINKAGE FLUID
I f i nspecti on or di agnosi s i ndi cates addi ti onal fl ui d
may be needed, use Mopar௡ brake fl ui d, or an equi v-
al ent meeti ng standards SAE J1703 and DOT 3. Do
not use any other type of fl ui d.
TJ CLUTCH 6 - 9
DIAGNOSIS AND TESTING (Continued)
CLUTCH FLUID LEVEL
The cl utch fl ui d reservoi r, master cyl i nder, sl ave
cyl i nder and fl ui d l i nes are pre-fi l l ed wi th fl ui d at
the factory duri ng assembl y operati ons.
The hydraul i c system shoul d not requi re addi ti onal
fl ui d under normal ci rcumstances. The reservoir
fluid level will actually increase as normal
clutch wear occurs. Avoid overfilling, or remov-
ing fluid from the reservoir.
Cl utch fl ui d l evel i s checked at the master cyl i nder
reservoi r (Fi g. 9). An i ndi cator ri ng i s provi ded on the
outsi de of the reservoi r. Wi th the cap and di aphragm
removed, fl ui d l evel shoul d not be above i ndi cator
ri ng.
To avoi d contami nati ng the hydraul i c fl ui d duri ng
i nspecti on, wi pe reservoi r and cover cl ean before
removi ng the cap.
FLYWHEEL
I nspect the fl ywheel whenever the cl utch di sc,
cover and housi ng are removed for servi ce. Check
condi ti on of the fl ywheel face, hub, ri ng gear teeth,
and fl ywheel bol ts.
Mi nor scratches, burrs, or gl azi ng on the fl ywheel
face can be reduced wi th 180 gri t emery cl oth. How-
ever, the fl ywheel shoul d be repl aced i f the di sc con-
tact surface i s severel y scored, heat checked, cracked,
or obvi ousl y worn.
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel surface i s manufactured wi th a uni que contour
that woul d be negated by machi ni ng. However,
cl eanup of mi nor fl ywheel scori ng can be performed
by hand wi th 180 gri t emery, or wi th surface gri nd-
i ng equi pment. Repl ace the fl ywheel i f scori ng i s
deeper than 0.0762 mm (0.003 i n.).
Heavy stock removal by gri ndi ng i s not recom-
mended. Excessi ve stock removal can resul t i n fl y-
wheel cracki ng or warpage after i nstal l ati on. I t can
al so weaken the fl ywheel and i nterfere wi th proper
cl utch rel ease.
Check fl ywheel runout i f mi sal i gnment i s sus-
pected. Runout shoul d not exceed 0.08 mm (0.003
i n.). Measure runout at the outer edge of the fl y-
wheel face wi th a di al i ndi cator. Mount the di al i ndi -
cator on a stud i nstal l ed i n pl ace of one of the cl utch
housi ng attachi ng bol ts.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout.
Check condi ti on of the fl ywheel hub and attachi ng
bol ts. Repl ace the fl ywheel i f the hub exhi bi ts cracks
i n the area of the attachi ng bol t hol es.
I nstal l new attachi ng bol ts whenever the fl ywheel
i s repl aced and use Mopar௡ Lock N’ Seal , or Locti te
242 on the repl acement bol t threads.
Recommended fl ywheel bol t torques are:
• 142 N·m (105 ft. l bs.) for 6-cyl i nder fl ywheel s
• 68 N·m (50 ft. l bs.) pl us an addi ti onal turn of
60° for 4-cyl i nder fl ywheel s
I nspect the teeth on the starter ri ng gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom-
mended and preferred method of repair.
I n cases where a new fl ywheel i s not readi l y avai l -
abl e, a repl acement ri ng gear can be i nstal l ed. How-
ever, the fol l owi ng precauti ons must be observed to
avoi d damagi ng the fl ywheel and repl acement gear.
(1) Mark posi ti on of the ol d gear for al i gnment ref-
erence on the fl ywheel . Use a scri ber for thi s pur-
pose.
(2) Wear protecti ve goggl es or approved safety
gl asses. Al so wear heat resi stent gl oves when han-
dl i ng a heated ri ng gear.
(3) Remove the ol d gear by cutti ng most of the way
through i t (at one poi nt) wi th an abrasi ve cut-off
wheel . Then compl ete removal wi th a col d chi sel or
punch.
(4) The ri ng gear i s a shri nk fi t on the fl ywheel .
Thi s means the gear must be expanded by heati ng i n
order to i nstal l i t. The method of heating and
expanding the gear is extremely important.
Every surface of the gear must be heated at the same
ti me to produce uni form expansi on. An oven or si mi -
l ar encl osed heati ng devi ce must be used. Tempera-
ture requi red for uni form expansi on i s approxi matel y
375° F.
Fig. 9 Clutch Master Cylinder Reservoir And Cap
1 – CAP
2 – FILL LINE
3 – CLUTCH MASTER CYLINDER
4 – RESERVOIR
6 - 10 CLUTCH TJ
SERVICE PROCEDURES (Continued)
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
(5) The heated gear must be i nstal l ed evenl y to
avoi d mi sal i gnment or di storti on. A shop press and
sui tabl e press pl ates shoul d be used to i nstal l the
gear i f at al l possi bl e.
(6) Be sure to wear eye and hand protecti on. Heat
resi stent gl oves and safety goggl es are needed for
personal safety. Al so use metal tongs, vi se gri ps, or
si mi l ar tool s to posi ti on the gear as necessary for
i nstal l ati on.
(7) Al l ow the fl ywheel and ri ng gear to cool down
before i nstal l ati on. Set the assembl y on a workbench
and l et i t cool i n normal shop ai r.
CAUTION: Do not use water, or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.
REMOVAL AND INSTALLATION
CLUTCH COVER AND DISC
REMOVAL
(1) Remove transmi ssi on. Refer to procedures i n
Group 21.
(2) I f ori gi nal cl utch cover wi l l be rei nstal l ed, mark
posi ti on of cover on fl ywheel for assembl y reference.
Use pai nt or a scri ber for thi s purpose.
(3) I f cl utch cover i s to be repl aced, cover bol ts can
be removed i n any sequence. However, i f ori gi nal
cover wi l l be rei nstal l ed, l oosen cover bol ts evenl y
and i n rotati on to rel i eve spri ng tensi on equal l y. Thi s
i s necessary to avoi d warpi ng cover.
(4) Remove cover bol ts and remove cover and di sc
(Fi g. 10).
INSTALLATION
(1) Li ghtl y scuff sand fl ywheel face wi th 180 gri t
emery cl oth. Then cl ean surface wi th a wax and
grease remover.
(2) Lubri cate pi l ot beari ng wi th Mopar hi gh tem-
perature beari ng grease.
(3) Check runout and free operati on of new cl utch
di sc as fol l ows:
(a) Sl i de di sc onto transmi ssi on i nput shaft
spl i nes. Di sc shoul d sl i de freel y on spl i nes.
(b) Leave di sc on shaft and check face runout
wi th di al i ndi cator. Check runout at di sc hub and
about 6 mm (1/4 i n.) from outer edge of faci ng.
(c) Face runout shoul d not exceed 0.5 mm (0.020
i n.). Obtai n another cl utch di sc i f runout exceeds
thi s l i mi t.
(4) Posi ti on cl utch di sc on fl ywheel . Be sure si de of
di sc marked fl ywheel si de i s posi ti oned agai nst fl y-
wheel (Fi g. 10). I f di sc i s not marked, be sure fl at
si de of di sc hub i s toward fl ywheel .
(5) I nspect condi ti on of pressure pl ate surface of
cl utch cover (Fi g. 10). Repl ace cover i f thi s surface i s
worn, heat checked, cracked, or scored.
(6) I nsert cl utch al i gnment tool i n cl utch di sc (Fi g.
11).
(7) I nsert al i gnment tool i n pi l ot beari ng and posi -
ti on di sc on fl ywheel . Be sure di sc hub i s posi ti oned
correctl y. Si de of hub marked Fl ywheel Si de shoul d
face fl ywheel (Fi g. 10). I f di sc i s not marked, pl ace
fl at si de of di sc agai nst fl ywheel .
(8) Posi ti on cl utch cover over di sc and on fl ywheel
(Fi g. 11).
(9) I nstal l cl utch cover bol ts fi nger ti ght.
(10) Ti ghten cover bol ts evenl y and i n rotati on a
few threads at a ti me. Cover bolts must be tight-
ened evenly and to specified torque to avoid
distorting cover. Tightening torques are 31 N·m
(23 ft. lbs.) on 2.5L engines and 52 N·m (38 ft.
lbs.) on 4.0 L engines.
(a) Start al l 6 bol ts by hand.
(b) Ti ghten 3 pi l ot hol e bol ts 3/4s of the way
(any sequence).
Fig. 10 Clutch Disc And Pressure Plate Inspection
1 – DISC
2 – INSPECT THIS SURFACE
3 – CLUTCH COVER
4 – “FLYWHEEL SIDE” STAMPED ON THIS SURFACE
TJ CLUTCH 6 - 11
SERVICE PROCEDURES (Continued)
(c) Starti ng 180 degrees from the l ast pi l ot bol t,
ti ghten 3 l arge hol e bol ts 3/4s of the way (any
sequence).
(d) Ti ghten 3 pi l ot hol e bol ts al l the way (any
sequence).
(e) Starti ng 180 degrees from l ast pi l ot bol t,
ti ghten 3 l arge bol ts al l the way (any sequence).
(11) Appl y l i ght coat of Mopar௡ hi gh temperature
beari ng grease to cl utch di sc hub and spl i nes of
transmi ssi on i nput shaft. Do not over lubricate
shaft splines. This will result in grease contam-
ination of disc.
(12) I nstal l transmi ssi on.
RELEASE BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Di sconnect rel ease beari ng from rel ease l ever
and remove beari ng (Fi g. 12).
(3) I nspect beari ng sl i de surface of transmi ssi on
front beari ng retai ner. Repl ace retai ner i f sl i de sur-
face i s scored, worn, or cracked.
(4) I nspect rel ease fork and fork pi vot. Be sure
pi vot i s secure and i n good condi ti on. Be sure fork i s
not di storted or worn. Repl ace rel ease fork retai ner
spri ng i f bent or damaged.
INSTALLATION
(1) Lubri cate crankshaft pi l ot beari ng wi th Mopar௡
hi gh temperature beari ng grease. Appl y grease to
end of l ong shank, smal l di ameter fl at bl ade screw-
dri ver. Then i nsert tool through cl utch di sc hub to
reach beari ng.
(2) Lubri cate i nput shaft spl i nes, beari ng retai ner
sl i de surface, fork pi vot and rel ease fork pi vot surface
wi th Mopar௡ hi gh temperature grease.
(3) I nstal l new rel ease beari ng. Be sure beari ng i s
properl y secured to rel ease fork.
(4) I nstal l transmi ssi on.
PILOT BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Remove cl utch cover and di sc.
(3) Remove pi l ot beari ng. Use i nternal (bl i nd hol e)
pul l er such those as suppl i ed i n Snap–On௡ Tool Set
CG40CB to remove beari ng.
INSTALLATION
(1) Lubri cate new beari ng wi th Mopar௡ hi gh tem-
perature beari ng grease.
(2) Start new beari ng i nto crankshaft by hand.
Then seat beari ng wi th cl utch al i gnment tool (Fi g. 13).
(3) Li ghtl y scuff sand fl ywheel surface wi th 180
gri t emery cl oth. Then cl ean surface wi th wax and
grease remover.
(4) I nstal l cl utch di sc and cover as descri bed i n
thi s secti on.
(5) I nstal l transmi ssi on.
CLUTCH HOUSING
The cl utch housi ng i s removabl e and can be
repl aced when the transmi ssi on i s out of the vehi cl e.
The bol ts attachi ng the housi ng to the transmi s-
si on case are l ocated i nsi de the housi ng (Fi g. 14).
Recommended ti ghteni ng torque for the cl utch hous-
i ng-to-transmi ssi on bol ts i s 46 N·m (34 ft. l bs.).
Fig. 11 Typical Method Of Aligning Clutch Disc
1 – FLYWHEEL
2 – CLUTCH COVER AND DISC
3 – CLUTCH DISC ALIGNMENT TOOL
Fig. 12 Release Bearing Attachment
1 – RETURN SPRING
2 – PIVOT BALL STUD
3 – CLUTCH HOUSING
4 – RELEASE FORK
5 – RELEASE BEARING
6 - 12 CLUTCH TJ
REMOVAL AND INSTALLATION (Continued)
NOTE: Be sure the transmission and housing mat-
ing surfaces are clean before installing an original,
or replacement clutch housing. Dirt/foreign material
trapped between the housing and transmission will
cause misalignment. If misalignment is severe
enough, the result will be clutch drag, incomplete
release and hard shifting.
CLUTCH HYDRAULIC LINKAGE
The cl utch master cyl i nder, sl ave cyl i nder and con-
necti ng l i ne are servi ced as an assembl y onl y. The
l i nkage components cannot be overhaul ed or servi ced
separatel y. The cyl i nders and connecti ng l i ne are
seal ed uni ts. Al so note that removal /i nstal l ati on pro-
cedures for ri ght and l eft hand dri ve model s are basi -
cal l y the same. Onl y master cyl i nder l ocati on i s
di fferent.
REMOVAL
(1) Rai se vehi cl e.
(2) Remove fasteners attachi ng sl ave cyl i nder to
cl utch housi ng.
(3) Remove sl ave cyl i nder from cl utch housi ng
(Fi g. 15).
(4) Di sengage cl utch fl ui d l i ne from body cl i ps.
(5) Lower vehi cl e.
(6) Veri fy that cap on cl utch master cyl i nder reser-
voi r i s ti ght. Thi s i s necessary to avoi d spi l l i ng fl ui d
duri ng removal .
(7) Remove cl utch master cyl i nder attachi ng nuts
(Fi g. 15) or (Fi g. 16).
(8) Di sengage captured bushi ng on cl utch master
cyl i nder actuator from pi vot pi n on pedal arm.
(9) Sl i de actuator off pi vot pi n.
(10) Di sconnect cl utch i nterl ock safety swi tch
wi res.
(11) Remove cl utch hydraul i c l i nkage through
engi ne compartment.
INSTALLATION
(1) Be sure reservoi r cover on cl utch master cyl i n-
der i s ti ght to avoi d spi l l s.
(2) Posi ti on cl utch l i nkage components i n vehi cl e.
Work connecti ng l i ne and sl ave cyl i nder downward
past engi ne and adjacent to cl utch housi ng (Fi g. 15)
or (Fi g. 16).
(3) Posi ti on cl utch master cyl i nder on dash panel
(Fi g. 15) or (Fi g. 16).
(4) Attach cl utch master cyl i nder actuator to pi vot
pi n on cl utch pedal .
(5) I nstal l and ti ghten cl utch master cyl i nder
attachi ng nuts to 38 N·m (28 ft. l bs.) torque.
(6) Rai se vehi cl e.
(7) I nsert sl ave cyl i nder push rod through cl utch
housi ng openi ng and i nto rel ease l ever. Be sure cap
on end of rod i s securel y engaged i n l ever. Check thi s
before i nstal l i ng cyl i nder attachi ng nuts.
(8) I nstal l and ti ghten sl ave cyl i nder attachi ng
nuts to 23 N·m (17 ft. l bs.) torque.
(9) Secure cl utch fl ui d l i ne i n body and transmi s-
si on cl i ps.
(10) Lower vehi cl e.
(11) Connect cl utch i nterl ock safety swi tch wi res.
Fig. 13 Pilot Bearing Installation
1 – PILOT BEARING
2 – ALIGNMENT TOOL
Fig. 14 Clutch Housing Attachment
1 – HOUSING —TO— TRANSMISSION BOLTS (46 N·m/34 ft. lbs.)
2 – CLUTCH HOUSING
3 – TRANSMISSION
TJ CLUTCH 6 - 13
REMOVAL AND INSTALLATION (Continued)
CLUTCH PEDAL
REMOVAL
(1) Remove steeri ng col umn l ower cover and knee
bl ocker for access. Refer to Group 8E, I nstrument
Panel for procedure.
(2) Di sconnect cl utch pedal posi ti on swi tch wi res.
(3) Di sengage captured bushi ng l ock tabs attach-
i ng cl utch master cyl i nder actuator to pedal pi vot
(Fi g. 17) or (Fi g. 18).
(4) Remove nuts attachi ng pedal and bracket to
dash panel and upper cowl support (Fi g. 17) or (Fi g.
18).
(5) Separate pedal assembl e from vehi cl e.
INSTALLATION
(1) Pl ace cl utch pedal and bracket over studs on
dash panel and cowl support (Fi g. 17) or (Fi g. 18).
(2) I nstal l nuts to attach pedal and bracket to
dash panel and upper cowl support (Fi g. 17) or (Fi g.
18). Ti ghten nuts to 39 N·m (29 ft. l bs.) torque
(3) Engage captured bushi ng and actuator on
brake pedal pi vot (Fi g. 17) or (Fi g. 18).
(4) Connect cl utch pedal posi ti on swi tch wi res.
Fig. 15 Slave Cylinder and Left Hand Drive Clutch
Master Cylinder
1 – CLUTCH HOUSING
2 – FLUID LINE
3 – BRACKET
4 – FLUID LINE
5 – CLIP
6 – CAPTURED BUSHING
7 – CLUTCH SLAVE CYLINDER
8 – CLUTCH MASTER CYLINDER
9 – DASH PANEL
Fig. 16 Right Hand Drive Clutch Master Cylinder
1 – DASH PANEL
2 – FLUID LINE
3 – CLIP
4 – HOLD DOWN STRAP
5 – CLUTCH MASTER CYLINDER
6 – CAPTURED BUSHING
Fig. 17 Clutch Pedal Mounting
1 – CLUTCH CYLINDER ACTUATOR
2 – CAPTURED BUSHING
3 – UPPER COWL SUPPORT
4 – PIVOT
5 – CLUTCH PEDAL
6 – BRACKET
7 – DASH PANEL
6 - 14 CLUTCH TJ
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Bol ts, cl utch cover 2.5 L . . . . . . . 31 N·m (23 ft. l bs)
Bol ts, cl utch cover 4.0 L . . . . . . . 50 N·m (37 ft. l bs)
Bol t/Nut, cl utch cyl . mount . . . 23 N·m (200 i n. l bs)
Bol t, cl utch housi ng M12 . . . . . . 75 N·m (55 ft. l bs)
Bol t, cl utch housi ng 3/8 . . . . . . . 37 N·m (27 ft. l bs)
Bol t, cl utch housi ng 7/16 . . . . . . 58 N·m (43 ft. l bs)
Bol t, cl utch housi ng/trans. . . . . . 46 N·m (34 ft. l bs)
Bol t, dust shi el d M8 . . . . . . . . . . 8 N·m (72 i n. l bs)
Bol t, dust shi el d l ower . . . . . . . . 50 N·m (37 ft. l bs)
Bol t, X-member/frame . . . . . . . . 41 N·m (30 ft. l bs)
Bol t, X-member/rear support . . . 45 N·m (33 ft. l bs.)
Bol ts, fl ywheel 4.0 L . . . . . . . . 142 N·m (105 ft. l bs)
Bol ts, fl ywheel 2.5 L . . . . . . . . . 95 N·m (70 ft. l bs)
Bol t, starter motor . . . . . . . . . . . 45 N·m (33 ft. l bs)
Bol ts, U-joi nts . . . . . . . . . . . . . 19 N·m (170 i n. l bs.)
Fig. 18 Clutch Pedal Mounting—Right Hand Drive
1 – CLUTCH CYLINDER ACTUATOR
2 – CAPTURED BUSHING
3 – UPPER COWL SUPPORT
4 – PIVOT
5 – CLUTCH PEDAL
6 – BRACKET
7 – DASH PANEL
TJ CLUTCH 6 - 15
REMOVAL AND INSTALLATION (Continued)
COOLING SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TRANSMISSION OIL COOLER . . . . . . . . . . . . . . . 3
COOLANT RESERVOIR/OVERFLOW SYSTEM . . . 3
THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RADIATOR PRESSURE CAP. . . . . . . . . . . . . . . . . 4
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VISCOUS FAN DRIVE. . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . . 7
ACCESSORY DRIVE BELT DIAGNOSIS. . . . . . . . . 7
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . . . 9
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . . 10
RADIATOR COOLANT FLOW CHECK . . . . . . . . . 17
COOLING SYSTEM—TESTING FOR LEAKS. . . . 17
VISCOUS FAN DRIVE. . . . . . . . . . . . . . . . . . . . . 18
RADIATOR CAP TO FILLER NECK
SEAL—PRESSURE RELIEF CHECK. . . . . . . . . 19
RADIATOR CAP—PRESSURE TESTING. . . . . . . 20
COOLANT—LOW LEVEL AERATION . . . . . . . . . 20
COOLING SYSTEM DEAERATION. . . . . . . . . . . . 20
SERVICE PROCEDURES
COOLANT LEVEL—ROUTINE CHECK. . . . . . . . . 21
COOLANT—ADDING ADDITIONAL. . . . . . . . . . . 21
SERVICE COOLANT LEVEL. . . . . . . . . . . . . . . . . 21
COOLING SYSTEM—DRAINING. . . . . . . . . . . . . 21
COOLING SYSTEM—REFILLING . . . . . . . . . . . . 21
COOLING SYSTEM—REVERSE FLUSHING . . . . 22
COOLANT PERFORMANCE. . . . . . . . . . . . . . . . . 22
COOLANT SELECTION AND ADDITIVES . . . . . . 22
REMOVAL AND INSTALLATION
AUTOMATIC TRANSMISSION OIL COOLER. . . . 22
COOLANT RESERVE/OVERFLOW BOTTLE. . . . . 23
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 23
THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 28
VISCOUS FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
VISCOUS FAN DRIVE. . . . . . . . . . . . . . . . . . . . . 31
ACCESSORY DRIVE BELT. . . . . . . . . . . . . . . . . . 31
CLEANING AND INSPECTION
RADIATOR PRESSURE CAP. . . . . . . . . . . . . . . . 33
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FAN BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ADJUSTMENTS
ACCESSORY DRIVE BELT—2.5L ENGINE . . . . . 33
SPECIFICATIONS
COOLING SYSTEM CAPACITIES. . . . . . . . . . . . . 34
ACCESSORY DRIVE BELT TENSION—2.5L . . . . 34
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION AND OPERATION
COOLING SYSTEM
DESCRIPTION
The cool i ng system i s desi gned to mai ntai n engi ne
temperature at an effi ci ent l evel duri ng al l engi ne
operati ng condi ti ons.
The components of the cool i ng system are:
• A heavy duty radi ator
• Cool i ng fan (mechani cal )
• Thermal vi scous fan dri ve
• Fan shroud
• Radi ator pressure cap
• Thermostat
• Cool ant reserve/overfl ow system
• Automati c transmi ssi on oi l cool er (i nternal to
radi ator)
• Cool ant
• Water pump
• Cool ant hoses and cl amps
OPERATION
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e. I t al so
mai ntai ns normal operati ng temperature and pre-
vents overheati ng.
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
TJ COOLING SYSTEM 7 - 1
pump on al l engi nes to ci rcul ate cool ant throughout
the system.
A “Heavy Duty” Cool i ng Package i s not avai l abl e.
The current package provi des suffi ci ent enough cool -
i ng capaci ty for vehi cl es used under extreme condi -
ti ons such as trai l er towi ng i n hi gh ambi ent
temperatures.
RADIATOR
DESCRIPTION
CAUTION: Plastic tanks, while stronger than brass,
are subject to damage by impact, such as
wrenches, mishandling, etc.
A heavy duty down-fl ow al umi num/pl asti c radi ator
i s used. The radi ator consi sts of an al umi num core
and pl asti c end tanks, whi ch are fastened to the core
wi th cl i nch tabs and seal ed wi th a hi gh temperature
rubber gasket. On automati c transmi ssi on equi pped
vehi cl es, the l ower tank contai ns a concentri c-tube
transmi ssi on oi l cool er.
I f the pl asti c tank has been damaged, i ndi vi dual
parts are not avai l abl e, and the radi ator must be
repl aced.
OPERATION
As ai r passes through the radi ator core, the heat
wi thi n the cool ant i s di ssi pated i nto the ambi ent ai r.
BLOCK HEATER
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
An opti onal engi ne bl ock heater i s avai l abl e for al l
model s. The heater i s equi pped wi th a power cord.
The cord i s attached to an engi ne compartment com-
ponent wi th ti e-straps. The heater warms the engi ne
provi di ng easi er engi ne starti ng and faster warm-up
i n l ow temperatures. The heater i s mounted i n a core
hol e of the engi ne cyl i nder bl ock (i n pl ace of a freeze
pl ug) wi th the heati ng el ement i mmersed i n engi ne
cool ant.
Fig. 1 Coolant Circulation—2.5L Engine
1 – RADIATOR LOWER HOSE
2 – TO COOLANT RECOVERY BOTTLE
3 – RADIATOR UPPER HOSE
4 – TO WATER PUMP
5 – HEATER CORE
7 - 2 COOLING SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
Connecti ng the power cord to a grounded 110-120
vol t AC el ectri cal outl et wi th a grounded, three-wi re
extensi on cord, suppl i es the el ectri ci ty requi red to
heat the el ement thus heati ng the engi ne cool ant.
TRANSMISSION OIL COOLER
DESCRIPTION
Al l model s equi pped wi th an automati c transmi s-
si on are equi pped wi th a transmi ssi on oi l cool er
(water-to-oi l ) mounted i nternal l y wi thi n the radi ator
tank. Thi s i nternal cool er i s suppl i ed as standard
equi pment on al l model s equi pped wi th an automati c
transmi ssi on.
OPERATION
Transmi ssi on oi l i s cool ed when i t passes through
thi s separate cool er. I n case of a l eak i n the i nternal
radi ator mounted transmi ssi on oi l cool er, engi ne cool -
ant may become mi xed wi th transmi ssi on fl ui d or
transmi ssi on fl ui d may enter the cool i ng system.
Both cool i ng system and transmi ssi on shoul d be
drai ned and i nspected i f the i nternal radi ator
mounted transmi ssi on cool er i s l eaki ng.
COOLANT RESERVOIR/OVERFLOW SYSTEM
DESCRIPTION
The cool ant reserve/overfl ow system consi sts of a
radi ator mounted pressuri zed cap, a pl asti c cool ant
recovery bottl e (Fi g. 6), a tube (hose) connecti ng the
Fig. 2 Coolant Circulation—4.0L Engine
1 – FROM THERMOSTAT
2 – TO WATER PUMP
3 – RADIATOR
Fig. 3 Downflow Radiator—Typical
1 – DOWNFLOW RADIATOR
2 – INTEGRAL TRANSMISSION OIL COOLER (INTERNAL TO
RADIATOR)
Fig. 4 Block Heater—Typical
1 – ENGINE BLOCK HEATER
TJ COOLING SYSTEM 7 - 3
DESCRIPTION AND OPERATION (Continued)
radi ator and recovery bottl e, and an overfl ow tube on
the si de of the bottl e.
The reservoi r bottl e al so has an anti -sl osh i nsert
l ocated wi thi n the bottl e, thi s i nsert wi l l ai d i n
reduci ng cool ant l oss from spl ash and spi l l age.
OPERATION
The system works al ong wi th the radi ator pressure
cap. Thi s i s done by usi ng thermal expansi on and
contracti on of the cool ant to keep the cool ant free of
trapped ai r. I t provi des:
• A vol ume for cool ant expansi on and contracti on.
• A conveni ent and safe method for checki ng/ad-
justi ng cool ant l evel at atmospheri c pressure. Thi s i s
done wi thout removi ng the radi ator pressure cap.
• Some reserve cool ant to the radi ator to cover
mi nor l eaks and evaporati on or boi l i ng l osses.
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
THERMOSTAT
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on al l gas powered engi nes i s
l ocated beneath the thermostat housi ng at the front
of the i ntake mani fol d.
The thermostat i s a wax pel l et dri ven, reverse pop-
pet choke type.
Cool ant l eakage i nto the pel l et contai ner wi l l cause
the thermostat to fai l i n the open posi ti on. Thermo-
stats very rarel y sti ck. Do not attempt to free a ther-
mostat wi th a pryi ng devi ce.
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes l onger engi ne
warmup ti me, unrel i abl e warmup performance,
i ncreased exhaust emi ssi ons and crankcase condensa-
ti on that can resul t i n sl udge formati on.
OPERATION
The wax pel l et i s l ocated i n a seal ed contai ner at
the spri ng end of the thermostat. When heated, the
pel l et expands, overcomi ng cl osi ng spri ng tensi on
and water pump pressure to force the val ve to open.
RADIATOR PRESSURE CAP
DESCRIPTION
Al l radi ators are equi pped wi th a pressure cap.
Thi s cap rel eases pressure at some poi nt wi thi n a
range of 83-124 kPa (12-18 psi ). The pressure rel i ef
poi nt (i n pounds) i s engraved on top of the cap (Fi g.
8).
A rubber gasket seal s the radi ator fi l l er neck. Thi s
i s done to mai ntai n vacuum duri ng cool ant cool -down
and to prevent l eakage when system i s under pres-
sure.
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
Fig. 5 Radiator with Integral Transmission Oil
Cooler
1 – DOWNFLOW RADIATOR
2 – INTEGRAL TRANSMISSION OIL COOLER (INTERNAL TO
RADIATOR)
Fig. 6 Coolant Recovery Bottle
1 – RADIATOR PRESSURE CAP
2 – HOSE
3 – COOLANT RECOVERY BOTTLE
7 - 4 COOLING SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap contai ns a spri ng-
l oaded pressure rel i ef val ve. Thi s val ve opens when
system pressure reaches the rel ease range of 83-124
kPa (12-18 psi ).
OPERATION
A vent val ve i n the center of the cap al l ows a smal l
cool ant fl ow through the cap when cool ant i s bel ow
boi l i ng temperature. The val ve i s compl etel y cl osed
when boi l i ng poi nt i s reached. As cool ant cool s, i t
contracts and creates a vacuum i n the cool i ng sys-
tem. Thi s causes the vacuum val ve to open and cool -
ant i n reserve/overfl ow tank to be drawn through
connecti ng hose i nto radi ator. I f the vacuum val ve i s
stuck shut, radi ator hoses wi l l col l apse on cool -down.
WATER PUMP
DESCRIPTION
CAUTION: All 4.0L 6-cylinder engines are equipped
with a reverse (counterclockwise) rotating water
pump and thermal viscous fan drive assembly.
REVERSE is stamped or imprinted on the cover of
the viscous fan drive and inner side of the fan. The
letter R is stamped into the back of the water pump
impeller. Engines from previous model years,
depending upon application, may have been
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump or vis-
cous fan drive will cause engine over heating.
Thi s al umi num water pump i s the heart of the cool -
i ng system. The water pump i s l ocated at the front of
the cyl i nder bl ock, above the ti mi ng chai n cover
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary.
OPERATION
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t on al l engi nes.
Fig. 7 Thermostat—Typical
1 – LONG BOLT
2 – GASKET
3 – THERMOSTAT
4 – THERMOSTAT HOUSING
5 – SHORT BOLT
Fig. 8 Radiator Pressure Cap
1 – FILLER NECK SEAL
2 – VACUUM VENT VALVE
3 – PRESSURE RATING
4 – PRESSURE VALVE
TJ COOLING SYSTEM 7 - 5
DESCRIPTION AND OPERATION (Continued)
VISCOUS FAN DRIVE
DESCRIPTION
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
The thermal vi scous fan dri ve (Fi g. 10) i s a si l i -
cone-fl ui d-fi l l ed coupl i ng used to connect the fan
bl ades to the water pump shaft. The coupl i ng al l ows
the fan to be dri ven i n a normal manner. Thi s i s
done at l ow engi ne speeds whi l e l i mi ti ng the top
speed of the fan to a predetermi ned maxi mum l evel
at hi gher engi ne speeds.
OPERATION
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t (a typi cal
vi scous uni t i s shown i n (Fi g. 12) (Fi g. 13). Thi s
spri ng coi l reacts to the temperature of the radi ator
di scharge ai r. I t engages the vi scous fan dri ve for
hi gher fan speed i f the ai r temperature from the
radi ator ri ses above a certai n poi nt. Unti l addi ti onal
engi ne cool i ng i s necessary, the fan wi l l remai n at a
reduced rpm regardl ess of engi ne speed.
Fig. 9 Water Pump—4.0L
1 – HEATER HOSE FITTING BORE
2 – WATER PUMP
3 – WATER PUMP HUB
Fig. 10 Water Pump Mounted Fan Drive—2.5L
Engine
1 – THERMAL VISCOUS FAN DRIVE
2 – (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 – (4) FAN HUB-TO-PUMP PULLEY STUDS
4 – WATER PUMP
5 – WATER PUMP PULLEY
6 – FAN BLADE
7 – (4) FAN HUB-TO-PUMP PULLEY NUTS
Fig. 11 Water Pump Mounted Fan Drive—4.0L
Engine
1 – FAN AND FAN DRIVE
2 – WATER PUMP PULLEY
7 - 6 COOLING SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
Onl y when suffi ci ent heat i s present, wi l l the vi s-
cous fan dri ve engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
DIAGNOSIS AND TESTING
ON-BOARD DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Powertrai n Control Modul e (PCM) has been
programmed to moni tor the certai n fol l owi ng cool i ng
system components:
• I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC’s and to obtai n cool i ng system data,
refer to Group 25, Emi ssi on Control Systems for
proper procedures.
ACCESSORY DRIVE BELT DIAGNOSIS
VISUAL DIAGNOSIS
When di agnosi ng serpenti ne accessory dri ve bel ts,
smal l cracks that run across the ri bbed surface of the
bel t from ri b to ri b (Fi g. 14), are consi dered normal .
These are not a reason to repl ace the bel t. However,
cracks runni ng al ong a ri b (not across) are not nor-
mal . Any bel t wi th cracks runni ng al ong a ri b must
be repl aced (Fi g. 14). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
Refer to the Accessory Dri ve Bel t Di agnosi s charts
for further bel t di agnosi s.
Fig. 12 Viscous Fan Drive—2.5L Engine
1 – VISCOUS FAN DRIVE
2 – MOUNTING HUB
3 – THERMOSTATIC SPRING
Fig. 13 Viscous Fan Drive—4.0L Engine
1 – VISCOUS FAN DRIVE
2 – THERMOSTATIC SPRING
3 – MOUNTING NUT TO WATER PUMP HUB
Fig. 14 Belt Wear Patterns
1 – NORMAL CRACKS BELT OK
2 – NOT NORMAL CRACKS REPLACE BELT
TJ COOLING SYSTEM 7 - 7
DESCRIPTION AND OPERATION (Continued)
NOISE DIAGNOSIS
Noi ses generated by the accessory dri ve bel t are
most noti ceabl e at i dl e. Before repl aci ng a bel t to
resol ve a noi se condi ti on, i nspect al l of the accessory
dri ve pul l eys for al i gnment, gl azi ng, or excessi ve end
pl ay.
ACCESSORY DRIVE BELT DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
RIB CHUNKING (One or more ribs
has separated from belt body)
1. Foreign objects imbedded in
pulley grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove
tips
4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of
insufficient tension
1. Adjust tension (2.5L)
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)
2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)
3. Replace faulty component or
bearing
4. Belt glazed or hardened from
heat and excessive slippage
4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove
1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member
2. Replace belt
ЉGROOVE JUMPING”
(Belt does not maintain correct
position on pulley)
1. Belt tension either too low or too
high
1. Adjust belt tension (2.5L)
2. Pulley(s) not within design
tolerance
2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
7 - 8 COOLING SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
1. Excessive tension 1. Replace belt and adjust tension
to specification
2. Tensile member damaged during
belt installation
2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
NOISE (Objectionable squeal,
squeak, or rumble is heard or felt
while drive belt is in operation)
1. Belt slippage 1. Adjust belt tension (2.5L)
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration
5. Locate defective driven
component and repair
6. System resonant frequency
induced vibration
6. Vary belt tension within
specifications.
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)
1. Tension sheeting contacting
stationary object
1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age
2. Replace belt
3. Tension sheeting splice has
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)
1. Excessive tension 1. Adjust belt tension (2.5L)
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
4. Replace belt and adjust tension
to specifications
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause.
PROLONGED IDLE, VERY HIGH AMBIENT TEMPERATURE,
SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC
JAMS, HIGH SPEED, OR STEEP GRADES:
Dri vi ng techni ques that avoi d overheati ng are:
• I dl e wi th A/C off when temperature gauge i s at
end of normal range.
• I ncreasi ng engi ne speed for more ai r fl ow i s rec-
ommended.
TRAILER TOWING
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
AIR CONDITIONING; ADD-ON OR AFTER MARKET
These model s are equi pped wi th a “heavy duty”
cool i ng system and therefore wi l l accommodate
add-on or aftermarket ai r condi ti oni ng. No modi fi ca-
ti ons are necessary to the cool i ng system.
RECENT SERVICE OR ACCIDENT REPAIR:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
• Engi ne adjustments (i ncorrect ti mi ng)
• Sl i ppi ng engi ne accessory dri ve bel t(s)
• Brakes (possi bl y draggi ng)
• Changed parts (i ncorrect water pump rotati ng i n
wrong di recti on)
• Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under- fi l l ed or ai r trapped i n system).
TJ COOLING SYSTEM 7 - 9
DIAGNOSIS AND TESTING (Continued)
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
COOLING SYSTEM DIAGNOSIS
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open engine thermostat.
1. Refer to group 25, Emission
Control Systems. Replace
thermostat if necessary. If a
Diagnostic Trouble Code (DTC) has
not been set, the problem may be
with the temperature gauge.
2. Temperature gauge (if equipped)
disconnected from the temperature
gauge coolant sensor on the engine
2. Check the engine temperature
sensor connector in the engine
compartment. Refer to Group 8E.
Repair as necessary.
3. Defective temperature gauge (if
equipped)
3. Check gauge operation. Refer to
Group 8E. Repair as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.
4. Check coolant level in the coolant
reserve/overflow tank and the
radiator. Inspect system for leaks.
Repair leaks as necessary. Refer to
the Coolant section of the manual
text for Warnings and precautions
before removing the radiator cap.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as
necessary. Refer to Group 24,
Heating and Air Conditioning for
procedures.
6. Electric fan functioning when not
required.
6. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to Group
8W for electric cooling fan and relay
circuit schematic data.
7 - 10 COOLING SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM
COOLING SYSTEM
1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.
1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to normal range,
determine the cause for overheating
and repair. Refer to POSSIBLE
CAUSES (numbers 2 through 18).
2. Defective temperature gauge (if
equipped)
2. Check gauge. Refer to Group 8E.
Repair as necessary.
3. Defective temperature warning
lamp (if equipped)
3. Check warning lamp operation.
Refer to Group 8E. Repair as
necessary.
4. Coolant low in coolant reserve/
overflow tank and radiator?
4. Check for coolant leaks and
repair as necessary. Refer to
Testing Cooling System for Leaks in
this group.
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 6.
5. Tighten cap.
6. Poor seals at radiator cap. 6. (a) Check condition of cap and
cap seals. Refer to Radiator Cap.
Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. Coolant level low in radiator but
not in coolant reserve/overflow
tank. This means the radiator is not
drawing coolant from the coolant
reserve/overflow tank as the engine
cools.
As the engine cools, a vacuum is
formed in the cooling system of the
engine and radiator. If radiator cap
seals are defective, or cooling
system has leaks, a vacuum can
not be formed.
7. (a) Check condition of radiator
cap and cap seals. Refer to
Radiator Cap in this group. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check the condition of the hose
from the radiator to the coolant tank.
It should fit tight at both ends
without any kinks or tears. Replace
hose if necessary.
(d) Check coolant reserve/overflow
tank and tank hoses for blockage.
Repair as necessary
8. Freeze point of antifreeze not
correct. Mixture may be too rich.
8. Check antifreeze. Refer to
Coolant section of this group. Adjust
antifreeze-to-water ratio as required.
TJ COOLING SYSTEM 7 - 11
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM
COOLING SYSTEM
9. Coolant not flowing through
system.
9. Check for coolant flow at radiator
filler neck with some coolant
removed, engine warm and
thermostat open. Coolant should be
observed flowing through radiator. If
flow is not observed, determine
reason for lack of flow and repair as
necessary.
10. Radiator or A/C condenser fins
dirty or clogged.
10. Clean insects or debris. Refer to
Radiator Cleaning in this group.
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or
replaced.
12. Fuel or ignition system
problems.
12. Refer to Fuel and Ignition
System groups for diagnosis. Also
refer to the appropriate Powertrain
Diagnostic Procedures service
manual for operation of the DRB
scan tool.
13. Dragging brakes. 13. Check and correct as
necessary. Refer to Group 5,
Brakes in the manual text.
14. Bug screen is being used
reducing airflow.
14. Remove bug screen.
15. Thermostat partially or
completely shut. This is more
prevalent of high mileage vehicles.
15. Check thermostat operation and
replace as necessary. Refer to
Thermostats in this group.
16. Thermal viscous fan drive not
operating properly.
16. Check fan drive operation and
replace if necessary. Refer to
Viscous Fan Drive in this group.
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket
leaks. Refer to Testing Cooling
System for Leaks in this group. For
repair, refer to Group 9, Engines.
18. Heater core leaking. 18. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning. Repair as necessary.
19. Electric fan not functioning. 19. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to Group
8W for electric cooling fan and relay
circuit schematic data.
7 - 12 COOLING SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)
1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.
1. A normal condition. No correction
is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in the circuit.
2. Check operation of gauge and
repair if necessary. Refer to Group
8E, Instrument Panel and Gauges.
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running).
3. A normal condition. No correction
is necessary. Gauge reading should
return to normal range after vehicle
is driven.
4. Gauge reading high after
restarting a warmed-up (hot)
engine.
4. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).
5. Check and correct coolant leaks.
Refer to Testing Cooling System for
Leaks in this group.
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing thermostat
to open late.
6. (a) Check for cylinder head
gasket leaks with a commercially
available Block Leak Tester. Repair
as necessary.
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.
7. Check water pump and replace
as necessary. Refer to Water
Pumps in this group.
8. Loose accessory drive belt
(water pump slipping).
8. Refer to Engine Accessory Drive
Belts in this group. Check and
correct as necessary.
9. Air leak on the suction side of
water pump allows air to build up in
cooling system causing thermostat
to open late.
9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK
1. Pressure relief valve in radiator
cap is defective.
1. Check condition of radiator cap
and cap seals. Refer to Radiator
Caps in this group. Replace cap as
necessary.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE IS
READING HIGH OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.
1. Pressure test and repair as
necessary. Refer to Testing Cooling
System for Leaks in this group.
TJ COOLING SYSTEM 7 - 13
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of antifreeze not
correct. Mixture is too rich or too
lean.
2. Check antifreeze. Refer to the
Coolant section of this group. Adjust
antifreeze-to-water ratio as required.
HOSE OR HOSES COLLAPSED
WHEN ENGINE IS COOLING
1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reserve/overflow system.
1. (a) Radiator cap relief valve
stuck. Refer to Radiator Cap in this
group. Replace if necessary.
(b) Hose between coolant
reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow tank is interally
blocked or plugged. Check for
blockage and repair as necessary.
NOISY FAN 1. Fan blades loose. 1. Replace fan blade assembly.
Refer to Cooling System Fans in
this group.
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or
clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has
defective bearing.
4. Replace fan drive. Bearing is not
serviceable. Refer to Viscous Fan
Drive in this group.
5. A certain amount of fan noise
(roaring) may be evident from the
thermal viscous fan drive. Some of
this noise is normal.
5. Refer to Viscous Fan Drive in this
group for an explanation of normal
fan noise.
7 - 14 COOLING SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)
1. Radiator and/or A/C condenser is
restricted, obstructed or dirty
(insects, leaves etc.)
1. Remove restriction and/or clean
as necessary. Refer to Radiator
Cleaning in this group.
2. Electric fan not functioning. 2. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section.
3. Engine is overheating (heat may
be transferred from radiator to A/C
condenser. High underhood
temperatures due to engine
overheating may also transfer heat
to A/C components).
3. Correct overheating condition.
Refer to text in Group 7, Cooling.
4. All models with are equipped
with air seals at the radiator and/or
A/C condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.
4. Check for missing or damaged air
seals and repair as necessary.
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
1. Has a diagnostic trouble code
(DTC) been set?
1. Refer to group 25, Emission
Control System and replace
thermostat if necessary.
2. Coolant level low. 2. Refer to Testing Cooling System
for Leaks in the manual text. Repair
as necessary.
3. Obstructions in heater hose
fittings at engine.
3. Remove heater hoses at both
ends and check for obstructions.
Repair as necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping
water to heater core. When the
engine is fully warmed up, both
heater hoses should be hot to the
touch. If only one of the hoses is
hot, the water pump may not be
operating correctly. The accessory
drive belt may also be slipping
causing poor water pump operation.
5. Refer to Water Pumps in this
group. Repair as necessary. If a
slipping belt is detected, refer to
Engine Accessory Drive Belts in this
group. Repair as necessary.
TJ COOLING SYSTEM 7 - 15
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
HEAT ODOR 1. Various heat shields are used at
certain drive line components. One
or more of these shields may be
missing.
1. Locate missing shields and
replace or repair as necessary.
2. Engine running hot 2. Preform thermostat, water pump
and fan test. Repair or replace as
necessary.
3. Cooling fan malfunctioning. 3. Refer to Cooling System Fan in
this group for diagnosis. Repair as
necessary
4. Undercoating or other
contaminate applied to cooling or
exhaust system.
4. Clean as necessary.
5. Engine may be running rich
causing the catalytic converter to
overheat.
5. Refer to the DRB scan tool and
the appropriate Powertrain
Diagnostic Procedures service
manual. Repair as necessary.
POOR DRIVEABILITY
(THERMOSTAT POSSIBLY STUCK
OPEN). GAUGE MAY BE READING
LOW
1. For proper driveability, good
vehicle emissions and for
preventing build-up of engine oil
sludge, the thermostat must be
operating properly. Has a diagnostic
trouble code (DTC) been set?
1. Refer to group 25, Emission
Control System. DTC’s may also be
checked using the DRB scan tool.
Refer to the proper Powertrain
Diagnostics Procedures service
manual for checking the thermostat
using the DRB scan tool. Replace
thermostat if necessary.
STEAM IS COMING FROM FRONT
OF VEHICLE NEAR GRILL AREA
WHEN WEATHER IS WET,
ENGINE IS WARMED UP AND
RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture
contacts the hot radiator, steam
may be emitted. This usually occurs
in cold weather with no fan or
airflow to blow it away.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
1. Refer to Coolant in this group for
antifreeze tests. Adjust antifreeze-to-
water ratio as necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the tank was between
the FULL and ADD marks at normal
engine operating temperature, the
level should return to within that
range after operation at elevated
temperatures.
1. A normal condition. No repair is
necessary.
7 - 16 COOLING SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
RADIATOR COOLANT FLOW CHECK
The fol l owi ng procedure wi l l determi ne i f cool ant i s
fl owi ng through the cool i ng system.
I f engi ne i s col d, i dl e engi ne unti l normal operati ng
temperature i s reached. Then feel the upper radi ator
hose. I f hose i s hot, the thermostat i s open and water
i s ci rcul ati ng through cool i ng system.
COOLING SYSTEM— TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
Al l Jeep model s have a l eak detecti on addi ti ve
added to the cool i ng system before they l eave the fac-
tory. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). I f the factory ori gi nal cool ant has
been drai ned, pour one ounce of addi ti ve i nto the
cool i ng system. The addi ti ve i s avai l abl e through the
part’s department. Pl ace the heater control uni t i n
HEAT posi ti on. Start and operate the engi ne unti l
the radi ator upper hose i s warm to the touch. Ai m
the commerci al l y avai l abl e bl ack l i ght tool at the
components to be checked. I f l eaks are present, the
bl ack l i ght wi l l cause the addi ti ve to gl ow a bri ght
green col or.
The bl ack l i ght can be used al ong wi th a pressure
tester to determi ne i f any external l eaks exi st (Fi g.
15).
PRESSURE TESTER METHOD
The engi ne shoul d be at the normal operati ng tem-
perature. Recheck the system col d i f the cause of
cool ant l oss i s not l ocated duri ng warm engi ne exam-
i nati on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Careful l y remove the radi ator pressure cap from
the fi l l er neck and check the cool ant l evel . Push
down on the cap to di sengage i t from the stop tabs.
Wi pe the i nner part of the fi l l er neck and exami ne
the l ower i nsi de seal i ng seat for ni cks, cracks, pai nt,
di rt and sol der resi due. I nspect the reserve/overfl ow
tank tube for i nternal obstructi ons. I nsert a wi re
through the tube to be sure i t i s not obstructed.
I nspect the cams on the outsi de part of the fi l l er
neck. I f the cams are bent, seati ng of pressure cap
val ve and tester seal wi l l be affected. Repl ace cap i f
cams are bent.
Attach pressure tester 7700 (or an equi val ent) to
the radi ator fi l l er neck (Fi g. 16).
Operate the tester pump to appl y 124 kPa (18 psi )
pressure to the system. I f the hoses enl arge exces-
si vel y or bul ge whi l e testi ng, repl ace as necessary.
Observe the gauge poi nter and determi ne the condi -
ti on of the cool i ng system accordi ng to the fol l owi ng
cri teri a:
• Hol ds Steady: I f the poi nter remai ns steady for
two mi nutes, there are no seri ous cool ant l eaks i n
the system. However, there coul d be an i nternal l eak
that does not appear wi th normal system test pres-
sure. I nspect for i nteri or l eakage or do the I nternal
Leakage Test. Do thi s i f i t i s certai n that cool ant i s
bei ng l ost and no l eaks can be detected.
• Drops Sl owl y: Shows a smal l l eak or seepage i s
occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect the radi ator,
hoses, gasket edges and heater. Seal any smal l l eak
Fig. 15 Leak Detection Using Black Light—Typical
1 – TYPICAL BLACK LIGHT TOOL
Fig. 16 Pressurizing System—Typical
1 – TYPICAL COOLING SYSTEM PRESSURE TESTER
TJ COOLING SYSTEM 7 - 17
DIAGNOSIS AND TESTING (Continued)
hol es wi th a Seal er Lubri cant or equi val ent. Repai r
l eak hol es and rei nspect the system wi th pressure
appl i ed.
• Drops Qui ckl y: Shows that a seri ous l eakage i s
occurri ng. Exami ne the system for seri ous external
l eakage. I f no l eaks are vi si bl e, i nspect for i nternal
l eakage. Large radi ator l eak hol es shoul d be repai red
by a reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove the engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . Cool ant, bei ng heavi er
than engi ne oi l , wi l l drai n fi rst. Another way of test-
i ng i s to operate the engi ne and check for water gl ob-
ul es on the engi ne oi l di psti ck. Al so i nspect the
automati c transmi ssi on oi l di psti ck for water gl ob-
ul es. I nspect the automati c transmi ssi on fl ui d cool er
for l eakage. Operate the engi ne wi thout the pressure
cap on the radi ator unti l thermostat opens.
Attach a pressure tester to the fi l l er neck. I f pres-
sure bui l ds up qui ckl y, a l eak exi sts as a resul t of a
faul ty cyl i nder head gasket or crack i n the engi ne.
Repai r as necessary.
WARNING: DO NOT ALLOW PRESSURE TO
EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.
I f there i s no i mmedi ate pressure i ncrease, pump
the pressure tester unti l the i ndi cated pressure i s
wi thi n the system range. Vi brati on of the gauge
poi nter i ndi cates compressi on or combusti on l eakage
i nto the cool i ng system.
WARNING: DO NOT DISCONNECT THE SPARK
PLUG WIRES WHILE THE ENGINE IS OPERATING.
CAUTION: Do not operate the engine with a spark
plug shorted for more than a minute. The catalytic
converter may be damaged.
I sol ate the compressi on l eak by shorti ng each
spark pl ug to the cyl i nder bl ock. The gauge poi nter
shoul d stop or decrease vi brati on when spark pl ug
for l eaki ng cyl i nder i s shorted. Thi s happens because
of the absence of combusti on pressure.
COMBUSTION LEAKAGE TEST (WITHOUT
PRESSURE TESTER)
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow for thermostat
removal . Refer to Thermostat Repl acement. Di scon-
nect the water pump dri ve bel t.
Di sconnect the upper radi ator hose from the ther-
mostat housi ng. Remove the housi ng and thermostat.
I nstal l the thermostat housi ng.
Add cool ant to the radi ator to bri ng the l evel to
wi thi n 6.3 mm (1/4 i n) of the top of the thermostat
housi ng.
CAUTION: Avoid overheating. Do not operate the
engine for an excessive period of time. Open the
draincock immediately after the test to eliminate
boil over of coolant.
Start the engi ne and accel erate rapi dl y three ti mes
(to approxi matel y 3000 rpm) whi l e observi ng the
cool ant. I f i nternal engi ne combusti on gases are l eak-
i ng i nto the cool i ng system, bubbl es wi l l appear i n
the cool ant. I f bubbl es do not appear, there i s no
i nternal combusti on gas l eakage.
VISCOUS FAN DRIVE
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
• The underhood temperature i s above the engage-
ment poi nt for the vi scous dri ve coupl i ng. Thi s may
occur when ambi ent (outsi de ai r temperature) i s very
hi gh.
• Engi ne l oads and temperatures are hi gh such as
when towi ng a trai l er.
• Cool si l i cone fl ui d wi thi n the fan dri ve uni t i s
bei ng redi stri buted back to i ts normal di sengaged
(warm) posi ti on. Thi s can occur duri ng the fi rst 15
seconds to one mi nute after engi ne start-up on a col d
engi ne.
LEAKS
Vi scous fan dri ve operati on i s not affected by smal l
oi l stai ns near the dri ve beari ng. I f l eakage appears
excessi ve, repl ace the fan dri ve uni t.
TESTING
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
7 - 18 COOLING SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18°-to-
105°C (0°-to-220° F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght (ti mi ng l i ght i s to be used as a strobe
l i ght).
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 88° C (190° F).
Fan dri ve engagement shoul d have started to occur
at between 74° to 85° C (165° to 185° F). Engage-
ment i s di sti ngui shabl e by a defi ni te increase i n fan
fl ow noi se (roari ng). The ti mi ng l i ght al so wi l l i ndi -
cate an i ncrease i n the speed of the fan.
(7) When the ai r temperature reaches 88° C (190°
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 57° to
82° C (135° to 180° F). A defi ni te decrease of fan
fl ow noi se (roari ng) shoul d be noti ced. I f not, repl ace
the defecti ve vi scous fan dri ve uni t.
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
RADIATOR CAP TO FILLER NECK SEAL—
PRESSURE RELIEF CHECK
Wi th radi ator cap i nstal l ed on fi l l er neck, remove
cool ant reserve/overfl ow tank hose from ni ppl e on
fi l l er neck. Connect a hand operated vacuum pump
to ni ppl e. Operate pump unti l a readi ng of 47 to 61
kPa (14 to 18 i n. Hg) appears on gauge. I f the read-
i ng stays steady, or drops sl i ghtl y and then remai ns
steady, the pressure val ve seal i s good. Repl ace radi -
ator cap i f readi ng does not hol d.
WARNING: THE WARNING WORDS (DO NOT OPEN
HOT) ON THE RADIATOR PRESSURE CAP (Fig. 17)
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT AND/OR UNDER PRESSURE.
There i s no need to remove the radi ator cap
except for the fol l owi ng purposes:
(1) To check and adjust anti freeze freeze poi nt.
(2) To refi l l system wi th new anti freeze.
(3) For conducti ng servi ce procedures.
(4) When checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT AT LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER THE CAP AND
WITHOUT PUSHING DOWN, ROTATE CAP
COUNTER-CLOCKWISE TO THE FIRST STOP.
ALLOW FLUID TO ESCAPE THROUGH OVERFLOW
HOSE INTO COOLANT RESERVE/OVERFLOW
TANK. SQUEEZE RADIATOR UPPER HOSE TO
DETERMINE WHEN PRESSURE HAS BEEN
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.
TJ COOLING SYSTEM 7 - 19
DIAGNOSIS AND TESTING (Continued)
RADIATOR CAP— PRESSURE TESTING
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l the cap on pressure tester (tool 7700 or
an equi val ent) (Fi g. 18).
Operate the tester pump and observe the gauge
poi nter at i ts hi ghest poi nt. The cap rel ease pressure
shoul d be 83 to 124 kPa (12 to 18 psi ). The cap i s
sati sfactory when the pressure hol ds steady. I t i s al so
good i f i t hol ds pressure wi thi n the 83 to 124 kPa (12
to 18 psi ) range for 30 seconds or more. I f the poi nter
drops qui ckl y, repl ace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
COOLANT— LOW LEVEL AERATION
I f the cool ant l evel i n radi ator drops bel ow top of
radi ator core tubes, ai r wi l l enter cool i ng system.
Low cool ant l evel can cause thermostat pel l et to be
suspended i n ai r i nstead of cool ant. Thi s wi l l cause
thermostat to open l ater, whi ch i n turn causes hi gher
cool ant temperature. Ai r trapped i n cool i ng system
al so reduces amount of cool ant ci rcul ati ng i n heater
core resul ti ng i n l ow heat output.
COOLING SYSTEM DEAERATION
As the engi ne operates, any ai r trapped i n cool i ng
system gathers under the radi ator cap. The next ti me
the engi ne i s operated, thermal expansi on of cool ant
wi l l push any trapped ai r past radi ator cap i nto the
cool ant reserve/overfl ow tank. Here i t escapes to the
atmosphere i nto the tank. When the engi ne cool s
down the cool ant, i t wi l l be drawn from the reserve/
overfl ow tank i nto the radi ator to repl ace any
removed ai r.
Fig. 17 Radiator Pressure Cap
1 – FILLER NECK SEAL
2 – VACUUM VENT VALVE
3 – PRESSURE RATING
4 – PRESSURE VALVE
Fig. 18 Pressure Testing Radiator Pressure
Cap—Typical
1 – PRESSURE CAP
2 – TYPICAL COOLING SYSTEM PRESSURE TESTER
7 - 20 COOLING SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
SERVICE PROCEDURES
COOLANT LEVEL— ROUTINE CHECK
NOTE: Do not remove radiator cap for routine
coolant level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
The cool ant reserve/overfl ow system provi des a
qui ck vi sual method for determi ni ng cool ant l evel
wi thout removi ng radi ator pressure cap. Wi th engi ne
i dl i ng and at normal operati ng temperature, observe
cool ant l evel i n reserve/overfl ow tank. The cool ant
l evel shoul d be between ADD and FULL marks.
COOLANT— ADDING ADDITIONAL
Do not remove radiator cap to add coolant to
system. When addi ng cool ant to mai ntai n correct
l evel , do so at cool ant reserve/overfl ow tank. Use a
50/50 mi xture of ethyl ene-gl ycol anti freeze contai ni ng
l ow mi neral content water. Remove radi ator cap onl y
for testi ng or when refi l l i ng system after servi ce.
Removi ng cap unnecessari l y can cause l oss of cool ant
and al l ow ai r to enter system, whi ch produces corro-
si on.
SERVICE COOLANT LEVEL
The cool i ng system i s cl osed and desi gned to mai n-
tai n cool ant l evel to top of radi ator.
WARNING: DO NOT OPEN RADIATOR DRAINCOCK
WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
AND COOLING SYSTEM IS UNDER PRESSURE.
When vehi cl e servi ci ng requi res a cool ant l evel
check i n radi ator, drai n several ounces of cool ant
from radi ator drai n cock. Do thi s whi l e observi ng
cool ant reserve/overfl ow system tank. The cool ant
l evel i n reserve/overfl ow tank shoul d drop sl i ghtl y. I f
not, i nspect for a l eak between radi ator and cool ant
reserve/overfl ow system connecti on. Remove radi ator
cap. The cool ant l evel shoul d be to top of radi ator. I f
not and i f cool ant l evel i n reserve/overfl ow tank i s at
ADD mark, check for:
• An ai r l eak i n cool ant reserve/overfl ow tank or
i ts hose
• An ai r l eak i n radi ator fi l l er neck
• Leak i n pressure cap seal to radi ator fi l l er neck
COOLING SYSTEM— DRAINING
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
DO NOT remove the radi ator cap when drai ni ng
the cool ant from the reserve/overfl ow tank. Open the
radi ator drai ncock and when the tank i s empty,
remove the radi ator cap. The cool ant does not have
to be removed from the tank unl ess the system i s
bei ng refi l l ed wi th a fresh mi xture.
(1) Drai n the cool ant from the radi ator by l oosen-
i ng the drai ncock.
(2) Drai n cool ant from engi ne bl ock by removi ng
drai n pl ug at l eft rear si de of bl ock (Fi g. 19).
COOLING SYSTEM— REFILLING
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s).
(2) Fi l l system usi ng a 50/50 mi xture of water and
anti freeze. Thi s i s descri bed i n the Cool ant secti on of
thi s group. Fi l l the radi ator to the top and i nstal l the
radi ator cap. Add suffi ci ent cool ant to the reserve/
overfl ow tank to rai se the l evel to the FULL mark.
(3) Operate the engi ne wi th both the radi ator cap
and reserve/overfl ow tank cap i n pl ace. After the
engi ne has reached the normal operati ng tempera-
ture, shut the engi ne off and al l ow i t to cool .
(4) Add cool ant to the reserve/overfl ow tank as
necessary. Only add coolant when the engine is
cold. Coolant level in a warm engine will be
higher due to thermal expansion.
Fig. 19 Draining Coolant From Block—2.5L/4.0L
Engines
1 – EXHAUST MANIFOLD
2 – CYLINDER BLOCK COOLANT DRAIN PLUG
TJ COOLING SYSTEM 7 - 21
COOLING SYSTEM— REVERSE FLUSHING
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
CAUTION: The cooling system normally operates at
97 to 124 kPa (14 to 18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Al l ow the radi ator to fi l l wi th water. When radi ator
i s fi l l ed, appl y ai r i n short bl asts al l owi ng radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
cool i ng tube passages. For more i nformati on, refer to
operati ng i nstructi ons suppl i ed wi th fl ushi ng equi p-
ment. Have radi ator cl eaned more extensi vel y by a
radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system. Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
Connect the water suppl y hose and ai r suppl y hose
to the fl ushi ng gun. Al l ow the engi ne to fi l l wi th
water. When the engi ne i s fi l l ed, appl y ai r i n short
bl asts, al l owi ng the system to fi l l between ai r bl asts.
Conti nue unti l cl ean water fl ows through the l ead
away hose. For more i nformati on, refer to operati ng
i nstructi ons suppl i ed wi th fl ushi ng equi pment.
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng and i nstal l thermostat. I nstal l the ther-
mostat housi ng wi th a repl acement gasket. Refer to
Thermostat Repl acement. Connect the radi ator
hoses. Refi l l the cool i ng system wi th the correct anti -
freeze/water mi xture.
COOLANT PERFORMANCE
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water- Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol- The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149°C
(300°F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water -I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37°C (-34°F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7°C (-90°F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
Cool ant shoul d be mai ntai ned at the speci fi ed l evel
wi th a mi xture of ethyl ene gl ycol -based anti freeze
and l ow mi neral content water.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
REMOVAL AND INSTALLATION
AUTOMATIC TRANSMISSION OIL COOLER
The i nternal transmi ssi on oi l cool er l ocated wi thi n
the radi ator i s not servi ceabl e. I f i t requi res servi ce,
the radi ator must be repl aced.
Once the repai red or repl acement radi ator has
been i nstal l ed, fi l l the cool i ng system and i nspect for
l eaks. Refer to the Fi l l i ng Cool i ng System and Test-
i ng Cool i ng System For Leaks secti ons i n thi s group.
I f the transmi ssi on operates properl y after repai ri ng
the l eak, drai n the transmi ssi on and remove the
transmi ssi on oi l pan. I nspect for sl udge. I nspect for a
di rty or pl ugged i nl et fi l ter. I f none of these condi -
7 - 22 COOLING SYSTEM TJ
SERVICE PROCEDURES (Continued)
ti ons are found, the transmi ssi on and torque con-
verter may requi re recondi ti oni ng. Refer to Group 21
for automati c transmi ssi on servi ci ng.
COOLANT RESERVE/OVERFLOW BOTTLE
REMOVAL/INSTALLATION
(1) Di sconnect the hose from radi ator fi l l er neck.
(2) Remove cool ant recovery bottl e (Fi g. 20).
(3) Reverse the precedi ng steps for i nstal l ati on.
WATER PUMP
CAUTION: If the water pump is replaced because of
mechanical damage, the fan blades and viscous fan
drive should also be inspected. These components
could have been damaged due to excessive vibra-
tion.
REMOVAL
The water pump can be removed wi thout di scharg-
i ng the ai r condi ti oni ng system (i f equi pped).
CAUTION: All engines have a reverse (counter-
clockwise) rotating water pump. The letter R is
stamped into the back of the water pump impeller
(Fig. 21) to identify. Engines from previous model
years, depending upon application, may be
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump will
cause engine over heating.
The water pump i mpel l er i s pressed on the rear of
the pump shaft and beari ng assembl y. The water
pump i s servi ced onl y as a compl ete assembl y.
Fig. 20 Coolant Reserve/Overflow Bottle
1 – RADIATOR PRESSURE CAP
2 – HOSE
3 – COOLANT RECOVERY BOTTLE
Fig. 21 Reverse Rotating Water Pump—2.5L Engine
1 – R STAMPED INTO IMPELLER
Fig. 22 Water Pump—4.0L Engine
1 – HEATER HOSE FITTING BORE
2 – WATER PUMP
3 – WATER PUMP HUB
TJ COOLING SYSTEM 7 - 23
REMOVAL AND INSTALLATION (Continued)
WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n cool ant i nto a cl ean contai ner for
reuse.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Drai n the cool i ng system.
(3) 2.5L Engine Loosen (but do not remove at
thi s ti me) the four fan hub-to-water pump pul l ey
mounti ng nuts (Fi g. 23).
NOTE: The engine accessory drive belt must be
removed prior to removing the fan.
(4) Remove accessory dri ve bel t.
(5) 4.0L Engine The thermal vi scous fan dri ve/
fan bl ade assembl y i s attached (threaded) to water
pump hub shaft. Remove fan bl ade/vi scous fan dri ve
assembl y from water pump by turni ng mounti ng nut
countercl ockwi se as vi ewed from front. Threads on
vi scous fan dri ve are RIGHT HAND. Usi ng a sui t-
abl e fan wrench l oosen the fan dri ve.
(6) Remove power steeri ng pump (Fi g. 25). (Refer
to Group 19 Steeri ng).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 26) SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 27). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(7) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump fi tti ng.
(8) 2.5L Engine Remove four nuts previ ousl y
l oosened and remove the fan bl ade assembl y and pul -
l ey.
(9) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
(10) Remove the four pump mounti ng bol ts (Fi g.
28) and remove pump from vehi cl e. Di scard ol d gas-
ket. Note that one of the four bol ts i s l onger than the
other bol ts.
(11) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
Fig. 23 Fan Mounting Nuts—2.5L Engine
1 – THERMAL VISCOUS FAN DRIVE
2 – (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 – (4) FAN HUB-TO-PUMP PULLEY STUDS
4 – WATER PUMP
5 – WATER PUMP PULLEY
6 – FAN BLADE
7 – (4) FAN HUB-TO-PUMP PULLEY NUTS
Fig. 24 Fan and Fan Drive Mounting—4.0L Engine
1 – FAN AND FAN DRIVE
2 – WATER PUMP PULLEY
7 - 24 COOLING SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose fi tti ng to the pump. Use a seal ant on the fi tti ng
such as Mopar௡ Thread Seal ant Wi th Tefl on. Refer to
the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
pump mati ng surfaces for erosi on or damage from
cavi tati on.
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 23 N·m (200 i n. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
(5) 2.5L Engine Posi ti on water pump pul l ey to
water pump hub.
(6) 2.5L Engine I nstal l fan and four nuts to
water pump hub. Ti ghten or nuts to 27 N·m (20 ft.
l bs.) torque.
(7) I nstal l power steeri ng pump.
(8) 4.0L Engine Thread the fan and fan hub i nto
the water pump hub shaft.
Fig. 25 Power Steering Pump Attachment—2.5L and 4.0L
1 – PUMP ASSEMBLY 2.5L 2 – PUMP ASSEMBLY 4.0L
3 – TENSIONER PULLEY AND BRACKET 2.5L
Fig. 26 Hose Clamp Tool–Typical
1 – HOSE CLAMP TOOL 6094
2 – HOSE CLAMP
TJ COOLING SYSTEM 7 - 25
REMOVAL AND INSTALLATION (Continued)
CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. Refer to
the Belt Removal and Installation in this group for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.
(9) I nstal l accessory dri ve bel t. 2.5L Engine Ten-
si on dri ve bel ts. Refer to Accessory Dri ve Bel t
removal and i nstal l ati on i n thi s group.
(10) Fi l l cool i ng system wi th cool ant and check for
l eaks. Refer to Refi l l i ng Cool i ng System i n thi s
group.
(11) Connect battery cabl e to battery.
(12) Start and warm the engi ne. Check for l eaks.
THERMOSTAT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
(1) Drai n the cool ant from the radi ator unti l the
l evel i s bel ow the thermostat housi ng.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 26). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 27). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
Fig. 27 Clamp Number/Letter Location
1 – TYPICAL CONSTANT TENSION HOSE CLAMP
2 – CLAMP NUMBER/LETTER LOCATION
3 – TYPICAL HOSE
Fig. 28 Water Pump Remove/Install—2.5L Engine
1 – HEATER HOSE FITTING
2 – BOLTS (3) SHORT
3 – UPPER VENT HOLE
4 – PUMP GASKET
5 – WATER PUMP
6 – LOWER VENT HOLE
7 – LONG BOLT
7 - 26 COOLING SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(2) Remove radi ator upper hose and heater hose at
thermostat housi ng.
(3) Di sconnect wi ri ng connector at engi ne cool ant
temperature sensor.
(4) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng, gasket and thermostat (Fi g. 30).
Di scard ol d gasket.
(5) Cl ean the gasket mati ng surfaces.
INSTALLATION
(1) I nstal l the repl acement thermostat so that the
pel l et, whi ch i s enci rcl ed by a coi l spri ng, faces the
engi ne. Al l thermostats are marked on the outer
fl ange to i ndi cate the proper i nstal l ed posi ti on.
(2) Observe the recess groove i n the engi ne cyl i n-
der head (Fi g. 31).
(3) Posi ti on thermostat i nto thi s groove wi th arrow
and ai r bl eed hol e on outer fl ange poi nti ng up.
(4) I nstal l repl acement gasket and thermostat
housi ng.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
may result in a cracked housing.
(5) Ti ghten the housi ng bol ts to 20 N·m (15 ft. l bs.)
torque.
(6) I nstal l hoses to thermostat housi ng.
(7) I nstal l el ectri cal connector to cool ant tempera-
ture sensor.
Fig. 29 Water Pump Remove/Install—4.0L Engine
1 – HEATER HOSE FITTING
2 – PUMP GASKET
3 – WATER PUMP
4 – LONG BOLT
5 – BOLTS (4) SHORT
Fig. 30 Thermostat Removal/Installation
1 – LONG BOLT
2 – GASKET
3 – THERMOSTAT
4 – THERMOSTAT HOUSING
5 – SHORT BOLT
Fig. 31 Thermostat Recess
1 – GROOVE
TJ COOLING SYSTEM 7 - 27
REMOVAL AND INSTALLATION (Continued)
(8) Be sure that the radi ator drai ncock i s ti ghtl y
cl osed. Fi l l the cool i ng system to the correct l evel
wi th the requi red cool ant mi xture. Refer to Refi l l i ng
Cool i ng System i n thi s group.
(9) Start and warm the engi ne. Check for l eaks.
RADIATOR
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Observe the previ ous WARNING. Remove the
radi ator cap.
(3) Remove the condenser l ower seal from the
l ower core support (Fi g. 32).
(4) Posi ti on drai n pan under drai ncock. Open radi -
ator drai ncock and drai n radi ator. DO NOT WASTE
reusabl e cool ant. I f sol uti on i s cl ean, drai n cool ant
i nto a cl ean contai ner for reuse.
(5) Remove radi ator upper and l ower hose cl amps.
Remove radi ator hoses.
(6) Di sconnect cool ant reserve/overfl ow tank hose
from radi ator.
(7) Remove the four fan shroud mounti ng bol ts
(Fi g. 33). On some model s the power steeri ng fl ui d
reservoi r tank i s attached to the si de of the fan
shroud. Ti e the reservoi r back to prevent spi l l age.
Posi ti on the fan shroud back over the fan bl ades.
(8) I f equi pped, di sconnect and pl ug automati c
transmi ssi on fl ui d cool er l i nes.
(9) Remove si x radi ator mounti ng bol ts. Posi ti on
the front axl e vent hose (Fi g. 33) to the si de.
(10) Li ft radi ator strai ght up and out of vehi cl e
taki ng care not to damage radi ator fi ns.
(11) When removi ng radi ator, note posi ti on of the
rubber seal s l ocated on the top and bottom of radi a-
tor (on certai n model s onl y) (Fi g. 33). To prevent pos-
si bl e overheati ng, these seal s must be i nstal l ed to
thei r ori gi nal posi ti ons.
INSTALLATION
(1) Posi ti on the radi ator. I nstal l and ti ghten the
si x mounti ng bol ts (Fi g. 33) to 8 N·m (72 i n. l bs.)
torque.
(2) Cl ose radi ator drai ncock.
(3) Posi ti on fan shroud and power steeri ng reser-
voi r tank (i f equi pped). I nstal l and ti ghten four
mounti ng bol ts to 8 N·m (72 i n. l bs.) torque.
(4) I f equi pped, remove pl ugs and connect auto-
mati c transmi ssi on fl ui d cool er l i nes and constant
tensi on cl amps.
(5) Connect radi ator hoses and i nstal l hose cl amps.
(6) Posi ti on and i nstal l the condenser l ower seal
(Fi g. 32).
(7) Connect battery negati ve cabl e.
(8) Fi l l cool i ng system wi th correct cool ant. Refer
to Cool i ng Sytem Refi l l i ng i n thi s group.
(9) Connect cool ant recovery bottl e hose.
(10) I nstal l radi ator cap.
(11) Check and adjust automati c transmi ssi on
fl ui d l evel (i f equi pped).
(12) Start engi ne and check for l eaks.
BLOCK HEATER
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
(1) Drai n cool ant from radi ator and engi ne cyl i n-
der bl ock.
(2) Unpl ug power cord from bl ock heater.
(3) Loosen screw i n center of bl ock heater (Fi g. 34)
or (Fi g. 35).
(4) Remove bl ock heater from cyl i nder bl ock.
INSTALLATION
(1) Thoroughl y cl ean the engi ne core hol e and the
bl ock heater seat.
Fig. 32 Condenser Lower Seal
7 - 28 COOLING SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(2) I nsert bl ock heater assembl y i nto core hol e
wi th el ement l oop poi nti ng Up.
(3) Seat bl ock heater fl ush agai nst bl ock face.
Ti ghten mounti ng screw to 4 N·m (31 i n. l bs.) torque.
(4) Fi l l cool i ng system wi th cool ant. Pressuri ze
system and i nspect for l eaks.
(5) Pl ug power cord i nto bl ock heater. Route cord
away from movi ng parts, l i nkages and exhaust sys-
tem components. Secure cord i n pl ace wi th ti e-straps.
VISCOUS FAN
REMOVAL
(1) 2.5L Engine Loosen but do not remove at thi s
ti me, the four fan hub mounti ng nuts (Fi g. 36).
(2) 4.0L Engine The thermal vi scous fan dri ve/
fan bl ade assembl y i s attached (threaded) to water
pump hub shaft. Remove fan bl ade/vi scous fan dri ve
assembl y from water pump by turni ng mounti ng nut
countercl ockwi se as vi ewed from front. Threads on
vi scous fan dri ve are RIGHT HAND. Usi ng a sui t-
abl e fan wrench l oosen the fan dri ve (Fi g. 37).
(3) Remove accessory dri ve bel t. Refer to Bel t Ser-
vi ce i n the Engi ne Accessory Dri ve Bel t secti on of
thi s group.
Fig. 33 Radiator—Remove/Install
1 – A/C CONDENSER SEALS
2 – FAN SHROUD (4.0L)
3 – FAN SHROUD (2.5L)
4 – TRANSMISSION OIL COOLER LINES RETAINER CLIPS
5 – COOLANT RECOVERY BOTTLE
6 – TRANSMISSION COOLER LINES (IF EQUIPPED)
7 – FRONT AXLE VENT HOSE
Fig. 34 Block Heater and Cord—2.5L Engine
1 – POWER CORD
2 – BLOCK HEATER
3 – TIE-STRAPS
TJ COOLING SYSTEM 7 - 29
REMOVAL AND INSTALLATION (Continued)
(4) Some model s wi th certai n engi nes may requi re
the removal of the fan shroud to remove the vi scous
fan dri ve. The fan shroud and fan bl ade/vi scous fan
dri ve shoul d be removed from the vehi cl e as one
assembl y.
(5) 2.5L Engine Remove four fan hub mounti ng
nuts (Fi g. 36) and remove fan/vi scous fan dri ve
assembl y from vehi cl e.
(6) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
INSTALLATION
(1) Assembl e fan bl ade to vi scous fan dri ve.
Ti ghten mounti ng bol ts to 27 N·m (20 ft. l bs.) torque.
(2) 2.5L Engine Posi ti on mounti ng fl ange of fan
bl ade/vi scous fan dri ve assembl y onto hub. I nstal l
four nuts and ti ghten to 24 N·m (18 ft. l bs.) torque.
Ti ghten the fi rst two nuts 180 degrees apart. Then
ti ghten l ast two nuts.
(3) 4.0L Engine Thread the fan and fan dri ve
onto the water pump pul l ey.
Fig. 35 Block Heater and Cord—4.0L Engine
1 – POWER CORD
2 – FWD
3 – BLOCK HEATER
4 – TIE-STRAPS
Fig. 36 Fan Mount—2.5L Engine
1 – THERMAL VISCOUS FAN DRIVE
2 – (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 – (4) FAN HUB-TO-PUMP PULLEY STUDS
4 – WATER PUMP
5 – WATER PUMP PULLEY
6 – FAN BLADE
7 – (4) FAN HUB-TO-PUMP PULLEY NUTS
Fig. 37 Fan and Fan Drive—4.0L Engine
1 – FAN AND FAN DRIVE
2 – WATER PUMP PULLEY
7 - 30 COOLING SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. Refer to Serpentine
Drive Belt Removal and Installation in this group for
correct belt routing.
VISCOUS FAN DRIVE
Refer to Cool i ng System Fan for removal and
i nstal l ati on procedures of the vi scous dri ve uni t.
Viscous Fan Drive Fluid Pump Out Require-
ment: After i nstal l i ng a new vi scous fan dri ve, bri ng
the engi ne speed up to approxi matel y 2000 rpm and
hol d for approxi matel y two mi nutes. Thi s wi l l ensure
proper fl ui d di stri buti on wi thi n the dri ve.
ACCESSORY DRIVE BELT
Correct dri ve bel t tensi on i s requi red to ensure
opti mum performance of the bel t dri ven engi ne acces-
sori es. There are di fferent types of adjustment
gauges for checki ng ei ther a serpenti ne or a V-type
bel t. Refer to the i nstructi ons suppl i ed wi th the
gauge. Use the correct gauge when checki ng bel t ten-
si on. Pl ace gauge i n the mi ddl e of the secti on of bel t
bei ng tested (between two pul l eys) to check tensi on.
Do not al l ow the gauge (or gauge adapter) to contact
anythi ng but the bel t.
BELT SCHEMATICS
The bel t routi ng schemati cs are publ i shed from the
l atest i nformati on avai l abl e at the ti me of publ i ca-
ti on. Vehi cl es not equi pped wi th Power Steeri ng have
an i dl er pul l ey i n pl ace of the power steeri ng pump
pul l ey. If anything differs between these sche-
matics and the Belt Routing Label, use the
schematics on Belt Routing Label. Thi s l abel i s
l ocated i n the engi ne compartment.
Refer to (Fi g. 38) (Fi g. 39) (Fi g. 40) (Fi g. 41) for
correct bel t routi ng, or refer to Bel t Routi ng Label
l ocated i n the vehi cl e engi ne compartment.
Fig. 39 4.0L Engines–With A/C
1 – GENERATOR PULLEY
2 – IDLER PULLEY
3 – POWER STEERING PUMP PULLEY
4 – AIR CONDITIONING COMPRESSOR PULLEY
5 – CRANKSHAFT PULLEY
6 – WATER PUMP PULLEY
7 – TENSIONER PULLEY
Fig. 38 2.5L Engines–With A/C
1 – GENERATOR PULLEY
2 – AIR CONDITIONING COMPRESSOR PULLEY
3 – IDLER PULLEY
4 – POWER STEERING PUMP PULLEY
5 – WATER PUMP PULLEY
6 – IDLER PULLEY
7 – CRANKSHAFT PULLEY
TJ COOLING SYSTEM 7 - 31
REMOVAL AND INSTALLATION (Continued)
BELT REPLACEMENT
REMOVAL
Bel t tensi on i s adjusted at the power steeri ng
pump bracket and i dl er pul l ey assembl y.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Loosen i dl er pul l ey bol t (Fi g. 42).
(3) Loosen tensi on adjusti ng bol t (Fi g. 42) and
remove accessory dri ve bel t.
INSTALLATION
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine acces-
sory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water
pump rotating in the wrong direction. Refer to (Fig.
38) (Fig. 39) (Fig. 40) (Fig. 41) for correct belt rout-
ing.
(2) I nstal l new bel t. I nstal l bel t tensi on gauge
C-4162 and ti ghten adjustment bol t (Fi g. 42) unti l
bel t tensi on i s wi thi n speci fi cati on range. Refer to the
end of thi s group for Dri ve Bel t Tensi on speci fi ca-
ti ons.
(3) Ti ghten i dl er pul l ey bol t and re-check bel t ten-
si on. Adjust i f necessary.
Fig. 40 2.5L Engines—Without A/C
1 – GENERATOR PULLEY
2 – IDLER PULLEY
3 – WATER PUMP PULLEY
4 – POWER STEERING PUMP PULLEY
5 – IDLER PULLEY
6 – CRANKSHAFT PULLEY
Fig. 41 4.0L Engines—Without A/C
1 – GENERATOR PULLEY
2 – IDLER PULLEY
3 – POWER STEERING PUMP PULLEY
4 – WATER PUMP PULLEY
5 – CRANKSHAFT PULLEY
6 – TENSIONER PULLEY
Fig. 42 Power Steering Pump Bracket and Idler
Pulley—2.5L
1 – ADJUSTMENT BOLT
2 – IDLER BOLT/ANCHOR BOLT
3 – ACCESSORY DRIVE BELT
7 - 32 COOLING SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
CLEANING AND INSPECTION
RADIATOR PRESSURE CAP
CLEANING
Use onl y a mi l d soap and water to cl ean the radi -
ator cap. Usi ng any type sol vent may cause damage
to the seal i n the radi ator cap.
INSPECTION
Hol d cap at eye l evel , ri ght si de up. The vent val ve
at bottom of cap shoul d open. I f rubber gasket has
swol l en and prevents vent val ve from openi ng,
repl ace cap.
Hol d cap at eye l evel , upsi de down. I f any l i ght can
be seen between vent val ve and rubber gasket,
repl ace cap. Do not use a replacement cap that
has a spring to hold vent shut. A repl acement cap
must be the type desi gned for a cool ant reserve/over-
fl ow system wi th a compl etel y seal ed di aphragm
spri ng and a rubber gasket. Thi s gasket i s used to
seal to radi ator fi l l er neck top surface. Use of proper
cap wi l l al l ow cool ant return to radi ator.
RADIATOR
CLEANING
Cl ean radi ator fi ns. Wi th the engi ne col d, appl y
col d water and compressed ai r to the back (engi ne
si de) of the radi ator to fl ush the radi ator and/or A/C
condenser of debri s.
INSPECTION
The radi ator cool i ng fi ns shoul d be checked for
damage or deteri orati on. I nspect cool i ng fi ns to make
sure they are not bent or crushed, these areas resul t
i n reduced heat exchange causi ng the cool i ng system
to operate at hi gher temperatures. I nspect the pl asti c
end tanks for cracks, damage or l eaks.
I nspect the radi ator neck for damage or di storti on.
FAN BLADE
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan bl ade assembl y from vi scous fan
dri ve uni t (four bol ts).
(2) Lay fan on a fl at surface wi th l eadi ng edge fac-
i ng down. Wi th ti p of bl ade touchi ng fl at surface,
repl ace fan i f cl earance between opposi te bl ade and
surface i s greater than 2.0 mm (.090 i nch). Rocki ng
moti on of opposi te bl ades shoul d not exceed 2.0 mm
(.090 i nch). Test al l bl ades i n thi s manner.
(3) I nspect fan assembl y for cracks, bends, l oose
ri vets or broken wel ds. Repl ace fan i f any damage i s
found.
ADJ USTMENTS
ACCESSORY DRIVE BELT— 2. 5L ENGINE
Correct dri ve bel t tensi on i s requi red to ensure
opti mum performance of the bel t dri ven engi ne acces-
sori es. There are di fferent types of adjustment
gauges for checki ng ei ther a serpenti ne or a V-type
bel t. Refer to the i nstructi ons suppl i ed wi th the
gauge. Use the correct gauge when checki ng bel t ten-
si on. Pl ace gauge i n the mi ddl e of the secti on of bel t
bei ng tested (between two pul l eys) to check tensi on.
Do not al l ow the gauge (or gauge adapter) to contact
anythi ng but the bel t.
Wi th the engi ne off (not runni ng), vi sual l y i nspect
accessory dri ve bel t for gl azi ng, cracks or chunks
mi ssi ng. Al so i nspect pul l eys for mi sal i gnment or
defects. Refer to accessory dri ve bel t di agnosi s i n thi s
group for the correct bel t di agnosti c procedures.
(1) Di sconnect battery negati ve cabl e.
(2) I nstal l bel t tensi on gauge C-4162 and compare
readi ng wi th those i n the accessory dri ve bel t tensi on
speci fi cati on chart.
ACCESSORY DRIVE BELT TENSION CHART
BELT TENSION
**NEW SERPENTINE
BELT
800-900 N (180-200 lbs.)
USED SERPENTINE
BELT
623-712 N (140-160 lbs.)
**Belt is considered new if it has been used 15
minutes or less.
Specifications for use with a belt tension gauge. Refer
to operating instructions supplied with gauge.
TJ COOLING SYSTEM 7 - 33
I f tensi on i s wi thi n speci fi cati ons and no adjust-
ment i s needed, remove bel t tensi on gauge C-4162
and connect battery negati ve cabl e.
I f bel t tensi on i s out of speci fi cati on and adjust-
ment i s necessary, conti nue wi th the fol l owi ng proce-
dure.
(3) Loosen i dl er pul l ey bol t (Fi g. 43).
(4) Adjust tensi on adjusti ng bol t (Fi g. 43) unti l
readi ng i s wi thi n speci fi cati on.
(5) Ti ghten i dl er pul l ey bol t and re-check bel t ten-
si on. Adjust i f necessary.
SPECIFICATIONS
COOLING SYSTEM CAPACITIES
NOTE: Cooling system capacity does not vary with
or without A/C since the components are the same.
ACCESSORY DRIVE BELT TENSION— 2. 5L
TORQUE
Fig. 43 Power Steering Pump Bracket and Idler
Pulley
1 – ADJUSTING BOLT
2 – IDLER PULLEY BOLT
ENGINE CAPACITY
2.5L 8.5L (9.0 Qts.)
4.0L 9.9L (10.5 Qts.)
BELT TENSION
**NEW SERPENTINE
BELT
800-900 N (180-200 lbs.)
USED SERPENTINE
BELT
623-712 N (140-160 lbs.)
**Belt is considered new if it has been used 15
minutes or less.
Specifications for use with a belt tension gauge. Refer
to operating instructions supplied with gauge.
TORQUE CHART
DESCRIPTION N·m Ft In
Lbs Lbs
Block Heater—Fastener 4 — 31
Fan Blade–to–Viscous
Fan
Drive—Bolts 24 18 —
Fan Shroud—Screws 8 — 72
Generator Pivot—Bolt
(2.5L)
27 20 —
Radiator Mounting—
Bolts
8 — 72
Thermostat Housing—
Bolts
20 15 —
Transmission Cooler
Lines
Fittings at Radiator 16 — 140
Pressure Fitting at
Trans.
20 — 180
Viscous Fan Drive-to-
Water
Pump—Nuts (2.5L) 23 — 200
Viscous Fan Drive to
Water
Pump—Studs (2.5L) 11 — 100
Water Pump—Bolts 23 — 200
7 - 34 COOLING SYSTEM TJ
ADJ USTMENTS (Continued)
SPECIAL TOOLS
COOLING
Hose Clamp Pliers—6094
Belt Tension Gauge —C-4162
Cooling System Pressure Tester—7700–A
Quick Disconnect Tool—6935
TJ COOLING SYSTEM 7 - 35
BATTERY
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . . 3
BATTERY HOLD DOWNS . . . . . . . . . . . . . . . . . . . 4
BATTERY THERMOGUARD. . . . . . . . . . . . . . . . . . 4
BATTERY TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING
BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE PROCEDURES
BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . 16
REMOVAL AND INSTALLATION
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . 18
BATTERY HOLD DOWNS . . . . . . . . . . . . . . . . . . 19
BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BATTERY THERMOGUARD. . . . . . . . . . . . . . . . . 21
BATTERY TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . 21
CLEANING AND INSPECTION
BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION AND OPERATION
BATTERY
DESCRIPTION
A l arge capaci ty, l ow-mai ntenance storage battery
(Fi g. 1) i s standard factory-i nstal l ed equi pment on
thi s model . Mal e post type termi nal s made of a soft
l ead materi al protrude from the top of the mol ded
pl asti c battery case to provi de the means for connect-
i ng the battery to the vehi cl e el ectri cal system. The
battery posi ti ve termi nal post i s vi si bl y l arger i n
di ameter than the negati ve termi nal post, for easy
i denti fi cati on. The l etters POS and NEG are al so
mol ded i nto the top of the battery case adjacent to
thei r respecti ve posi ti ve and negati ve termi nal posts
for addi ti onal i denti fi cati on confi rmati on. Refer to
Battery Cables i n the i ndex of thi s servi ce manual
for the l ocati on of more i nformati on on the battery
cabl es that connect the battery to the vehi cl e el ectri -
cal system.
Thi s battery i s desi gned to provi de a safe, effi ci ent
and rel i abl e means of stori ng el ectri cal energy i n a
chemi cal form. Thi s means of energy storage al l ows
the battery to produce the el ectri cal energy requi red
to operate the engi ne starti ng system, as wel l as to
operate many of the other vehi cl e accessory systems
for l i mi ted durati ons whi l e the engi ne and/or the
chargi ng system are not operati ng. The battery i s
made up of si x i ndi vi dual cel l s that are connected i n
seri es. Each cel l contai ns posi ti vel y charged pl ate
groups that are connected wi th l ead straps to the
posi ti ve termi nal post, and negati vel y charged pl ate
groups that are connected wi th l ead straps to the
negati ve termi nal post. Each pl ate consi sts of a sti ff
mesh framework or gri d coated wi th l ead di oxi de
(posi ti ve pl ate) or sponge l ead (negati ve pl ate). I nsu-
l ators or pl ate separators made of a non-conducti ve
materi al are i nserted between the posi ti ve and nega-
ti ve pl ates to prevent them from contacti ng or short-
i ng agai nst one another. These di ssi mi l ar metal
Fig. 1 Low-Maintenance Battery - Typical
1 – POSITIVE POST
2 – VENT
3 – CELL CAP
4 – TEST INDICATOR
5 – CELL CAP
6 – VENT
7 – NEGATIVE POST
8 – GREEN BALL
9 – ELECTROLYTE LEVEL
10 – PLATE GROUPS
11 – LOW-MAINTENANCE BATTERY
TJ BATTERY 8A - 1
pl ates are submerged i n a sul furi c aci d and water
sol uti on cal l ed an el ectrol yte.
The factory-i nstal l ed battery has a bui l t-i n test
i ndi cator (hydrometer). The col or vi si bl e i n the si ght
gl ass of the i ndi cator wi l l reveal the battery condi -
ti on. For more i nformati on on the use of the bui l t-i n
test i ndi cator, refer to Battery i n the i ndex of thi s
servi ce manual for the l ocati on of the proper battery
di agnosi s and testi ng procedures. The factory-in-
stalled low-maintenance battery has removable
battery cell caps. Water can be added to thi s bat-
tery. The battery i s not seal ed and has vent hol es i n
the cel l caps. The chemi cal composi ti on of the metal
coated pl ates wi thi n the l ow-mai ntenance battery
reduces battery gassi ng and water l oss, at normal
charge and di scharge rates. Therefore, the battery
shoul d not requi re addi ti onal water i n normal ser-
vi ce. I f the el ectrol yte l evel i n thi s battery does
become l ow, water must be added. However, rapi d
l oss of el ectrol yte can be caused by an overchargi ng
condi ti on. Be certai n to di agnose the chargi ng system
after repl eni shi ng the water i n the battery for a l ow
el ectrol yte condi ti on and before returni ng the vehi cl e
to servi ce. Refer to Charging Systemi n the i ndex of
thi s servi ce manual for the l ocati on of the proper
chargi ng system di agnosi s and testi ng procedures.
For battery mai ntenance schedul es and jump start-
i ng procedures, see the owner’s manual i n the vehi cl e
gl ove box. Opti onal l y, refer to Maintenance Sched-
ules and J ump Starting, Towing and Hoisting i n
the i ndex of thi s servi ce manual for the l ocati on of
the recommended battery mai ntenance schedul es and
the proper battery jump starti ng procedures. Whi l e
battery chargi ng can be consi dered a mai ntenance
procedure, the battery chargi ng procedures and i nfor-
mati on are l ocated i n the servi ce procedures secti on
of thi s servi ce manual . Thi s was done because the
battery must be ful l y-charged before any battery
di agnosi s or testi ng procedures can be performed.
Refer to Battery Charging i n the i ndex of thi s ser-
vi ce manual for the l ocati on of the proper battery
chargi ng procedures.
BATTERY SIZE AND RATINGS
The battery Group Si ze number, the Col d Cranki ng
Amperage (CCA) rati ng, and the Reserve Capaci ty
(RC) rati ng or Ampere-Hours (AH) rati ng can be
found on the ori gi nal equi pment battery l abel . Be
certai n that a repl acement battery has the correct
Group Si ze number, as wel l as CCA, and RC or AH
rati ngs that equal or exceed the ori gi nal equi pment
speci fi cati on for the vehi cl e bei ng servi ced. Refer to
Battery i n the i ndex of thi s servi ce manual for the
l ocati on of the proper factory-i nstal l ed battery speci -
fi cati ons. Battery si zes and rati ngs are di scussed i n
more detai l bel ow.
• Group Si ze
The outsi de di mensi ons and termi nal pl acement of
the battery conform to standards establ i shed by the
Battery Counci l I nternati onal (BCI ). Each battery i s
assi gned a BCI Group Si ze number to hel p i denti fy a
correctl y-si zed repl acement.
• Col d Cranki ng Amperage
The Col d Cranki ng Amperage (CCA) rati ng speci fi es
how much current (i n amperes) the battery can
del i ver for thi rty seconds at -18° C (0° F). Termi nal
vol tage must not fal l bel ow 7.2 vol ts duri ng or after
the thi rty second di scharge peri od. The CCA requi red
i s general l y hi gher as engi ne di spl acement i ncreases,
dependi ng al so upon the starter current draw
requi rements.
• Reserve Capaci ty
The Reserve Capaci ty (RC) rati ng speci fi es the ti me
(i n mi nutes) i t takes for battery termi nal vol tage to
fal l bel ow 10.5 vol ts, at a di scharge rate of 25
amperes. RC i s determi ned wi th the battery ful l y-
charged at 26.7° C (80° F). Thi s rati ng esti mates how
l ong the battery mi ght l ast after a chargi ng system
fai l ure, under mi ni mum el ectri cal l oad.
• Ampere-Hours
The Ampere-Hours (AH) rati ng speci fi es the current
(i n amperes) that a battery can del i ver steadi l y for
twenty hours, wi th the vol tage i n the battery not fal l -
i ng bel ow 10.5 vol ts. Thi s rati ng i s al so someti mes
i denti fi ed as the twenty-hour di scharge rati ng.
OPERATION
When an el ectri cal l oad i s appl i ed to the termi nal s
of the battery, an el ectrochemi cal reacti on occurs.
Thi s reacti on causes the battery to di scharge el ectri -
cal current from i ts termi nal s. As the battery di s-
charges, a gradual chemi cal change takes pl ace
wi thi n each cel l . The sul furi c aci d i n the el ectrol yte
combi nes wi th the pl ate materi al s, causi ng both
pl ates to sl owl y change to l ead sul fate. At the same
ti me, oxygen from the posi ti ve pl ate materi al com-
bi nes wi th hydrogen from the sul furi c aci d, causi ng
the el ectrol yte to become mai nl y water. The chemi cal
changes wi thi n the battery are caused by the move-
ment of excess or free el ectrons between the posi ti ve
and negati ve pl ate groups. Thi s movement of el ec-
trons produces a fl ow of el ectri cal current through
the l oad devi ce attached to the battery termi nal s.
As the pl ate materi al s become more si mi l ar chem-
i cal l y, and the el ectrol yte becomes l ess aci d, the vol t-
age potenti al of each cel l i s reduced. However, by
chargi ng the battery wi th a vol tage hi gher than that
of the battery i tsel f, the battery di schargi ng process
i s reversed. Chargi ng the battery gradual l y changes
the sul fated l ead pl ates back i nto sponge l ead and
8A - 2 BATTERY TJ
DESCRIPTION AND OPERATION (Continued)
l ead di oxi de, and the water back i nto sul furi c aci d.
Thi s acti on restores the di fference i n the el ectron
charges deposi ted on the pl ates, and the vol tage
potenti al of the battery cel l s. For a battery to remai n
useful , i t must be abl e to produce hi gh-amperage cur-
rent over an extended peri od. A battery must al so be
abl e to accept a charge, so that i ts vol tage potenti al
may be restored.
The battery i s vented to rel ease excess hydrogen
gas that i s created when the battery i s bei ng charged
or di scharged. However, even wi th these vents,
hydrogen gas can col l ect i n or around the battery. I f
hydrogen gas i s exposed to fl ame or sparks, i t may
i gni te. I f the el ectrol yte l evel i s l ow, the battery may
arc i nternal l y and expl ode. I f the battery i s equi pped
wi th removabl e cel l caps, add di sti l l ed water when-
ever the el ectrol yte l evel i s bel ow the top of the
pl ates. I f the battery cel l caps cannot be removed, the
battery must be repl aced i f the el ectrol yte l evel
becomes l ow.
I n addi ti on to produci ng and stori ng el ectri cal
energy, the battery serves as a capaci tor and vol tage
stabi l i zer for the el ectri cal system of the vehi cl e. I t
absorbs most abnormal or transi ent vol tages caused
by the swi tchi ng of any of the el ectri cal components
i n the vehi cl e.
BATTERY CABLES
DESCRIPTION
The battery cabl es (Fi g. 2) are l arge gauge,
stranded copper wi res sheathed wi thi n a heavy pl as-
ti c or syntheti c rubber i nsul ati ng jacket. The wi re
used i n the battery cabl es combi nes excel l ent fl exi bi l -
i ty and rel i abi l i ty wi th hi gh el ectri cal current carry-
i ng capaci ty. Refer to Wiring Diagrams i n the i ndex
of thi s servi ce manual for the l ocati on of the proper
battery cabl e wi re gauge i nformati on.
A cl ampi ng type femal e battery termi nal made of
soft l ead i s di e cast onto one end of the battery cabl e
wi re. A square headed pi nch-bol t and hex nut are
i nstal l ed at the open end of the femal e battery termi -
nal cl amp. Large eyel et type termi nal s are cri mped
onto the opposi te end of the battery cabl e wi re and
then sol der-di pped. The battery posi ti ve cabl e wi res
have a red i nsul ati ng jacket to provi de vi sual i denti -
fi cati on and features a l arger femal e battery termi nal
cl amp to al l ow connecti on to the l arger battery posi -
ti ve termi nal post. The battery negati ve cabl e wi res
have a bl ack i nsul ati ng jacket and a smal l er femal e
battery termi nal cl amp.
The battery cabl es cannot be repai red and, i f dam-
aged or faul ty they must be repl aced. Both the bat-
tery posi ti ve and negati ve cabl es are avai l abl e for
servi ce repl acement onl y as a uni t wi th the battery
wi re harness, whi ch may i ncl ude porti ons of the wi r-
i ng ci rcui ts for the generator and other components
on some model s. Refer to Wiring Diagrams i n the
i ndex of thi s servi ce manual for the l ocati on of more
i nformati on on the vari ous wi ri ng ci rcui ts i ncl uded i n
the battery wi re harness for the vehi cl e bei ng ser-
vi ced.
OPERATION
The battery cabl es connect the battery termi nal
posts to the vehi cl e el ectri cal system. These cabl es
al so provi de a return path for el ectri cal current gen-
erated by the chargi ng system for restori ng the vol t-
age potenti al of the battery. The femal e battery
termi nal cl amps on the ends of the battery cabl e
wi res provi de a strong and rel i abl e connecti on of the
battery cabl e to the battery termi nal posts. The ter-
mi nal pi nch bol ts al l ow the femal e termi nal cl amps
to be ti ghtened around the mal e termi nal posts on
the top of the battery. The eyel et termi nal s secured
to the ends of the battery cabl e wi res opposi te the
femal e battery termi nal cl amps provi de secure and
rel i abl e connecti on of the battery to the vehi cl e el ec-
tri cal system.
The battery posi ti ve cabl e termi nal cl amp i s di e
cast onto the ends of two wi res. One wi re has a two-
hol ed eyel et termi nal that connects the battery posi -
ti ve cabl e to the B(+) termi nal studs of the Power
Fig. 2 Battery Cables
1 – POSITIVE CABLE
2 – TERMINAL CLAMPS
3 – DASH PANEL
4 – NEGATIVE CABLE
5 – POWER DISTRIBUTION CENTER
6 – FENDER
TJ BATTERY 8A - 3
DESCRIPTION AND OPERATION (Continued)
Di stri buti on Center (PDC), and the other wi re has an
eyel et termi nal that connects the battery posi ti ve
cabl e to the B(+) termi nal stud of the engi ne starter
motor sol enoi d. The battery negati ve cabl e termi nal
cl amp i s al so di e cast onto the ends of two wi res. One
wi re has an eyel et termi nal that connects the battery
negati ve cabl e to the vehi cl e powertrai n through a
stud on the ri ght si de of the engi ne bl ock. The other
wi re has an eyel et termi nal that connects the battery
negati ve cabl e to the vehi cl e body through a ground
screw on the ri ght si de of the dash panel , near the
battery.
BATTERY HOLD DOWNS
DESCRIPTION
The battery hol d down hardware (Fi g. 3) i ncl udes
two J-bol ts, a hol d down bracket and two hex nuts
wi th coned washers. The battery hol d down bracket
consi sts of a stamped steel bracket that i s then pl as-
ti c-coated for corrosi on protecti on.
When i nstal l i ng a battery i nto the battery tray, be
certai n that the hol d down hardware i s properl y
i nstal l ed and that the fasteners are ti ghtened to the
proper speci fi cati ons. I mproper hol d down fastener
ti ghtness, whether too l oose or too ti ght, can resul t i n
damage to the battery, the vehi cl e or both. Refer to
Battery Hold Downs i n the i ndex of thi s servi ce
manual for the l ocati on of the proper battery hol d
down i nstal l ati on procedures, i ncl udi ng the proper
hol d down fastener ti ghtness speci fi cati ons.
OPERATION
The battery hol d down hardware secures the bat-
tery to the battery tray i n the engi ne compartment.
Thi s hardware i s desi gned to prevent battery move-
ment duri ng vehi cl e operati on. Unrestrai ned battery
movement duri ng vehi cl e operati on can resul t i n
damage to the vehi cl e, the battery or both.
The hol d down J-bol ts are i nstal l ed a hol e i n the
front and rear fl anges of the battery tray from the
top, wi th the threaded ends of the bol ts extendi ng
upward. The hooked end of each J-bol t i s then
engaged i n a second hol e i n the front and rear
fl anges of the battery tray from the bottom. The bat-
tery hol d down bracket i s i nstal l ed across the top of
the battery case and over the two upri ght threaded
ends of the J-bol ts. A hex nut wi th coned washer i s
then i nstal l ed and ti ghtened onto each of the J-bol ts
to securel y hol d down the battery i n the battery tray.
BATTERY THERMOGUARD
DESCRIPTION
A fl exi bl e pl asti c bubbl e-wrap styl e thermoguard
(Fi g. 4) sl i des over the battery case to encl ose the
si des of the battery. The thermoguard consi sts of a
heavy bl ack pl asti c outer ski n and two l i ghter pl i es of
pl asti c that have been formed i nto a sheet wi th hun-
dreds of smal l ai r pockets entrapped between them.
The resul ti ng materi al i s very si mi l ar to the bubbl e-
wrap used to protect i tems i n many parcel packagi ng
and shi ppi ng appl i cati ons.
Fig. 3 Battery Hold Downs
1 – J-BOLT (2)
2 – NUT (2)
3 – BRACKET
4 – BATTERY
Fig. 4 Battery Thermoguard
1 – THERMOGUARD
2 – BATTERY
8A - 4 BATTERY TJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
The thermoguard protects the battery from engi ne
compartment temperature extremes. The ai r trapped
between the pl asti c pl i es of the thermoguard create a
dead ai r space, whi ch hel ps to i nsul ate the si des of
the battery case from the surroundi ng engi ne com-
partment ai r temperature.
BATTERY TRAY
DESCRIPTION
The battery i s mounted i n a stamped steel tray
(Fi g. 5) l ocated i n the passenger si de rear corner of
the engi ne compartment. The battery tray i s secured
by four hex screws wi th washers to the rei nforcement
l ocated between the engi ne compartment si de of the
dash panel and the rear of the front fender wheel -
house i nner panel . Refer to Front Fender i n the
i ndex of thi s servi ce manual for the l ocati on of more
i nformati on on thi s rei nforcement, whi ch serves as
the battery tray support.
A hol e i n the bottom of the battery tray i s fi tted
wi th a battery temperature sensor. Refer to Battery
Temperature Sensor i n the i ndex of thi s servi ce
manual for the l ocati on of more i nformati on on the
battery temperature sensor. Refer to Battery Hold
Downs i n the i ndex of thi s servi ce manual for the
l ocati on of more i nformati on on the battery hol d
down hardware.
OPERATION
The battery tray provi des a mounti ng l ocati on and
support for the vehi cl e battery. The battery tray al so
provi des anchor poi nts for the battery hol d down
hardware. The battery tray and the battery hol d
down hardware combi ne to secure and stabi l i ze the
battery i n the engi ne compartment, whi ch prevents
battery movement duri ng vehi cl e operati on. Unre-
strai ned battery movement duri ng vehi cl e operati on
can resul t i n damage to the vehi cl e, the battery or
both.
DIAGNOSIS AND TESTING
BATTERY
DIAGNOSIS
The battery, starti ng system and chargi ng system
i n the vehi cl e operate wi th one another, and must be
tested as a compl ete system. I n order for the engi ne
to start and the battery to charge properl y, al l of the
components that are used i n these systems must per-
form wi thi n speci fi cati ons. I t i s i mportant that the
battery, starti ng system and chargi ng system be thor-
oughl y tested and i nspected any ti me a battery needs
to be charged or repl aced. The cause of abnormal di s-
charge, overchargi ng or earl y battery fai l ure must be
di agnosed and corrected before a battery i s repl aced
and before a vehi cl e i s returned to servi ce. The ser-
vi ce i nformati on for these systems has been sepa-
rated wi thi n thi s servi ce manual to make i t easi er to
l ocate the speci fi c i nformati on you are seeki ng. How-
ever, when attempti ng to di agnose any of these sys-
tems, i t i s i mportant that you keep thei r
i nterdependency i n mi nd.
The di agnosti c procedures used for the battery,
starti ng system and chargi ng system i ncl ude the
most basi c conventi onal di agnosti c methods, to the
more sophi sti cated On-Board Di agnosti cs (OBD) bui l t
i nto the Powertrai n Control Modul e (PCM). Use of an
i nducti on-type mi l l i ampere ammeter, a vol t/ohmme-
ter, a battery charger, a carbon pi l e rheostat (l oad
tester) and a 12-vol t test l amp may be requi red. Al l
OBD-sensed systems are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for any fai l ure i t detects. Refer to
Charging System, On-Board Diagnostic Test i n
the i ndex of thi s servi ce manual for the l ocati on of
the proper on-board di agnosti c test procedures.
The battery must be compl etel y charged and the
top, posts and termi nal cl amps shoul d be properl y
cl eaned and i nspected before di agnosti c procedures
Fig. 5 Battery Tray
1 – BATTERY TEMPERATURE SENSOR
2 – REINFORCEMENT
3 – BATTERY TRAY
4 – POWER DISTRIBUTION CENTER
TJ BATTERY 8A - 5
DESCRIPTION AND OPERATION (Continued)
are performed. Refer to Battery i n the i ndex of thi s
servi ce manual for the l ocati on of the proper battery
cl eani ng and i nspecti on procedures. Refer to Battery
Charging i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery chargi ng procedures.
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
The condi ti on of a battery i s determi ned by two cri -
teri a:
1. State-Of-Charge
Thi s can be determi ned by checki ng the speci fi c grav-
i ty of the battery el ectrol yte (bui l t-i n test i ndi cator or
hydrometer test), or by checki ng the battery vol tage
(open-ci rcui t vol tage test).
2. Cranki ng Capaci ty
Thi s can be determi ned by performi ng a battery l oad
test, whi ch measures the abi l i ty of the battery to
suppl y hi gh-amperage current.
Fi rst, determi ne the battery state-of-charge. Thi s
can be done i n one of three ways. I f the battery has a
bui l t-i n test i ndi cator, vi ew the test i ndi cator to
determi ne the state-of-charge. I f the battery has no
test i ndi cator but does have removabl e cel l caps, per-
form the hydrometer test to determi ne the state-of-
charge. I f the battery cel l caps are not removabl e, or
a hydrometer i s not avai l abl e, perform the open-ci r-
cui t vol tage test to determi ne the state-of-charge.
The battery must be charged before proceedi ng
wi th a l oad test i f:
• The battery bui l t-i n test i ndi cator has a bl ack or
dark col or vi si bl e.
• The temperature corrected speci fi c gravi ty of the
battery el ectrol yte i s l ess than 1.235.
• The battery open-ci rcui t vol tage i s l ess than 12.4
vol ts.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
requi red. A ful l y-charged battery must be l oad tested
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Battery
Charging in the index of this service manual for the
location of the proper battery charging procedures.
A battery i s ful l y-charged when:
• Al l battery cel l s are gassi ng freel y duri ng charg-
i ng.
• A green col or i s vi si bl e i n the si ght gl ass of the
battery bui l t-i n test i ndi cator.
• Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty of the battery el ectrol yte.
• Open-ci rcui t vol tage of the battery i s 12.4 vol ts
or greater.
8A - 6 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
Battery Diagnosis
Condition Possible Causes Correction
The battery seems weak or
dead when attempting to start
the engine.
1. The battery has an
incorrect size or rating for
this vehicle.
2. The battery is physically
damaged.
3. The battery terminal
connections are loose or
corroded.
4. The battery is discharged.
5. The electrical system
ignition-off draw is excessive.
6. The battery is faulty.
7. The starting system is
faulty.
8. The charging system is
faulty.
1. Refer to Battery in the index of this service
manual for the location of the proper battery
specifications. Replace an incorrect battery, as
required.
2. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
3. Refer to Battery Cables in the index of this
service manual for the location of the proper
battery cable diagnosis and testing procedures.
Clean and tighten the battery terminal
connections, as required.
4. Determine the battery state-of-charge. Refer to
Built-In Test Indicator, Hydrometer Test, or
Open-Circuit Voltage Test in this section for the
proper test procedures. Charge the faulty battery,
as required.
5. Refer to Ignition-Off Draw Test in this section
for the proper test procedures. Repair the faulty
electrical system, as required.
6. Determine the battery cranking capacity. Refer
to Load Test in this section for the proper test
procedures. Replace the faulty battery, as
required.
7. Determine if the starting system is performing
to specifications. Refer to Starting System in the
index of this service manual for the location of the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. Determine if the charging system is performing
to specifications. Refer to Charging System in the
index of this service manual for the location of the
proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
TJ BATTERY 8A - 7
DIAGNOSIS AND TESTING (Continued)
Battery Diagnosis
Condition Possible Causes Correction
The battery state-of-charge
cannot be maintained.
1. The battery has an
incorrect size or rating for
this vehicle.
2. The battery terminal
connections are loose or
corroded.
3. The generator drive belt is
slipping.
4. The electrical system
ignition-off draw is excessive.
5. The battery is faulty.
6. The starting system is
faulty.
7. The charging system is
faulty.
8. Electrical loads exceed the
output of the charging
system.
9. Slow driving or prolonged
idling with high-amperage
draw systems in use.
1. Refer to Battery in the index of this service
manual for the location of the proper battery
specifications. Replace an incorrect battery, as
required.
2. Refer to Battery Cables in the index of this
service manual for the location of the proper
battery cable diagnosis and testing procedures.
Clean and tighten the battery terminal
connections, as required.
3. Refer to Accessory Drive Belt Diagnosis in the
index of this service manual for the location of the
proper accessory drive belt diagnosis and testing
procedures. Replace or adjust the faulty
generator drive belt, as required.
4. Refer to Ignition-Off Draw Test in this section
for the proper test procedures. Repair the faulty
electrical system, as required.
5. Determine the battery cranking capacity. Refer
to Load Test in this section for the proper test
procedures. Replace the faulty battery, as
required.
6. Determine if the starting system is performing
to specifications. Refer to Starting System in the
index of this service manual for the location of the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
7. Determine if the charging system is performing
to specifications. Refer to Charging System in the
index of this service manual for the location of the
proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Advise the vehicle operator, as required.
The battery will not accept a
charge.
1. The battery is faulty. 1. Refer to Battery Charging in the index of this
service manual for the location of the proper
battery charging procedures. Charge or replace
the faulty battery, as required.
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
1. Corroded or l oose battery posts and termi nal
cl amps.
2. A l oose or worn generator dri ve bel t.
3. El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
4. Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
5. A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw.
6. A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Charging System i n the i ndex of thi s
servi ce manual for the l ocati on of the proper charg-
i ng system di agnosi s and testi ng procedures.
7. A faul ty or i ncorrect starti ng system component.
Refer to Starting System i n the i ndex of thi s ser-
8A - 8 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
vi ce manual for the l ocati on of the proper starti ng
system di agnosi s and testi ng procedures.
8. A faul ty or i ncorrect battery.
TESTING
BUILT-IN TEST INDICATOR
A test i ndi cator (hydrometer) bui l t i nto the top of
the battery case provi des vi sual i nformati on for bat-
tery testi ng (Fi g. 6). Li ke a hydrometer, the bui l t-i n
test i ndi cator measures the speci fi c gravi ty of the
battery el ectrol yte. The test i ndi cator reveal s the bat-
tery state-of-charge; however, i t wi l l not reveal the
cranki ng capaci ty of the battery. A l oad test must be
performed to determi ne the battery cranki ng capac-
i ty. Refer to Load Test i n thi s secti on for the proper
battery l oad testi ng procedures.
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n test i ndi -
cator, i t i s i mportant that the battery be l evel and
have a cl ean si ght gl ass. Addi ti onal l i ght may be
requi red to vi ew the i ndi cator. Do not use open
flame as a source of additional light.
To read the bui l t-i n test i ndi cator, l ook i nto the
si ght gl ass and note the col or of the i ndi cator (Fi g. 7).
The battery condi ti on that each col or i ndi cates i s
descri bed i n the fol l owi ng l i st:
• Green
I ndi cates 75% to 100% battery state-of-charge. The
battery i s adequatel y charged for further testi ng or
return to servi ce. I f the starter wi l l not crank for a
mi ni mum of fi fteen seconds wi th a ful l y-charged bat-
tery, the battery must be l oad tested. Refer to Load
Test i n thi s secti on for the proper battery l oad test-
i ng procedures.
• Bl ack or Dark
I ndi cates 0% to 75% battery state-of-charge. The bat-
tery i s i nadequatel y charged and must be charged
unti l a green i ndi cati on i s vi si bl e i n the si ght gl ass
(12.4 vol ts or more), before the battery i s tested fur-
ther or returned to servi ce. Refer to Battery Charg-
ing i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery chargi ng procedures.
Al so refer to Abnormal Battery Discharging i n
thi s secti on for the possi bl e causes of the di scharged
battery condi ti on.
• Cl ear or Bri ght
I ndi cates a l ow battery el ectrol yte l evel . The el ectro-
l yte l evel i n the battery i s bel ow the test i ndi cator. A
mai ntenance-free battery wi th non-removabl e cel l
caps must be repl aced i f the el ectrol yte l evel i s l ow.
Water must be added to a l ow-mai ntenance battery
wi th removabl e cel l caps before i t i s charged. Refer to
Battery Charging i n the i ndex of thi s servi ce man-
ual for the l ocati on of the proper battery chargi ng
procedures. A l ow el ectrol yte l evel may be caused by
an overchargi ng condi ti on. Refer to Charging Sys-
tem i n the i ndex of thi s servi ce manual for the l oca-
ti on of the proper chargi ng system di agnosi s and
testi ng procedures.
HYDROMETER TEST
The hydrometer test reveal s the battery state-of-
charge by measuri ng the speci fi c gravi ty of the el ec-
trol yte. This test cannot be performed on
maintenance-free batteries with non-removable
cell caps. I f the battery has non-removabl e cel l caps,
refer to Built-In Test Indicator or Open-Circuit
Fig. 6 Built-In Test Indicator
1 – SIGHT GLASS
2 – PLASTIC ROD
3 – BATTERY TOP
4 – GREEN BALL
TJ BATTERY 8A - 9
DIAGNOSIS AND TESTING (Continued)
Voltage Test i n thi s secti on for the proper proce-
dures for performi ng these al ternate tests of the bat-
tery state-of-charge.
Speci fi c gravi ty i s a compari son of the densi ty of
the battery el ectrol yte to the densi ty of pure water.
Pure water has a speci fi c gravi ty of 1.000, and sul fu-
ri c aci d has a speci fi c gravi ty of 1.835. Sul furi c aci d
makes up approxi matel y 35% of the battery el ectro-
l yte by wei ght, or 24% by vol ume. I n a ful l y-charged
battery the el ectrol yte wi l l have a temperature-cor-
rected speci fi c gravi ty of 1.260 to 1.290. However, a
speci fi c gravi ty of 1.235 or above i s sati sfactory for
battery l oad testi ng and/or return to servi ce.
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. Then
remove the battery cel l caps and check the el ectrol yte
l evel . Add di sti l l ed water i f the el ectrol yte l evel i s
bel ow the top of the battery pl ates.
See the i nstructi ons provi ded by the manufacturer
of the hydrometer for recommendati ons on the cor-
rect use of the hydrometer that you are usi ng.
Remove onl y enough el ectrol yte from the battery cel l
so that the fl oat i s off the bottom of the hydrometer
barrel wi th pressure on the bul b rel eased. To read
the hydrometer correctl y, hol d i t wi th the top surface
of the el ectrol yte at eye l evel (Fi g. 8).
CAUTION: Exercise care when inserting the tip of
the hydrometer into a battery cell to avoid damag-
ing the plate separators. Damaged plate separators
can cause early battery failure.
Hydrometer fl oats are general l y cal i brated to i ndi -
cate the speci fi c gravi ty correctl y onl y at 26.7° C (80°
F). When testi ng the speci fi c gravi ty at any other
temperature, a correcti on factor i s requi red. The cor-
recti on factor i s approxi matel y a speci fi c gravi ty
val ue of 0.004, whi ch may al so be i denti fi ed as four
poi nts of speci fi c gravi ty. For each 5.5° C above 26.7°
C (10° F above 80° F), add four poi nts. For each 5.5°
C bel ow 26.7° C (10° F bel ow 80° F), subtract four
poi nts. Al ways correct the speci fi c gravi ty for temper-
ature vari ati on.
Fig. 7 Built-In Test Indicator Sight Glass
Fig. 8 Hydrometer - Typical
1 – BULB
2 – SURFACE COHESION
3 – SPECIFIC GRAVITY READING
4 – TEMPERATURE READING
5 – HYDROMETER BARREL
6 – FLOAT
8A - 10 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
EXAMPLE: A battery i s tested at -12.2° C (10° F)
and has a speci fi c gravi ty of 1.240. Determi ne the
actual speci fi c gravi ty as fol l ows:
(1) Determi ne the number of degrees above or
bel ow 26.7° C (80° F): 26.6° C - -12.2° C =38.8° C
(80° F - 10° F =70° F)
(2) Di vi de the resul t from Step 1 by 5.5° C (10° F):
38.8° C Ϭ 5.5° C =7 (70° F Ϭ 10° F =7)
(3) Mul ti pl y the resul t from Step 2 by the temper-
ature correcti on factor (0.004): 7 X 0.004 =0.028
(4) The temperature at testi ng was bel ow 26.7° C
(80° F); therefore, the temperature correcti on factor
i s subtracted: 1.240 - 0.028 =1.212
(5) The corrected speci fi c gravi ty of the battery cel l
i n thi s exampl e i s 1.212.
Test the speci fi c gravi ty of the el ectrol yte i n each
battery cel l . I f the speci fi c gravi ty of al l cel l s i s above
1.235, but the vari ati on between cel l s i s more than
fi fty poi nts (0.050), the battery shoul d be repl aced. I f
the speci fi c gravi ty of one or more cel l s i s l ess than
1.235, charge the battery at a rate of approxi matel y
fi ve amperes. Conti nue chargi ng the battery unti l
three consecuti ve speci fi c gravi ty tests, taken at one-
hour i nterval s, are constant. I f the cel l speci fi c grav-
i ty vari ati on i s more than fi fty poi nts (0.050) at the
end of the charge peri od, repl ace the battery.
When the speci fi c gravi ty of al l cel l s i s above 1.235,
and the cel l vari ati on i s l ess than fi fty poi nts (0.050),
the battery may be l oad tested to determi ne i ts
cranki ng capaci ty. Refer to Load Test i n thi s secti on
for the proper battery l oad testi ng procedures.
OPEN-CIRCUIT VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the state-of-charge of a battery. Thi s test can be
used i n pl ace of the hydrometer test when a hydrom-
eter i s not avai l abl e, or for mai ntenance-free batter-
i es wi th non-removabl e cel l caps.
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
Before proceedi ng wi th thi s test, compl etel y charge
the battery. Refer to Battery Charging i n the i ndex
of thi s servi ce manual for the l ocati on of the proper
battery chargi ng procedures.
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the headl amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (see the i nstructi ons provi ded by the manufac-
turer of the vol tmeter), measure the open-ci rcui t vol t-
age (Fi g. 9).
See the Open-Ci rcui t Vol tage chart. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty. Refer to Load Test i n thi s secti on for the
proper battery l oad testi ng procedures.
Fig. 9 Testing Open-Circuit Voltage - Typical
Open Circuit Voltage
Open Circuit Volts Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
TJ BATTERY 8A - 11
DIAGNOSIS AND TESTING (Continued)
LOAD TEST
A battery l oad test wi l l veri fy the battery cranki ng
capaci ty. The test i s based on the Col d Cranki ng
Amperage (CCA) rati ng of the battery. See the l abel
affi xed to the battery case, or refer to Battery i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper factory-i nstal l ed battery speci fi cati ons to
determi ne the battery CCA rati ng.
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
Before proceedi ng wi th thi s test, compl etel y charge
the battery. Refer to Battery Charging i n the i ndex
of thi s servi ce manual for the l ocati on of the proper
battery chargi ng procedures.
(1) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst. The battery top and posts shoul d be
cl ean.
(2) Connect a sui tabl e vol t-ammeter-l oad tester
(Fi g. 10) to the battery posts (Fi g. 11). See the
i nstructi ons provi ded by the manufacturer of the
tester you are usi ng. Check the open-ci rcui t vol tage
(no l oad) of the battery. Refer to Open-Circuit Volt-
age Test i n thi s secti on for the proper battery open-
ci rcui t vol tage test procedures. The battery open-
ci rcui t vol tage must be 12.4 vol ts or greater.
(3) Rotate the l oad control knob (carbon pi l e rheo-
stat) to appl y a 300 ampere l oad to the battery for
fi fteen seconds, then return the control knob to the
Off posi ti on (Fi g. 12). Thi s wi l l remove the surface
charge from the battery.
(4) Al l ow the battery to stabi l i ze to open-ci rcui t
vol tage. I t may take up to fi ve mi nutes for the bat-
tery vol tage to stabi l i ze.
(5) Rotate the l oad control knob to mai ntai n a l oad
equal to 50% of the CCA rati ng of the battery (Fi g.
13). After fi fteen seconds, record the l oaded vol tage
Fig. 10 Volt-Ammeter-Load Tester - Typical
Fig. 11 Volt-Ammeter-Load Tester Connections -
Typical
1 – INDUCTION AMMETER CLAMP
2 – NEGATIVE CLAMP
3 – POSITIVE CLAMP
Fig. 12 Remove Surface Charge from Battery -
Typical
8A - 12 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
readi ng, then return the l oad control knob to the Off
posi ti on.
(6) The vol tage drop wi l l vary wi th the battery
temperature at the ti me of the l oad test. The battery
temperature can be esti mated by usi ng the ambi ent
temperature duri ng the past several hours. I f the
battery has been charged, boosted, or l oaded a few
mi nutes pri or to the test, the battery wi l l be some-
what warmer. See the Load Test Temperature chart
for the proper l oaded vol tage readi ng.
(7) I f the vol tmeter readi ng fal l s bel ow 9.6 vol ts, at
a mi ni mum battery temperature of 21° C (70° F), the
battery i s faul ty and must be repl aced.
IGNITION-OFF DRAW TEST
The term I gni ti on-Off Draw (I OD) i denti fi es a nor-
mal condi ti on where power i s bei ng drai ned from the
battery wi th the i gni ti on swi tch i n the Off posi ti on. A
normal vehi cl e el ectri cal system wi l l draw from fi ve
to twenty-fi ve mi l l i amperes (0.005 to 0.025 ampere)
wi th the i gni ti on swi tch i n the Off posi ti on, and al l
non-i gni ti on control l ed ci rcui ts i n proper worki ng
order. The twenty-fi ve mi l l i amperes are needed to
enabl e the memory functi ons for the Powertrai n Con-
trol Modul e (PCM), di gi tal cl ock, el ectroni cal l y tuned
radi o, and other modul es whi ch may vary wi th the
vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the Power Di stri buti on Center (PDC). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
• El ectri cal i tems l eft on.
• Faul ty or i mproperl y adjusted swi tches.
• Faul ty or shorted el ectroni c modul es and compo-
nents.
• An i nternal l y shorted generator.
• I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over twenty-fi ve mi l l i amperes, the
probl em must be found and corrected before repl ac-
i ng a battery. I n most cases, the battery can be
charged and returned to servi ce after the excessi ve
I OD condi ti on has been corrected.
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th an i l l umi -
nated entry system or an el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes. See the El ectroni c Modul e I gni -
ti on-Off Draw tabl e for more i nformati on.
Electronic Module Ignition-Off Draw (IOD)
Module
Time Out?
(If Yes, Interval and Wake-Up Input)
IOD
IOD After Time
Out
Radio No
1 to 3
milliamperes
N/A
Audio Power
Amplifier
No
up to 1
milliampere
N/A
Powertrain Control
Module (PCM)
No 0.95 milliampere N/A
Fig. 13 Load 50% CCA Rating - Note Voltage -
Typical
Load Test Temperature
Minimum Voltage
Temperature
°F °C
9.6 volts 70°and above 21°and above
9.5 volts 60° 16°
9.4 volts 50° 10°
9.3 volts 40° 4°
9.1 volts 30° -1°
8.9 volts 20° -7°
8.7 volts 10° -12°
8.5 volts 0° -18°
TJ BATTERY 8A - 13
DIAGNOSIS AND TESTING (Continued)
Electronic Module Ignition-Off Draw (IOD)
Module
Time Out?
(If Yes, Interval and Wake-Up Input)
IOD
IOD After Time
Out
ElectroMechanical
Instrument Cluster
(EMIC)
No 0.44 milliampere N/A
Combination Flasher No 0.08 milliampere N/A
(2) Determi ne that the under-hood l amp i s operat-
i ng properl y, then di sconnect the l amp wi re harness
connector or remove the l amp bul b.
(3) Di sconnect the battery negati ve cabl e.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e ter-
mi nal cl amp and the battery negati ve termi nal post.
Make sure that the doors remai n cl osed so that the
i l l umi nated entry system i s not acti vated. The mul ti -
meter amperage readi ng may remai n hi gh for up to
three mi nutes, or may not gi ve any readi ng at al l
whi l e set i n the hi ghest amperage scal e, dependi ng
upon the el ectri cal equi pment i n the vehi cl e. The
mul ti -meter l eads must be securel y cl amped to the
battery negati ve cabl e termi nal cl amp and the bat-
tery negati ve termi nal post. I f conti nui ty between the
battery negati ve termi nal post and the negati ve cabl e
termi nal cl amp i s l ost duri ng any part of the I OD
test, the el ectroni c ti mer functi on wi l l be acti vated
and al l of the tests wi l l have to be repeated.
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or nonexi stent, dependi ng upon the el ectri cal
equi pment i n the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove and repl ace each fuse or ci rcui t
breaker i n the Power Di stri buti on Center (PDC) and
then i n the fusebl ock modul e one at a ti me (refer to
Power Distribution Center and Fuse/Fuse Block
i n the i ndex of thi s servi ce manual for the l ocati on of
compl ete PDC and fusebl ock modul e fuse and ci rcui t
breaker i denti fi cati on contai ned i n the wi ri ng di a-
grams) unti l the amperage readi ng becomes very l ow,
or nonexi stent. Thi s wi l l i sol ate each ci rcui t and
i denti fy the ci rcui t that i s the source of the hi gh-am-
perage I OD. I f the amperage readi ng remai ns hi gh
after removi ng and repl aci ng each fuse and ci rcui t
breaker, di sconnect the wi re harness from the gener-
ator. I f the amperage readi ng now becomes very l ow
or nonexi stent, refer to Charging System i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper chargi ng system di agnosi s and testi ng proce-
dures. After the hi gh-amperage I OD has been cor-
rected, swi tch the mul ti -meter to progressi vel y l ower
amperage scal es and, i f necessary, repeat the fuse
and ci rcui t breaker remove-and-repl ace process to
i denti fy and correct al l sources of excessi ve I OD. I t i s
now safe to sel ect the l owest mi l l i ampere scal e of the
mul ti -meter to check the l ow-amperage I OD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed twenty-fi ve mi l l i am-
peres (0.025 ampere). I f the current draw exceeds
twenty-fi ve mi l l i amperes, i sol ate each ci rcui t usi ng
the fuse and ci rcui t breaker remove-and-repl ace pro-
cess i n Step 5. The mul ti -meter readi ng wi l l drop to
wi thi n the acceptabl e l i mi t when the source of the
excessi ve current draw i s di sconnected. Repai r thi s
ci rcui t as requi red; whether a wi ri ng short, i ncorrect
swi tch adjustment, or a component fai l ure i s at faul t.
BATTERY CABLES
DIAGNOSIS
A vol tage drop test wi l l determi ne i f there i s exces-
si ve resi stance i n the battery cabl e termi nal connec-
ti ons or the battery cabl es. I f excessi ve resi stance i s
found i n the battery cabl e connecti ons, the connec-
ti on poi nt shoul d be di sassembl ed, cl eaned of al l cor-
rosi on or forei gn materi al , then reassembl ed.
Fol l owi ng reassembl y, check the vol tage drop for the
battery cabl e connecti on and the battery cabl e agai n
to confi rm repai r.
When performi ng the vol tage drop test, i t i s i mpor-
tant to remember that the vol tage drop i s gi vi ng an
i ndi cati on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached. EXAM-
PLE: When testi ng the resi stance of the battery pos-
i ti ve cabl e, touch the vol tmeter l eads to the battery
posi ti ve cabl e termi nal cl amp and to the battery pos-
i ti ve cabl e eyel et termi nal at the starter sol enoi d
B(+) termi nal stud. I f you probe the battery posi ti ve
termi nal post and the battery posi ti ve cabl e eyel et
termi nal at the starter sol enoi d B(+) termi nal stud,
you are readi ng the combi ned vol tage drop i n the
battery posi ti ve cabl e termi nal cl amp-to-termi nal
post connecti on and the battery posi ti ve cabl e.
8A - 14 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
TESTING
VOLTAGE DROP TEST
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng thi s
test, be certai n that the fol l owi ng procedures are
accompl i shed:
• The battery i s ful l y-charged and l oad tested.
Refer to Battery Charging i n the i ndex of thi s ser-
vi ce manual for the l ocati on of the proper battery
chargi ng procedures. Refer to Battery i n the i ndex of
thi s servi ce manual for the l ocati on of the battery
di agnosi s and testi ng procedures, i ncl udi ng the
proper battery l oad test procedures.
• Ful l y engage the parki ng brake.
• I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
• Veri fy that al l l amps and accessori es are turned
off.
• To prevent the engi ne from starti ng, remove the
Automati c ShutDown (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e termi nal cl amp (Fi g. 14). Rotate and hol d the
i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct the poor con-
necti on between the battery negati ve cabl e termi nal
cl amp and the battery negati ve termi nal post.
(2) Connect the posi ti ve l ead of the vol tmeter to
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
termi nal cl amp (Fi g. 15). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor connecti on
between the battery posi ti ve cabl e termi nal cl amp
and the battery posi ti ve termi nal post.
Fig. 14 Test Battery Negative Connection
Resistance - Typical
1 – VOLTMETER
2 – BATTERY
Fig. 15 Test Battery Positive Connection Resistance
- Typical
1 – VOLTMETER
2 – BATTERY
TJ BATTERY 8A - 15
DIAGNOSIS AND TESTING (Continued)
(3) Connect the vol tmeter to measure between the
battery posi ti ve cabl e termi nal cl amp and the starter
sol enoi d B(+) termi nal stud (Fi g. 16). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery posi ti ve cabl e eyel et termi nal con-
necti on at the starter sol enoi d B(+) termi nal stud.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
(4) Connect the vol tmeter to measure between the
battery negati ve cabl e termi nal cl amp and a good
cl ean ground on the engi ne bl ock (Fi g. 17). Rotate
and hol d the i gni ti on swi tch i n the Start posi ti on.
Observe the vol tmeter. I f the readi ng i s above 0.2
vol t, cl ean and ti ghten the battery negati ve cabl e
eyel et termi nal connecti on to the engi ne bl ock.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery negati ve cabl e.
SERVICE PROCEDURES
BATTERY CHARGING
Battery chargi ng i s the means by whi ch the bat-
tery can be restored to i ts ful l vol tage potenti al . A
battery i s ful l y-charged when:
• Al l of the battery cel l s are gassi ng freel y duri ng
battery chargi ng.
• A green col or i s vi si bl e i n the si ght gl ass of the
battery bui l t-i n test i ndi cator.
• Three hydrometer tests, taken at one-hour i nter-
val s, i ndi cate no i ncrease i n the temperature-cor-
rected speci fi c gravi ty of the battery el ectrol yte.
• Open-ci rcui t vol tage of the battery i s 12.4 vol ts
or above.
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
Fig. 16 Test Battery Positive Cable Resistance -
Typical
1 – BATTERY
2 – VOLTMETER
3 – STARTER MOTOR
Fig. 17 Test Ground Circuit Resistance - Typical
1 – VOLTMETER
2 – ENGINE GROUND
3 – BATTERY
8A - 16 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
CAUTION:
• Always disconnect and isolate the battery neg-
ative cable before charging a battery. Do not exceed
sixteen volts while charging a battery. Damage to
the vehicle electrical system components may
result.
• Battery electrolyte will bubble inside the bat-
tery case during normal battery charging. Electro-
lyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
• The battery should not be hot to the touch. If
the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing
the charging operation. Damage to the battery may
result.
Some battery chargers are equi pped wi th pol ari ty-
sensi ng ci rcui try. Thi s ci rcui try protects the battery
charger and the battery from bei ng damaged i f they
are i mproperl y connected. I f the battery state-of-
charge i s too l ow for the pol ari ty-sensi ng ci rcui try to
detect, the battery charger wi l l not operate. Thi s
makes i t appear that the battery wi l l not accept
chargi ng current. See the i nstructi ons provi ded by
the manufacturer of the battery charger for detai l s
on how to bypass the pol ari ty-sensi ng ci rcui try.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty. Refer to Battery i n the i ndex of
thi s servi ce manual for the l ocati on of the battery
di agnosi s and testi ng procedures for more i nforma-
ti on on the proper battery l oad testi ng procedures. I f
the battery wi l l endure a l oad test, return the bat-
tery to servi ce. I f the battery wi l l not endure a l oad
test, i t i s faul ty and must be repl aced.
Cl ean and i nspect the battery hol d downs, tray,
termi nal s, posts, and top before compl eti ng battery
servi ce. Refer to Battery i n the i ndex of thi s servi ce
manual for the l ocati on of the proper battery cl ean-
i ng and i nspecti on procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 18). I f the
readi ng i s bel ow ten vol ts, the battery chargi ng cur-
rent wi l l be l ow. I t coul d take some ti me before the
battery accepts a current greater than a few mi l l i am-
peres. Such l ow current may not be detectabl e on the
ammeters bui l t i nto many battery chargers.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the battery charger and
the battery from bei ng damaged i f they are i mprop-
erl y connected. I f the battery state-of-charge i s too
l ow for the pol ari ty-sensi ng ci rcui try to detect, the
battery charger wi l l not operate. Thi s makes i t
appear that the battery wi l l not accept chargi ng cur-
rent. See the i nstructi ons provi ded by the manufac-
turer of the battery charger for detai l s on how to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e chargi ng
current at vari ous vol tages i s shown i n the Charge
Rate chart. I f the chargi ng current i s sti l l not mea-
surabl e at the end of the chargi ng ti me, the battery
i s faul ty and must be repl aced. I f the chargi ng cur-
rent i s measurabl e duri ng the chargi ng ti me, the bat-
tery may be good and the chargi ng shoul d be
compl eted i n the normal manner.
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
• Battery Capaci ty
A compl etel y di scharged heavy-duty battery requi res
twi ce the chargi ng ti me of a smal l capaci ty battery.
Fig. 18 Voltmeter Accurate to 1/10 Volt Connected -
Typical
Charge Rate
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
TJ BATTERY 8A - 17
SERVICE PROCEDURES (Continued)
• Temperature
A l onger ti me wi l l be needed to charge a battery at
-18° C (0° F) than at 27° C (80° F). When a fast bat-
tery charger i s connected to a col d battery, the cur-
rent accepted by the battery wi l l be very l ow at fi rst.
As the battery warms, i t wi l l accept a hi gher charg-
i ng current rate (amperage).
• Charger Capaci ty
A battery charger that suppl i es onl y fi ve amperes
wi l l requi re a l onger chargi ng ti me. A battery charger
that suppl i es twenty amperes or more wi l l requi re a
shorter chargi ng ti me.
• State-Of-Charge
A compl etel y di scharged battery requi res more charg-
i ng ti me than a parti al l y di scharged battery. El ectro-
l yte i s nearl y pure water i n a compl etel y di scharged
battery. At fi rst, the chargi ng current (amperage) wi l l
be l ow. As the battery charges, the speci fi c gravi ty of
the el ectrol yte wi l l gradual l y ri se.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1° C or 30° F) BAT-
TERY. THE BATTERY MAY ARC INTERNALLY AND
EXPLODE. PERSONAL INJURY AND/OR VEHICLE
DAMAGE MAY RESULT.
REMOVAL AND INSTALLATION
BATTERY CABLES
Both the battery negati ve cabl e and the battery
posi ti ve cabl e are servi ced i n the battery wi re har-
ness. I f ei ther battery cabl e i s damaged or faul ty, the
battery wi re harness uni t must be repl aced.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post.
(4) Loosen the battery posi ti ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
(6) Unl atch and remove the B(+) termi nal stud
cover from the rear of the Power Di stri buti on Center
(PDC).
(7) Remove the two nuts that secure the battery
posi ti ve cabl e and the generator output cabl e eyel et
termi nal to the two B(+) termi nal studs on the PDC.
(8) Remove the battery posi ti ve cabl e and the gen-
erator output eyel et termi nal from the two B(+) ter-
mi nal studs on the PDC.
(9) Remove the screw that secures the battery neg-
ati ve cabl e eyel et termi nal to the dash panel near the
battery.
(10) Unl atch and remove the cover from the gener-
ator output termi nal stud housi ng on the back of the
generator.
(11) Remove the nut that secures the generator
output cabl e eyel et termi nal to the generator output
termi nal stud.
(12) Remove the generator output cabl e eyel et ter-
mi nal from the generator output termi nal stud.
(13) Remove the nut that secures the battery neg-
ati ve cabl e ground eyel et termi nal to the stud on the
ri ght si de of the engi ne bl ock.
(14) Remove the battery negati ve cabl e ground
eyel et termi nal from the engi ne bl ock stud.
(15) Remove the nut that secures the battery pos-
i ti ve cabl e eyel et termi nal to the B(+) termi nal stud
on the starter sol enoi d.
(16) Remove the battery posi ti ve cabl e eyel et ter-
mi nal from the B(+) termi nal stud on the starter
sol enoi d.
(17) Remove the battery wi re harness from the
engi ne compartment.
INSTALLATION
(1) Cl ean and i nspect the battery cabl e termi nal
cl amps and the battery termi nal posts. Refer to Bat-
tery i n the i ndex of thi s servi ce manual for the l oca-
ti on of the proper battery cabl e termi nal cl amp and
battery termi nal post cl eani ng and i nspecti on proce-
dures.
(2) Posi ti on the battery wi re harness i nto the
engi ne compartment.
Battery Charging Timetable
Charging
Amperage
5
Amperes
10
Amperes
20
Amperes
Open
Circuit
Voltage
Hours Charging at 21°C (70°F)
12.25 to
12.49
6 hours 3 hours 1.5 hours
12.00 to
12.24
10 hours 5 hours 2.5 hours
10.00 to
11.99
14 hours 7 hours 3.5 hours
*Below
10.00
18 hours 9 hours 4.5 hours
*Refer to Charging A Completely Discharged Battery
8A - 18 BATTERY TJ
SERVICE PROCEDURES (Continued)
(3) I nstal l the battery posi ti ve cabl e eyel et termi -
nal onto the B(+) termi nal stud on the starter sol e-
noi d.
(4) I nstal l and ti ghten the nut that secures the
battery posi ti ve cabl e eyel et termi nal to the B(+) ter-
mi nal stud on the starter sol enoi d. Ti ghten the nut to
10 N·m (90 i n. l bs.).
(5) I nstal l the battery negati ve cabl e ground eyel et
termi nal onto the stud on the ri ght si de of the engi ne
bl ock.
(6) I nstal l and ti ghten the nut that secures the
battery negati ve cabl e ground eyel et termi nal to the
stud on the ri ght si de of the engi ne bl ock. Ti ghten
the nut to 16.9 N·m (150 i n. l bs.).
(7) I nstal l the generator output cabl e eyel et termi -
nal onto the generator output termi nal stud.
(8) I nstal l and ti ghten the nut that secures the
generator output cabl e eyel et termi nal to the genera-
tor output termi nal stud. Ti ghten the nut to 8.4 N·m
(75 i n. l bs.).
(9) Posi ti on the cover for the generator output ter-
mi nal stud housi ng onto the back of the generator
and snap i t i nto pl ace.
(10) I nstal l and ti ghten the screw that secures the
battery negati ve cabl e eyel et termi nal to the dash
panel near the battery. Ti ghten the screw to 48.7
N·m (36 ft. l bs.).
(11) I nstal l the battery posi ti ve cabl e and the gen-
erator output cabl e eyel et termi nal onto the PDC
B(+) termi nal studs.
(12) I nstal l and ti ghten the two nuts that secure
the battery posi ti ve cabl e and the generator output
cabl e eyel et termi nal to the PDC B(+) termi nal studs.
Ti ghten the nuts to 11.3 N·m (100 i n. l bs.).
(13) Engage the tabs on the l ower edge of the B(+)
termi nal stud cover i n the sl ots on the rear of the
PDC housi ng, then engage the l atch on the top of the
cover wi th the l atch tabs on the PDC housi ng.
(14) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
(15) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
(16) Appl y a thi n coati ng of petrol eum jel l y or
chassi s grease to the exposed surfaces of the battery
cabl e termi nal cl amps and the battery termi nal
posts.
BATTERY HOLD DOWNS
Al l of the battery hol d down hardware can be ser-
vi ced wi thout removal of the battery or the battery
tray.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post.
(4) Remove the nut wi th washer from the threaded
end of each of the two J-bol ts (Fi g. 19).
(5) Remove the battery hol d down bracket from
the threaded ends of the two J-bol ts and the top of
the battery case.
(6) Di sengage the hooked end of each J-bol t from
the hol es i n the front or rear fl ange of the battery
tray and remove the two J-bol ts.
INSTALLATION
(1) Cl ean and i nspect the battery hol d down hard-
ware. Refer to Battery i n the i ndex of thi s servi ce
manual for the l ocati on of the proper battery hol d
down hardware cl eani ng and i nspecti on procedures.
(2) Engage the hooked end of each J-bol t i nto the
hol es i n the front or rear fl ange of the battery tray
and posi ti on the two J-bol ts.
Fig. 19 Battery Hold Downs Remove/Install
1 – J-BOLT (2)
2 – NUT (2)
3 – BRACKET
4 – BATTERY
TJ BATTERY 8A - 19
REMOVAL AND INSTALLATION (Continued)
(3) Posi ti on the battery hol d down bracket onto the
threaded ends of the two J-bol ts and across the top of
the battery case.
(4) I nstal l and ti ghten the nut wi th washer onto
the threaded end of each of the two J-bol ts. Ti ghten
the nuts to 4.7 N·m (42 i n. l bs.).
(5) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
BATTERY
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post (Fi g. 20).
(4) Loosen the battery posi ti ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
(6) Remove the battery hol d downs from the bat-
tery. Refer to Battery Hold Downs i n the i ndex of
thi s servi ce manual for the l ocati on of the proper bat-
tery hol d down removal procedures.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(7) Remove the battery and the battery thermo-
guard from the battery tray as a uni t.
(8) Remove the battery thermoguard from the bat-
tery case. Refer to Battery Thermoguard i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper battery thermoguard removal procedures.
INSTALLATION
(1) Cl ean and i nspect the battery. Refer to Bat-
tery i n the i ndex of thi s servi ce manual for the l oca-
ti on of the proper battery cl eani ng and i nspecti on
procedures.
(2) Rei nstal l the battery thermoguard onto the
battery case. Refer to Battery Thermoguard i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper battery thermoguard i nstal l ati on procedures.
(3) Posi ti on the battery and the battery thermo-
guard onto the battery tray as a uni t. Ensure that
the battery posi ti ve and negati ve termi nal posts are
correctl y posi ti oned. The battery cabl e termi nal
cl amps must reach the correct battery termi nal post
wi thout stretchi ng the cabl es (Fi g. 21).
(4) Rei nstal l the battery hol d downs onto the bat-
tery. Refer to Battery Hold Downs i n the i ndex of
thi s servi ce manual for the l ocati on of the proper bat-
tery hol d down i nstal l ati on procedures.
Fig. 20 Remove Battery Cable Terminal Clamp -
Typical
1 – BATTERY
2 – BATTERY TERMINAL PULLER
Fig. 21 Battery Cables
1 – POSITIVE CABLE
2 – TERMINAL CLAMPS
3 – DASH PANEL
4 – NEGATIVE CABLE
5 – POWER DISTRIBUTION CENTER
6 – FENDER
8A - 20 BATTERY TJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reversed battery polarity may damage
electrical components of the vehicle.
(5) Cl ean the battery cabl e termi nal cl amps and
the battery termi nal posts. Refer to Battery i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper battery cl eani ng and i nspecti on procedures.
(6) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
(7) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
(8) Appl y a thi n coati ng of petrol eum jel l y or chas-
si s grease to the exposed surfaces of the battery cabl e
termi nal cl amps and the battery termi nal posts.
BATTERY THERMOGUARD
REMOVAL
(1) Remove the battery and the battery thermo-
guard from the battery tray as a uni t. Refer to Bat-
tery i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery removal procedures.
(2) Careful l y and evenl y sl i de the battery thermo-
guard up off of the battery case (Fi g. 22).
INSTALLATION
(1) Cl ean and i nspect the battery thermoguard.
Refer to Battery i n the i ndex of thi s servi ce manual
for the l ocati on of the proper battery thermoguard
cl eani ng and i nspecti on procedures.
(2) Careful l y and evenl y sl i de the battery thermo-
guard down over the battery case.
(3) I nstal l the battery and the battery thermo-
guard i nto the battery tray as a uni t. Refer to Bat-
tery i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery i nstal l ati on procedures.
BATTERY TRAY
REMOVAL
(1) Remove the battery from the battery tray.
Refer to Battery i n the i ndex of thi s servi ce manual
for the l ocati on of the proper battery removal proce-
dures.
(2) Remove the battery temperature sensor from
the battery tray. Refer to Battery Temperature
Sensor i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery temperature sensor
removal procedures.
(3) Remove the four screws wi th washers that
secure the battery tray to the rei nforcement l ocated
between the dash panel and the rear of the front
wheel house i nner panel i n the engi ne compartment
(Fi g. 23).
(4) Remove the battery tray from the rei nforce-
ment i n the engi ne compartment.
INSTALLATION
(1) Cl ean and i nspect the battery tray. Refer to
Battery i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery tray cl eani ng and
i nspecti on procedures.
Fig. 22 Battery Thermoguard Remove/Install
1 – THERMOGUARD
2 – BATTERY
Fig. 23 Battery Tray Remove/Install
1 – BATTERY TRAY
2 – SCREW (4)
3 – REINFORCEMENT
4 – BATTERY TEMPERATURE SENSOR MOUNTING HOLE
TJ BATTERY 8A - 21
REMOVAL AND INSTALLATION (Continued)
(2) Posi ti on the battery tray onto the rei nforce-
ment i n the engi ne compartment.
(3) I nstal l and ti ghten the four screws wi th wash-
ers that secure the battery tray to the rei nforcement
l ocated between the dash panel and the rear of the
front wheel house i nner panel i n the engi ne compart-
ment. Ti ghten the screws to 22.6 N·m (200 i n. l bs.).
(4) I nstal l the battery temperature sensor onto the
battery tray. Refer to Battery Temperature Sensor
i n the i ndex of thi s servi ce manual for the l ocati on of
the proper battery temperature sensor i nstal l ati on
procedures.
(5) I nstal l the battery onto the battery tray. Refer
to Battery i n the i ndex of thi s servi ce manual for
the l ocati on of the proper battery i nstal l ati on proce-
dures.
CLEANING AND INSPECTION
BATTERY
The fol l owi ng i nformati on detai l s the recommended
cl eani ng and i nspecti on procedures for the battery
and rel ated components. I n addi ti on to the mai nte-
nance schedul es found i n thi s servi ce manual and the
owner’s manual , i t i s recommended that these proce-
dures be performed any ti me the battery or rel ated
components must be removed for vehi cl e servi ce.
CLEANING
(1) Cl ean the battery cabl e termi nal cl amps of al l
corrosi on. Remove any corrosi on usi ng a wi re brush
or a post and termi nal cl eani ng tool , and a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on (Fi g. 24).
(2) Cl ean the battery tray and battery hol d down
hardware of al l corrosi on. Remove any corrosi on
usi ng a wi re brush and a sodi um bi carbonate (baki ng
soda) and warm water cl eani ng sol uti on. Pai nt any
exposed bare metal .
(3) I f the removed battery i s to be rei nstal l ed,
cl ean the outsi de of the battery case and the top
cover wi th a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on usi ng a sti ff bri stl e
parts cl eani ng brush to remove any aci d fi l m (Fi g.
25). Ri nse the battery wi th cl ean water. Ensure that
the cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, refer to Battery i n the i ndex of thi s servi ce
manual for the l ocati on of the factory-i nstal l ed bat-
tery speci fi cati ons. Confi rm that the repl acement bat-
tery i s the correct si ze and has the correct rati ngs for
the vehi cl e.
(4) Cl ean the battery thermoguard wi th a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on usi ng a sti ff bri stl e parts cl eani ng brush to
remove any aci d fi l m.
(5) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
Fig. 24 Clean Battery Cable Terminal Clamp -
Typical
1 – TERMINAL BRUSH
2 – BATTERY CABLE
Fig. 25 Clean Battery - Typical
1 – CLEANING BRUSH
2 – WARM WATER AND BAKING SODA SOLUTION
3 – BATTERY
8A - 22 BATTERY TJ
REMOVAL AND INSTALLATION (Continued)
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 26).
INSPECTION
(1) I nspect the battery cabl e termi nal cl amps for
damage. Repl ace any battery cabl e that has a dam-
aged or deformed termi nal cl amp.
(2) I nspect the battery tray and battery hol d down
hardware for damage. Repl ace any damaged parts.
(3) Sl i de the thermoguard off of the battery case.
I nspect the battery case for cracks or other damage
that coul d resul t i n el ectrol yte l eaks. Al so, check the
battery termi nal posts for l ooseness. Batteri es wi th
damaged cases or l oose termi nal posts must be
repl aced.
(4) I nspect the battery thermoguard for tears,
cracks, deformati on or other damage. Repl ace any
battery thermoguard that has been damaged.
(5) I nspect the el ectrol yte l evel i n the battery. Use
a putty kni fe or another sui tabl e wi de fl at-bl aded tool
to pry the cel l caps off (Fi g. 27). Do not use a screw-
dri ver. Add di sti l l ed water to each cel l unti l the l i q-
ui d reaches the bottom of the vent wel l . DO NOT
OVERFILL.
(6) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass for an i ndi cati on of the battery condi ti on. I f the
battery i s di scharged, charge as requi red. Refer to
Battery i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery di agnosi s and testi ng
procedures for more i nformati on on the use of the
battery bui l t-i n test i ndi cator. Al so refer to Battery
Charging i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery chargi ng procedures.
SPECIFICATIONS
BATTERY
Battery Classifications and Ratings
Part Number
BCI Group Size
Classification
Cold Cranking
Amperage
Reserve
Capacity
Ampere-Hours
Load Test
Amperage
56027960 34 500 110 Minutes 60 250
56041003 34 600 120 Minutes 66 300
Fig. 26 Clean Battery Terminal Post - Typical
1 – TERMINAL BRUSH
2 – BATTERY CABLE
3 – BATTERY Fig. 27 Removing Battery Cell Caps - Typical
1 – PUTTY KNIFE
TJ BATTERY 8A - 23
CLEANING AND INSPECTION (Continued)
STARTING SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2
STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . 4
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 5
STARTER MOTOR NOISE - 2.5L ENGINE . . . . . 10
STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . 11
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL AND INSTALLATION
STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . 13
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 15
CLEANING AND INSPECTION
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 16
TJ STARTING SYSTEMS 8B - 1
DESCRIPTION AND OPERATION
STARTING SYSTEM
DESCRIPTION
Fig. 1 Starting System
8B - 2 STARTING SYSTEMS TJ
An el ectri cal l y operated engi ne starti ng system
(Fi g. 1) i s standard factory-i nstal l ed equi pment on
thi s model . The starti ng system i s desi gned to pro-
vi de the vehi cl e operator wi th a conveni ent, effi ci ent
and rel i abl e means of cranki ng and starti ng the
i nternal combusti on engi ne used to power the vehi cl e
and al l of i ts accessory systems. The starti ng system
i ncl udes the fol l owi ng major components:
• Battery
• Battery cabl es
• Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
• I gni ti on swi tch
• Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
• Starter motor (i ncl udi ng the i ntegral starter
sol enoi d)
• Starter rel ay.
The starti ng system consi sts of two separate ci r-
cui ts. A hi gh-amperage feed ci rcui t that feeds the
starter motor between 150 and 350 amperes of bat-
tery current, and a l ow-amperage control ci rcui t that
operates on l ess than 20 amperes of battery current.
The starti ng system hi gh-amperage feed ci rcui t
i ncl udes the battery, the battery cabl es, the contact
di sc porti on of the starter sol enoi d, and the starter
motor. The fol l owi ng starti ng system feed ci rcui t
components are covered i n more detai l i n other areas
of thi s servi ce manual :
• The battery i s l ocated i n the passenger si de rear
corner of the engi ne compartment, near the dash
panel and provi des the el ectri cal current needed to
operate the starti ng system. Refer to Battery i n the
i ndex of thi s servi ce manual for the l ocati on of more
i nformati on on the battery.
• The battery cabl es connect the battery to the
el ectri cal system of the vehi cl e and to the starti ng
system. Refer to Battery Cables i n the i ndex of thi s
servi ce manual for the l ocati on of more i nformati on
on the battery cabl es.
The starti ng system l ow-amperage control ci rcui t
i ncl udes the i gni ti on swi tch, the cl utch pedal posi ti on
swi tch (manual transmi ssi on), the park/neutral posi -
ti on swi tch (automati c transmi ssi on), the starter
rel ay, the el ectromagneti c wi ndi ngs of the starter
sol enoi d, and the wi re harnesses that connect these
components. The fol l owi ng starti ng system control
ci rcui t components are covered i n more detai l i n
other areas of thi s servi ce manual :
• The i gni ti on swi tch i s mounted on the bottom of
the steeri ng col umn and actuates the starti ng system
when a properl y coded i gni ti on key i s i nserted i n the
i gni ti on l ock cyl i nder on the ri ght si de of the steeri ng
col umn and turned to the spri ng-l oaded momentary
Start posi ti on. Refer to Ignition Switch and Key
Lock Cylinder i n the i ndex of thi s servi ce manual
for the l ocati on of more i nformati on on the i gni ti on
swi tch.
• The cl utch pedal posi ti on swi tch i s i ntegral to
the master cyl i nder of the cl utch hydraul i c l i nkage
assembl y on model s equi pped wi th a manual trans-
mi ssi on. Refer to Clutch Hydraulic Linkage i n the
i ndex of thi s servi ce manual for the l ocati on of more
i nformati on on the cl utch pedal posi ti on swi tch.
• The park/neutral posi ti on swi tch i s threaded
i nto the l eft si de of the automati c transmi ssi on case
and has a spri ng-l oaded pl unger that i s actuated by a
cam i ntegral to the gearshi ft mechani sm wi thi n the
transmi ssi on. The back up l amp swi tch i s al so i nte-
gral to the park/neutral posi ti on swi tch. Refer to
Park/Neutral Position Switch i n the i ndex of thi s
servi ce manual for the l ocati on of more i nformati on
on the park/neutral posi ti on swi tch.
Fol l owi ng are general descri pti ons of the starter
rel ay and the starter motor. See the owner’s manual
i n the vehi cl e gl ove box for more i nformati on on the
features, use and operati on of the starti ng system.
Refer to Starting System i n the i ndex of thi s ser-
vi ce manual for the l ocati on of compl ete wi ri ng di a-
grams for the starti ng system.
OPERATION
I f the vehi cl e i s equi pped wi th a manual transmi s-
si on, the cl utch pedal posi ti on swi tch i s i nstal l ed i n
seri es between the i gni ti on swi tch and the coi l bat-
tery termi nal of the starter rel ay. Thi s normal l y open
swi tch prevents the starter rel ay from bei ng ener-
gi zed when the i gni ti on swi tch i s turned to the
momentary Start posi ti on, unl ess the cl utch pedal i s
ful l y depressed. Thi s feature prevents starter motor
operati on whi l e the cl utch di sc and the fl ywheel are
engaged. The starter rel ay coi l ground termi nal i s
al ways grounded on vehi cl es wi th a manual trans-
mi ssi on.
I f the vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, battery vol tage i s suppl i ed through the l ow-
amperage control ci rcui t to the coi l battery termi nal
of the starter rel ay when the i gni ti on swi tch i s
turned to the momentary Start posi ti on. The park/
1 – CLUTCH PEDAL POSITION SWITCH
2 – PARK/NEUTRAL POSITION SWITCH
3 – IGNITION SWITCH
4 – STARTER MOTOR
5 – STARTER RELAY (IN POWER DISTRIBUTION CENTER)
6 – BATTERY
7 – STARTER SOLENOID
TJ STARTING SYSTEMS 8B - 3
DESCRIPTION AND OPERATION (Continued)
neutral posi ti on swi tch i s i nstal l ed i n seri es between
the starter rel ay coi l ground termi nal and ground.
Thi s normal l y open swi tch prevents the starter rel ay
from bei ng energi zed and the starter motor from
operati ng unl ess the automati c transmi ssi on gear
sel ector i s i n the Neutral or Park posi ti ons.
When the starter rel ay coi l wi ndi ngs are energi zed,
the rel ay di rects battery current to the starter sol e-
noi d coi l wi ndi ngs. When the starter sol enoi d coi l
wi ndi ngs are energi zed, the sol enoi d di rects battery
current to the starter motor, whi ch cranks the engi ne
by engagi ng the starter pi ni on gear wi th the starter
ri ng gear. Once the engi ne starts, the i gni ti on swi tch
key i s rel eased by the vehi cl e operator. When the
i gni ti on swi tch key i s rel eased, the swi tch automati -
cal l y returns to the On posi ti on, whi ch de-energi zes
the starti ng system.
STARTER MOTOR
DESCRIPTION
The starter motors used for both the 2.5L and the
4.0L engi nes avai l abl e i n thi s model are not i nter-
changeabl e (Fi g. 2). However, each of these starter
motors i ncorporates several of the same features to
create a rel i abl e, effi ci ent, compact, l i ghtwei ght and
powerful uni t. Both starters feature hi gh torque
di rect current el ectri c motors. I nsi de both starter
motors the commutator of the rotati ng motor arma-
ture i s contacted by four brushes. The starter motor
for the 2.5L engi ne i s dri ven by four permanent mag-
net fi el d pol es, whi l e the starter motor for the 4.0L
engi ne i s dri ven by four el ectromagneti c fi el d coi l s
wound around four pol e shoes. The 2.5L starter
motor i s rated at 1.2 ki l owatts (about 1.6 horse-
power) output at 12 vol ts, whi l e the 4.0L starter
motor i s rated at 1.4 ki l owatts (about 1.9 horse-
power) output at 12 vol ts.
These starter motors are equi pped wi th a pl ane-
tary gear reducti on (i ntermedi ate transmi ssi on) sys-
tem. The pl anetary gear reducti on system consi sts of
a gear that i s i ntegral to the output end of the el ec-
tri c motor armature shaft that i s i n conti nual
engagement wi th a l arger gear that fi ts on a spl i ne
on the i nput end of the starter pi ni on gear shaft.
Thi s feature makes i t possi bl e to reduce the di men-
si ons of the starter. At the same ti me, i t al l ows
hi gher armature rotati onal speed and del i vers
i ncreased torque through the starter pi ni on gear.
Both starter motors use an overrunni ng cl utch and
starter pi ni on gear uni t to engage and dri ve the
starter ri ng gear, whi ch i s i ntegral to the fl ywheel
(manual transmi ssi on) or torque converter dri ve
pl ate (automati c transmi ssi on) mounted on the rear
crankshaft fl ange. Shi ms are avai l abl e and can be
used to adjust the 2.5L starter motor mounti ng posi -
ti on to correct for i mproper starter pi ni on gear to
starter ri ng gear engagement.
The starter motors for both engi nes are acti vated
by an i ntegral heavy duty starter sol enoi d swi tch
mounted to the overrunni ng cl utch housi ng. Thi s
el ectromechani cal swi tch connects and di sconnects
the feed of battery current to the starter motor
through a movabl e contact on one end of the sol enoi d
core or pl unger. At the same ti me, the sol enoi d
pl unger actuates a shi ft fork that engages and di sen-
gages the starter pi ni on gear wi th a starter ri ng
gear. The starter sol enoi d has two el ectromagneti c
wi ndi ngs or coi l s, a pul l -i n coi l and a hol d-i n coi l . The
pul l -i n coi l requi res more battery current and pro-
duces a stronger el ectromagneti c fi el d than the
hol d-i n coi l .
Both starter motors are servi ced onl y as a uni t
wi th thei r starter sol enoi ds, and cannot be repai red.
I f ei ther component i s faul ty or damaged, the enti re
starter motor and starter sol enoi d uni t must be
repl aced.
OPERATION
When the starter sol enoi d pul l -i n coi l wi ndi ngs are
energi zed the sol enoi d pl unger i s drawn i nto the el ec-
tromagneti c coi l . The sol enoi d pl unger pul l s the shi ft
l ever i n the starter motor. Thi s engages the starter
overrunni ng cl utch and pi ni on gear wi th the starter
ri ng gear on the manual transmi ssi on fl ywheel or on
the automati c transmi ssi on torque converter dri ve
pl ate. As the sol enoi d pl unger reaches the end of i ts
travel , i t moves the sol enoi d contact di sc to compl ete
the hi gh-amperage starter feed ci rcui t and energi zes
the sol enoi d hol d-i n coi l wi ndi ngs. Battery current
now fl ows between the sol enoi d battery termi nal and
the starter fi el d termi nal , energi zi ng the starter and
cranki ng the engi ne.
Fig. 2 Starter Motors
1 – STARTER SOLENOID
8B - 4 STARTING SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter motor from damage by al l owi ng the
starter pi ni on gear to spi n faster than the pi ni on
shaft. When the sol enoi d pl unger hol d-i n coi l i s de-
energi zed, the sol enoi d pl unger return spri ng returns
the pl unger to i ts rel axed posi ti on. Thi s causes the
sol enoi d contact di sc to open the starter feed ci rcui t,
and the shi ft l ever to di sengage the overrunni ng
cl utch and pi ni on gear uni t from the starter ri ng
gear.
STARTER RELAY
DESCRIPTION
The starter rel ay (Fi g. 3) i s an el ectromechani cal
devi ce that swi tches battery current to the pul l -i n
coi l of the starter sol enoi d when the i gni ti on swi tch
i s turned to the Start posi ti on. The starter rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the i nsi de surface of the PDC
cover for starter rel ay i denti fi cati on and l ocati on.
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO) mi cro-rel ay. Rel ays conformi ng to
the I SO speci fi cati ons have common physi cal di men-
si ons, current capaci ti es, termi nal patterns, and ter-
mi nal functi ons. The I SO mi cro-rel ay termi nal
functi ons are the same as a conventi onal I SO rel ay.
However, the I SO mi cro-rel ay termi nal pattern (or
footpri nt) i s di fferent, the current capaci ty i s l ower,
and the physi cal di mensi ons are smal l er than those
of the conventi onal I SO rel ay.
The starter rel ay cannot be repai red or adjusted
and, i f faul ty or damaged, i t must be repl aced.
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When the el ec-
tromagneti c coi l i s energi zed, i t draws the movabl e
contact away from the normal l y cl osed fi xed contact,
and hol ds i t agai nst the other (normal l y open) fi xed
contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor or di ode i s con-
nected i n paral l el wi th the el ectromagneti c coi l i n the
rel ay, and hel ps to di ssi pate vol tage spi kes that are
produced when the coi l i s de-energi zed.
DIAGNOSIS AND TESTING
STARTING SYSTEM
DIAGNOSIS
The battery, starti ng system and chargi ng system
i n the vehi cl e operate wi th one another, and must be
tested as a compl ete system. I n order for the engi ne
to start and the battery to charge properl y, al l of the
components that are used i n these systems must per-
form wi thi n speci fi cati ons. The servi ce i nformati on
for these systems has been separated wi thi n thi s ser-
vi ce manual to make i t easi er to l ocate the speci fi c
i nformati on you are seeki ng. However, when
attempti ng to di agnose any of these systems, i t i s
i mportant that you keep thei r i nterdependency i n
mi nd.
The di agnosti c procedures used for the battery,
starti ng system and chargi ng system i ncl ude the
most basi c conventi onal di agnosti c methods, to the
more sophi sti cated On-Board Di agnosti cs (OBD) bui l t
i nto the Powertrai n Control Modul e (PCM). Use of an
i nducti on-type mi l l i ampere ammeter, a vol t/ohmme-
ter, a battery charger, a carbon pi l e rheostat (l oad
tester) and a 12-vol t test l amp may be requi red. Al l
OBD-sensed systems are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for any fai l ure i t detects. Refer to
Charging System, On-Board Diagnostic Test i n
the i ndex of thi s servi ce manual for the l ocati on of
the proper on-board di agnosti c test procedures.
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 3 Starter Relay
TJ STARTING SYSTEMS 8B - 5
DESCRIPTION AND OPERATION (Continued)
Starting System Diagnosis
Condition Possible Cause Correction
Starter fails to operate. 1. Battery discharged or
faulty.
2. On models with an
automatic transmission,
the clutch interlock
ignition fuse is faulty or
missing.
3. Starting circuit wiring
faulty.
4. Starter relay faulty.
5. Ignition switch faulty.
6. Clutch pedal position
switch faulty.
7. Park/Neutral position
switch faulty or
misadjusted.
8. Starter solenoid faulty.
9. Starter motor faulty.
1. Refer to Battery in the index of this service manual for
the location of the proper battery diagnosis and testing
procedures. Replace the faulty battery, as required.
2. Check the fuse in cavity 20 of the fuseblock module.
Replace the faulty or missing fuse, as required.
3. Refer to Starting System in the index of this service
manual for the location of complete starting system wiring
diagrams. Test and repair the faulty starter feed and/or
control circuits, as required.
4. Refer to Starter Relay in the index of this service
manual for the location ofr the proper starter relay
diagnosis and testing procedures. Replace the faulty
starter relay, as required.
5. Refer to Ignition Switch and Key Lock Cylinder in the
index of this service manual for the location of the proper
ignition switch diagnosis and testing procedures. Replace
the faulty ignition switch, as required.
6. Refer to Clutch Pedal Position Switch in the index of
this service manual for the location of the proper clutch
pedal position switch diagnosis and testing procedures.
Replace the faulty clutch hydraulic linkage unit, as
required.
7. Refer to Park/Neutral Position Switch in the index of
this service manual for the location of the proper
park/neutral position switch diagnosis and testing
procedures. Replace the faulty park/neutral position
switch, as required.
8. Refer to Starter Motor in the index of this service
manual for the location of the proper starter solenoid
diagnosis and testing procedures. Replace the faulty
starter motor, as required.
9. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
diagnosis and testing procedures. Replace the faulty
starter motor, as required.
Starter engages, fails to
turn engine.
1. Battery discharged or
faulty.
2. Starting circuit wiring
faulty.
3. Starter motor faulty.
4. Engine seized.
1. Refer to Battery in the index of this service manual for
the location of the proper battery diagnosis and testing
procedures. Replace the faulty battery, as required.
2. Refer to Starting System in the index of this service
manual for the location of complete starting system wiring
diagrams. Test and repair the faulty starter feed and/or
control circuits, as required.
3. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
diagnosis and testing procedures. Replace the faulty
starter motor, as required.
4. Refer to Engine Diagnosis in the index of this service
manual for the location of the proper engine diagnosis
and testing procedures. Repair or replace the faulty
engine, as required.
8B - 6 STARTING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
Starting System Diagnosis
Condition Possible Cause Correction
Starter engages, spins
out before engine starts.
1. Starter ring gear faulty.
2. Starter motor faulty.
1. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
removal and installation procedures. Remove the starter
motor to inspect the starter ring gear. Replace the faulty
starter ring gear, as required.
2. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
diagnosis and testing procedures. Replace the faulty
starter motor, as required.
Starter does not
disengage.
1. Starter motor
improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter motor faulty.
1. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
installation procedures. Tighten the starter motor
mounting hardware to the correct tightness specifications,
as required.
2. Refer to Starter Relay in the index of this service
manual for the location of the proper starter relay
diagnosis and testing procedures. Replace the faulty
starter relay, as required.
3. Refer to Ignition Switch and Key Lock Cylinder in the
index of this service manual for the location of the proper
ignition switch diagnosis and testing procedures. Replace
the faulty ignition switch, as required.
4. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
diagnosis and testing procedures. Replace the faulty
starter motor, as required.
TESTING
Before testi ng the starti ng system perform a vi sual
i nspecti on of the starti ng system components and
connecti ons. Refer to Starting System i n the i ndex
of thi s servi ce manual for the l ocati on of the proper
starti ng system cl eani ng and i nspecti on procedures.
COLD CRANKING TEST
Refer to Starting System i n the i ndex of thi s ser-
vi ce manual for the l ocati on of compl ete starti ng sys-
tem wi ri ng di agrams. Before performi ng thi s test, be
certai n that the fol l owi ng procedures are accom-
pl i shed:
• The battery i s ful l y-charged and l oad tested.
Refer to Battery Charging i n the i ndex of thi s ser-
vi ce manual for the l ocati on of the proper battery
chargi ng procedures. Refer to Battery i n the i ndex of
thi s servi ce manual for the l ocati on of the battery
di agnosi s and testi ng procedures, i ncl udi ng the
proper battery l oad test procedures.
• Ful l y engage the parki ng brake.
• I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
• Veri fy that al l l amps and accessori es are turned
off.
• To prevent the engi ne from starti ng, remove the
Automati c ShutDown (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect a sui tabl e vol t-ampere tester to the
battery termi nal s (Fi g. 4). See the i nstructi ons pro-
vi ded by the manufacturer of the vol t-ampere tester
bei ng used.
(2) Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Note the cranki ng vol tage and current
(amperage) draw readi ngs shown on the vol t-ampere
tester.
(a) I f the vol tage reads bel ow 9.6 vol ts, refer to
Starter Motor i n the i ndex of thi s servi ce manual
for the l ocati on of the proper starter motor di agno-
si s and testi ng procedures. I f the starter motor
tests OK, refer to Engine Diagnosis i n the i ndex
of thi s servi ce manual for the l ocati on of the proper
engi ne di agnosi s and testi ng procedures. I f the
TJ STARTING SYSTEMS 8B - 7
DIAGNOSIS AND TESTING (Continued)
starter motor i s not OK, repl ace the faul ty starter
motor.
(b) I f the vol tage reads above 9.6 vol ts and the
current (amperage) draw reads bel ow speci fi ca-
ti ons, refer to the Feed Circuit Test i n thi s sec-
ti on.
(c) I f the vol tage reads 12.5 vol ts or greater and
the starter motor does not turn, refer to the Con-
trol Circuit Test i n thi s secti on.
(d) I f the vol tage reads 12.5 vol ts or greater and
the starter motor turns very sl owl y, refer to the
Feed Circuit Test i n thi s secti on.
NOTE: A cold engine will increase the starter cur-
rent (amperage) draw reading, and reduce the bat-
tery voltage reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n the
hi gh-amperage starter feed ci rcui t. Refer to Starting
System i n the i ndex of thi s servi ce manual for the
l ocati on of compl ete starti ng system wi ri ng di agrams.
When performi ng the vol tage drop test, i t i s i mpor-
tant to remember that the vol tage drop i s gi vi ng an
i ndi cati on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached. EXAM-
PLE: When testi ng the resi stance of the battery pos-
i ti ve cabl e, touch the vol tmeter l eads to the battery
posi ti ve cabl e termi nal cl amp and to the battery pos-
i ti ve cabl e eyel et termi nal at the starter sol enoi d
B(+) termi nal stud. I f you probe the battery posi ti ve
termi nal post and the battery posi ti ve cabl e eyel et
termi nal at the starter sol enoi d B(+) termi nal stud,
you are readi ng the combi ned vol tage drop i n the
battery posi ti ve cabl e termi nal cl amp-to-termi nal
post connecti on and the battery posi ti ve cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng thi s
test, be certai n that the fol l owi ng procedures are
accompl i shed:
• The battery i s ful l y-charged and l oad tested.
Refer to Battery Charging i n the i ndex of thi s ser-
vi ce manual for the l ocati on of the proper battery
chargi ng procedures. Refer to Battery i n the i ndex of
thi s servi ce manual for the l ocati on of the battery
di agnosi s and testi ng procedures, i ncl udi ng the
proper battery l oad test procedures.
• Ful l y engage the parki ng brake.
• I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
• Veri fy that al l l amps and accessori es are turned
off.
• To prevent the engi ne from starti ng, remove the
Automati c ShutDown (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e termi nal cl amp (Fi g. 5). Rotate and hol d the
i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct the poor con-
tact between the battery negati ve cabl e termi nal
cl amp and the battery negati ve termi nal post.
Fig. 4 Volts-Amps Tester Connections - Typical
1 – POSITIVE CLAMP
2 – NEGATIVE CLAMP
3 – INDUCTION AMMETER CLAMP
Fig. 5 Test Battery Negative Connection Resistance
- Typical
1 – VOLTMETER
2 – BATTERY
8B - 8 STARTING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
(2) Connect the posi ti ve l ead of the vol tmeter to
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
termi nal cl amp (Fi g. 6). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor connecti on
between the battery posi ti ve cabl e termi nal cl amp
and the battery posi ti ve termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve cabl e termi nal cl amp and the starter
sol enoi d B(+) termi nal stud (Fi g. 7). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery posi ti ve cabl e eyel et termi nal con-
necti on at the starter sol enoi d B(+) termi nal stud.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
(4) Connect the vol tmeter to measure between the
battery negati ve cabl e termi nal cl amp and a good
cl ean ground on the engi ne bl ock (Fi g. 8). Rotate and
hol d the i gni ti on swi tch i n the Start posi ti on.
Observe the vol tmeter. I f the readi ng i s above 0.2
vol t, cl ean and ti ghten the battery negati ve cabl e
eyel et termi nal connecti on to the engi ne bl ock.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery negati ve cabl e.
(5) Connect the posi ti ve l ead of the vol tmeter to
the starter housi ng. Connect the negati ve l ead of the
vol tmeter to the battery negati ve termi nal post (Fi g.
9). Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Observe the vol tmeter. I f the readi ng i s
above 0.2 vol t, correct the poor starter to engi ne
bl ock ground contact.
I f the resi stance tests detect no feed ci rcui t prob-
l ems, refer to Starter Motor i n the i ndex of thi s ser-
vi ce manual for the l ocati on of the proper starter
motor di agnosi s and testi ng procedures.
CONTROL CIRCUIT TEST
The starter control ci rcui t components shoul d be
tested i n the order i n whi ch they are l i sted, as fol -
l ows:
• Starter Rel ay Refer to Starter Relay i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper starter rel ay di agnosi s and testi ng procedures.
• Starter Sol enoi d Refer to Starter Motor i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper starter sol enoi d di agnosi s and testi ng proce-
dures.
Fig. 6 Test Battery Positive Connection Resistance -
Typical
1 – VOLTMETER
2 – BATTERY
Fig. 7 Test Battery Positive Cable Resistance -
Typical
1 – BATTERY
2 – VOLTMETER
3 – STARTER MOTOR
Fig. 8 Test Ground Circuit Resistance - Typical
1 – VOLTMETER
2 – BATTERY
3 – ENGINE GROUND
TJ STARTING SYSTEMS 8B - 9
DIAGNOSIS AND TESTING (Continued)
• I gni ti on Swi tch Refer to Ignition Switch and
Key Lock Cylinder i n the i ndex of thi s servi ce
manual for the l ocati on of the proper i gni ti on swi tch
di agnosi s and testi ng procedures.
• Cl utch Pedal Posi ti on Swi tch I f the vehi cl e i s
equi pped wi th a manual transmi ssi on, refer to
Clutch Pedal Position Switch i n the i ndex of thi s
servi ce manual for the l ocati on of the proper cl utch
pedal posi ti on swi tch di agnosi s and testi ng proce-
dures.
• Park/Neutral Posi ti on Swi tch I f the vehi cl e i s
equi pped wi th an automati c transmi ssi on, refer to
Park/Neutral Position Switch i n the i ndex of thi s
servi ce manual for the l ocati on of the proper park/
neutral posi ti on swi tch di agnosi s and testi ng proce-
dures.
STARTER MOTOR NOISE - 2. 5L ENGINE
See the Starter Motor Noi se Di agnosi s chart (Fi g.
10). I f the compl ai nt i s si mi l ar to Condi ti ons 1 and 2
i n the chart, correcti on can be made by pl aci ng shi ms
between the starter motor and the engi ne bl ock usi ng
the fol l owi ng procedures:
CONDITION POSSIBLE CAUSE CORRECTION
1. VERY HIGH FREQUENCY
WHINE BEFORE ENGINE
STARTS; ENGINE STARTS OK.
1. Excessive distance between pinion
gear and flywheel/drive plate gear.
1. Move starter motor toward
flywheel/drive plate by removing
shim(s), if possible.
2. VERY HIGH FREQUENCY
WHINE AFTER ENGINE STARTS
WITH IGNITION KEY RELEASED.
ENGINE STARTS OK.
2. Insufficient distance between
starter motor pinion gear and
flywheel/drive plate runout can cause
noise to be intermittent.
2. Shim starter motor away from
flywheel/drive plate. Inspect
flywheel/drive plate for damage;
bent, unusual wear, and excessive
runout. Replace flywheel/drive
plate as necessary.
3. A LOUD “WHOOP” AFTER
ENGINE STARTS WHILE
STARTER MOTOR IS ENGAGED.
3. Most probably cause is defective
overrunning clutch.
3. Replace starter motor.
4. A “RUMBLE,” “GROWL,” OR
“KNOCK” AS STARTER MOTOR
COASTS TO STOP AFTER
ENGINE STARTS.
4. Most probable cause is bent or
unbalanced starter motor armature.
4. Replace starter motor.
NOTE: A hi gh frequency whi ne duri ng cranki ng i s normal for thi s starter motor.
FIG. 10 STARTER MOTOR NOISE DIAGNOSIS
(1) I f the compl ai nt i s si mi l ar to Condi ti on 1, the
starter motor must be moved toward the starter ri ng
gear by removi ng shi ms from both starter mounti ng
pads on the engi ne bl ock (Fi g. 11). Refer to Starter
Motor i n the i ndex of thi s servi ce manual for the
l ocati on of the proper starter motor removal and
i nstal l ati on procedures.
NOTE: The shim thickness is 0.381 mm (0.015 in.).
These shims may be stacked if additional thickness is
required.
(2) I f the compl ai nt i s si mi l ar to Condi ti on 2, the
starter motor must be moved away from the starter ri ng
gear. Thi s i s done by i nstal l i ng shi m(s) across both
starter mounti ng pads on the engi ne bl ock. More than
one shi m may be requi red. Refer to Starter Motor i n
the i ndex of thi s servi ce manual for the l ocati on of the
proper removal and i nstal l ati on procedures.
Fig. 9 Test Starter Ground - Typical
1 – STARTER MOTOR
2 – BATTERY
3 – VOLTMETER
8B - 10 STARTING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
NOTE: This is a condition that will generally cause
broken starter (flywheel/torque converter drive
plate) ring gear teeth or broken starter motor hous-
ings.
STARTER MOTOR
Correct starter motor operati on can be confi rmed
by performi ng the fol l owi ng free runni ng bench test.
Thi s test can onl y be performed wi th the starter
motor removed from the vehi cl e. Refer to Starting
System i n the i ndex of thi s servi ce manual for the
l ocati on of the proper starter motor speci fi cati ons.
CAUTION: The 2.5L engine uses a permanent mag-
net starter. Permanent magnet starters are highly
sensitive to hammering, shocks, external pressure
and reverse polarity. This starter motor must never
be clamped in a vise by the starter field frame. The
starter should only be clamped by the mounting
flange. Do not reverse the battery cable connec-
tions to this starter motor when testing. The perma-
nent magnets may be damaged and the starter
rendered unserviceable if it is subjected to any of
these conditions.
STARTER MOTOR
(1) Remove the starter motor from the vehi cl e.
Refer to Starter Motor i n the i ndex of thi s servi ce
manual for the l ocati on of the proper starter motor
removal and i nstal l ati on procedures.
(2) Mount the starter motor securel y i n a soft-
jawed bench vi se. The vi se jaws shoul d be cl amped
on the mounti ng fl ange of the starter motor. Never
cl amp on the starter motor by the fi el d frame.
(3) Connect a sui tabl e vol t-ampere tester and a
12-vol t battery to the starter motor i n seri es, and set
the ammeter to the 100 ampere scal e. See the
i nstructi ons provi ded by the manufacturer of the
vol t-ampere tester bei ng used.
(4) I nstal l a jumper wi re from the sol enoi d termi -
nal to the sol enoi d B(+) termi nal stud. The starter
motor shoul d operate. I f the starter motor fai l s to
operate, repl ace the faul ty starter motor.
(5) Adjust the carbon pi l e l oad of the tester to
obtai n the free runni ng test vol tage. Refer to Start-
ing System i n the i ndex of thi s servi ce manual for
the l ocati on of the proper starter motor free runni ng
test vol tage speci fi cati ons.
(6) Note the readi ng on the ammeter and compare
thi s readi ng to the free runni ng test maxi mum
amperage draw. Refer to Starting System i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper starter motor free runni ng test maxi mum
amperage draw speci fi cati ons.
(7) I f the ammeter readi ng exceeds the maxi mum
amperage draw speci fi cati on, repl ace the faul ty
starter motor.
STARTER SOLENOID
Thi s test can onl y be performed wi th the starter
motor removed from the vehi cl e.
(1) Remove the starter motor from the vehi cl e.
Refer to Starter Motor i n the i ndex of thi s servi ce
manual for the l ocati on of the proper starter motor
removal and i nstal l ati on procedures.
(2) Di sconnect the wi re from the sol enoi d fi el d coi l
termi nal .
(3) Check for conti nui ty between the sol enoi d ter-
mi nal and the sol enoi d fi el d coi l termi nal wi th a con-
ti nui ty tester (Fi g. 12). There shoul d be conti nui ty. I f
OK, go to Step 4. I f not OK, repl ace the faul ty starter
motor.
(4) Check for conti nui ty between the sol enoi d ter-
mi nal and the sol enoi d case (Fi g. 13). There shoul d
be conti nui ty. I f not OK, repl ace the faul ty starter
motor.
Fig. 11 Starter Motor Shim
1 – STARTER MOTOR SHIM
Fig. 12 Continuity Test Between Solenoid Terminal
and Field Coil Terminal - Typical
1 – SOLENOID
2 – SOLENOID TERMINAL
3 – OHMMETER
4 – FIELD COIL TERMINAL
TJ STARTING SYSTEMS 8B - 11
DIAGNOSIS AND TESTING (Continued)
STARTER RELAY
The starter rel ay (Fi g. 14) i s l ocated i n the Power
Di stri buti on Center (PDC), i n the engi ne compart-
ment. Refer to the fuse and rel ay l ayout l abel affi xed
to the undersi de of the PDC cover for starter rel ay
i denti fi cati on and l ocati on. Refer to Starting Sys-
tem i n the i ndex of thi s servi ce manual for the l oca-
ti on of compl ete starti ng system wi ri ng di agrams.
RELAY TEST
(1) Remove the starter rel ay from the PDC. Refer
to Starter Relay i n the i ndex of thi s servi ce manual
for the l ocati on of the proper starter rel ay removal
and i nstal l ati on procedures.
(2) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 3. I f not OK, repl ace the faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 Ϯ 5 ohms. I f OK, go to Step
4. I f not OK, repl ace the faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform the Rel ay Ci rcui t Test that
fol l ows. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the fused B(+) fuse i n the PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the starter sol enoi d fi el d coi l . There shoul d be con-
ti nui ty between the cavi ty for rel ay termi nal 87 and
the starter sol enoi d termi nal at al l ti mes. I f OK, go
to Step 4. I f not OK, repai r the open engi ne starter
motor rel ay output ci rcui t to the starter sol enoi d as
requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s energi zed when
the i gni ti on swi tch i s hel d i n the Start posi ti on. On
vehi cl es wi th a manual transmi ssi on, the cl utch
pedal must be bl ocked i n the ful l y depressed posi ti on
for thi s test. Check for battery vol tage at the cavi ty
for rel ay termi nal 86 wi th the i gni ti on swi tch i n the
Start posi ti on, and no vol tage when the i gni ti on
swi tch i s rel eased to the On posi ti on. I f OK, go to
Step 5. I f not OK wi th a manual transmi ssi on, di s-
connect the cl utch pedal posi ti on swi tch wi re harness
connector and i nstal l a jumper wi re between the two
cavi ti es i n the body hal f of the connector and check
for battery vol tage agai n at the cavi ty for rel ay ter-
mi nal 86. I f now OK, repl ace the faul ty cl utch pedal
posi ti on swi tch. I f sti l l not OK wi th a manual trans-
mi ssi on or i f not OK wi th an automati c transmi ssi on,
check for an open or shorted fused i gni ti on swi tch
output (start) ci rcui t to the i gni ti on swi tch and
repai r, as requi red. I f the fused i gni ti on swi tch out-
put (start) ci rcui t i s OK, refer to Ignition Switch
and Key Lock Cylinder i n the i ndex of thi s servi ce
manual for the l ocati on of the proper i gni ti on swi tch
di agnosi s and testi ng procedures.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. On vehi cl es wi th a
manual transmi ssi on, i t i s grounded at al l ti mes. On
vehi cl es wi th an automati c transmi ssi on, i t i s
Fig. 13 Continuity Test Between Solenoid Terminal
and Solenoid Case - Typical
1 – SOLENOID
2 – SOLENOID TERMINAL
3 – OHMMETER
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 14 Starter Relay
8B - 12 STARTING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
grounded through the park/neutral posi ti on swi tch
onl y when the gearshi ft sel ector l ever i s i n the Park
or Neutral posi ti ons. Check for conti nui ty to ground
at the cavi ty for rel ay termi nal 85. I f not OK wi th a
manual transmi ssi on, repai r the open park/neutral
posi ti on swi tch sense ci rcui t to ground as requi red. I f
not OK wi th an automati c transmi ssi on, check for an
open or shorted park/neutral posi ti on swi tch sense
ci rcui t to the park/neutral posi ti on swi tch and repai r,
as requi red. I f the park/neutral posi ti on swi tch sense
ci rcui t checks OK, refer to Park/Neutral Position
Switch i n the i ndex of thi s servi ce manual for the
l ocati on of the proper park/neutral posi ti on swi tch
di agnosi s and testi ng procedures.
REMOVAL AND INSTALLATION
STARTER MOTOR
REMOVAL
2. 5L ENGINE
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Rai se and support the vehi cl e.
(3) Whi l e supporti ng the starter motor wi th one
hand, use the other hand to remove the two screws
that secure the starter motor to the engi ne bl ock
(Fi g. 15).
(4) Lower the starter motor from the engi ne bl ock
far enough to access and remove the nut that secures
the battery posi ti ve cabl e eyel et termi nal to the
starter sol enoi d B(+) termi nal stud (Fi g. 16). Al ways
support the starter motor duri ng thi s process. Do not
l et the starter motor hang from the wi re harness.
(5) Remove the battery posi ti ve cabl e eyel et termi -
nal from the starter sol enoi d B(+) termi nal stud.
Al ways support the starter motor duri ng thi s process.
Do not l et the starter motor hang from the wi re har-
ness.
(6) Di sconnect the sol enoi d termi nal wi re harness
connector from the connector receptacl e on the
starter sol enoi d. Al ways support the starter motor
duri ng thi s process. Do not l et the starter motor
hang from the wi re harness.
(7) Remove the starter motor and any starter
motor shi ms (i f used) from the engi ne bl ock.
4. 0L ENGINE
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Rai se and support the vehi cl e.
(3) Remove the l ower screw (forward faci ng) that
secures the starter motor to the manual transmi ssi on
cl utch housi ng or the automati c transmi ssi on torque
converter housi ng (Fi g. 17).
(4) Whi l e supporti ng the starter motor wi th one
hand, use the other hand to remove the upper screw
(rearward faci ng) that secures the starter motor to
Fig. 15 Starter Motor Remove/Install - 2.5L Engine
1 – STARTER MOTOR
2 – SCREW (2)
3 – SHIM
Fig. 16 Starter Connections Remove/Install - Typical
1 – STARTER MOTOR
2 – SOLENOID B(+) TERMINAL STUD
3 – BATTERY POSITIVE CABLE EYELET TERMINAL
4 – NUT
5 – SOLENOID TERMINAL WIRE HARNESS CONNECTOR
6 – SOLENOID TERMINAL CONNECTOR RECEPTACLE
TJ STARTING SYSTEMS 8B - 13
DIAGNOSIS AND TESTING (Continued)
the manual transmi ssi on cl utch housi ng or the auto-
mati c transmi ssi on torque converter housi ng.
(5) Lower the starter motor from the front of the
manual transmi ssi on cl utch housi ng or automati c
transmi ssi on torque converter housi ng far enough to
access and remove the nut that secures the battery
posi ti ve cabl e eyel et termi nal to the starter sol enoi d
B(+) termi nal stud (Fi g. 16). Al ways support the
starter motor duri ng thi s process. Do not l et the
starter motor hang from the wi re harness.
(6) Remove the battery posi ti ve cabl e eyel et termi -
nal from the sol enoi d B(+) termi nal stud. Al ways
support the starter motor duri ng thi s process. Do not
l et the starter motor hang from the wi re harness.
(7) Di sconnect the sol enoi d termi nal wi re harness
connector from the connector receptacl e on the
starter sol enoi d. Al ways support the starter motor
duri ng thi s process. Do not l et the starter motor
hang from the wi re harness.
(8) Remove the starter motor from the manual
transmi ssi on cl utch housi ng or automati c transmi s-
si on torque converter housi ng.
INSTALLATION
2. 5L ENGINE
(1) Posi ti on the starter motor to the engi ne bl ock.
(2) Reconnect the sol enoi d termi nal wi re harness
connector to the connector receptacl e on the starter
sol enoi d. Al ways support the starter motor duri ng
thi s process. Do not l et the starter motor hang from
the wi re harness.
(3) I nstal l the battery posi ti ve cabl e eyel et termi -
nal onto the starter sol enoi d B(+) termi nal stud.
Al ways support the starter motor duri ng thi s process.
Do not l et the starter motor hang from the wi re har-
ness.
(4) I nstal l and ti ghten the nut that secures the
battery posi ti ve cabl e eyel et termi nal to the starter
sol enoi d B(+) termi nal stud. Ti ghten the nut to 11.3
N·m (100 i n. l bs.). Al ways support the starter motor
duri ng thi s process. Do not l et the starter motor
hang from the wi re harness.
(5) Posi ti on the starter motor and any starter
motor shi ms that were removed duri ng the starter
motor removal procedure to the engi ne bl ock. Loosel y
i nstal l the two starter motor mounti ng screws to
secure the starter motor and shi ms to the engi ne
bl ock.
NOTE: Shim thickness available is 0.381 mm (0.015
in.). Refer to Starter Motor Noise - 2.5L Engine in
the index of this service manual for the location of
the proper starter motor noise diagnosis and test-
ing procedures.
(6) Ti ghten the two screws that secure the starter
motor and shi ms to the engi ne bl ock. Ti ghten the
screws to 44.7 N·m (33 ft. l bs.).
(7) Lower the vehi cl e.
(8) Reconnect the battery negati ve cabl e.
4. 0L ENGINE
(1) Posi ti on the starter motor to the manual trans-
mi ssi on cl utch housi ng or automati c transmi ssi on
torque converter housi ng.
(2) Reconnect the sol enoi d termi nal wi re harness
connector to the connector receptacl e on the starter
sol enoi d. Al ways support the starter motor duri ng
thi s process. Do not l et the starter motor hang from
the wi re harness.
(3) I nstal l the battery posi ti ve cabl e eyel et termi -
nal onto the starter sol enoi d B(+) termi nal stud.
Al ways support the starter motor duri ng thi s process.
Do not l et the starter motor hang from the wi re har-
ness.
(4) I nstal l and ti ghten the nut that secures the
battery posi ti ve cabl e eyel et termi nal to the starter
sol enoi d B(+) termi nal stud. Ti ghten the nut to 11.3
N·m (100 i n. l bs.). Al ways support the starter motor
duri ng thi s process. Do not l et the starter motor
hang from the wi re harness.
(5) Posi ti on the starter motor to the manual trans-
mi ssi on cl utch housi ng or automati c transmi ssi on
torque converter housi ng. Loosel y i nstal l the two
starter motor mounti ng screws to secure the starter
motor to the manual transmi ssi on cl utch housi ng or
automati c transmi ssi on torque converter housi ng.
Fig. 17 Starter Motor Remove/Install - 4.0L Engine
1 – SCREW
2 – STARTER MOTOR
3 – SCREW
8B - 14 STARTING SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(6) Ti ghten the l ower (forward faci ng) screw that
secures the starter motor to the manual transmi ssi on
cl utch housi ng or automati c transmi ssi on torque con-
verter housi ng. Ti ghten the screw to 40.7 N·m (30 ft.
l bs.).
(7) Ti ghten the upper (rearward faci ng) screw that
secures the starter motor to the manual transmi ssi on
cl utch housi ng or automati c transmi ssi on torque con-
verter housi ng. Ti ghten the screw to 47.5 N·m (35 ft.
l bs.).
(8) Lower the vehi cl e.
(9) Reconnect the battery negati ve cabl e.
STARTER RELAY
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unl atch and open the cover on the Power Di s-
tri buti on Center (PDC) (Fi g. 18).
(3) See the fuse and rel ay l ayout l abel affi xed to
the undersi de of the PDC cover for starter rel ay i den-
ti fi cati on and l ocati on.
(4) Remove the starter rel ay from the PDC.
INSTALLATION
(1) See the fuse and rel ay l ayout l abel affi xed to
the undersi de of the PDC cover for the proper starter
rel ay l ocati on.
(2) Posi ti on the starter rel ay i n the proper recep-
tacl e i n the PDC.
(3) Al i gn the starter rel ay termi nal s wi th the ter-
mi nal cavi ti es i n the PDC receptacl e.
(4) Push down fi rml y on the starter rel ay unti l the
termi nal s are ful l y seated i n the termi nal cavi ti es i n
the PDC receptacl e.
(5) Cl ose and l atch the PDC cover.
(6) Reconnect the battery negati ve cabl e.
CLEANING AND INSPECTION
STARTING SYSTEM
The fol l owi ng components of the starti ng system
shoul d be careful l y i nspected whenever any starti ng
system probl em i s encountered.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• Battery Vi sual l y i nspect the battery for i ndi ca-
ti ons of physi cal damage and l oose or corroded cabl e
connecti ons. Determi ne the state-of-charge and
cranki ng capaci ty of the battery. Charge or repl ace
the battery, i f requi red. Refer to Battery i n the i ndex
of thi s servi ce manual for the l ocati on of the proper
battery cl eani ng and i nspecti on procedures.
• I gni ti on Swi tch Vi sual l y i nspect the i gni ti on
swi tch for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons. Cl ean corroded
connecti ons as requi red. Refer to Wiring Diagrams
i n the i ndex of thi s servi ce manual for the l ocati on of
the proper wi ri ng repai r or connector and termi nal
servi ce procedures. Refer to Ignition Switch and
Key Lock Cylinder i n the i ndex of thi s servi ce
manual for the l ocati on of the proper i gni ti on swi tch
servi ce procedures.
• Cl utch Pedal Posi ti on Swi tch I f the vehi cl e i s
equi pped wi th a manual transmi ssi on, vi sual l y
i nspect the cl utch pedal posi ti on swi tch for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
harness connecti ons. Cl ean corroded connecti ons as
requi red. Refer to Wiring Diagrams i n the i ndex of
thi s servi ce manual for the l ocati on of the proper wi r-
i ng repai r or connector and termi nal servi ce proce-
dures. Refer to Clutch Hydraulic Linkage i n the
i ndex of thi s servi ce manual for the l ocati on of the
Fig. 18 Power Distribution Center
1 – POWER DISTRIBUTION CENTER
2 – LATCHES
3 – PDC COVER
4 – RIGHT FRONT FENDER
TJ STARTING SYSTEMS 8B - 15
REMOVAL AND INSTALLATION (Continued)
proper cl utch pedal posi ti on swi tch servi ce proce-
dures.
• Park/Neutral Posi ti on Swi tch I f the vehi cl e i s
equi pped wi th an automati c transmi ssi on, vi sual l y
i nspect the park/neutral posi ti on swi tch for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
harness connecti ons. Cl ean corroded connecti ons as
requi red. Refer to Wiring Diagrams i n the i ndex of
thi s servi ce manual for the l ocati on of the proper wi r-
i ng repai r or connector and termi nal servi ce proce-
dures. Refer to Park/Neutral Position Switch i n
the i ndex of thi s servi ce manual for the l ocati on of
the proper park/neutral posi ti on swi tch servi ce proce-
dures.
• Starter Rel ay Vi sual l y i nspect the starter rel ay
for i ndi cati ons of physi cal damage and l oose or cor-
roded wi re harness connecti ons. Cl ean corroded con-
necti ons as requi red. Refer to Wiring Diagrams i n
the i ndex of thi s servi ce manual for the l ocati on of
the proper wi ri ng repai r or connector and termi nal
servi ce procedures. Refer to Starter Relay i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper starter rel ay servi ce procedures.
• Starter Motor Vi sual l y i nspect the starter motor
for i ndi cati ons of physi cal damage and l oose or cor-
roded wi re harness connecti ons. Cl ean corroded con-
necti ons as requi red. Refer to Wiring Diagrams i n
the i ndex of thi s servi ce manual for the l ocati on of
the proper wi ri ng repai r or connector and termi nal
servi ce procedures. I f the probl em bei ng di agnosed
i nvol ves i mproper starter engagement, di sengage-
ment or noi se compl ai nts the starter motor shoul d be
removed. Wi th the starter motor removed, i nspect
the starter pi ni on and ri ng gears for damaged or
mi ssi ng teeth. Repl ace faul ty components as
requi red. Refer to Starter Motor i n the i ndex of thi s
servi ce manual for the l ocati on of the proper starter
motor removal and i nstal l ati on procedures.
• Starter Sol enoi d Vi sual l y i nspect the starter
sol enoi d for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons. Cl ean corroded
connecti ons as requi red. Refer to Wiring Diagrams
i n the i ndex of thi s servi ce manual for the l ocati on of
the proper wi ri ng repai r or connector and termi nal
servi ce procedures. Refer to Starter Motor i n the
i ndex of thi s servi ce manual for the l ocati on of the
proper starter sol enoi d servi ce procedures.
• Wi ri ng Vi sual l y i nspect the starti ng system wi re
harnesses for i ndi cati ons of physi cal damage. Repai r
or repl ace any faul ty wi ri ng, as requi red. Refer to
Starting Systemi n the i ndex of thi s servi ce manual
for the l ocati on of compl ete starti ng system wi ri ng
di agrams. Refer to Wiring Diagrams i n the i ndex of
thi s servi ce manual for the l ocati on of the proper wi r-
i ng repai r or connector and termi nal servi ce proce-
dures.
SPECIFICATIONS
STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer Mitsubishi
Engine Application 2.5L, 4.0L
Power Rating
2.5L - 1.2 Kilowatt (1.6 Horsepower)
4.0L - 1.4 Kilowatt (1.9 Horsepower)
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.2 Volts
Free Running Test Maximum Amperage Draw 90 Amperes
Free Running Test Minimum Speed
2.5L - 2600 rpm
4.0L - 2500 rpm
Solenoid Closing Maximum Voltage Required 7.8 Volts
*Cranking Amperage Draw Test
2.5L - 130 Amperes
4.0L - 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
8B - 16 STARTING SYSTEMS TJ
CLEANING AND INSPECTION (Continued)
CHARGING SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 1
GENERATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BATTERY TEMPERATURE SENSOR . . . . . . . . . . . 2
ELECTRONIC VOLTAGE REGULATOR. . . . . . . . . . 2
DIAGNOSIS AND TESTING
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 2
ON-BOARD DIAGNOSTIC TEST FOR
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
GENERATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BATTERY TEMPERATURE SENSOR . . . . . . . . . . . 4
SPECIFICATIONS
GENERATOR RATINGS . . . . . . . . . . . . . . . . . . . . . 5
TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION AND OPERATION
CHARGING SYSTEM
DESCRIPTION
The chargi ng system consi sts of:
• Generator
• El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM)
• I gni ti on swi tch (refer to Group 8D, I gni ti on Sys-
tem for i nformati on)
• Battery (refer to Group 8A, Battery for i nforma-
ti on)
• Battery temperature sensor
• Generator Lamp (i f equi pped)
• Check Gauges Lamp (i f equi pped)
• Vol tmeter (refer to Group 8E, I nstrument Panel
and Gauges for i nformati on)
• Wi ri ng harness and connecti ons (refer to Group
8W, Wi ri ng for i nformati on)
OPERATION
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. The system i s on when the engi ne i s
runni ng and the ASD rel ay i s energi zed. When the
ASD rel ay i s on, vol tage i s suppl i ed to the ASD rel ay
sense ci rcui t at the PCM. Thi s vol tage i s connected
through the PCM and suppl i ed to one of the genera-
tor fi el d termi nal s (Gen. Source +) at the back of the
generator.
The amount of DC current produced by the gener-
ator i s control l ed by the EVR (fi el d control ) ci rcui try
contai ned wi thi n the PCM. Thi s ci rcui try i s con-
nected i n seri es wi th the second rotor fi el d termi nal
and ground.
A battery temperature sensor, l ocated i n the bat-
tery tray housi ng, i s used to sense battery tempera-
ture. Thi s temperature data, al ong wi th data from
moni tored l i ne vol tage, i s used by the PCM to vary
the battery chargi ng rate. Thi s i s done by cycl i ng the
ground path to control the strength of the rotor mag-
neti c fi el d. The PCM then compensates and regul ates
generator current output accordi ngl y.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng EVR
(fi el d control ) ci rcui try, are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for certai n fai l ures i t detects. Refer to
On-Board Di agnosti cs i n Group 25, Emi ssi on Control
System for more DTC i nformati on.
The Check Gauges Lamp (i f equi pped) moni tors:
charging system voltage, engi ne cool ant tempera-
ture and engi ne oi l pressure. I f an extreme condi ti on
i s i ndi cated, the l amp wi l l be i l l umi nated. Thi s i s
done as remi nder to check the three gauges. The si g-
nal to acti vate the l amp i s sent vi a the CCD bus ci r-
cui ts. The l amp i s l ocated on the i nstrument panel .
Refer to Group 8E, I nstrument Panel and Gauges for
addi ti onal i nformati on.
GENERATOR
DESCRIPTION
The generator i s bel t-dri ven by the engi ne usi ng a
serpenti ne type dri ve bel t. I t i s servi ced onl y as a
compl ete assembl y. I f the generator fai l s for any rea-
son, the enti re assembl y must be repl aced.
OPERATION
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
TJ CHARGING SYSTEM 8C - 1
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
The Y type stator wi ndi ng connecti ons del i ver the
i nduced AC current to 3 posi ti ve and 3 negati ve
di odes for recti fi cati on. From the di odes, recti fi ed DC
current i s del i vered to the vehi cl e el ectri cal system
through the generator battery termi nal .
Al though the generators appear the same exter-
nal l y, di fferent generators wi th di fferent output rat-
i ngs are used on thi s vehi cl e. Be certai n that the
repl acement generator has the same output rati ng
and part number as the ori gi nal uni t. Refer to Gen-
erator Rati ngs i n the Speci fi cati ons secti on at the
back of thi s group for amperage rati ngs and part
numbers.
Noi se emi tti ng from the generator may be caused
by: worn, l oose or defecti ve beari ngs; a l oose or defec-
ti ve dri ve pul l ey; i ncorrect, worn, damaged or mi sad-
justed fan dri ve bel t; l oose mounti ng bol ts; a
mi sal i gned dri ve pul l ey or a defecti ve stator or di ode.
BATTERY TEMPERATURE SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) i s attached
to the battery tray l ocated under the battery.
OPERATION
The BTS i s used to determi ne the battery temper-
ature and control battery chargi ng rate. Thi s temper-
ature data, al ong wi th data from moni tored l i ne
vol tage, i s used by the PCM to vary the battery
chargi ng rate. System vol tage wi l l be hi gher at col der
temperatures and i s gradual l y reduced at warmer
temperatures.
The PCM sends 5 vol ts to the sensor and i s
grounded through the sensor return l i ne. As temper-
ature i ncreases, resi stance i n the sensor decreases
and the detecti on vol tage at the PCM i ncreases.
The BTS i s al so used for OBD I I di agnosti cs. Cer-
tai n faul ts and OBD I I moni tors are ei ther enabl ed
or di sabl ed, dependi ng upon BTS i nput (for exampl e,
di sabl e purge and enabl e Leak Detecti on Pump
(LDP) and O2 sensor heater tests). Most OBD I I
moni tors are di sabl ed bel ow 20°F.
ELECTRONIC VOLTAGE REGULATOR
DESCRIPTION
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the Powertrai n Control
Modul e (PCM). The EVR i s not servi ced separatel y. I f
repl acement i s necessary, the PCM must be repl aced.
OPERATION
The amount of DC current produced by the gener-
ator i s control l ed by EVR ci rcui try contai ned wi thi n
the PCM. Thi s ci rcui try i s connected i n seri es wi th
the generators second rotor fi el d termi nal and i ts
ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage (B+) and
battery temperature (refer to Battery Temperature
Sensor for more i nformati on). I t then determi nes a
target chargi ng vol tage. I f sensed battery vol tage i s
0.5 vol ts or l ower than the target vol tage, the PCM
grounds the fi el d wi ndi ng unti l sensed battery vol t-
age i s 0.5 vol ts above target vol tage. A ci rcui t i n the
PCM cycl es the ground si de of the generator fi el d up
to 100 ti mes per second (100Hz), but has the capabi l -
i ty to ground the fi el d control wi re 100% of the ti me
(ful l fi el d) to achi eve the target vol tage. I f the charg-
i ng rate cannot be moni tored (l i mp-i n), a duty cycl e
of 25% i s used by the PCM i n order to have some
generator output. Al so refer to Chargi ng System
Operati on for addi ti onal i nformati on.
DIAGNOSIS AND TESTING
CHARGING SYSTEM
The fol l owi ng procedures may be used to di agnose
the chargi ng system i f:
• the generator l amp (i f equi pped) i s i l l umi nated
wi th the engi ne runni ng
• the vol tmeter (i f equi pped) does not regi ster
properl y
• an undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
• accessori es bei ng l eft on wi th the engi ne not
runni ng
• a faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. See I gni ti on-Off Draw Test
i n Group 8A, Battery for more i nformati on.
INSPECTION
To perform a compl ete test of the chargi ng system,
refer to the appropri ate Powertrai n Di agnosti c Proce-
dures servi ce manual and the DRB scan tool . Per-
form the fol l owi ng i nspecti ons before attachi ng the
scan tool .
(1) I nspect the battery condi ti on. Refer to Group
8A, Battery for procedures.
(2) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
8C - 2 CHARGING SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
(3) I nspect al l fuses i n both the fusebl ock and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n Group 7, Cool i ng Sys-
tem.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to Group 7, Cool i ng System for i nformati on.
(7) I nspect generator el ectri cal connecti ons at gen-
erator fi el d, battery output, and ground termi nal (i f
equi pped). Al so check generator ground wi re connec-
ti on at engi ne (i f equi pped). They shoul d al l be cl ean
and ti ght. Repai r as requi red.
ON-BOARD DIAGNOSTIC TEST FOR CHARGING
SYSTEM
The Powertrai n Control Modul e (PCM) moni tors
cri ti cal i nput and output ci rcui ts of the chargi ng sys-
tem, maki ng sure they are operati onal . A Di agnosti c
Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some ci rcui ts are checked conti nu-
ousl y and some are checked onl y under certai n con-
di ti ons.
For DTC i nformati on, refer to Di agnosti c Troubl e
Codes i n Group 25, Emi ssi on Control System. Thi s
wi l l i ncl ude a compl ete l i st of DTC’s i ncl udi ng DTC’s
for the chargi ng system.
REMOVAL AND INSTALLATION
GENERATOR
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Remove generator dri ve bel t. Refer to Group 7,
Cool i ng System for procedure.
(3) Remove generator pi vot and mounti ng bol ts/nut
(Fi g. 1) or (Fi g. 2). Posi ti on generator for access to
wi re connectors.
(4) I f equi pped, unsnap pl asti c cover from B+ ter-
mi nal .
(5) Remove B+ cabl e output termi nal mounti ng
nut at rear of generator (Fi g. 3) or (Fi g. 4). Di scon-
nect termi nal from generator.
(6) Di sconnect fi el d wi re connector at rear of gen-
erator by pushi ng on connector tab.
(7) Remove generator from vehi cl e.
Fig. 1 Generator Remove/Install—2.5L Engine
1 – UPPER MOUNTING BRACKET
2 – GENERATOR
3 – UPPER BOLT
4 – LOWER BOLT
Fig. 2 Generator Remove/Install—4.0L Engine
1 – GENERATOR
2 – UPPER BOLT
3 – LOWER BOLT
TJ CHARGING SYSTEM 8C - 3
DIAGNOSIS AND TESTING (Continued)
INSTALLATION
(1) Posi ti on generator to engi ne and snap fi el d
wi re connector i nto rear of generator.
(2) I nstal l B+ termi nal to generator mounti ng
stud. Ti ghten mounti ng nut to 8.5 N·m (75 i n. l bs.)
torque.
(3) I f equi pped, snap pl asti c cover to B+ termi nal .
(4) I nstal l generator mounti ng fasteners and
ti ghten as fol l ows:
• Generator mounti ng bol t—55 N·m (41 ft. l bs.)
torque.
• Generator pi vot bol t/nut—55 N·m (41 ft. l bs.)
torque.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.
(5) I nstal l generator dri ve bel t. Refer to Group 7,
Cool i ng System for procedure.
(6) I nstal l negati ve battery cabl e to battery.
BATTERY TEMPERATURE SENSOR
The battery temperature sensor i s l ocated under
the vehi cl e battery and i s attached to a mounti ng
hol e on battery tray.
Fig. 3 Generator Connectors—2.5L Engine—Typical
Denso
1 – FIELD WIRES
2 – B+ (OUTPUT TERMINAL)
3 – FIELD WIRE CONNECTOR
Fig. 4 Generator Connectors—4.0L Engine
1 – FIELD WIRE CONNECTOR
2 – B+ CABLE
3 – GENERATOR
4 – B+ CABLE MOUNTING NUT
5 – CABLE PROTECTOR
Fig. 5 Battery Temperature Sensor Remove/Install
1 – BATTERY TEMPERATURE SENSOR
2 – BATTERY TRAY
8C - 4 CHARGING SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Remove battery. Refer to Group 8A, Battery for
procedures.
(2) Di sconnect sensor pi gtai l harness from engi ne
wi re harness.
(3) Pry sensor strai ght up from battery tray
mounti ng hol e.
INSTALLATION
(1) Feed pi gtai l harness through hol e i n top of bat-
tery tray and press sensor i nto top of battery tray.
(2) Connect pi gtai l harness.
(3) I nstal l battery. Refer to Group 8A, Battery for
procedures.
SPECIFICATIONS
GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56041685AA 117 4.0L 88
DENSO 56041565AA 81 4.0L 57
DENSO 56005684AB 81 2.5L 57
DENSO 56005685AC 117 2.5L 88
DENSO 56041822AA 124 2.5L/4.0L 90
TORQUE CHART
Description Torque
Generator Upper Mounti ng Bol t/Nut—
2.5L/4.0L Engi ne . . . . . . . . . . 55 N·m (41 ft. l bs.)
Generator Lower Mounti ng Bol t—
2.5L/4.0L Engi ne . . . . . . . . . . 55 N·m (41 ft. l bs.)
Battery Termi nal Nut . . . . . . . 8.5 N·m (75 i n. l bs.)
Ground Termi nal Nut . . . . . . . 8.5 N·m (75 i n. l bs.)
Harness Hol d-down Nut . . . . . 8.5 N·m (75 i n. l bs.)
Fi el d Termi nal Nuts . . . . . . . . 2.8 N·m (25 i n. l bs.)
TJ CHARGING SYSTEM 8C - 5
REMOVAL AND INSTALLATION (Continued)
IGNITION SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 1
DISTRIBUTOR-2.5L ENGINE. . . . . . . . . . . . . . . . . 2
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPARK PLUG CABLES-2.5L ENGINE . . . . . . . . . . 2
IGNITION COIL-2.5L ENGINE. . . . . . . . . . . . . . . . 3
IGNITION COIL—4.0L ENGINE. . . . . . . . . . . . . . . 3
CRANKSHAFT POSITION SENSOR. . . . . . . . . . . . 4
CAMSHAFT POSITION SENSOR-2.5L ENGINE. . . 4
CAMSHAFT POSITION SENSOR—
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IGNITION SWITCH AND KEY LOCK
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
DISTRIBUTOR CAP-2.5L ENGINE. . . . . . . . . . . . . 6
DISTRIBUTOR ROTOR-2.5L ENGINE. . . . . . . . . . 6
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . . 7
SPARK PLUG CONDITIONS . . . . . . . . . . . . . . . . . 8
IGNITION SWITCH
AND KEY LOCK CYLINDER. . . . . . . . . . . . . . . 10
REMOVAL AND INSTALLATION
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . 10
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IGNITION COIL—2.5L ENGINE. . . . . . . . . . . . . . 12
IGNITION COIL—4.0L ENGINE. . . . . . . . . . . . . . 12
CRANKSHAFT POSITION (CKP) SENSOR . . . . . 13
CAMSHAFT POSITION SENSOR—
2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CAMSHAFT POSITION SENSOR—
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DISTRIBUTOR—2.5L ENGINE . . . . . . . . . . . . . . 17
IGNITION SWITCH AND KEY CYLINDER. . . . . . 20
SHIFTER/IGNITION INTERLOCK. . . . . . . . . . . . . 22
SPECIFICATIONS
IGNITION TIMING. . . . . . . . . . . . . . . . . . . . . . . . 22
ENGINE FIRING ORDER—
2.5L 4-CYLINDER ENGINE . . . . . . . . . . . . . . . 22
ENGINE FIRING ORDER—
4.0L 6-CYLINDER ENGINE . . . . . . . . . . . . . . . 22
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPARK PLUG CABLE RESISTANCE . . . . . . . . . . 23
IGNITION COIL RESISTANCE—2.5L ENGINE . . 23
IGNITION COIL RESISTANCE—4.0L ENGINE . . 23
TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION AND OPERATION
IGNITION SYSTEM
DESCRIPTION
Two di fferent i gni ti on systems are used. One type
i s used for the 2.5L 4–cyl i nder engi ne. The other i s
used for the 4.0L 6–cyl i nder engi ne.
OPERATION
2.5L 4–Cylinder Engine:
The i gni ti on system i s control l ed by the Powertrai n
Control Modul e (PCM).
The i gni ti on system consi sts of:
• Spark Pl ugs
• I gni ti on Coi l
• Secondary I gni ti on Cabl es
• Di stri butor (contai ns rotor and camshaft posi ti on
sensor)
• Powertrai n Control Modul e (PCM)
• Crankshaft Posi ti on, Camshaft Posi ti on, Throt-
tl e Posi ti on and MAP Sensors
4.0L 6–Cylinder Engine:
The 4.0L 6–cyl i nder engi ne uses a one-pi ece coi l
rai l contai ni ng three i ndependent coi l s. Al though cyl -
i nder fi ri ng order i s the same as 4.0L engi nes of pre-
vi ous years, spark pl ug fi ri ng i s not. The 3 coi l s dual -
fi re the spark pl ugs on cyl i nders 1–6, 2–5 and/or 3–4.
When one cyl i nder i s bei ng fi red (on compressi on
stroke), the spark to the opposi te cyl i nder i s bei ng
wasted (on exhaust stroke). The one-pi ece coi l bol ts
di rectl y to the cyl i nder head. Rubber boots seal the
secondary termi nal ends of the coi l s to the top of al l
6 spark pl ugs. One el ectri cal connector (l ocated at
the rear end of the coi l rai l ) i s used for al l three coi l s.
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used on ei ther engi ne. A distrib-
utor is not used wi th the 4.0L engi ne.
The i gni ti on system i s control l ed by the Powertrai n
Control Modul e (PCM).
The i gni ti on system consi sts of:
• Spark Pl ugs
• I gni ti on Coi l (s)
• Powertrai n Control Modul e (PCM)
TJ IGNITION SYSTEM 8D - 1
• Crankshaft Posi ti on Sensor
• Camshaft Posi ti on Sensor
• The MAP, TPS, I AC and ECT al so have an effect
on the control of the i gni ti on system.
DISTRIBUTOR-2. 5L ENGINE
DESCRIPTION
The 2.5L engi ne i s equi pped wi th a camshaft
dri ven mechani cal di stri butor (Fi g. 1) contai ni ng a
shaft dri ven di stri butor rotor. The di stri butor i s al so
equi pped wi th an i nternal camshaft posi ti on (fuel
sync) sensor (Fi g. 1).
OPERATION
The di stri butor does not have bui l t i n centri fugal
or vacuum assi sted advance. Base i gni ti on ti mi ng
and al l ti mi ng advance i s control l ed by the Power-
trai n Control Modul e (PCM). Because i gni ti on ti mi ng
i s control l ed by the PCM, base ignition timing is
not adjustable.
The di stri butor i s l ocked i n pl ace by a fork wi th a
sl ot l ocated on the di stri butor housi ng base. The di s-
tri butor hol ddown cl amp bol t passes through thi s sl ot
when i nstal l ed. Because the di stri butor posi ti on i s
l ocked when i nstal l ed, i ts rotati onal posi ti on can not
be changed. Do not attempt to modify the dis-
tributor housing to get distributor rotation.
Distributor position will have no effect on igni-
tion timing. The position of the distributor will
determine fuel synchronization only.
Al l di stri butors contai n an i nternal oi l seal that
prevents oi l from enteri ng the di stri butor housi ng.
The seal i s not servi ceabl e.
SPARK PLUGS
DESCRIPTION
Resi stor type spark pl ugs are used.
Spark pl ug resi stance val ues range from 6,000 to
20,000 ohms (when checked wi th at l east a 1000 vol t
spark pl ug tester). Do not use an ohmmeter to
check the resistance values of the spark plugs.
Inaccurate readings will result.
OPERATION
To prevent possi bl e pre-i gni ti on and/or mechani cal
engi ne damage, the correct type/heat range/number
spark pl ug must be used.
Al ways use the recommended torque when ti ghten-
i ng spark pl ugs. I ncorrect torque can di stort the
spark pl ug and change pl ug gap. I t can al so pul l the
pl ug threads and do possi bl e damage to both the
spark pl ug and the cyl i nder head.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken por-
cel ai n i nsul ators. Keep pl ugs arranged i n the order
i n whi ch they were removed from the engi ne. A si n-
gl e pl ug di spl ayi ng an abnormal condi ti on i ndi cates
that a probl em exi sts i n the correspondi ng cyl i nder.
Repl ace spark pl ugs at the i nterval s recommended i n
Group O, Lubri cati on and Mai ntenance
Spark pl ugs that have l ow mi l eage may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Al so refer to Spark Pl ug Condi ti ons.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
SPARK PLUG CABLES-2. 5L ENGINE
DESCRIPTION
Spark pl ug cabl es are used onl y on the 2.5L
engi ne. They are someti mes referred to as secondary
i gni ti on wi res.
OPERATION
The spark pl ug cabl es transfer el ectri cal current
from the i gni ti on coi l (s) and/or di stri butor, to i ndi vi d-
ual spark pl ugs at each cyl i nder. The resi sti ve spark
pl ug cabl es are of nonmetal l i c constructi on. The
cabl es provi de suppressi on of radi o frequency emi s-
si ons from the i gni ti on system.
Fig. 1 Distributor and Camshaft Position Sensor-
2.5L Engine
1 – SYNC SIGNAL GENERATOR
2 – CAMSHAFT POSITION SENSOR
3 – PULSE RING
4 – DISTRIBUTOR ASSEMBLY
8D - 2 IGNITION SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
IGNITION COIL-2. 5L ENGINE
DESCRIPTION
A si ngl e i gni ti on coi l i s used wi th the 2.5L 4–cyl i n-
der engi ne. The coi l i s not oi l fi l l ed. The coi l wi ndi ngs
are embedded i n an epoxy compound. Thi s provi des
heat and vi brati on resi stance that al l ows the coi l to
be mounted on the engi ne.
OPERATION
The Powertrai n Control Modul e (PCM) opens and
cl oses the i gni ti on coi l ground ci rcui t for i gni ti on coi l
operati on.
Battery vol tage i s suppl i ed to the i gni ti on coi l posi ti ve
termi nal from the ASD rel ay. I f the PCM does not see a
si gnal from the crankshaft and camshaft sensors (i ndi -
cati ng the i gni ti on key i s ON but the engi ne i s not run-
ni ng), i t wi l l shut down the ASD ci rcui t.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
IGNITION COIL— 4. 0L ENGINE
DESCRIPTION
A one-pi ece coi l rai l assembl y contai ni ng three
i ndi vi dual coi l s i s used on the 4.0L 6–cyl i nder engi ne
(Fi g. 2). The coi l rai l must be repl aced as one assem-
bl y. The bottom of the coi l i s equi pped wi th 6 i ndi vi d-
ual rubber boots (Fi g. 2) to seal the 6 spark pl ugs to
the coi l . I nsi de each rubber boot i s a spri ng. The
spri ng i s used for a mechani cal contact between the
coi l and the top of the spark pl ug. These rubber boots
and spri ngs are a permanent part of the coi l and are
not servi ced separatel y.
(1) The coi l i s bol ted di rectl y to the cyl i nder head
(Fi g. 3). One el ectri cal connector (l ocated at rear of
coi l ) i s used for al l three coi l s.
OPERATION
Al though cyl i nder fi ri ng order i s the same as 4.0L
Jeep engi nes of previ ous years, spark pl ug fi ri ng i s
not. The 3 coi l s dual -fi re the spark pl ugs on cyl i nders
1–6, 2–5 and/or 3–4. When one cyl i nder i s bei ng fi red
(on compressi on stroke), the spark to the opposi te
cyl i nder i s bei ng wasted (on exhaust stroke).
Battery vol tage i s suppl i ed to the three i gni ti on
coi l s from the ASD rel ay. The Powertrai n Control
Modul e (PCM) opens and cl oses the i gni ti on coi l
ground ci rcui t for i gni ti on coi l operati on.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
Fig. 2 Ignition Coil Assembly—4.0L 6–Cylinder
Engine
1 – CYL. #6
2 – CYL. #5
3 – CYL. #4
4 – CYL. #3
5 – CYL. #2
6 – CYL. #1
7 – COILS (3)
8 – MOUNTING BOLTS (4)
9 – BOLT BASES (4)
10 – RUBBER BOOTS (6)
Fig. 3 Coil Location—4.0L Engine
1 – COIL RAIL
2 – COIL MOUNTING BOLTS (4)
3 – COIL
4 – COIL ELECTRICAL CONNECTION
TJ IGNITION SYSTEM 8D - 3
DESCRIPTION AND OPERATION (Continued)
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used. The cabl es are i ntegral
wi thi n the coi l rai l .
CRANKSHAFT POSITION SENSOR
DESCRIPTION
The Crankshaft Posi ti on (CKP) sensor i s l ocated
near the outer edge of the fl ywheel (starter ri ngear).
OPERATION
Engi ne speed and crankshaft posi ti on are provi ded
through the CKP sensor. The sensor generates pul ses
that are the i nput sent to the Powertrai n Control
Modul e (PCM). The PCM i nterprets the sensor i nput
to determi ne the crankshaft posi ti on. The PCM then
uses thi s posi ti on, al ong wi th other i nputs, to deter-
mi ne i njector sequence and i gni ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
The fl ywheel /dri ve pl ate has groups of four notches
at i ts outer edge. On 2.5L 4-cyl i nder engi nes there
are two sets of notches (Fi g. 4). On 4.0L 6-cyl i nder
engi nes there are three sets of notches (Fi g. 5).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on there are two
groups of four pul ses generated on 2.5L 4-cyl i nder
engi nes. There are 3 groups of four pul ses generated
on 4.0L 6-cyl i nder engi nes.
The trai l i ng edge of the fourth notch, whi ch causes
the pul se, i s four degrees before top dead center
(TDC) of the correspondi ng pi ston.
The engi ne wi l l not operate i f the PCM does not
recei ve a CKP sensor i nput.
CAMSHAFT POSITION SENSOR-2. 5L ENGINE
DESCRIPTION
On the 2.5L 4–cyl i nder engi ne the Camshaft Posi -
ti on (CMP) sensor i s l ocated i n the di stri butor.
OPERATION
The sensor contai ns a hal l effect devi ce cal l ed a sync
si gnal generator to generate a fuel sync si gnal . Thi s
sync si gnal generator detects a rotati ng pul se ri ng
(shutter) on the di stri butor shaft. The pul se ri ng rotates
180 degrees through the sync si gnal generator. I ts si g-
nal i s used i n conjuncti on wi th the Crankshaft Posi ti on
(CKP) sensor to di fferenti ate between fuel i njecti on and
spark events. I t i s al so used to synchroni ze the fuel
i njectors wi th thei r respecti ve cyl i nders.
Fig. 4 Sensor Operation—2.5L 4-Cyl. Engine
1 – CRANKSHAFT POSITION SENSOR
2 – NOTCHES
3 – FLYWHEEL
Fig. 5 Sensor Operation—4.0L 6-Cyl. Engine
1 – CRANKSHAFT POSITION SENSOR
2 – FLYWHEEL
3 – FLYWHEEL NOTCHES
8D - 4 IGNITION SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
When the l eadi ng edge of the pul se ri ng (shutter)
enters the sync si gnal generator, the fol l owi ng occurs:
The i nterrupti on of magneti c fi el d causes the vol tage
to swi tch hi gh resul ti ng i n a sync si gnal of approxi -
matel y 5 vol ts.
When the trai l i ng edge of the pul se ri ng (shutter)
l eaves the sync si gnal generator, the fol l owi ng occurs:
The change of the magneti c fi el d causes the sync si g-
nal vol tage to swi tch l ow to 0 vol ts.
CAMSHAFT POSITION SENSOR— 4. 0L ENGINE
DESCRIPTION
The Camshaft Posi ti on Sensor (CMP) on the 4.0L
6–cyl i nder engi ne i s bol ted to the top of the oi l pump
dri ve shaft assembl y (Fi g. 6). The sensor and dri ve
shaft assembl y i s l ocated on the ri ght si de of the
engi ne near the oi l fi l ter (Fi g. 7).
OPERATION
The CMP sensor contai ns a hal l effect devi ce cal l ed
a sync si gnal generator to generate a fuel sync si g-
nal . Thi s sync si gnal generator detects a rotati ng
pul se ri ng (shutter) on the oi l pump dri ve shaft (Fi g.
6). The pul se ri ng rotates 180 degrees through the
sync si gnal generator. I ts si gnal i s used i n conjunc-
ti on wi th the crankshaft posi ti on sensor to di fferenti -
ate between fuel i njecti on and spark events. I t i s al so
used to synchroni ze the fuel i njectors wi th thei r
respecti ve cyl i nders.
When the l eadi ng edge of the pul se ri ng (shutter)
enters the sync si gnal generator, the fol l owi ng occurs:
The i nterrupti on of magneti c fi el d causes the vol tage
to swi tch hi gh resul ti ng i n a sync si gnal of approxi -
matel y 5 vol ts.
When the trai l i ng edge of the pul se ri ng (shutter)
l eaves the sync si gnal generator, the fol l owi ng occurs:
The change of the magneti c fi el d causes the sync si g-
nal vol tage to swi tch l ow to 0 vol ts.
Fig. 6 CMP and Oil Pump Drive Shaft—4.0L Engine
1 – CAMSHAFT POSITION SENSOR
2 – MOUNTING BOLTS (2)
3 – PULSE RING
4 – DRIVE GEAR (TO CAMSHAFT)
5 – OIL PUMP DRIVESHAFT
6 – SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
Fig. 7 CMP Location—4.0L Engine
1 – OIL FILTER
2 – CAMSHAFT POSITION SENSOR
3 – CLAMP BOLT
4 – HOLD-DOWN CLAMP
5 – MOUNTING BOLTS (2)
6 – ELEC. CONNECTOR
TJ IGNITION SYSTEM 8D - 5
DESCRIPTION AND OPERATION (Continued)
IGNITION SWITCH AND KEY LOCK CYLINDER
DESCRIPTION
The el ectri cal i gni ti on swi tch i s l ocated on the
steeri ng col umn. I t i s used as the mai n on/off swi tch-
i ng devi ce for most el ectri cal components. The
mechani cal key l ock cyl i nder i s used to engage/di sen-
gage the el ectri cal i gni ti on swi tch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a floor mounted shifter: a cabl e i s
used to connect the i nterl ock devi ce i n the steeri ng
col umn assembl y, to the transmi ssi on fl oor shi ft
l ever. Thi s i nterl ock devi ce i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s rotated to the LOCKED or ACCES-
SORY posi ti on. The i nterl ock devi ce wi thi n the steer-
i ng col umn i s not servi ceabl e. I f repai r i s necessary,
the steeri ng col umn assembl y must be repl aced.
Refer to Group 19, Steeri ng for procedures.
I f the i gni ti on key i s di ffi cul t to rotate to or from
the LOCK or ACCESSORY posi ti on, i t may not be
the faul t of the key cyl i nder or the steeri ng col umn
components. The brake transmi ssi on shi ft i nterl ock
cabl e may be out of adjustment. Refer to Brake
Transmi ssi on Shi ft I nterl ock Cabl e Adjustment i n
Group 21, Transmi ssi ons for adjustment procedures.
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an i nterl ock devi ce i s l ocated wi thi n the steeri ng col -
umn. Thi s i nterl ock devi ce i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s i n the LOCKED or ACCESSORY
posi ti on. I f i t i s di ffi cul t to rotate the key to or from
the LOCK or ACCESSORY posi ti on, the i nterl ock
devi ce wi thi n the steeri ng col umn may be defecti ve.
Thi s devi ce i s not servi ceabl e. I f repai r i s necessary,
the steeri ng col umn assembl y must be repl aced.
Refer to Group 19, Steeri ng for procedures.
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter: on certai n mod-
el s, a l ever i s l ocated on the steeri ng col umn behi nd
the i gni ti on key l ock cyl i nder. The l ever must be
manual l y operated to al l ow rotati on of the i gni ti on
key l ock cyl i nder to the LOCK or ACCESSORY posi -
ti on. I f i t i s di ffi cul t to rotate the key to the LOCK or
ACCESSORY posi ti on, the l ever mechani sm may be
defecti ve. Thi s mechani sm i s not servi ceabl e. I f
repai r i s necessary, the steeri ng col umn assembl y
must be repl aced. Refer to Group 19, Steeri ng for
procedures.
On other model s, the i gni ti on key cyl i nder must be
depressed to al l ow i t to be rotated i nto the LOCK or
ACCESSORY posi ti on. I f i t i s di ffi cul t to rotate the
key to the LOCK or ACCESSORY posi ti on, the l ock
mechani sm wi thi n the steeri ng col umn may be defec-
ti ve. Thi s mechani sm i s not servi ceabl e. I f repai r i s
necessary, the steeri ng col umn assembl y must be
repl aced. Refer to Group 19, Steeri ng for procedures.
DIAGNOSIS AND TESTING
DISTRIBUTOR CAP-2. 5L ENGINE
Remove the di stri butor cap and wi pe i t cl ean wi th
a dry l i nt free cl oth. Vi sual l y i nspect the cap for
cracks, carbon paths, broken towers or damaged
rotor button (Fi g. 8) or (Fi g. 9). Al so check for whi te
deposi ts on the i nsi de (caused by condensati on enter-
i ng the cap through cracks). Repl ace any cap that
di spl ays charred or eroded termi nal s. The machi ned
surface of a termi nal end (faces toward rotor) wi l l
i ndi cate some evi dence of erosi on from normal oper-
ati on. Exami ne the termi nal ends for evi dence of
mechani cal i nterference wi th the rotor ti p.
DISTRIBUTOR ROTOR-2. 5L ENGINE
Vi sual l y i nspect the rotor (Fi g. 10) for cracks, evi -
dence of corrosi on or the effects of arci ng on the
metal ti p. Al so check for evi dence of mechani cal
i nterference wi th the cap. Some charri ng i s normal
on the end of the metal ti p. The si l i cone-di el ectri c-
varni sh-compound appl i ed to the rotor ti p for radi o
i nterference noi se suppressi on, wi l l appear charred.
Thi s i s normal . Do not remove the charred com-
pound. Test the spri ng for i nsuffi ci ent tensi on.
Repl ace a rotor that di spl ays any of these adverse
condi ti ons.
Fig. 8 Cap Inspection—External—Typical
1 – BROKEN TOWER
2 – DISTRIBUTOR CAP
3 – CARBON PATH
4 – CRACK
8D - 6 IGNITION SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
SPARK PLUG CABLES
TESTING
Check the spark pl ug cabl e connecti ons for good
contact at the coi l (s), di stri butor cap towers, and
spark pl ugs. Termi nal s shoul d be ful l y seated. The
i nsul ators shoul d be i n good condi ti on and shoul d fi t
ti ghtl y on the coi l , di stri butor and spark pl ugs. Spark
pl ug cabl es wi th i nsul ators that are cracked or torn
must be repl aced.
Cl ean hi gh vol tage i gni ti on cabl es wi th a cl oth
moi stened wi th a non-fl ammabl e sol vent. Wi pe the
cabl es dry. Check for bri ttl e or cracked i nsul ati on.
When testi ng secondary cabl es for damage wi th an
osci l l oscope, fol l ow the i nstructi ons of the equi pment
manufacturer.
I f an osci l l oscope i s not avai l abl e, spark pl ug cabl es
may be tested as fol l ows:
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Wi th the engi ne runni ng, remove spark pl ug cabl e
from spark pl ug (one at a ti me) and hol d next to a
good engi ne ground. I f the cabl e and spark pl ug are
i n good condi ti on, the engi ne rpm shoul d drop and
the engi ne wi l l run poorl y. I f engi ne rpm does not
drop, the cabl e and/or spark pl ug may not be operat-
i ng properl y and shoul d be repl aced. Al so check
engi ne cyl i nder compressi on.
Wi th the engi ne not runni ng, connect one end of a
test probe to a good ground. Start the engi ne and run
the other end of the test probe al ong the enti re
l ength of al l spark pl ug cabl es. I f cabl es are cracked
or punctured, there wi l l be a noti ceabl e spark jump
from the damaged area to the test probe. The cabl e
runni ng from the i gni ti on coi l to the di stri butor cap
can be checked i n the same manner. Cracked, dam-
aged or faul ty cabl es shoul d be repl aced wi th resi s-
tance type cabl e. Thi s can be i denti fi ed by the words
ELECTRONI C SUPPRESSI ON pri nted on the cabl e
jacket.
Use an ohmmeter to test for open ci rcui ts, exces-
si ve resi stance or l oose termi nal s. Remove the di s-
tri butor cap from the di stri butor. Do not remove
cables from cap. Remove cabl e from spark pl ug.
Connect ohmmeter to spark pl ug termi nal end of
cabl e and to correspondi ng el ectrode i n di stri butor
cap. Resi stance shoul d be 250 to 1000 Ohms per i nch
of cabl e. I f not, remove cabl e from di stri butor cap
tower and connect ohmmeter to the termi nal ends of
cabl e. I f resi stance i s not wi thi n speci fi cati ons as
found i n the SPARK PLUG CABLE RESI STANCE
chart, repl ace the cabl e. Test al l spark pl ug cabl es i n
thi s manner.
Fig. 9 Cap Inspection—Internal—Typical
1 – CHARRED OR ERODED TERMINALS
2 – WORN OR DAMAGED ROTOR BUTTON
3 – CARBON PATH
Fig. 10 Rotor Inspection—Typical
1 – INSUFFICIENT SPRING TENSION
2 – CRACKS
3 – EVIDENCE OF PHYSICAL CONTACT WITH CAP
4 – ROTOR TIP CORRODED
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
TJ IGNITION SYSTEM 8D - 7
DIAGNOSIS AND TESTING (Continued)
To test i gni ti on coi l -to-di stri butor cap cabl e, do not
remove the cabl e from the cap. Connect ohmmeter to
rotor button (center contact) of di stri butor cap and
termi nal at i gni ti on coi l end of cabl e. I f resi stance i s
not wi thi n speci fi cati ons as found i n the Spark Pl ug
Cabl e Resi stance chart, remove the cabl e from the
di stri butor cap. Connect the ohmmeter to the termi -
nal ends of the cabl e. I f resi stance i s not wi thi n spec-
i fi cati ons as found i n the Spark Pl ug Cabl e
Resi stance chart, repl ace the cabl e. I nspect the i gni -
ti on coi l tower for cracks, burns or corrosi on.
SPARK PLUG CONDITIONS
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
(Fi g. 11). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than
approxi matel y 0.025 mm (.001 i n) per 3200 km (2000
mi l es) of operati on. Spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes
fi l ed, have the gap set and then be i nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance may be
affected by MMT deposi ts.
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 11). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 12), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 13).
Fig. 11 Normal Operation and Cold (Carbon) Fouling
1 – NORMAL
2 – DRY BLACK DEPOSITS
3 – COLD (CARBON) FOULING
Fig. 12 Oil or Ash Encrusted
8D - 8 IGNITION SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 14). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 15). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PREIGNITION DAMAGE
Prei gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 16). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
17). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 2000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
Fig. 13 Electrode Gap Bridging
1 – GROUND ELECTRODE
2 – DEPOSITS
3 – CENTER ELECTRODE
Fig. 14 Scavenger Deposits
1 – GROUND ELECTRODE COVERED WITH WHITE OR
YELLOW DEPOSITS
2 – CENTER ELECTRODE
Fig. 15 Chipped Electrode Insulator
1 – GROUND ELECTRODE
2 – CENTER ELECTRODE
3 – CHIPPED INSULATOR
TJ IGNITION SYSTEM 8D - 9
DIAGNOSIS AND TESTING (Continued)
IGNITION SWITCH AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For i gni ti on swi tch el ectri cal schemati cs, refer to
I gni ti on Swi tch i n Group 8W, Wi ri ng Di agrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
Vehicles equipped with an automatic trans-
mission and a floor mounted shifter: a cabl e i s
used to connect the i nterl ock devi ce i n the steeri ng
col umn assembl y, to the transmi ssi on fl oor shi ft
l ever. Thi s i nterl ock devi ce i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s rotated to the LOCKED or ACCES-
SORY posi ti on. The i nterl ock devi ce wi thi n the steer-
i ng col umn i s not servi ceabl e. I f repai r i s necessary,
the steeri ng col umn assembl y must be repl aced.
Refer to Group 19, Steeri ng for procedures.
I f the i gni ti on key i s di ffi cul t to rotate to or from
the LOCK or ACCESSORY posi ti on, i t may not be
the faul t of the key cyl i nder or the steeri ng col umn
components. The brake transmi ssi on shi ft i nterl ock
cabl e may be out of adjustment. Refer to Brake
Transmi ssi on Shi ft I nterl ock Cabl e Adjustment i n
Group 21, Transmi ssi ons for adjustment procedures.
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an i nterl ock devi ce i s l ocated wi thi n the steeri ng col -
umn. Thi s i nterl ock devi ce i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s i n the LOCKED or ACCESSORY
posi ti on. I f i t i s di ffi cul t to rotate the key to or from
the LOCK or ACCESSORY posi ti on, the i nterl ock
devi ce wi thi n the steeri ng col umn may be defecti ve.
Thi s devi ce i s not servi ceabl e. I f repai r i s necessary,
the steeri ng col umn assembl y must be repl aced.
Refer to Group 19, Steeri ng for procedures.
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter: on certai n mod-
el s, a l ever i s l ocated on the steeri ng col umn behi nd
the i gni ti on key l ock cyl i nder. The l ever must be
manual l y operated to al l ow rotati on of the i gni ti on
key l ock cyl i nder to the LOCK or ACCESSORY posi -
ti on. I f i t i s di ffi cul t to rotate the key to the LOCK or
ACCESSORY posi ti on, the l ever mechani sm may be
defecti ve. Thi s mechani sm i s not servi ceabl e. I f
repai r i s necessary, the steeri ng col umn assembl y
must be repl aced. Refer to Group 19, Steeri ng for
procedures.
On other model s, the i gni ti on key cyl i nder must be
depressed to al l ow i t to be rotated i nto the LOCK or
ACCESSORY posi ti on. I f i t i s di ffi cul t to rotate the
key to the LOCK or ACCESSORY posi ti on, the l ock
mechani sm wi thi n the steeri ng col umn may be defec-
ti ve. Thi s mechani sm i s not servi ceabl e. I f repai r i s
necessary, the steeri ng col umn assembl y must be
repl aced. Refer to Group 19, Steeri ng for procedures.
REMOVAL AND INSTALLATION
SPARK PLUG CABLES
REMOVAL
CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 18). Grasp the boot (not the cable) and
pull it off with a steady, even force.
Fig. 16 Preignition Damage
1 – GROUND ELECTRODE STARTING TO DISSOLVE
2 – CENTER ELECTRODE DISSOLVED
Fig. 17 Spark Plug Overheating
1 – BLISTERED WHITE OR GRAY COLORED INSULATOR
8D - 10 IGNITION SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
INSTALLATION
Push the cabl e fi rml y onto the sparkpl ug.
SPARK PLUGS
PLUG REMOVAL
On the 4.0L 6–cyl i nder engi ne the spark pl ugs are
l ocated bel ow the coi l rai l assembl y. To gai n access to
any/al l spark pl ug(s), refer to I gni ti on Coi l -4.0L
Engi ne Removal /I nstal l ati on.
(1) 2.5L 4–Cyl i nder Engi ne: Al ways remove spark
pl ug or i gni ti on coi l cabl es by graspi ng at the cabl e
boot (Fi g. 18). Turn the cabl e boot 1/2 turn and pul l
strai ght back i n a steady moti on. Never pul l di rectl y
on the cabl e. I nternal damage to cabl e wi l l resul t.
(2) Pri or to removi ng the spark pl ug, spray com-
pressed ai r around the spark pl ug hol e and the area
around the spark pl ug. Thi s wi l l hel p prevent forei gn
materi al from enteri ng the combusti on chamber.
(3) Remove the spark pl ug usi ng a qual i ty socket
wi th a rubber or foam i nsert.
(4) I nspect the spark pl ug condi ti on. Refer to
Spark Pl ugs Condi ti ons.
PLUG CLEANING
The pl ugs may be cl eaned usi ng commerci al l y
avai l abl e spark pl ug cl eani ng equi pment. After cl ean-
i ng, fi l e the center el ectrode fl at wi th a smal l poi nt
fi l e or jewel ers fi l e before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
PLUG GAP ADJUSTMENT
Check the spark pl ug gap wi th a gap gauge tool . I f
the gap i s not correct, adjust i t by bendi ng the
ground el ectrode (Fi g. 19). Never attempt to adjust
the gap by bending the center electrode.
SPARK PLUG GAP
• 2.5L 4-Cyl i nder Engi ne Spark Pl ug Gap:.89 mm
(.035 i n).
• 4.0L 6-Cyl i nder Engi ne Spark Pl ug Gap:.89 mm
(.035 i n).
PLUG INSTALLATION
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on. Thi s may resul t
i n a change i n the spark pl ug gap, or a cracked por-
cel ai n i nsul ator.
When repl aci ng the spark pl ug and i gni ti on coi l
cabl es, route the cabl es correctl y and secure them i n
the appropri ate retai ners. Fai l ure to route the cabl es
properl y can cause the radi o to reproduce i gni ti on
noi se. I t coul d cause cross i gni ti on of the spark pl ugs,
or short ci rcui t the cabl es to ground.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Ti ghten the spark pl ugs to 35-41 N·m (26-30 ft.
l bs.) torque.
(3) 2.5L 4–Cyl i nder Engi ne: I nstal l spark pl ug
cabl es over spark pl ugs.
(4) 4.0L 6–Cyl i nder Engi ne: I nstal l coi l rai l . Refer
to I gni ti on Coi l -4.0L Engi ne Removal /I nstal l ati on.
Fig. 18 Cable Removal
1 – SPARK PLUG CABLE AND BOOT
2 – SPARK PLUG BOOT PULLER
3 – TWIST AND PULL
4 – SPARK PLUG
Fig. 19 Setting Spark Plug Gap—Typical
1 – GAUGE
2 – SPARK PLUG
TJ IGNITION SYSTEM 8D - 11
REMOVAL AND INSTALLATION (Continued)
IGNITION COIL— 2. 5L ENGINE
REMOVAL
The i gni ti on coi l i s an epoxy fi l l ed type. I f the coi l
i s repl aced, i t must be repl aced wi th the same type.
On the 2.5L 4-cyl i nder engi ne, the i gni ti on coi l i s
mounted to a bracket on si de of engi ne (to rear of
di stri butor) (Fi g. 20).
(1) Di sconnect i gni ti on coi l secondary cabl e from
i gni ti on coi l .
(2) Di sconnect engi ne harness connector from i gni -
ti on coi l .
(3) Remove i gni ti on coi l mounti ng bol ts (nuts are
used on back si de of bracket on some coi l s).
(4) Remove coi l from vehi cl e.
INSTALLATION
(1) I nstal l i gni ti on coi l to bracket on cyl i nder bl ock
wi th mounti ng bol ts (and nuts i f equi pped). I f
equi pped wi th nuts and bol ts, ti ghten to 11 N·m (100
i n. l bs.) torque. I f equi pped wi th bol ts onl y, ti ghten to
5 N·m (50 i n. l bs.) torque.
(2) Connect engi ne harness connector to coi l .
(3) Connect i gni ti on coi l cabl e to i gni ti on coi l .
IGNITION COIL— 4. 0L ENGINE
REMOVAL
A one-pi ece coi l rai l assembl y contai ni ng three
i ndi vi dual coi l s i s used on the 4.0L engi ne (Fi g. 21).
The coi l rai l must be repl aced as one assembl y. The
bottom of the coi l i s equi pped wi th 6 i ndi vi dual rub-
ber boots (Fi g. 21) to seal the 6 spark pl ugs to the
coi l . I nsi de each rubber boot i s a spri ng. The spri ng
i s used for an el ectri cal contact between the coi l and
the top of the spark pl ug. These rubber boots and
spri ngs are a permanent part of the coi l and are not
servi ced separatel y.
(1) Di sconnect negati ve battery cabl e at battery.
(2) The coi l i s bol ted di rectl y to the cyl i nder head.
Remove 4 coi l mounti ng bol ts (Fi g. 22).
(3) Careful l y pry up coi l assembl y from spark
pl ugs. Do thi s by pryi ng al ternatel y at each end of
coi l unti l rubber boots have di sengaged from al l
spark pl ugs. I f boots wi l l not rel ease from spark
pl ugs, use a commerci al l y avai l abl e spark pl ug boot
removal tool . Twi st and l oosen a few boots from a few
spark pl ugs to hel p remove coi l .
(4) After coi l has cl eared spark pl ugs, posi ti on coi l
for access to pri mary el ectri cal connector. Di sconnect
connector from coi l by pushi ng sl i de tab outwards to
ri ght si de of vehi cl e (Fi g. 23). After sl i de tab has been
posi ti oned outwards, push i n on secondary rel ease
l ock (Fi g. 23) on si de of connector and pul l connector
from coi l .
(5) Remove coi l from vehi cl e.
Fig. 20 Ignition Coil—2.5L Engine
1 – IGNITION COIL
2 – ELECTRICAL CONNECTOR
3 – MOUNTING BOLTS (2)
4 – SECONDARY CABLE
Fig. 21 Ignition Coil Assembly—4.0L 6–Cylinder
Engine
1 – CYL. #6
2 – CYL. #5
3 – CYL. #4
4 – CYL. #3
5 – CYL. #2
6 – CYL. #1
7 – COILS (3)
8 – MOUNTING BOLTS (4)
9 – BOLT BASES (4)
10 – RUBBER BOOTS (6)
8D - 12 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on i gni ti on coi l rubber boots to al l spark
pl ugs. Push down on coi l assembl y unti l bol t bases
have contacted cyl i nder head
(2) I nstal l 4 coi l mounti ng bol ts. Loosel y ti ghten 4
bol ts just enough to al l ow bol t bases to contact cyl i n-
der head. Do a fi nal ti ghteni ng of each bol t i n steps
down to 29 N·m (250 i n. l bs.) torque. Do not appl y
ful l torque to any bol t fi rst.
(3) Connect engi ne harness connector to coi l by
snappi ng i nto posi ti on. Move sl i de tab towards
engi ne (Fi g. 23) for a posi ti ve l ock.
(4) Connect negati ve battery cabl e to battery.
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
The crankshaft posi ti on (CKP) sensor i s mounted
to the transmi ssi on bel l housi ng at the l eft/rear si de
of the engi ne bl ock.
The sensor may be mounted to the transmi ssi on
wi th one of the fol l owi ng three di fferent confi gura-
ti ons:
• wi th one bol t (Fi g. 24). I f sensor i s equi pped
wi th one mounti ng bol t, it is adjustable..
• wi th two nuts (Fi g. 25).
• wi th two bol ts (Fi g. 26).
Fig. 22 Ignition Coil Rail Location—4.0L 6–Cylinder
Engine
1 – COIL RAIL
2 – COIL MOUNTING BOLTS (4)
3 – COIL
4 – COIL ELECTRICAL CONNECTION
Fig. 23 Ignition Coil Electrical Connector—4.0L
6–Cylinder Engine
1 – REAR OF VALVE COVER
2 – COIL RAIL
3 – SLIDE TAB
4 – RELEASE LOCK
5 – COIL CONNECTOR
Fig. 24 Crankshaft Position Sensor—One-Bolt
Mounting
1 – SENSOR PIGTAIL
2 – CRANKSHAFT POSITION SENSOR
3 – MOUNTING BOLT
4 – TRANSMISSION HOUSING
5 – PAPER SPACER
6 – SLOTTED HOLE
TJ IGNITION SYSTEM 8D - 13
REMOVAL AND INSTALLATION (Continued)
(1) Near ri ght-rear si de of engi ne, di sconnect sen-
sor pi gtai l harness (el ectri cal connector) from mai n
el ectri cal harness.
(2) Dependi ng upon appl i cati on, remove ei ther sen-
sor mounti ng bol t(s) or nuts.
(3) Remove sensor from engi ne.
INSTALLATION
Sensor With 2–Bolt Mounting:
(1) I nstal l sensor fl ush agai nst openi ng i n trans-
mi ssi on housi ng.
(2) I nstal l and ti ghten two sensor mounti ng bol ts
to 19 N·m (14 ft. l bs.) torque. The two sensor mount-
i ng bol ts are speci al l y machi ned to correctl y space
uni t to fl ywheel . Do not attempt to i nstal l any other
bol ts.
Sensor With 2–Nut Mounting:
(3) I nstal l and ti ghten two sensor mounti ng nuts
to 19 N·m (14 ft. l bs.) torque.
Sensor With One-Bolt Mounting:
New repl acement sensors wi l l be equi pped wi th a
paper spacer gl ued to bottom of sensor. I f i nstal l i ng
(returni ng) a used sensor to vehi cl e, a new paper
spacer must be i nstal l ed to bottom of sensor. Thi s
spacer wi l l be ground off the fi rst ti me engi ne i s
started. I f spacer i s not used, sensor wi l l be broken
the fi rst ti me engi ne i s started.
(4) New Sensors: Be sure paper spacer i s i nstal l ed
to bottom of sensor. I f not, obtai n spacer
PN05252229.
(5) Used Sensors: Cl ean bottom of sensor and
i nstal l spacer PN05252229.
(6) I nstal l sensor i nto transmi ssi on bel l housi ng
hol e.
(7) Push sensor agai nst fl ywheel /dri ve pl ate. Wi th
sensor pushed agai nst fl ywheel /dri ve pl ate, ti ghten
mounti ng bol t to 7 N·m (60 i n. l bs.) torque.
(8) Connect sensor pi gtai l harness el ectri cal con-
nector to mai n wi ri ng harness.
CAMSHAFT POSITION SENSOR— 2. 5L ENGINE
On 2.5L engi nes, the camshaft posi ti on sensor i s
l ocated i n the di stri butor (Fi g. 27).
REMOVAL
Di stri butor removal i s not necessary to remove
camshaft posi ti on sensor.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Remove di stri butor cap from di stri butor (two
screws).
(3) Di sconnect camshaft posi ti on sensor wi ri ng
harness from mai n engi ne wi ri ng harness.
Fig. 25 Crankshaft Position Sensor—Two-Nut
Mounting
1 – TRANSMISSION BELLHOUSING
2 – MOUNTING NUTS (2)
3 – CRANKSHAFT POSITION SENSOR
4 – MOUNTING STUDS (2)
5 – RUBBER GROMMET
6 – SENSOR PIGTAIL
Fig. 26 Crankshaft Position Sensor—Two-Bolt
Mounting
1 – TRANSMISSION BELLHOUSING
2 – MOUNTING BOLTS (2)
3 – CRANKSHAFT POSITION SENSOR
4 – RUBBER GROMMET
5 – SENSOR PIGTAIL
8D - 14 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(4) Remove di stri butor rotor from di stri butor shaft.
(5) Li ft camshaft posi ti on sensor assembl y from
di stri butor housi ng (Fi g. 27).
INSTALLATION
(1) I nstal l camshaft posi ti on sensor to di stri butor.
Al i gn sensor i nto notch on di stri butor housi ng.
(2) Connect wi ri ng harness.
(3) I nstal l rotor.
(4) I nstal l di stri butor cap. Ti ghten mounti ng
screws.
CAMSHAFT POSITION SENSOR— 4. 0L ENGINE
The Camshaft Posi ti on Sensor (CMP) on the 4.0L
6–cyl i nder engi ne i s bol ted to the top of the oi l pump
dri ve shaft assembl y (Fi g. 28). The sensor and dri ve
shaft assembl y i s l ocated on the ri ght si de of the
engi ne near the oi l fi l ter (Fi g. 29).
The rotati onal posi ti on of oi l pump dri ve deter-
mi nes fuel synchroni zati on onl y. I t does not deter-
mi ne i gni ti on ti mi ng.
NOTE: Do not attempt to rotate the oil pump drive
to modify ignition timing.
Two different procedures are needed for
removal and i nstal l ati on. The fi rst procedure wi l l
detai l removal and i nstal l ati on of the sensor onl y.
The second procedure wi l l detai l removal and i nstal -
l ati on of the sensor and oi l pump dri ve shaft assem-
bl y. The second procedure i s to be used i f the engi ne
has been di sassembl ed.
An i nternal oi l seal i s used i n the dri ve shaft hous-
i ng that prevents engi ne oi l at the bottom of the sen-
sor. The seal i s not servi ceabl e.
REMOVAL— SENSOR ONLY
(1) Di sconnect el ectri cal connector at CMP sensor
(Fi g. 29).
(2) Remove 2 sensor mounti ng bol ts (Fi g. 28) or
(Fi g. 29).
(3) Remove sensor from oi l pump dri ve.
INSTALLATION— SENSOR ONLY
(1) I nstal l sensor to oi l pump dri ve.
(2) I nstal l 2 sensor mounti ng bol ts and ti ghten to
2 N·m (15 i n. l bs.) torque.
(3) Connect el ectri cal connector to CMP sensor.
REMOVAL— OIL PUMP DRIVE AND SENSOR
If the CMP and oil pump drive are to be
removed and installed, do not allow engine
crankshaft or camshaft to rotate. CMP sensor
relationship will be lost.
(1) Di sconnect el ectri cal connector at CMP sensor
(Fi g. 29).
(2) Remove 2 sensor mounti ng bol ts (Fi g. 28) or
(Fi g. 29).
(3) Remove sensor from oi l pump dri ve.
Fig. 27 Camshaft Position Sensor—2.5L Engine
1 – SYNC SIGNAL GENERATOR
2 – CAMSHAFT POSITION SENSOR
3 – PULSE RING
4 – DISTRIBUTOR ASSEMBLY
Fig. 28 CMP and Oil Pump Drive Shaft—4.0L Engine
1 – CAMSHAFT POSITION SENSOR
2 – MOUNTING BOLTS (2)
3 – PULSE RING
4 – DRIVE GEAR (TO CAMSHAFT)
5 – OIL PUMP DRIVESHAFT
6 – SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
TJ IGNITION SYSTEM 8D - 15
REMOVAL AND INSTALLATION (Continued)
(4) Before proceedi ng to next step, mark and note
rotati onal posi ti on of oi l pump dri ve i n rel ati onshi p
to engi ne bl ock. After i nstal l ati on, the CMP sensor
shoul d face rear of engi ne 0°.
(5) Remove hol d-down bol t and cl amp (Fi g. 29).
(6) Whi l e pul l i ng assembl y from engi ne, note di rec-
ti on and posi ti on of pul se ri ng (Fi g. 28). After
removal , l ook down i nto top of oi l pump and note
di recti on and posi ti on of sl ot at top of oi l pump gear.
(7) Remove and di scard ol d oi l pump dri ve-to-en-
gi ne bl ock gasket.
INSTALLATION— OIL PUMP DRIVE AND SENSOR
(1) Cl ean oi l pump dri ve mounti ng hol e area of
engi ne bl ock.
(2) I nstal l new oi l pump dri ve-to-engi ne bl ock gas-
ket.
(3) Temporari l y i nstal l a toothpi ck or si mi l ar tool
through access hol e at si de of oi l pump dri ve housi ng.
Al i gn toothpi ck i nto mati ng hol e on pul se ri ng (Fi g.
30).
(4) I nstal l oi l pump dri ve i nto engi ne whi l e al i gn-
i ng i nto sl ot on oi l pump. Rotate oi l pump dri ve back
to i ts ori gi nal posi ti on and i nstal l hol d-down cl amp
and bol t. Fi nger ti ghten bol t. Do not do a fi nal ti ght-
eni ng of bol t at thi s ti me.
(5) I f engi ne crankshaft or camshaft has been
rotated, such as duri ng engi ne tear-down, CMP sen-
sor rel ati onshi p must be reestabl i shed.
(a) Remove i gni ti on coi l rai l assembl y. Refer to
I gni ti on Coi l Removal /I nstal l ati on.
Fig. 29 CMP Location—4.0L Engine
1 – OIL FILTER
2 – CAMSHAFT POSITION SENSOR
3 – CLAMP BOLT
4 – HOLD-DOWN CLAMP
5 – MOUNTING BOLTS (2)
6 – ELEC. CONNECTOR
Fig. 30 CMP Pulse Ring Alignment—4.0L Engine
1 – PULSE RING (SHUTTER)
2 – TOOTHPICK
3 – SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
Fig. 31 Align Timing Marks—4.0L Engine
1 – CRANKSHAFT VIBRATION DAMPER TIMING MARK
8D - 16 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(b) Remove cyl i nder number 1 spark pl ug.
(c) Hol d a fi nger over the open spark pl ug hol e.
Rotate engi ne at vi brati on dampener bol t unti l
compressi on (pressure) i s fel t.
(d) Sl owl y conti nue to rotate engi ne. Do thi s
unti l ti mi ng i ndex mark on vi brati on damper pul -
l ey al i gns wi th top dead center (TDC) mark (0
degree) on ti mi ng degree scal e (Fi g. 31). Al ways
rotate engi ne i n di recti on of normal rotati on. Do
not rotate engi ne backward to al i gn ti mi ng marks.
(e) I nstal l oi l pump dri ve i nto engi ne whi l e
al i gni ng i nto sl ot on oi l pump. I f pump dri ve wi l l
not drop down fl ush to engi ne bl ock, the oi l pump
sl ot i s not al i gned. Remove oi l pump dri ve and
al i gn sl ot i n oi l pump to shaft at bottom of dri ve.
I nstal l i nto engi ne. Rotate oi l pump dri ve back to
i ts ori gi nal posi ti on and i nstal l hol d-down cl amp
and bol t. Fi nger ti ghten bol t. Do not do a fi nal
ti ghteni ng of bol t at thi s ti me.
(f) Remove toothpi ck from housi ng.
(6) I nstal l sensor to oi l pump dri ve. After i nstal l a-
ti on, the CMP sensor shoul d face rear of engi ne 0°.
(7) I nstal l 2 sensor mounti ng bol ts and ti ghten to
2 N·m (15 i n. l bs.) torque.
(8) Connect el ectri cal connector to CMP sensor.
(9) I f removed, i nstal l spark pl ug and i gni ti on coi l
rai l .
To veri fy correct rotati onal posi ti on of oi l pump
dri ve, the DRB scan tool must be used.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
(10) Connect DRB scan tool to data l i nk connector.
The data l i nk connector i s l ocated i n passenger com-
partment, bel ow and to l eft of steeri ng col umn.
(11) Gai n access to SET SYNC screen on DRB.
(12) Fol l ow di recti ons on DRB screen and start
engi ne. Bri ng to operati ng temperature (engi ne must
be i n “cl osed l oop” mode).
(13) Wi th engi ne runni ng at idle speed, the words
I N RANGE shoul d appear on screen al ong wi th 0°.
Thi s i ndi cates correct posi ti on of oi l pump dri ve.
(14) I f a pl us (+) or a mi nus (-) i s di spl ayed next to
degree number, and/or the degree di spl ayed i s not
zero, l oosen but do not remove hol d-down cl amp bol t.
Rotate oi l pump dri ve unti l I N RANGE appears on
screen. Conti nue to rotate oi l pump dri ve unti l
achi evi ng as cl ose to 0° as possi bl e.
The degree scal e on SET SYNC screen of DRB i s
referri ng to fuel synchroni zati on onl y. It is not
referring to ignition timing. Because of thi s, do
not attempt to adjust i gni ti on ti mi ng usi ng thi s
method. Rotati ng oi l pump dri ve wi l l have no effect
on i gni ti on ti mi ng. Al l i gni ti on ti mi ng val ues are con-
trol l ed by powertrai n control modul e (PCM).
(15) Ti ghten hol d-down cl amp bol t to 23 N·m (17
ft. l bs.) torque.
DISTRIBUTOR— 2. 5L ENGINE
The di stri butor contai ns an i nternal oi l seal that
prevents oi l from enteri ng the di stri butor housi ng.
The seal i s not servi ceabl e.
Factory repl acement di stri butors are equi pped wi th
a pl asti c al i gnment pi n al ready i nstal l ed. The pi n i s
l ocated i n an access hol e on the bottom of the di stri b-
utor housi ng (Fi g. 32). I t i s used to temporari l y l ock
the rotor to the cyl i nder number 1 posi ti on duri ng
i nstal l ati on. The pi n must be removed after i nstal l -
i ng the di stri butor.
The camshaft posi ti on sensor i s l ocated i n the di s-
tri butor (Fi g. 33). For removal /i nstal l ati on proce-
dures, refer to Camshaft Posi ti on Sensor. Di stri butor
removal i s not necessary for sensor removal .
Refer to (Fi g. 33) for an expl oded vi ew of the di s-
tri butor.
A fork wi th a sl ot i s suppl i ed on the bottom of the
di stri butor housi ng where the housi ng base seats
agai nst the engi ne bl ock (Fi g. 33). The centerl i ne of
the sl ot al i gns wi th the di stri butor hol ddown bol t
hol e i n the engi ne bl ock. Because of the fork, the di s-
tri butor cannot be rotated. Di stri butor rotati on i s not
necessary as al l i gni ti on ti mi ng requi rements are
handl ed by the Powertrai n Control Modul e (PCM).
The posi ti on of the di stri butor determi nes fuel syn-
chroni zati on onl y. I t does not determi ne i gni ti on ti m-
i ng.
Fig. 32 Plastic Alignment Pin—2.5L Engine
1 – PLASTIC ALIGNMENT PIN
TJ IGNITION SYSTEM 8D - 17
REMOVAL AND INSTALLATION (Continued)
NOTE: Do not attempt to modify this fork to attain
ignition timing.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Di sconnect coi l secondary cabl e at coi l .
(3) Remove di stri butor cap from di stri butor (2
screws). Do not remove cabl es from cap. Do not
remove rotor.
(4) Di sconnect di stri butor wi ri ng harness from
mai n engi ne harness.
(5) Remove cyl i nder number 1 spark pl ug.
(6) Hol d a fi nger over open spark pl ug hol e. Rotate
engi ne at vi brati on dampener bol t unti l compressi on
(pressure) i s fel t.
(7) Sl owl y conti nue to rotate engi ne. Do thi s unti l
ti mi ng i ndex mark on vi brati on damper pul l ey al i gns
wi th Top Dead Center (TDC) mark (0 degree) on ti m-
i ng degree scal e (Fi g. 34). Al ways rotate engi ne i n
di recti on of normal rotati on. Do not rotate engi ne
backward to al i gn ti mi ng marks.
(8) On model s equi pped wi th A/C, remove el ectri -
cal cool i ng fan and shroud assembl y from radi ator.
Refer to Group 7, Cool i ng System for procedures.
(9) Thi s wi l l provi de room to turn engi ne crank-
shaft wi th a socket and ratchet usi ng vi brati on
damper bol t.
(10) Remove di stri butor hol ddown bol t and cl amp.
(11) Remove di stri butor from engi ne by sl owl y l i ft-
i ng strai ght up.
(12) Note that rotor wi l l rotate sl i ghtl y i n a coun-
tercl ockwi se di recti on whi l e l i fti ng up di stri butor.
The oi l pump gear wi l l al so rotate sl i ghtl y i n a coun-
tercl ockwi se di recti on whi l e l i fti ng up di stri butor.
Thi s i s due to the hel i cal cut gears on di stri butor and
camshaft.
(13) Note removed posi ti on of rotor duri ng di stri b-
utor removal . Duri ng i nstal l ati on, thi s wi l l be
referred to as the Pre-posi ti on.
(14) Observe sl ot i n oi l pump gear through hol e on
si de of engi ne. I t shoul d be sl i ghtl y before (counter-
cl ockwi se of) 10 o’cl ock posi ti on (Fi g. 35).
(15) Remove and di scard the ol d di stri butor-to-en-
gi ne bl ock gasket.
Fig. 33 Distributor—2.5L Engine—Typical
1 – CAP
2 – CAMSHAFT POSITION SENSOR
3 – HOUSING
4 – FORK WITH SLOT
5 – DRIVE GEAR
6 – ROLL PIN
7 – WASHER
8 – GASKET
9 – HOLDDOWN CLAMP
10 – HOLDDOWN BOLT
11 – SHAFT
12 – PULSE RING
13 – ROTOR
Fig. 34 Align Timing Marks—2.5L Engine
1 – CRANKSHAFT VIBRATION DAMPER TIMING MARK
8D - 18 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I f engi ne crankshaft has been rotated after di s-
tri butor removal , cyl i nder number 1 must be
returned to i ts proper fi ri ng stroke. Refer to previ ous
REMOVAL Step 5 and Step 6. These steps must be
done before i nstal l i ng di stri butor.
(2) Check posi ti on of sl ot on oi l pump gear. On the
2.5L engi ne, i t shoul d be just sl i ghtl y before (counter-
cl ockwi se of) 10 o’cl ock posi ti on (Fi g. 35). I f not, pl ace
a fl at bl ade screwdri ver i nto oi l pump gear and
rotate i t i nto proper posi ti on.
(3) Factory repl acement di stri butors are equi pped
wi th a pl asti c al i gnment pi n al ready i nstal l ed (Fi g.
32). Thi s pi n i s used to temporari l y hol d rotor to cyl -
i nder number 1 fi ri ng posi ti on duri ng di stri butor
i nstal l ati on. I f pi n i s i n pl ace, proceed to Step 8. I f
not, proceed to next step.
(4) I f ori gi nal di stri butor i s to be rei nstal l ed, such
as duri ng engi ne overhaul , the pl asti c pi n wi l l not be
avai l abl e. A 3/16 i nch dri ft pi n punch tool may be
substi tuted for pl asti c pi n.
(5) Remove camshaft posi ti on sensor from di stri b-
utor housi ng. Li ft strai ght up.
(6) Four di fferent al i gnment hol es are provi ded on
pl asti c ri ng (Fi g. 36). Note that 2.5L and 4.0L
engines have different alignment holes (Fig.
36).
(7) Rotate di stri butor shaft and i nstal l pi n punch
tool through proper al i gnment hol e i n pl asti c ri ng
(Fi g. 36) and i nto mati ng access hol e i n di stri butor
housi ng. Thi s wi l l prevent di stri butor shaft and rotor
from rotati ng.
(8) Cl ean di stri butor mounti ng hol e area of engi ne
bl ock.
(9) I nstal l new di stri butor-to-engi ne bl ock gasket
(Fi g. 33).
(10) I nstal l rotor to di stri butor shaft.
(11) Pre-posi ti on di stri butor i nto engi ne whi l e
hol di ng centerl i ne of base sl ot i n 1 o’cl ock posi ti on
(Fi g. 37). Conti nue to engage di stri butor i nto engi ne.
The rotor and di stri butor wi l l rotate cl ockwi se duri ng
i nstal l ati on. Thi s i s due to the hel i cal cut gears on
di stri butor and camshaft. When di stri butor i s ful l y
seated to engi ne bl ock, the centerl i ne of base sl ot
shoul d be al i gned to cl amp bol t mounti ng hol e on
engi ne (Fi g. 38). The rotor shoul d al so be poi nted
sl i ghtl y past (cl ockwi se of) 3 o’cl ock posi ti on.
I t may be necessary to rotate rotor and di stri butor
shaft (very sl i ghtl y) to engage di stri butor shaft wi th
sl ot i n oi l pump gear. The same may have to be done
to engage di stri butor gear wi th camshaft gear.
The distributor is correctly installed when:
• rotor i s poi nted at 3 o’cl ock posi ti on.
• pl asti c al i gnment pi n (or pi n punch tool ) i s sti l l
i nstal l ed to di stri butor.
• number 1 cyl i nder pi ston i s set at top dead cen-
ter (TDC) (compressi on stroke).
• centerl i ne of sl ot at base of di stri butor i s al i gned
to centerl i ne of di stri butor hol ddown bol t hol e on
engi ne. I n thi s posi ti on, the hol ddown bol t shoul d
easi l y pass through sl ot and i nto engi ne.
No adjustments are necessary. Proceed to next
step.
Fig. 35 Slot At 10 O’clock Position—2.5L Engine
1 – 10 0’CLOCK POSITION
2 – OIL PUMP SLOT
Fig. 36 Pin Alignment Holes—2.5L Engine
1 – DISTRIBUTOR HOUSING (TOP VIEW)
2 – PULSE RING
3 – 4.0L 6–CYLINDER ENGINE ALIGN. HOLE
4 – 2.5L 4–CYLINDER ENGINE ALIGN. HOLE
5 – MATING ACCESS HOLE IN DISTRIBUTOR HOUSING
6 – PLASTIC RING
TJ IGNITION SYSTEM 8D - 19
REMOVAL AND INSTALLATION (Continued)
(12) I nstal l di stri butor hol ddown cl amp and bol t.
Ti ghten bol t to 23 N·m (17 ft. l bs.) torque.
(13) Remove pi n punch tool from di stri butor. Or, i f
pl asti c al i gnment pi n was used, remove i t strai ght
down from bottom of di stri butor. Di scard pl asti c pi n.
(14) I f removed, i nstal l camshaft posi ti on sensor to
di stri butor. Al i gn wi ri ng harness grommet to notch i n
di stri butor housi ng.
(15) I nstal l rotor.
CAUTION: If the distributor cap is incorrectly posi-
tioned on distributor housing, cap or rotor may be
damaged when engine is started.
(16) I nstal l di stri butor cap. Ti ghten di stri butor cap
hol ddown screws to 3 N·m (26 i n. l bs.) torque.
(17) I f removed, i nstal l spark pl ug cabl es to di s-
tri butor cap. For proper fi ri ng order, refer to Engi ne
Fi ri ng Order.
(18) Connect di stri butor wi ri ng harness to mai n
engi ne harness.
(19) Connect battery cabl e to battery.
IGNITION SWITCH AND KEY CYLINDER
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
KEY CYLINDER REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) I f equi pped wi th an automati c transmi ssi on,
pl ace shi fter i n PARK posi ti on.
(3) Rotate key to ON posi ti on.
(4) A rel ease tang i s l ocated on bottom of key cyl -
i nder (Fi g. 39).
Fig. 37 Distributor Pre-position—2.5L Engine
1 – 1 O’CLOCK POSITION
2 – BASE SLOT
3 – DISTRIBUTOR BASE
Fig. 38 Distributor Engaged Position—2.5L Engine
1 – DISTRIBUTOR BASE SLOT
2 – CLAMP BOLT MOUNTING HOLE (ON ENGINE)
3 – DISTRIBUTOR BASE
Fig. 39 Key Cylinder Release Tang
1 – KEY CYLINDER
2 – RELEASE TANG
8D - 20 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(5) Posi ti on a smal l screwdri ver or pi n punch i nto
tang access hol e on bottom of steeri ng col umn l ower
cover (Fi g. 40).
(6) Push the pi n punch up whi l e pul l i ng key cyl i n-
der from steeri ng col umn.
IGNITION SWITCH REMOVAL
(1) Remove key cyl i nder. Refer to previ ous steps.
(2) Remove l ower steeri ng col umn cover screws
and remove cover (Fi g. 40).
(3) Remove i gni ti on swi tch mounti ng screw (Fi g.
43). Use tamper proof torx bi t (Snap-On௡ SDMTR10
or equi val ent) to remove the screw.
(4) Usi ng a smal l screwdri ver, push on l ocki ng tab
(Fi g. 41) and remove swi tch from steeri ng col umn.
(5) Di sconnect two el ectri cal connectors at rear of
i gni ti on swi tch (Fi g. 43).
IGNITION SWITCH INSTALLATION
(1) Before i nstal l i ng i gni ti on swi tch, rotate the sl ot
i n the swi tch to the ON posi ti on (Fi g. 42).
(2) Connect two el ectri cal connectors to rear of
i gni ti on swi tch. Make sure that l ocki ng tabs are ful l y
seated i nto wi ri ng connectors.
(3) Posi ti on swi tch to col umn and i nstal l tamper
proof screw. Ti ghten screw to 3 N·m (26 i n. l bs.).
(4) I nstal l steeri ng col umn l ower cover.
KEY CYLINDER INSTALLATION
(1) I f equi pped wi th an automati c transmi ssi on,
pl ace shi fter i n PARK posi ti on.
(2) Posi ti on key cyl i nder i nto steeri ng col umn as i t
woul d normal l y be i n the ON posi ti on.
(3) Press key cyl i nder i nto col umn unti l i t snaps
i nto posi ti on.
Fig. 40 Key Cylinder and Cover Removal
1 – LOWER COVER
2 – ACCESS HOLE
3 – PIN PUNCH
4 – COVER SCREWS (3)
Fig. 41 Ignition Switch Lock Tab
1 – LOCK TAB
2 – IGNITION SWITCH
3 – SCREWDRIVER
Fig. 42 Switch In ON Position
1 – IGNITION SWITCH
2 – ROTATE TO ON POSITION
TJ IGNITION SYSTEM 8D - 21
REMOVAL AND INSTALLATION (Continued)
(4) Check mechani cal operati on of swi tch. Auto-
matic Transmission: Be sure transmi ssi on l ever i s
l ocked i n PARK posi ti on after key removal . I f key i s
di ffi cul t to rotate or i s di ffi cul t to remove, the shi ft
l ever-to-steeri ng col umn cabl e may be out of adjust-
ment or defecti ve. Refer to Group 21, Transmi ssi on
for procedures. Manual Transmission: Be sure key
cannot be removed unti l rel ease l ever i s operated. I f
key can be removed, rel ease l ever mechani sm may be
defecti ve. Rel ease l ever mechani sm i s not servi ced
separatel y. I f repai r i s necessary, the steeri ng col umn
must be repl aced. Refer to Group 19, Steeri ng for
procedures.
(5) Connect negati ve cabl e to battery.
(6) Check el ectri cal operati on of swi tch.
SHIFTER/IGNITION INTERLOCK
REMOVAL/INSTALLATION
On model s equi pped wi th an automati c transmi s-
si on, a cabl e connects the i gni ti on swi tch wi th the
fl oor shi ft l ever. The shi fter wi l l be l ocked i n the
PARK posi ti on when the i gni ti on key i s i n the LOCK
or ACCESSORY posi ti ons. The cabl e can be adjusted
or repl aced. Refer to Group 21, Transmi ssi ons for
procedures. The i gni ti on i nterl ock devi ce wi thi n the
steeri ng col umn i s not servi ceabl e. I f servi ce i s nec-
essary, the steeri ng col umn must be repl aced. Refer
to Group 19, Steeri ng for procedures.
SPECIFICATIONS
IGNITION TIMING
I gni ti on ti mi ng i s not adjustabl e on any engi ne.
ENGINE FIRING ORDER— 2. 5L 4-CYLINDER
ENGINE
ENGINE FIRING ORDER— 4. 0L 6-CYLINDER
ENGINE
Fig. 43 Ignition Switch Removal/Installation
1 – TAMPER PROOF SCREW
2 – IGNITION SWITCH
3 – ELECTRICAL CONNECTORS
8D - 22 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
SPARK PLUGS SPARK PLUG CABLE RESISTANCE
IGNITION COIL RESISTANCE— 2. 5L ENGINE
COIL
MANUFACTURER
PRIMARY RESISTANCE @
21-27°C (70-80°F)
SECONDARY RESISTANCE @ 21-27°C
(70-80°F)
Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms
Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms
IGNITION COIL RESISTANCE— 4. 0L ENGINE
TORQUE CHART
DESCRIPTION TORQUE
Camshaft Posi ti on Sensor–
to–base bol ts—4.0L . . . . . . . 28 N·m (15 i n. l bs.)
Crankshaft Posi ti on Sensor Bol ts—
wi th manual transmi ssi on . . . 19 N·m (14 ft. l bs.)
Crankshaft Posi ti on Sensor Nuts—
2.5L wi th auto.trans. . . . . . . . 19 N·m (14 ft. l bs.)
Crankshaft Posi ti on Sensor Bol t—
4.0L wi th auto. trans. . . . . . . . 7 N·m (60 i n. l bs.)
Di stri butor Hol d Down Bol t—2.5L . . . . . . . 23 N·m
(17 ft. l bs.)
Di stri butor Cap Screws—2.5L . . 3 N·m (26 i n. l bs.)
I gni ti on Coi l Mounti ng (i f tapped bol ts are used)—
2.5L . . . . . . . . . . . . . . . . . . . . 5 N·m (50 i n. l bs.)
I gni ti on Coi l Mounti ng (i f nuts/bol ts are used)—
2.5L . . . . . . . . . . . . . . . . . . 11 N·m (100 i n. l bs.)
I gni ti on Coi l Rai l Mounti ng Bol ts—4.0L . . . 29 N·m
(250 i n. l bs.)
Oi l Pump Dri ve Hol d-down Bol t—4.0L . . . . 23 N·m
(17 ft. l bs.)
Spark Pl ugs (al l engi nes) . . . . . 41 N·m (30 ft. l bs.)
ENGINE PLUG TYPE ELECTRODE GAP
2.5L RC12ECC 0.89 mm (0.035 in.)
4.0L RC12ECC 0.89 mm (0.035 in.)
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
PRIMARY RESISTANCE
21-27°C (70-80°F)
0.71 - 0.88 Ohms
TJ IGNITION SYSTEM 8D - 23
SPECIFICATIONS (Continued)
INSTRUMENT PANEL SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
INSTRUMENT PANEL SYSTEM . . . . . . . . . . . . . . 1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . 1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 2
INSTRUMENT PANEL CIGAR LIGHTER . . . . . . . . 3
ACCESSORY RELAY . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 4
ACCESSORY RELAY . . . . . . . . . . . . . . . . . . . . . . . 9
INSTRUMENT PANEL CIGAR LIGHTER . . . . . . . 10
REMOVAL AND INSTALLATION
STEERING COLUMN OPENING COVER . . . . . . . 10
KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . . . . 11
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 12
INSTRUMENT PANEL TOP COVER. . . . . . . . . . . 12
CLUSTER BEZEL. . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . 14
INSTRUMENT CLUSTER COMPONENTS . . . . . . 14
INSTRUMENT PANEL CENTER BEZEL . . . . . . . . 17
INSTRUMENT PANEL ACCESSORY SWITCH
BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ACCESSORY RELAY . . . . . . . . . . . . . . . . . . . . . . 18
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
GLOVE BOX COMPONENTS . . . . . . . . . . . . . . . . 19
GLOVE BOX LATCH STRIKER . . . . . . . . . . . . . . 21
INSTRUMENT PANEL GRAB HANDLE . . . . . . . . 22
INSTRUMENT PANEL GRAB HANDLE BEZEL . . 22
INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . . 23
INSTRUMENT PANEL BASE TRIM. . . . . . . . . . . 24
DESCRIPTION AND OPERATION
INSTRUMENT PANEL SYSTEM
DESCRIPTION
The i nstrument panel serves as the command cen-
ter of the vehi cl e, whi ch necessari l y makes i t a very
compl ex uni t. The i nstrument panel i s desi gned to
house the control s and moni tors for standard and
opti onal powertrai ns, cl i mate control systems, audi o
systems, l i ghti ng systems, safety systems and many
other comfort or conveni ence i tems. The i nstrument
panel i s al so desi gned so that al l of the vari ous con-
trol s can be safel y reached and the moni tors can be
easi l y vi ewed by the vehi cl e operator when dri vi ng,
whi l e sti l l al l owi ng rel ati ve ease of access to each of
these i tems for servi ce. See the owner’s manual i n
the vehi cl e gl ove box for more i nformati on on the fea-
tures, use and operati on of al l of the i nstrument
panel components and systems.
Thi s group i s responsi bl e for coveri ng servi ce i nfor-
mati on for the vehi cl e i nstrument panel systems.
However, compl ete servi ce i nformati on coverage for
al l of the systems and components housed i n the
i nstrument panel i n a si ngl e secti on of the servi ce
manual woul d not be practi cal . Therefore, the servi ce
i nformati on for any component wi l l be found i n the
group desi gnated to cover the vehi cl e system that the
component bel ongs to, even though the component i s
mounted on or i n the i nstrument panel . I f you cannot
l ocate a l i sti ng for the component or system you are
servi ci ng i n the tabl e of contents for thi s group, or i f
you are uncertai n as to whi ch vehi cl e system a com-
ponent bel ongs to, i t i s suggested that you refer to
the al phabeti cal Component and System Index
found at the back of thi s servi ce manual .
INSTRUMENT PANEL
DESCRIPTION
Modul ar i nstrument panel constructi on al l ows al l
of the gauges and control s to be servi ced from the
front of the panel . I n addi ti on, most of the i nstru-
ment panel el ectri cal or heati ng and ai r condi ti oni ng
components can be accessed wi thout compl ete i nstru-
ment panel removal . I f necessary, the i nstrument
panel can be removed from the vehi cl e as an assem-
bl y.
Removal of the steeri ng col umn openi ng cover and
the knee bl ocker provi des access to the steeri ng col -
umn mounts, the steeri ng col umn wi ri ng, the gear-
shi ft i nterl ock mechani sm, the headl amp swi tch, and
much of the i nstrument panel wi ri ng. Removal of the
gl ove box provi des access to the fusebl ock modul e,
addi ti onal i nstrument panel wi ri ng, and many of the
heati ng and ai r condi ti oni ng components.
Removal of the i nstrument cl uster bezel al l ows
access to the cl uster assembl y. Removal of the cl uster
assembl y al l ows access to the cl uster i l l umi nati on
TJ INSTRUMENT PANEL SYSTEMS 8E - 1
and i ndi cator l amp bul bs, and more of the i nstru-
ment panel wi ri ng.
Removal of the i nstrument panel center bezel
al l ows access to the radi o, the heati ng and ai r condi -
ti oni ng control s, the power outl et or ci gar l i ghter, and
the accessory swi tches. The power outl et/ci gar l i ghter
i s servi ced onl y as a uni t wi th the accessory swi tch
bezel .
A bezel on each outboard end of the l ower i nstru-
ment panel i s removed to servi ce the i nstrument
panel speakers. Removal of the compl ete i nstrument
panel i s requi red for servi ce of the passenger si de
ai rbag modul e and most i nternal components of the
heati ng and ai r condi ti oni ng system housi ng.
INSTRUMENT CLUSTER
DESCRIPTION
A si ngl e i nstrument cl uster i s offered on thi s
model . Thi s cl uster i s an el ectromechani cal uni t that
uti l i zes i ntegrated ci rcui try and i nformati on carri ed
on the Chrysl er Col l i si on Detecti on (CCD) data bus
network for control of al l gauges and many of the
i ndi cator l amps. Thi s cl uster al so i ncorporates a di g-
i tal Vacuum Fl uorescent Di spl ay (VFD) for the odom-
eter/tri p odometer di spl ay functi ons. Some vari ati ons
of thi s cl uster exi st due to opti onal equi pment and
regul atory requi rements.
The cl uster i ncl udes the fol l owi ng anal og gauges:
• Cool ant temperature gauge
• Fuel gauge
• Oi l pressure gauge
• Speedometer
• Tachometer
• Vol tmeter.
Thi s cl uster al so i ncl udes provi si ons for the fol l ow-
i ng i ndi cator l amps:
• Ai rbag i ndi cator l amp
• Anti -l ock Brake System (ABS) l amp
• Brake warni ng l amp
• Check gauges l amp
• Crui se-on i ndi cator l amp
• Four-wheel dri ve i ndi cator l amp
• Headl amp hi gh beam i ndi cator l amp
• Low fuel warni ng l amp
• Mal functi on I ndi cator Lamp (MI L)
• Seat bel t remi nder l amp
• Sentry Key I mmobi l i zer System (SKI S) i ndi cator
l amp
• Turn si gnal i ndi cator l amps
• Upshi ft i ndi cator l amp (manual transmi ssi on).
The i nstrument cl uster ci rcui try has a sel f-di agnos-
ti c actuator test capabi l i ty, whi ch wi l l test each of the
CCD bus message-control l ed functi ons of the cl uster
by l i ghti ng the appropri ate i ndi cator l amps and posi -
ti oni ng the gauge needl es at several predetermi ned
l ocati ons on the gauge faces i n a prescri bed sequence.
For more i nformati on on thi s functi on, refer to
Instrument Cluster i n the Di agnosi s and Testi ng
secti on of thi s group.
The i nstrument cl uster ci rcui try al so i ntegrates a
chi me tone generator and a ti mer ci rcui t. These
i tems repl ace the chi me or buzzer modul e, and the
separate ti mer ci rcui t for the rear wi ndow defogger
system. Refer to Chime Warning System i n the
Descri pti on and Operati on secti on of Group 8U -
Chi me/Buzzer Warni ng Systems for more i nformati on
on the chi me functi ons of the i nstrument cl uster.
Refer to Rear Window Defogger System i n the
Descri pti on and Operati on secti on of Group 8N -
El ectri cal l y Heated Systems for more i nformati on on
the ti mer functi on of the i nstrument cl uster.
The i nstrument cl uster for thi s model i s servi ced
onl y as a compl ete uni t. I f a cl uster gauge or the
cl uster ci rcui t board are faul ty, the enti re cl uster
must be repl aced. The cl uster l ens, the cl uster hood
and mask, the rear cl uster housi ng cover, the odom-
eter reset knob boot and the i ncandescent l amp bul bs
and hol ders are avai l abl e for servi ce repl acement.
OPERATION
GAUGE
Wi th the i gni ti on swi tch i n the On or Start posi -
ti ons, vol tage i s suppl i ed to al l gauges through the
i nstrument cl uster el ectroni c ci rcui t board. Wi th the
i gni ti on swi tch i n the Off posi ti on, vol tage i s not sup-
pl i ed to the gauges. The gauges do not accuratel y
i ndi cate any vehi cl e condi ti on unl ess the i gni ti on
swi tch i s i n the On or Start posi ti ons.
Al l of the i nstrument cl uster gauges, except the
odometer, are ai r core magneti c uni ts. Two fi xed el ec-
tromagneti c coi l s are l ocated wi thi n the gauge. These
coi l s are wrapped at ri ght angl es to each other
around a movabl e permanent magnet. The movabl e
magnet i s suspended wi thi n the coi l s on one end of a
shaft. The gauge needl e i s attached to the other end
of the shaft.
One of the coi l s has a fi xed current fl owi ng
through i t to mai ntai n a constant magneti c fi el d
strength. Current fl ow through the second coi l
changes, whi ch causes changes i n i ts magneti c fi el d
strength. The current fl owi ng through the second coi l
i s changed by the i nstrument cl uster el ectroni c ci r-
cui try i n response to messages recei ved on the
Chrysl er Col l i si on Detecti on (CCD) data bus network.
The gauge needl e moves as the movabl e permanent
magnet al i gns i tsel f to the changi ng magneti c fi el ds
created around i t by the el ectromagnets. The i nstru-
ment cl uster ci rcui try i s programmed to move al l of
the gauge needl es back to the l ow end of thei r respec-
8E - 2 INSTRUMENT PANEL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
ti ve scal es after the i gni ti on swi tch i s turned to the
Off posi ti on.
INDICATOR LAMP
I ndi cator l amps are l ocated i n the i nstrument cl us-
ter and are served by the cl uster ci rcui t board and
connectors. Many of the i ndi cator l amps i n the
i nstrument cl uster are control l ed by the i nstrument
cl uster ci rcui try i n response to messages recei ved
over the Chrysl er Col l i si on Detecti on (CCD) data bus
network.
The anti -l ock brake system l amp, brake warni ng
l amp, four-wheel dri ve i ndi cator l amp, headl amp
hi gh beam i ndi cator l amp, and turn si gnal i ndi cator
l amps are hard wi red. The seat bel t remi nder l amp i s
control l ed by the i nstrument cl uster programmi ng.
The Mal functi on I ndi cator Lamp (MI L) i s normal l y
control l ed by CCD data bus messages from the Pow-
ertrai n Control Modul e (PCM); however, i f the i nstru-
ment cl uster detects a l oss of CCD data bus
communi cati on, the cl uster wi l l automati cal l y turn
the MI L on and di spl ay the message “NO BUS” i n
the odometer VFD unti l CCD data bus communi ca-
ti on i s restored. The i nstrument cl uster ci rcui try uses
CCD data bus messages from the PCM, Ai rbag Con-
trol Modul e (ACM), and the Sentry Key I mmobi l i zer
Modul e (SKI M) to control al l of the remai ni ng i ndi -
cator l amps.
Each of the i ndi cator l amps i n the i nstrument cl us-
ter uses i ncandescent bul bs and hol ders, whi ch are
avai l abl e for servi ce repl acement.
CLUSTER ILLUMINATION LAMP
The cl uster i l l umi nati on l amps are hard wi red i n
the i nstrument cl uster. When the park or head l amps
are turned on, the cl uster i l l umi nati on l amps l i ght.
I l l umi nati on bri ghtness i s adjusted by rotati ng the
headl amp swi tch knob (cl ockwi se to di m, counter-
cl ockwi se to bri ghten). The i nstrument cl uster i l l umi -
nati on l amps recei ve battery feed from the panel
di mmer rheostat i n the headl amp swi tch through a
fuse i n the fusebl ock modul e.
The i nstrument cl uster el ectroni c ci rcui try al so
moni tors the cl uster i l l umi nati on l amp di mmi ng l evel
whenever the park or head l amps are turned on. The
i nstrument cl uster el ectroni c ci rcui try responds by
adjusti ng the di mmi ng l evel of the odometer Vacuum
Fl uorescent Di spl ay (VFD). When the park l amps or
headl amps are turned off, the VFD i s i l l umi nated at
ful l bri ghtness for i mproved dayl i ght vi si bi l i ty.
Each of the cl uster i l l umi nati on l amps i s l ocated on
the i nstrument cl uster ci rcui t board. Each cl uster
i l l umi nati on l amp has a repl aceabl e bul b and bul b
hol der.
INSTRUMENT PANEL CIGAR LIGHTER
DESCRIPTION
An i nstrument panel ci gar l i ghter i s standard fac-
tory-i nstal l ed equi pment on thi s model . The ci gar
l i ghter i s i nstal l ed i n the i nstrument panel accessory
swi tch bezel , whi ch i s l ocated near the bottom of the
i nstrument panel center bezel area, next to the ash
recei ver.
The ci gar l i ghter base i s servi ced onl y as a part of
the accessory swi tch bezel uni t. I f the base i s faul ty
or damaged, the accessory swi tch bezel uni t must be
repl aced. The ci gar l i ghter knob and heati ng el ement
uni t i s avai l abl e for servi ce. Thi s component cannot
be repai red and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
The ci gar l i ghter base or receptacl e shel l i s con-
nected to ground, and an i nsul ated contact i n the
bottom of the shel l i s connected to battery current.
The ci gar l i ghter recei ves battery vol tage from a fuse
i n the Power Di stri buti on Center (PDC) through the
accessory rel ay onl y when the i gni ti on swi tch i s i n
the Accessory or On posi ti ons. Refer to Accessory
Relay i n the Descri pti on and Operati on secti on of
thi s group for more i nformati on on thi s component.
The ci gar l i ghter knob and heati ng el ement are
encased wi thi n a spri ng-l oaded housi ng, whi ch al so
features a sl i di ng protecti ve heat shi el d. When the
knob and heati ng el ement are i nserted i n the recep-
tacl e shel l , the heati ng el ement resi stor coi l i s
grounded through i ts housi ng to the receptacl e shel l .
I f the ci gar l i ghter knob i s pushed i nward, the heat
shi el d sl i des up toward the knob exposi ng the heat-
i ng el ement, and the heati ng el ement extends from
the housi ng toward the i nsul ated contact i n the bot-
tom of the receptacl e shel l .
Two smal l spri ng-cl i p retai ners are l ocated on
ei ther si de of the i nsul ated contact i nsi de the bottom
of the receptacl e shel l . These cl i ps engage and hol d
the heati ng el ement of the ci gar l i ghter agai nst the
i nsul ated contact l ong enough for the resi stor coi l to
heat up. When the heati ng el ement i s engaged wi th
the contact, battery current can fl ow through the
resi stor coi l to ground, causi ng the resi stor coi l to
heat.
When the resi stor coi l becomes suffi ci entl y heated,
excess heat radi ates from the heati ng el ement caus-
i ng the spri ng-cl i ps to expand. Once the spri ng-cl i ps
expand far enough to rel ease the heati ng el ement,
the spri ng-l oaded housi ng forces the knob and heat-
i ng el ement to pop back outward to thei r rel axed
posi ti on. When the ci gar l i ghter knob and el ement
are pul l ed out of the receptacl e shel l , the protecti ve
heat shi el d sl i des downward on the housi ng so that
TJ INSTRUMENT PANEL SYSTEMS 8E - 3
DESCRIPTION AND OPERATION (Continued)
the heati ng el ement i s recessed and shi el ded around
i ts ci rcumference for safety.
ACCESSORY RELAY
DESCRIPTION
The accessory rel ay i s an el ectromechani cal devi ce
that swi tches fused battery current to the standard
factory-i nstal l ed ci gar l i ghter when the i gni ti on
swi tch i s turned to the Accessory or On posi ti ons.
The accessory rel ay i s l ocated i n a wi re harness con-
nector that i s secured to the 100-way connector
bracket under the dri ver si de of the i nstrument
panel , near the cowl si de i nner panel i n the passen-
ger compartment.
The accessory rel ay i s a I nternati onal Standards
Organi zati on (I SO) rel ay. Rel ays conformi ng to the
I SO speci fi cati ons have common physi cal di mensi ons,
current capaci ti es, termi nal patterns, and termi nal
functi ons.
The accessory rel ay cannot be repai red or adjusted
and, i f faul ty or damaged, i t must be repl aced.
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When the el ec-
tromagneti c coi l i s energi zed, i t draws the movabl e
contact away from the normal l y cl osed fi xed contact,
and hol ds i t agai nst the other (normal l y open) fi xed
contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor or di ode i s con-
nected i n paral l el wi th the el ectromagneti c coi l i n the
rel ay, and hel ps to di ssi pate vol tage spi kes that are
produced when the coi l i s de-energi zed.
DIAGNOSIS AND TESTING
INSTRUMENT CLUSTER
I f al l of the gauges and/or i ndi cator l amps are i nop-
erati ve, perform the Prel i mi nary Di agnosi s. I f an
i ndi vi dual gauge or Chrysl er Col l i si on Detecti on
(CCD) data bus message-control l ed i ndi cator l amp i s
i noperati ve, go di rectl y to the Actuator Test. I f an
i ndi vi dual hard wi red i ndi cator l amp i s i noperati ve,
refer to Instrument Cluster - Hard Wired Lamp
Diagnosis i n the Di agnosi s and Testi ng secti on of
thi s group for the procedures to di agnosi s that l amp.
For compl ete ci rcui t di agrams, refer to Instrument
Cluster i n the Contents of Group 8W - Wi ri ng Di a-
grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
PRELIMINARY DIAGNOSIS
(1) I f the i ndi cator l amps operate, but none of the
gauges operate, go to Step 2. I f al l of the gauges and
the CCD data bus message-control l ed i ndi cator l amps
are i noperati ve, go to Step 5.
(2) Check the fused B(+) fuse i n the Power Di stri -
buti on Center (PDC). I f OK, go to Step 3. I f not OK,
repai r the shorted ci rcui t or component as requi red
and repl ace the faul ty fuse.
(3) Check for battery vol tage at the fused B(+) fuse
i n the PDC. I f OK, go to Step 4. I f not OK, repai r the
open fused B(+) ci rcui t to the battery as requi red.
(4) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster. Connect the
battery negati ve cabl e. Check for battery vol tage at
the fused B(+) ci rcui t cavi ty of the i nstrument cl uster
wi re harness connector A. I f OK, refer to Instru-
ment Cluster - Actuator Test i n the Di agnosi s and
Testi ng secti on of thi s group. I f not OK, repai r the
open fused B(+) ci rcui t to the fuse i n the PDC as
requi red.
(5) Check the fused i gni ti on swi tch output (run/
start) fuse i n the fusebl ock modul e. I f OK, go to Step
6. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
(6) Turn the i gni ti on swi tch to the On posi ti on and
check for battery vol tage at the fused i gni ti on swi tch
output (run/start) fuse i n the fusebl ock modul e. I f
OK, go to Step 7. I f not OK, repai r the open fused
i gni ti on swi tch output (run/start) ci rcui t to the i gni -
ti on swi tch as requi red.
(7) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
I nstal l the i nstrument cl uster. Connect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
posi ti on. Set the park brake. The red brake warni ng
l amp shoul d l i ght. I f OK, go to Step 8. I f not OK, go
to Step 9.
(8) Turn the i gni ti on swi tch to the Off posi ti on.
Turn on the park l amps and adjust the panel l amps
di mmer rheostat i n the headl amp swi tch to the ful l
bri ght posi ti on. The cl uster i l l umi nati on l amps
shoul d l i ght. I f OK, refer to Instrument Cluster -
Actuator Test i n the Di agnosi s and Testi ng secti on
of thi s group. I f not OK, go to Step 10.
8E - 4 INSTRUMENT PANEL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(9) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the i nstrument cl uster. Connect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
posi ti on. Check for battery vol tage at the fused i gni -
ti on swi tch output (run/start) ci rcui t cavi ty of the
i nstrument cl uster wi re harness connector A. I f OK,
refer to Instrument Cluster - Actuator Test i n the
Di agnosi s and Testi ng secti on of thi s group. I f not
OK, repai r the open fused i gni ti on swi tch output
(run/start) ci rcui t to the fuse i n the fusebl ock modul e
as requi red.
(10) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster. Check for con-
ti nui ty between the ground ci rcui t cavi ty of the
i nstrument cl uster wi re harness connector A and a
good ground. There shoul d be conti nui ty. I f OK, refer
to Instrument Cluster - Actuator Test i n the
Di agnosi s and Testi ng secti on of thi s group. I f not
OK, repai r the open ground ci rcui t to ground as
requi red.
ACTUATOR TEST
The i nstrument cl uster actuator test wi l l put the
i nstrument cl uster i nto i ts sel f-di agnosti c mode. I n
thi s mode the i nstrument cl uster can perform a sel f-
di agnosti c test that wi l l confi rm that the i nstrument
cl uster ci rcui try, the gauges, and the CCD data bus
message control l ed i ndi cator l amps are capabl e of
operati ng as desi gned. Duri ng the actuator test the
i nstrument cl uster ci rcui try wi l l posi ti on each of the
gauge needl es at vari ous speci fi ed cal i brati on poi nts,
and turn al l of the CCD data bus message-control l ed
l amps on and off at speci fi ed ti me i nterval s (Fi g. 1).
Successful compl eti on of the actuator test wi l l con-
fi rm that the i nstrument cl uster i s operati onal . How-
ever, there may sti l l be a probl em wi th the CCD data
bus, the Powertrai n Control Modul e (PCM), the Ai r-
bag Control Modul e (ACM), the Sentry Key I mmobi -
l i zer Modul e (SKI M) or the i nputs to one of these
el ectroni c control modul es. Use a DRB scan tool and
the proper Di agnosti c Procedures manual for testi ng
of these components.
I f an i ndi vi dual gauge does not respond properl y,
or does not respond at al l duri ng the actuator test,
the i nstrument cl uster shoul d be removed. However,
check that the gauge mounti ng screws on the i nstru-
ment cl uster el ectroni c ci rcui t board for proper ti ght-
ness before consi deri ng i nstrument cl uster
repl acement. I f the gauge mounti ng screws check
OK, repl ace the faul ty cl uster.
I f an i ndi vi dual i ndi cator l amp does not i l l umi nate
duri ng the actuator test, the i nstrument cl uster
shoul d be removed. However, check that the i ncan-
descent l amp bul b i s not faul ty and that the bul b
hol der i s properl y i nstal l ed on the i nstrument cl uster
el ectroni c ci rcui t board before consi deri ng i nstrument
cl uster repl acement. I f the bul b and bul b hol der
check OK, repl ace the faul ty i nstrument cl uster.
(1) Begi n the test wi th the i gni ti on swi tch i n the
Off posi ti on.
(2) Depress the tri p odometer reset button.
(3) Whi l e hol di ng the tri p odometer reset button
depressed, turn the i gni ti on swi tch to the On posi -
ti on, but do not start the engi ne.
(4) Rel ease the tri p odometer reset button.
(5) Compare the operati on of the suspect gauge(s)
and/or i ndi cator l amp(s) wi th the I nstrument Cl uster
Actuator Test chart (Fi g. 1).
(6) The i nstrument cl uster wi l l automati cal l y exi t
the sel f-di agnosti c mode and return to normal opera-
ti on at the compl eti on of the test, i f the i gni ti on
swi tch i s turned to the Off posi ti on duri ng the test,
or i f a vehi cl e speed message i ndi cati ng that the
vehi cl e i s movi ng i s recei ved from the PCM on the
CCD data bus duri ng the test.
(7) Go back to Step 1 to repeat the test, i f
requi red.
HARD WIRED LAMP DIAGNOSIS
Each of the l amps found i n thi s secti on depends
upon a hard wi red ci rcui t i nput to the i nstrument
cl uster for proper operati on. The fol l owi ng procedures
wi l l hel p to di agnose condi ti ons that may cause an
i noperati ve hard wi red l amp ci rcui t condi ti on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
ANTI-LOCK BRAKE SYSTEM LAMP
The di agnosi s found here addresses an i noperati ve
Anti -l ock Brake System (ABS) l amp condi ti on. I f the
ABS l amp stays on wi th the i gni ti on swi tch i n the
On posi ti on, or comes on and stays on whi l e dri vi ng,
refer to Antilock Brakes i n the Di agnosi s and Test-
i ng secti on of Group 5 - Brakes for di agnosi s. I f no
ABS probl em i s found, the fol l owi ng procedure wi l l
hel p l ocate a short or open i n the ABS l amp ci rcui t.
For compl ete ci rcui t descri pti ons, refer to Instru-
ment Cluster i n the Contents of Group 8W - Wi ri ng
Di agrams.
(1) Check the fused i gni ti on swi tch output (run/
start) fuse i n the fusebl ock modul e. I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
TJ INSTRUMENT PANEL SYSTEMS 8E - 5
DIAGNOSIS AND TESTING (Continued)
Fig. 1 Instrument Cluster Actuator Test
8E - 6 INSTRUMENT PANEL SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run/start) fuse i n the fusebl ock modul e. I f
OK, go to Step 3. I f not OK, repai r the open fused
i gni ti on swi tch output (run/start) ci rcui t to the i gni -
ti on swi tch as requi red.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the i nstrument cl uster. Connect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
posi ti on and wi thi n fi ve seconds check for conti nui ty
between the ABS warni ng i ndi cator dri ver ci rcui t
cavi ty of the i nstrument cl uster wi re harness connec-
tor A and a good ground. There shoul d be conti nui ty
for fi ve seconds after i gni ti on On, and then an open
ci rcui t. I f OK, repl ace the faul ty bul b. I f not OK, go
to Step 4.
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Di sconnect the Control l er Anti -l ock Brake (CAB) wi re
harness connector. Check for conti nui ty between the
ABS warni ng i ndi cator dri ver ci rcui t cavi ty of the
i nstrument cl uster wi re harness connector A and a
good ground. There shoul d be no conti nui ty. I f OK, go
to Step 5. I f not OK, repai r the shorted ABS warni ng
i ndi cator dri ver ci rcui t as requi red.
(5) Check for conti nui ty between the ABS warni ng
i ndi cator dri ver ci rcui t cavi ti es of the i nstrument
cl uster wi re harness connector A and the CAB wi re
harness connector. There shoul d be conti nui ty. I f OK,
refer to Antilock Brakes i n the Di agnosi s and Test-
i ng secti on of Group 5 - Brakes for di agnosi s of the
CAB. I f not OK, repai r the open ABS warni ng i ndi -
cator dri ver ci rcui t as requi red.
BRAKE WARNING LAMP
The di agnosi s found here addresses an i noperati ve
brake warni ng l amp condi ti on. I f the brake warni ng
l amp stays on wi th the i gni ti on swi tch i n the On
posi ti on and the park brake rel eased, or comes on
whi l e dri vi ng, refer to Base Brake System for vehi -
cl es not equi pped wi th the four wheel anti -l ock brake
system, or refer to Antilock Brakes for vehi cl es
equi pped wi th the four wheel anti -l ock brake system
i n the Di agnosi s and Testi ng secti on of Group 5 -
Brakes for further di agnosi s. I f no brake system
probl em i s found, the fol l owi ng procedure wi l l hel p
l ocate a short or open ci rcui t, or a faul ty swi tch. For
compl ete ci rcui t di agrams, refer to Instrument
Cluster i n the Contents of Group 8W - Wi ri ng Di a-
grams.
(1) Check the fused i gni ti on swi tch output (run/
start) fuse i n the fusebl ock modul e. I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run/start) fuse i n the fusebl ock modul e. I f
OK, go to Step 3. I f not OK, repai r the open fused
i gni ti on swi tch output (run/start) ci rcui t to the i gni -
ti on swi tch as requi red.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Di sconnect the wi re harness connector at the park
brake swi tch. Wi th the park brake rel eased, check for
conti nui ty between the park brake swi tch termi nal
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 4. I f not OK, adjust or repl ace the
faul ty park brake swi tch.
(4) Di sconnect the wi re harness connector at the
brake warni ng swi tch. Check for conti nui ty between
the two termi nal s of the brake warni ng swi tch. There
shoul d be conti nui ty. I f OK, go to Step 5. I f not OK,
repl ace the faul ty brake warni ng swi tch.
(5) Check for conti nui ty between each of the two
brake warni ng swi tch termi nal s and a good ground.
I n each case, there shoul d be no conti nui ty. I f OK, go
to Step 6. I f not OK, repl ace the faul ty brake warn-
i ng swi tch.
(6) Wi th both the park brake swi tch and the brake
warni ng swi tch wi re harness connectors sti l l di scon-
nected, check for conti nui ty between the red brake
warni ng i ndi cator dri ver ci rcui t cavi ty of the park
brake swi tch wi re harness connector and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 7. I f not OK, repai r the shorted red brake warn-
i ng i ndi cator dri ver ci rcui t as requi red.
(7) Wi th the i gni ti on swi tch hel d i n the Start posi -
ti on, check for conti nui ty between the red brake
warni ng i ndi cator dri ver ci rcui t cavi ty of the park
brake swi tch wi re harness connector and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
8. I f not OK, repai r the open red brake warni ng i ndi -
cator dri ver ci rcui t to the i gni ti on swi tch as requi red.
(8) Turn the i gni ti on swi tch to the Off posi ti on.
Remove the i nstrument cl uster. Check for conti nui ty
between the red brake warni ng i ndi cator dri ver ci r-
cui t cavi ty of the i nstrument cl uster wi re harness
connector A and a good ground. There shoul d be no
conti nui ty. I f OK, go to Step 9. I f not OK, repai r the
shorted red brake warni ng i ndi cator dri ver ci rcui t as
requi red.
(9) Check for conti nui ty between the red brake
warni ng i ndi cator dri ver ci rcui t cavi ti es of the i nstru-
ment cl uster wi re harness connector A and the brake
warni ng swi tch wi re harness connector. There shoul d
be conti nui ty. I f OK, repl ace the faul ty bul b. I f not
OK, repai r the open red brake warni ng i ndi cator
dri ver ci rcui t as requi red.
TJ INSTRUMENT PANEL SYSTEMS 8E - 7
DIAGNOSIS AND TESTING (Continued)
CLUSTER ILLUMINATION LAMP
The di agnosi s found here addresses an i noperati ve
i nstrument cl uster i l l umi nati on l amp condi ti on. I f
the probl em bei ng di agnosed i ncl udes i noperati ve
exteri or l i ghti ng control l ed by the headl amp swi tch,
that system needs to be repai red fi rst. I f the exteri or
l amps control l ed by the headl amp swi tch are i noper-
ati ve, refer to Headlamp Diagnosis i n the Di agno-
si s and Testi ng secti on of Group 8L - Lamps for
di agnosi s. I f no exteri or l i ghti ng system probl ems are
found, the fol l owi ng procedure wi l l hel p l ocate a
short or open i n the cl uster i l l umi nati on l amp ci rcui t.
I f the probl em bei ng di agnosed i nvol ves a l ack of
di mmi ng control for the odometer/tri p odometer Vac-
uum Fl uorescent Di spl ay (VFD), but al l of the other
cl uster i l l umi nati on l amps can be di mmed, repai r the
open headl amp swi tch output ci rcui t i nput to the
i nstrument cl uster. For compl ete ci rcui t di agrams,
refer to Instrument Cluster i n the Contents of
Group 8W - Wi ri ng Di agrams.
(1) Check the panel l amps di mmer fuse i n the
fusebl ock modul e. I f OK, go to Step 2. I f not OK,
repai r the shorted ci rcui t or component as requi red
and repl ace the faul ty fuse.
(2) Turn the park l amps on wi th the headl amp
swi tch. Rotate the headl amp swi tch knob counter-
cl ockwi se to just before the i nteri or l amps detent.
Check for battery vol tage at the panel l amps di mmer
fuse i n the fusebl ock modul e. Rotate the headl amp
swi tch knob cl ockwi se whi l e observi ng the test vol t-
meter. The readi ng shoul d go from battery vol tage to
zero vol ts. I f OK, go to Step 3. I f not OK, repai r the
open panel l amps di mmer swi tch si gnal ci rcui t to the
headl amp swi tch as requi red. I f the ci rcui t tests OK,
refer to Headlamp Diagnosis i n the Di agnosi s and
Testi ng secti on of Group 8L - Lamps to di agnose the
headl amp swi tch.
(3) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster. Turn the head-
l amp swi tch off. Remove the panel l amps di mmer
fuse from the fusebl ock modul e. Probe the fused
panel l amps di mmer swi tch si gnal ci rcui t cavi ty of
the i nstrument cl uster wi re harness connector A.
Check for conti nui ty to a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 4. I f not OK,
repai r the shorted fused panel l amps di mmer swi tch
si gnal ci rcui t as requi red.
(4) I nstal l the panel l amps di mmer fuse i n the
fusebl ock modul e. Connect the battery negati ve
cabl e. Turn the park l amps on wi th the headl amp
swi tch. Rotate the headl amp swi tch knob counter-
cl ockwi se to just before the i nteri or l amps detent.
Check for battery vol tage at the fused panel l amps
di mmer swi tch si gnal ci rcui t cavi ty of the i nstrument
cl uster wi re harness connector A. I f OK, repl ace the
faul ty cl uster i l l umi nati on l amp bul b(s) and bul b
hol der(s). I f not OK, repai r the open fused panel
l amps di mmer swi tch si gnal ci rcui t as requi red.
FOUR-WHEEL DRIVE INDICATOR LAMP
The di agnosi s found here addresses an i noperati ve
four-wheel dri ve i ndi cator l amp condi ti on. I f the
probl em bei ng di agnosed i s rel ated to l amp accuracy,
be certai n to confi rm that the probl em i s wi th the
l amp or swi tch and not wi th a damaged or i nopera-
ti ve transfer case or transfer case l i nkage. Refer to
NV231 Diagnosis i n the Di agnosi s and Testi ng sec-
ti on of Group 21 - Transmi ssi on for more i nforma-
ti on. I f no transfer case probl em i s found, the
fol l owi ng procedure wi l l hel p l ocate a short or open
i n the i ndi cator l amp ci rcui t. For compl ete ci rcui t
di agrams, refer to Instrument Cluster i n Group 8W
- Wi ri ng Di agrams.
(1) Check the fused i gni ti on swi tch output (run/
start) fuse i n the fusebl ock modul e. I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run/start) fuse i n the fusebl ock modul e. I f
OK, go to Step 3. I f not OK, repai r the open fused
i gni ti on swi tch output (run/start) ci rcui t to the i gni -
ti on swi tch as requi red.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Di sconnect the transfer case swi tch wi re harness con-
nector. Check for conti nui ty between the ground ci r-
cui t cavi ty of the transfer case swi tch wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 4. I f not OK, repai r the open
ground ci rcui t to ground as requi red.
(4) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. I nstal l a jumper
wi re between the part ti me four wheel dri ve i ndi cator
l amp dri ver ci rcui t cavi ty of the transfer case swi tch
wi re harness connector and a good ground. The four-
wheel dri ve i ndi cator l amp shoul d l i ght. I f OK,
repl ace the faul ty transfer case swi tch. I f not OK, go
to Step 5.
(5) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the i nstrument cl uster. Wi th the transfer
case swi tch wi re harness connector sti l l di sconnected,
check for conti nui ty between the part ti me four
wheel dri ve i ndi cator l amp dri ver ci rcui t cavi ty of the
i nstrument cl uster wi re harness connector B and a
good ground. There shoul d be no conti nui ty. I f OK, go
to Step 6. I f not OK, repai r the shorted part ti me
four wheel dri ve i ndi cator l amp dri ver ci rcui t as
requi red.
(6) Check for conti nui ty between the part ti me
four wheel dri ve i ndi cator l amp dri ver ci rcui t cavi ti es
8E - 8 INSTRUMENT PANEL SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
of the i nstrument cl uster wi re harness connector B
and the transfer case swi tch wi re harness connector.
There shoul d be conti nui ty. I f OK, repl ace the faul ty
bul b. I f not OK, repai r the open part ti me four wheel
dri ve i ndi cator l amp dri ver ci rcui t as requi red.
HEADLAMP HIGH BEAM INDICATOR LAMP
The di agnosi s found here addresses an i noperati ve
headl amp hi gh beam i ndi cator l amp condi ti on. I f the
probl em bei ng di agnosed i s rel ated to i noperati ve
headl amp hi gh beams, refer to Headlamp Diagno-
sis i n the Di agnosi s and Testi ng secti on of Group 8L
- Lamps for di agnosi s of the headl amp system. I f no
headl amp system probl ems are found, the fol l owi ng
procedure wi l l hel p l ocate an open i n the hi gh beam
i ndi cator l amp ci rcui t. For compl ete ci rcui t di agrams,
refer to Instrument Cluster i n the Contents of
Group 8W - Wi ri ng Di agrams.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster.
(2) Connect the battery negati ve cabl e. Turn the
headl amps on and sel ect the hi gh beams wi th the
mul ti -functi on swi tch stal k. Check for battery vol tage
at the hi gh beam i ndi cator dri ver ci rcui t cavi ty of the
i nstrument cl uster wi re harness connector A. I f OK,
repl ace the faul ty bul b. I f not OK, repai r the open
hi gh beam i ndi cator dri ver ci rcui t to the headl amp
di mmer (mul ti -functi on) swi tch as requi red.
TURN SIGNAL INDICATOR LAMP
The di agnosi s found here addresses an i noperati ve
turn si gnal i ndi cator l amp condi ti on. For any other
turn si gnal probl em, refer to Turn Signal and Haz-
ard Warning Systems i n the Di agnosi s and Testi ng
secti on of Group 8J - Turn Si gnal and Hazard Warn-
i ng Systems for further di agnosi s. I f no turn si gnal or
hazard warni ng system probl em i s found, the fol l ow-
i ng procedure wi l l hel p l ocate a short or open i n the
i ndi cator l amp ci rcui t. For compl ete ci rcui t di agrams,
refer to Instrument Cluster i n the Contents of
Group 8W - Wi ri ng Di agrams.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster.
(2) Connect the battery negati ve cabl e. Acti vate
the hazard warni ng system by movi ng the hazard
warni ng swi tch button to the On posi ti on. Check for
battery vol tage at the i noperati ve (ri ght or l eft) turn
si gnal ci rcui t cavi ty of the i nstrument cl uster wi re
harness connector (connector A - l eft, or connector B -
ri ght). There shoul d be a swi tchi ng (on and off) bat-
tery vol tage si gnal . I f OK, repl ace the faul ty (ri ght or
l eft) i ndi cator l amp bul b. I f not OK, repai r the open
(ri ght or l eft) turn si gnal ci rcui t to the turn si gnal /
hazard warni ng (mul ti -functi on) swi tch as requi red.
ACCESSORY RELAY
The accessory rel ay (Fi g. 2) i s l ocated i n a wi re
harness connector that i s secured to the 100-way con-
nector bracket under the dri ver si de of the i nstru-
ment panel , near the cowl si de i nner panel i n the
passenger compartment. For compl ete ci rcui t di a-
grams, refer to Horn/Cigar Lighter i n the Contents
of Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the accessory rel ay from i ts wi re har-
ness connector. Refer to Accessory Relay i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(2) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 3. I f not OK, repl ace the faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 Ϯ 5 ohms. I f OK, go to Step
4. I f not OK, repl ace the faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform the Rel ay Ci rcui t Test that
fol l ows. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal (30) i s con-
nected to battery vol tage and shoul d be hot at al l
ti mes. Check for battery vol tage at the fused B(+) ci r-
cui t cavi ty of the accessory rel ay wi re harness con-
nector. I f OK, go to Step 2. I f not OK, repai r the
fused B(+) ci rcui t to the fuse i n the Power Di stri bu-
ti on Center (PDC) as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the ci gar l i ghter when the rel ay i s energi zed by
the i gni ti on swi tch. There shoul d be conti nui ty
between the accessory rel ay wi re harness connector
cavi ty for rel ay termi nal 87 and the accessory rel ay
output ci rcui t cavi ty i n the ci gar l i ghter wi re harness
connector at al l ti mes. I f OK, go to Step 4. I f not OK,
TJ INSTRUMENT PANEL SYSTEMS 8E - 9
DIAGNOSIS AND TESTING (Continued)
repai r the open accessory rel ay output ci rcui t to the
ci gar l i ghter wi re harness connector as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. The accessory rel ay
wi re harness connector cavi ty for thi s termi nal
shoul d have conti nui ty to ground at al l ti mes. I f OK,
go to Step 5. I f not OK, repai r the open ground ci r-
cui t to ground as requi red.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. I t recei ves battery
feed to energi ze the accessory rel ay when the i gni ti on
swi tch i s i n the Accessory or On posi ti ons. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (acc/run)
ci rcui t cavi ty of the accessory rel ay wi re harness con-
nector. I f not OK, repai r the open fused i gni ti on
swi tch output (acc/run) ci rcui t to the i gni ti on swi tch
as requi red.
INSTRUMENT PANEL CIGAR LIGHTER
For compl ete ci rcui t di agrams, refer to Horn/Ci-
gar Lighter i n the Contents of Group 8W - Wi ri ng
Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the ci gar l i ghter knob and el ement
from the ci gar l i ghter receptacl e shel l . Check for con-
ti nui ty between the i nsi de ci rcumference of the ci gar
l i ghter receptacl e shel l and a good ground. there
shoul d be conti nui ty. I f OK, go to Step 2. I f not OK,
go to Step 3.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the i nsul ated contact
l ocated at the back of the ci gar l i ghter receptacl e
shel l . I f OK, repl ace the faul ty ci gar l i ghter knob and
el ement. I f not OK, go to Step 3.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the i nstrument panel accessory swi tch bezel .
Check for conti nui ty between the ground ci rcui t cav-
i ty of the ci gar l i ghter wi re harness connector and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 4. I f not OK, repai r the open ground ci rcui t to
ground as requi red.
(4) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the Accessory or On posi ti ons.
Check for battery vol tage at the accessory rel ay out-
put ci rcui t cavi ty of the ci gar l i ghter wi re harness
connector. I f OK, repl ace the faul ty accessory swi tch
bezel uni t. I f not OK, refer to Accessory Relay i n
the Di agnosi s and Testi ng secti on of thi s group for
further di agnosi s.
REMOVAL AND INSTALLATION
STEERING COLUMN OPENING COVER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) I f the vehi cl e i s so equi pped, move the ti l t
steeri ng col umn to the ful l y rai sed posi ti on.
(3) Remove the knob and shaft from the headl amp
swi tch. Refer to Headlamp Switch i n the Removal
and I nstal l ati on secti on of thi s group for the proce-
dures.
(4) Remove the two screws that secure the steeri ng
col umn openi ng cover to the i nstrument panel (Fi g.
3).
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 2 Accessory Relay
8E - 10 INSTRUMENT PANEL SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
(5) Pul l the upper edge of the steeri ng col umn
openi ng cover strai ght back and down away from the
i nstrument panel as far as possi bl e.
(6) Rock the l ower edge of the steeri ng col umn
openi ng cover rearward to di sengage the hi nge hook
formati ons on the l ower edge of the cover from the
hi nge pi ns on the l ower edge of the i nstrument panel .
(7) Remove the steeri ng col umn openi ng cover
from the i nstrument panel .
INSTALLATION
(1) Posi ti on the steeri ng col umn openi ng cover to
the i nstrument panel .
(2) Engage the hi nge hook formati ons on the l ower
edge of the steeri ng col umn openi ng cover wi th the
hi nge pi ns on the l ower edge of the i nstrument panel .
(3) Ti l t the upper edge of the steeri ng col umn
openi ng cover up i nto posi ti on onto the i nstrument
panel .
(4) I nstal l and ti ghten the two screws that secure
the steeri ng col umn openi ng cover to the i nstrument
panel . Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(5) Reconnect the battery negati ve cabl e.
KNEE BLOCKER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . Refer to Steering Col-
umn Opening Cover i n the Removal and I nstal l a-
ti on secti on of thi s group for the procedures.
(3) Remove the four screws that secure the knee
bl ocker to the i nstrument panel (Fi g. 4).
(4) Remove the knee bl ocker from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the knee bl ocker to the i nstrument
panel .
(2) I nstal l and ti ghten the four screws that secure
the knee bl ocker to the i nstrument panel . Ti ghten
the screws to 2.2 N·m (20 i n. l bs.).
(3) I nstal l the steeri ng col umn openi ng cover onto
the i nstrument panel . Refer to Steering Column
Opening Cover i n the Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(4) Reconnect the battery negati ve cabl e.
Fig. 3 Steering Column Opening Cover Remove/
Install
1 – HEADLAMP SWITCH KNOB
2 – STEERING COLUMN COVER
3 – MOUNTING SCREWS
Fig. 4 Knee Blocker Remove/Install
1 – HEADLAMP SWITCH
2 – KNEE BLOCKER
3 – MOUNTING SCREWS
TJ INSTRUMENT PANEL SYSTEMS 8E - 11
REMOVAL AND INSTALLATION (Continued)
HEADLAMP SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: IF THE HEADLAMP SWITCH WAS ON,
WAIT FIVE MINUTES TO ALLOW THE CERAMIC
DIMMER RESISTOR TO COOL. IF THE CERAMIC
DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT
CAN BURN YOUR FINGERS.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Pul l the headl amp swi tch control knob out to
the On posi ti on stop.
(3) Reach up under the i nstrument panel outboard
of the steeri ng col umn to access and depress the
headl amp swi tch control knob and shaft rel ease but-
ton on the top of the swi tch body (Fi g. 5).
(4) Whi l e hol di ng the rel ease button depressed,
pul l the headl amp swi tch control knob and shaft uni t
out of the headl amp swi tch.
(5) Remove the knee bl ocker from the i nstrument
panel . Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(6) Remove the spanner nut that secures the head-
l amp swi tch to the i nstrument panel mounti ng
bracket.
(7) Pul l the headl amp swi tch away from the
i nstrument panel mounti ng bracket far enough to
access the i nstrument panel wi re harness connectors.
(8) Di sconnect the two i nstrument panel wi re har-
ness connectors from the headl amp swi tch.
(9) Remove the headl amp swi tch from the i nstru-
ment panel .
INSTALLATION
(1) Posi ti on the headl amp swi tch to the i nstru-
ment panel .
(2) Reconnect the two i nstrument panel wi re har-
ness connectors to the headl amp swi tch.
(3) Posi ti on the headl amp swi tch behi nd the
mounti ng bracket on the i nstrument panel .
(4) I nstal l and ti ghten the spanner nut that
secures the headl amp swi tch to the i nstrument panel
mounti ng bracket. Ti ghten the nut to 2.7 N·m (24 i n.
l bs.).
(5) I nstal l the knee bl ocker onto the i nstrument
panel . Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(6) I nsert the shaft of the headl amp swi tch control
knob and shaft uni t through the openi ng i n the steer-
i ng col umn openi ng cover and i nto the headl amp
swi tch.
(7) Push the headl amp swi tch control knob and
shaft uni t al l the way i nto the headl amp swi tch body.
(8) Reconnect the battery negati ve cabl e.
INSTRUMENT PANEL TOP COVER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the i nstrument panel top
cover up and away from the i nstrument panel far
enough to di sengage the fi ve snap cl i p retai ners from
thei r receptacl es i n the i nstrument panel (Fi g. 6).
Fig. 5 Headlamp Switch Remove/Install
1 – KNOB AND SHAFT
2 – HEADLAMP SWITCH
3 – RELEASE BUTTON
4 – WIRE HARNESS CONNECTORS
5 – BRACKET
6 – SPANNER NUT
8E - 12 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(3) Remove the top cover from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the top cover onto the i nstrument
panel .
(2) Al i gn the snap cl i ps on the top cover wi th the
snap cl i p receptacl es i n the i nstrument panel .
(3) Press fi rml y downward on the top cover over
each of the snap cl i p l ocati ons unti l each of the snap
cl i ps i s ful l y seated i n thei r receptacl es i n the i nstru-
ment panel .
(4) Reconnect the battery negati ve cabl e.
CLUSTER BEZEL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . Refer to Steering Col-
umn Opening Cover i n the Removal and I nstal l a-
ti on secti on of thi s group for the procedures.
(3) Remove the top cover from the i nstrument
panel . Refer to Instrument Panel Top Cover i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(4) Remove the two screws that secure the l ower
mounti ng tabs of the cl uster bezel to the i nstrument
panel (Fi g. 7).
(5) Remove the three screws that secure the upper
mounti ng fl ange of the cl uster bezel to the i nstru-
ment panel (Fi g. 8).
(6) Remove the cl uster bezel from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the cl uster bezel to the i nstrument
panel .
Fig. 6 Instrument Panel Top Cover Remove/Install
1 – INSTRUMENT PANEL TOP COVER
Fig. 7 Cluster Bezel Lower Screws Remove/Install
1 – CLUSTER BEZEL
2 – LOWER MOUNTING SCREWS
Fig. 8 Cluster Bezel Upper Screws Remove/Install
1 – UPPER MOUNTING SCREWS
2 – CLUSTER BEZEL
TJ INSTRUMENT PANEL SYSTEMS 8E - 13
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l and ti ghten the three screws that secure
the upper mounti ng fl ange of the cl uster bezel to the
i nstrument panel . Ti ghten the screws to 2.2 N·m (20
i n. l bs.).
(3) I nstal l and ti ghten the two screws that secure
the l ower mounti ng tabs of the cl uster bezel to the
i nstrument panel . Ti ghten the screws to 2.2 N·m (20
i n. l bs.).
(4) I nstal l the top cover onto the i nstrument panel .
Refer to Instrument Panel Top Cover i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(5) I nstal l the steeri ng col umn openi ng cover onto
the i nstrument panel . Refer to Steering Column
Opening Cover i n the Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(6) Reconnect the battery negati ve cabl e.
INSTRUMENT CLUSTER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cl uster bezel from the i nstrument
panel . Refer to Cluster Bezel i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(3) Remove the four screws that secure the i nstru-
ment cl uster to the i nstrument panel (Fi g. 9).
(4) Pul l the i nstrument cl uster rearward far
enough to di sengage the two sel f-docki ng i nstrument
panel wi re harness connectors from the connector
receptacl es on the back of the cl uster housi ng.
(5) Remove the i nstrument cl uster from the i nstru-
ment panel .
INSTALLATION
(1) Posi ti on the i nstrument cl uster to the i nstru-
ment panel .
(2) Al i gn the i nstrument cl uster wi th the cl uster
openi ng i n the i nstrument panel and push the cl uster
fi rml y and evenl y i nto pl ace. The i nstrument panel
has two sel f-docki ng wi re harness connectors that
wi l l be automati cal l y al i gned wi th, and connected to
the cl uster connector receptacl es when the cl uster i s
i nstal l ed i n the i nstrument panel .
(3) I nstal l and ti ghten the four screws that secure
the i nstrument cl uster to the i nstrument panel .
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(4) I nstal l the cl uster bezel onto the i nstrument
panel . Refer to Cluster Bezel i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(5) Reconnect the battery negati ve cabl e.
INSTRUMENT CLUSTER COMPONENTS
Some of the components for the i nstrument cl uster
used i n thi s vehi cl e are servi ced i ndi vi dual l y. The
servi ced components i ncl ude: the i ncandescent
i nstrument cl uster i ndi cator l amp and i l l umi nati on
l amp bul bs (i ncl udi ng the i ntegral bul b hol ders), the
odometer reset knob boot, the cl uster l ens, the cl us-
ter hood and mask uni t, and the i nstrument cl uster
housi ng rear cover. Fol l owi ng are the servi ce proce-
dures for the i nstrument cl uster components.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp or i ndi cator l amp bul b and
Fig. 9 Instrument Cluster Remove/Install
1 – SELF-DOCKING WIRE HARNESS CONNECTORS
2 – INSTRUMENT CLUSTER
3 – SCREW
4 – INSTRUMENT PANEL
8E - 14 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
bul b hol der uni ts. However, the i l l umi nati on l amps
and the i ndi cator l amps use di fferent bul b and bul b
hol der uni t si zes. They must never be i nterchanged.
Be certai n that any bul b and bul b hol der uni t
removed from the cl uster el ectroni c ci rcui t board i s
rei nstal l ed i n the correct posi ti on. Al ways use the
correct bul b si ze and type for repl acement. An i ncor-
rect bul b si ze or type may overheat and cause dam-
age to the i nstrument cl uster, the el ectroni c ci rcui t
board and/or the gauges.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(3) Turn the bul b hol der countercl ockwi se about
si xty degrees on the cl uster el ectroni c ci rcui t board.
(4) Pul l the bul b and bul b hol der uni t strai ght
back to remove i t from the bul b mounti ng hol e i n the
cl uster el ectroni c ci rcui t board (Fi g. 10).
CLUSTER LENS
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(3) Work around the peri meter of the cl uster hous-
i ng to di sengage each of the l atches that secure the
cl uster l ens to the cl uster housi ng (Fi g. 11).
(4) Gentl y pul l the cl uster l ens away from the cl us-
ter housi ng.
ODOMETER RESET KNOB BOOT
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(3) Remove the cl uster l ens from the cl uster hous-
i ng. Refer to Instrument Cluster Components -
Cluster Lens i n the Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(4) Remove the odometer reset knob boot by pul l -
i ng i t out of the cl uster l ens.
CLUSTER HOOD AND MASK
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(3) Remove the cl uster l ens from the cl uster hous-
i ng. Refer to Instrument Cluster Components -
Cluster Lens i n the Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(4) Work around the peri meter of the cl uster hous-
i ng to di sengage each of the l atches that secure the
cl uster hood and mask uni t to the cl uster housi ng
(Fi g. 11).
(5) Gentl y pul l the cl uster hood and mask uni t
away from the cl uster housi ng.
CLUSTER HOUSING REAR COVER
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(3) Work around the peri meter of the cl uster hous-
i ng to di sengage each of the l atches that secure the
rear cover to the cl uster housi ng (Fi g. 11).
(4) Gentl y pul l the rear cover away from the back
of the cl uster housi ng.
INSTALLATION
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp or i ndi cator l amp bul b and
bul b hol der uni ts. However, the i l l umi nati on l amps
and the i ndi cator l amps use di fferent bul b and bul b
hol der uni t si zes. They must never be i nterchanged.
Be certai n that any bul b and bul b hol der uni t
removed from the cl uster el ectroni c ci rcui t board i s
rei nstal l ed i n the correct posi ti on.
CAUTION: Always use the correct bulb size and
type for replacement. An incorrect bulb size or type
may overheat and cause damage to the instrument
cluster, the electronic circuit board and/or the
gauges.
Fig. 10 Cluster Bulb Locations
1 – CLUSTER ILLUMINATION BULBS
TJ INSTRUMENT PANEL SYSTEMS 8E - 15
REMOVAL AND INSTALLATION (Continued)
(1) I nsert the bul b and bul b hol der uni t strai ght
i nto the correct bul b mounti ng hol e i n the cl uster
el ectroni c ci rcui t board.
(2) Wi th the bul b hol der ful l y seated agai nst the
cl uster el ectroni c ci rcui t board, turn the bul b hol der
cl ockwi se about si xty degrees to l ock i t i nto pl ace.
(3) I nstal l the i nstrument cl uster onto the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(4) Reconnect the battery negati ve cabl e.
CLUSTER LENS
(1) Al i gn the cl uster l ens wi th the cl uster hood and
mask uni t.
(2) Press fi rml y and evenl y on the cl uster l ens to
i nstal l i t onto the cl uster housi ng.
(3) Work around the peri meter of the cl uster hous-
i ng to be certai n that each of the l atches that secure
the cl uster l ens to the cl uster housi ng i s ful l y
engaged.
(4) I nstal l the i nstrument cl uster onto the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(5) Reconnect the battery negati ve cabl e.
ODOMETER RESET KNOB BOOT
(1) Posi ti on the odometer reset knob to the mount-
i ng hol e from the back of the cl uster l ens.
(2) Pul l the odometer reset knob i nto the mounti ng
hol e from the face of the cl uster l ens.
(3) I nstal l the cl uster l ens onto the cl uster hous-
i ng. Refer to Instrument Cluster Components -
Cluster Lens i n the Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(4) I nstal l the i nstrument cl uster onto the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(5) Reconnect the battery negati ve cabl e.
CLUSTER HOOD AND MASK
(1) Al i gn the hood and mask uni t wi th the cl uster
housi ng.
(2) Press fi rml y and evenl y on the hood and mask
uni t to i nstal l i t onto the cl uster housi ng.
(3) Work around the peri meter of the cl uster hous-
i ng to be certai n that each of the l atches that secure
the hood and mask uni t to the cl uster housi ng i s
ful l y engaged.
Fig. 11 Instrument Cluster Components
1 – CLUSTER REAR COVER
2 – CLUSTER HOOD AND MASK
3 – CLUSTER LENS
4 – ODOMETER RESET KNOB BOOT
5 – INSTRUMENT CLUSTER HOUSING
8E - 16 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l the cl uster l ens onto the cl uster hous-
i ng. Refer to Instrument Cluster Components -
Cluster Lens i n the Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(5) I nstal l the i nstrument cl uster onto the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(6) Reconnect the battery negati ve cabl e.
CLUSTER HOUSING REAR COVER
(1) Posi ti on the rear cover to the back of the cl us-
ter housi ng.
(2) Press fi rml y and evenl y on the rear cover unti l
each of the l atches that secure the rear cover to the
cl uster housi ng i s ful l y engaged.
(3) I nstal l the i nstrument cl uster onto the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(4) Reconnect the battery negati ve cabl e.
INSTRUMENT PANEL CENTER BEZEL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the top cover from the i nstrument
panel . Refer to Instrument Panel Top Cover i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(3) Remove the ash recei ver from the ash recei ver
housi ng i n the l ower porti on of the i nstrument panel
center bezel .
(4) Remove the one screw from the back of the ash
recei ver housi ng that secures the l ower porti on of the
center bezel to the i nstrument panel (Fi g. 12).
(5) Remove the two screws that secure the top of
the center bezel to the top of the i nstrument panel .
(6) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the l ower edge of the cen-
ter bezel away from the i nstrument panel .
(7) Pul l the l ower edge of the center bezel away
from the i nstrument panel far enough to di sengage
the four snap cl i p retai ners that secure i t from the
receptacl es i n the i nstrument panel .
(8) Remove the center bezel from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the center bezel to the i nstrument
panel .
(2) Al i gn the snap cl i ps on the center bezel wi th
the receptacl es i n the i nstrument panel .
(3) Press fi rml y on the center bezel over each of
the snap cl i p l ocati ons unti l each of the snap cl i ps i s
ful l y engaged i n i ts receptacl e on the i nstrument
panel .
(4) I nstal l and ti ghten the two screws that secure
the top of the center bezel to the top of the i nstru-
ment panel . Ti ghten the screws to 2.2 N·m (20 i n.
l bs.).
I nstal l and ti ghten the one screw i nto the back of
the ash recei ver housi ng that secures the l ower por-
ti on of the center bezel to the i nstrument panel .
Ti ghten the screw to 2.2 N·m (20 i n. l bs.).
(5) I nstal l the ash recei ver i nto the ash recei ver
housi ng i n the l ower porti on of the i nstrument panel
center bezel .
Fig. 12 Instrument Panel Center Bezel Remove/
Install
1 – INSTRUMENT PANEL
2 – SCREW
3 – SCREW
4 – CENTER BEZEL
5 – ACCESSORY SWITCH BEZEL
TJ INSTRUMENT PANEL SYSTEMS 8E - 17
REMOVAL AND INSTALLATION (Continued)
(6) I nstal l the top cover onto the i nstrument panel .
Refer to Instrument Panel Top Cover i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(7) Reconnect the battery negati ve cabl e.
INSTRUMENT PANEL ACCESSORY SWITCH
BEZEL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the center bezel from the i nstrument
panel . Refer to Instrument Panel Center Bezel i n
the Removal and I nstal l ati on secti on of thi s group for
the procedures.
(3) Remove the four screws that secure the acces-
sory swi tch bezel to the i nstrument panel (Fi g. 13).
(4) Pul l the accessory swi tch bezel away from the
i nstrument panel far enough to access the i nstru-
ment panel wi re harness connectors.
(5) Di sconnect the i nstrument panel wi re harness
connectors from the connector receptacl es, the acces-
sory swi tches and the ci gar l i ghter/power outl et on
the back of the accessory swi tch bezel .
(6) Remove the accessory swi tch bezel from the
i nstrument panel .
INSTALLATION
(1) Posi ti on the accessory swi tch bezel to the
i nstrument panel .
(2) Reconnect the i nstrument panel wi re harness
connectors to the connector receptacl es, the accessory
swi tches and the ci gar l i ghter/power outl et on the
back of the accessory swi tch bezel .
(3) Posi ti on the accessory swi tch bezel onto the
i nstrument panel .
(4) I nstal l and ti ghten the four screws that secure
the accessory swi tch bezel to the i nstrument panel .
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(5) I nstal l the center bezel onto the i nstrument
panel . Refer to Instrument Panel Center Bezel i n
the Removal and I nstal l ati on secti on of thi s group for
the procedures.
(6) Reconnect the battery negati ve cabl e.
ACCESSORY RELAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Reach up under the i nstrument panel outboard
of the steeri ng col umn to access the accessory rel ay
and the accessory rel ay wi re harness connector,
whi ch i s secured to the 100-way wi re harness connec-
tor mounti ng bracket (Fi g. 14).
(3) Di sconnect the accessory rel ay from the acces-
sory rel ay wi re harness connector.
(4) Remove the accessory rel ay from under the
i nstrument panel .
Fig. 13 Instrument Panel Accessory Switch Bezel
Remove/Install
1 – INSTRUMENT PANEL
2 – WIRE HARNESS CONNECTORS
3 – SCREW
4 – CIGAR LIGHTER
5 – ACCESSORY SWITCH BEZEL
8E - 18 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on the accessory rel ay to the accessory
rel ay wi re harness connector under the i nstrument
panel .
(2) Al i gn the termi nal s of the accessory rel ay wi th
the cavi ti es i n the accessory rel ay wi re harness con-
nector.
(3) Push on the accessory rel ay case fi rml y and
evenl y unti l al l of the rel ay termi nal s are ful l y seated
wi thi n the cavi ti es of the accessory rel ay wi re har-
ness connector.
(4) Reconnect the battery negati ve cabl e.
GLOVE BOX
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Rel ease the gl ove box l atch and open the gl ove
box door.
(3) Whi l e supporti ng the gl ove box door wi th one
hand, grasp the check strap as cl ose to the gl ove box
door as possi bl e and sl i de the rol l ed end of the check
strap out of the sl ot i n the edge of the door (Fi g. 15).
(4) Lower the gl ove box door far enough to di sen-
gage the hi nge hook formati ons on the l ower edge of
the door from the hi nge pi ns on the l ower edge of the
i nstrument panel .
(5) Remove the gl ove box from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the gl ove box to the i nstrument panel .
(2) Engage the hi nge hook formati ons on the l ower
edge of the gl ove box door wi th the hi nge pi ns on the
l ower edge of the i nstrument panel .
(3) Ti l t the upper edge of the gl ove box door up
toward the i nstrument panel far enough to engage
the check strap wi th the door.
(4) Whi l e supporti ng the gl ove box door wi th one
hand, grasp the check strap as cl ose to the gl ove box
door as possi bl e and sl i de the rol l ed end of the check
strap i nto the sl ot i n the edge of the door.
(5) Cl ose the gl ove box door.
(6) Reconnect the battery negati ve cabl e.
GLOVE BOX COMPONENTS
Servi ce of al l of the gl ove box components (Fi g. 16)
must be performed wi th the gl ove box removed from
the i nstrument panel .
Fig. 14 Accessory Relay Remove/Install
1 – 100–WAY CONNECTOR
2 – ACCESSORY RELAY
3 – LEFT STEERING COLUMN SUPPORT
4 – SCREW
5 – MOUNTING BRACKET
Fig. 15 Glove Box Remove/Install
1 – GLOVE BOX DOOR
2 – CHECK STRAP
3 – SLOT
TJ INSTRUMENT PANEL SYSTEMS 8E - 19
REMOVAL AND INSTALLATION (Continued)
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
GLOVE BOX DOOR AND BIN
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(3) Remove the screws that secure the gl ove box
l atch and handl e to the gl ove box door.
(4) Remove the screws that secure the i nner door
and bi n uni t to the outer gl ove box door.
(5) Remove the i nner door and bi n uni t from the
outer gl ove box door.
GLOVE BOX CHECK STRAP
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(3) Remove the screw that secures the gl ove box
check strap to the i nstrument panel above the gl ove
box openi ng.
(4) Remove the check strap from the i nstrument
panel .
GLOVE BOX LATCH AND HANDLE
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(3) Remove the four screws that secure the gl ove
box l atch and handl e to the gl ove box door from the
i nsi de of the gl ove box.
(4) Remove the l atch and handl e from the gl ove
box door.
GLOVE BOX LOCK CYLINDER
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(3) Remove the gl ove box l atch and handl e from
the gl ove box. Refer to Glove Box Components -
Glove Box Latch and Handle i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(4) I nsert the key i nto the gl ove box l ock cyl i nder.
(5) I nsert a smal l screwdri ver i nto the retai ni ng
tumbl er rel ease sl ot and depress the retai ni ng tum-
bl er (Fi g. 17).
(6) Pul l the l ock cyl i nder out of the gl ove box l atch
handl e by usi ng a gentl e twi sti ng and pul l i ng acti on
on the key.
Fig. 16 Glove Box Components
1 – GLOVE BOX DOOR AND BIN
2 – SCREW
3 – CHECK STRAP
4 – LATCH AND HANDLE
5 – LOCK CYLINDER
Fig. 17 Glove Box Lock Cylinder Remove/Install
1 – GLOVE BOX LATCH
2 – RELEASE SLOT
3 – SMALL SCREWDRIVER
8E - 20 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
GLOVE BOX DOOR AND BIN
(1) Posi ti on the i nner door and bi n uni t onto the
outer gl ove box door.
(2) I nstal l and ti ghten the screws that secure the
i nner door and bi n uni t to the outer gl ove box door.
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(3) I nstal l and ti ghten the screws that secure the
gl ove box l atch and handl e to the gl ove box door.
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(4) I nstal l the gl ove box onto the i nstrument panel .
Refer to Glove Box i n the Removal and I nstal l ati on
secti on of thi s group for the procedures.
(5) Reconnect and i sol ate the battery negati ve
cabl e.
GLOVE BOX CHECK STRAP
(1) Posi ti on the check strap to the i nstrument
panel .
(2) I nstal l and ti ghten the screw that secures the
gl ove box check strap to the i nstrument panel above
the gl ove box openi ng. Ti ghten the screw to 2.2 N·m
(20 i n. l bs.).
(3) I nstal l the gl ove box onto the i nstrument panel .
Refer to Glove Box i n the Removal and I nstal l ati on
secti on of thi s group for the procedures.
(4) Reconnect the battery negati ve cabl e.
GLOVE BOX LATCH AND HANDLE
(1) Posi ti on the l atch and handl e onto the gl ove
box door.
(2) I nstal l and ti ghten the four screws that secure
the gl ove box l atch and handl e to the gl ove box door
from the i nsi de of the gl ove box. Ti ghten the screws
to 2.2 N·m (20 i n. l bs.).
(3) I nstal l the gl ove box onto the i nstrument panel .
Refer to Glove Box i n the Removal and I nstal l ati on
secti on of thi s group for the procedures.
(4) Reconnect the battery negati ve cabl e.
GLOVE BOX LOCK CYLINDER
(1) I nsert the key i nto the gl ove box l ock cyl i nder.
(2) Push the l ock cyl i nder i nto the gl ove box l atch
handl e by usi ng a gentl e twi sti ng and pushi ng acti on
on the key.
(3) I nstal l the gl ove box l atch and handl e onto the
gl ove box. Refer to Glove Box Components - Glove
Box Latch and Handle i n the Removal and I nstal -
l ati on secti on of thi s group for the procedures.
(4) I nstal l the gl ove box onto the i nstrument panel .
Refer to Glove Box i n the Removal and I nstal l ati on
secti on of thi s group for the procedures.
(5) Reconnect the battery negati ve cabl e.
GLOVE BOX LATCH STRIKER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(3) Remove the two screws that secure the l atch
stri ker to the grab handl e bezel at the top of the
i nstrument panel gl ove box openi ng (Fi g. 18).
(4) Remove the l atch stri ker from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the l atch stri ker onto the i nstrument
panel .
(2) I nstal l and ti ghten the two screws that secure
the l atch stri ker to the grab handl e bezel at the top
of the i nstrument panel gl ove box openi ng. Ti ghten
the screws to 2.2 N·m (20 i n. l bs.).
(3) I nstal l the gl ove box onto the i nstrument panel .
Refer to Glove Box i n the Removal and I nstal l ati on
secti on of thi s group for the procedures.
(4) Reconnect the battery negati ve cabl e.
Fig. 18 Glove Box Latch Striker Remove/Install
1 – MOUNTING SCREWS
2 – STRIKER
TJ INSTRUMENT PANEL SYSTEMS 8E - 21
REMOVAL AND INSTALLATION (Continued)
INSTRUMENT PANEL GRAB HANDLE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n Removal and I nstal l a-
ti on secti on of thi s group for the procedures.
(3) Reach through and above the gl ove box openi ng
to access and remove the two nuts that secure the
stud on each end of the grab handl e to the i nstru-
ment panel (Fi g. 19). Di scard the used grab handl e
mounti ng nuts.
(4) Remove the grab handl e from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the grab handl e onto the i nstrument
panel .
(2) Reach through and above the gl ove box openi ng
to i nstal l and ti ghten the two nuts that secure the
stud on each end of the grab handl e to the i nstru-
ment panel . Ti ghten the nuts to 5.6 N·m (50 i n. l bs.).
(3) I nstal l the gl ove box onto the i nstrument panel .
Refer to Glove Box i n Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(4) Reconnect the battery negati ve cabl e.
INSTRUMENT PANEL GRAB HANDLE BEZEL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the grab handl e from the i nstrument
panel . Refer to Instrument Panel Grab Handle i n
the Removal and I nstal l ati on secti on of thi s group for
the procedures.
(3) Remove the gl ove box l atch stri ker from the
i nstrument panel . Refer to Glove Box Latch
Striker i n the Removal and I nstal l ati on secti on of
thi s group for the procedures.
(4) Remove the two screws that secure the grab
handl e bezel to the i nstrument panel (Fi g. 20).
(5) Remove the grab handl e bezel from the i nstru-
ment panel .
INSTALLATION
(1) Posi ti on the grab handl e bezel onto the i nstru-
ment panel .
(2) I nstal l and ti ghten the two screws that secure
the grab handl e bezel to the i nstrument panel .
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(3) I nstal l the gl ove box l atch stri ker onto the
i nstrument panel . Refer to Glove Box Latch
Striker i n the Removal and I nstal l ati on secti on of
thi s group for the procedures.
(4) I nstal l the grab handl e onto the i nstrument
panel . Refer to Instrument Panel Grab Handle i n
Fig. 19 Instrument Panel Grab Handle Remove/
Install
1 – NUTS
2 – GLOVE BOX OPENING
3 – PASSENGER’S AIRBAG MODULE
Fig. 20 Instrument Panel Grab Handle Bezel
Remove/Install
1 – BEZEL
2 – MOUNTING SCREWS
3 – GRAB HANDLE
4 – STRIKER
8E - 22 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
the Removal and I nstal l ati on secti on of thi s group for
the procedures.
(5) Reconnect the battery negati ve cabl e.
INSTRUMENT PANEL ASSEMBLY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel . Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(3) Remove the steeri ng col umn from the vehi cl e,
but do not remove the dri ver si de ai rbag modul e, the
steeri ng wheel , or the swi tches from the steeri ng col -
umn. Be certai n that the steeri ng wheel i s l ocked
and secured from rotati on to prevent the l oss of
cl ockspri ng centeri ng. Refer to Steering Column i n
the Removal and I nstal l ati on secti on of Group 19 -
Steeri ng for the procedures.
(4) From under the dri ver si de of the i nstrument
panel , perform the fol l owi ng:
(a) Di sconnect the i nstrument panel wi re har-
ness connectors from the 100-way wi re harness
connector near the l eft cowl si de i nner panel .
(b) Di sconnect the si de wi ndow demi ster hose at
the heater-A/C housi ng demi ster/defroster duct
(dri ver si de).
(5) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(6) Reach through the i nstrument panel gl ove box
openi ng to perform the fol l owi ng:
(a) Di sconnect the two hal ves of the heater-A/C
system vacuum harness connector.
(b) Di sconnect the i nstrument panel wi re har-
ness connector from the heater-A/C system wi re
harness connector.
(c) Di sconnect the i nstrument panel wi re har-
ness connector from the passenger si de ai rbag
modul e wi re harness connector.
(d) Di sconnect the si de wi ndow demi ster hose at
the heater-A/C housi ng demi ster/defroster duct
(passenger si de).
(e) Di sconnect the two hal ves of the radi o
antenna coaxi al cabl e connector.
(f) Di sconnect the two i nstrument panel wi re
harness connectors from the passenger ai rbag
on/off swi tch wi re harness connectors.
(g) Di sengage the passenger si de ai rbag on/off
swi tch wi re harness from the retai ner cl i p on the
pl enum bracket that supports the heater-A/C hous-
i ng just i nboard of the fusebl ock modul e.
(h) Remove the two nuts that secure the l ower
passenger si de ai rbag modul e bracket to the studs
on the dash panel (Fi g. 21).
(7) Remove the top cover from the i nstrument
panel . Refer to Instrument Panel Top Cover i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(8) Remove the three screws that secure each end
of the i nstrument panel to the door hi nge pi l l ars (Fi g.
22).
(9) Remove the four nuts that secure the top of the
i nstrument panel to the studs on the top of the dash
panel .
(10) Wi th the ai d of an assi stant, l i ft the i nstru-
ment panel assembl y off of the dash panel studs and
remove i t from the vehi cl e.
INSTALLATION
(1) Wi th the ai d of an assi stant, i nstal l the i nstru-
ment panel assembl y onto the dash panel studs i n
the vehi cl e.
Fig. 21 Passenger Airbag Module Lower Bracket
Nuts Remove/Install
1 – GRAB HANDLE
2 – NUT
3 – GLOVE BOX OPENING
4 – LOWER AIRBAG BRACKET
TJ INSTRUMENT PANEL SYSTEMS 8E - 23
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l and ti ghten the four nuts that secure
the top of the i nstrument panel to the studs on the
top of the dash panel . Ti ghten the nuts to 12 N·m
(105 i n. l bs.).
(3) I nstal l and ti ghten the three screws that secure
each end of the i nstrument panel to the door hi nge
pi l l ars. Ti ghten the screws to 12 N·m (105 i n. l bs.).
(4) I nstal l the top cover onto the i nstrument panel .
Refer to Instrument Panel Top Cover i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(5) Reach through the i nstrument panel gl ove box
openi ng to perform the fol l owi ng:
(a) I nstal l and ti ghten the two nuts that secure
the l ower passenger si de ai rbag modul e bracket to
the studs on the dash panel . Ti ghten the nuts to 28
N·m (250 i n. l bs.).
(b) Engage the passenger si de ai rbag on/off
swi tch wi re harness i n the retai ner cl i p on the pl e-
num bracket that supports the heater-A/C housi ng
just i nboard of the fusebl ock modul e.
(c) Reconnect the two i nstrument panel wi re
harness connectors to the passenger ai rbag on/off
swi tch wi re harness connectors.
(d) Reconnect the two hal ves of the radi o
antenna coaxi al cabl e connector.
(e) Reconnect the si de wi ndow demi ster hose to
the heater-A/C housi ng demi ster/defroster duct
(passenger si de).
(f) Reconnect the i nstrument panel wi re harness
connector to the passenger si de ai rbag modul e wi re
harness connector.
(g) Reconnect the i nstrument panel wi re harness
connector to the heater-A/C system wi re harness
connector.
(h) Reconnect the two hal ves of the heater-A/C
system vacuum harness connector.
(6) I nstal l the gl ove box onto the i nstrument panel .
Refer to Glove Box i n the Removal and I nstal l ati on
secti on of thi s group for the procedures.
(7) From under the dri ver si de of the i nstrument
panel , perform the fol l owi ng:
(a) Reconnect the si de wi ndow demi ster hose to
the heater-A/C housi ng demi ster/defroster duct
(dri ver si de).
(b) Reconnect the i nstrument panel wi re harness
connectors to the 100-way wi re harness connector
near the l eft cowl si de i nner panel .
(8) I nstal l the steeri ng col umn i nto the vehi cl e. Be
certai n that the steeri ng wheel i s l ocked and secured
from rotati on to prevent the l oss of cl ockspri ng cen-
teri ng. Refer to Steering Column i n the Removal
and I nstal l ati on secti on of Group 19 - Steeri ng for
the procedures.
(9) I nstal l the knee bl ocker onto the i nstrument
panel . Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(10) Reconnect the battery negati ve cabl e.
INSTRUMENT PANEL BASE TRIM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(3) Remove the accessory swi tch bezel from the
i nstrument panel . Refer to Instrument Panel
Accessory Switch Bezel i n the Removal and I nstal -
l ati on secti on of thi s group for the procedures.
(4) Remove the grab handl e bezel from the i nstru-
ment panel . Refer to Instrument Panel Grab Han-
dle Bezel i n the Removal and I nstal l ati on secti on of
thi s group for the procedures.
(5) Remove the speaker bezel s from the i nstru-
ment panel . Refer to Instrument Panel Speakers
i n the Removal and I nstal l ati on secti on of Group 8F -
Audi o Systems for the procedures.
Fig. 22 Instrument Panel Assembly Remove/Install
1 – STUDS
2 – NUT
3 – SCREW
8E - 24 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(6) Remove the radi o from the i nstrument panel .
Refer to Radio i n the Removal and I nstal l ati on sec-
ti on of Group 8F - Audi o Systems for the procedures.
(7) Remove the heater-A/C control from the i nstru-
ment panel . Refer to Heater-A/C Control i n the
Removal and I nstal l ati on secti on of Group 24 - Heat-
i ng and Ai r Condi ti oni ng Systems for the procedures.
(8) Remove the outboard heater-A/C panel outl ets
from the i nstrument panel . Refer to Ducts and Out-
lets i n the Removal and I nstal l ati on secti on of Group
24 - Heati ng and Ai r Condi ti oni ng Systems for the
procedures.
(9) Remove the i nstrument panel assembl y from
the vehi cl e. Refer to Instrument Panel Assembly
i n the Removal and I nstal l ati on secti on of thi s group
for the procedures.
(10) Pl ace the i nstrument panel on a sui tabl e work
surface. Be certai n to take the proper precauti ons to
protect the i nstrument panel from any possi bl e cos-
meti c damage.
(11) Remove the passenger si de ai rbag door from
the i nstrument panel . Refer to Passenger Side Air-
bag Door i n the Removal and I nstal l ati on secti on of
Group 8M - Passi ve Restrai nt Systems for the proce-
dures.
(12) Remove the two screws that secure the
16-way data l i nk wi re harness connector to the
i nstrument panel .
(13) Remove the screws around the peri meter that
secure the base tri m to the i nstrument panel .
(14) Remove the base tri m from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the base tri m onto the i nstrument
panel .
(2) I nstal l and ti ghten the screws around the
peri meter that secure the base tri m to the i nstru-
ment panel . Ti ghten the screws to 2.2 N·m (20 i n.
l bs.).
(3) I nstal l and ti ghten the two screws that secure
the 16-way data l i nk wi re harness connector to the
i nstrument panel . Ti ghten the screws to 2.2 N·m (20
i n. l bs.).
(4) I nstal l the passenger si de ai rbag door onto the
i nstrument panel . Refer to Passenger Side Airbag
Door i n the Removal and I nstal l ati on secti on of
Group 8M - Passi ve Restrai nt Systems for the proce-
dures.
(5) I nstal l the i nstrument panel assembl y i nto the
vehi cl e. Refer to Instrument Panel Assembly i n
the Removal and I nstal l ati on secti on of thi s group for
the procedures.
(6) I nstal l the outboard heater-A/C panel outl ets
onto the i nstrument panel . Refer to Ducts and Out-
lets i n the Removal and I nstal l ati on secti on of Group
24 - Heati ng and Ai r Condi ti oni ng Systems for the
procedures.
(7) I nstal l the heater-A/C control onto the i nstru-
ment panel . Refer to Heater-A/C Control i n the
Removal and I nstal l ati on secti on of Group 24 - Heat-
i ng and Ai r Condi ti oni ng Systems for the procedures.
(8) I nstal l the radi o onto the i nstrument panel .
Refer to Radio i n the Removal and I nstal l ati on sec-
ti on of Group 8F - Audi o Systems for the procedures.
(9) I nstal l the speaker bezel s onto the i nstrument
panel . Refer to Instrument Panel Speakers i n the
Removal and I nstal l ati on secti on of Group 8F - Audi o
Systems for the procedures.
(10) I nstal l the grab handl e bezel onto the i nstru-
ment panel . Refer to Instrument Panel Grab Han-
dle Bezel i n the Removal and I nstal l ati on secti on of
thi s group for the procedures.
(11) I nstal l the accessory swi tch bezel onto the
i nstrument panel . Refer to Instrument Panel
Accessory Switch Bezel i n the Removal and I nstal -
l ati on secti on of thi s group for the procedures.
(12) I nstal l the i nstrument cl uster onto the i nstru-
ment panel . Refer to Instrument Cluster i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
(13) Reconnect the battery negati ve cabl e.
TJ INSTRUMENT PANEL SYSTEMS 8E - 25
REMOVAL AND INSTALLATION (Continued)
INSTRUMENT PANEL SYSTEMS
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
HEADLAMP LEVELING SWITCH. . . . . . . . . . . . . . 1
REAR FOG LAMP SWITCH. . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
HEADLAMP LEVELING SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Usi ng a fl at bl ade screwdri ver or si mi l ar tool
between the headl amp l evel i ng swi tch and the steer-
i ng col umn cover (Fi g. 1). Gentl y pry the headl amp
l evel i ng swi tch out of the steeri ng col umn cover.
(2) Di sconnect the headl amp l evel i ng swi tch el ec-
tri cal connector (Fi g. 2) and remove the headl amp
l evel i ng swi tch.
INSTALLATION
(1) Connect the headl amp l evel i ng swi tch el ectri cal
connector.
(2) I nstal l the headl amp l evel i ng swi tch i nto the
steeri ng col umn cover.
Fig. 1 Headlamp Leveling Switch
1 – HEADLAMP LEVELING SWITCH
2 – I/P CENTER BEZEL
3 – STEERING COLUMN COVER
TJ INSTRUMENT PANEL SYSTEMS 8E - 1
2000 JEEP WRANGLER
REAR FOG LAMP SWITCH
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Usi ng a fl at bl ade screwdri ver or si mi l ar fl at-
bl aded tool , gentl y pry the i nstrument panel top
cover up and away from the i nstrument panel to
rel ease the snap cl i p retai ners (Fi g. 3).
(2) Remove the i nstrument panel top cover from
the vehi cl e.
(3) Remove the ash recei ver from the center bezel .
(4) Remove the screw l ocated i n back of the ash
recei ver housi ng that secures the center bezel to the
l ower i nstrument panel (Fi g. 4).
(5) Remove the screws that secure the center bezel
to the top of the i nstrument panel (Fi g. 5).
(6) Remove the i nstrument panel center bezel .
Fig. 2 Headlamp Leveling Switch Electrical
Connector
1 – I/P CENTER BEZEL
2 – HEADLAMP LEVELING SWITCH ELECTRICAL CONNECTOR
3 – STEERING COLUMN COVER
4 – HEADLAMP LEVELING SWITCH
Fig. 3 Instrument Panel Top Cover
1 – INSTRUMENT PANEL TOP COVER
2 – INSTRUMENT PANEL
Fig. 4 Center Bezel Lower Screw
1 – INSTRUMENT PANEL
2 – SCREW
3 – SCREW
4 – CENTER BEZEL
5 – ACCESSORY SWITCH BEZEL
8E - 2 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP WRANGLER
(7) Remove the screws attachi ng the accessory
swi tch bezel to the i nstrument panel .
(8) Di sconnect the rear fog l amp swi tch el ectri cal
connector.
(9) Remove the rear fog l amp swi tch from the
accessory swi tch bezel .
INSTALLATION
(1) I nstal l the rear fog l amp swi tch to the acces-
sory swi tch bezel .
(2) Connect the rear fog l amp swi tch el ectri cal con-
nector to the swi tch.
(3) I nstal l the screws attachi ng the accessory
swi tch bezel to the i nstrument panel .
(4) I nstal l the i nstrument panel center bezel and
attachi ng screws.
(5) I nstal l the ash recei ver.
(6) I nstal l the i nstrument panel top cover.
Fig. 5 Center Bezel Mounting Screws
1 – I/P CENTER BEZEL MOUNTING SCREWS
2 – INSTRUMENT PANEL
3 – I/P CENTER BEZEL
TJ INSTRUMENT PANEL SYSTEMS 8E - 3
REMOVAL AND INSTALLATION (Continued)
2000 JEEP WRANGLER
2000 JEEP WRANGLER
AUDIO SYSTEMS
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . . . 1
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
RADIO NOISE SUPPRESSION . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2
RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RADIO FREQUENCY INTERFERENCE. . . . . . . . . . 6
REMOVAL AND INSTALLATION
RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SOUND BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RADIO NOISE SUPPRESSION COMPONENTS. . 10
GENERAL INFORMATION
INTRODUCTION
An audi o system i s standard factory-i nstal l ed
equi pment on thi s model , unl ess the vehi cl e i s
ordered wi th an avai l abl e radi o del ete opti on. Refer
to 8W-47 - Audi o System i n Group 8W - Wi ri ng Di a-
grams for compl ete ci rcui t descri pti ons and di agrams.
DESCRIPTION AND OPERATION
RADIO
Avai l abl e factory-i nstal l ed radi o recei vers for thi s
model i ncl ude an AM/FM (RAL sal es code), an
AM/FM/cassette (RAS sal es code) and an AM/FM/CD/
cassette/3-band graphi c equal i zer (RAZ sal es code).
Al l factory-i nstal l ed radi o recei vers are stereo El ec-
troni cal l y Tuned Radi os (ETR), and i ncl ude an el ec-
troni c di gi tal cl ock functi on.
Model s equi pped wi th the RAZ sal es code radi o
recei ver al so i ncl ude a CD radi o bracket, whi ch pro-
vi des addi ti onal support to the radi o to reduce CD
ski ppi ng. The two ends of thi s formed wi re bracket
fi t over the top of two of the wel d-studs that secure
the i nstrument panel to the dash panel bel ow the
wi ndshi el d. The radi o ground strap screw i s then
i nstal l ed through a tab wel ded to the center of the
CD bracket, through the radi o ground strap and i nto
the back of the radi o recei ver chassi s to securel y
anchor the back of the radi o recei ver.
The radi o can onl y be servi ced by an authori zed
radi o repai r stati on. Refer to the l atest Warranty Pol -
i ci es and Procedures manual for a current l i sti ng of
authori zed radi o repai r stati ons.
For more i nformati on on radi o features, setti ng
procedures, and control functi ons refer to the owner’s
manual i n the vehi cl e gl ove box.
IGNITION-OFF DRAW FUSE
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse that i s removed when the vehi cl e i s
shi pped from the factory. Thi s fuse feeds vari ous
accessori es that requi re battery current when the
i gni ti on swi tch i s i n the Off posi ti on, i ncl udi ng the
cl ock and radi o stati on preset memory functi ons. The
fuse i s removed to prevent battery di scharge duri ng
vehi cl e storage.
When removi ng or i nstal l i ng the I OD fuse, i t i s
i mportant that the i gni ti on swi tch be i n the Off posi -
ti on. Fai l ure to pl ace the i gni ti on swi tch i n the Off
posi ti on can cause the radi o di spl ay to become scram-
bl ed when the I OD fuse i s removed and repl aced.
Removi ng and repl aci ng the I OD fuse agai n, wi th the
i gni ti on swi tch i n the Off posi ti on, wi l l correct the
scrambl ed di spl ay condi ti on.
The I OD fuse shoul d be checked i f the radi o i s
i noperati ve. The I OD fuse i s l ocated i n the Power
Di stri buti on Center (PDC). Refer to the PDC l abel for
I OD fuse i denti fi cati on and l ocati on.
SPEAKER
The standard equi pment speaker system i ncl udes
four ful l -range speakers. The two front speakers are
mounted behi nd a removabl e bezel l ocated on each
outboard end of the l ower i nstrument panel . The two
rear speakers are mounted behi nd a gri l l e l ocated on
each outboard end of the sound bar, whi ch i s
attached from si de-to-si de to the sport bar above the
rear seati ng area of the vehi cl e.
TJ AUDIO SYSTEMS 8F - 1
ANTENNA
Al l model s use a bl ack pai nted fi xed-l ength stai n-
l ess steel rod-type antenna mast, i nstal l ed on the
ri ght front cowl si de panel of the vehi cl e. The
antenna mast i s connected to the center wi re of the
coaxi al antenna cabl e, and i s not grounded to any
part of the vehi cl e.
To el i mi nate stati c, the antenna base must have a
good ground. The antenna coaxi al cabl e shi el d (the
outer wi re mesh of the cabl e) i s grounded to the
antenna base and the radi o chassi s.
The antenna coaxi al cabl e has an addi ti onal di s-
connect, l ocated behi nd the ri ght end of the i nstru-
ment panel between the radi o and the ri ght cowl si de
panel . Thi s addi ti onal di sconnect al l ows the i nstru-
ment panel assembl y to be removed and i nstal l ed
wi thout removi ng the radi o.
The factory-i nstal l ed El ectroni cal l y Tuned Radi os
(ETRs) automati cal l y compensate for radi o antenna
tri m. Therefore, no antenna tri mmer adjustment i s
requi red or possi bl e when repl aci ng the recei ver or
the antenna.
RADIO NOISE SUPPRESSION
DESCRIPTION
Radi o Frequency I nterference (RFI ) and El ectro-
Magneti c I nterference (EMI ) noi se suppressi on i s
accompl i shed pri mari l y through ci rcui try i nternal to
the radi o recei vers. These i nternal suppressi on
devi ces are onl y servi ced as part of the radi o recei ver.
External suppressi on devi ces that are used on thi s
vehi cl e to control RFI or EMI noi se i ncl ude the fol -
l owi ng:
• Radi o antenna base ground
• Radi o recei ver chassi s ground wi re or strap
• Engi ne-to-body ground strap
• Engi ne-to-frame ground strap
• Resi stor-type spark pl ugs
• Radi o suppressi on-type secondary i gni ti on wi r-
i ng.
For more i nformati on on the spark pl ugs and sec-
ondary i gni ti on components, refer to Ignition Sys-
tem i n the Descri pti on and Operati on secti on of
Group 8D - I gni ti on System.
DIAGNOSIS AND TESTING
AUDIO SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
8F - 2 AUDIO SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
Audio System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
6. Speakers faulty.
1. Check radio fuse and Ignition-Off Draw fuse in Power
Distribution Center. Replace fuses, if required.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Exchange or replace radio, if required.
6. See speaker diagnosis, in this group.
NO DISPLAY. 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
1. Check radio fuse and Ignition-Off Draw fuse in Power
Distribution Center. Replace fuses, if required.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Exchange or replace radio, if required.
CLOCK WILL
NOT KEEP SET
TIME.
1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
1. Check ignition-off draw fuse. Replace fuse, if required.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Exchange or replace radio, if required.
POOR RADIO
RECEPTION.
1. Antenna faulty.
2. Ground faulty.
3. Radio faulty.
1. See antenna diagnosis, in this group. Repair or replace
antenna, if required.
2. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required..
3. Exchange or replace radio, if required.
NO/POOR TAPE
OPERATION.
1. Faulty tape.
2. Foreign objects behind
tape door.
3. Dirty cassette tape
head.
4. Faulty tape deck.
1. Insert known good tape and test operation.
2. Remove foreign objects and test operation.
3. Clean head with Mopar Cassette Head Cleaner.
4. Exchange or replace radio, if required.
NO COMPACT
DISC
OPERATION
1. Faulty CD.
2. Foreign material on
CD.
3. Condensation on CD
or optics.
4. Faulty CD player.
1. Insert known good CD and test operation.
2. Clean CD and test operation.
3. Allow temperature of vehicle interior to stabilize and test
operation.
4. Exchange or replace radio, if required.
TJ AUDIO SYSTEMS 8F - 3
DIAGNOSIS AND TESTING (Continued)
RADIO
For ci rcui t descri pti ons and di agrams, refer to
8W-47 - Audi o System i n Group 8W - Wi ri ng Di a-
grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: The speaker output of the radio is a
“floating ground” system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
(1) Check the radi o fuse and the I gni ti on-Off Draw
(I OD) fuse i n the Power Di stri buti on Center (PDC).
I f OK, go to Step 2. I f not OK, repai r the shorted ci r-
cui t or component as requi red and repl ace the faul ty
fuse(s).
(2) Check for battery vol tage at the radi o fuse and
the I OD fuse i n the PDC. I f OK, go to Step 3. I f not
OK, repai r the open ci rcui t to the battery and/or the
i gni ti on swi tch as requi red.
(3) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the radi o, but do not unpl ug the radi o
wi re harness connectors. Check for conti nui ty
between the radi o chassi s and a good ground. There
shoul d be conti nui ty. I f OK, go to Step 4. I f not OK,
repai r the open radi o chassi s ground ci rcui t as
requi red.
(4) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (accesso-
ry/run) ci rcui t cavi ty of the l eft (gray) radi o wi re har-
ness connector. I f OK, go to Step 5. I f not OK, repai r
the open ci rcui t as requi red.
(5) Turn the i gni ti on swi tch to the Off posi ti on.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the l eft (gray) radi o wi re harness connector.
I f OK, repl ace the faul ty radi o. I f not OK, repai r the
open ci rcui t to the I gni ti on-Off Draw (I OD) fuse as
requi red.
SPEAKER
For ci rcui t descri pti ons and di agrams, refer to
8W-47 - Audi o System i n Group 8W - Wi ri ng Di a-
grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: The speaker output of the radio is a
“floating ground” system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
(1) Turn the i gni ti on swi tch to the On posi ti on.
Turn the radi o on. Adjust the bal ance and fader con-
trol s to check the performance of each i ndi vi dual
speaker. Note the speaker l ocati ons that are not per-
formi ng correctl y. Go to Step 2.
(2) Turn the radi o off. Di sconnect and i sol ate the
battery negati ve cabl e. Remove the radi o. Unpl ug the
wi re harness connectors at the radi o. Check both the
speaker feed (+) ci rcui t and return (–) ci rcui t cavi ti es
for the i noperati ve speaker l ocati on(s) at the radi o
wi re harness connectors for conti nui ty to ground. I n
each case, there shoul d be no conti nui ty. I f OK, go to
Step 4. I f not OK, go to Step 3.
(3) Leave the radi o wi re harness connectors
unpl ugged. Unpl ug the wi re harness connector at the
i noperati ve speaker. Check both the speaker feed (+)
ci rcui t and return (–) ci rcui t cavi ti es of the speaker
wi re harness connector for conti nui ty to ground. I n
each case, there shoul d be no conti nui ty. I f OK,
repl ace the shorted speaker. I f not OK, repai r the
shorted ci rcui t as requi red.
(4) Pl ug i n the speaker wi re harness connector.
Check the resi stance between the speaker feed (+)
ci rcui t and return (–) ci rcui t cavi ti es of the radi o wi re
harness connectors for the i noperati ve speaker l oca-
ti on(s). The meter shoul d read between 3 and 8 ohms
(speaker resi stance). I f OK, go to Step 5. I f not OK,
go to Step 6.
(5) I nstal l a known good radi o. Connect the bat-
tery negati ve cabl e. Turn the i gni ti on swi tch to the
On posi ti on. Turn on the radi o and test the speaker
operati on. I f OK, repl ace the faul ty radi o. I f not OK,
repl ace the faul ty speaker.
(6) Turn the radi o off. Turn the i gni ti on swi tch to
the Off posi ti on. Di sconnect and i sol ate the battery
negati ve cabl e. Remove the test radi o. Unpl ug the
speaker wi re harness connector at the i noperati ve
speaker. Check the resi stance between the speaker
8F - 4 AUDIO SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
feed (+) ci rcui t cavi ti es of the radi o wi re harness con-
nector and the speaker wi re harness connector.
Repeat the check between the speaker return (–) ci r-
cui t cavi ti es of the radi o wi re harness connector and
the speaker wi re harness connector. I n each case,
there shoul d be no measurabl e resi stance. I f OK,
repl ace the faul ty speaker. I f not OK, repai r the
speaker wi re harness ci rcui t(s) as requi red.
ANTENNA
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
• Test 1 - Mast to ground test
• Test 2 - Ti p-of-mast to ti p-of-conductor test
• Test 3 - Body ground to battery ground test
• Test 4 - Body ground to coaxi al shi el d test.
The ohmmeter test l ead connecti ons for each test
are shown i n Antenna Tests (Fi g. 1).
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the
coaxial cable connection under the right end of the
instrument panel near the right cowl side inner
panel to the antenna base, and then from the coax-
ial cable connection to the radio chassis connec-
tion.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from the base. Proceed as fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s and i sol ate.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
antenna base. Check for conti nui ty.
(3) There shoul d be no conti nui ty. I f conti nui ty i s
found, repl ace the faul ty or damaged antenna base
and cabl e assembl y.
TEST 2
Test 2 checks the antenna for an open ci rcui t as
fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
center pi n of the antenna coaxi al cabl e connector.
(3) Conti nui ty shoul d exi st (the ohmmeter shoul d
onl y regi ster a fracti on of an ohm). Hi gh or i nfi ni te
resi stance i ndi cates damage to the base and cabl e
assembl y. Repl ace the faul ty base and cabl e, i f
requi red.
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. Thi s test shoul d be performed
wi th the battery posi ti ve cabl e removed from the bat-
tery. Di sconnect both battery cabl es, the negati ve
cabl e fi rst. Reconnect the battery negati ve cabl e and
perform the test as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the battery
negati ve post.
(2) The resi stance shoul d be l ess than one ohm.
(3) I f the resi stance i s more than one ohm, check
the brai ded ground strap connected to the engi ne and
the vehi cl e body for bei ng l oose, corroded, or dam-
aged. Repai r the ground strap connecti on, i f requi red.
TEST 4
Test 4 checks the condi ti on of the ground between
the antenna base and the vehi cl e body as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the outer cri mp
on the antenna coaxi al cabl e connector.
(2) The resi stance shoul d be l ess then one ohm.
(3) I f the resi stance i s more then one ohm, cl ean
and/or ti ghten the antenna base to fender mounti ng
hardware.
Fig. 1 Antenna Tests
TJ AUDIO SYSTEMS 8F - 5
DIAGNOSIS AND TESTING (Continued)
RADIO FREQUENCY INTERFERENCE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
For compl ete ci rcui t di agrams, see Group 8W -
Wi ri ng Di agrams. I nspect the ground paths and con-
necti ons at the fol l owi ng l ocati ons:
• Bl ower motor
• El ectri c fuel pump
• Engi ne-to-body ground strap
• Engi ne-to-frame ground strap
• Generator
• I gni ti on modul e
• Radi o antenna base ground
• Radi o recei ver chassi s ground wi re or strap
• Wi per motor.
I f the source of RFI or EMI noi se i s i denti fi ed as a
component on the vehi cl e (i .e., generator, bl ower
motor, etc.), the ground path for that component
shoul d be checked. I f excessi ve resi stance i s found i n
any ground ci rcui t, cl ean, ti ghten, or repai r the
ground ci rcui ts or connecti ons to ground as requi red
before consi deri ng any component repl acement.
For servi ce and i nspecti on of secondary i gni ti on
components, refer to the Di agnosi s and Testi ng sec-
ti on of Group 8D - I gni ti on Systems. I nspect the fol -
l owi ng secondary i gni ti on system components:
• Di stri butor cap and rotor
• I gni ti on coi l
• Spark pl ugs
• Spark pl ug wi re routi ng and condi ti on.
Reroute the spark pl ug wi res or repl ace the faul ty
components as requi red.
I f the source of the RFI or EMI noi se i s i denti fi ed
as two-way mobi l e radi o or tel ephone equi pment,
check the equi pment i nstal l ati on for the fol l owi ng:
• Power connecti ons shoul d be made di rectl y to
the battery, and fused as cl osel y to the battery as
possi bl e.
• The antenna shoul d be mounted on the roof or
toward the rear of the vehi cl e. Remember that mag-
neti c antenna mounts on the roof panel can adversel y
affect the operati on of an overhead consol e compass,
i f the vehi cl e i s so equi pped.
• The antenna cabl e shoul d be ful l y shi el ded coax-
i al cabl e, shoul d be as short as i s practi cal , and
shoul d be routed away from the factory-i nstal l ed
vehi cl e wi re harnesses whenever possi bl e.
• The antenna and cabl e must be careful l y
matched to ensure a l ow Standi ng Wave Rati o
(SWR).
Fl eet vehi cl es are avai l abl e wi th an extra-cost RFI -
suppressed Powertrai n Control Modul e (PCM). Thi s
uni t reduces i nterference generated by the PCM on
some radi o frequenci es used i n two-way radi o com-
muni cati ons. However, thi s uni t wi l l not resol ve com-
pl ai nts of RFI i n the commerci al AM or FM radi o
frequency ranges.
REMOVAL AND INSTALLATION
RADIO
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument panel top cover from
the i nstrument panel . Refer to I nstrument Panel Top
Cover i n Group 8E - I nstrument Panel Systems for
the procedures.
(3) Remove the ash recei ver from the ash recei ver
housi ng i n the l ower i nstrument panel center bezel .
(4) Remove the one screw l ocated i n the back of
the ash recei ver housi ng that secures the center
bezel to the l ower i nstrument panel (Fi g. 2).
8F - 6 AUDIO SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
(5) Remove the two screws that secure the center
bezel to the top of the i nstrument panel .
(6) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the l ower edge of the cen-
ter bezel away from the i nstrument panel .
(7) Li ft the l ower edge of the center bezel upwards
to rel ease the four snap cl i p retai ners that secure i t
to the i nstrument panel .
(8) Remove the center bezel from the i nstrument
panel .
(9) Remove the two screws that secure the radi o to
the i nstrument panel (Fi g. 3).
(10) I f the vehi cl e i s equi pped wi th the CD radi o
recei ver, go to Step 11. I f the vehi cl e i s not equi pped
wi th the CD radi o recei ver, go to Step 13.
(11) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n the i ndex of thi s ser-
vi ce manual for the l ocati on of the proper gl ove box
removal and i nstal l ati on procedures.
(12) Reach through the i nstrument panel gl ove box
openi ng to access and remove the screw that secures
the CD radi o bracket and the ground strap to the
back of the radi o recei ver chassi s (Fi g. 4).
(13) Pul l the radi o out from the i nstrument panel
far enough to access the wi re harness connectors and
the antenna coaxi al cabl e connector (Fi g. 4).
(14) Unpl ug the wi re harness connectors and the
antenna coaxi al cabl e connector from the rear of the
radi o.
(15) I f the vehi cl e i s not equi pped wi th the CD
radi o recei ver, remove the screw that secures the
ground strap to the back of the radi o recei ver chas-
si s.
(16) Remove the radi o from the i nstrument panel .
(17) Reverse the removal procedures to i nstal l .
Ti ghten the radi o mounti ng screws to 5 N·m (45 i n.
l bs.). Ti ghten the radi o recei ver ground strap screw
to 5.6 N·m (50 i n. l bs.). Ti ghten the i nstrument panel
center bezel mounti ng screws to 2.2 N·m (20 i n. l bs.).
Fig. 2 Center Bezel Remove/Install
1 – INSTRUMENT PANEL
2 – SCREW
3 – SCREW
4 – CENTER BEZEL
5 – ACCESSORY SWITCH BEZEL
Fig. 3 Radio Remove/Install
1 – MOUNTING SCREWS
Fig. 4 Radio Connections - Typical
1 – RADIO RECEIVER
2 – INSTRUMENT PANEL WIRE HARNESS
3 – CD RADIO BRACKET
4 – SCREW
5 – GROUND STRAP
6 – ANTENNA CABLE
TJ AUDIO SYSTEMS 8F - 7
REMOVAL AND INSTALLATION (Continued)
SPEAKER
INSTRUMENT PANEL SPEAKER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the two screws that secure the out-
board end of the speaker bezel to the i nstrument
panel (Fi g. 5).
(3) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry at the top and bottom
edges of the speaker bezel to rel ease the two snap
cl i p retai ners that secure the bezel to the i nstrument
panel .
(4) Remove the speaker bezel from the i nstrument
panel .
(5) Remove the four screws that secure the
speaker to the i nstrument panel armature (Fi g. 6).
(6) Pul l the speaker away from the i nstrument
panel far enough to access the speaker wi re harness
connector.
(7) Unpl ug the wi re harness connector from the
speaker.
(8) Remove the speaker from the i nstrument
panel .
(9) Reverse the removal procedures to i nstal l .
Ti ghten the speaker mounti ng screws to 1.1 N·m (10
i n. l bs.). Ti ghten the speaker bezel mounti ng screws
to 2.2 N·m (20 i n. l bs.).
SOUND BAR SPEAKER
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the four screws that secure the
speaker gri l l e and speaker to the sound bar.
(3) Lower the speaker and gri l l e from the sound
bar far enough to access the speaker wi re harness
connector.
(4) Unpl ug the wi re harness connector from the
speaker.
(5) Remove the speaker and gri l l e from the sound
bar as a uni t.
(6) Remove the speaker gri l l e from the speaker.
(7) Reverse the removal procedures to i nstal l .
Ti ghten the mounti ng screws to 1.1 N·m (10 i n. l bs.).
SOUND BAR
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) I f the vehi cl e i s equi pped wi th the opti onal
hard top, remove the hard top from the vehi cl e. Refer
to Hard Top i n Group 23 - Body for the procedures.
(3) I f the vehi cl e i s equi pped wi th the standard
soft top, l ower the soft top. Refer to Fol di ng Down
the Fabri c Top i n the Owner’s Manual for the proce-
dures.
(4) Rel ease the hook and l oop cl osure on each out-
board end fl ap of the sound bar tri m cover.
Fig. 5 Instrument Panel Speaker Bezel Remove/
Install
1 – PRY HERE
2 – SPEAKER BEZEL
3 – PRY HERE
4 – MOUNTING SCREWS
Fig. 6 Instrument Panel Speaker Remove/Install
1 – INSTRUMENT PANEL
2 – SPEAKER
3 – SCREW
8F - 8 AUDIO SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(5) Li ft the l eft outboard end fl ap of the sound bar
tri m cover over the top of the sport bar far enough to
access the wi re harness connector (Fi g. 7).
(6) Unpl ug the sound bar wi re harness connector.
(7) Li ft each outboard end fl ap of the sound bar
cover over the top of the sport bar far enough to
access the mounti ng screws (Fi g. 8).
(8) Remove the two screws that secure each end of
the sound bar to the sport bar.
(9) Li ft the sound bar up off of the sport bar to
remove i t from the vehi cl e.
(10) Reverse the removal procedures to i nstal l .
Ti ghten the sound bar mounti ng screws to 11 N·m
(100 i n. l bs.).
ANTENNA
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Gl ove Box i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Reach through the i nstrument panel gl ove box
openi ng to unpl ug the antenna coaxi al cabl e connec-
tor. Unpl ug the connector by pul l i ng i t apart whi l e
twi sti ng the metal connector hal ves. Do not pul l on
the cabl e.
(4) Unscrew the antenna mast from the antenna
body base on the ri ght outer cowl si de panel (Fi g. 9).
Fig. 7 Sound Bar Wire Harness Connector Remove/
Install
1 – SPORT BAR
2 – SOUND BAR
3 – CONNECTOR
Fig. 8 Sound Bar Remove/Install
1 – SOUND BAR
2 – SPORT BAR
Fig. 9 Antenna Remove/Install
1 – RIGHT COWL SIDE PANEL
2 – BASE & CABLE
3 – GROMMET
4 – SCREW
5 – COVER
6 – MAST
TJ AUDIO SYSTEMS 8F - 9
REMOVAL AND INSTALLATION (Continued)
(5) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the edge of the antenna
base tri m cover to unsnap i t from the antenna body
base.
(6) Remove the three screws that secure the
antenna body base to the ri ght outer cowl si de panel .
(7) From i nsi de the passenger compartment, push
the coaxi al cabl e grommet on the antenna body hal f
of the coaxi al cabl e out through the hol e i n the ri ght
i nner cowl si de panel .
(8) From the outsi de of the vehi cl e, pul l the
antenna body base and cabl e assembl y out through
the hol e i n the ri ght outer cowl si de panel .
(9) Reverse the removal procedures to i nstal l .
Ti ghten the antenna body base mounti ng screws to 2
N·m (17 i n. l bs.). Ti ghten the antenna mast to 3.3
N·m (30 i n. l bs.).
RADIO NOISE SUPPRESSION COMPONENTS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
ENGINE-TO-BODY GROUND STRAP
(1) Remove the screw that secures the engi ne-to-
body ground strap eyel et to the hood panel center
rei nforcement (Fi g. 10).
(2) Remove the screw that secures the engi ne-to-
body ground strap eyel et to the dash panel .
(3) Remove the nut that secures the engi ne-to-body
ground strap eyel et to the stud on the l eft upper rear
corner of the engi ne cyl i nder head.
(4) Remove the engi ne-to-body ground strap eyel et
from the stud on the l eft upper rear corner of the
engi ne cyl i nder head.
(5) Remove the engi ne-to-body ground strap from
the engi ne compartment.
Fig. 10 Engine-To-Body Ground Strap Remove/
Install
1 – HOOD PANEL
2 – GROUND STRAP
3 – DASH PANEL
4 – SCREW
5 – ENGINE
6 – STUD
7 – NUT
8 – SCREW
8F - 10 AUDIO SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
ENGINE-TO-FRAME GROUND STRAP
(1) Remove the nut that secures the engi ne-to-
frame ground strap eyel et to the forward i gni ti on coi l
mounti ng stud on the ri ght si de of the engi ne
(Fi g. 11) or (Fi g. 12).
(2) Remove the engi ne-to-frame ground strap eye-
l et from the forward i gni ti on coi l mounti ng stud on
the ri ght si de of the engi ne.
(3) Remove the screw that secures the engi ne-to-
frame ground strap eyel et to the top of the ri ght
frame rai l .
(4) Remove the engi ne-to-frame ground strap from
the engi ne compartment.
INSTALLATION
ENGINE-TO-BODY GROUND STRAP
(1) Posi ti on the engi ne-to-body ground strap i n the
engi ne compartment.
(2) Posi ti on the engi ne-to-body ground strap eyel et
over the stud on the l eft upper rear corner of the
engi ne cyl i nder head.
(3) I nstal l and ti ghten the nut that secures the
engi ne-to-body ground strap eyel et to the stud on the
l eft upper rear corner of the engi ne cyl i nder head.
Ti ghten the nut to 5.6 N·m (50 i n. l bs.).
(4) I nstal l and ti ghten the screw that secures the
engi ne-to-body ground strap eyel et to the dash panel .
Ti ghten the screw to 48.5 N·m (430 i n. l bs.).
(5) I nstal l and ti ghten the screw that secures the
engi ne-to-body ground strap eyel et to the hood panel
center rei nforcement. Ti ghten the screw to 1.9 N·m
(17 i n. l bs.).
ENGINE-TO-FRAME GROUND STRAP
(1) Posi ti on the engi ne-to-frame ground strap i nto
the engi ne compartment. The ground strap eyel et
wi th a 45 degree bend i n i t i s to be mounted on the
ri ght frame rai l .
(2) I nstal l and ti ghten the screw that secures the
engi ne-to-frame ground strap eyel et to the top of the
ri ght frame rai l . Ti ghten the screw to 22.6 N·m (200
i n. l bs.).
(3) I nstal l the engi ne-to-frame ground strap eyel et
over the forward i gni ti on coi l mounti ng stud on the
ri ght si de of the engi ne.
(4) I nstal l and ti ghten the nut that secures the
engi ne-to-frame ground strap eyel et to the forward
i gni ti on coi l mounti ng stud on the ri ght si de of the
engi ne. Ti ghten the nut to 22.6 N·m (200 i n. l bs.).
Fig. 11 Engine-To-Frame Ground Strap Remove/
Install - 2.5L Engine
1 – IGNITION COIL
2 – GENERATOR GROUND EYELET
3 – RIGHT FRAME RAIL
4 – SCREW
5 – GROUND STRAP
6 – NUT
Fig. 12 Engine-To-Frame Ground Strap Remove/
Install - 4.0L Engine
1 – IGNITION COIL
2 – NUT
3 – SCREW
4 – RIGHT FRAME RAIL
5 – GROUND STRAP
6 – GENERATOR GROUND EYELET
TJ AUDIO SYSTEMS 8F - 11
REMOVAL AND INSTALLATION (Continued)
HORN SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
HORN SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
HORN SYSTEM
DESCRIPTION
A dual -note el ectri c horn system i s standard facto-
ry-i nstal l ed equi pment on thi s model . The standard
equi pment horn system features a one l ow-note horn
uni t and one hi gh-note horn uni t. The horn system
uses a non-swi tched source of battery current so that
the system wi l l remai n functi onal , regardl ess of the
i gni ti on swi tch posi ti on. The horn system i ncl udes
the fol l owi ng components:
• Cl ockspri ng
• Horn(s)
• Horn rel ay
• Horn swi tch
Refer to Clockspring i n the Descri pti on and Oper-
ati on secti on of Group 8M - Passi ve Restrai nt Sys-
tems for more i nformati on on thi s component. Refer
to Horn/Cigar Lighter i n the Contents of Group 8W
- Wi ri ng Di agrams for compl ete ci rcui t di agrams. Fol -
l owi ng are general descri pti ons of the remai ni ng
major components i n the horn system.
OPERATION
The horn system i s acti vated by a horn swi tch con-
ceal ed beneath the dri ver si de ai rbag modul e tri m
cover i n the center of the steeri ng wheel . Depressi ng
the center of the dri ver si de ai rbag modul e tri m cover
cl oses the horn swi tch. Cl osi ng the horn swi tch acti -
vates the horn rel ay. The acti vated horn rel ay then
swi tches the battery current needed to energi ze the
horns.
Refer to the owner’s manual i n the vehi cl e gl ove
box for more i nformati on on the features, use and
operati on of the horn system.
HORN
DESCRIPTION
The dual el ectromagneti c di aphragm-type horns
are standard equi pment on thi s model . Each horn i s
secured wi th a bracket to the l eft front i nner fender
shi el d just ahead of the l eft front wheel house i n the
engi ne compartment. The two horn brackets are
mounted i n the same l ocati on, one on top of the
other. The hi gh-note horn for the opti onal dual -note
horn system i s connected i n paral l el wi th and
secured wi th a bracket just forward of the l ow-note
horn.
The two horns are connected i n paral l el . Each horn
i s grounded through i ts wi re harness connector and
ci rcui t to an eyel et secured to the engi ne compart-
ment si de of the gri l l e/headl amp mounti ng panel
near the l eft headl amp, and recei ves battery feed
through the cl osed contacts of the horn rel ay.
The horns cannot be repai red or adjusted and, i f
faul ty or damaged, they must be i ndi vi dual l y
repl aced.
OPERATION
Wi thi n the two hal ves of the mol ded pl asti c horn
housi ng are a fl exi bl e di aphragm, a pl unger, an el ec-
tromagneti c coi l and a set of contact poi nts. The di a-
phragm i s secured i n suspensi on around i ts
peri meter by the mati ng surfaces of the horn hous-
i ng. The pl unger i s secured to the center of the di a-
phragm and extends i nto the center of the
el ectromagnet. The contact poi nts control the current
fl ow through the el ectromagnet.
When the horn i s energi zed, el ectri cal current
fl ows through the cl osed contact poi nts to the el ectro-
magnet. The resul ti ng el ectromagneti c fi el d draws
the pl unger and di aphragm toward i t unti l that
movement mechani cal l y opens the contact poi nts.
When the contact poi nts open, the el ectromagneti c
TJ HORN SYSTEMS 8G - 1
fi el d col l apses al l owi ng the pl unger and di aphragm to
return to thei r rel axed posi ti ons and cl osi ng the con-
tact poi nts agai n. Thi s cycl e conti nues repeati ng at a
very rapi d rate produci ng the vi brati on and move-
ment of ai r that creates the sound that i s di rected
through the horn outl et.
HORN RELAY
DESCRIPTION
The horn rel ay i s a el ectromechani cal devi ce that
swi tches battery current to the horn when the horn
swi tch grounds the rel ay coi l . The horn rel ay i s
l ocated i n the Power Di stri buti on Center (PDC) i n
the engi ne compartment. I f a probl em i s encountered
wi th a conti nuousl y soundi ng horn, i t can usual l y be
qui ckl y resol ved by removi ng the horn rel ay from the
PDC unti l further di agnosi s i s compl eted. See the
fuse and rel ay l ayout l abel affi xed to the i nsi de sur-
face of the PDC cover for horn rel ay i denti fi cati on
and l ocati on.
The horn rel ay i s a I nternati onal Standards Orga-
ni zati on (I SO) mi cro-rel ay. Rel ays conformi ng to the
I SO speci fi cati ons have common physi cal di mensi ons,
current capaci ti es, termi nal patterns, and termi nal
functi ons. The I SO mi cro-rel ay termi nal functi ons
are the same as a conventi onal I SO rel ay. However,
the I SO mi cro-rel ay termi nal pattern (or footpri nt) i s
di fferent, the current capaci ty i s l ower, and the phys-
i cal di mensi ons are smal l er than those of the conven-
ti onal I SO rel ay.
The horn rel ay cannot be repai red or adjusted and,
i f faul ty or damaged, i t must be repl aced.
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When the el ec-
tromagneti c coi l i s energi zed, i t draws the movabl e
contact away from the normal l y cl osed fi xed contact,
and hol ds i t agai nst the other (normal l y open) fi xed
contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor or di ode i s con-
nected i n paral l el wi th the el ectromagneti c coi l i n the
rel ay, and hel ps to di ssi pate vol tage spi kes that are
produced when the coi l i s de-energi zed.
HORN SWITCH
DESCRIPTION
A center-bl ow, normal l y open, resi sti ve membrane-
type horn swi tch i s secured wi th heat stakes to the
back si de of the dri ver si de ai rbag modul e tri m cover
i n the center of the steeri ng wheel (Fi g. 1). The
swi tch consi sts of two pl asti c membranes, one that i s
fl at and one that i s sl i ghtl y convex. These two mem-
branes are secured to each other around the peri me-
ter. I nsi de the swi tch, the centers of the faci ng
surfaces of these membranes each has a gri d made
wi th an el ectri cal l y conducti ve materi al appl i ed to i t.
One of the gri ds i s connected to a ci rcui t that pro-
vi des i t wi th conti nui ty to ground at al l ti mes. The
gri d of the other membrane i s connected to the horn
rel ay control ci rcui t.
The steeri ng wheel and steeri ng col umn must be
properl y grounded i n order for the horn swi tch to
functi on properl y. The horn swi tch i s onl y servi ced as
a part of the dri ver si de ai rbag modul e tri m cover. I f
the horn swi tch i s damaged or faul ty, or i f the dri ver
si de ai rbag i s depl oyed, the dri ver si de ai rbag modul e
tri m cover and horn swi tch must be repl aced as a
uni t.
OPERATION
When the center area of the dri ver si de ai rbag tri m
cover i s depressed, the el ectri cal l y conducti ve gri ds
on the faci ng surfaces of the horn swi tch membranes
contact each other, cl osi ng the swi tch ci rcui t. The
compl eted horn swi tch ci rcui t provi des a ground for
the control coi l si de of the horn rel ay, whi ch acti vates
the rel ay. When the horn swi tch i s rel eased, the
Fig. 1 Driver Side Airbag Module Trim Cover and
Horn Switch - Typical
1 – RETAINER SLOTS
2 – TRIM COVER
3 – LOCKING BLOCKS
4 – RETAINER SLOTS
5 – HORN SWITCH
8G - 2 HORN SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
resi sti ve tensi on of the convex membrane separates
the two el ectri cal l y conducti ve gri ds and opens the
swi tch ci rcui t.
DIAGNOSIS AND TESTING
HORN RELAY
The horn rel ay (Fi g. 2) i s l ocated i n the Power Di s-
tri buti on Center (PDC) behi nd the battery on the
dri ver si de of the engi ne compartment. I f a probl em
i s encountered wi th a conti nuousl y soundi ng horn, i t
can usual l y be qui ckl y resol ved by removi ng the horn
rel ay from the PDC unti l further di agnosi s i s com-
pl eted. See the fuse and rel ay l ayout l abel affi xed to
the i nsi de surface of the PDC cover for horn rel ay
i denti fi cati on and l ocati on. For compl ete ci rcui t di a-
grams, refer to Horn/Cigar Lighter i n the Contents
of Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the horn rel ay from the PDC. Refer to
Horn Relay i n the Removal and I nstal l ati on secti on
of thi s group for the procedures.
(2) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 3. I f not OK, repl ace the faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 Ϯ 5 ohms. I f OK, go to Step
4. I f not OK, repl ace the faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform the Rel ay Ci rcui t Test that
fol l ows. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the fuse i n the PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the horn(s). There shoul d be conti nui ty between
the cavi ty for rel ay termi nal 87 and the horn rel ay
output ci rcui t cavi ty of each horn wi re harness con-
nector at al l ti mes. I f OK, go to Step 4. I f not OK,
repai r the open ci rcui t to the horn(s) as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s connected to bat-
tery vol tage and shoul d be hot at al l ti mes. Check for
battery vol tage at the cavi ty for rel ay termi nal 86. I f
OK, go to Step 5. I f not OK, repai r the open ci rcui t to
the fuse i n the PDC as requi red.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. I t i s grounded
through the horn swi tch when the horn swi tch i s
depressed. Check for conti nui ty to ground at the cav-
i ty for rel ay termi nal 85. There shoul d be conti nui ty
wi th the horn swi tch depressed, and no conti nui ty
wi th the horn swi tch rel eased. I f not OK, refer to
Horn Switch i n the Di agnosi s and Testi ng secti on of
thi s group.
HORN SWITCH
For compl ete ci rcui t di agrams, refer to Horn/Ci-
gar Lighter i n the Contents of Group 8W - Wi ri ng
Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the knee bl ocker from the i nstrument
panel .
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 2 Horn Relay
TJ HORN SYSTEMS 8G - 3
DESCRIPTION AND OPERATION (Continued)
(2) Check for conti nui ty between the metal steer-
i ng col umn jacket and a good ground. There shoul d
be conti nui ty. I f OK, go to Step 3. I f not OK, refer to
Steering Column i n the Removal and I nstal l ati on
secti on of Group 19 - Steeri ng for proper i nstal l ati on
of the steeri ng col umn.
(3) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . Di sconnect the horn swi tch wi re har-
ness connectors from the dri ver si de ai rbag modul e.
(4) Remove the horn rel ay from the Power Di stri -
buti on Center (PDC). Check for conti nui ty between
the steeri ng col umn hal f of the horn swi tch feed wi re
harness connector and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 5. I f not OK,
repai r the shorted horn rel ay control ci rcui t to the
horn rel ay i n the PDC as requi red.
(5) Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and the horn rel ay control ci rcui t cavi ty for
the horn rel ay i n the PDC. There shoul d be conti nu-
i ty. I f OK, go to Step 6. I f not OK, repai r the open
horn rel ay control ci rcui t to the horn rel ay i n the
PDC as requi red.
(6) Check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
dri ver si de ai rbag modul e. There shoul d be no conti -
nui ty. I f OK, go to Step 7. I f not OK, repl ace the
faul ty horn swi tch.
(7) Depress the center of the dri ver si de ai rbag
modul e tri m cover and check for conti nui ty between
the horn swi tch feed wi re and the horn swi tch
ground wi re on the dri ver si de ai rbag modul e. There
shoul d now be conti nui ty. I f not OK, repl ace the
faul ty horn swi tch.
HORN
For compl ete ci rcui t di agrams, refer to Horn/Ci-
gar Lighter i n the Contents of Group 8W - Wi ri ng
Di agrams.
(1) Di sconnect the wi re harness connectors from
the horn connector receptacl es. Measure the resi s-
tance between the ground ci rcui t cavi ty of the horns
wi re harness connectors and a good ground. There
shoul d be no measurabl e resi stance. I f OK, go to Step
2. I f not OK, repai r the open ground ci rcui t to ground
as requi red.
(2) Check for battery vol tage at the horn rel ay out-
put ci rcui t cavi ty of the horns wi re harness connec-
tors. There shoul d be zero vol ts. I f OK, go to Step 3.
I f not OK, repai r the shorted horn rel ay output ci r-
cui t or repl ace the faul ty horn rel ay as requi red.
(3) Depress the horn swi tch. There shoul d now be
battery vol tage at the horn rel ay output ci rcui t cavi ty
of the horns wi re harness connectors. I f OK, repl ace
the faul ty horns. I f not OK, repai r the open horn
rel ay output ci rcui t to the horn rel ay as requi red.
REMOVAL AND INSTALLATION
HORN RELAY
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unl atch and open the cover on the Power Di s-
tri buti on Center (PDC) (Fi g. 3).
(3) See the fuse and rel ay l ayout l abel on the
undersi de of the PDC cover for horn rel ay i denti fi ca-
ti on and l ocati on.
(4) Remove the horn rel ay from the PDC.
INSTALLATION
(1) Posi ti on the horn rel ay i n the proper receptacl e
i n the PDC.
(2) Al i gn the horn rel ay termi nal s wi th the termi -
nal cavi ti es i n the PDC receptacl e.
(3) Push down fi rml y on the horn rel ay unti l the
termi nal s are ful l y seated i n the termi nal cavi ti es i n
the PDC receptacl e.
(4) Cl ose and l atch the cover onto the PDC.
(5) Reconnect the battery negati ve cabl e.
HORN
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the wi re harness connectors from
the horn connector receptacl es (Fi g. 4).
(3) Remove the two screws that secure the horn
and mounti ng bracket uni ts to the l eft front i nner
fender shi el d.
Fig. 3 Power Distribution Center
1 – POWER DISTRIBUTION CENTER
2 – LATCHES
3 – PDC COVER
4 – RIGHT FRONT FENDER
8G - 4 HORN SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
(4) Remove the horn and mounti ng bracket uni ts
from the l eft front i nner fender shi el d.
INSTALLATION
(1) Posi ti on the horn and mounti ng bracket uni ts
onto the l eft front i nner fender shi el d.
(2) I nstal l and ti ghten the screw that secures the
horn and mounti ng bracket uni ts to the l eft front
i nner fender shi el d. Ti ghten the screw to 6.8 N·m (5
ft. l bs.).
(3) Reconnect the wi re harness connectors to the
horn connector receptacl es.
(4) Reconnect the battery negati ve cabl e.
Fig. 4 Horns Remove/Install
1 – HIGH NOTE HORN AND BRACKET
2 – LOW NOTE HORN AND BRACKET
3 – SCREWS
4 – INNER FENDER
5 – HORN CONNECTORS
TJ HORN SYSTEMS 8G - 5
REMOVAL AND INSTALLATION (Continued)
SPEED CONTROL SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . 1
SPEED CONTROL SERVO. . . . . . . . . . . . . . . . . . . 2
SPEED CONTROL SOLENOID CIRCUITS . . . . . . . 2
SPEED CONTROL SWITCHES . . . . . . . . . . . . . . . 2
BRAKE LAMP SWITCH. . . . . . . . . . . . . . . . . . . . . 3
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . . 3
VEHICLE SPEED SENSOR (SPEED CONTROL
OPERATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VACUUM SUPPLY TEST. . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
SPEED CONTROL SERVO. . . . . . . . . . . . . . . . . . . 4
SPEED CONTROL SWITCH. . . . . . . . . . . . . . . . . . 5
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION AND OPERATION
SPEED CONTROL SYSTEM
DESCRIPTION
The speed control system i s el ectroni cal l y con-
trol l ed and vacuum operated. El ectroni c control of
the speed control system i s i ntegrated i nto the Pow-
ertrai n Control Modul e (PCM). The control s consi st
of two steeri ng wheel mounted swi tches. The
swi tches are l abel ed: ON/OFF, RES/ACCEL, SET,
COAST, and CANCEL.
The system i s desi gned to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIPPERY.
OPERATION
When speed control i s sel ected by depressi ng the
ON swi tch, the PCM al l ows a set speed to be stored
i n PCM RAM for speed control . To store a set speed,
depress the SET swi tch whi l e the vehi cl e i s movi ng
at a speed between 35 and 85 mph. I n order for the
speed control to engage, the brakes cannot be
appl i ed, nor can the gear sel ector be i ndi cati ng the
transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
• Steppi ng on the brake pedal
• Depressi ng the OFF swi tch
• Depressi ng the CANCEL swi tch.
• Depressi ng the cl utch pedal (i f equi pped).
NOTE: Depressing the OFF switch or turning off
the ignition switch will erase the set speed stored
in the PCM.
For added safety, the speed control system i s pro-
grammed to di sengage for any of the fol l owi ng condi -
ti ons:
• An i ndi cati on of Park or Neutral
• A rapi d i ncrease rpm (i ndi cates that the cl utch
has been di sengaged)
• Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
• The speed si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the coeffi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
• The speed si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
Once the speed control has been di sengaged,
depressi ng the RES/ACCEL swi tch (when speed i s
greater than 30 mph) restores the vehi cl e to the tar-
get speed that was stored i n the PCM.
Whi l e the speed control i s engaged, the dri ver can
i ncrease the vehi cl e speed by depressi ng the RES/AC-
CEL swi tch. The new target speed i s stored i n the
PCM when the RES/ACCEL i s rel eased. The PCM
al so has a “tap-upЉ feature i n whi ch vehi cl e speed
i ncreases at a rate of approxi matel y 2 mph for each
momentary swi tch acti vati on of the RES/ACCEL
swi tch.
A “tap down” feature i s used to decel erate wi thout
di sengagi ng the speed control system. To decel erate
from an exi sti ng recorded target speed, momentari l y
depress the COAST swi tch. For each swi tch acti va-
ti on, speed wi l l be l owered approxi matel y 1 mph.
TJ SPEED CONTROL SYSTEM 8H - 1
SPEED CONTROL SERVO
DESCRIPTION
The servo uni t consi sts of a sol enoi d val ve body,
and a vacuum chamber. The sol enoi d val ve body con-
tai ns three sol enoi ds:
• Vacuum
• Vent
• Dump
The vacuum chamber contai ns a di aphragm wi th a
cabl e attached to control the throttl e l i nkage.
OPERATION
The Powertrai n Control Modul e (PCM) control s the
sol enoi d val ve body. The sol enoi d val ve body control s
the appl i cati on and rel ease of vacuum to the di a-
phragm of the vacuum servo. The servo uni t cannot
be repai red and i s servi ced onl y as a compl ete assem-
bl y.
Power i s suppl i ed to the servo’s by the PCM
through the brake swi tch. The PCM control s the
ground path for the vacuum and vent sol enoi ds.
The dump sol enoi d i s energi zed anyti me i t recei ves
power. I f power to the dump sol enoi d i s i nterrupted,
the sol enoi d dumps vacuum i n the servo. Thi s pro-
vi des a safety backup to the vent and vacuum sol e-
noi ds.
The vacuum and vent sol enoi ds must be grounded
at the PCM to operate. When the PCM grounds the
vacuum servo sol enoi d, the sol enoi d al l ows vacuum
to enter the servo and pul l open the throttl e pl ate
usi ng the cabl e. When the PCM breaks the ground,
the sol enoi d cl oses and no more vacuum i s al l owed to
enter the servo. The PCM al so operates the vent sol e-
noi d vi a ground. The vent sol enoi d opens and cl oses a
passage to bl eed or hol d vacuum i n the servo as
requi red.
The PCM duty cycl es the vacuum and vent sol e-
noi ds to mai ntai n the set speed, or to accel erate and
decel erate the vehi cl e. To i ncrease throttl e openi ng,
the PCM grounds the vacuum and vent sol enoi ds. To
decrease throttl e openi ng, the PCM removes the
grounds from the vacuum and vent sol enoi ds. When
the brake i s rel eased, i f vehi cl e speed exceeds 30
mph to resume, 35 mph to set, and the RES/ACCEL
swi tch has been depressed, ground for the vent and
vacuum ci rcui ts i s restored.
SPEED CONTROL SOLENOID CIRCUITS
OPERATION
When al l of the speed control parameters are met,
and the SET button i s pressed, the PCM actuates the
vent sol enoi d and “duty-cycl es” the vacuum sol enoi d
to open the throttl e and bri ng the vehi cl e up to tar-
get speed. When the vehi cl e i s at target speed, i t wi l l
actuate the vent sol enoi d wi th the vacuum sol enoi d
de-acti vated to mai ntai n the vehi cl e at target speed.
When the vehi cl e i s above target speed, the PCM wi l l
“duty-cycl e” the vent sol enoi d wi th the vacuum sol e-
noi d sti l l de-acti vated to cl ose the throttl e to return
to target speed.
SPEED CONTROL SWITCHES
DESCRIPTION
There are two separate swi tch pods that operate
the speed control system. The steeri ng-wheel -
mounted swi tches use mul ti pl exed ci rcui ts to provi de
i nputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owner’s manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures.
The i ndi vi dual swi tches cannot be repai red. I f one
swi tch fai l s, the enti re swi tch modul e must be
repl aced.
OPERATION
When speed control i s sel ected by depressi ng the
ON, OFF swi tch, the PCM al l ows a set speed to be
stored i n i ts RAM for speed control . To store a set
speed, depress the SET swi tch whi l e the vehi cl e i s
movi ng at a speed between approxi matel y 35 and 85
mph. I n order for the speed control to engage, the
brakes cannot be appl i ed, nor can the gear sel ector
be i ndi cati ng the transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
• Steppi ng on the brake pedal
• Depressi ng the OFF swi tch
• Depressi ng the CANCEL swi tch.
The speed control can be di sengaged al so by any of
the fol l owi ng condi ti ons:
• An i ndi cati on of Park or Neutral
• The VSS si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the co-effi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
• Depressi ng the cl utch pedal .
• Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
• The VSS si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
• I f the actual speed i s not wi thi n 20 mph of the
set speed
The previ ous di sengagement condi ti ons are pro-
grammed for added safety.
Once the speed control has been di sengaged,
depressi ng the ACCEL swi tch restores the vehi cl e to
the target speed that was stored i n the PCM’s RAM.
NOTE: Depressing the OFF switch will erase the
set speed stored in the PCM’s RAM.
8H - 2 SPEED CONTROL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
I f, whi l e the speed control i s engaged, the dri ver
wi shes to i ncrease vehi cl e speed, the PCM i s pro-
grammed for an accel erati on feature. Wi th the
ACCEL swi tch hel d cl osed, the vehi cl e accel erates
sl owl y to the desi red speed. The new target speed i s
stored i n the PCM’s RAM when the ACCEL swi tch i s
rel eased. The PCM al so has a “tap-up” feature i n
whi ch vehi cl e speed i ncreases at a rate of approxi -
matel y 2 mph for each momentary swi tch acti vati on
of the ACCEL swi tch.
The PCM al so provi des a means to decel erate wi th-
out di sengagi ng speed control . To decel erate from an
exi sti ng recorded target speed, depress and hol d the
COAST swi tch unti l the desi red speed i s reached.
Then rel ease the swi tch. The ON, OFF swi tch oper-
ates two components: the PCM’s ON, OFF i nput, and
the battery vol tage to the brake swi tch, whi ch powers
the speed control servo.
Multiplexing
The PCM sends out 5 vol ts through a fi xed resi stor
and moni tors the vol tage change between the fi xed
resi stor and the swi tches. I f none of the swi tches are
depressed, the PCM wi l l measure 5 vol ts at the sen-
sor poi nt (open ci rcui t). I f a swi tch wi th no resi stor i s
cl osed, the PCM wi l l measure 0 vol ts (grounded ci r-
cui t). Now, i f a resi stor i s added to a swi tch, then the
PCM wi l l measure some vol tage proporti onal to the
si ze of the resi stor. By addi ng a di fferent resi stor to
each swi tch, the PCM wi l l see a di fferent vol tage
dependi ng on whi ch swi tch i s pushed.
Another resi stor has been added to the ’at rest ci r-
cui t’ causi ng the PCM to never see 5 vol ts. Thi s was
done for di agnosti c purposes. I f the swi tch ci rcui t
shoul d open (bad connecti on), then the PCM wi l l see
the 5 vol ts and know the ci rcui t i s bad. The PCM wi l l
then set an open ci rcui t faul t.
BRAKE LAMP SWITCH
DESCRIPTION
The swi tch i s mounted on the brake pedal mount-
i ng bracket under the i nstrument panel .
OPERATION
Vehi cl es equi pped wi th the speed control opti on use
a dual functi on brake l amp swi tch. The PCM moni -
tors the state of the dual functi on brake l amp swi tch.
Refer to the Brake secti on for more i nformati on on
brake l amp swi tch servi ce and adjustment proce-
dures.
The brake swi tch i s equi pped wi th three sets of
contacts, one normal l y open and the other two nor-
mal l y cl osed (brakes di sengaged). The PCM sends a
12 vol t si gnal to one of the normal l y cl osed contacts
i n the brake swi tch, whi ch i s returned to the PCM as
a brake swi tch state si gnal . Wi th the contacts cl osed,
the 12 vol t si gnal i s pul l ed to ground causi ng the si g-
nal to go l ow. The l ow vol tage si gnal , moni tored by
the PCM, i ndi cates that the brakes are not appl i ed.
When the brakes are appl i ed, the contacts open,
causi ng the PCM’s output brake si gnal to go hi gh,
di sengagi ng the speed control , cutti ng off PCM power
to the speed control sol enoi ds.
The second set of normal l y cl osed contacts suppl i es
12 vol ts from the PCM any ti me speed control i s
turned on. Through the brake swi tch, current i s
routed to the speed control servo sol enoi ds. The
speed control sol enoi ds (vacuum, vent and dump) are
provi ded thi s current any ti me the speed control i s
ON and the brakes are di sengaged.
When the dri ver appl i es the brakes, the contacts
open and current i s i nterrupted to the sol enoi ds. The
normal l y open contacts are fed battery vol tage. When
the brakes are appl i ed, battery vol tage i s suppl i ed to
the brake l amps.
SERVO CABLE
DESCRIPTION
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage.
OPERATION
Thi s cabl e causes the throttl e control l i nkage to
open or cl ose the throttl e val ve i n response to move-
ment of the vacuum servo di aphragm.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s a pl asti c storage tank con-
nected to an engi ne vacuum source by vacuum l i nes.
OPERATION
The vacuum reservoi r i s used to suppl y the vac-
uum needed to mai ntai n proper speed control opera-
ti on when engi ne vacuum drops, such as i n cl i mbi ng
a grade whi l e dri vi ng. A one-way check val ve i s used
i n the vacuum l i ne between the reservoi r and the
vacuum source. Thi s check val ve i s used to trap
engi ne vacuum i n the reservoi r. On certai n vehi cl e
appl i cati ons, thi s reservoi r i s shared wi th the heat-
i ng/ai r-condi ti oni ng system. The vacuum reservoi r
cannot be repai red and must be repl aced i f faul ty.
TJ SPEED CONTROL SYSTEM 8H - 3
DESCRIPTION AND OPERATION (Continued)
VEHICLE SPEED SENSOR (SPEED CONTROL
OPERATION)
DESCRIPTION
The Vehi cl e Speed Sensor (VSS) i s mounted to an
adapter near the transmi ssi on output shaft. The sen-
sor i s dri ven through the adapter by a speedometer
pi ni on gear.
OPERATION
The VSS i s a pul se generator. The VSS pul se si g-
nal to the speedometer/odometer i s moni tored by the
PCM speed control ci rcui try to determi ne vehi cl e
speed and to mai ntai n speed control set speed.
DIAGNOSIS AND TESTING
ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d
be corrected before proceedi ng. Refer to Group 8E,
I nstrument Panel and Gauges for speedometer di ag-
nosi s.
I f a road test veri fi es a system probl em and the
speedometer operates properl y, check for:
• A Di agnosti c Troubl e Code (DTC). I f a DTC
exi sts, conduct tests per the Powertrai n Di agnosti c
Procedures servi ce manual .
• A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
• Loose, damaged or corroded el ectri cal connec-
ti ons at the servo. Corrosi on shoul d be removed from
el ectri cal termi nal s and a l i ght coati ng of Mopar
Mul ti Purpose Grease, or equi val ent, appl i ed.
• Leaki ng vacuum reservoi r.
• Loose or l eaki ng vacuum hoses or connecti ons.
• Defecti ve one-way vacuum check val ve.
• Secure attachment of both ends of the speed con-
trol servo cabl e.
• Smooth operati on of throttl e l i nkage and throttl e
body ai r val ve.
• Fai l ed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
VACUUM SUPPLY TEST
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at vacuum reservoi r. To l ocate and gai n
access to reservoi r, refer to Vacuum Reservoi r Remov-
al /I nstal l ati on i n thi s group. Di sconnect vacuum l i ne
at reservoi r and connect a hand-operated vacuum
pump to reservoi r fi tti ng. Appl y vacuum. Reservoi r
vacuum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace reservoi r.
(5) Veri fy operati on of one-way check val ve and
check i t for l eaks.
(a) Locate one-way check val ve. The val ve i s
l ocated i n vacuum l i ne between vacuum reservoi r
and engi ne vacuum source. Di sconnect vacuum
hoses (l i nes) at each end of val ve.
(b) Connect a hand-operated vacuum pump to
reservoi r end of check val ve. Appl y vacuum. Vac-
uum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace one-way check val ve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check val ve. Appl y vacuum.
Vacuum shoul d fl ow through val ve. I f vacuum i s
not fl owi ng, repl ace one-way check val ve. Seal the
fi tti ng at opposi te end of val ve wi th a fi nger and
appl y vacuum. I f vacuum wi l l not hol d, di aphragm
wi thi n check val ve has ruptured. Repl ace val ve.
REMOVAL AND INSTALLATION
SPEED CONTROL SERVO
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Di sconnect vacuum l i ne at servo (Fi g. 1).
(3) Di sconnect el ectri cal connector at servo.
(4) Di sconnect servo cabl e at throttl e body. Refer to
Servo Cabl e Removal /I nstal l ati on.
(5) Remove 2 mounti ng nuts hol di ng servo cabl e
sl eeve to bracket (Fi g. 1) or (Fi g. 2).
8H - 4 SPEED CONTROL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
(6) Pul l speed control cabl e sl eeve and servo away
from servo mounti ng bracket to expose cabl e retai n-
i ng cl i p (Fi g. 2) and remove cl i p. Note: The servo
mounti ng bracket di spl ayed i n (Fi g. 2) i s a typi cal
bracket and may/may not be appl i cabl e to thi s model
vehi cl e.
(7) Remove servo from mounti ng bracket. Whi l e
removi ng, note ori entati on of servo to bracket.
INSTALLATION
(1) Posi ti on servo to mounti ng bracket.
(2) Al i gn hol e i n cabl e connector wi th hol e i n servo
pi n. I nstal l cabl e-to-servo retai ni ng cl i p.
(3) I nsert servo mounti ng studs through hol es i n
servo mounti ng bracket.
(4) I nstal l servo mounti ng nuts and ti ghten to 8.5
N·m (75 i n. l bs.).
(5) Connect vacuum l i ne at servo.
(6) Connect el ectri cal connector at servo.
(7) Connect servo cabl e to throttl e body. Refer to
Servo Cabl e Removal /I nstal l ati on.
(8) Connect negati ve battery cabl e to battery.
(9) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
SPEED CONTROL SWITCH
WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR
RELATED STEERING WHEEL AND STEERING COL-
UMN COMPONENTS YOU MUST FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM
CAPACITOR TO DISCHARGE BEFORE FURTHER
SYSTEM SERVICE. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
REMOVAL
(1) Di sconnect and i sol ate negati ve battery cabl e
from battery.
(2) Remove ai rbag modul e. Refer to Group 8M,
Passi ve Restrai nt Systems.
(3) From undersi de of steeri ng wheel , remove
speed control swi tch mounti ng screw (Fi g. 3).
(4) Remove swi tch from steeri ng wheel and unpl ug
el ectri cal connector.
INSTALLATION
(1) Pl ug el ectri cal connector i nto swi tch.
(2) Posi ti on swi tch to steeri ng wheel .
(3) I nstal l swi tch mounti ng screw and ti ghten to
1.5 N·m (14 i n. l bs.) torque.
(4) I nstal l ai rbag modul e. Refer to Group 8M, Pas-
si ve Restrai nt Systems.
(5) Connect negati ve battery cabl e to battery.
Fig. 1 Speed Control Servo Location
1 – SERVO MOUNTING BRACKET
2 – VACUUM LINE
3 – SPEED CONTROL SERVO
4 – CABLE SLEEVE
5 – SERVO MOUNTING NUTS (2)
6 – ELECTRICAL CONNECTOR
Fig. 2 Servo Cable Clip Remove/Install—Typical
1 – SERVO MOUNTING NUTS (2)
2 – SERVO
3 – CABLE RETAINING CLIP
4 – SERVO CABLE AND SLEEVE
TJ SPEED CONTROL SYSTEM 8H - 5
REMOVAL AND INSTALLATION (Continued)
SERVO CABLE
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Usi ng fi nger pressure onl y, remove cabl e con-
nector by pushi ng connector off the throttl e body
bel l crank pi n (Fi g. 4). DO NOT try to pull cable
connector off perpendicular to the bellcrank
pin. Connector will be broken.
(3) Two rel ease tabs are l ocated on si des of speed
control cabl e at cabl e bracket (Fi g. 4). Squeeze tabs
together and push cabl e out of bracket.
(4) Uncl i p cabl e from cabl e gui de at val ve cover.
(5) Di sconnect servo cabl e at servo. Refer to Speed
Control Servo Removal /I nstal l ati on.
INSTALLATION
(1) Attach end of cabl e to speed control servo.
Refer to Speed Control Servo Removal /I nstal l ati on.
(2) I nstal l cabl e i nto cabl e bracket (snaps i n).
(3) I nstal l cabl e connector at throttl e body
bel l crank pi n (snaps on).
(4) Cl i p cabl e to cabl e gui de at val ve cover.
(5) Connect negati ve battery cabl e to battery.
(6) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
VACUUM RESERVOIR
The vacuum reservoi r i s l ocated under the vehi cl e
battery tray (Fi g. 5).
Fig. 3 Speed Control Switch Remove/Install
1 – MOUNTING SCREW
2 – SPEED CONTROL SWITCH
Fig. 4 Speed Control Servo Cable at Throttle Body
1 – ACCELERATOR CABLE
2 – OFF
3 – OFF
4 – THROTTLE BODY BELLCRANK
5 – SPEED CONTROL CABLE
6 – RELEASE TABS
7 – BRACKET
Fig. 5 Vacuum Reservoir Removal/Installation
1 – TEE
2 – VACUUM CHECK VALVE
3 – INTAKE MANIFOLD
4 – INNER FENDER
5 – RESERVOIR
6 – SCREW
7 – VACUUM SUPPLY LINE
8H - 6 SPEED CONTROL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Remove battery and battery tray. Refer to Bat-
tery Removal /I nstal l ati on.
(2) Di sconnect vacuum suppl y l i ne at reservoi r
(Fi g. 5).
(3) Remove screw securi ng reservoi r to i nner
fender.
(4) Remove reservoi r from vehi cl e.
INSTALLATION
(1) Posi ti on reservoi r to vehi cl e and i nstal l mount-
i ng screw.
(2) Ti ghten screw to 1.2 N·m (10 i n. l bs.) torque.
(3) Connect vacuum l i ne to reservoi r.
(4) I nstal l battery and battery tray. Refer to Bat-
tery Removal /I nstal l ati on.
SPECIFICATIONS
TORQUE CHART
Description Torque
Servo Mounti ng Bracket-to-Servo Nuts . . . 8.5 N·m
(75 i n. l bs.)
Speed Control Swi tch Mounti ng Screws . . . 1.5 N·m
(14 i n. l bs.)
Vacuum Reservoi r Mounti ng Screw . . . . . . 1.2 N·m
(10 i n. l bs.)
TJ SPEED CONTROL SYSTEM 8H - 7
REMOVAL AND INSTALLATION (Continued)
TURN SIGNAL AND HAZARD WARNING SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
TURN SIGNAL SYSTEM. . . . . . . . . . . . . . . . . . . . 1
HAZARD WARNING SYSTEM. . . . . . . . . . . . . . . . 1
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH. . . . . . . . . . . . . . . . . . . . . . 2
TURN SIGNAL CANCELLING CAM. . . . . . . . . . . . 3
COMBINATION FLASHER . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
TURN SIGNAL AND HAZARD WARNING
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH. . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
COMBINATION FLASHER . . . . . . . . . . . . . . . . . . . 5
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH. . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION
TURN SIGNAL SYSTEM
DESCRIPTION
A turn si gnal system i s standard factory-i nstal l ed
safety equi pment on thi s model . The turn si gnal sys-
tem uses i gni ti on swi tched battery current, and wi l l
operate onl y when the i gni ti on swi tch i s i n the On or
Accessory posi ti ons. The turn si gnal system i ncl udes
the fol l owi ng components:
• Combi nati on fl asher
• Front si de marker l amps
• Turn si gnal cancel l i ng cam
• Turn si gnal i ndi cator l amps
• Turn si gnal l amps
• Turn si gnal swi tch.
Refer to Lamp i n the proper secti on of Group 8L -
Lamps for more i nformati on on the exteri or turn si g-
nal l amps. Refer to Instrument Cluster i n the
proper secti on of Group 8E - I nstrument Panel Sys-
tems for more i nformati on on the turn si gnal i ndi ca-
tor l amps. Fol l owi ng are general descri pti ons of the
major components i n the turn si gnal system. For
compl ete ci rcui t di agrams, refer to Turn Signals i n
the Contents of Group 8W - Wi ri ng Di agrams.
OPERATION
Wi th the i gni ti on swi tch i n the On or Accessory
posi ti on, and the turn si gnal (mul ti -functi on) swi tch
control stal k moved up (ri ght turn) or down (l eft
turn), the turn si gnal system i s acti vated. When the
turn si gnal system i s acti vated, the ci rcui try of the
turn si gnal swi tch and the combi nati on fl asher wi l l
cause the sel ected (ri ght or l eft) turn si gnal i ndi cator
l amp, front park/turn si gnal l amp, front si de marker
l amp and rear tai l /stop/turn si gnal l amp to fl ash on
and off. I f the exteri or l amps are turned off, the front
park/turn si gnal l amp and the front si de marker
l amp wi l l fl ash i n uni son. I f the exteri or l amps are
turned on, the front park/turn si gnal l amp and the
front si de marker l amp wi l l fl ash al ternatel y.
See the owner’s manual i n the vehi cl e gl ove box for
more i nformati on on the features, use and operati on
of the turn si gnal system.
HAZARD WARNING SYSTEM
DESCRIPTION
A hazard warni ng system i s standard factory-i n-
stal l ed safety equi pment on thi s model . Unl i ke the
turn si gnal system, the hazard warni ng system uses
a non-swi tched source of battery current so that the
system wi l l operate regardl ess of the i gni ti on swi tch
posi ti on. The hazard warni ng system i ncl udes the fol -
l owi ng components:
• Combi nati on fl asher
• Front si de marker l amps
• Hazard warni ng swi tch
• Turn si gnal i ndi cator l amps
• Turn si gnal l amps.
Refer to Lamp i n the proper secti on of Group 8L -
Lamps for more i nformati on on the exteri or turn si g-
nal l amps. Refer to Instrument Cluster i n the
proper secti on of Group 8E - I nstrument Panel Sys-
tems for more i nformati on on the turn si gnal i ndi ca-
tor l amps. Fol l owi ng are general descri pti ons of the
major components i n the hazard warni ng system. For
compl ete ci rcui t di agrams, refer to Turn Signals i n
the Contents of Group 8W - Wi ri ng Di agrams.
TJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1
OPERATION
Wi th the hazard warni ng swi tch i n the On posi -
ti on, the hazard warni ng system i s acti vated. When
the hazard warni ng system i s acti vated, the ci rcui try
of the hazard warni ng swi tch and the combi nati on
fl asher wi l l cause both the ri ght si de and the l eft si de
turn si gnal i ndi cator l amps, front park/turn si gnal
l amps, front si de marker l amps and rear tai l /stop/
turn si gnal l amps to fl ash on and off. I f the exteri or
l amps are turned off, the front park/turn si gnal
l amps and the front si de marker l amps wi l l fl ash i n
uni son. I f the exteri or l amps are turned on, the front
park/turn si gnal l amps and the front si de marker
l amps wi l l fl ash al ternatel y.
See the owner’s manual i n the vehi cl e gl ove box for
more i nformati on on the features, use and operati on
of the hazard warni ng system.
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH
DESCRIPTION
The turn si gnal and hazard warni ng swi tches are
i ntegral to the mul ti -functi on swi tch uni t, whi ch i s
secured to the l eft si de of the steeri ng col umn (Fi g.
1). The onl y vi si bl e parts of the mul ti -functi on swi tch
are the control stal k that extends from the l eft si de
of the steeri ng col umn, and the hazard warni ng
swi tch button that protrudes from the top of the
steeri ng col umn. The mul ti -functi on swi tch control
stal k has i nternati onal control symbol s on i t, whi ch
i denti fy i ts functi ons. The hazard warni ng swi tch
button i s i denti fi ed wi th a doubl e tri angl e, whi ch i s
the i nternati onal control symbol for hazard warni ng.
The remai nder of the mul ti -functi on swi tch i s con-
ceal ed beneath the steeri ng col umn shrouds.
The mul ti -functi on swi tch al so contai ns ci rcui try
for the fol l owi ng functi ons:
• Headl amp beam sel ecti on
• Headl amp opti cal horn
The i nformati on contai ned i n thi s group addresses
onl y the mul ti -functi on swi tch turn si gnal and haz-
ard warni ng functi ons. For i nformati on rel ati ve to
the other systems that are control l ed by and ci rcui ts
that are i ntegral to the mul ti -functi on swi tch, see the
group i n thi s servi ce manual that covers that system.
However, the turn si gnal and hazard warni ng
swi tches cannot be repai red. I f these swi tches or any
other ci rcui t or component of the mul ti -functi on
swi tch uni t i s faul ty or damaged, the enti re mul ti -
functi on swi tch uni t must be repl aced.
OPERATION
TURN SIGNAL SWITCH
The mul ti -functi on swi tch control stal k that
extends from the l eft si de of the steeri ng col umn just
bel ow the steeri ng wheel i s moved up or down to
acti vate the turn si gnal swi tch. When the control
stal k i s moved i n the upward di recti on, the ri ght
turn si gnal swi tch ci rcui try i s acti vated; and, when
the control stal k i s moved i n the downward di recti on,
the l eft turn si gnal swi tch ci rcui try i s acti vated. The
turn si gnal swi tch has a detent posi ti on i n each
di recti on that provi des turn si gnal s wi th automati c
cancel l ati on, and an i ntermedi ate momentary posi -
ti on i n each di recti on that provi des turn si gnal s onl y
unti l the mul ti -functi on swi tch control stal k i s
rel eased.
When the turn si gnal swi tch i s i n a detent posi -
ti on, i t i s turned off by one of two turn si gnal cancel -
l i ng cam l obes that are i ntegral to the rotor of the
cl ockspri ng mechani sm. Turni ng the steeri ng wheel
causes the turn si gnal cancel l i ng cam l obes to contact
a cancel actuator i n the mul ti -functi on swi tch, and
the turn si gnal swi tch automati cal l y returns to the
off posi ti on.
HAZARD WARNING SWITCH
The hazard warni ng swi tch i s control l ed by the
hazard warni ng swi tch button. Sl i de the swi tch but-
ton to the l eft to turn the swi tch on and acti vate the
hazard warni ng system, and sl i de the button to the
ri ght agai n to turn the swi tch and the hazard warn-
i ng system off.
Fig. 1 Multi-Function Switch
1 – HAZARD WARNING BUTTON
2 – CANCEL ACTUATOR
3 – CONTROL STALK
8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
TURN SIGNAL CANCELLING CAM
DESCRIPTION
The turn si gnal cancel l i ng cam i s conceal ed wi thi n
the steeri ng col umn bel ow the steeri ng wheel . The
turn si gnal cancel l i ng cam consi sts of two l obes that
are i ntegral to the l ower surface of the cl ockspri ng
rotor. The cl ockspri ng mechani sm provi des turn si g-
nal cancel l ati on as wel l as a constant el ectri cal con-
necti on between the horn swi tch, dri ver si de ai rbag
modul e and speed control swi tches on the steeri ng
wheel and the i nstrument panel wi re harness on the
steeri ng col umn. The housi ng of the cl ockspri ng i s
secured to the steeri ng col umn and remai ns stati on-
ary. The rotor of the cl ockspri ng, i ncl udi ng the turn
si gnal cancel l i ng cam l obes rotate wi th the steeri ng
wheel .
The turn si gnal cancel l i ng cam i s i ntegral to the
cl ockspri ng and cannot be repai red. I f faul ty or dam-
aged, the enti re cl ockspri ng assembl y must be
repl aced. Refer to Clockspring i n the Removal and
I nstal l ati on secti on of Group 8M - Passi ve Restrai nt
Systems for the cl ockspri ng servi ce procedures.
OPERATION
The turn si gnal cancel l i ng cam has two l obes
mol ded i nto the l ower surface of the cl ockspri ng
rotor. When the turn si gnal s are acti vated by movi ng
the mul ti -functi on swi tch control stal k to a detent
posi ti on, a turn si gnal cancel actuator i s extended
from the i nsi de surface of the mul ti -functi on swi tch
housi ng toward the cl ockspri ng rotor. When the
steeri ng wheel i s rotated duri ng the turn, one of the
two turn si gnal cancel l i ng cam l obes wi l l contact the
turn si gnal cancel actuator, rel easi ng the mul ti -func-
ti on swi tch control stal k from i ts detent and cancel -
l i ng the turn si gnal event.
COMBINATION FLASHER
DESCRIPTION
The combi nati on fl asher i s a smart rel ay that func-
ti ons as both the turn si gnal system and the hazard
warni ng system fl asher. The combi nati on fl asher con-
tai ns acti ve el ectroni c I ntegrated Ci rcui try (I C) el e-
ments. Thi s fl asher i s desi gned to handl e the current
fl ow requi rements of the factory-i nstal l ed l i ghti ng. I f
suppl emental l i ghti ng i s added to the turn si gnal
l amp ci rcui ts, such as when towi ng a trai l er wi th
l i ghts, the combi nati on fl asher wi l l automati cal l y try
to compensate to keep the fl ash rate the same.
Whi l e the combi nati on fl asher has a I nternati onal
Standards Organi zati on (I SO)-type rel ay termi nal
confi gurati on or footpri nt, the i nternal ci rcui try i s
much di fferent. The combi nati on fl asher does not use
standard I SO-rel ay i nputs or provi de I SO-rel ay type
outputs or functi ons. The combi nati on fl asher shoul d
never be substi tuted for an I SO-rel ay or repl aced
wi th an I SO-rel ay, or el se component and vehi cl e
damage may occur.
Because of the acti ve el ectroni c el ements wi thi n
the combi nati on fl asher, i t cannot be tested wi th con-
venti onal automoti ve el ectri cal test equi pment. I f the
combi nati on fl asher i s bel i eved to be faul ty, test the
turn si gnal system and hazard warni ng system ci r-
cui ts as descri bed i n thi s group. Then repl ace the
combi nati on fl asher wi th a known good uni t to con-
fi rm system operati on.
The combi nati on fl asher has fi ve bl ade-type termi -
nal s i ntended for the fol l owi ng i nputs and outputs:
fused B(+), fused i gni ti on swi tch output, ground, turn
si gnal ci rcui t, and hazard warni ng ci rcui t. Constant
battery vol tage and ground are suppl i ed to the
fl asher so that i t can perform the hazard warni ng
functi on, and i gni ti on swi tched battery vol tage i s
suppl i ed for the turn si gnal functi on. Refer to Turn
Signals i n the Contents of Group 8W - Wi ri ng Di a-
grams for compl ete ci rcui t di agrams.
The combi nati on fl asher i s l ocated i n a bracket
secured wi th a screw to the undersi de of the upper
steeri ng col umn support bracket, to the ri ght of the
steeri ng col umn under the i nstrument panel . The
combi nati on fl asher cannot be repai red or adjusted
and, i f faul ty or damaged, i t must be repl aced.
OPERATION
The I C wi thi n the combi nati on fl asher (Fi g. 2) con-
tai ns the l ogi c that control s the fl asher operati on and
the fl ash rate. Pi n 6 of the I C recei ves a sense vol t-
age from the hazard warni ng ci rcui t of the mul ti -
functi on swi tch. When the hazard warni ng swi tch i s
turned on, the Љhazard on sense” vol tage wi l l become
l ow due to the ci rcui t bei ng grounded through the
turn si gnal bul bs. Thi s l ow vol tage sense si gnal s the
I C to energi ze the fl ash control Posi ti ve-Negati ve-
Posi ti ve (PNP) transi stor at a pre-cal i brated fl ash
rate or frequency. Each ti me the PNP transi stor ener-
gi zes the hazard warni ng ci rcui t, the pi n 6 “hazard
on sense” vol tage wi l l become hi gh and the I C si gnal s
the PNP transi stor to de-energi ze the ci rcui t. Thi s
cycl i ng wi l l conti nue unti l the hazard warni ng swi tch
i s turned off.
Li kewi se, pi n 8 of the I C recei ves a sense vol tage
from the turn si gnal ci rcui ts of the mul ti -functi on
swi tch. When the l eft or ri ght turn si gnal swi tch i s
turned on, the “turn si gnal on sense” vol tage wi l l
become l ow due to the ci rcui t bei ng grounded
through the turn si gnal bul bs. Thi s l ow vol tage sense
si gnal s the I C to energi ze the fl ash control PNP tran-
si stor at a pre-cal i brated fl ash rate or frequency.
Each ti me the PNP transi stor energi zes the turn si g-
nal ci rcui t, the pi n 8 “turn si gnal on sense” vol tage
TJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3
DESCRIPTION AND OPERATION (Continued)
wi l l become hi gh and the I C si gnal s the PNP transi s-
tor to de-energi ze the ci rcui t. Thi s cycl i ng wi l l con-
ti nue unti l the ri ght or l eft turn si gnal swi tch i s
turned off.
A speci al desi gn feature of the combi nati on fl asher
al l ows i t to “sense” that a turn si gnal ci rcui t or bul b
i s not operati ng, and provi de the dri ver an i ndi cati on
of the condi ti on by fl ashi ng the remai ni ng bul bs i n
the affected ci rcui t at a hi gher rate (120 fl ashes-per-
mi nute or hi gher). Conventi onal fl ashers ei ther con-
ti nue fl ashi ng at thei r typi cal rate (heavy-duty type),
or di sconti nue fl ashi ng the affected ci rcui t enti rel y
(standard-duty type). Duri ng turn si gnal operati on,
the combi nati on fl asher I C compares normal battery
vol tage i nput on pi n 2 wi th the shunt resi stor vol tage
i nput on pi n 7. I f the I C “senses” that the vol tage di f-
ference between pi n 2 and pi n 7 i s di fferent than the
pre-cal i brated val ue of the I C, i t wi l l i ncrease the
rate at whi ch i t si gnal s the PNP transi stor to ener-
gi ze the pi n 1 output. Thus, the i noperati ve hal f (l eft
or ri ght si de) of the turn si gnal ci rcui t wi l l fl ash
faster.
DIAGNOSIS AND TESTING
TURN SIGNAL AND HAZARD WARNING
SYSTEMS
When di agnosi ng the turn si gnal or hazard warn-
i ng ci rcui ts, remember that hi gh generator output
can burn out bul bs rapi dl y and repeatedl y. I f thi s i s a
probl em on the vehi cl e bei ng di agnosed, refer to
Charging System i n the Di agnosi s and Testi ng sec-
ti on of Group 8C - Chargi ng System for further di ag-
nosi s of a possi bl e generator overchargi ng condi ti on.
I f the probl em bei ng di agnosed i s rel ated to a fai l -
ure of the turn si gnal s to automati cal l y cancel fol l ow-
i ng compl eti on of a turn, i nspect the mul ti -functi on
swi tch for a faul ty or damaged cancel actuator and
i nspect the turn si gnal cancel l i ng cam l obes on the
cl ockspri ng mechani sm for damage or i mproper
i nstal l ati on. For compl ete ci rcui t di agrams, refer to
Turn Signals i n the Contents of Group 8W - Wi ri ng
Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Turn the i gni ti on swi tch to the On posi ti on.
Actuate the turn si gnal swi tch or the hazard warni ng
swi tch. Observe the turn si gnal i ndi cator l amp(s) i n
the i nstrument cl uster. I f the fl ash rate i s very hi gh,
check for a turn si gnal bul b that i s not l i t or i s very
di ml y l i t. Repai r the ci rcui ts to that l amp or repl ace
the faul ty bul b, as requi red. I f the turn si gnal i ndi -
cator(s) fai l to l i ght, go to Step 2.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Check the turn si gnal fuse i n the fusebl ock modul e
and/or the hazard warni ng fuse i n the Power Di stri -
buti on Center (PDC). I f OK, go to Step 3. I f not OK,
repai r the shorted ci rcui t or component as requi red
and repl ace the faul ty fuse(s).
(3) Check for battery vol tage at the hazard warn-
i ng fuse i n the PDC. I f OK, go to Step 4. I f not OK,
repai r the open fused B(+) ci rcui t to the battery as
requi red.
(4) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the turn si gnal fuse i n
the fusebl ock modul e. I f OK, go to Step 5. I f not OK,
repai r the open fused i gni ti on swi tch output (accesso-
ry/run) ci rcui t to the i gni ti on swi tch as requi red.
(5) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the combi nati on fl asher from i ts wi re har-
ness connector and repl ace i t wi th a known good
uni t. Connect the battery negati ve cabl e. Test the
operati on of the turn si gnal and hazard warni ng sys-
tems. I f OK, di scard the faul ty combi nati on fl asher.
I f not OK, remove the test fl asher and go to Step 6.
(6) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the combo fl asher i nput
ci rcui t cavi ty i n the combi nati on fl asher wi re harness
connector. I f OK, go to Step 7. I f not OK, go to Step
9.
Fig. 2 Combination Flasher - Typical
8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(7) Turn the i gni ti on swi tch to the Off posi ti on.
Pl ace the hazard warni ng swi tch i n the On posi ti on.
Check for battery vol tage agai n at the combo fl asher
i nput ci rcui t cavi ty i n the combi nati on fl asher wi re
harness connector. I f OK, go to Step 8. I f not OK, go
to Step 9.
(8) Di sconnect and i sol ate the battery negati ve
cabl e. Check for conti nui ty between the ground ci r-
cui t cavi ty of the combi nati on fl asher wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 9. I f not OK, repai r the open
ground ci rcui t to ground as requi red.
(9) Di sconnect the i nstrument panel wi re harness
connector from the mul ti -functi on swi tch connector
receptacl e. Check for conti nui ty between the combo
fl asher i nput ci rcui t cavi ti es i n the combi nati on
fl asher wi re harness connector and i n the i nstrument
panel wi re harness connector for the mul ti -functi on
swi tch. There shoul d be conti nui ty. I f OK, go to Step
10. I f not OK, repai r the open combo fl asher i nput
ci rcui t as requi red.
(10) Check for conti nui ty between the combo
fl asher output ci rcui t cavi ti es i n the combi nati on
fl asher wi re harness connector and i n the i nstrument
panel wi re harness connector for the mul ti -functi on
swi tch. There shoul d be conti nui ty. I f OK, refer to
Turn Signal Switch and Hazard Warning Switch
i n the Di agnosi s and Testi ng secti on of thi s group. I f
not OK, repai r the open combo fl asher output ci rcui t
as requi red.
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH
The turn si gnal swi tch and the hazard warni ng
swi tch are i ntegral to the mul ti -functi on swi tch.
Refer to Turn Signal and Hazard Warning Sys-
tems i n the Di agnosi s and Testi ng secti on of thi s
group before testi ng the mul ti -functi on swi tch. For
compl ete ci rcui t di agrams, refer to Turn Signals i n
the Contents of Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the i nstrument panel wi re harness
connector from the mul ti -functi on swi tch connector
receptacl e.
(2) Usi ng an ohmmeter, perform the swi tch conti -
nui ty checks at the connector receptacl e termi nal s as
shown i n the Mul ti -Functi on Swi tch Conti nui ty chart
(Fi g. 3).
(3) I f the turn si gnal swi tch or hazard warni ng
swi tch fai l s any of the conti nui ty checks, repl ace the
faul ty mul ti -functi on swi tch assembl y as requi red. I f
the swi tch ci rcui ts are OK, repai r the l i ghti ng ci r-
cui ts as requi red.
REMOVAL AND INSTALLATION
COMBINATION FLASHER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel . Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of Group 8E - I nstrument Panel
Systems for the procedures.
Fig. 3 Multi-Function Switch Continuity
SWITCH POSITION CONTINUITY
BETWEEN
TURN
SIGNAL
HAZARD
WARNING
NEUTRAL OFF F and H
F and K
A and E
LEFT OFF F and H
C and K
C and I
A and E
RIGHT OFF F and K
C and H
C and J
A and E
NEUTRAL ON B and E
C and H
C and K
C and I
C and J
TJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5
DIAGNOSIS AND TESTING (Continued)
NOTE: The combination flasher and flasher bracket
are serviced only as a unit.
(3) Reach through the i nboard si de of the i nstru-
ment panel steeri ng col umn openi ng to access and
remove the screw that secures the combi nati on
fl asher bracket to the upper steeri ng col umn mount-
i ng bracket to the ri ght of the steeri ng col umn (Fi g.
4).
(4) Lower the combi nati on fl asher and bracket far
enough to access the wi re harness connector.
(5) Remove the combi nati on fl asher from the wi re
harness connector.
(6) Remove the combi nati on fl asher and bracket
from under the i nstrument panel as a uni t.
INSTALLATION
(1) Posi ti on the combi nati on fl asher and bracket
under the i nstrument panel as a uni t.
(2) Al i gn the combi nati on fl asher termi nal s wi th
the termi nal cavi ti es i n the wi re harness connector.
(3) Push i n fi rml y on the combi nati on fl asher unti l
the termi nal s are ful l y seated i n the termi nal cavi ti es
i n the wi re harness connector.
(4) Posi ti on the combi nati on fl asher and bracket to
the upper steeri ng col umn mounti ng bracket to the
ri ght of the steeri ng col umn under the i nstrument
panel .
(5) I nstal l and ti ghten the screw that secures the
combi nati on fl asher and bracket to the upper steer-
i ng col umn mounti ng bracket. Ti ghten the screw to 4
N·m (35 i n. l bs.).
(6) I nstal l the knee bl ocker onto the i nstrument
panel . Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of Group 8E - I nstrument Panel
Systems for the procedures.
(7) Reconnect the battery negati ve cabl e.
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel . Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of Group 8E - I nstrument Panel
Systems for the procedures.
(3) Remove the three screws that secure the l ower
steeri ng col umn shroud to the upper shroud (Fi g. 5).
(4) I f the vehi cl e i s equi pped wi th a standard non-
ti l t steeri ng col umn, l oosen the two upper steeri ng
col umn mounti ng nuts. I f the vehi cl e i s equi pped
wi th the opti onal ti l t steeri ng col umn, move the ti l t
steeri ng col umn to the ful l y l owered posi ti on.
(5) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(6) Remove the two screws that secure the mul ti -
functi on swi tch water shi el d and bracket to the top of
the steeri ng col umn (Fi g. 6).
(7) Remove the one screw l ocated bel ow the mul ti -
functi on swi tch control stal k that secures the mul ti -
functi on swi tch water shi el d and bracket to the
steeri ng col umn (Fi g. 7).
(8) Gentl y pul l the l ower mounti ng tab of the
mul ti -functi on swi tch water shi el d bracket away from
the steeri ng col umn far enough to cl ear the screw
boss bel ow the mul ti -functi on swi tch control stal k.
Fig. 4 Combination Flasher Remove/Install
1 – UPPER STEERING COLUMN SUPPORT BRACKET
2 – COWL PANEL
3 – COMBINATION FLASHER
4 – SCREW
5 – BRACKET
6 – STEERING COLUMN
7 – WIPER/WASHER SWITCH LEVER
8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(9) Li ft the water shi el d and bracket wi th the
mul ti -functi on swi tch off of the l eft si de of the steer-
i ng col umn far enough to access the two mul ti -func-
ti on swi tch wi re harness connectors. I f the vehi cl e i s
equi pped wi th the opti onal ti l t steeri ng col umn, l i ft-
i ng gentl y upward on the ti l t rel ease l ever wi l l pro-
vi de addi ti onal cl earance to ease mul ti -functi on
swi tch removal .
(10) Di sconnect the two i nstrument panel wi re
harness connectors from the mul ti -functi on swi tch
connector receptacl es.
(11) Remove the mul ti -functi on swi tch and water
shi el d from the steeri ng col umn as a uni t.
(12) Gentl y and careful l y remove the water shi el d
from the swi tch by pul l i ng i t over the hazard warn-
i ng swi tch button and the mul ti -functi on swi tch con-
trol stal k.
INSTALLATION
(1) Gentl y and careful l y i nstal l the water shi el d
onto the swi tch by pul l i ng i t over the hazard warni ng
swi tch button and the mul ti -functi on swi tch control
stal k.
(2) Posi ti on the mul ti -functi on swi tch and water
shi el d near i ts mounts on the steeri ng col umn as a
uni t.
(3) Reconnect the two i nstrument panel wi re har-
ness connectors to the mul ti -functi on swi tch connec-
tor receptacl es.
(4) Posi ti on the mul ti -functi on swi tch onto i ts
mounts on the l eft si de of the steeri ng col umn. I f the
vehi cl e i s equi pped wi th the opti onal ti l t steeri ng col -
umn, l i fti ng gentl y upward on the ti l t rel ease l ever
wi l l provi de addi ti onal cl earance to ease mul ti -func-
ti on swi tch i nstal l ati on.
Fig. 5 Steering Column Shrouds Remove/Install
1 – UPPER SHROUD
2 – SCREW (3)
3 – LOWER SHROUD
4 – STEERING WHEEL
Fig. 6 Water Shield Upper Screws Remove/Install
1 – MOUNTING SCREWS
2 – HAZARD WARNING SWITCH KNOB
3 – MULTI-FUNCTION SWITCH LEVER
4 – WATER SHIELD AND BRACKET
5 – WIPER SWITCH LEVER
Fig. 7 Water Shield Lower Screw Remove/Install
1 – MULTI-FUNCTION SWITCH LEVER
2 – WATER SHIELD AND BRACKET
3 – LOWER MOUNTING SCREW
4 – LOWER MOUNTING TAB
TJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7
REMOVAL AND INSTALLATION (Continued)
(5) Posi ti on the l ower mounti ng tab of the mul ti -
functi on swi tch water shi el d bracket to the steeri ng
col umn screw boss bel ow the mul ti -functi on swi tch
control stal k.
(6) I nstal l and ti ghten the one screw l ocated bel ow
the mul ti -functi on swi tch control stal k that secures
the mul ti -functi on swi tch water shi el d and bracket to
the steeri ng col umn. Ti ghten the screw to 1.1 N·m
(10 i n. l bs.).
(7) I nstal l and ti ghten the two screws that secure
the mul ti -functi on swi tch water shi el d and bracket to
the top of the steeri ng col umn. Ti ghten the screws to
2.2 N·m (20 i n. l bs.).
(8) Posi ti on both the upper and l ower shrouds onto
the steeri ng col umn.
(9) I nstal l and ti ghten the three screws that secure
the l ower steeri ng col umn shroud to the upper
shroud. Ti ghten the screws to 2 N·m (18 i n. l bs.).
(10) I f the vehi cl e i s so equi pped, ti ghten the two
nuts that secure the non-ti l t steeri ng col umn upper
mounti ng bracket to the dash panel steeri ng col umn
support bracket studs. Ti ghten the nuts to 22 N·m
(200 i n. l bs.).
(11) I nstal l the knee bl ocker onto the i nstrument
panel . Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of Group 8E - I nstrument Panel
Systems for the procedures.
(12) Reconnect the battery negati ve cabl e.
8J - 8 TURN SIGNAL AND HAZARD WARNING SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
WIPER AND WASHER SYSTEMS
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
WINDSHIELD WIPER SYSTEM . . . . . . . . . . . . . . 1
WINDSHIELD WASHER SYSTEM. . . . . . . . . . . . . 1
REAR WIPER AND WASHER SYSTEM . . . . . . . . 1
WIPER ARM AND BLADE. . . . . . . . . . . . . . . . . . . 2
WIPER LINKAGE AND PIVOT. . . . . . . . . . . . . . . . 2
WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WIPER SWITCH AND WASHER SWITCH. . . . . . . 3
WASHER RESERVOIR . . . . . . . . . . . . . . . . . . . . . 3
WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WASHER NOZZLE AND PLUMBING. . . . . . . . . . . 3
DIAGNOSIS AND TESTING
WIPER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . 4
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 6
WIPER SWITCH AND WASHER SWITCH. . . . . . . 7
REMOVAL AND INSTALLATION
WIPER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIPER ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIPER LINKAGE AND PIVOT. . . . . . . . . . . . . . . . 9
WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WIPER SWITCH AND WASHER SWITCH. . . . . . 11
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 13
GENERAL INFORMATION
INTRODUCTION
Fol l owi ng are general descri pti ons of the major
components i n the wi per and washer systems. Refer
to 8W-53 - Wi pers i n Group 8W - Wi ri ng Di agrams
for compl ete ci rcui t descri pti ons and di agrams.
DESCRIPTION AND OPERATION
WINDSHIELD WIPER SYSTEM
A two-speed wi ndshi el d wi per system i s standard
equi pment on thi s model . An i ntermi ttent wi ndshi el d
wi per system i s opti onal . The standard system l ets
the dri ver sel ect from two wi per speeds, l ow or hi gh.
The i ntermi ttent wi per system adds an i ntermi ttent
wi pe del ay feature.
On model s equi pped wi th the i ntermi ttent wi per
system, the i ntermi ttent wi pe mode del ay ti mes are
dri ver adjustabl e from about one second to about fi f-
teen seconds. The i ntermi ttent wi pe mode i s provi ded
by del ay l ogi c and rel ay control ci rcui try contai ned
wi thi n the i ntermi ttent wi per/washer swi tch. The
i ntermi ttent wi pe rel ay i s al so contai ned wi thi n the
swi tch.
The wi ndshi el d wi pers wi l l operate onl y when the
i gni ti on swi tch i s i n the Accessory or On posi ti ons. A
fuse l ocated i n the fusebl ock modul e protects the ci r-
cui try of ei ther wi ndshi el d wi per system. Refer to the
owner’s manual for more i nformati on on the wi nd-
shi el d wi per system control s and operati on.
WINDSHIELD WASHER SYSTEM
An el ectri cal l y operated wi ndshi el d washer system
i s standard equi pment. A washer reservoi r i n the
engi ne compartment hol ds the washer fl ui d, whi ch i s
pressuri zed by a pump when the wi ndshi el d washer
swi tch l ever i s actuated. The wi ndshi el d washer
pump feeds the pressuri zed washer fl ui d through the
washer system pl umbi ng to the wi ndshi el d washer
nozzl es.
I f the vehi cl e i s equi pped wi th the two-speed wi per
system and the wi pers are not al ready turned on
when the washers are acti vated, the wi per swi tch
wi l l be turned on to the l ow speed posi ti on automat-
i cal l y. The wi pers must be turned off manual l y fol -
l owi ng a washer swi tch acti vati on. I f the vehi cl e i s
equi pped wi th the i ntermi ttent wi pe system and the
wi pers are not turned on when the washers are acti -
vated, the wi pers wi l l be automati cal l y cycl ed for one
or two wi pes, then be turned off.
The washers wi l l operate onl y when the i gni ti on
swi tch i s i n the Accessory or On posi ti ons. A fuse
l ocated i n the fusebl ock modul e protects the ci rcui try
of the washer system. Refer to the owner’s manual
for more i nformati on on the wi ndshi el d washer sys-
tem control s and operati on.
REAR WIPER AND WASHER SYSTEM
A rear wi per and washer system i s standard equi p-
ment on model s equi pped wi th the opti onal hardtop.
The rear wi per system provi des the fol l owi ng operat-
i ng modes:
• Conti nuous fi xed-cycl e wi pe.
• A rear washer mode.
TJ WIPER AND WASHER SYSTEMS 8K - 1
• A park mode that operates the wi per motor unti l
the bl ade reaches i ts park posi ti on when the rear
wi per swi tch i s pl aced i n the Off posi ti on.
A si ngl e swi tch i n the i nstrument panel accessory
swi tch bezel control s both the rear wi per and washer
functi ons. The rear washer system shares the reser-
voi r of the wi ndshi el d washer system, but has i ts
own dedi cated washer pump and pl umbi ng.
The rear wi per and washer systems wi l l operate
onl y when the i gni ti on swi tch i s i n the On posi ti on. A
fuse i n the fusebl ock modul e protects the ci rcui try of
both the rear wi per and washer systems.
Refer to the owner’s manual for more i nformati on
on the rear wi per and washer system control s and
operati on.
WIPER ARM AND BLADE
Al l model s have two 33.02-centi meter (13-i nch)
wi ndshi el d wi per bl ades wi th non-repl aceabl e rubber
el ements (squeegees). The rear wi per uses a si ngl e
45.72-centi meter (18-i nch) wi per bl ade wi th a non-re-
pl aceabl e rubber el ement (squeegee).
Cauti on shoul d be exerci sed to protect the rubber
squeegees from any petrol eum-based cl eaners or con-
tami nants, whi ch wi l l rapi dl y deteri orate the rubber.
I f the squeegees are damaged, worn, or contami -
nated, the enti re wi per bl ade assembl y must be
repl aced.
Wi per squeegees exposed to the el ements for a l ong
ti me tend to l ose thei r wi pi ng effecti veness. Peri odi c
cl eani ng of the squeegees i s suggested to remove
deposi ts of sal t and road fi l m. The wi per bl ades,
arms, and wi ndshi el d or rear l i ftgl ass shoul d be
cl eaned wi th a sponge or cl oth and wi ndshi el d
washer fl ui d, a mi l d detergent, or a non-abrasi ve
cl eaner. I f the squeegees conti nue to streak or smear,
the wi per bl ades shoul d be repl aced.
The bl ades are mounted to spri ng-l oaded wi per
arms. The spri ng tensi on of the wi per arms control s
the pressure appl i ed to the bl ades on the gl ass. The
wi ndshi el d wi per arms are secured by an i ntegral
l atch to the two wi per pi vots on the cowl pl enum cov-
er/gri l l e panel at the base of the wi ndshi el d. The rear
wi per arm i s secured by an i ntegral l atch di rectl y to
the rear wi per motor output shaft on the l i ftgl ass.
The wi per arms and bl ades cannot be adjusted or
repai red. I f faul ty or damaged, they must be
repl aced.
WIPER LINKAGE AND PIVOT
The wi per l i nkage and pi vot modul e i s secured
wi th screws to the cowl pl enum panel beneath the
cowl pl enum cover/gri l l e panel . The wi per motor i s
secured wi th screws to the center of the l i nkage and
pi vot modul e bracket. The wi per pi vots are secured
to the ends of the modul e bracket.
The dri ver si de wi per pi vot crank arm and the
wi per motor crank arm each have bal l studs on thei r
ends. The passenger si de crank arm has two bal l
studs. A dri ve l i nk i s connected from the motor crank
arm bal l stud to one bal l stud on the passenger si de
pi vot crank arm. A connecti ng l i nk i s connected from
the other bal l stud on the passenger si de pi vot crank
arm to the dri ver si de pi vot crank arm bal l stud.
Both the dri ve l i nk and the connector l i nk have a
pl asti c socket-type bushi ng on each end. Each of the
socket-type bushi ngs are snap-fi t over thei r respec-
ti ve bal l studs.
The wi per l i nkage, pi vots, bushi ngs, motor, crank
arm, and mounti ng bracket are onl y servi ced as a
compl ete uni t. I f any part of thi s assembl y except the
motor i s faul ty or damaged, the enti re uni t must be
repl aced. The wi per motor i s al so avai l abl e as a sep-
arate servi ce i tem.
WIPER MOTOR
FRONT
The two-speed permanent magnet wi per motor has
an i ntegral transmi ssi on and park swi tch. The motor
al so contai ns an i nternal automati c resetti ng ci rcui t
breaker to protect the motor from overl oads. The
motor i s secured to the wi per l i nkage and pi vot mod-
ul e bracket wi th three screws and i s protected by a
rubber boot. The wi per motor output shaft passes
through a hol e i n the modul e bracket, where a nut
secures the wi per motor crank arm to the motor out-
put shaft.
Wi per speed i s control l ed by current fl ow to the
proper set of brushes. The wi per motor compl etes i ts
wi pe cycl e when the wi ndshi el d wi per swi tch stal k i s
moved to the Off posi ti on, and parks the bl ades i n
the l owest porti on of the wi pe pattern.
The wi ndshi el d wi per motor cannot be repai red. I f
faul ty or damaged, the enti re wi per motor and boot
assembl y must be repl aced. The wi per l i nkage and
pi vots modul e, whi ch i ncl udes the wi per motor, i s
al so avai l abl e for servi ce.
REAR
The rear wi per motor i s secured on the i nsi de of
the l i ftgl ass wi th a sl otted bracket that fi ts onto a
grommet under the ri ght l i ftgl ass hi nge mounti ng
nut. The motor output shaft passes through the l i ft-
gl ass, where a rubber gasket and a pl asti c bezel and
nut uni t seal and secure the output shaft to the out-
si de of the l i ftgl ass. The rear wi per arm i s secured
di rectl y to the motor output shaft.
The rear wi per motor uni t contai ns an i nternal
park swi tch. The motor al so contai ns an automati c
resetti ng thermal swi tch for overl oad protecti on.
8K - 2 WIPER AND WASHER SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
The rear wi per motor cannot be repai red. I f faul ty
or damaged, the enti re rear wi per motor assembl y
must be repl aced.
WIPER SWITCH AND WASHER SWITCH
FRONT
The wi ndshi el d wi per and washer swi tches are
mounted on the ri ght si de of the steeri ng col umn
(Fi g. 1). The swi tch stal k i s moved up or down to
sel ect the wi per swi tch mode, and pul l ed towards the
steeri ng wheel to acti vate the washer system. Model s
wi th the i ntermi ttent wi per system al so have a knob
on the end of the swi tch stal k, whi ch i s rotated to
sel ect the desi red del ay i nterval . The wi ndshi el d
wi per and washer swi tch contai ns ci rcui try for the
fol l owi ng functi ons:
• Wi ndshi el d wi pers
• I ntermi ttent wi per del ay rel ay control and l ogi c
(i f the vehi cl e i s so equi pped)
• I ntermi ttent wi pe rel ay (i f the vehi cl e i s so
equi pped)
• Wi ndshi el d washers.
The wi ndshi el d wi per and washer swi tch cannot be
repai red. I f any functi on of the swi tch i s faul ty, or i f
the swi tch i s damaged, the enti re swi tch uni t must
be repl aced.
REAR
The si ngl e two-functi on rear wi per and washer
swi tch i s i nstal l ed i n the i nstrument panel accessory
swi tch bezel , whi ch i s l ocated near the bottom of the
i nstrument panel center bezel area, next to the ash
recei ver. The rear wi per and washer swi tch control s
the rear wi per and washer functi ons.
The toggl e-type swi tch features a detent i n the On
posi ti on, and a momentary Wash posi ti on. The rear
wi per and washer swi tch al so has an i ntegral i l l umi -
nati on l amp wi th a servi ceabl e bul b. The swi tch knob
i s pushed down to i ts detent to acti vate the rear
wi per system, and down agai n to the momentary
posi ti on to acti vate the rear washer system. Both the
rear wi per and rear washer motors wi l l operate con-
ti nuousl y for as l ong as the swi tch i s hel d i n the
momentary Wash posi ti on.
The rear wi per and washer swi tch cannot be
repai red and, i f faul ty or damaged, the enti re swi tch
uni t must be repl aced.
WASHER RESERVOIR
A si ngl e washer fl ui d reservoi r i s used for both the
front and rear washer systems. The washer fl ui d res-
ervoi r i s secured to the i nner fender shi el d, over the
l eft front wheel house i n the engi ne compartment.
Each washer pump and motor uni t has a barbed
ni ppl e, whi ch i s i nstal l ed through a rubber grommet
seal i nserted i n a hol e near the bottom of the reser-
voi r. The washer pumps are retai ned by an i nterfer-
ence fi t between the barbed ni ppl e and the grommet
seal , whi ch i s a l i ght press fi t.
The washer reservoi r has a snap-fi t fi l l er cap wi th
a rubber gasket. The cap hi nges on and i s secured to
a mol ded-i n hook formati on on the reservoi r behi nd
the fi l l er neck.
The washer reservoi r and fi l l er cap are each avai l -
abl e for servi ce.
WASHER PUMP
The washer pumps and motors are mounted near
the bottom of the washer reservoi r. A barbed ni ppl e
on the pump housi ng passes through a rubber grom-
met seal i nstal l ed i n a hol e near the bottom of the
reservoi r. The washer pump i s retai ned by an i nter-
ference fi t between the barbed pump ni ppl e and the
grommet seal , whi ch i s a l i ght press fi t.
A permanentl y l ubri cated and seal ed motor i s cou-
pl ed to a rotor-type pump. Washer fl ui d i s gravi ty-fed
from the reservoi r to the pump. When the motor i s
energi zed, the pump pressuri zes the washer fl ui d
and forces i t through the pl umbi ng to the nozzl es.
The washer pump and motor uni t cannot be
repai red. I f faul ty, the enti re washer pump and
motor uni t must be repl aced.
WASHER NOZZLE AND PLUMBING
FRONT
Pressuri zed washer fl ui d i s fed through a si ngl e
hose, attached to a barbed ni ppl e on the front washer
pump. The hose i s routed to a tee fi tti ng l ocated near
the rear i nner hood panel rei nforcement. Hoses from
the tee fi tti ng are routed to the two nozzl es.
A check val ve i s l ocated i n the washer suppl y l i ne
near each of the two front nozzl es, whi ch prevents
washer fl ui d drai n-back or si phoni ng from occurri ng.
Fig. 1 Windshield Wiper Switch and Washer Switch
TJ WIPER AND WASHER SYSTEMS 8K - 3
DESCRIPTION AND OPERATION (Continued)
The nozzl es are snapped i nto openi ngs i n the hood
panel bel ow the wi ndshi el d
The two washer nozzl es each emi t two streams of
washer fl ui d i nto the wi pe pattern (Fi g. 2). I f the ai m
of the washer fl ui d streams i s unacceptabl e, each
stream can be adjusted usi ng a pi n i nserted i n the
nozzl e ori fi ce to rotate the nozzl e bal l .
The nozzl es, check val ves and hose fi tti ngs cannot
be repai red and, i f faul ty or damaged, they must be
repl aced.
REAR
Pressuri zed washer fl ui d i s fed through a si ngl e
hose, attached to a barbed ni ppl e on the rear washer
pump. The hose i s routed from the front of the vehi -
cl e to the l i ftgl ass wi th the l eft body wi re harness. At
the l eft rear corner of the hardtop, the hose connects
to a check val ve, whi ch prevents washer fl ui d drai n-
back or si phoni ng from occurri ng.
There i s al so a washer hose cap attached to the
hose bel ow the check val ve (Fi g. 3). When the hard-
top i s removed from the vehi cl e, the body hal f of the
washer hose must be di sconnected from the check
val ve. The washer hose cap i s used to pl ug the body
hal f of the washer hose after i t i s di sconnected from
the check val ve.
From the check val ve, another si ngl e hose i s routed
through the rear l i ftgl ass openi ng rei nforcements of
the hardtop to the rear wi per motor cover. Behi nd
the rear wi per motor cover, the hose attaches to the
rear washer nozzl e ni ppl e.
The fl ui di c rear washer nozzl e and a seal are
i nstal l ed from the outsi de through a hol e i n the l i ft-
gl ass near the rear wi per motor output shaft. The
nozzl e i s secured on the i nsi de of the gl ass by a pl as-
ti c hex nut.
The rear washer nozzl e cannot be adjusted. The
nozzl e, check val ve, and hose fi tti ngs cannot be
repai red and, i f faul ty or damaged, they must be
repl aced.
DIAGNOSIS AND TESTING
WIPER SYSTEM
FRONT
For ci rcui t descri pti ons and di agrams, refer to
8W-53 - Wi pers i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Check the fuse i n the fusebl ock modul e. I f OK,
go to Step 2. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. Unpl ug the wi ndshi el d wi per swi tch wi re har-
ness connector. Connect the battery negati ve cabl e.
Turn the i gni ti on swi tch to the On posi ti on. Check
for battery vol tage at the fused i gni ti on swi tch out-
put (run/acc) ci rcui t cavi ty of the wi per swi tch wi re
harness connector. I f OK, go to Step 3. I f not OK,
repai r the open ci rcui t to the fusebl ock modul e as
requi red.
(3) I f the vehi cl e i s equi pped wi th the opti onal
i ntermi ttent wi per system and the probl em bei ng
di agnosed i nvol ves onl y the pul se wi pe, wi pe-after-
wash, or i ntermi ttent wi pe modes, go to Step 4. I f
not, go to Step 5.
Fig. 2 Windshield Washer Nozzles
1 – HOOD
2 – ADJUST WITH A PIN
3 – NOZZLE
Fig. 3 Rear Washer Hose Cap
1 – CAP
2 – WASHER FLUID TUBE
8K - 4 WIPER AND WASHER SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the wi per swi tch wi re harness connector and a
good ground. There shoul d be conti nui ty. I f OK,
repl ace the faul ty swi tch. I f not OK, repai r the open
ci rcui t to ground as requi red.
(5) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the wi ndshi el d wi per and washer swi tch and
check the swi tch conti nui ty. See Wi per Swi tch and
Washer Swi tch i n the Di agnosi s and Testi ng secti on
of thi s group for the procedures. I f OK, go to Step 6.
I f not OK, repl ace the faul ty swi tch.
(6) Unpl ug the wi ndshi el d wi per motor wi re har-
ness connector. Check for conti nui ty between the
ground ci rcui t cavi ty i n the body hal f of the wi per
motor wi re harness connector and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 7. I f not
OK, repai r the open ci rcui t to ground as requi red.
(7) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (run/acc) ci r-
cui t cavi ty i n the body hal f of the wi per motor wi re har-
ness connector. I f OK, go to Step 8. I f not OK, repai r
the open ci rcui t to the fusebl ock modul e as requi red.
(8) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Wi th the wi ndshi el d wi per and washer swi tch wi re
harness connector sti l l unpl ugged, check the cavi ti es
for each of the fol l owi ng ci rcui ts i n the body hal f of
the wi per motor wi re harness connector for conti nu-
i ty to ground. I n each case, there shoul d be no conti -
nui ty. I f OK, go to Step 9. I f not OK, repai r the short
ci rcui t as requi red.
• Wi per park swi tch sense
• Wi per swi tch l ow speed output
• Wi per swi tch hi gh speed output.
(9) Check for conti nui ty between the cavi ti es i n
the body hal f of the wi per motor wi re harness con-
nector and the cavi ti es i n the wi ndshi el d wi per and
washer swi tch wi re harness connector for each of the
fol l owi ng ci rcui ts. I n each case, there shoul d be con-
ti nui ty. I f OK, repl ace the faul ty wi per motor. I f not
OK, repai r the open ci rcui t as requi red.
• Wi per park swi tch sense
• Wi per swi tch l ow speed output
• Wi per swi tch hi gh speed output.
REAR
For ci rcui t descri pti ons and di agrams, refer to
8W-53 - Wi pers i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Check the fuse i n the fusebl ock modul e. I f OK,
go to Step 2. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the accessory swi tch bezel and unpl ug
the wi re harness connector from the rear wi per and
washer swi tch. Connect the battery negati ve cabl e.
Turn the i gni ti on swi tch to the On posi ti on. Check
for battery vol tage at the rear washer swi tch output
ci rcui t cavi ty of the rear wi per and washer swi tch
wi re harness connector. I f OK, go to Step 3. I f not
OK, repai r the open ci rcui t to the fusebl ock modul e
as requi red.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the rear wi per and washer swi tch wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 4. I f not OK, repai r the open
ci rcui t to ground as requi red.
(4) Test the rear wi per and washer swi tch conti nu-
i ty. See Wi per Swi tch and Washer Swi tch i n the
Di agnosi s and Testi ng secti on of thi s group for the
procedures. I f OK, go to Step 5. I f not OK, repl ace
the faul ty swi tch.
(5) Remove the rear wi per motor cover and unpl ug
the rear wi per motor wi re harness connector. Con-
nect the battery negati ve cabl e. Turn the i gni ti on
swi tch to the On posi ti on. Check for battery vol tage
at the fused i gni ti on swi tch output (run) ci rcui t cav-
i ty of the rear wi per motor wi re harness connector. I f
OK, go to Step 6. I f not OK, repai r the open ci rcui t to
the fusebl ock modul e as requi red.
(6) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the rear wi per motor wi re harness connector
and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 7. I f not OK, repai r the open ci rcui t to
ground as requi red.
(7) Check for conti nui ty between the rear wi per
motor control ci rcui t cavi ty of the rear wi per motor
wi re harness connector and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 8. I f not
OK, repai r the short ci rcui t as requi red.
(8) Check for conti nui ty between the rear wi per
motor control ci rcui t cavi ti es of the rear wi per motor
wi re harness connector and the rear wi per and
washer swi tch wi re harness connector. There shoul d
be conti nui ty. I f OK, repl ace the faul ty rear wi per
motor. I f not OK, repai r the open ci rcui t as requi red.
TJ WIPER AND WASHER SYSTEMS 8K - 5
DIAGNOSIS AND TESTING (Continued)
WASHER SYSTEM
FRONT
The di agnosi s found here addresses an i noperati ve
front washer pump. I f the washer pump operates,
but no washer fl ui d i s emi tted from the washer noz-
zl es, be certai n to check the fl ui d l evel i n the reser-
voi r. Check for i ce or other forei gn materi al i n the
reservoi r, and for pi nched, di sconnected, broken, or
i ncorrectl y routed washer system pl umbi ng. For ci r-
cui t descri pti ons and di agrams, refer to 8W-53 - Wi p-
ers i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Turn the i gni ti on swi tch to the On posi ti on.
Turn the wi per swi tch to the Low or Hi gh speed posi -
ti on. Check whether the wi pers operate. I f OK, go to
Step 2. I f not OK, see the Wi per System di agnosi s i n
thi s group.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Unpl ug the front washer pump wi re harness connec-
tor. Check for conti nui ty between the ground ci rcui t
cavi ty of the front washer pump wi re harness connec-
tor and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 3. I f not OK, repai r the open ci rcui t to
ground as requi red.
(3) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the front washer swi tch output ci rcui t cav-
i ty of the front washer pump wi re harness connector
whi l e actuati ng the washer swi tch. I f OK, repl ace the
faul ty washer pump. I f not OK, go to Step 4.
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Unpl ug the wi ndshi el d wi per/washer swi tch wi re
harness connector. Check for conti nui ty between the
front washer swi tch output ci rcui t cavi ty of the front
washer pump wi re harness connector and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 5 I f not OK, repai r the short ci rcui t as requi red.
(5) Check for conti nui ty between the front washer
swi tch output ci rcui t cavi ti es of the front washer
pump wi re harness connector and the wi per/washer
swi tch wi re harness connector. There shoul d be con-
ti nui ty. I f OK, repl ace the faul ty swi tch. I f not OK,
repai r the open ci rcui t as requi red.
REAR
The di agnosi s found here addresses an i noperati ve
rear washer pump. I f the washer pump operates, but
no washer fl ui d i s emi tted from the washer nozzl e, be
certai n to check the fl ui d l evel i n the reservoi r. Check
for i ce or other forei gn materi al i n the reservoi r, and
for pi nched, di sconnected, broken, or i ncorrectl y
routed washer system pl umbi ng. For ci rcui t descri p-
ti ons and di agrams, refer to 8W-53 - Wi pers i n Group
8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Turn the i gni ti on swi tch to the On posi ti on.
Pl ace the rear wi per/washer swi tch i n the Wi pe posi -
ti on. Check whether the rear wi per i s operati ng. I f
OK, go to Step 2. I f not OK, see the Wi per System
di agnosi s i n thi s group.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Unpl ug the rear washer pump wi re harness connec-
tor. Check for conti nui ty between the ground ci rcui t
cavi ty of the rear washer pump wi re harness connec-
tor and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 3. I f not OK, repai r the open ci rcui t to
ground as requi red.
(3) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the rear washer motor control ci rcui t cav-
i ty of the rear washer pump wi re harness connector
whi l e the rear washer swi tch i s actuated. I f OK,
repl ace the faul ty pump. I f not OK, go to Step 4.
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Unpl ug the rear wi per/washer swi tch wi re harness
connector. Check for conti nui ty between the rear
washer motor control ci rcui t cavi ty of the rear
washer pump wi re harness connector and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 5. I f not OK, repai r the short ci rcui t as
requi red.
(5) Check for conti nui ty between the rear washer
motor control ci rcui t cavi ti es of the rear washer
pump wi re harness connector and the rear wi per/
washer swi tch wi re harness connector. There shoul d
be conti nui ty. I f OK, repl ace the faul ty swi tch. I f not
OK, repai r the open ci rcui t as requi red.
8K - 6 WIPER AND WASHER SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
WIPER SWITCH AND WASHER SWITCH
FRONT
Perform the di agnosi s for the front wi per system
and/or washer system as descri bed i n thi s group
before testi ng the front wi per and washer swi tch. For
ci rcui t descri pti ons and di agrams, see 8W-53 - Wi p-
ers i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the front wi per and washer swi tch
from the steeri ng col umn and unpl ug the wi re har-
ness connector from the swi tch.
(3) Usi ng an ohmmeter, perform the swi tch conti -
nui ty checks at the swi tch termi nal s as shown i n the
Wi ndshi el d Wi per Swi tch and Washer Swi tch Conti -
nui ty chart (Fi g. 4).
(4) I f the swi tch fai l s any of the conti nui ty checks,
repl ace the faul ty swi tch. I f the swi tch i s OK, repai r
the wi per system and/or washer system wi re harness
ci rcui ts as requi red.
REAR
Perform the di agnosi s for the rear wi per system
and/or washer system as descri bed i n thi s group
before testi ng the rear wi per and washer swi tch. For
ci rcui t descri pti ons and di agrams, see 8W-53 - Wi p-
ers i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the accessory swi tch bezel from the
i nstrument panel and unpl ug the rear wi per and
washer swi tch wi re harness connector.
(2) Usi ng an ohmmeter, check the rear wi per and
washer swi tch conti nui ty at the swi tch termi nal s as
shown i n the Rear Wi per Swi tch and Washer Swi tch
Conti nui ty chart (Fi g. 5).
(3) I f the swi tch fai l s any of the conti nui ty checks,
repl ace the faul ty swi tch. I f the swi tch i s OK, repai r
the rear wi per system and/or washer system wi re
harness ci rcui ts as requi red.
SWITCH POSITION CONTINUITY BETWEEN
OFF PIN P2 AND PIN L
LOW PIN P1 AND PIN L
HIGH PIN P1 AND PIN H
WASH PIN P1 AND PIN W
INTERMITTENT CANNOT BE CHECKED
Fig. 4 Windshield Wiper Switch and Washer Switch
Continuity
SWITCH POSITION CONTINUITY BETWEEN
OFF 1 AND 4
WIPE 4 AND 5
WASH 2 AND 5, 4 AND 5
ILLUMINATION LAMP 1 AND 3
Fig. 5 Rear Wiper Switch and Washer Switch
Continuity
TJ WIPER AND WASHER SYSTEMS 8K - 7
DIAGNOSIS AND TESTING (Continued)
REMOVAL AND INSTALLATION
WIPER BLADE
FRONT
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.
(1) Li ft the wi per arm to rai se the wi per bl ade and
el ement off of the wi ndshi el d gl ass.
(2) To remove the wi per bl ade from the wi per arm,
push the rel ease tab under the arm ti p and sl i de the
bl ade away from the ti p towards the pi vot end of the
arm (Fi g. 6).
(3) To i nstal l the wi per bl ade on the wi per arm,
sl i de the bl ade retai ner i nto the U-shaped formati on
on the ti p of the wi per arm unti l the rel ease tab
snaps i nto i ts l ocked posi ti on. Be certai n that the
notched retai ner for the wi per el ement i s ori ented
towards the end of the wi per bl ade that i s nearest to
the wi per pi vot.
REAR
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.
(1) Li ft the rear wi per arm to rai se the wi per bl ade
and el ement off of the rear l i ftgl ass.
(2) To remove the wi per bl ade from the wi per arm,
push the rel ease tab under the arm ti p and sl i de the
bl ade away from the ti p towards the rear wi per
motor output shaft end of the arm (Fi g. 6).
(3) To i nstal l the wi per bl ade on the wi per arm,
sl i de the bl ade retai ner i nto the U-shaped formati on
on the ti p of the wi per arm unti l the rel ease tab
snaps i nto i ts l ocked posi ti on. Be certai n that the
notched retai ner for the wi per el ement i s ori ented
towards the end of the wi per bl ade that i s nearest to
the rear wi per motor output shaft.
WIPER ARM
CAUTION: The use of a screwdriver or other prying
tool to remove a wiper arm may distort it. This dis-
tortion could allow the arm to come off of the pivot
shaft, regardless of how carefully it is installed.
FRONT
(1) Li ft the wi per arm to permi t the l atch to be
pul l ed out to i ts hol di ng posi ti on, then rel ease the
arm (Fi g. 7). The arm wi l l remai n off the wi ndshi el d
wi th the l atch i n thi s posi ti on.
(2) Remove the arm from the pi vot usi ng a rocki ng
moti on.
(3) I nstal l the arm and bl ade wi th the wi per motor
i n the Park posi ti on. See the Front Wi per Arm
I nstal l ati on i l l ustrati on (Fi g. 8).
(4) Mount the arms on the pi vot shafts so that the
ti p of the wi per bl ade i s on the upper edge of the
l ower wi ndshi el d bl ackout area, + 15 mm/– 0 mm (+
0.59 i n./ – 0 i n.).
(5) Li ft the wi per arm away from the wi ndshi el d
sl i ghtl y to rel i eve the spri ng tensi on on the l atch.
Push the l atch i nto the l ocked posi ti on and sl owl y
rel ease the arm unti l the wi per bl ade rests on the
wi ndshi el d.
(6) Operate the wi pers wi th the wi ndshi el d gl ass
wet, then turn the wi per swi tch to the Off posi ti on.
Check for the correct wi per arm posi ti oni ng and
readjust i f requi red.
Fig. 6 Wiper Blade Remove/Install - Typical
1 – RELEASE TAB
Fig. 7 Wiper Arm Remove/Install
1 – LOCKING LATCH
2 – ARM
8K - 8 WIPER AND WASHER SYSTEMS TJ
REAR
(1) Li ft the wi per arm to permi t the l atch to be
pul l ed out to i ts hol di ng posi ti on, then rel ease the
arm (Fi g. 7). The arm wi l l remai n off the l i ftgl ass
wi th the l atch i n thi s posi ti on.
(2) Remove the wi per arm from the motor output
shaft usi ng a rocki ng moti on.
(3) I nstal l the rear wi per arm wi th the wi per
motor i n the Park posi ti on. Pl ace the rear wi per
bl ade on the l i ftgl ass so that i t i s paral l el to or ti pped
down from the upper edge of the l i ftgl ass a maxi mum
of 80 mm (3.14 i n.) (Fi g. 9).
(4) Li ft the wi per arm away from the l i ftgl ass
sl i ghtl y to rel i eve the spri ng tensi on on the l atch.
Push the l atch i nto the l ocked posi ti on and sl owl y
rel ease the arm unti l the wi per bl ade rests on the
l i ftgl ass.
(5) Operate the wi per wi th the l i ftgl ass wet, then
turn the wi per swi tch to the Off posi ti on. Check for
the correct wi per arm posi ti oni ng and readjust i f
requi red.
WIPER LINKAGE AND PIVOT
The wi per l i nkage and pi vots can onl y be removed
from or i nstal l ed i n the vehi cl e as a uni t wi th the
wi per motor. See Wi per Motor i n thi s group for the
servi ce procedures.
WIPER MOTOR
FRONT
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the wi per arms from the wi per pi vots.
See Wi per Arm i n thi s group for the procedures.
(3) Remove the one screw that secures the center
of the cowl pl enum cover/gri l l e panel to the cowl pl e-
num panel .
(4) Remove the four screws that secure the cowl
pl enum cover/gri l l e panel to the cowl panel near the
base of the wi ndshi el d.
(5) Open and support the hood
(6) Pul l each end of the cowl to hood seal away
from the metal fl ange where the dash panel and cowl
pl enum panel meet far enough to access the one
screw that secures each outboard end of the cowl pl e-
num cover/gri l l e panel to the cowl pl enum panel (Fi g.
10).
(7) Remove the one screw that secures each out-
board end of the cowl pl enum cover/gri l l e panel to
the cowl pl enum panel .
(8) Careful l y remove the cowl pl enum cover/gri l l e
panel from the vehi cl e, so as not to damage the pai nt
around the pi vot openi ngs of the panel .
(9) Reach i nto the cowl pl enum and unpl ug the
wi per motor wi re harness connector.
(10) Remove the three screws that secure the
wi per modul e mounti ng bracket to the cowl pl enum
panel (Fi g. 11).
(11) Remove the wi per modul e from the cowl pl e-
num as a uni t.
(12) Rel ease the retai ner that secures the wi per
motor wi re harness connector to the wi per modul e
bracket.
(13) Turn the wi per modul e over and remove the
nut that secures the wi per l i nkage crank arm to the
wi per motor output shaft.
(14) Remove the three screws that secure the
wi per motor to the wi per modul e mounti ng bracket.
(15) Remove the wi per motor from the wi per mod-
ul e bracket.
(16) Reverse the removal procedures to i nstal l .
Ti ghten the mounti ng hardware as fol l ows:
• Wi per motor screws - 6 N·m (53 i n. l bs.)
• Crank arm nut - 11.5 N·m (101 i n. l bs.)
• Wi per modul e bracket screws - 7.9 N·m (70 i n.
l bs.)
Fig. 8 Front Wiper Arm Installation
1 – WINDSHIELD BLACKOUT AREA
2 – PARK BLADE ON UPPER EDGE OF BLACKOUT AREA
+15 mm — 0 mm (+0.59 in. — 0 in.)
Fig. 9 Rear Wiper Arm Installation
1 – TIP OF BLADE PARALLEL TO OR TIPPED DOWN FROM
EDGE OF GLASS MAXIMUM 80 mm (3.14 in.)
TJ WIPER AND WASHER SYSTEMS 8K - 9
REMOVAL AND INSTALLATION (Continued)
• Cowl pl enum cover/gri l l e panel screws - 1.7 N·m
(15 i n. l bs.).
REAR
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) From the outsi de of the l i ftgl ass, remove the
rear wi per arm from the rear wi per motor output
shaft. See Wi per Arm i n thi s group for the proce-
dures.
(3) From the outsi de of the l i ftgl ass, remove the
rear wi per motor output shaft nut and bezel uni t
(Fi g. 12).
(4) From the outsi de of the l i ftgl ass, remove the
rear wi per motor output shaft rubber gasket.
(5) From the i nsi de of the l i ftgl ass, remove the
three screws that secure the rear wi per motor cover
to the motor.
(6) Unpl ug the rear wi per motor wi re harness con-
nector.
Fig. 10 Cowl Plenum Cover/Grille Panel Remove/
Install
1 – SEAL
2 – SCREW
3 – COWL PLENUM COVER/GRILLE PANEL
4 – SCREW
5 – U–NUT
6 – COWL PLENUM PANEL
7 – DASH PANEL
8 – COWL TO HOOD SEAL
9 – U–NUT
10 – PLASTIC NUT
11 – SCREW
Fig. 11 Wiper Module Assembly Remove/Install
1 – SCREW
2 – LINKAGE ASSEMBLY
3 – CONNECTOR
4 – WIPER MOTOR
Fig. 12 Rear Wiper and Washer System
1 – COVER
2 – OUTPUT SHAFT
3 – NUT
4 – NOZZLE
5 – HINGE COVER
6 – NUT
7 – NOZZLE
8 – MOTOR
9 – SCREW
10 – HOSE
11 – CONNECTOR
8K - 10 WIPER AND WASHER SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(7) Loosen, but do not remove, the ri ght l i ftgl ass
hi nge nut.
(8) From the i nsi de of the l i ftgl ass, gentl y pul l the
rear wi per motor away from the l i ftgl ass unti l the
output shaft cl ears the hol e i n the l i ftgl ass.
(9) Move the motor towards the ri ght si de of the
vehi cl e unti l the sl otted hol e i n the motor mounti ng
bracket cl ears the grommet under the ri ght l i ftgl ass
hi nge nut.
(10) Remove the rear wi per motor from the vehi -
cl e.
(11) Reverse the removal procedures to i nstal l .
Ti ghten the mounti ng hardware as fol l ows:
• Wi per motor output shaft nut - 3.3 N·m (30 i n.
l bs.)
• Li ftgl ass hi nge nut - 6 N·m (53 i n. l bs.)
• Wi per motor cover screws - 1.1 N·m (10 i n. l bs.).
WIPER SWITCH AND WASHER SWITCH
FRONT
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel . See Knee Bl ocker i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Remove the three screws that secure the l ower
steeri ng col umn shroud to the upper shroud (Fi g. 13).
(4) I f the vehi cl e i s equi pped wi th a standard non-
ti l t steeri ng col umn, l oosen the two upper steeri ng
col umn mounti ng nuts. I f the vehi cl e i s equi pped
wi th the opti onal ti l t steeri ng col umn, move the ti l t
steeri ng col umn to the ful l y l owered posi ti on.
(5) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(6) Remove the two screws that secure the swi tch
water shi el d and bracket to the top of the steeri ng
col umn (Fi g. 14).
(7) Remove the one screw l ocated bel ow the mul ti -
functi on swi tch l ever that secures the swi tch water
shi el d and bracket to the steeri ng col umn (Fi g. 15).
(8) Gentl y pul l the l ower mounti ng tab of the
swi tch water shi el d bracket away from the steeri ng
col umn far enough to cl ear the screw boss bel ow the
mul ti -functi on swi tch l ever.
Fig. 13 Steering Column Shrouds Remove/Install
1 – UPPER SHROUD
2 – SCREW (3)
3 – LOWER SHROUD
4 – STEERING WHEEL
Fig. 14 Water Shield Upper Screws Remove/Install
1 – MOUNTING SCREWS
2 – HAZARD WARNING SWITCH KNOB
3 – MULTI-FUNCTION SWITCH LEVER
4 – WATER SHIELD AND BRACKET
5 – WIPER SWITCH LEVER
TJ WIPER AND WASHER SYSTEMS 8K - 11
REMOVAL AND INSTALLATION (Continued)
(9) Li ft the water shi el d and bracket wi th the
mul ti -functi on swi tch off of the l eft si de of the steer-
i ng col umn as a uni t and move i t out of the way. I f
the vehi cl e i s equi pped wi th the opti onal ti l t steeri ng
col umn, l i fti ng gentl y upward on the ti l t rel ease l ever
wi l l provi de addi ti onal cl earance to ease mul ti -func-
ti on swi tch removal .
(10) Gentl y pul l the wi ndshi el d wi per and washer
swi tch up and away from the ri ght si de of the steer-
i ng col umn far enough to access the wi re harness
connector.
(11) Unpl ug the wi re harness connector from the
wi ndshi el d wi per and washer swi tch.
(12) Remove the wi ndshi el d wi per and washer
swi tch from the steeri ng col umn.
(13) Reverse the removal procedures to i nstal l .
Ti ghten the upper swi tch mounti ng screws to 2.2
N·m (20 i n. l bs.). Ti ghten the l ower swi tch water
shi el d and bracket screw to 1.1 N·m (10 i n. l bs.).
Ti ghten the non-ti l t steeri ng col umn mounti ng nuts
to 22 N·m (200 i n. l bs.) and the steeri ng col umn
shroud mounti ng screws to 2 N·m (18 i n. l bs.).
REAR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the center bezel from the i nstrument
panel . See I nstrument Panel Center Bezel i n Group
8E - I nstrument Panel Systems for the procedures.
(3) Remove the four screws that secure the acces-
sory swi tch bezel to the i nstrument panel (Fi g. 16).
(4) Pul l the accessory swi tch bezel out from the
i nstrument panel far enough to access the wi re har-
ness connectors.
(5) Unpl ug the wi re harness connectors from the
rear of the accessory swi tches and the ci gar l i ghter.
(6) Remove the accessory swi tch bezel from the
i nstrument panel .
(7) Wi th a smal l thi n-bl aded screwdri ver, gentl y
pry the snap cl i ps at the top and bottom of the rear
wi per and washer swi tch receptacl e on the back of
the accessory swi tch bezel and pul l the swi tch out of
the bezel .
(8) Reverse the removal procedures to i nstal l . Be
certai n that both of the swi tch snap cl i p retai ners i n
the receptacl e on the back of the accessory swi tch
bezel are ful l y engaged. Ti ghten the mounti ng screws
to 2.2 N·m (20 i n. l bs.).
Fig. 15 Water Shield Lower Screw Remove/Install
1 – MULTI-FUNCTION SWITCH LEVER
2 – WATER SHIELD AND BRACKET
3 – LOWER MOUNTING SCREW
4 – LOWER MOUNTING TAB
Fig. 16 Accessory Switch Bezel Remove/Install
1 – INSTRUMENT PANEL
2 – WIRE HARNESS CONNECTORS
3 – SCREW
4 – CIGAR LIGHTER
5 – ACCESSORY SWITCH BEZEL
8K - 12 WIPER AND WASHER SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
WASHER SYSTEM
WASHER RESERVOIR
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the three screws that secure the
washer reservoi r to the i nner fender (Fi g. 17).
(3) Li ft the reservoi r far enough to access the
washer pump(s).
(4) Remove the washer suppl y hose(s) from the
washer pump(s) and drai n the washer fl ui d from the
reservoi r i nto a cl ean contai ner for reuse.
(5) Unpl ug the wi re harness connector(s) from the
washer pump(s).
(6) Remove the washer reservoi r from the vehi cl e.
(7) Reverse the removal procedures to i nstal l .
Ti ghten the reservoi r mounti ng screws to 4 N·m (35
i n. l bs.).
WASHER PUMP
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the washer suppl y hose(s) from the
barbed outl et ni ppl e of the washer pump(s) and drai n
the washer fl ui d from the reservoi r i nto a cl ean con-
tai ner for reuse.
(3) Unpl ug the wi re harness connector(s) from the
washer pump(s).
(4) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the barbed i nl et ni ppl e of
the washer pump out of the rubber grommet seal i n
the reservoi r. Care must be taken not to damage the
reservoi r.
(5) Remove the rubber grommet seal from the res-
ervoi r and di scard.
(6) Reverse the removal procedures to i nstal l .
Al ways use a new rubber grommet seal on the reser-
voi r.
WASHER NOZZLE
FRONT
(1) Open and support the hood.
(2) From under the rear of the hood, di sconnect
the washer suppl y hose from the barbed ni ppl e of the
washer nozzl e (Fi g. 18).
(3) From under the rear of the hood, gentl y
squeeze the nozzl e retai ners and push the nozzl e out
through the top of the hood panel .
(4) Reverse the removal procedures to i nstal l . See
Washer Nozzl es and Pl umbi ng i n thi s group for the
nozzl e adjustment procedures.
Fig. 17 Washer Reservoir Remove/Install
1 – SCREW
2 – FRONT PUMP
3 – INNER FENDER
4 – REAR WASHER HOSE
5 – DASH PANEL
6 – FRONT WASHER HOSE
7 – RESERVOIR
8 – REAR PUMP
Fig. 18 Front Washer Nozzles Remove/Install
1 – NOZZLES
2 – CHECK VALVES
3 – HOOD
4 – TO RESERVOIR
5 – HOSE
6 – CLIPS
7 – REAR HOOD REINFORCEMENT
TJ WIPER AND WASHER SYSTEMS 8K - 13
REMOVAL AND INSTALLATION (Continued)
REAR
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) From the i nsi de of the l i ftgl ass, remove the
three screws that secure the rear wi per motor cover
to the motor (Fi g. 19).
(3) Remove the rear wi per motor cover.
(4) Di sconnect the washer suppl y hose from the
barbed rear washer nozzl e ni ppl e.
(5) Whi l e hol di ng the nozzl e securel y from the out-
si de of the l i ftgl ass, remove the pl asti c nut that
secures the threaded nozzl e ni ppl e from the i nsi de of
the l i ftgl ass.
(6) Push the nozzl e and seal out through the l i ft-
gl ass from the i nsi de.
(7) Reverse the removal procedures to i nstal l .
Ti ghten the washer nozzl e nut to 0.9 N·m (8 i n. l bs.).
CHECK VALVE
A check val ve i s l ocated under the hood i n the
washer suppl y l i ne near each of the front washer
nozzl es. Model s wi th the opti onal rear washer system
al so have a check val ve i n the washer suppl y l i ne i n
the l eft rear pi l l ar of the hardtop, near where the
hardtop joi ns the vehi cl e body.
(1) Di sconnect the washer suppl y hoses from the
barbed ni ppl es on each end of the front or rear
washer system check val ve.
(2) Remove the check val ve from the vehi cl e.
(3) When rei nstal l i ng the check val ve, be certai n
the val ve i s properl y ori ented wi thi n the system fl ow
(Fi g. 20).
(4) Reverse the remai ni ng removal procedures to
compl ete the i nstal l ati on.
Fig. 19 Rear Washer Nozzle Remove/Install
1 – COVER
2 – OUTPUT SHAFT
3 – NUT
4 – NOZZLE
5 – HINGE COVER
6 – NUT
7 – NOZZLE
8 – MOTOR
9 – SCREW
10 – HOSE
11 – CONNECTOR
Fig. 20 Washer System Check Valve
1 – TO RESERVOIR
2 – CHECKBALL
3 – SPRING
4 – TO NOZZLE
8K - 14 WIPER AND WASHER SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
LAMPS
TABLE OF CONTENTS
page page
LAMP SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 3
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . . 6
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . . . 9
LAMP SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LAMP SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . 16
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . . . 17
LAMP SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION
LAMP SYSTEMS
Each vehi cl e i s equi pped wi th vari ous l amp assem-
bl i es. A good ground i s necessary for proper l i ghti ng
operati on. Groundi ng i s provi ded through a separate
ground wi re.
HEADLAMPS
DESCRIPTION
Headl amps on the Wrangl er are seal ed beam uni ts.
Each uni t contai ns a hi gh and l ow beam.
OPERATION
The headl amps are control l ed by the headl amp
swi tch and the mul ti functi on swi tch. Each headl amp
uni t can be servi ced i ndi vi dual l y.
HEADLAMP SWITCH
DESCRIPTION
The headl amp swi tch i s l ocated on the i nstrument
panel . The headl amp swi tch control s the parki ng
l amps, the headl amps, the i nteri or l amps, and
i nstrument cl uster i l l umi nati on. The headl amp
swi tch al so contai ns a rheostat for control l i ng the
i l l umi nati on l evel of the i nstrument cl uster l amps.
OPERATION
The headl amp swi tch has an off posi ti on, a parki ng
l amp posi ti on, and a headl amp on posi ti on. Hi gh
beams are control l ed by the mul ti functi on swi tch on
the steeri ng col umn. The headl amp swi tch cannot be
repai red, i t must be repl aced. Refer to Group 8E for
removal and i nstal l ati on procedures, and Group 8W
for ci rcui t i nformati on.
TAIL/TURN SIGNAL/STOP/BACK-UP LAMP
DESCRIPTION
The rear tai l l amp modul es are mounted on rear of
the vehi cl e, outboard of the tai l gate. Each modul e
contai ns two bul bs, a l ens, and a housi ng. One bul b
i s a two fi l ament bul b used for tai l , stop, and turn
si gnal functi ons. The other bul b i s a si ngl e fi l ament
bul b used for back-up l i ght i l l umi nati on.
OPERATION
Each tai l l amp modul e can be servi ced separatel y.
Each bul b can al so be servi ced separatel y. The head-
l amp swi tch control s tai l l amp operati on. The mul ti -
functi on swi tch control s turn si gnal operati on, and
the back-up l i ght swi tch control s the back-up l i ght
operati on. The brake l amp swi tch control s the stop
l amp functi on.
TJ LAMPS 8L - 1
FRONT TURN SIGNAL/PARKING LAMP
DESCRIPTION
The front turn si gnal /parki ng l amp i s a separate
modul e. Each modul e contai ns a housi ng, a l ens, and
bul b. The components are servi ceabl e separatel y.
OPERATION
The parki ng l i ght functi on i s control l ed by the
headl amp swi tch l ocated on the i nstrument panel .
The turn si gnal functi on i s control l ed by the mul ti -
functi on swi tch l ocated on the steeri ng col umn. Each
front turn si gnal /parki ng l amp modul e can be ser-
vi ced separatel y.
CHMSL LAMP (CENTER HIGH MOUNTED STOP
LAMP)
DESCRIPTION
The center hi gh mounted stop l amp (CHMSL) i s
mounted on a bracket above the spare ti re carri er.
OPERATION
CHMSL operati on i s control l ed by the brake l amp
swi tch through button contacts on the tai l gate hi nge.
DAYTIME RUNNING LAMPS
DESCRIPTION
The Dayti me Runni ng Li ghts (Headl amps) System
i s i nstal l ed on vehi cl es manufactured for sal e i n Can-
ada onl y. A separate modul e, mounted on the cowl ,
control s the DRL.
OPERATION
The headl amps are i l l umi nated when the engi ne i s
runni ng and the parki ng brake i s OFF. The l amps
are i l l umi nated at l ess than normal i ntensi ty.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges are not hol di ng the com-
ponent i n pl ace.
8L - 2 LAMPS TJ
DESCRIPTION AND OPERATION (Continued)
LAMP DIAGNOSIS
TABLE OF CONTENTS
page page
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 3
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DAYTIME RUNNING LAMP . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When a vehi cl e experi ences probl ems wi th the
headl amp system, veri fy the condi ti on of the battery
connecti ons, fuses, chargi ng system, headl amp bul bs,
wi re connectors, rel ay, hi gh beam swi tch, di mmer
swi tch, and headl amp swi tch. Refer to Group 8W,
Wi ri ng Di agrams for component l ocati ons and ci rcui t
i nformati on.
HEADLAMP
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
OR IGNITION TURNED
OFF
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge, refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS BURN
OUT
1. Charging system output too high. 1. Test and repair charging system, refer to
Group 8A.
FREQUENTLY 2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
1. Charging system output too low. 1. Test and repair charging system, refer to
Group 8A.
ABOVE IDLE* 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH
RANDOMLY
1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
2. High resistance in headlamp
circuit.
2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.
TJ LAMPS 8L - 3
CONDITION POSSIBLE CAUSES CORRECTION
3. Faulty headlamps switch circuit
breaker.
3. Replace headlamp switch. Refer to Goup
8E.
4. Loose or corroded terminals or
splices in circuit.
4. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS DO NOT
ILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch. Refer to
Group 8E.
4. Faulty headlamp dimmer
(multi-function) switch.
4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.
5. Repair connector terminal or wire splice.
6. Both headlamp bulbs defective. 6. Replace both headlamp bulbs.
*Canada vehicles must have lamps ON.
FOG LAMP
FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF.
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
FOG LAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. Refer to
Group 8A.
2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices. Refer to Group 8W.
FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system. Refer to
Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY
1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
8L - 4 LAMPS TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.
4. Inspect and repair all connectors and
splices. Refer to Group 8W.
FOG LAMPS DO NOT
ILLUMINATE
1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group 8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to Group
8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.
4. Repair connector terminal or wire splice.
5. Defective or burned out bulb. 5. Replace bulb.
DAYTIME RUNNING LAMP
DAYTIME RUNNING LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
DAYTIME RUNNING LAMPS DO
NOT WORK
1. Poor connection at DRL module.
2. Parking brake engaged.
3. Parking brake circuit shorted to
ground.
4. Headlamp circuit shorted to
ground.
5. Defective DRL module.
1. Secure connector on DRL
module.
2. Disengage parking brake.
3. Check voltage on pin 3 of
module, refer to Group 8W.
4. Check L3 circuit, refer to Group
8W.
5. Replace DRL module.
TJ LAMPS 8L - 5
DIAGNOSIS AND TESTING (Continued)
HEADLAMP ALIGNMENT
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . . 6
LAMP ALIGNMENT SCREEN PREPARATION. . . . . 6
VEHICLE PREPARATION FOR HEADLAMP
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HEADLAMP ADJUSTMENT . . . . . . . . . . . . . . . . . . 6
FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . . 8
SERVICE PROCEDURES
HEADLAMP ALIGNMENT
Headl amps can be al i gned usi ng the screen method
provi ded i n thi s secti on. Al i gnment Tool C-4466-A or
equi val ent can al so be used. Refer to i nstructi ons
provi ded wi th the tool for proper procedures.
LAMP ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 7.62 meters (25 ft) away from front
of headl amp l ens (Fi g. 1).
(2) I f necessary, tape a l i ne on the fl oor 7.62
meters (25 ft) away from and paral l el to the wal l .
(3) Measure from the fl oor up 1.27 meters (5 ft)
and tape a l i ne on the wal l at the centerl i ne of the
vehi cl e. Si ght al ong the centerl i ne of the vehi cl e
(from rear of vehi cl e forward) to veri fy accuracy of
the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for
up/down adjustment reference.
(7) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
VEHICLE PREPARATION FOR HEADLAMP
ALIGNMENT
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) Correct defecti ve components that coul d hi nder
proper headl amp al i gnment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean headl amp l enses.
(5) Veri fy that l uggage area i s not heavi l y l oaded.
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
HEADLAMP ADJUSTMENT
(1) Pl ace headl amps on LOW beam.
(2) Cover front of the headl amp that i s not bei ng
adjusted.
(3) Turn the upper, outboard (up/down) adjustment
screw (Fi g. 2) unti l the headl amp beam pattern on
screen/wal l i s si mi l ar to the pattern depi cted i n (Fi g.
1).
NOTE: When using a headlamp aiming screen:
• Adjust the headl amps so that the beam hori zon-
tal posi ti on i s at 0.
• Adjust the beam verti cal posi ti on i s 25 mm (1
i n) downward from the l amp hori zontal centerl i ne.
(4) Rotate the l ower, i nboard (l eft/ri ght) adjust-
ment screw (Fi g. 2) unti l the headl amp beam pattern
on the ai mi ng screen/wal l si mi l ar to the pattern i n
(Fi g. 1).
(5) Cover front of the headl amp that has been
adjusted and adjust the other headl amp beam as
i nstructed above.
8L - 6 LAMPS TJ
FOG LAMP ADJUSTMENT
Prepare an al i gnment screen. A properl y al i gned
fog l amp wi l l project a pattern on the al i gnment
screen 100 mm (4 i n.) bel ow the fog l amp centerl i ne
and strai ght ahead (Fi g. 3).
(1) Loosen the nut attachi ng the fog l amp to the
mounti ng bracket (Fi g. 4).
(2) Move the fog l amp to adjust beam hei ght.
(3) Ti ghten the nut attachi ng the fog l amp to the
mounti ng bracket.
Fig. 1 Headlamp Alignment Screen—Typical
1 – CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS
2 – TOP EDGE OF HIGH INTENSITY ZONE
3 – FLOOR TO CENTER OF HEADLAMP LENS
4 – 7.62 METERS (25 FEET)
5 – FRONT OF HEADLAMP
6 – VEHICLE CENTERLINE
7 – LEFT EDGE OF HIGH INTENSITY ZONE
Fig. 2 Headlamp Adjustment Screws
1 – UP/DOWN ADJUSTMENT SCREW
2 – LEFT/RIGHT ADJUSTMENT SCREW
TJ LAMPS 8L - 7
SERVICE PROCEDURES (Continued)
SPECIAL TOOLS
HEADLAMP ALIGNMENT
Fig. 3 Fog Lamp Alignment —Typical
1 – VEHICLE CENTERLINE
2 – CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS
3 – HIGH-INTENSITY AREA
4 – FLOOR TO CENTER OF FOG LAMP LENS
5 – 100 mm (4 in.)
6 – 7.62 METERS (25 FEET)
7 – FRONT OF FOG LAMP
Fig. 4 Fog Lamp Adjustment
1 – FOG LAMP
2 – BUMPER
3 – MOUNTING BRACKET
4 – NUT
Headlamp Aiming Kit C-4466–A
8L - 8 LAMPS TJ
SERVICE PROCEDURES (Continued)
LAMP BULB SERVICE
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . . 9
FOG LAMP BULB. . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT PARK/TURN SIGNAL LAMP BULB. . . . . . . 9
SIDE MARKER LAMP BULB. . . . . . . . . . . . . . . . . . 9
TAIL/BRAKE/TURN SIGNAL/BACK-UP LAMP
BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BACK-UP LAMP BULB . . . . . . . . . . . . . . . . . . . . . 10
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . . . 10
UNDERHOOD LAMP BULB . . . . . . . . . . . . . . . . . 10
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL AND INSTALLATION
HEADLAMP BULB
The headl amp i s a seal ed uni t. Refer to the Head-
l amp Removal /I nstal l ati on procedure l ocated i n the
Lamp Servi ce secti on of thi s group.
FOG LAMP BULB
REMOVAL
(1) Remove the screws that attach the refl ector to
the l amp housi ng.
(2) Separate the refl ector from the l amp housi ng.
(3) Squeeze the bul b retai ner together to di sengage
i t from the refl ector.
(4) Remove the bul b/el ement from the refl ector
(Fi g. 1).
(5) Di sconnect the el ectri cal connector.
INSTALLATION
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) Connect the el ectri cal connector.
(2) Posi ti on the bul b/el ement i n the refl ector.
(3) Engage the bul b retai ner.
(4) Posi ti on the refl ector i n the l amp housi ng.
(5) I nstal l the screws that attach the refl ector to
the l amp housi ng.
FRONT PARK/TURN SIGNAL LAMP BULB
REMOVAL
(1) Remove the park/turn si gnal l amp bul b socket
vi a the undersi de of the fender.
(2) Rotate the bul b socket one-thi rd turn counter-
cl ockwi se and separate i t from the l amp housi ng.
(3) Pul l the bul b strai ght out of the socket.
INSTALLATION
(1) I nstal l the bul b i n the socket.
(2) I nstal l the bul b and socket i n the l amp hous-
i ng.
SIDE MARKER LAMP BULB
REMOVAL
(1) Remove si de marker bul b socket vi a the under-
si de of the fender. Rotate i t one-thi rd turn counter-
cl ockwi se and separate i t from the si de marker l amp
housi ng.
(2) Remove the bul b from the socket by pul l i ng i t
strai ght outward.
INSTALLATION
(1) I nstal l a repl acement bul b i n the socket.
Fig. 1 Fog Lamp Bulb
1 – BULB
2 – FOG LAMP HOUSING
3 – BULB RETAINER
4 – FRONT BUMPER
5 – REFLECTOR HOUSING
TJ LAMPS 8L - 9
(2) I nstal l the bul b and socket i n the si de marker
l amp housi ng.
TAIL/BRAKE/TURN SIGNAL/BACK-UP LAMP
BULB
REMOVAL
(1) Remove the screws attachi ng the l ens to the
tai l l amp housi ng (Fi g. 2).
(2) Separate the l ens from the tai l l amp housi ng.
(3) Push the bul b i nward and rotate counter-cl ock-
wi se.
(4) Remove the bul b from the l amp socket.
INSTALLATION
(1) I nstal l a repl acement bul b i n the l amp socket.
(2) Posi ti on the l ens on the l amp housi ng.
(3) I nstal l the screws. Ti ghten the screws securel y.
BACK-UP LAMP BULB
The back-up l amp bul b i s l ocated wi th-i n the tai l
l amp. Refer to the Tai l Lamp Bul b Removal /I nstal l a-
ti on procedure.
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB
REMOVAL
(1) Remove the screws attachi ng the CHMSL l ens
to the CHMSL (Fi g. 3).
(2) Rotate the bul b socket one thi rd turn counter-
cl ockwi se and separate from l amp housi ng.
(3) Pul l the bul b strai ght out of the socket.
INSTALLATION
(1) I nstal l the bul b.
(2) Posi ti on the l ens on the CHMSL and i nstal l the
screws.
UNDERHOOD LAMP BULB
REMOVAL
(1) I nsert a smal l fl at bl ade i n the access sl ot
between the l amp base and l amp l ens.
(2) Pry the l amp l ens upward and remove the
l amp l ens (Fi g. 4).
(3) Depress the bul b termi nal i nward (Fi g. 5) to
rel ease the bul b.
INSTALLATION
(1) Engage the repl acement bul b wi re l oop to the
termi nal cl osest to the l amp base wi re connector.
(2) Depress the opposi te termi nal i nward and
engage the remai ni ng bul b wi re l oop.
(3) Posi ti on the l amp l ens on the l amp base and
press i nto pl ace.
Fig. 2 Lens Removal
Fig. 3 CHMSL Bulb
1 – SOCKET
2 – CHMSL
3 – BULB
Fig. 4 Underhood Lamp Lens
1 – LAMP
2 – LAMP LENS
8L - 10 LAMPS TJ
REMOVAL AND INSTALLATION (Continued)
DOME LAMP
SOUND BAR DOME LAMP BULB REMOVAL
(1) I nsert a smal l fl at bl ade between the l amp
housi ng and l amp l ens. Careful l y pry l amp l ens to
di sengage l ens retai ni ng tabs.
(2) Separate l ens from l amp housi ng.
(3) Grasp bul b and pul l from l amp.
SOUND BAR DOME LAMP BULB INSTALLATION
(1) Posi ti on bul b i n l amp socket and press i nto
pl ace.
(2) Posi ti on l amp l ens on l amp housi ng and press
i nto pl ace.
CARGO AREA DOME LAMP BULB REMOVAL
(1) Remove the dome/cargo l amp l ens by squeezi ng
i t at the l ens at the top and bottom (Fi g. 6). Thi s wi l l
separate the l ens retai ni ng tabs from the l amp hous-
i ng shoul ders.
(2) Remove the l ens from the l amp housi ng.
(3) Pul l the bul b strai ght out to remove from the
bul b hol der.
CARGO AREA DOME LAMP BULB INSTALLATION
(1) I nsert the repl acement bul b i n the bul b hol der.
(2) Posi ti on l ens at the l amp housi ng and press
i nto the housi ng unti l the retai ner tabs are seated.
Fig. 5 Underhood Lamp Bulb
1 – BULB
2 – DEPRESS TERMINAL INWARD
3 – BULB WIRE LOOP
4 – LAMP BASE
Fig. 6 Cargo Area Dome Lamp
1 – SQUEEZE THE LENS
TJ LAMPS 8L - 11
REMOVAL AND INSTALLATION (Continued)
LAMP SERVICE
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FOG LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FRONT PARK/TURN SIGNAL LAMP. . . . . . . . . . . 13
SIDE MARKER LAMP. . . . . . . . . . . . . . . . . . . . . . 13
TAIL/BRAKE/TURN SIGNAL/BACK-UP LAMP . . . . 13
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . . . 14
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL AND INSTALLATION
HEADLAMP
REMOVAL
(1) Remove the screws that attach the headl amp
bezel (Fi g. 1).
(2) Remove the screws that attach the headl amp
retai ni ng ri ng (Fi g. 2).
(3) Di sconnect the headl amp wi re harness connec-
tor and remove the bul b from the bucket (Fi g. 3).
INSTALLATION
(1) Connect the wi re harness connector and posi -
ti on the bul b i n the bucket.
(2) Posi ti on retai ni ng ri ng on the headl amp bul b
and i nstal l screws.
(3) I nstal l the headl amp bezel . Ti ghten the screws
securel y.
Fig. 1 Headlamp Bezel
1 – HEADLAMP BEZEL
2 – GRILLE
3 – NUT
Fig. 2 Headlamp Retaining Ring
1 – HEADLAMP
2 – HEADLAMP RETAINER
Fig. 3 Headlamp Connector
1 – HEADLAMP
2 – CONNECTOR
8L - 12 LAMPS TJ
FOG LAMP
REMOVAL
(1) Di sconnect the fog l amp wi re harness connec-
tor.
(2) Remove the nut attachi ng the fog l amp to the
front bumper.
(3) Separate the fog l amp from the bumper.
INSTALLATION
(1) Posi ti on the fog l amp on the bumper.
(2) I nstal l the nut attachi ng the fog l amp to the
front bumper.
(3) Connect the fog l amp wi re harness connector.
FRONT PARK/TURN SIGNAL LAMP
REMOVAL
(1) Remove the park/turn si gnal l amp housi ng
screws (Fi g. 4).
(2) Separate the park/turn si gnal l amp housi ng
from the fender.
(3) Rotate bul b socket one thi rd turn counter-cl ock-
wi se and separate bul b socket from l amp.
INSTALLATION
(1) I nstal l the bul b socket i n the l amp housi ng.
(2) Posi ti on the park/turn si gnal l amp housi ng i n
the fender.
(3) I nstal l the park/turn si gnal l amp housi ng
screws.
SIDE MARKER LAMP
REMOVAL
(1) From undersi de of the fender, remove nut
attachi ng marker l amp to fender.
(2) Separate l amp from fender.
(3) Rotate bul b socket one-thi rd turn counter-cl ock-
wi se and separate socket from l amp housi ng.
INSTALLATION
(1) Posi ti on bul b socket i n l amp housi ng and
rotate bul b socket one-thi rd turn cl ockwi se.
(2) Posi ti on l amp i n fender.
(3) I nstal l nut attachi ng marker l amp to fender.
TAIL/BRAKE/TURN SIGNAL/BACK-UP LAMP
REMOVAL
(1) From the undersi de of the vehi cl e, remove the
push-i n fastener attachi ng the bottom rear edge of
the rear wheel house spl ash shi el d to the body.
(2) Pul l the rear of the wheel house spl ash shi el d
away from the body and reach upward to di sengage
the tai l l amp el ectri cal connector.
(3) Remove the screws attachi ng the l ens to the
tai l l amp housi ng.
(4) Remove the bol ts attachi ng the tai l l amp hous-
i ng to the body (Fi g. 5).
(5) Separate the l amp housi ng from the body.
INSTALLATION
(1) Engage the el ectri cal connector.
(2) I nstal l the push-i n fastener attachi ng the bot-
tom rear edge of the rear wheel house spl ash shi el d to
the body.
(3) Posi ti on the l amp housi ng on the body.
(4) I nstal l the bol ts attachi ng the tai l l amp hous-
i ng to the body.
(5) I nstal l the screws attachi ng the l ens to the tai l
l amp housi ng.
Fig. 4 Park/Turn Signal Lamp
Fig. 5 Tail Lamp Housing
1 – BODY
2 – TAIL LAMP
3 – LAMP LENS
TJ LAMPS 8L - 13
REMOVAL AND INSTALLATION (Continued)
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)
REMOVAL
NOTE: It may be necessary to remove spare tire.
(1) Remove screws attachi ng CHMSL l amp/bracket
to spare ti re carri er bracket.
(2) Di sengage CHMSL wi re harness from retai ni ng
cl i ps.
(3) Remove cover from CHMSL contact buttons.
(4) Careful l y pul l wi re harness termi nal ends from
contact buttons (Fi g. 6).
(5) Route wi re harness through tai l gate and sepa-
rate CHMSL from vehi cl e.
INSTALLATION
(1) Posi ti on CHMSL l amp/bracket on spare ti re
carri er bracket and i nstal l screws.
(2) Route wi re harness through tai l gate.
(3) I nstal l wi re harness termi nal ends onto contact
buttons.
(4) I nstal l cover over CHMSL contact buttons.
(5) Posi ti on CHMSL wi re harness i nto CHMSL
bracket retai ni ng cl i ps and engage cl i ps.
UNDERHOOD LAMP
REMOVAL
(1) Di sconnect the wi re harness connector from the
l amp.
(2) Remove l amp l ens.
(3) Remove bul b.
(4) Remove screw attachi ng underhood l amp to the
i nner hood panel .
(5) Separate underhood l amp from vehi cl e.
INSTALLATION
(1) I nstal l bul b.
(2) I nstal l l amp l ens.
(3) Posi ti on the underhood l amp fl ange on the
hood i nner panel .
(4) I nstal l the attachi ng screw through the l amp
fl ange and i nto the hood panel (Fi g. 7). Ti ghten the
screw securel y.
(5) Fol d l amp housi ng over and fi rml y press onto
base to snap i nto pl ace.
(6) Connect the wi re harness connector to the
l amp.
DOME LAMP
SOUND BAR DOME LAMP REMOVAL
(1) I nsert a smal l fl at bl ade between the l amp
housi ng and l amp l ens. Careful l y pry l amp l ens from
the l amp housi ng.
(2) Separate l ens from l amp.
(3) Remove the screws attachi ng the l amp to the
sound bar (Fi g. 8).
(4) Di sengage l amp el ectri cal connector.
Fig. 6 CHMSL Contact Buttons
1 – CHMSL MOUNTING BRACKET
2 – CHMSL CONTACT BUTTON TAILGATE CLAMP
3 – BODY
4 – CONTACT BUTTONS
5 – BODY
6 – SPARE TIRE MOUNTING BRACKET
Fig. 7 Underhood Lamp
1 – UNDER HOOD LAMP
2 – HOOD
8L - 14 LAMPS TJ
REMOVAL AND INSTALLATION (Continued)
SOUND BAR DOME LAMP INSTALLATION
(1) Engage l amp el ectri cal connector.
(2) Posi ti on l amp i n sound bar.
(3) I nstal l the screws attachi ng the l amp to the
sound bar.
(4) Posi ti on l amp l ens on l amp housi ng and press
i nto pl ace.
CARGO AREA DOME LAMP REMOVAL
Vehi cl es equi pped wi th a hardtop have a dome
l amp l ocated above the rear wi ndow l i ft gl ass.
(1) Remove the dome/cargo l amp l ens by squeezi ng
i t at the top and bottom. Thi s wi l l separate the l ens
retai ni ng tabs from the l amp housi ng shoul ders.
(2) Remove the l ens from the l amp housi ng.
(3) Remove the bul b.
(4) Remove the screws that attach the l amp to the
hardtop.
(5) Separate the l amp from the hardtop.
(6) Di sconnect the l amp wi re connector.
CARGO AREA DOME LAMP INSTALLATION
(1) Connect the l amp wi re connector.
(2) Posi ti on the l amp i n the hardtop.
(3) I nstal l the screws that attach the l amp to the
hardtop.
(4) I nstal l the bul b.
(5) Posi ti on the l ens on the l amp housi ng and
press i nto pl ace.
Fig. 8 Sound Bar Dome Lamp
1 – SOUND BAR
2 – DOME LAMP HOUSING
3 – DOME LAMP LENS
4 – SCREW
TJ LAMPS 8L - 15
REMOVAL AND INSTALLATION (Continued)
LAMP SYSTEMS
REMOVAL AND INSTALLATION
DAYTIME RUNNING LAMP (DRL) MODULE
REMOVAL
(1) Di sconnect the wi re harness connector from the
modul e.
(2) Remove the screws that attach the modul e to
the cowl (Fi g. 1).
(3) Separate the modul e from the vehi cl e.
INSTALLATION
(1) Posi ti on the DRL modul e on the cowl .
(2) I nstal l the screws.
(3) Connect the wi re harness connector to the mod-
ul e.
Fig. 1 DRL Module
1 – COWL
2 – DAYTIME RUNNING LAMP MODULE
8L - 16 LAMPS TJ
BULB APPLICATION
TABLE OF CONTENTS
page page
SPECIFICATIONS
EXTERIOR LAMPS. . . . . . . . . . . . . . . . . . . . . . . . 17
INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica-
tion Table. Damage to lamp can result. Do not touch
halogen bulbs with fingers or other oily surfaces.
Bulb life will be reduced.
The fol l owi ng Bul b Appl i cati on Tabl e l i sts the l amp
ti tl e on the l eft si de of the col umn and trade number
or part number on the ri ght.
LAMP BULB
Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1156
Center Hi gh Mounted Stopl amp . . . . 921 or W16W
Fog l amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3
Front Si de Marker . . . . . . . . . . . . . . . 168 or W3W
Headl amp/Seal ed Beam . . . . . . . . . . . . . . . . H6024
Park/Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . . 3157
Tai l /Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1157
INTERIOR LAMPS
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica-
tion Table. Damage to lamp can result.
Servi ce procedures for most of the l amps i n the
i nstrument panel , I nstrument cl uster and swi tches
are l ocated i n Group 8E, I nstrument Panel and
Gauges. Some components have l amps that can onl y
be servi ced by an Authori zed Servi ce Center (ASC)
after the component i s removed from the vehi cl e.
The fol l owi ng Bul b Appl i cati on Tabl e l i sts the l amp
ti tl e on the l eft si de of the col umn and trade number
or part number on the ri ght.
LAMP BULB
Dome/Cargo (Hard Top) . . . . . . . . . . . . . . . . . 212–2
Dome (Sound Bar) . . . . . . . . . . . . . . . . . . . . . . . 912
Under Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Underpanel Courtesy . . . . . . . . . . . . . . . . . . . . 906
I nstrument Cl uster I l l umi nati on . . . . . . . . . . . . 103
I nstrument Cl uster Warni ng . . . . . . . . . . . . . . . . 74
Automati c Transmi ssi on I ndi cator . . . . . . . . . . 658
TJ LAMPS 8L - 17
LAMPS
TABLE OF CONTENTS
page page
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 1
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . . . 5
LAMP SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . . . 12
LAMP DIAGNOSIS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
HEADLAMP LEVELING MOTOR. . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
HEADLAMP LEVELING MOTOR
Thi s vehi cl e i s equi pped wi th a remote headl amp
l evel i ng system. Thi s system al l ows the dri ver to
adjust the verti cal headl amp ai m from the i nteri or of
the vehi cl e to compensate for passenger or cargo
l oad. A headl amp l evel i ng swi tch i s l ocated i n the
i nstrument panel and control s the headl amp l evel i ng
motor found on the back of the head l amp assembl y.
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Each vehi cl e i s equi pped wi th vari es l amp assem-
bl i es. A good ground i s necessary for proper l i ghti ng
operati on. Groundi ng i s provi ded by the l amp socket
when i t comes i n contact wi th the metal body, or
through a separate ground wi re.
When changi ng l amp bul bs check the sockets for
corrosi on. I f corrosi on i s present, cl ean i t wi th a wi re
brush and coat the i nsi de of the socket l i ghtl y wi th
Mopar Mul ti -Purpose Grease or equi val ent.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surfaces,
reduced bulb life can result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application Table at the end of
this group. Damage to lamp can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
When i t necessary to remove components to servi ce
another, i t shoul d not be necessary to appl y excessi ve
force or bend a component to remove i t. Before dam-
agi ng a tri m component, veri fy hi dden fasteners or
captured edges are not hol di ng the component i n
pl ace.
DIAGNOSTIC PROCEDURES
When a vehi cl e experi ences probl ems wi th the
headl amp system, veri fy the condi ti on of the battery
connecti ons, chargi ng system, headl amp bul bs, wi re
connectors, rel ay, hi gh beam di mmer swi tch and
headl amp swi tch. Refer to Group 8W, Wi ri ng Di a-
grams, for component l ocati ons and ci rcui t i nforma-
ti on.
TJ LAMPS 8L - 1
2000 JEEP WRANGLER
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn alternator drive
belt.
2. Adjust or replace alternator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
HEADLAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. Refer to
Group 8A.
2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices. Refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system. Refer to
Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp circuit.
HEADLAMPS FLASH
RANDOMLY
1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
2. High resistance in headlamp
circuit.
2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or
splices in circuit.
3. Inspect and repair all connectors and
splices. Refer to Group 8W.
HEADLAMPS DO NOT
ILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit. Refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground. Refer to Group
8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer
(multi-function) switch.
4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.
5. Repair connector terminal or wire splice.
6. Defective or burned out bulb. 6. Replace bulb.
7. Body controller malfunction. 7. Refer to appropriate body controller
diagnostics.
8L - 2 LAMPS TJ
DIAGNOSIS AND TESTING (Continued)
2000 JEEP WRANGLER
FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF.
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn alternator drive
belt.
2. Adjust or replace alternator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
FOG LAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. Refer to
Group 8A.
2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices. Refer to Group 8W.
FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system. Refer to
Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY
1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.
4. Inspect and repair all connectors and
splices. Refer to Group 8W.
FOG LAMPS DO NOT
ILLUMINATE
1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group 8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to Group
8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.
4. Repair connector terminal or wire splice.
5. Defective or burned out bulb. 5. Replace bulb.
TJ LAMPS 8L - 3
DIAGNOSIS AND TESTING (Continued)
2000 JEEP WRANGLER
HEADLAMP LEVELING MOTOR DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
ONE MOTOR DOES NOT
OPERATE
1. Poor connection at motor. 1. Secure connector on motor.
2. No voltage at motor. 2. Repair circuit. Refer to Group 8W,
Wiring.
3. Defective motor. 3. Replace motor.
BOTH MOTORS DO NOT
OPERATE
1. No voltage at headlamp leveling
switch.
1. Repair circuit or replace fuse. Refer to
Group 8W, Wiring.
2. No voltage at both motors. 2. Repair circuit or replace fuse. Refer to
Group 8W, Wiring.
3. Poor connection at motors. 3. Secure connectors on motors.
4. Both motors defective. 4. Replace motors.
8L - 4 LAMPS TJ
DIAGNOSIS AND TESTING (Continued)
2000 JEEP WRANGLER
LAMP BULB SERVICE
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT POSITION LAMP BULB . . . . . . . . . . . . . 5
TAIL LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR FOG LAMP BULB . . . . . . . . . . . . . . . . . . . 6
LICENSE PLATE LAMP BULB . . . . . . . . . . . . . . . 7
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB. . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Rel ease the hood l atches and open hood.
(2) Di sconnect the headl amp wi re harness connec-
tors.
(3) Remove the headl amp bezel retai ni ng screws
and bezel (Fi g. 1).
(4) Remove the headl amp retai ni ng ri ng screws
and retai ni ng ri ng (Fi g. 2).
(5) Remove the headl amp from vehi cl e.
(6) Remove rubber seal boot (Fi g. 3).
(7) Di sengage wi re retai ni ng ri ng from headl amp
(Fi g. 4).
(8) Pul l the headl amp bul b from back of headl amp
assembl y (Fi g. 5).
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
FRONT POSITION LAMP BULB
REMOVAL
(1) Remove the headl amp from the vehi cl e. Refer
to the headl amp Removal /I nstal l ati on procedure
l ocated i n thi s group.
(2) Remove rubber boot seal .
Fig. 1 Headlamp Bezel
1 – HEADLAMP BEZEL ATTACHING SCREWS
Fig. 2 Headlamp Retaining Ring
1 – HEADLAMP RETAINER ATTACHING SCREWS
Fig. 3 Headlamp Rubber Seal Boot
1 – HEADLAMP
2 – HEADLAMP RUBBER SEAL BOOT
TJ LAMPS 8L - 5
2000 JEEP WRANGLER
(3) Remove front posi ti on l amp bul b socket from
the headl amp (Fi g. 6).
(4) Remove front posi ti on bul b from i ts socket by
rotati ng counter cl ockwi se and pul l i ng strai ght out.
INSTALLATION
(1) I nstal l the front posi ti on l amp bul b i n i ts
socket.
(2) Veri fy l amp operati on
(3) I nstal l the posi ti on l amp i n the headl amp
assembl y.
(4) I nstal l the rubber boot seal .
(5) I nstal l the headl amp i n the vehi cl e. Refer to
the headl amp Removal /I nstal l ati on procedure l ocated
i n thi s group.
TAIL LAMP BULB
REMOVAL
(1) Remove the tai l l amp l ense retai ni ng screws
(Fi g. 8).
(2) Separate the tai l l amp l ense from the tai l l amp
housi ng.
(3) Remove the tai l l amp bul b from the bul b socket
(Fi g. 9).
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
REAR FOG LAMP BULB
REMOVAL
(1) Remove the rear fog l amp l ense attachi ng
screws and l ense (Fi g. 10).
Fig. 4 Headlamp Bulb Retaining Ring
1 – HEADLAMP
2 – HEADLAMP WIRE RETAINING RING
Fig. 5 Headlamp Bulb
1 – HEADLAMP
2 – HEADLAMP BULB
Fig. 6 Front Position Lamp Location
1 – HEADLAMP
2 – FRONT POSITION LAMP SOCKET AND BULB
Fig. 7 Front Position Lamp
1 – FRONT POSITION LAMP SOCKET
2 – FRONT POSITION LAMP BULB
8L - 6 LAMPS TJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP WRANGLER
(2) Remove the bul b from the fog l amp socket (Fi g.
11).
INSTALLATION
(1) I nstal l the bul b i n the fog l amp socket (Fi g. 11).
(2) Veri fy l amp operati on.
(3) I nstal l the rear fog l amp l ense and attachi ng
screws (Fi g. 10).
LICENSE PLATE LAMP BULB
REMOVAL
(1) Remove the l i cense pl ate l amp l ense attachi ng
screws and l ense.
(2) Remove the bul b from the socket.
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
Fig. 8 Tail Lamp Lense
Fig. 9 Tail Lamp Bulbs
1 – TAILLAMP ASSEMBLY
2 – STOP LAMP BULB
3 – REVERSE LAMP BULB
4 – TURN SIGNAL LAMP BULB
Fig. 10 Rear Fog Lamp Lense
1 – REAR FOG LAMP
2 – FOG LAMP LENSE ATTACHING SCREWS
Fig. 11 Rear Fog Lamp Bulb
1 – REAR FOG LAMP HOUSING
2 – REAR FOG LAMP BULB
TJ LAMPS 8L - 7
REMOVAL AND INSTALLATION (Continued)
2000 JEEP WRANGLER
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB
REMOVAL
(1) Remove the screws attachi ng the center hi gh
mounted stop l amp (CHMSL) l ense assembl y to the
housi ng.
(2) Separate the CHMSL l ense assembl y from the
housi ng.
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
8L - 8 LAMPS TJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP WRANGLER
LAMP SERVICE
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
HEADLAMP ASSEMBLY . . . . . . . . . . . . . . . . . . . 9
HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . 9
TAIL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL AND INSTALLATION
HEADLAMP ASSEMBLY
REMOVAL
(1) Remove the headl amp bezel attachi ng screws
(Fi g. 1).
(2) Remove the headl amp assembl y retai ni ng ri ng
attachi ng screws (Fi g. 2).
(3) Di sconnect the headl amp assembl y el ectri cal
connectors and remove the headl amp assembl y from
the bucket.
Installation
(1) Perform the removal procedure i n reverse
order.
HEADLAMP LEVELING MOTOR
REMOVAL
(1) Remove the headl amp bezel attachi ng screws
and bezel (Fi g. 3).
(2) Di sconnect the headl amp and headl amp l evel -
i ng motor el ectri cal connectors.
(3) Remove the headl amp housi ng attachi ng
screws (Fi g. 4).
(4) Rotate l evel i ng motor one quarter turn counter-
cl ockwi se.
(5) Pul l the l evel i ng motor from the headl amp
housi ng.
(6) Separate the l evel i ng motor from the headl amp
housi ng (Fi g. 5).
NOTE: The headlamp leveling motor arm is
snapped into the headlamp housing very securely.
Use a firm, steady pull to disengage motor arm
from the headlamp housing.
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
TAIL LAMP
REMOVAL
(1) Remove the tai l l amp l ense attachi ng screws
and l ense (Fi g. 6).
Fig. 1 Headlamp Bezel
1 – HEADLAMP BEZEL ATTACHING SCREWS
Fig. 2 Headlamp Retaining Ring
1 – HEADLAMP RETAINER ATTACHING SCREWS
TJ LAMPS 8L - 9
2000 JEEP WRANGLER
(2) Remove the tai l l amp housi ng attachi ng bol ts
(Fi g. 7).
(3) Separate the l amp housi ng from the body.
(4) Di sconnect the tai l l amp el ectri cal connector
and remove tai l l amp housi ng.
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)
REMOVAL
NOTE: It may be necessary to remove the spare
tire.
(1) Remove the CHMSL housi ng to CHMSL
bracket attachi ng screws.
Fig. 3 Headlamp Bezel
1 – HEADLAMP BEZEL ATTACHING SCREWS
Fig. 4 Headlamp Housing
1 – HEADLAMP HOUSING ATTACHING NUTS
2 – HEADLAMP LEVELING MOTOR
Fig. 5 Headlamp Leveling Motor
1 – HEADLAMP LEVELING MOTOR
2 – HEADLAMP HOUSING
Fig. 6 Tail Lamp Lense
8L - 10 LAMPS TJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP WRANGLER
(2) Di sconnect the CHMSL wi re harness from the
retai ni ng cl i ps.
(3) Remove the cover from the CHMSL contact
buttons.
(4) Careful l y pul l the wi re harness termi nal ends
from the contact buttons (Fi g. 8).
(5) Route wi re harness through tai l gate and sepa-
rate CHMSL from vehi cl e.
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
REAR FOG LAMP
REMOVAL
(1) Remove the rear fog l amp attachi ng screws
(Fi g. 9).
(2) Di sconnect the rear fog l amp el ectri cal connec-
tor.
INSTALLATION
(1) Connect the rear fog l amp el ectri cal connector.
(2) I nstal l the rear fog l amp attachi ng screws (Fi g.
9).
Fig. 7 Tail Lamp Housing
1 – TAILLAMP ASSEMBLY
2 – ATTACHING SCREWS
Fig. 8 CHMSL Assembly
1 – CHMSL MOUNTING BRACKET
2 – CHMSL CONTACT BUTTON TAILGATE CLAMP
3 – BODY
4 – CONTACT BUTTONS
5 – BODY
6 – SPARE TIRE MOUNTING BRACKET
Fig. 9 Rear Fog Lamp
1 – REAR FOG LAMP ASSEMBLY
2 – REAR BUMPER ASSEMBLY
TJ LAMPS 8L - 11
REMOVAL AND INSTALLATION (Continued)
2000 JEEP WRANGLER
BULB APPLICATION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
BULB INFORMATION. . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS
EXTERIOR LAMPS. . . . . . . . . . . . . . . . . . . . . . . . 12
INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION AND OPERATION
BULB INFORMATION
(1) The fol l owi ng bul b Appl i cati on tabl es l i sts the
l amp ti tl e on the l eft si de of the col umn and trade
number on the ri ght.
CAUTION: Do not use bulbs that have a higher can-
dle power the bulb listed in the Bulb Application
Table. Damage to lamp can result. Do not touch
halogen bulbs with fingers or other oily surfaces.
Bulb life will be reduced.
SPECIFICATIONS
EXTERIOR LAMPS
LAMP BULB
Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P21W
Center Hi gh Mounted Stop . . . . . . . . . . . . . W16W
Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-4
Li cense Pl ate . . . . . . . . . . . . . . . . . . . . . . . . . W5W
Front Turn Si gnal . . . . . . . . . . . . . . . . . . . . P27/7W
Tai l /Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . P21/5W
Rear Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . P21W
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . P21W
Ci tyl i ght . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4W
Si de Repeater . . . . . . . . . . . . . . . . . . . . . . . . . W5W
INTERIOR LAMPS
Servi ce procedures for most of the l amps i n the
i nstrument panel , I nstrument cl uster and swi tches
are l ocated i n Group 8E, I nstrument panel and
Gauges. Some components have l amps than can onl y
be servi ced by an Authori zed Servi ce Center (ASC)
after the component i s removed from the vehi cl e.
Contact a l ocal deal er for l ocati on of nearest ASC.
LAMP BULB
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC74
Ai rbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC74
Brake Warni ng System I ndi cator . . . . . . . . . . PC74
Cl i mate Control s . . . . . . . . . . . . . . . . . . . . . . . . 203
Consol e Gear Sel ector . . . . . . . . . . . . . . . . . . . . 658
Dome Li ght . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Hi gh Beam I ndi cator . . . . . . . . . . . . . . . . . . . PC74
Rear Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . 212-2
Seat Bel t I ndi cator . . . . . . . . . . . . . . . . . . . . . PC74
Servi ce Engi ne Soon . . . . . . . . . . . . . . . . . . . . PC74
Turn Si gnal I ndi cator . . . . . . . . . . . . . . . . . . . PC74
Underhood . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Under Dash Courtesy Lamps . . . . . . . . . . . . . . 906
I . P. Rocker Swi tches . . . . . . . . . . . . . . . See Deal er
8L - 12 LAMPS TJ
2000 JEEP WRANGLER
PASSIVE RESTRAINT SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
DRIVER SIDE AIRBAG MODULE . . . . . . . . . . . . . 2
PASSENGER SIDE AIRBAG MODULE. . . . . . . . . . 3
PASSENGER SIDE AIRBAG ON/OFF SWITCH . . . 3
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . . 4
CLOCKSPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
DRIVER SIDE AIRBAG MODULE . . . . . . . . . . . . . 6
DRIVER SIDE AIRBAG MODULE TRIM
COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PASSENGER SIDE AIRBAG MODULE. . . . . . . . . 10
PASSENGER SIDE AIRBAG DOOR. . . . . . . . . . . 11
PASSENGER SIDE AIRBAG ON/OFF SWITCH . . 13
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . 14
CLOCKSPRING. . . . . . . . . . . . . . . . . . . . . . . . . . 16
ADJUSTMENTS
CLOCKSPRING CENTERING. . . . . . . . . . . . . . . . 18
SPECIAL TOOLS
PASSIVE RESTRAINT SYSTEMS . . . . . . . . . . . . 19
DESCRIPTION AND OPERATION
AIRBAG SYSTEM
DESCRIPTION
A dual front ai rbag system i s standard factory-i n-
stal l ed safety equi pment on thi s model . The pri mary
passenger restrai nts i n thi s vehi cl e are the standard
equi pment factory-i nstal l ed seat bel ts, whi ch requi re
acti ve use by the vehi cl e occupants. The ai rbag sys-
tem i s a suppl emental passi ve restrai nt that was
desi gned and i s i ntended to enhance the protecti on
for the front seat occupants of the vehi cl e only when
used i n conjuncti on wi th the seat bel ts. See the own-
er’s manual i n the vehi cl e gl ove box for more i nfor-
mati on on the features, use and operati on of al l of
the factory-i nstal l ed passenger restrai nts, i ncl udi ng
the ai rbag system.
The dual front ai rbag system consi sts of the fol l ow-
i ng components:
• Ai rbag Control Modul e (ACM)
• Ai rbag i ndi cator l amp
• Cl ockspri ng
• Dri ver and passenger si de ai rbag modul es
(i ncl udi ng the ai rbag i nfl ators)
• Dri ver and passenger si de knee bl ockers
• Passenger si de ai rbag on/off swi tch
• Wi re harness and connecti ons.
Thi s group provi des compl ete servi ce i nformati on
for the ACM, both ai rbag modul es, the cl ockspri ng,
and the passenger si de ai rbag on/off swi tch. Com-
pl ete servi ce i nformati on for the other ai rbag system
components can be l ocated as fol l ows:
• Refer to Instrument Cluster i n the proper sec-
ti on of Group 8E - I nstrument Panel Systems for
compl ete servi ce i nformati on for the ai rbag i ndi cator
l amp.
• Refer to Knee Blocker i n the Removal and
I nstal l ati on secti on of Group 8E - I nstrument Panel
Systems for compl ete servi ce i nformati on on the
dri ver si de knee bl ocker.
• Refer to Glove Box i n the Removal and I nstal -
l ati on secti on of Group 8E - I nstrument Panel Sys-
tems for compl ete servi ce i nformati on on the
passenger si de knee bl ocker.
• Refer to Airbag System i n the Contents of
Group 8W - Wi ri ng Di agrams for compl ete servi ce
i nformati on and ci rcui t di agrams for the ai rbag sys-
tem wi ri ng components.
See the proper Di agnosti c Procedures manual to
test or di agnose a probl em wi th any component of
the ai rbag system.
OPERATION
The ai rbag system el ectri cal ci rcui ts are conti nu-
ousl y moni tored and control l ed by a mi croprocessor
and software contai ned wi thi n the Ai rbag Control
Modul e (ACM). The ACM al so contai ns an i mpact
sensor and a safi ng sensor, whi ch are moni tored by
the ACM to determi ne when an i mpact occurs that i s
severe enough to requi re ai rbag system protecti on.
When a frontal i mpact i s severe enough, the ACM
si gnal s the i nfl ator uni ts of both ai rbag modul es to
depl oy the ai rbags.
TJ PASSIVE RESTRAINT SYSTEMS 8M - 1
An ai rbag i ndi cator l amp i n the i nstrument cl uster
l i ghts for about seven seconds as a bul b test, each
ti me the i gni ti on swi tch i s turned to the On or Start
posi ti ons. Fol l owi ng the bul b test, the ai rbag i ndi ca-
tor l amp i s turned on or off by the ACM to i ndi cate
the status of the ai rbag system. I f the ai rbag i ndi ca-
tor l amp comes on at any ti me other than duri ng the
bul b test, i t i ndi cates that there i s a probl em i n the
ai rbag system ci rcui ts. Such a probl em may cause
the ai rbags not to depl oy when requi red, or to depl oy
when not requi red.
The dri ver si de ai rbag modul e i ncl udes an i nfl at-
abl e ai rbag and an i nfl ator uni t behi nd a tri m cover
i n the hub area of the steeri ng wheel . The passenger
si de ai rbag modul e i ncl udes a second i nfl atabl e ai r-
bag and an i nfl ator uni t behi nd an ai rbag door i n the
i nstrument panel above the gl ove box.
Duri ng a frontal vehi cl e i mpact, the knee bl ockers
work i n concert wi th properl y adjusted seat bel ts to
restrai n the dri ver and front seat passenger i n the
proper posi ti on for an ai rbag depl oyment. The knee
bl ockers al so work to absorb and di stri bute the crash
energy from the dri ver and front seat passenger to
the structure of the i nstrument panel . The dri ver
si de knee bl ocker i s a stamped metal rei nforcement
l ocated behi nd the i nstrument panel steeri ng col umn
openi ng cover. The passenger si de knee bl ocker i s
i ntegral to the gl ove box door.
Fol l owi ng are general descri pti ons of the major
components i n the ai rbag system.
WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• THE DRIVER SIDE AIRBAG MODULE INFLATOR
ASSEMBLY CONTAINS SODIUM AZIDE AND POTAS-
SIUM NITRATE. THESE MATERIALS ARE POISON-
OUS AND EXTREMELY FLAMMABLE. CONTACT
WITH ACID, WATER, OR HEAVY METALS MAY PRO-
DUCE HARMFUL AND IRRITATING GASES (SODIUM
HYDROXIDE IS FORMED IN THE PRESENCE OF
MOISTURE) OR COMBUSTIBLE COMPOUNDS. THE
PASSENGER AIRBAG MODULE CONTAINS ARGON
GAS PRESSURIZED TO OVER 2500 PSI. DO NOT
ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR
TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE,
INCINERATE, OR BRING INTO CONTACT WITH
ELECTRICITY. DO NOT STORE AT TEMPERATURES
EXCEEDING 93° C (200° F).
• REPLACE AIRBAG SYSTEM COMPONENTS
ONLY WITH PARTS SPECIFIED IN THE CHRYSLER
MOPAR PARTS CATALOG. SUBSTITUTE PARTS
MAY APPEAR INTERCHANGEABLE, BUT INTERNAL
DIFFERENCES MAY RESULT IN INFERIOR OCCU-
PANT PROTECTION.
• THE FASTENERS, SCREWS, AND BOLTS ORIG-
INALLY USED FOR THE AIRBAG SYSTEM COMPO-
NENTS HAVE SPECIAL COATINGS AND ARE
SPECIFICALLY DESIGNED FOR THE AIRBAG SYS-
TEM. THEY MUST NEVER BE REPLACED WITH ANY
SUBSTITUTES. ANY TIME A NEW FASTENER IS
NEEDED, REPLACE IT WITH THE CORRECT FAS-
TENERS PROVIDED IN THE SERVICE PACKAGE OR
SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT-
ALOG.
• WHEN A STEERING COLUMN HAS AN AIRBAG
MODULE ATTACHED, NEVER PLACE THE COLUMN
ON THE FLOOR OR ANY OTHER SURFACE WITH
THE STEERING WHEEL OR AIRBAG MODULE FACE
DOWN.
DRIVER SIDE AIRBAG MODULE
DESCRIPTION
The dri ver si de ai rbag modul e protecti ve tri m cover
i s the most vi si bl e part of the dri ver si de ai rbag sys-
tem. The dri ver si de ai rbag modul e i s mounted
di rectl y to the steeri ng wheel . Located under the ai r-
bag modul e tri m cover are the horn swi tch, the
fol ded ai rbag cushi on, and the ai rbag cushi on sup-
porti ng components. The resi sti ve membrane-type
horn swi tch i s secured wi th heat stakes to the i nsi de
surface of the ai rbag modul e tri m cover, between the
tri m cover and the fol ded ai rbag cushi on.
The dri ver si de ai rbag modul e cannot be repai red,
and must be repl aced i f depl oyed or i n any way dam-
aged. The dri ver si de ai rbag modul e tri m cover and
the horn swi tch are avai l abl e as a uni t for servi ce
repl acement.
OPERATION
The dri ver si de ai rbag modul e i ncl udes a stamped
metal housi ng to whi ch the cushi on and an i nfl ator
uni t are attached and seal ed. The conventi onal pyro-
techni c-type i nfl ator assembl y i s mounted to studs on
the back of the ai rbag modul e housi ng. The i nfl ator
seal s the hol e i n the ai rbag cushi on so i t can di s-
charge the gas i t produces di rectl y i nto the cushi on
when suppl i ed wi th the proper el ectri cal si gnal . Fol -
l owi ng an ai rbag depl oyment, the ai rbag cushi on
8M - 2 PASSIVE RESTRAINT SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
qui ckl y defl ates by venti ng thi s gas towards the
i nstrument panel through the porous fabri c materi al
used on the steeri ng wheel si de of the ai rbag cushi on.
The protecti ve tri m cover i s fi tted to the front of
the ai rbag modul e and forms a decorati ve cover i n
the center of the steeri ng wheel . The i nsi de of the
tri m cover has l ocki ng bl ocks mol ded i nto i t that
engage a l i p on the ai rbag modul e metal housi ng.
Two stamped metal retai ners then fi t over the i nfl a-
tor mounti ng studs on the back of the ai rbag modul e
housi ng and are engaged i n sl ots on the i nsi de of the
cover, securel y l ocki ng the tri m cover i nto pl ace. The
tri m cover wi l l spl i t at predetermi ned breakout l i nes,
then fol d back out of the way al ong wi th the horn
swi tch upon ai rbag depl oyment.
PASSENGER SIDE AIRBAG MODULE
DESCRIPTION
The passenger si de ai rbag door on the i nstrument
panel above the gl ove box i s the most vi si bl e part of
the passenger si de ai rbag system. Located under the
ai rbag door are the passenger si de ai rbag cushi on
and the ai rbag cushi on supporti ng components.
The passenger si de ai rbag modul e i ncl udes a
stamped metal housi ng wi thi n whi ch the cushi on and
i nfl ator are mounted and seal ed. The ai rbag housi ng
has three stamped metal mounti ng brackets spot
wel ded to i t. The mounti ng brackets at the top and
at the l ower rear of the ai rbag modul e secure the
modul e to the i nstrument panel armature. The
stamped metal mounti ng bracket at the l ower front
of the housi ng secures the passenger si de ai rbag
modul e to two studs on the dash panel , behi nd the
gl ove box. A pl asti c end bracket encl oses the i nboard
end of the housi ng and retai ns the wi re harness con-
nector for the i nfl ator.
Fol l owi ng a passenger si de ai rbag depl oyment, the
passenger si de ai rbag modul e, the passenger si de ai r-
bag door and the i nstrument panel assembl y must be
repl aced. The passenger si de ai rbag modul e cannot
be repai red, and must be repl aced i f depl oyed or i n
any way damaged. The passenger si de ai rbag door i s
avai l abl e as a separate servi ce i tem.
OPERATION
The hybri d-type i nfl ator assembl y i ncl udes a smal l
cani ster of hi ghl y compressed argon gas. The i nfl ator
seal s the hol e i n the ai rbag cushi on so i t can di s-
charge the gas i t produces di rectl y i nto the cushi on
when suppl i ed wi th the proper el ectri cal si gnal . Fol -
l owi ng an ai rbag depl oyment, the ai rbag cushi on
qui ckl y defl ates by venti ng thi s gas through the
porous fabri c materi al used on each end panel of the
ai rbag cushi on.
The mol ded pl asti c passenger si de ai rbag door i s
secured to the i nstrument panel at the upper and
l ower fl anges wi th screws. A stamped metal bracket
l ocated on the back si de of the ai rbag door i s secured
to the i nstrument panel armature wi th one screw on
each end, and serves as the hi nge for the door upon
an ai rbag depl oyment. The ai rbag door has predeter-
mi ned breakout l i nes conceal ed beneath i ts decora-
ti ve cover. Upon ai rbag depl oyment, the ai rbag door
wi l l spl i t at the breakout l i nes and the door wi l l fol d
back over the top of the i nstrument panel , out of the
way.
PASSENGER SIDE AIRBAG ON/OFF SWITCH
DESCRIPTION
A passenger si de ai rbag on/off swi tch, whi ch i s
l ocated on the forward end of the fl oor consol e (both
ful l and mi ni versi ons), al l ows the passenger si de ai r-
bag system to be di sabl ed when certai n chi l d
restrai nt devi ces are bei ng used i n the ri ght front
seati ng posi ti on. The passenger si de ai rbag on/off
swi tch i s equi pped wi th a key actuator that i s
desi gned so that the swi tch posi ti on can be changed
usi ng an i gni ti on key. The key i s i nserted i nto the
actuator far enough to ful l y depress a spri ng-l oaded
l ocki ng pl unger, then rotated to the desi red posi ti on.
The key wi l l not i nsert al l the way i nto the actuator,
and the spri ng-l oaded l ocki ng pl unger prevents the
user from l eavi ng a key i n the actuator. When the
i gni ti on swi tch i s i n the On posi ti on and the passen-
ger si de ai rbag system i s di sabl ed, a Li ght-Emi tti ng
Di ode (LED) i l l umi nates an Off i ndi cator l amp on
the face pl ate of the swi tch.
The passenger si de ai rbag on/off swi tch cannot be
adjusted or repai red and, i f faul ty or damaged, the
swi tch assembl y must be repl aced. The swi tch bezel
i s avai l abl e for servi ce repl acement.
OPERATION
To actuate the passenger si de ai rbag on/off swi tch,
i nsert the i gni ti on key i n the swi tch key actuator far
enough to ful l y depress the spri ng-l oaded l ocki ng
pl unger. The swi tch key actuator i s then rotated wi th
the i gni ti on key to i ts cl ockwi se stop (the key actua-
tor sl ot wi l l be al i gned wi th the Off i ndi cator l amp)
to di sabl e the passenger si de ai rbag system. When
the swi tch key actuator i s rotated wi th the i gni ti on
key to i ts countercl ockwi se stop (the key actuator sl ot
wi l l be i n a verti cal posi ti on), the Off i ndi cator l amp
wi l l be exti ngui shed and the passenger si de ai rbag
system wi l l be enabl ed.
TJ PASSIVE RESTRAINT SYSTEMS 8M - 3
DESCRIPTION AND OPERATION (Continued)
AIRBAG CONTROL MODULE
DESCRIPTION
The Ai rbag Control Modul e (ACM) i s secured wi th
screws to a mounti ng bracket that i s secured wi th
four screws onto the fl oor panel transmi ssi on tunnel
bel ow the i nstrument panel and forward of the center
fl oor consol e i n the passenger compartment of the
vehi cl e. The ACM contai ns an el ectroni c mi croproces-
sor, an el ectroni c i mpact sensor, an el ectromechani cal
safi ng sensor, and an energy storage capaci tor.
The ACM i s servi ced as a uni t wi th the mounti ng
bracket. The ACM cannot be repai red or adjusted
and, i f damaged or faul ty, the ACM and mounti ng
bracket uni t must be repl aced.
OPERATION
The mi croprocessor i n the ACM contai ns the ai rbag
system l ogi c. The ai rbag system l ogi c i ncl udes
On-Board Di agnosti cs (OBD), and the abi l i ty to com-
muni cate wi th the i nstrument cl uster ci rcui try over
the Chrysl er Col l i si on Detecti on (CCD) data bus to
control the ai rbag i ndi cator l amp. The mi croprocessor
conti nuousl y moni tors al l of the ai rbag system el ec-
tri cal ci rcui ts to determi ne the system readi ness. I f
the ACM detects a moni tored system faul t, i t sends
messages to the i nstrument cl uster over the CCD
data bus to turn on the ai rbag i ndi cator l amp. Refer
to Instrument Cluster i n the proper secti on of
Group 8E - I nstrument Panel Systems for more i nfor-
mati on on the ai rbag i ndi cator l amp.
One el ectroni c i mpact sensor i s used i n thi s ai rbag
system. The i mpact sensor i s an accel erometer that
senses the rate of vehi cl e decel erati on, whi ch pro-
vi des veri fi cati on of the di recti on and severi ty of an
i mpact. The i mpact sensor i s cal i brated for the spe-
ci fi c vehi cl e, and i s onl y servi ced as a uni t wi th the
ACM. A pre-programmed deci si on al gori thm i n the
ACM mi croprocessor determi nes when the decel era-
ti on rate as si gnal ed by the i mpact sensor i ndi cates
an i mpact that i s severe enough to requi re ai rbag
system protecti on. When the programmed condi ti ons
are met, the ACM sends an el ectri cal si gnal to depl oy
the ai rbags.
I n addi ti on to the el ectroni c i mpact sensor, there i s
an el ectromechani cal sensor wi thi n the ACM cal l ed a
safi ng sensor. The safi ng sensor i s a normal l y open
seri es swi tch l ocated i n the ai rbag depl oyment ci rcui t
of the ACM. Thi s sensor detects i mpact energy of a
l esser magni tude than the el ectroni c i mpact sensor,
and must be cl osed i n order for the ai rbags to depl oy.
The ACM al so contai ns an energy-storage capaci -
tor. Thi s capaci tor stores enough el ectri cal energy to
depl oy the ai rbags for up to one second fol l owi ng a
battery di sconnect or fai l ure duri ng an i mpact. The
purpose of the capaci tor i s to provi de ai rbag system
protecti on i n a severe secondary i mpact, i f the i ni ti al
i mpact has damaged or di sconnected the battery, but
was not severe enough to depl oy the ai rbags.
CLOCKSPRING
DESCRIPTION
The cl ockspri ng assembl y i s secured wi th two i nte-
gral pl asti c l atches onto the steeri ng col umn l ock
housi ng near the top of the steeri ng col umn behi nd
the steeri ng wheel . The cl ockspri ng i s used to mai n-
tai n a conti nuous el ectri cal ci rcui t between the fi xed
cl ockspri ng wi re harness on the steeri ng col umn and
several el ectri cal components that rotate wi th the
steeri ng wheel . The rotati ng components i ncl ude the
dri ver si de ai rbag modul e, the horn swi tch and, i f the
vehi cl e i s so equi pped, the vehi cl e speed control
swi tches.
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the dri ver si de ai rbag
has been depl oyed, the cl ockspri ng must be repl aced.
OPERATION
The cl ockspri ng assembl y consi sts of a pl asti c case
whi ch contai ns a fl at, ri bbon-l i ke, el ectri cal l y conduc-
ti ve tape that wi nds and unwi nds l i ke a cl ockspri ng
wi th the steeri ng wheel rotati on. The el ectri cal l y con-
ducti ve tape consi sts of several fi ne gauge copper
wi re l eads sandwi ched between two narrow stri ps of
pl asti c fi l m.
Li ke the cl ockspri ng i n a ti mepi ece, the cl ockspri ng
tape has travel l i mi ts and can be damaged by bei ng
wound too ti ghtl y. To prevent thi s from occurri ng, the
cl ockspri ng i s centered when i t i s i nstal l ed on the
steeri ng col umn. Centeri ng the cl ockspri ng i ndexes
the cl ockspri ng tape to other steeri ng components so
that i t can operate wi thi n i ts desi gned travel l i mi ts.
However, i f the cl ockspri ng i s removed for servi ce or
i f the steeri ng col umn i s di sconnected from the steer-
i ng gear al l owi ng the cl ockspri ng tape to change posi -
ti on rel ati ve to the other steeri ng components, i t
must be re-centered fol l owi ng compl eti on of the ser-
vi ce or i t may be damaged. Refer to Clockspring
Centering i n the Adjustments secti on of thi s group
for the proper centeri ng procedures.
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a l ocki ng pi n i nstal l ed. Thi s l ock-
i ng pi n shoul d not be removed unti l the cl ockspri ng
has been i nstal l ed on the steeri ng col umn. I f the
l ocki ng pi n i s removed before the cl ockspri ng i s
i nstal l ed on a steeri ng col umn, the cl ockspri ng cen-
teri ng procedure must be performed.
8M - 4 PASSIVE RESTRAINT SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
AIRBAG SYSTEM
A DRB scan tool i s requi red for di agnosi s of the
ai rbag system. See the proper Di agnosti c Procedures
manual for more i nformati on.
(1) Connect the DRB scan tool to the 16-way data
l i nk wi re harness connector. The connector i s l ocated
on the dri ver si de l ower edge of the i nstrument
panel , outboard of the steeri ng col umn (Fi g. 1).
(2) Turn the i gni ti on swi tch to the On posi ti on.
Exi t the vehi cl e wi th the DRB. Be certai n that the
DRB contai ns the l atest versi on of the proper DRB
software.
(3) Usi ng the DRB, read and record the acti ve
Di agnosti c Troubl e Code (DTC) data.
(4) Read and record any stored DTC data.
(5) See the proper Di agnosti c Procedures manual i f
any DTC i s found i n Step 3 or Step 4.
(6) After compl eti ng the necessary repai rs, try to
erase the stored DTC data. I f any probl ems remai n,
the stored DTC data wi l l not erase. See the proper
Di agnosti c Procedures manual for the procedures to
di agnose any stored DTC that wi l l not erase.
(7) Wi th the i gni ti on swi tch sti l l i n the On posi -
ti on, check to be certai n that nobody i s i n the vehi cl e.
(8) From outsi de of the vehi cl e (away from the ai r-
bags i n case of an acci dental depl oyment) turn the
i gni ti on swi tch to the Off posi ti on for about ten sec-
onds, and then back to the On posi ti on. Observe the
ai rbag i ndi cator l amp i n the i nstrument cl uster. I t
shoul d l i ght for si x to ei ght seconds, and then go out.
Thi s i ndi cates that the ai rbag system i s functi oni ng
normal l y.
NOTE: If the airbag indicator lamp fails to light, or
lights and stays on, there is an airbag system mal-
function. See the proper Diagnostic Procedures
manual to diagnose the problem.
SERVICE PROCEDURES
AIRBAG SYSTEM
NON-DEPLOYED
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of an ai rbag
modul e. When carryi ng a non-depl oyed ai rbag mod-
ul e, the tri m cover or ai rbag si de of the modul e
shoul d be poi nted away from the body to mi ni mi ze
i njury i n the event of an acci dental depl oyment. I f
the modul e i s pl aced on a bench or any other surface,
the tri m cover or ai rbag si de of the modul e shoul d be
face up to mi ni mi ze movement i n the event of an
acci dental depl oyment.
I n addi ti on, the ai rbag system shoul d be di sarmed
whenever any steeri ng wheel , steeri ng col umn, or
i nstrument panel components requi re di agnosi s or
servi ce. Fai l ure to observe thi s warni ng coul d resul t
i n acci dental ai rbag depl oyment and possi bl e per-
sonal i njury. Refer to Group 8E - Instrument
Panel Systems for addi ti onal servi ce procedures on
the i nstrument panel components. Refer to Group
19 - Steering for addi ti onal servi ce procedures on
the steeri ng wheel and steeri ng col umn components.
DISPOSAL OF NON-DEPLOYED AIRBAG MODULES
Al l damaged or faul ty and non-depl oyed dri ver si de
or passenger si de ai rbag modul es whi ch are repl aced
on vehi cl es are to be returned. I f an ai rbag modul e
assembl y i s faul ty or damaged and non-depl oyed,
refer to the parts return l i st i n the current Chrysl er
Corporati on Warranty Pol i ci es and Procedures man-
ual for the proper handl i ng and di sposal procedures.
DEPLOYED
Any vehi cl e whi ch i s to be returned to use after an
ai rbag depl oyment, must have both ai rbag modul es,
the i nstrument panel assembl y, the passenger si de
ai rbag modul e door and the cl ockspri ng repl aced.
These components wi l l be damaged or weakened as a
resul t of an ai rbag depl oyment, whi ch may or may
not be obvi ous duri ng a vi sual i nspecti on, and are
not i ntended for reuse.
Fig. 1 16-Way Data Link Connector - Typical
1 – 16–WAY DATA LINK CONNECTOR
2 – BOTTOM OF INSTRUMENT PANEL
TJ PASSIVE RESTRAINT SYSTEMS 8M - 5
Other vehi cl e components shoul d be cl osel y
i nspected, but are to be repl aced onl y as requi red by
the extent of the vi si bl e damage i ncurred.
STORAGE
An ai rbag modul e must be stored i n i ts ori gi nal ,
speci al contai ner unti l used for servi ce. Al so, i t must
be stored i n a cl ean, dry envi ronment; away from
sources of extreme heat, sparks, and hi gh el ectri cal
energy. Al ways pl ace or store an ai rbag modul e on a
surface wi th i ts tri m cover or ai rbag si de faci ng up,
to mi ni mi ze movement i n case of an acci dental
depl oyment.
CLEANUP PROCEDURE
Fol l owi ng an ai rbag system depl oyment, the vehi -
cl e i nteri or wi l l contai n a powdery resi due. Thi s res-
i due consi sts pri mari l y of harml ess parti cul ate
by-products of the smal l pyrotechni c charge used to
i ni ti ate the ai rbag depl oyment propel l ant. However,
thi s resi due wi l l al so contai n traces of sodi um
hydroxi de powder, a chemi cal by-product of the pro-
pel l ant materi al that i s used to generate the ni trogen
gas that i nfl ates the ai rbag. Si nce sodi um hydroxi de
powder can i rri tate the ski n, eyes, nose, or throat, be
sure to wear safety gl asses, rubber gl oves, and a
l ong-sl eeved shi rt duri ng cl eanup (Fi g. 2).
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
IRRITATION OF THE NOSE OR THROAT, EXIT THE
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
CIAN.
Begi n the cl eanup by removi ng the ai rbag modul es
from the vehi cl e. Refer to Driver SideAirbag Mod-
ule and Passenger Side Airbag Module i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
Use a vacuum cl eaner to remove any resi dual pow-
der from the vehi cl e i nteri or. Cl ean from outsi de the
vehi cl e and work your way i nsi de, so that you avoi d
kneel i ng or si tti ng on a non-cl eaned area.
Be sure to vacuum the heater and ai r condi ti oni ng
outl ets as wel l (Fi g. 3). Run the heater and ai r con-
di ti oner bl ower on the l owest speed setti ng and vac-
uum any powder expel l ed from the outl ets. You may
need to vacuum the i nteri or of the vehi cl e a second
ti me to recover al l of the powder.
Pl ace the depl oyed ai rbag modul es i n your vehi cu-
l ar scrap pi l e.
REMOVAL AND INSTALLATION
DRIVER SIDE AIRBAG MODULE
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged dri ver si de ai rbag modul e. I f the
dri ver si de ai rbag has been depl oyed, the cl ockspri ng
must al so be repl aced. Refer to Clockspring i n the
Removal and I nstal l ati on secti on of thi s group for the
addi ti onal servi ce procedures for the cl ockspri ng.
Fig. 2 Wear Safety Glasses and Rubber Gloves -
Typical
Fig. 3 Vacuum Heater and A/C Outlets - Typical
8M - 6 PASSIVE RESTRAINT SYSTEMS TJ
SERVICE PROCEDURES (Continued)
WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MOD-
ULE, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f ei ther of the ai rbags has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) From the undersi de of the steeri ng wheel ,
remove the two screws that secure the dri ver si de
ai rbag modul e to the steeri ng wheel (Fi g. 4).
(3) Pul l the ai rbag modul e away from the steeri ng
wheel far enough to access the two wi re harness con-
nectors on the back of the ai rbag modul e.
(4) Di sconnect the cl ockspri ng horn swi tch wi re
harness connector from the horn swi tch feed wi re
connector, whi ch i s l ocated on the back of the ai rbag
modul e.
(5) The cl ockspri ng ai rbag wi re harness connector
i s a ti ght snap-fi t i nto the ai rbag modul e connector
receptacl e, whi ch i s l ocated on the ai rbag i nfl ator on
the back of the ai rbag modul e. Fi rml y grasp and pul l
or gentl y pry on the cl ockspri ng ai rbag wi re harness
connector to di sconnect i t from the ai rbag modul e.
Do not pull on the clockspring wire harness to
disengage the connector from the airbag mod-
ule connector receptacle.
(6) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel .
(7) I f the dri ver si de ai rbag has been depl oyed, the
cl ockspri ng must be repl aced. Refer to Clockspring
i n the Removal and I nstal l ati on secti on of thi s group
for the cl ockspri ng servi ce procedures.
INSTALLATION
WARNING:
• USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE DRIVER
SIDE AIRBAG MODULE, OR BECOMING
ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE DRIVER SIDE AIRBAG TRIM COVER.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN OCCUPANT INJURIES UPON AIRBAG
DEPLOYMENT.
• THE DRIVER SIDE AIRBAG MODULE TRIM
COVER MUST NEVER BE PAINTED. REPLACEMENT
TRIM COVERS ARE SERVICED IN THE ORIGINAL
COLORS. PAINT MAY CHANGE THE WAY IN WHICH
THE MATERIAL OF THE TRIM COVER RESPONDS
TO AN AIRBAG DEPLOYMENT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) When i nstal l i ng the dri ver si de ai rbag modul e,
reconnect the cl ockspri ng ai rbag wi re harness con-
nector to the ai rbag modul e connector receptacl e by
pressi ng strai ght i n on the connector. You can be cer-
tai n that the connector i s ful l y engaged by l i steni ng
careful l y for a di sti nct audi bl e cl i ck as the connector
snaps i nto pl ace.
(2) Reconnect the cl ockspri ng horn swi tch wi re
harness connector to the horn swi tch feed wi re con-
nector, whi ch i s l ocated on the back of the ai rbag
modul e.
(3) Careful l y posi ti on the dri ver si de ai rbag mod-
ul e i n the steeri ng wheel . Be certai n that the cl ock-
Fig. 4 Driver Side Airbag Module Remove/Install
1 – STEERING WHEEL
2 – DRIVER’S AIRBAG MODULE
3 – HORN SWITCH WIRE
4 – AIRBAG WIRE
5 – CLOCKSPRING
6 – SCREW
TJ PASSIVE RESTRAINT SYSTEMS 8M - 7
REMOVAL AND INSTALLATION (Continued)
spri ng wi re harnesses i n the steeri ng wheel hub area
are not pi nched between the ai rbag modul e and the
steeri ng wheel .
(4) From the undersi de of the steeri ng wheel ,
i nstal l and ti ghten the two dri ver si de ai rbag modul e
mounti ng screws. Ti ghten the screws to 10.2 N·m (90
i n. l bs.).
(5) Do not reconnect the battery negati ve cabl e at
thi s ti me. Refer to Airbag System i n the Di agnosi s
and Testi ng secti on of thi s group for the proper pro-
cedures.
DRIVER SIDE AIRBAG MODULE TRIM COVER
The horn swi tch i s i ntegral to the dri ver si de ai r-
bag modul e tri m cover. I f ei ther component i s faul ty
or damaged, the enti re dri ver si de ai rbag modul e
tri m cover and horn swi tch uni t must be repl aced.
WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• THE HORN SWITCH IS INTEGRAL TO THE AIR-
BAG MODULE TRIM COVER. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f ei ther of the ai rbags has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . Refer to Driver Side Airbag Mod-
ule i n the Removal and I nstal l ati on secti on of thi s
group for the procedures.
(3) Remove the pl asti c horn swi tch feed wi re
retai ner(s) from the stud(s) on the back of the dri ver
si de ai rbag housi ng (Fi g. 5) or (Fi g. 6).
(4) Remove the four nuts that secure the upper
and l ower tri m cover retai ners to the studs on the
back of the dri ver si de ai rbag housi ng (Fi g. 7) or (Fi g.
8).
(5) Remove the upper and l ower tri m cover retai n-
ers from the ai rbag housi ng studs.
(6) Remove the horn swi tch ground wi re eyel et
from the upper ai rbag housi ng stud.
(7) Di sengage the four tri m cover l ocki ng bl ocks
from the l i p around the outsi de edge of the dri ver
si de ai rbag housi ng and remove the housi ng from the
cover (Fi g. 9) or (Fi g. 10).
Fig. 5 Horn Switch Feed Wire Remove/Install - w/o
Speed Control
1 – HORN SWITCH FEED WIRE
2 – WIRE RETAINERS
3 – HORN SWITCH GROUND WIRE
Fig. 6 Horn Switch Feed Wire Remove/Install -
w/Speed Control
1 – HORN SWITCH FEED WIRE
2 – HORN SWITCH GROUND WIRE
3 – WIRE RETAINER
8M - 8 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
WARNING:
• USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE DRIVER
SIDE AIRBAG MODULE, OR BECOMING
ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE DRIVER SIDE AIRBAG TRIM COVER.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN OCCUPANT INJURIES UPON AIRBAG
DEPLOYMENT.
• THE DRIVER SIDE AIRBAG MODULE TRIM
COVER MUST NEVER BE PAINTED. REPLACEMENT
TRIM COVERS ARE SERVICED IN THE ORIGINAL
COLORS. PAINT MAY CHANGE THE WAY IN WHICH
THE MATERIAL OF THE TRIM COVER RESPONDS
TO AN AIRBAG DEPLOYMENT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Careful l y posi ti on the dri ver si de ai rbag mod-
ul e i n the tri m cover. Be certai n that the horn swi tch
feed and ground wi res are not pi nched between the
ai rbag housi ng and the tri m cover l ocki ng bl ocks.
Fig. 7 Driver Side Airbag Trim Cover Retainers
Remove/Install - w/o Speed Control
1 – UPPER RETAINER
2 – AIRBAG HOUSING
3 – NUT (4)
4 – RETAINER SLOTS
5 – LOWER RETAINER
6 – TRIM COVER
7 – STUDS
8 – INFLATOR
Fig. 8 Driver Side Airbag Trim Cover Retainers
Remove/Install - w/Speed Control
1 – UPPER RETAINER
2 – AIRBAG HOUSING
3 – NUT (4)
4 – RETAINER SLOTS
5 – LOWER RETAINER
6 – TRIM COVER
7 – STUDS
8 – INFLATOR
Fig. 9 Driver Side Airbag Trim Cover Remove/Install
- w/o Speed Control
1 – RETAINER SLOTS
2 – TRIM COVER
3 – LOCKING BLOCKS
4 – RETAINER SLOTS
5 – HORN SWITCH
TJ PASSIVE RESTRAINT SYSTEMS 8M - 9
REMOVAL AND INSTALLATION (Continued)
(2) Engage the upper and l ower tri m cover l ocki ng
bl ocks wi th the l i p of the dri ver si de ai rbag housi ng,
then engage the l ocki ng bl ocks on each si de of the
tri m cover wi th the l i p of the housi ng. Be certai n
that each of the l ocki ng bl ocks i s ful l y engaged on
the l i p of the ai rbag housi ng (Fi g. 11).
(3) I nstal l the horn swi tch ground wi re eyel et over
the upper ai rbag housi ng stud.
(4) I nstal l the upper and l ower ai rbag tri m cover
retai ners over the ai rbag housi ng studs. Be certai n
that the tabs on each retai ner are engaged i n the
retai ner sl ots of the upper and l ower tri m cover l ock-
i ng bl ocks (Fi g. 9) or (Fi g. 10).
(5) I nstal l and ti ghten the tri m cover retai ner
mounti ng nuts on the ai rbag housi ng studs. Ti ghten
the nuts to 10 N·m (90 i n. l bs.).
(6) I nstal l the dri ver si de ai rbag modul e onto the
steeri ng wheel . Refer to Driver Side Airbag Mod-
ule i n the Removal and I nstal l ati on secti on of thi s
group for the procedures.
PASSENGER SIDE AIRBAG MODULE
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged passenger si de ai rbag modul e. I f
the passenger si de ai rbag modul e has been depl oyed,
the i nstrument panel assembl y must be repl aced.
The i nstrument panel assembl y i ncl udes the passen-
ger si de ai rbag modul e and the passenger si de ai rbag
door. Refer to Instrument Panel Assembly i n the
Removal and I nstal l ati on secti on of Group 8E -
I nstrument Panel Systems for the i nstrument panel
assembl y servi ce procedures.
WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MOD-
ULE, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
Fig. 10 Driver Side Airbag Trim Cover Remove/
Install - w/Speed Control
1 – RETAINER SLOTS
2 – TRIM COVER
3 – LOCKING BLOCKS
4 – RETAINER SLOTS
5 – HORN SWITCH
Fig. 11 Driver Side Airbag Trim Cover Locking
Blocks Engaged
1 – LIP
2 – TRIM COVER
3 – HORN SWITCH
4 – AIRBAG HOUSING
5 – LOCKING BLOCK
8M - 10 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f ei ther of the ai rbags has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) Remove the i nstrument panel assembl y from
the passenger compartment of the vehi cl e. Refer to
Instrument Panel Assembly i n the Removal and
I nstal l ati on secti on of Group 8E - I nstrument Panel
Systems for the procedures.
(3) Pl ace the i nstrument panel on a sui tabl e work
surface. Be certai n to take the proper precauti ons to
protect the i nstrument panel from any possi bl e cos-
meti c damage.
(4) Remove the three nuts that secure the passen-
ger si de ai rbag modul e to the studs on the i nstru-
ment panel armature (Fi g. 12).
(5) Remove the passenger si de ai rbag modul e from
the i nstrument panel .
INSTALLATION
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
PASSENGER SIDE AIRBAG MODULE, OR BECOM-
ING ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE PASSENGER SIDE AIRBAG DOOR. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Careful l y posi ti on the passenger si de ai rbag
modul e i n the i nstrument panel .
(2) I nstal l and ti ghten the three nuts that secure
the passenger si de ai rbag modul e upper and l ower
mounti ng brackets to the studs on the i nstrument
panel armature. Ti ghten the nuts to 12 N·m (105 i n.
l bs.).
(3) I nstal l the i nstrument panel assembl y i nto the
passenger compartment of the vehi cl e. Refer to
Instrument Panel Assembly i n the Removal and
I nstal l ati on secti on of Group 8E - I nstrument Panel
Systems for the procedures. When i nstal l i ng the
i nstrument panel , be certai n to reconnect the passen-
ger si de ai rbag modul e wi re harness to the cross-
body wi re harness, and that the connector i s ful l y
engaged and l atched.
(4) Do not reconnect the battery negati ve cabl e at
thi s ti me. Refer to Airbag System i n the Di agnosi s
and Testi ng secti on of thi s group for the proper pro-
cedures.
PASSENGER SIDE AIRBAG DOOR
WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MOD-
ULE, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f ei ther of the ai rbags has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) Remove the passenger si de ai rbag modul e from
the i nstrument panel . Refer to Passenger Side Air-
bag Module i n the Removal and I nstal l ati on secti on
of thi s group for the procedures.
(3) Remove the fi ve screws that secure the passen-
ger si de ai rbag door upper fl ange to the top of the
i nstrument panel (Fi g. 13).
(4) Remove the grab handl e bezel from the i nstru-
ment panel . Refer to Instrument Panel Grab Han-
dle Bezel i n the Removal and I nstal l ati on secti on of
Group 8E - I nstrument Panel Systems for the proce-
dures.
Fig. 12 Passenger Side Airbag Module Remove/
Install
1 – INSTRUMENT PANEL ARMATURE
2 – NUTS (3)
3 – PASSENGER’S AIRBAG MODULE
TJ PASSIVE RESTRAINT SYSTEMS 8M - 11
REMOVAL AND INSTALLATION (Continued)
(5) Remove the fi ve screws that secure the passen-
ger si de ai rbag door l ower fl ange to the i nstrument
panel above the gl ove box openi ng.
(6) Remove the two screws that secure the ends of
the passenger si de ai rbag door bracket to the i nstru-
ment panel armature (Fi g. 14).
(7) Remove and di scard the two passenger si de ai r-
bag door bracket J-nuts from the i nstrument panel
armature. These J-nuts must be repl aced wi th new
parts whenever the passenger si de ai rbag door
bracket screws are removed.
(8) Remove the passenger si de ai rbag door from
the i nstrument panel .
INSTALLATION
WARNING:
• USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER SIDE AIRBAG MODULE, OR BECOMING
ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE PASSENGER SIDE AIRBAG DOOR. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
• THE PASSENGER SIDE AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT AIRBAG
DOORS ARE SERVICED IN THE ORIGINAL COL-
ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE AIRBAG DOOR RESPONDS TO
AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) I nstal l two new passenger ai rbag door bracket
J-nuts onto the i nstrument panel armature. These
J-nuts must be repl aced wi th new parts whenever
the passenger si de ai rbag door bracket screws are
removed.
(2) Posi ti on the passenger si de ai rbag door to the
i nstrument panel and al i gn the mounti ng hol es i n
each end of the ai rbag door bracket wi th the J-nuts
on the i nstrument panel armature.
(3) I nstal l and ti ghten the two screws that secure
the passenger si de ai rbag door bracket to the i nstru-
ment panel armature. Ti ghten the screws to 12 N·m
(105 i n. l bs.).
(4) I nstal l and ti ghten the fi ve screws that secure
the passenger si de ai rbag door l ower fl ange to the
i nstrument panel above the gl ove box openi ng.
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(5) I nstal l the grab handl e bezel onto the i nstru-
ment panel . Refer to Instrument Panel Grab Han-
dle Bezel i n the Removal and I nstal l ati on secti on of
Group 8E - I nstrument Panel Systems for the proce-
dures.
(6) I nstal l and ti ghten the fi ve screws that secure
the passenger si de ai rbag door upper fl ange to the
top of the i nstrument panel . Ti ghten the screws to
2.2 N·m (20 i n. l bs.).
(7) I nstal l the passenger si de ai rbag modul e onto
the i nstrument panel . Refer to Passenger Side Air-
bag Module i n the Removal and I nstal l ati on secti on
of thi s group for the procedures.
Fig. 13 Passenger Side Airbag Door Upper Screws
Remove/Install
1 – MOUNTING SCREWS
2 – AIRBAG DOOR
Fig. 14 Passenger Side Airbag Door Remove/Install
1 – J-NUTS
2 – PASSENGER AIRBAG DOOR
3 – INSTRUMENT PANEL ARMATURE
4 – MOUNTING SCREWS
8M - 12 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
PASSENGER SIDE AIRBAG ON/OFF SWITCH
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
PASSENGER SIDE AIRBAG ON/OFF SWITCH
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f ei ther of the ai rbags has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Glove Box i n the Removal and
I nstal l ati on secti on of Group 8E - I nstrument Panel
Systems for the procedures.
(3) Reach through the gl ove box openi ng to access
and di sconnect the two passenger si de ai rbag on/off
swi tch wi re harness connectors from the i nstrument
panel wi re harness. These connectors are retai ned on
a bracket l ocated on the outboard gl ove box openi ng
rei nforcement (Fi g. 15).
(4) Sti l l reachi ng through the gl ove box openi ng,
di sengage the passenger si de ai rbag on/off swi tch
wi re harness from the retai ner cl i p on the pl enum
bracket that supports the heater-A/C housi ng just
i nboard of the fusebl ock modul e.
(5) Remove the ful l fl oor consol e or mi ni -fl oor con-
sol e from the fl oor panel transmi ssi on tunnel . Refer
to Full Floor Console or Mini Floor Console i n
the Removal and I nstal l ati on secti on of Group 23 -
Body for the procedures.
(6) From the undersi de of the consol e, remove the
three screws that secure the passenger si de ai rbag
on/off swi tch to the back of the swi tch bezel (Fi g. 16).
(7) Remove the passenger si de ai rbag on/off swi tch
from the swi tch bezel .
PASSENGER SIDE AIRBAG ON/OFF SWITCH BEZEL
The passenger si de ai rbag on/off swi tch can be ser-
vi ced wi thout removi ng the swi tch bezel from the
fl oor consol e. I f the passenger si de ai rbag on/off
swi tch bezel i s removed from the fl oor consol e, i t
must be repl aced. The l atch tabs that secure the
bezel to the consol e wi l l be damaged duri ng the
removal process.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f ei ther of the ai rbags has not been depl oyed,
Fig. 15 Passenger Side Airbag On/Off Switch Wire
Harness Connectors
1 – PASSENGER AIRBAG ON/OFF SWITCH CONNECTORS
Fig. 16 Passenger Side Airbag On/Off Switch
Remove/Install
1 – PASSENGER SIDE AIRBAG ON/OFF SWITCH
2 – BEZEL
3 – CAP
4 – LATCH TABS (4)
5 – SCREW (3)
6 – WIRE HARNESS CONNECTORS
TJ PASSIVE RESTRAINT SYSTEMS 8M - 13
REMOVAL AND INSTALLATION (Continued)
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) Remove the passenger si de ai rbag on/off swi tch
from the bezel . Refer to Passenger Side Airbag
On/Off Switch i n the Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(3) From the undersi de of the consol e, rel ease the
four l atch tabs that secure the passenger si de ai rbag
on/off swi tch bezel to the mounti ng hol e i n the front
of the ful l fl oor consol e or mi ni fl oor consol e.
(4) Remove the passenger si de ai rbag on/off swi tch
bezel from the top of the ful l fl oor consol e or mi ni
fl oor consol e.
INSTALLATION
PASSENGER SIDE AIRBAG ON/OFF SWITCH
(1) From the undersi de of the consol e, posi ti on the
passenger si de ai rbag on/off swi tch to the back of the
swi tch bezel .
(2) I nstal l and ti ghten the three screws that secure
the passenger si de ai rbag on/off swi tch to the swi tch
bezel . Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(3) I nstal l the ful l fl oor consol e or mi ni fl oor con-
sol e onto the fl oor panel transmi ssi on tunnel . Refer
to Full Floor Console or Mini Floor Console i n
the Removal and I nstal l ati on secti on of Group 23 -
Body for the procedures.
(4) Reach through the gl ove box openi ng to engage
the passenger si de ai rbag on/off swi tch wi re harness
i n the retai ner cl i p on the pl enum bracket that sup-
ports the heater-A/C housi ng just i nboard of the fuse-
bl ock modul e.
(5) Sti l l reachi ng through the gl ove box openi ng,
access and reconnect the two passenger si de ai rbag
on/off swi tch wi re harness connectors to the i nstru-
ment panel wi re harness. These connectors are
retai ned on a bracket l ocated on the outboard gl ove
box openi ng rei nforcement. Be certai n that both con-
nectors are ful l y engaged and l atched.
(6) I nstal l the gl ove box onto the i nstrument panel .
Refer to Glove Box i n the Removal and I nstal l ati on
secti on of Group 8E - I nstrument Panel Systems for
the procedures.
(7) Do not reconnect the battery negati ve cabl e at
thi s ti me. Refer to Airbag System i n the Di agnosi s
and Testi ng secti on of thi s group for the proper pro-
cedures.
PASSENGER SIDE AIRBAG ON/OFF SWITCH BEZEL
(1) Posi ti on the passenger si de ai rbag on/off swi tch
bezel to the mounti ng hol e at the front of the ful l
fl oor consol e or mi ni fl oor consol e.
(2) Press down fi rml y and evenl y on the passenger
si de ai rbag on/off swi tch bezel unti l each of the four
l atch tabs on the bezel i s ful l y engaged wi th the
mounti ng hol e of the ful l fl oor consol e or mi ni fl oor
consol e.
(3) I nstal l the passenger si de ai rbag on/off swi tch
onto the bezel . Refer to Passenger Side Airbag
On/Off Switch i n the Removal and I nstal l ati on sec-
ti on of thi s group for the procedures.
(4) Do not reconnect the battery negati ve cabl e at
thi s ti me. Refer to Airbag System i n the Di agnosi s
and Testi ng secti on of thi s group for the proper pro-
cedures.
AIRBAG CONTROL MODULE
WARNING:
• THE AIRBAG CONTROL MODULE CONTAINS
THE IMPACT SENSOR, WHICH ENABLES THE SYS-
TEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT-
ING TO DIAGNOSE OR SERVICE ANY AIRBAG
SYSTEM OR RELATED STEERING WHEEL, STEER-
ING COLUMN, OR INSTRUMENT PANEL COMPO-
NENTS YOU MUST FIRST DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• NEVER STRIKE OR KICK THE AIRBAG CON-
TROL MODULE, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. IF AN AIR-
BAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f ei ther of the ai rbags has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) Pul l back the carpet from the fl oor panel trans-
mi ssi on tunnel area under the heater-A/C housi ng
fl oor duct and forward of the ful l fl oor consol e or
mi ni fl oor consol e.
(3) I f the vehi cl e i s equi pped wi th the opti onal
Anti -l ock Brake System (ABS), remove the accel era-
ti on swi tch and mounti ng bracket from the fl oor
panel transmi ssi on tunnel (Fi g. 17). Refer to Accel-
eration Switch i n the Removal and I nstal l ati on sec-
ti on of Group 5 - Brakes for the procedures.
8M - 14 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
NOTE: Always remove and replace the airbag con-
trol module and its mounting bracket as a unit.
Replacement modules include a replacement
mounting bracket. Do not transfer the module to
another mounting bracket.
(4) Remove the four screws that secure the Ai rbag
Control Modul e (ACM) mounti ng bracket to the fl oor
panel transmi ssi on tunnel (Fi g. 18).
(5) Sl i de the ACM and mounti ng bracket out from
under the heater-A/C housi ng fl oor duct far enough
to access the ACM wi re harness connector.
(6) Di sconnect the cross-body wi re harness connec-
tor from the ACM. To di sconnect the cross-body wi re
harness connector from the ACM (Fi g. 19) :
(a) Pul l the two whi te l ocks out about 3 mi l l i me-
ters (0.125 i n.) from each si de of the connector.
(b) Squeeze the two connector l atch tabs
between the thumb and forefi nger and pul l the
connector strai ght away from the ACM connector
receptacl e.
(7) Remove the ACM and mounti ng bracket from
the fl oor panel transmi ssi on tunnel as a uni t.
INSTALLATION
(1) Reconnect the cross-body wi re harness connec-
tor to the ACM connector receptacl e. Be certai n that
Fig. 17 Acceleration Switch Remove/Install
1 – ACCELERATION SWITCH
2 – MOUNTING BRACKET
Fig. 18 Airbag Control Module Remove/Install
1 – SCREW
2 – AIRBAG CONTROL MODULE
3 – FLOOR TRANSMISSION TUNNEL
4 – CONNECTOR
5 – DASH PANEL
Fig. 19 Airbag Control Module Connector Removal
1 – AIRBAG CONTROL MODULE
2 – PULL TWO LOCKS OUT
3 – SQUEEZE LATCHES
4 – PULL
5 – PULL
6 – SQUEEZE LATCHES
7 – MALE CONNECTOR
TJ PASSIVE RESTRAINT SYSTEMS 8M - 15
REMOVAL AND INSTALLATION (Continued)
the connector l atches are ful l y engaged and that the
whi te connector l ocks are pushed i n.
(2) Careful l y posi ti on the ACM and mounti ng
bracket uni t to the fl oor panel transmi ssi on tunnel .
When the ACM i s correctl y posi ti oned the arrow on
the ACM l abel wi l l be poi nted forward i n the vehi cl e.
(3) I nstal l and ti ghten the four screws that secure
the ACM mounti ng bracket to the fl oor panel trans-
mi ssi on tunnel . Ti ghten the screws to 10.7 N·m (95
i n. l bs.).
(4) I f the vehi cl e i s equi pped wi th the opti onal
ABS brakes, i nstal l the accel erati on swi tch and
mounti ng bracket onto the fl oor panel transmi ssi on
tunnel . Refer to Acceleration Switch i n the
Removal and I nstal l ati on secti on of Group 5 - Brakes
for the procedures.
(5) Do not reconnect the battery negati ve cabl e at
thi s ti me. Refer to Airbag System i n the Di agnosi s
and Testi ng secti on of thi s group for the proper pro-
cedures.
CLOCKSPRING
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver si de
ai rbag has been depl oyed.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . Refer to Driver Side Airbag Mod-
ule i n the Removal and I nstal l ati on secti on of thi s
group for the procedures.
(3) I f the vehi cl e i s so equi pped, di sconnect the
upper cl ockspri ng wi re harness connector from the
steeri ng wheel wi re harness for the vehi cl e speed
control swi tches l ocated wi thi n the hub cavi ty of the
steeri ng wheel .
(4) Remove the nut that secures the steeri ng wheel
armature to the steeri ng col umn upper shaft, whi ch
i s l ocated wi thi n the hub cavi ty of the steeri ng wheel .
(5) Pul l the steeri ng wheel off of the steeri ng col -
umn upper shaft spl i ne usi ng a steeri ng wheel pul l er
(Speci al Tool C-3428-B).
(6) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . Refer to Steering Col-
umn Opening Cover i n the Removal and I nstal l a-
ti on secti on of Group 8E - I nstrument Panel Systems
for the procedures.
(7) I f the vehi cl e i s so equi pped, move the ti l t
steeri ng col umn to the ful l y rai sed posi ti on.
(8) Remove the three screws that secure the l ower
steeri ng col umn shroud to the upper shroud (Fi g. 20).
(9) I f the vehi cl e i s equi pped wi th a standard non-
ti l t steeri ng col umn, l oosen the two upper steeri ng
col umn mounti ng nuts. I f the vehi cl e i s equi pped
wi th the opti onal ti l t steeri ng col umn, move the ti l t
steeri ng col umn to the ful l y l owered posi ti on.
(10) Remove both the upper and l ower shrouds
from the steeri ng col umn.
Fig. 20 Steering Column Shrouds Remove/Install
1 – UPPER SHROUD
2 – SCREW (3)
3 – LOWER SHROUD
4 – STEERING WHEEL
8M - 16 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(11) Di sconnect the two i nstrument panel wi re
harness connectors from the l ower cl ockspri ng con-
nector receptacl es (Fi g. 21).
(12) The mul ti -functi on swi tch water shi el d
bracket on the top of the steeri ng col umn has a smal l
access wi ndow whi ch al l ows access to the upper
cl ockspri ng l atch wi th a smal l screwdri ver (Fi g. 22).
Gentl y pry both pl asti c l atches of the cl ockspri ng
assembl y to rel ease them from the steeri ng col umn
upper housi ng.
NOTE: If the clockspring plastic latches are broken,
be certain to remove the broken pieces from the
steering column upper housing.
(13) Remove the cl ockspri ng from the steeri ng col -
umn. The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver si de
ai rbag has been depl oyed.
(14) I f the removed cl ockspri ng i s to be reused,
l ock the cl ockspri ng rotor to the cl ockspri ng case to
mai ntai n cl ockspri ng centeri ng unti l i t i s rei nstal l ed
on the steeri ng col umn. Thi s can be done by i nserti ng
a sti ff wi re through the smal l i ndex hol e l ocated at
about the 11 o’cl ock posi ti on i n the centered cl ock-
spri ng rotor and case. Refer to Clockspring Center-
ing i n the Adjustments secti on of thi s group for an
i l l ustrati on of the cl ockspri ng i ndex hol e. Bend the
wi re over after i t has been i nserted through the
i ndex hol e to prevent i t from fal l i ng out.
INSTALLATION
I f the cl ockspri ng i s not properl y centered i n rel a-
ti on to the steeri ng wheel , steeri ng shaft and steer-
i ng gear, i t may be damaged. Refer to Clockspring
Centering i n the Adjustments secti on of thi s group
before i nstal l i ng or rei nstal l i ng a cl ockspri ng.
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a l ocki ng pi n i nstal l ed. Thi s l ock-
i ng pi n shoul d not be removed unti l the cl ockspri ng
has been i nstal l ed on the steeri ng col umn. I f the
l ocki ng pi n i s removed before the cl ockspri ng i s
i nstal l ed on a steeri ng col umn, the cl ockspri ng cen-
teri ng procedure must be performed.
NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
position.
(1) I f the removed cl ockspri ng i s bei ng reused,
remove the wi re from the i ndex hol e that i s l ocki ng
the cl ockspri ng rotor to the cl ockspri ng case to mai n-
tai n cl ockspri ng centeri ng.
(2) Be certai n that the turn si gnal swi tch control
stal k i s i n the neutral posi ti on, then careful l y sl i de
the centered cl ockspri ng down over the steeri ng col -
umn upper shaft unti l the cl ockspri ng l atches engage
the steeri ng col umn upper housi ng.
(3) I f a new cl ockspri ng has been i nstal l ed, remove
the l ocki ng pi n that i s securi ng the cl ockspri ng rotor
to the cl ockspri ng case and mai ntai ni ng cl ockspri ng
centeri ng.
(4) Reconnect the two i nstrument panel wi re har-
ness connectors to the l ower cl ockspri ng connector
receptacl es. Be certai n that the connector l atches are
ful l y engaged.
Fig. 21 Clockspring Remove/Install
1 – CLOCKSPRING
2 – LATCHES
3 – WIRE HARNESS
4 – TURN SIGNAL SWITCH LEVER
5 – WATER SHIELD BRACKET
6 – STEERING COLUMN
7 – WIPER SWITCH LEVER
Fig. 22 Upper Clockspring Latch Access Window
1 – UPPER CLOCKSPRING LATCH ACCESS WINDOW
2 – CLOCKSPRING
3 – WATER SHIELD AND BRACKET
TJ PASSIVE RESTRAINT SYSTEMS 8M - 17
REMOVAL AND INSTALLATION (Continued)
(5) Posi ti on both the upper and l ower shrouds onto
the steeri ng col umn.
(6) I nstal l and ti ghten the three screws that secure
the l ower steeri ng col umn shroud to the upper
shroud. Ti ghten the screws to 2 N·m (18 i n. l bs.).
(7) I nstal l the steeri ng col umn openi ng cover onto
the i nstrument panel . Refer to Steering Column
Opening Cover i n the Removal and I nstal l ati on sec-
ti on of Group 8E - I nstrument Panel Systems for the
procedures.
(8) I nstal l the steeri ng wheel onto the steeri ng col -
umn upper shaft. Be certai n to i ndex the fl ats on the
hub of the steeri ng wheel wi th the formati ons on the
i nsi de of the cl ockspri ng rotor. Pul l the upper cl ock-
spri ng wi re harnesses through the l ower hol e i n the
steeri ng wheel armature.
(9) I nstal l and ti ghten the steeri ng wheel mount-
i ng nut. Ti ghten the nut to 61 N·m (45 ft. l bs.). Be
certai n not to pi nch the wi re harnesses between the
steeri ng wheel and the nut.
(10) I f the vehi cl e i s so equi pped, reconnect the
upper cl ockspri ng wi re harness connector to the
steeri ng wheel wi re harness for the vehi cl e speed
control swi tches.
(11) I nstal l the dri ver si de ai rbag modul e onto the
steeri ng wheel . Refer to Driver Side Airbag Mod-
ule i n the Removal and I nstal l ati on secti on of thi s
group for the procedures.
ADJ USTMENTS
CLOCKSPRING CENTERING
The cl ockspri ng i s desi gned to wi nd and unwi nd when
the steeri ng wheel i s rotated, but i s onl y desi gned to
rotate the same number of turns (about fi ve compl ete
rotati ons) as the steeri ng wheel can be turned from stop
to stop. Centeri ng the cl ockspri ng i ndexes the cl ock-
spri ng tape to other steeri ng components so that i t can
operate wi thi n i ts desi gned travel l i mi ts. The rotor of a
centered cl ockspri ng can be rotated two and one-hal f
turns i n ei ther di recti on from the centered posi ti on,
wi thout damagi ng the cl ockspri ng tape.
However, i f the cl ockspri ng i s removed for servi ce or i f
the steeri ng col umn i s di sconnected from the steeri ng
gear, the cl ockspri ng tape can change posi ti on rel ati ve
to the other steeri ng components. The cl ockspri ng must
then be re-centered fol l owi ng compl eti on of the servi ce
or the cl ockspri ng tape may be damaged.
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a l ocki ng pi n i nstal l ed. Thi s l ock-
i ng pi n shoul d not be removed unti l the cl ockspri ng
has been i nstal l ed on the steeri ng col umn. I f the
l ocki ng pi n i s removed before the cl ockspri ng i s
i nstal l ed on a steeri ng col umn, the cl ockspri ng cen-
teri ng procedure must be performed.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the cl ockspri ng from the steeri ng col -
umn. Refer to Clockspring i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
(3) Hol d the cl ockspri ng case i n one hand so that i t
i s ori ented as i t woul d be when i t i s i nstal l ed on the
steeri ng col umn (Fi g. 23).
Fig. 23 Clockspring
1 – LOCKING PIN
2 – ROTOR FLATS
3 – CASE
4 – UPPER CLOCKSPRING WIRE HARNESSES (WIRES NOT
SHOWN)
5 – ROTOR
6 – INDEX HOLE
8M - 18 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(4) Use your other hand to rotate the cl ockspri ng
rotor cl ockwi se to the end of i ts travel . Do not apply
excessive torque.
(5) From the end of the cl ockwi se travel , rotate the
rotor about two and one-hal f turns countercl ockwi se,
unti l the rotor fl ats are hori zontal . I f the upper cl ock-
spri ng wi re harnesses are not ori ented towards the
bottom of the cl ockspri ng, rotate the rotor another
one-hal f turn i n the countercl ockwi se di recti on.
(6) The cl ockspri ng i s now centered. Lock the
cl ockspri ng rotor to the cl ockspri ng case to mai ntai n
cl ockspri ng centeri ng unti l i t i s rei nstal l ed on the
steeri ng col umn. Thi s can be done by i nserti ng a sti ff
wi re through the smal l i ndex hol e l ocated at about
the 11 o’cl ock posi ti on i n the centered cl ockspri ng
rotor and case. Bend the wi re over after i t has been
i nserted through the i ndex hol e to prevent i t from
fal l i ng out.
(7) The front wheel s shoul d sti l l be i n the strai ght-
ahead posi ti on. I nstal l the cl ockspri ng onto the steer-
i ng col umn. Refer to Clockspring i n the Removal
and I nstal l ati on secti on of thi s group for the proce-
dures.
SPECIAL TOOLS
PASSIVE RESTRAINT SYSTEMS
Puller C-3428-B
TJ PASSIVE RESTRAINT SYSTEMS 8M - 19
ADJ USTMENTS (Continued)
ELECTRICALLY HEATED SYSTEMS
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
REAR GLASS HEATING GRID . . . . . . . . . . . . . . . 1
DEFOGGER SWITCH. . . . . . . . . . . . . . . . . . . . . . . 2
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 2
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2
REAR GLASS HEATING GRID . . . . . . . . . . . . . . . 3
DEFOGGER SWITCH. . . . . . . . . . . . . . . . . . . . . . . 3
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
REAR GLASS HEATING GRID REPAIR. . . . . . . . . 5
REMOVAL AND INSTALLATION
DEFOGGER SWITCH. . . . . . . . . . . . . . . . . . . . . . . 6
REAR WINDOW DEFOGGER RELAY. . . . . . . . . . . 6
GENERAL INFORMATION
INTRODUCTION
An el ectri cal l y heated rear wi ndow defogger i s
avai l abl e as factory-i nstal l ed equi pment on model s
equi pped wi th the hardtop opti on. The defogger wi l l
onl y operate when the i gni ti on swi tch i s i n the On
posi ti on. When the defogger swi tch i s i n the On posi -
ti on, an el ectri c heater gri d on the rear wi ndow gl ass
i s energi zed. Thi s gri d produces heat to hel p cl ear
the rear wi ndow gl ass of i ce, snow, or fog.
The defogger system i s control l ed by a swi tch
l ocated i n the accessory swi tch bezel , whi ch i s near
the bottom of the i nstrument panel center bezel and
next to the ash recei ver. An amber i ndi cator l amp i n
the swi tch button wi l l l i ght to i ndi cate when the
defogger system i s turned on. The i nstrument cl uster
ci rcui try, whi ch contai ns the defogger system ti mer
l ogi c, moni tors the state of the defogger swi tch
through a hard-wi red i nput. The i nstrument cl uster
ci rcui try control s the defogger system through a
hard-wi red control output to the defogger rel ay.
The defogger system wi l l be automati cal l y turned
off after a programmed ti me i nterval of about ten
mi nutes. After the i ni ti al ti me i nterval has expi red, i f
the defogger swi tch i s turned on agai n duri ng the
same i gni ti on cycl e, the defogger system wi l l auto-
mati cal l y turn off after about fi ve mi nutes.
The defogger system wi l l automati cal l y shut off i f
the i gni ti on swi tch i s turned to the Off posi ti on, or i t
can be turned off manual l y by depressi ng the i nstru-
ment panel swi tch. Refer to the owner’s manual for
more i nformati on on the defogger system control s
and operati on.
Fol l owi ng are general descri pti ons of the major
components i n the defogger system. Refer to 8W-48 -
Rear Wi ndow Defogger i n Group 8W - Wi ri ng Di a-
grams for compl ete ci rcui t descri pti ons and di agrams.
DESCRIPTION AND OPERATION
REAR GLASS HEATING GRID
The heated rear wi ndow gl ass has two el ectri cal l y
conducti ve verti cal bus bars and a seri es of hori zon-
tal gri d l i nes made of a si l ver-cerami c materi al ,
whi ch i s baked on and bonded to the i nsi de surface of
the gl ass. The gri d l i nes and bus bars compri se a
paral l el el ectri cal ci rcui t.
When the rear wi ndow defogger swi tch i s pl aced i n
the On posi ti on, el ectri cal current i s di rected to the
rear wi ndow gri d l i nes through the bus bars. The
gri d l i nes heat the rear wi ndow to cl ear the surface
of fog or snow. Protecti on for the heated gri d ci rcui t
i s provi ded by a fuse i n the Power Di stri buti on Cen-
ter (PDC).
The gri d l i nes and bus bars are hi ghl y resi stant to
abrasi on. However, i t i s possi bl e for an open ci rcui t
to occur i n an i ndi vi dual gri d l i ne, resul ti ng i n no
current fl ow through the l i ne.
The gri d l i nes can be damaged or scraped off wi th
sharp i nstruments. Care shoul d be taken when cl ean-
i ng the gl ass or removi ng forei gn materi al s, decal s,
or sti ckers from the gl ass. Normal gl ass cl eani ng sol -
vents or hot water used wi th rags or towel i ng i s rec-
ommended.
A repai r ki t i s avai l abl e to repai r the gri d l i nes and
bus bars, or to rei nstal l the heated gl ass pi gtai l
wi res.
TJ ELECTRICALLY HEATED SYSTEMS 8N - 1
DEFOGGER SWITCH
The rear wi ndow defogger swi tch i s i nstal l ed i n the
i nstrument panel accessory swi tch bezel , whi ch i s
l ocated near the bottom of the i nstrument panel cen-
ter bezel area, next to the ash recei ver. The momen-
tary-type swi tch provi des a hard-wi red ground si gnal
to the i nstrument cl uster each ti me i t i s depressed.
The i nstrument cl uster rear wi ndow defogger ti mer
and l ogi c ci rcui try responds by energi zi ng or de-ener-
gi zi ng the rear wi ndow defogger rel ay.
Energi zi ng the rear wi ndow defogger rel ay pro-
vi des el ectri cal current to the rear wi ndow defogger
gri d. An amber i ndi cator l amp i n the defogger swi tch,
whi ch l i ghts to i ndi cate when the defogger system i s
turned On, i s al so powered by the defogger rel ay out-
put.
The defogger swi tch i l l umi nati on l amp and i ndi ca-
tor l amp bul bs are servi ceabl e. The defogger swi tch
cannot be repai red and, i f faul ty or damaged, i t must
be repl aced.
INSTRUMENT CLUSTER
The i nstrument cl uster i s an el ectromechani cal
uni t that contai ns i ntegrated ci rcui try and i nternal
programmi ng to perform a vari ety of functi ons. The
i nstrument cl uster ci rcui try moni tors hard-wi red
swi tch i nputs, as wel l as message i nputs recei ved
from other vehi cl e el ectroni c control modul es on the
Chrysl er Col l i si on Detecti on (CCD) data bus network.
The i nstrument cl uster uses these many i nputs
al ong wi th i ts i nternal programmi ng and i ntegral
ti mer and l ogi c ci rcui try to perform the functi ons of
the rear wi ndow defogger ti mer on thi s model . The
i nstrument cl uster ci rcui try al so has a sel f-di agnosti c
capabi l i ty. Refer to I nstrument Cl uster i n Group 8E -
I nstrument Panel Systems for more i nformati on on
thi s feature.
However, there are no di agnosti cs avai l abl e for the
rear wi ndow defogger ti mer and l ogi c ci rcui try.
Therefore, the di agnosi s for thi s system consi sts of
confi rmi ng the presence of a rear wi ndow defogger
swi tch i nput si gnal at the i nstrument cl uster connec-
tor, and the resul ti ng rear wi ndow defogger rel ay
control output si gnal at the defogger rel ay. For di ag-
nosi s of the CCD data bus and the data bus message
i nputs, a DRB scan tool and the proper Di agnosti c
Procedures manual are recommended.
Refer to I nstrument Cl uster i n Group 8E - I nstru-
ment Panel Systems for the servi ce procedures for
the i nstrument cl uster. The rear wi ndow defogger
ti mer and l ogi c ci rcui try cannot be adjusted or
repai red and, i f faul ty or damaged, the i nstrument
cl uster assembl y must be repl aced.
DEFOGGER RELAY
The rear wi ndow defogger rel ay i s a I nternati onal
Standards Organi zati on (I SO)-type rel ay. The rear
wi ndow defogger rel ay i s a el ectromechani cal devi ce
that swi tches fused battery current to the rear gl ass
heati ng gri d and the i ndi cator l amp of the defogger
swi tch, when the i nstrument cl uster rear wi ndow
defogger ti mer and l ogi c ci rcui try grounds the rel ay
coi l . See Defogger Rel ay i n the Di agnosi s and Testi ng
secti on of thi s group for more i nformati on.
The rear wi ndow defogger rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) i n the engi ne com-
partment. Refer to the PDC l abel for rel ay i denti fi ca-
ti on and l ocati on.
The rear wi ndow defogger rel ay cannot be repai red
and, i f faul ty or damaged, i t must be repl aced.
DIAGNOSIS AND TESTING
DEFOGGER SYSTEM
For ci rcui t descri pti ons and di agrams, refer to
8W-48 - Rear Wi ndow Defogger i n Group 8W - Wi r-
i ng Di agrams. The operati on of the el ectri cal l y
heated rear wi ndow defogger system can be con-
fi rmed i n one of the fol l owi ng manners:
1. Turn the i gni ti on swi tch to the On posi ti on.
Whi l e moni tori ng the i nstrument panel vol tmeter, set
the defogger swi tch i n the On posi ti on. When the
defogger swi tch i s turned On, a di sti nct vol tmeter
needl e defl ecti on shoul d be noted.
2. Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The rear wi n-
dow defogger operati on can be checked by feel i ng the
rear wi ndow gl ass. A di sti nct di fference i n tempera-
ture between the gri d l i nes and the adjacent cl ear
gl ass can be detected wi thi n three to four mi nutes of
operati on.
3. Usi ng a 12-vol t DC vol tmeter, contact the rear
gl ass heati ng gri d termi nal A (ri ght si de) wi th the
negati ve l ead, and termi nal B (l eft si de) wi th the pos-
i ti ve l ead (Fi g. 1). The vol tmeter shoul d read battery
vol tage.
The above checks wi l l confi rm system operati on.
I l l umi nati on of the defogger swi tch i ndi cator l amp
means that there i s el ectri cal current avai l abl e at the
output of the defogger rel ay, but does not confi rm
that the el ectri cal current i s reachi ng the rear gl ass
heati ng gri d l i nes.
I f the defogger system does not operate, the prob-
l em shoul d be i sol ated i n the fol l owi ng manner:
(1) Confi rm that the i gni ti on swi tch i s i n the On
posi ti on.
(2) Ensure that the rear gl ass heati ng gri d feed
and ground wi res are connected to the gl ass. Confi rm
that the ground wi re has conti nui ty to ground.
8N - 2 ELECTRICALLY HEATED SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(3) Check the fuses i n the Power Di stri buti on Cen-
ter (PDC) and i n the fusebl ock modul e. The fuses
must be ti ght i n thei r receptacl es and al l el ectri cal
connecti ons must be secure.
When the above steps have been compl eted and the
rear gl ass heati ng gri d i s sti l l i noperati ve, one or
more of the fol l owi ng i s faul ty:
• Defogger swi tch
• Defogger rel ay
• I nstrument cl uster ci rcui try
• Rear wi ndow gri d l i nes (al l gri d l i nes woul d
have to be broken or one of the feed wi res di scon-
nected for the enti re system to be i noperati ve).
I f setti ng the defogger swi tch to the On posi ti on
produces a severe vol tmeter defl ecti on, check for a
short ci rcui t between the defogger rel ay output and
the rear gl ass heati ng gri d.
REAR GLASS HEATING GRID
For ci rcui t descri pti ons and di agrams, refer to
8W-48 - Rear Wi ndow Defogger i n Group 8W - Wi r-
i ng Di agrams. To detect breaks i n the gri d l i nes, the
fol l owi ng procedure i s requi red:
(1) Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The i ndi cator
l amp shoul d l i ght. I f OK, go to Step 2. I f not OK, see
the Defogger Rel ay di agnosi s i n thi s group.
(2) Usi ng a 12-vol t DC vol tmeter, contact the ver-
ti cal bus bar on the ri ght si de of the vehi cl e wi th the
negati ve l ead. Wi th the posi ti ve l ead, contact the ver-
ti cal bus bar on the l eft si de of the vehi cl e. The vol t-
meter shoul d read battery vol tage. I f OK, go to Step
3. I f not OK, repai r the open ci rcui t to the defogger
rel ay as requi red.
(3) Wi th the negati ve l ead of the vol tmeter, contact
a good body ground poi nt. The vol tage readi ng shoul d
not change. I f OK, go to Step 4. I f not OK, repai r the
ci rcui t to ground as requi red.
(4) Connect the negati ve l ead of the vol tmeter to
the ri ght si de bus bar and touch each gri d l i ne at
mi dpoi nt C wi th the posi ti ve l ead. A readi ng of
approxi matel y si x vol ts i ndi cates a l i ne i s good. A
readi ng of zero vol ts i ndi cates a break i n the gri d
l i ne between mi dpoi nt C and the l eft si de bus bar. A
readi ng of ten to fourteen vol ts i ndi cates a break
between mi dpoi nt C and the ri ght si de bus bar. Move
the posi ti ve l ead on the gri d l i ne towards the break
and the vol tage readi ng wi l l change as soon as the
break i s crossed.
DEFOGGER SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-48 - Rear Wi ndow Defogger i n Group 8W - Wi r-
i ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the accessory swi tch bezel from the
i nstrument panel and unpl ug the defogger swi tch
wi re harness connector.
(2) Check for conti nui ty between the ground ci r-
cui t cavi ty of the defogger swi tch wi re harness con-
nector and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 3. I f not OK, repai r the
open ci rcui t as requi red.
(3) Check for conti nui ty between the ground ci r-
cui t termi nal and the rear wi ndow defogger swi tch
sense ci rcui t termi nal on the back of the defogger
swi tch housi ng (Fi g. 2). There shoul d be momentary
conti nui ty as the defogger swi tch button i s depressed,
and then no conti nui ty. I f OK, see the di agnosi s for
the I nstrument Cl uster i n thi s group. I f not OK,
repl ace the faul ty swi tch.
Fig. 1 Rear Window Glass Grid Test
1 – TERMINAL “A”
2 – TERMINAL “B”
3 – FEED WIRE
4 – MID-POINT “C” (TYPICAL)
5 – HEATED REAR WINDOW DEFOGGER GRID
6 – GROUND WIRE
TJ ELECTRICALLY HEATED SYSTEMS 8N - 3
DIAGNOSIS AND TESTING (Continued)
DEFOGGER RELAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
RELAY TEST
The defogger rel ay (Fi g. 3) i s l ocated i n the Power
Di stri buti on Center (PDC), i n the engi ne compart-
ment. Remove the defogger rel ay from the PDC to
perform the fol l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 Ϯ 10 ohms. I f OK, go to
Step 3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Rel ay Ci rcui t Test i n thi s
group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the PDC fuse as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the rear gl ass heati ng gri d and the defogger
swi tch i ndi cator l amp. There shoul d be conti nui ty
between the cavi ty for rel ay termi nal 87 and the rear
wi ndow defogger rel ay output ci rcui t cavi ti es of the
rear gl ass heati ng gri d and defogger swi tch connec-
tors at al l ti mes. I f OK, go to Step 4. I f not OK,
repai r the open ci rcui t(s) as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. Thi s termi nal i s pro-
vi ded wi th ground by the i nstrument cl uster rear
wi ndow defogger ti mer and l ogi c ci rcui try to energi ze
the defogger rel ay. There shoul d be conti nui ty to
ground at the cavi ty for rel ay termi nal 86 when the
defogger swi tch i s turned On. However, wi th the
defogger rel ay removed, the defogger swi tch i ndi cator
l amp wi l l not l i ght to show that the defogger system
i s turned On. Be certai n that you depress the defog-
ger swi tch at l east twi ce to confi rm that the system
i s turned on duri ng thi s test. I f OK, go to Step 5. I f
not OK, repai r the open ci rcui t to the i nstrument
cl uster as requi red.
SWITCH POSITION CONTINUITY BETWEEN
OFF LAMPS
ON MOMENTARY 1 AND 2
ILLUMINATION LAMP 1 AND 4
INDICATOR LAMP 1 AND 3
Fig. 2 Defogger Switch Continuity
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 3 Defogger Relay
8N - 4 ELECTRICALLY HEATED SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. I t i s connected to
fused i gni ti on swi tch output vol tage and shoul d be
hot when the i gni ti on swi tch i s i n the On posi ti on.
Check for battery vol tage at the cavi ty for rel ay ter-
mi nal 85 wi th the i gni ti on swi tch i n the On posi ti on.
I f OK, see the di agnosi s for I nstrument Cl uster i n
thi s group. I f not OK, repai r the open ci rcui t to the
fuse i n the fusebl ock modul e as requi red.
INSTRUMENT CLUSTER
Before performi ng thi s test, compl ete the Defogger
Swi tch and the Defogger Rel ay tests as descri bed i n
thi s group. For ci rcui t descri pti ons and di agrams,
refer to 8W-48 - Rear Wi ndow Defogger i n Group 8W
- Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the defogger rel ay from the Power Di s-
tri buti on Center (PDC) and unpl ug the defogger
swi tch wi re harness connector.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Refer to I nstrument Cl uster i n Group 8E
- I nstrument Panel Systems for the procedures.
(3) Check for conti nui ty between the rear wi ndow
defogger swi tch sense ci rcui t cavi ty of the ri ght
i nstrument cl uster wi re harness connector (connector
B) and a good ground. There shoul d be no conti nui ty.
I f OK, go to Step 4. I f not OK, repai r the short ci rcui t
as requi red.
(4) Check for conti nui ty between the rear wi ndow
defogger swi tch sense ci rcui t cavi ti es of the ri ght
i nstrument cl uster wi re harness connector (connector
B) and the defogger swi tch wi re harness connector.
There shoul d be conti nui ty. I f OK, go to Step 5. I f not
OK, repai r the open ci rcui t as requi red.
(5) Check for conti nui ty between the rear wi ndow
defogger rel ay control ci rcui t cavi ty of the ri ght
i nstrument cl uster wi re harness connector (connector
B) and a good ground. There shoul d be no conti nui ty.
I f OK, go to Step 6. I f not OK, repai r the short ci rcui t
as requi red.
(6) Check for conti nui ty between the rear wi ndow
defogger rel ay control ci rcui t cavi ti es of the ri ght
i nstrument cl uster wi re harness connector (connector
B) and the defogger rel ay receptacl e (the cavi ty for
I SO rel ay termi nal 86) i n the PDC. There shoul d be
conti nui ty. I f OK, repl ace the faul ty i nstrument cl us-
ter. I f not OK, repai r the open ci rcui t as requi red.
SERVICE PROCEDURES
REAR GLASS HEATING GRID REPAIR
Repai r of the rear gl ass heati ng gri d l i nes, bus
bars, termi nal s or pi gtai l wi res can be accompl i shed
usi ng a Mopar Rear Wi ndow Defogger Repai r Ki t
(Part Number 4267922) or equi val ent.
WARNING: MATERIALS CONTAINED IN THE
REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.
THE KIT CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, WHICH ARE HARMFUL IF SWAL-
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) Mask the repai r area so that the conducti ve
epoxy can be appl i ed neatl y. Extend the epoxy appl i -
cati on onto the gri d l i ne or the bus bar on each si de
of the break (Fi g. 4).
(2) Fol l ow the i nstructi ons i n the repai r ki t for
prepari ng the damaged area.
(3) Remove the package separator cl amp and mi x
the two conducti ve epoxy components thoroughl y
wi thi n the packagi ng. Fol d the package i n hal f and
cut the center corner to di spense the epoxy.
Fig. 4 Grid Line Repair - Typical
1 – BREAK
2 – GRID LINE
3 – MASKING TAPE
TJ ELECTRICALLY HEATED SYSTEMS 8N - 5
DIAGNOSIS AND TESTING (Continued)
(4) For gri d l i ne repai rs, mask the area to be
repai red wi th maski ng tape or a templ ate.
(5) Appl y the epoxy through the sl i t i n the mask-
i ng tape or templ ate. Overl ap both ends of the break
by at l east 19 mi l l i meters (0.75 i nch).
(6) For a termi nal or pi gtai l wi re repl acement,
mask the adjacent areas so the epoxy can be
extended onto the adjacent gri d l i ne as wel l as the
bus bar. Appl y a thi n l ayer of epoxy to the area
where the termi nal or pi gtai l wi re was fastened and
onto the adjacent gri d l i ne.
(7) Appl y a thi n l ayer of conducti ve epoxy to the
termi nal or bare wi re end of the pi gtai l and pl ace i t
i n the proper l ocati on on the bus bar. To prevent the
termi nal or pi gtai l wi re from movi ng whi l e the epoxy
i s curi ng, i t must be wedged or cl amped.
(8) Careful l y remove the maski ng tape or tem-
pl ate.
CAUTION: Do not allow the glass surface to exceed
204° C (400° F) or the glass may fracture.
(9) Al l ow the epoxy to cure 24 hours at room tem-
perature, or use a heat gun wi th a 260° to 371° C
(500° to 700° F) range for fi fteen mi nutes. Hol d the
heat gun approxi matel y 25.4 centi meters (10 i nches)
from the repai r.
(10) After the conducti ve epoxy i s properl y cured,
remove the wedge or cl amp from the termi nal or pi g-
tai l wi re. Do not attach the wi re harness connectors
unti l the curi ng process i s compl ete.
(11) Check the operati on of the rear wi ndow defog-
ger gl ass heati ng gri d.
REMOVAL AND INSTALLATION
DEFOGGER SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the center bezel from the i nstrument
panel . See I nstrument Panel Center Bezel i n Group
8E - I nstrument Panel Systems for the procedures.
(3) Remove the four screws that secure the acces-
sory swi tch bezel to the i nstrument panel (Fi g. 5).
(4) Pul l the accessory swi tch bezel out from the
i nstrument panel far enough to access the wi re har-
ness connectors.
(5) Unpl ug the wi re harness connectors from the
rear of the accessory swi tches and the ci gar l i ghter/
power outl et.
(6) Remove the accessory swi tch bezel from the
i nstrument panel .
(7) Wi th a smal l thi n-bl aded screwdri ver, gentl y
pry the snap cl i ps at the top and bottom of the rear
wi ndow defogger swi tch receptacl e on the back of the
accessory swi tch bezel and pul l the swi tch out of the
bezel .
(8) Reverse the removal procedures to i nstal l . Be
certai n that both of the swi tch snap cl i p retai ners i n
the receptacl e on the back of the accessory swi tch
bezel are ful l y engaged. Ti ghten the mounti ng screws
to 2.2 N·m (20 i n. l bs.).
REAR WINDOW DEFOGGER RELAY
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unl atch and open the cover on the Power Di s-
tri buti on Center (PDC) (Fi g. 6).
(3) See the fuse and rel ay l ayout l abel on the
undersi de of the PDC cover for rear wi ndow defogger
rel ay i denti fi cati on and l ocati on.
Fig. 5 Accessory Switch Bezel Remove/Install
1 – INSTRUMENT PANEL
2 – WIRE HARNESS CONNECTORS
3 – SCREW
4 – CIGAR LIGHTER
5 – ACCESSORY SWITCH BEZEL
8N - 6 ELECTRICALLY HEATED SYSTEMS TJ
SERVICE PROCEDURES (Continued)
(4) Remove the rear wi ndow defogger rel ay from
the PDC.
INSTALLATION
(1) Posi ti on the rear wi ndow defogger rel ay i n the
proper receptacl e i n the PDC.
(2) Al i gn the rear wi ndow defogger rel ay termi nal s
wi th the termi nal cavi ti es i n the PDC receptacl e.
(3) Push down fi rml y on the rear wi ndow defogger
rel ay unti l the termi nal s are ful l y seated i n the ter-
mi nal cavi ti es i n the PDC receptacl e.
(4) Cl ose and l atch the cover onto the PDC.
(5) Reconnect the battery negati ve cabl e.
Fig. 6 Power Distribution Center
1 – POWER DISTRIBUTION CENTER
2 – LATCHES
3 – PDC COVER
4 – RIGHT FRONT FENDER
TJ ELECTRICALLY HEATED SYSTEMS 8N - 7
REMOVAL AND INSTALLATION (Continued)
POWER DISTRIBUTION SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWER DISTRIBUTION SYSTEM. . . . . . . . . . . . . 1
POWER DISTRIBUTION CENTER. . . . . . . . . . . . . 1
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . . . 2
FUSEBLOCK MODULE . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
POWER DISTRIBUTION CENTER. . . . . . . . . . . . . 3
POWER DISTRIBUTION CENTER BRACKET. . . . . 4
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . . . 4
FUSEBLOCK MODULE . . . . . . . . . . . . . . . . . . . . . 5
DISASSEMBLY AND ASSEMBLY
POWER DISTRIBUTION CENTER. . . . . . . . . . . . . 6
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS . . . . . . . . . . 10
DESCRIPTION AND OPERATION
POWER DISTRIBUTION SYSTEM
DESCRIPTION
Thi s group covers the vari ous standard and
opti onal power di stri buti on components used on thi s
model . The power di stri buti on system for thi s vehi cl e
consi sts of the fol l owi ng components:
• Power Di stri buti on Center (PDC)
• Fusebl ock Modul e.
The power di stri buti on system al so i ncorporates
vari ous types of ci rcui t control and protecti on fea-
tures, i ncl udi ng:
• Bl ade-type fuses
• Cartri dge fuses
• Rel ays.
Fol l owi ng are general descri pti ons of the major
components i n the power di stri buti on system. See the
owner’s manual i n the vehi cl e gl ove box for more
i nformati on on the features and use of al l of the
power di stri buti on system components. Refer to the
i ndex i n thi s servi ce manual for the l ocati on of com-
pl ete ci rcui t di agrams for the vari ous power di stri bu-
ti on system components.
OPERATION
The power di stri buti on system for thi s vehi cl e i s
desi gned to provi de safe, rel i abl e, and central i zed di s-
tri buti on poi nts for the el ectri cal current requi red to
operate al l of the many standard and opti onal facto-
ry-i nstal l ed el ectri cal and el ectroni c powertrai n,
chassi s, safety, securi ty, comfort and conveni ence sys-
tems. At the same ti me, the power di stri buti on sys-
tem was desi gned to provi de ready access to these
el ectri cal di stri buti on poi nts for the vehi cl e techni -
ci an to use when conducti ng di agnosi s and repai r of
faul ty ci rcui ts. The power di stri buti on system can
al so prove useful for the sourci ng of addi ti onal el ec-
tri cal ci rcui ts that may be requi red to provi de the
el ectri cal current needed to operate many accessori es
that the vehi cl e owner may choose to have i nstal l ed
i n the aftermarket.
POWER DISTRIBUTION CENTER
DESCRIPTION
Al l of the el ectri cal current di stri buted throughout
thi s vehi cl e i s di rected through the standard equi p-
ment Power Di stri buti on Center (PDC) (Fi g. 1). The
mol ded pl asti c PDC housi ng i s l ocated on the ri ght
si de of the engi ne compartment, forward of the bat-
tery on the top of the ri ght front i nner fender shi el d.
The PDC houses up to fi fteen maxi -type cartri dge
fuses, whi ch repl ace al l i n-l i ne fusi bl e l i nks. The PDC
al so houses up to thi rteen bl ade-type mi ni fuses, and
up to twel ve I nternati onal Standards Organi zati on
Fig. 1 Power Distribution Center Location
1 – POWER DISTRIBUTION CENTER
2 – LATCHES
3 – PDC COVER
4 – RIGHT FRONT FENDER
TJ POWER DISTRIBUTION SYSTEMS 8O - 1
(I SO) rel ays (four standard-type and ei ght mi cro-
type).
The PDC housi ng i s secured i n the engi ne compart-
ment at four poi nts. I ntegral mounts on both si des of
the PDC housi ng engage and l atch to stanchi ons that
are i ntegral to the stamped steel PDC bracket. The
PDC bracket i s secured to the top of the ri ght front
i nner fender shi el d wi th three screws, two at the
front of the bracket and one at the rear. The PDC i s
i ntegral to the dash wi re harness, whi ch exi ts from
the bottom of the PDC housi ng. The PDC housi ng
has a mol ded pl asti c cover that i ncl udes two i ntegral
l atches at the rear and pi vot hooks at the front that
snap over a hi nge pi n on the front of the PDC hous-
i ng. The PDC cover i s easi l y opened or removed for
servi ce access and has a conveni ent fuse and rel ay
l ayout map i ntegral to the i nsi de surface of the cover
to ensure proper component i denti fi cati on. A fuse
pul l er i s al so stored on the i nsi de of the PDC cover.
The PDC cover, the PDC housi ng l ower cover, the
PDC rel ay wedges, the PDC rel ay cassettes and the
PDC B(+) termi nal stud modul e are avai l abl e for ser-
vi ce repl acement. The PDC mai n housi ng uni t, the
fuse wedges and the bus bars cannot be repai red and
are onl y servi ced as a uni t wi th the dash wi re har-
ness. I f the PDC mai n housi ng uni t, fuse wedges or
the bus bars are faul ty or damaged, the dash wi re
harness uni t must be repl aced.
OPERATION
Al l of the current from the battery and the gener-
ator output enters the PDC through two cabl es and a
si ngl e two-hol ed eyel et that i s secured wi th nuts to
the two PDC B(+) termi nal studs near the back of
the PDC housi ng. The mol ded pl asti c PDC cover i s
unl atched and opened to access the battery and gen-
erator output connecti on B(+) termi nal studs. I nter-
nal connecti on of al l of the PDC ci rcui ts i s
accompl i shed by an i ntri cate combi nati on of hard
wi ri ng and bus bars. Refer to Power Distribution
i n the i ndex of thi s servi ce manual for the l ocati on of
compl ete PDC wi ri ng di agrams.
IGNITION-OFF DRAW FUSE
DESCRIPTION
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse (Fi g. 2) that i s removed from i ts
cavi ty i n the Power Di stri buti on Center (PDC) when
the vehi cl e i s shi pped from the factory. Deal er per-
sonnel are to remove the I OD fuse from the storage
l ocati on and i nstal l i t i nto PDC fuse cavi ty 25 as part
of the preparati on procedures performed just pri or to
new vehi cl e del i very.
The PDC has a mol ded pl asti c cover that can be
unl atched and opened to provi de servi ce access to al l
of the fuses and rel ays i n the PDC. An i ntegral l atch
and hi nge tabs are mol ded i nto the PDC cover for
easy removal . A fuse l ayout map i s i ntegral to the
undersi de of the PDC cover to ensure proper fuse
and rel ay i denti fi cati on. The I OD fuse i s a 10 ampere
mi ni bl ade-type fuse and, when removed, i t i s stored
i n the empty fuse cavi ty 27 of the PDC.
OPERATION
The term i gni ti on-off draw i denti fi es a normal con-
di ti on where power i s bei ng drai ned from the battery
wi th the i gni ti on swi tch i n the Off posi ti on. The I OD
fuse feeds the memory and sl eep mode functi ons for
many of the el ectroni c modul es i n the vehi cl e as wel l
as vari ous other accessori es that requi re battery cur-
rent when the i gni ti on swi tch i s i n the Off posi ti on,
i ncl udi ng the cl ock. The onl y reason the I OD fuse i s
removed i s to reduce the normal I OD of the vehi cl e
el ectri cal system duri ng new vehi cl e transportati on
and pre-del i very storage to reduce battery depl eti on,
whi l e sti l l al l owi ng vehi cl e operati on so that the
vehi cl e can be l oaded, unl oaded and moved as needed
by both vehi cl e transportati on company and deal er
personnel .
The I OD fuse i s removed from PDC fuse cavi ty 25
when the vehi cl e i s shi pped from the assembl y pl ant.
Deal er personnel must i nstal l the I OD fuse when the
vehi cl e i s bei ng prepared for del i very i n order to
restore ful l el ectri cal system operati on. Once the
vehi cl e i s prepared for del i very, the I OD functi on of
thi s fuse becomes transparent and the fuse that has
been assi gned the I OD desi gnati on becomes onl y
another Fused B(+) ci rcui t fuse. The I OD fuse serves
no useful purpose to the deal er techni ci an i n the ser-
vi ce or di agnosi s of any vehi cl e system or condi ti on,
Fig. 2 Ignition-Off Draw Fuse
1 – IGNITION-OFF DRAW FUSE
2 – IGNITION-OFF DRAW FUSE STORAGE LOCATION
3 – POWER DISTRIBUTION CENTER
8O - 2 POWER DISTRIBUTION SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
other than the same purpose as that of any other
standard ci rcui t protecti on devi ce.
The I OD fuse can be used by the vehi cl e owner as
a conveni ent means of reduci ng battery depl eti on
when a vehi cl e i s to be stored for peri ods not to
exceed about thi rty days. However, i t must be
remembered that removi ng the I OD fuse wi l l not
el i mi nate I OD, but onl y reduce thi s normal condi ti on.
I f a vehi cl e wi l l be stored for more than about thi rty
days, the battery negati ve cabl e shoul d be di scon-
nected to el i mi nate normal I OD; and, the battery
shoul d be tested and recharged at regul ar i nterval s
duri ng the vehi cl e storage peri od to prevent the bat-
tery from becomi ng di scharged or damaged. Refer to
Battery i n the i ndex of thi s servi ce manual for the
l ocati on of addi ti onal servi ce i nformati on coveri ng
the battery.
FUSEBLOCK MODULE
DESCRIPTION
An el ectri cal fusebl ock modul e i s mounted on the
dash panel i n the passenger compartment of the
vehi cl e (Fi g. 3). The fusebl ock modul e serves to di s-
tri bute el ectri cal current to many of the accessory
systems i n the vehi cl e. The fusebl ock modul e houses
up to twenty bl ade-type mi ni fuses.
The mol ded pl asti c fusebl ock modul e housi ng has
an i ntegral mounti ng bracket that i s secured wi th
two screws to a bracket wel ded on the dash panel
just above the heater and ai r condi ti oner housi ng.
The gl ove box i s rol l ed down from the i nstrument
panel for servi ce access of the fusebl ock modul e
fuses. An adhesi ve-backed fuse l ayout map i s l ocated
on the heater and ai r condi ti oner housi ng bel ow the
fusebl ock modul e to ensure proper fuse i denti fi cati on.
The fusebl ock modul e i s i ntegral to the cross body
wi re harness. I f any i nternal ci rcui t or the fusebl ock
modul e housi ng i s faul ty or damaged, the enti re fuse-
bl ock modul e and cross body harness uni t must be
repl aced.
OPERATION
Al l of the ci rcui ts enteri ng and l eavi ng the fuse-
bl ock modul e do so through the cross body wi re har-
ness. I nternal connecti on of al l of the fusebl ock
modul e ci rcui ts i s accompl i shed by an i ntri cate com-
bi nati on of hard wi ri ng and bus bars. Refer to Fuse/
Fuse Block i n the i ndex of thi s servi ce manual for
the l ocati on of compl ete fusebl ock modul e ci rcui t di a-
grams.
REMOVAL AND INSTALLATION
POWER DISTRIBUTION CENTER
The Power Di stri buti on Center (PDC) mai n hous-
i ng uni t, the PDC fuse wedges and the PDC bus bars
cannot be repai red and are onl y servi ced as a uni t
wi th the dash wi re harness. I f the PDC mai n housi ng
uni t, the fuse wedges or the bus bars are faul ty or
damaged, the enti re PDC and dash wi re harness uni t
must be repl aced.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect each of the dash wi re harness con-
nectors. Refer to Connector Locations i n the i ndex
of thi s servi ce manual for the l ocati on of more i nfor-
mati on on the dash wi re harness connector l ocati ons.
(3) Remove al l of the fasteners that secure each of
the dash wi re harness ground eyel ets to the vehi cl e
body and chassi s components. Refer to Connector
Locations i n the i ndex of thi s servi ce manual for the
l ocati on of more i nformati on on the ground eyel et
l ocati ons.
(4) Di sengage each of the retai ners that secure the
dash wi re harness to the vehi cl e body and chassi s
components. Refer to Connector Locations i n the
i ndex of thi s servi ce manual for the l ocati on of more
i nformati on on the dash wi re harness retai ner l oca-
ti ons.
(5) Unl atch and open the PDC cover (Fi g. 4).
(6) Remove the two nuts that secure the eyel et ter-
mi nal of the battery posi ti ve cabl e take out and the
engi ne wi re harness generator output take out to the
PDC B(+) termi nal studs.
Fig. 3 Fuseblock Module Location
1 – FUSE BLOCK
2 – FUSE BLOCK LABEL
3 – HEATER CASE
4 – GLOVE BOX OPENING
TJ POWER DISTRIBUTION SYSTEMS 8O - 3
DESCRIPTION AND OPERATION (Continued)
(7) Remove the battery posi ti ve cabl e take out and
the engi ne wi re harness generator output take out
eyel et termi nal from the B(+) termi nal studs.
(8) Di sengage the l atches on the PDC housi ng
mounts from the tabs on the PDC bracket stan-
chi ons, and pul l the PDC housi ng upward to di sen-
gage the mounts from the stanchi ons of the bracket.
(9) Remove the PDC and the dash wi re harness
from the engi ne compartment as a uni t.
INSTALLATION
NOTE: If the PDC is being replaced with a new unit,
be certain to transfer each of the fuses and relays
that have not been included with the replacement
PDC from the faulty PDC to the proper cavities of
the replacement unit. Refer to Power Distribution in
the index of this service manual for the location of
complete PDC wiring diagrams and cavity assign-
ments.
(1) Posi ti on the PDC and the dash wi re harness
uni t i n the engi ne compartment.
(2) Engage the mounts on the PDC housi ng wi th
the stanchi ons of the PDC bracket and push the uni t
downward unti l the mount l atches engage the
mounti ng tabs on the PDC bracket.
(3) I nstal l the eyel et termi nal of the battery posi -
ti ve cabl e take out and the engi ne wi re harness gen-
erator output take out onto the PDC B(+) termi nal
studs.
(4) I nstal l and ti ghten the two nuts that secure
the eyel et termi nal of the battery posi ti ve cabl e take
out and the engi ne wi re harness generator output
take out to the B(+) termi nal studs. Ti ghten the nuts
to 11.3 N·m (100 i n. l bs.).
(5) Engage the tabs on the l ower edge of the B(+)
termi nal stud cover i n the sl ots on the back of the
PDC housi ng, then engage the l atch on the top of the
cover wi th the l atch receptacl e on the PDC housi ng.
(6) Engage each of the retai ners that secure the
dash wi re harness to the vehi cl e body and chassi s
components. Refer to Connector Locations i n the
i ndex of thi s servi ce manual for the l ocati on of more
i nformati on on the dash wi re harness retai ner l oca-
ti ons.
(7) I nstal l al l of the fasteners that secure each of
the dash wi re harness ground eyel ets to the vehi cl e
body and chassi s components. Refer to Connector
Locations i n the i ndex of thi s servi ce manual for the
l ocati on of more i nformati on on the ground eyel et
l ocati ons.
(8) Reconnect each of the dash wi re harness con-
nectors. Refer to Connector Locations i n the i ndex
of thi s servi ce manual for the l ocati on of more i nfor-
mati on on the dash wi re harness connector l ocati ons.
(9) Reconnect the battery negati ve cabl e.
POWER DISTRIBUTION CENTER BRACKET
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the Power Di stri buti on Center (PDC)
from the PDC bracket. Refer to Power Distribution
Center i n the i ndex of thi s servi ce manual for the
l ocati on of the proper PDC removal procedures.
(3) Remove the three screws that secure the PDC
bracket to the ri ght front i nner fender (Fi g. 5).
(4) Remove the PDC bracket from the ri ght front
i nner fender.
INSTALLATION
(1) Posi ti on the PDC bracket onto the ri ght front
i nner fender.
(2) I nstal l and ti ghten the three screws that secure
the PDC mounti ng bracket to the ri ght front i nner
fender. Ti ghten the screws to 3.9 N·m (35 i n. l bs.).
(3) I nstal l the PDC onto the PDC bracket. Refer to
Power Distribution Center i n the i ndex of thi s
servi ce manual for the l ocati on of the proper PDC
i nstal l ati on procedures.
(4) Reconnect the battery negati ve cabl e.
IGNITION-OFF DRAW FUSE
The I gni ti on-Off Draw (I OD) fuse i s removed from
Power Di stri buti on Center (PDC) fuse cavi ty 25 (Fi g.
6) when the vehi cl e i s shi pped from the assembl y
pl ant. Deal er personnel must i nstal l the I OD fuse
when the vehi cl e i s bei ng prepared for del i very i n
order to restore ful l el ectri cal system operati on.
Fig. 4 Power Distribution Center
1 – POWER DISTRIBUTION CENTER
2 – LATCHES
3 – PDC COVER
4 – RIGHT FRONT FENDER
8O - 4 POWER DISTRIBUTION SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
NOTE: When removing or installing the IOD fuse, it
is important that the ignition switch be in the Off
position. Failure to place the ignition switch in the
Off position can cause the radio display to become
scrambled when the IOD fuse is installed. Remov-
ing and installing the IOD fuse again with the igni-
tion switch in the Off position will usually correct
the scrambled radio display condition.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on.
(2) Unl atch and open the cover from the PDC.
(3) Remove the I OD fuse from fuse cavi ty 25 of the
PDC.
(4) Store the removed I OD fuse by i nserti ng the
termi nal bl ades of the fuse i nto the empty fuse cavi ty
27 of the PDC.
(5) Cl ose and l atch the cover onto the PDC.
INSTALLATION
(1) Turn the i gni ti on swi tch to the Off posi ti on.
(2) Unl atch and open the cover from the PDC.
(3) Remove the stored I OD fuse from fuse cavi ty
27 of the PDC.
(4) Al i gn the termi nal bl ades of the I OD fuse wi th
the termi nal receptacl es i n fuse cavi ty 25 of the PDC.
(5) Use a thumb to press the I OD fuse fi rml y down
i nto PDC fuse cavi ty 25.
(6) Cl ose and l atch the cover onto the PDC.
FUSEBLOCK MODULE
The fusebl ock modul e i s servi ced as a uni t wi th the
cross body wi re harness. I f any i nternal ci rcui t of the
fusebl ock modul e or i f the fusebl ock modul e housi ng
i s faul ty or damaged, the enti re fusebl ock modul e
and the cross body wi re harness uni t must be
repl aced.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument panel assembl y from
the dash panel . Refer to Instrument Panel Assem-
bly i n the i ndex of thi s servi ce manual for the l oca-
ti on of the i nstrument panel removal procedures.
(3) Di sconnect each of the cross body wi re harness
connectors. Refer to Connector Locations i n the
i ndex of thi s servi ce manual for the l ocati on of more
Fig. 5 PDC Bracket Remove/Install
1 – SCREW (3)
2 – RIGHT FRONT FENDER
3 – PDC BRACKET
Fig. 6 Ignition-Off Draw Fuse
1 – IGNITION-OFF DRAW FUSE
2 – IGNITION-OFF DRAW FUSE STORAGE LOCATION
3 – POWER DISTRIBUTION CENTER
TJ POWER DISTRIBUTION SYSTEMS 8O - 5
REMOVAL AND INSTALLATION (Continued)
i nformati on on the cross body wi re harness connector
l ocati ons.
(4) Remove al l of the fasteners that secure each of
the cross body wi re harness ground eyel ets to the
vehi cl e body and chassi s components. Refer to Con-
nector Locations i n the i ndex of thi s servi ce man-
ual for the l ocati on of more i nformati on on the
ground eyel et l ocati ons.
(5) Di sengage each of the retai ners that secure the
cross body wi re harness to the vehi cl e body and chas-
si s components. Refer to Connector Locations i n
the i ndex of thi s servi ce manual for the l ocati on of
more i nformati on on the cross body wi re harness
retai ner l ocati ons.
(6) Remove the two screws that secure the fuse-
bl ock modul e to the bracket on the dash panel (Fi g.
7).
(7) Remove the fusebl ock modul e and the cross
body wi re harness from the dash panel as a uni t.
INSTALLATION
NOTE: If the fuseblock module is being replaced
with a new unit, be certain to transfer each of the
fuses from the faulty fuseblock module to the
proper cavities of the replacement fuseblock mod-
ule. Refer to Fuse/Fuse Block in the index of this
service manual for the location of complete fuse-
block module circuit diagrams and cavity assign-
ments.
(1) Posi ti on the fusebl ock modul e and the cross
body wi re harness onto the dash panel as a uni t.
(2) I nstal l and ti ghten the two screws that secure
the fusebl ock modul e to the bracket on the dash
panel . Ti ghten the screws to 3.3 N·m (30 i n. l bs.).
(3) Engage each of the retai ners that secure the
cross body wi re harness to the vehi cl e body and chas-
si s components. Refer to Connector Locations i n
the i ndex of thi s servi ce manual for the l ocati on of
more i nformati on on the cross body wi re harness
retai ner l ocati ons.
(4) I nstal l al l of the fasteners that secure each of
the cross body wi re harness ground eyel ets to the
vehi cl e body and chassi s components. Refer to Con-
nector Locations i n the i ndex of thi s servi ce man-
ual for the l ocati on of more i nformati on on the
ground eyel et l ocati ons.
(5) Reconnect each of the cross body wi re harness
connectors. Refer to Connector Locations i n the
i ndex of thi s servi ce manual for the l ocati on of more
i nformati on on the cross body wi re harness connector
l ocati ons.
(6) I nstal l the i nstrument panel assembl y onto the
dash panel . Refer to Instrument Panel Assembly
i n the i ndex of thi s servi ce manual for the l ocati on of
the i nstrument panel i nstal l ati on procedures.
(7) Reconnect the battery negati ve cabl e.
DISASSEMBLY AND ASSEMBLY
POWER DISTRIBUTION CENTER
The Power Di stri buti on Center (PDC) cover, the
PDC housi ng l ower cover, the PDC rel ay wedges, the
PDC rel ay cassettes and the PDC B(+) termi nal stud
modul e are avai l abl e for servi ce repl acement (Fi g. 8).
The PDC cover can be si mpl y unl atched and removed
from the PDC housi ng wi thout the PDC bei ng
removed or di sassembl ed. Servi ce of the remai ni ng
PDC components requi res that the PDC be removed
from i ts mounti ng and di sassembl ed. Refer to Wiring
Repair i n the i ndex of thi s servi ce manual for the
l ocati on of the proper wi ri ng repai r procedures.
DISASSEMBLY
PDC HOUSING LOWER COVER
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unl atch and remove the cover from the PDC.
(3) Unl atch and remove the B(+) termi nal stud
cover from the PDC.
(4) Remove the two nuts that secure the eyel et ter-
mi nal to the two B(+) termi nal studs of the PDC.
(5) Remove the eyel et termi nal from the PDC B(+)
termi nal studs.
(6) Di sengage the l atches on the PDC mounts from
the tabs on the PDC bracket stanchi ons, and pul l the
Fig. 7 Fuseblock Module Remove/Install
1 – CROSS BODY WIRE HARNESS
2 – BRACKET
3 – FUSEBLOCK MODULE
4 – SCREWS (2)
8O - 6 POWER DISTRIBUTION SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
PDC housi ng upward to di sengage the mounts from
the stanchi ons of the bracket.
(7) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the l atches on each si de
and one end of the PDC housi ng that secure the
housi ng l ower cover to the PDC and remove the
housi ng l ower cover (Fi g. 9).
PDC B(+) TERMINAL MODULE
(1) Remove the PDC housi ng l ower cover.
(2) From the top of the PDC housi ng, use a smal l
screwdri ver or a termi nal pi ck tool (Speci al Tool Ki t
6680) to rel ease the two l atches that secure the B(+)
termi nal modul e i n the PDC (Fi g. 10).
(3) Gentl y and evenl y press the two B(+) termi nal
studs down through the bus bar i n the PDC.
(4) From the bottom of the PDC housi ng, remove
the B(+) termi nal modul e from the PDC (Fi g. 11).
PDC RELAY WEDGE
(1) Remove the PDC housi ng l ower cover.
Fig. 8 Power Distribution Center Components -
Typical
1 – PIVOT HOOKS
2 – COVER
3 – LATCHES
4 – PDC HOUSING
5 – B(+) TERMINAL STUD MODULE
6 – HOUSING LOWER COVER
7 – WIRE HARNESS
8 – RELAY CASSETTE (TYPICAL)
9 – HINGE PIN
10 – RELAY WEDGE (TYPICAL)
Fig. 9 PDC Housing Lower Cover Remove/Install -
Typical
1 – TROUGH FORMATION
2 – LATCHES (5)
3 – PDC HOUSING LOWER COVER
4 – WIRE HARNESS
Fig. 10 PDC B(+) Terminal Module Latches
1 – FROM SPECIAL TOOL KIT 6680
2 – PDC HOUSING
3 – LATCHES
4 – BUS BAR
5 – B(+) TERMINAL STUDS
TJ POWER DISTRIBUTION SYSTEMS 8O - 7
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove each of the rel ays from the PDC rel ay
wedge to be removed.
(3) From the bottom of the PDC housi ng, use a
smal l screwdri ver or a termi nal pi ck tool (Speci al
Tool Ki t 6680) to rel ease the two l atches (yel l ow) that
secure the rel ay wedge to the PDC rel ay cassette.
(4) From the top of the PDC housi ng, remove the
rel ay wedge from the PDC rel ay cassette (Fi g. 12).
PDC RELAY CASSETTE
(1) Remove the rel ay wedge from the PDC rel ay
cassette to be removed.
NOTE: It may be necessary to remove relay cas-
settes that are not being serviced from the PDC
housing in order to obtain sufficient clearance to
service the faulty relay cassette. The same service
procedure is repeated as necessary to remove each
of the interfering relay wedges and relay cassettes
from the PDC housing.
(2) From the top of the PDC housi ng, use a smal l
screwdri ver or a termi nal pi ck tool (Speci al Tool Ki t
6680) to rel ease the two l atches that secure the rel ay
cassette i n the PDC (Fi g. 13).
(3) Gentl y and evenl y press the rel ay cassette
down through the PDC housi ng.
(4) From the bottom of the PDC housi ng, remove
the rel ay cassette from the PDC (Fi g. 14).
CAUTION: Do not remove the wiring and terminals
from the terminal cavities of the faulty PDC relay
cassette at this time. Refer to the Assembly proce-
dure that follows for the proper procedures for
transferring the wiring and terminals to the replace-
ment PDC relay cassette.
Fig. 11 PDC B(+) Terminal Module Remove/Install
1 – PDC HOUSING
2 – LATCHES
3 – B(+) TERMINAL MODULE
4 – BUS BAR
Fig. 12 PDC Relay Wedge Remove/Install - Typical
1 – RELAY WEDGE (TYPICAL)
2 – PDC HOUSING
Fig. 13 PDC Relay Cassette Latches - Typical
1 – LATCHES
2 – FROM SPECIAL TOOL KIT 6680
3 – PDC RELAY CASSETTES (TYPICAL)
8O - 8 POWER DISTRIBUTION SYSTEMS TJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
PDC RELAY CASSETTE
(1) Move the faul ty PDC rel ay cassette wi th i ts
wi ri ng away from the bottom of the PDC housi ng far
enough to al l ow the repl acement rel ay cassette to be
i nstal l ed i nto the PDC.
(2) Usi ng the faul ty rel ay cassette as a gui de, be
certai n that the repl acement rel ay cassette i s cor-
rectl y ori ented before i nstal l i ng i t i nto the PDC hous-
i ng.
(3) From the bottom of the PDC housi ng, al i gn and
i nsert the repl acement rel ay cassette i nto the PDC.
Press the rel ay cassette up i nto the PDC unti l both
of the l atches are ful l y engaged.
CAUTION: Proper care must be taken to be certain
that the wiring and terminals from the faulty PDC
relay cassette are installed in the correct terminal
cavities of the replacement relay cassette. To pre-
vent mistakes it is recommended that the wiring
and terminals be removed from the faulty relay cas-
sette one cavity at a time, repaired or spliced as
necessary, then installed securely into the correct
cavity of the replacement relay cassette. If you are
not absolutely certain into which cavity a terminal
should be installed, refer to Power Distribution in
the index of this service manual for the location of
complete PDC wiring diagrams.
(4) Whi l e pul l i ng gentl y on the wi re from the bot-
tom of the faul ty PDC rel ay cassette, use a termi nal
pi ck tool (Speci al Tool Ki t 6680) from the top of the
rel ay cassette to rel ease the l atch that secures the
termi nal i n the rel ay cassette termi nal cavi ty (Fi g.
15).
(5) From the bottom of the faul ty PDC rel ay cas-
sette, remove the wi re and termi nal from the rel ay
cassette termi nal cavi ty.
(6) Make al l necessary repai rs and spl i ces to the
wi re for the removed termi nal . Refer to Wiring
Repair i n the i ndex of thi s servi ce manual for the
l ocati on of the proper wi ri ng repai r procedures.
(7) From the bottom of the PDC housi ng, al i gn and
i nsert the removed wi re and termi nal i nto the correct
termi nal cavi ty of the repl acement rel ay cassette.
Push the wi re and termi nal up i nto the rel ay cassette
termi nal cavi ty unti l i t i s ful l y engaged by the l atch.
(8) Repeat Step 4, Step 5, Step 6 and Step 7 one
wi re and termi nal at a ti me unti l each of the wi res
and termi nal s have been transferred from the faul ty
PDC rel ay cassette i nto the repl acement rel ay cas-
sette.
(9) I nstal l the PDC rel ay wedge i nto the repl ace-
ment PDC rel ay cassette.
PDC RELAY WEDGE
(1) From the top of the PDC housi ng, al i gn and
i nsert the PDC rel ay wedge l atch arms i nto the cor-
rect cavi ti es i n the rel ay cassette.
(2) Gentl y and evenl y press the PDC rel ay wedge
down i nto the rel ay cassette unti l both of the l atches
are ful l y engaged.
Fig. 14 PDC Relay Cassette Remove/Install - Typical
1 – PDC HOUSING
2 – PDC RELAY CASSETTE (TYPICAL)
3 – LATCHES
Fig. 15 PDC Relay Cassette Terminal Remove/Install
1 – TERMINAL CAVITIES (TYPICAL)
2 – PDC RELAY CASSETTE (TYPICAL)
3 – TERMINAL LATCHES (TYPICAL)
4 – FROM SPECIAL TOOL KIT 6680
TJ POWER DISTRIBUTION SYSTEMS 8O - 9
DISASSEMBLY AND ASSEMBLY (Continued)
(3) I nstal l each of the removed rel ays i nto the
proper cavi ti es of the PDC rel ay wedge.
(4) I nstal l the PDC housi ng l ower cover.
PDC B(+) TERMINAL MODULE
(1) From the bottom of the PDC housi ng, al i gn and
i nsert the B(+) termi nal modul e i nto the PDC.
(2) From the bottom of the PDC housi ng, al i gn and
i nsert the two studs of the PDC B(+) termi nal mod-
ul e through the bus bar i n the PDC.
(3) From the bottom of the PDC housi ng, press the
B(+) termi nal modul e gentl y and evenl y i nto the PDC
unti l both of the l atches are ful l y engaged.
(4) I nstal l the PDC housi ng l ower cover.
PDC HOUSING LOWER COVER
(1) Al i gn the PDC housi ng l ower cover to the bot-
tom of the PDC.
(2) Press the PDC housi ng l ower cover gentl y and
evenl y onto the PDC unti l each of the l atches that
secure the cover to the PDC i s ful l y engaged.
(3) Engage the mounts on the PDC housi ng wi th
the stanchi ons of the PDC bracket and push the uni t
downward unti l the mount l atches ful l y engage the
mounti ng tabs on the PDC bracket.
(4) I nstal l the eyel et termi nal over the two PDC
B(+) termi nal studs.
(5) I nstal l and ti ghten the two nuts that secure
the eyel et termi nal to the B(+) termi nal studs.
Ti ghten the nuts to 11.3 N·m (100 i n. l bs.).
(6) I nstal l the B(+) termi nal stud cover onto the
PDC.
(7) I nstal l the cover onto the PDC.
(8) Reconnect the battery negati ve cabl e.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
Terminal Pick Kit 6680
8O - 10 POWER DISTRIBUTION SYSTEMS TJ
DISASSEMBLY AND ASSEMBLY (Continued)
VEHICLE THEFT/SECURITY SYSTEMS
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SENTRY KEY IMMOBILIZER SYSTEM. . . . . . . . . 1
DESCRIPTION AND OPERATION
SENTRY KEY IMMOBILIZER MODULE. . . . . . . . . 1
SENTRY KEY IMMOBILIZER TRANSPONDER . . . 2
SENTRY KEY IMMOBILIZER SYSTEM
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
SENTRY KEY IMMOBILIZER SYSTEM. . . . . . . . . 3
SERVICE PROCEDURES
SENTRY KEY IMMOBILIZER SYSTEM
TRANSPONDER PROGRAMMING. . . . . . . . . . . 4
REMOVAL AND INSTALLATION
SENTRY KEY IMMOBILIZER MODULE. . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
The Sentry Key I mmobi l i zer System (SKI S) i s
avai l abl e factory-i nstal l ed opti onal equi pment for thi s
model . Fol l owi ng are some general descri pti ons of the
features and components of the SKI S. Refer to the
vehi cl e owner’s manual for more i nformati on on the
use and operati on of the SKI S. Refer to 8W-30 - Fuel /
I gni ti on System i n Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams.
SENTRY KEY IMMOBILIZER SYSTEM
The Sentry Key I mmobi l i zer System (SKI S) i s
desi gned to provi de passi ve protecti on agai nst unau-
thori zed vehi cl e use by preventi ng the engi ne from
operati ng whi l e the system i s armed. The pri mary
components of thi s system are the Sentry Key I mmo-
bi l i zer Modul e (SKI M), the Sentry Key transponder,
the SKI S i ndi cator l amp, and the Powertrai n Control
Modul e (PCM).
The SKI M i s i nstal l ed on the steeri ng col umn near
the i gni ti on l ock cyl i nder. The transponder i s l ocated
under the mol ded rubber cap on the head of the i gni -
ti on key. The SKI S i ndi cator l amp i s l ocated i n the
i nstrument cl uster.
The SKI S i ncl udes two val i d Sentry Key transpon-
ders from the factory. I f the customer wi shes, addi -
ti onal non-coded bl ank Sentry Keys are avai l abl e.
These bl ank keys can be cut to match a val i d i gni ti on
key, but the engi ne wi l l not start unl ess the key tran-
sponder i s al so programmed to the vehi cl e usi ng the
Customer Learn programmi ng procedure or a
DRBI I I ௡ scan tool . The SKI S wi l l recogni ze no more
than ei ght val i d Sentry Key transponders at any one
ti me.
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store Di agnosti c Troubl e Codes (DTCs) i f a system
mal functi on i s detected. The SKI S can be di agnosed,
and any stored DTC can be retri eved usi ng a
DRBI I I ௡ scan tool as descri bed i n the proper Di ag-
nosti c Procedures manual .
DESCRIPTION AND OPERATION
SENTRY KEY IMMOBILIZER MODULE
The Sentry Key I mmobi l i zer Modul e (SKI M) con-
tai ns a Radi o Frequency (RF) transcei ver and a cen-
tral processi ng uni t, whi ch i ncl udes the Sentry Key
I mmobi l i zer System (SKI S) program l ogi c. The SKI S
programmi ng enabl es the SKI M to program and
retai n i n memory the codes of at l east one, but no
more than ei ght el ectroni cal l y coded Sentry Key
transponders. The SKI S programmi ng al so enabl es
the SKI M to communi cate over the Chrysl er Col l i si on
Detecti on (CCD) data bus network wi th the Power-
trai n Control Modul e (PCM), the i nstrument cl uster
and/or the DRBI I I ௡ scan tool .
The SKI M transmi ts and recei ves RF si gnal s
through a tuned antenna encl osed wi thi n a mol ded
pl asti c ri ng formati on that i s i ntegral to the SKI M
housi ng. When the SKI M i s properl y i nstal l ed on the
steeri ng col umn, the antenna ri ng i s ori ented around
the ci rcumference of the i gni ti on l ock cyl i nder hous-
i ng. Thi s antenna ri ng must be l ocated wi thi n ei ght
mi l l i meters (0.31 i nches) of the Sentry Key i n order
to ensure proper RF communi cati on between the
SKI M and the Sentry Key transponder.
For added system securi ty, each SKI M i s pro-
grammed wi th a uni que “Secret Key” code and a
securi ty code (PI N). The SKI M keeps the “Secret
Key” code i n memory. Thi s “Secret Key” code must be
transferred to the PCM memory duri ng the i ni ti al i za-
ti on/programmi ng of the SKI S when the vehi cl e i s
manufactured, and each ti me the PCM i s repl aced
TJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1
duri ng vehi cl e servi ce by the deal er techni ci an. The
SKI M al so transfers the “Secret Key” code to the
memory of each of the Sentry Key transponders dur-
i ng new key programmi ng. The securi ty code i s used
by the assembl y pl ant to access the SKI S for i ni ti al -
i zati on, or by the deal er techni ci an to access the sys-
tem for servi ce. The SKI M al so stores i n i ts memory
the Vehi cl e I denti fi cati on Number (VI N), whi ch i t
l earns through a CCD data bus message from the
PCM duri ng i ni ti al i zati on.
The SKI M and the PCM both use software that
i ncl udes a rol l i ng code al gori thm strategy, whi ch
hel ps to reduce the possi bi l i ty of unauthori zed SKI S
di sarmi ng. The rol l i ng code al gori thm ensures secu-
ri ty by preventi ng an overri de of the SKI S through
the unauthori zed substi tuti on of the SKI M or the
PCM. However, the use of thi s strategy al so means
that repl acement of ei ther the SKI M or the PCM
uni ts wi l l requi re a system i ni ti al i zati on procedure to
restore system operati on.
When the i gni ti on swi tch i s turned to the On or
Start posi ti ons, the SKI M transmi ts an RF si gnal to
exci te the Sentry Key transponder. The SKI M then
l i stens for a return RF si gnal from the transponder
of the Sentry Key that i s i nserted i n the i gni ti on l ock
cyl i nder. I f the SKI M recei ves an RF si gnal wi th
val i d “Secret Key” and transponder i denti fi cati on
codes, the SKI M sends a “val i d key” message to the
PCM over the CCD data bus. I f the SKI M recei ves
an i nval i d RF si gnal or no response, i t sends “i nval i d
key” messages to the PCM. The PCM wi l l enabl e or
di sabl e engi ne operati on based upon the status of the
SKI M messages.
The SKI M al so sends messages to the i nstrument
cl uster over the CCD data bus network to control the
SKI S i ndi cator l amp. The SKI M sends messages to
the i nstrument cl uster to turn the l amp on for about
three seconds when the i gni ti on swi tch i s turned to
the On posi ti on as a bul b test. After compl eti on of
the bul b test, the SKI M sends bus messages to keep
the l amp off for a durati on of about one second. Then
the SKI M sends messages to turn the l amp on or off
based upon the resul ts of the SKI S sel f-tests. I f the
SKI S i ndi cator l amp comes on and stays on after the
bul b test, i t i ndi cates that the SKI M has detected a
system mal functi on and/or that the SKI S has become
i noperati ve.
I f the SKI M detects an i nval i d key when the i gni ti on
swi tch i s turned to the On posi ti on, i t sends messages to
the i nstrument cl uster to fl ash the SKI S i ndi cator l amp.
The SKI M can al so send messages to the i nstrument
cl uster to fl ash the l amp and to generate a si ngl e audi -
bl e chi me tone. These functi ons serve as an i ndi cati on
to the customer that the SKI S has been pl aced i n i ts
“Customer Learn” programmi ng mode. See Sentry Key
I mmobi l i zer System Transponder Programmi ng i n thi s
group for more i nformati on on the “Customer Learn”
programmi ng mode.
For di agnosi s or i ni ti al i zati on of the SKI M and the
PCM, a DRBI I I ௡ scan tool and the proper Di agnosti c
Procedures manual are requi red. The SKI M cannot
be repai red and, i f faul ty or damaged, the uni t must
be repl aced.
SENTRY KEY IMMOBILIZER TRANSPONDER
The Sentry Key I mmobi l i zer System (SKI S) uses a
transponder that i s i ntegral to each of the two i gni ti on
keys that are suppl i ed wi th the vehi cl e when i t i s
shi pped from the factory. The transponder chi p i s i nsu-
l ated wi thi n a nyl on mount i nserted i n the head of the
key, and i nvi si bl e beneath a mol ded rubber cap (Fi g. 1).
Each Sentry Key transponder has a uni que tran-
sponder i denti fi cati on code programmed i nto i t by the
manufacturer. The Sentry Key I mmobi l i zer Modul e
(SKI M) has a uni que “Secret Key” code programmed
i nto i t by the manufacturer. Each ti me a new Sentry
Key transponder i s programmed, the SKI M l earns
the transponder i denti fi cati on code from the tran-
sponder, and the transponder l earns the “Secret Key”
code from the SKI M. Each of these codes i s stored
wi thi n the transponder and i n the nonvol ati l e mem-
ory of the SKI M. Therefore, bl ank keys for the SKI S
must be programmed and thei r transponder i denti fi -
cati on codes must be l earned by and stored i n the
SKI M memory, i n addi ti on to bei ng cut to match the
mechani cal codi ng of the i gni ti on l ock cyl i nder. See
Sentry Key I mmobi l i zer System Transponder Pro-
grammi ng i n thi s group for more i nformati on.
Fig. 1 Sentry Key Immobilizer Transponder
1 – MOLDED CAP
2 – TRANSPONDER
3 – MOLDED CAP REMOVED
4 – SENTRY KEY
8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
The Sentry Key transponder i s wi thi n the range of
the SKI M transcei ver antenna ri ng when i t i s i nserted
i n the i gni ti on l ock cyl i nder. When the i gni ti on swi tch i s
turned to the Start or On posi ti ons, the SKI M trans-
cei ver i ssues a Radi o Frequency (RF) si gnal that exci tes
the transponder chi p. The transponder chi p responds by
i ssui ng an RF si gnal contai ni ng i ts transponder i denti -
fi cati on code and the “Secret Key” code. The SKI M
transcei ver compares the transponder codes wi th the
codes stored i n i ts memory to determi ne whether a val i d
key i s i n the i gni ti on l ock cyl i nder.
The Sentry Key transponder cannot be repai red
and, i f faul ty or damaged, i t must be repl aced.
SENTRY KEY IMMOBILIZER SYSTEM
INDICATOR LAMP
The Sentry Key I mmobi l i zer System (SKI S) i ndi ca-
tor l amp gi ves an i ndi cati on when the SKI S i s faul ty
or when the vehi cl e has been i mmobi l i zed due to the
use of an i nval i d i gni ti on key. The l amp i s control l ed
by the i nstrument cl uster ci rcui try based upon mes-
sages recei ved from the Sentry Key I mmobi l i zer
Modul e (SKI M) on the Chrysl er Col l i si on Detecti on
(CCD) data bus.
The SKI M sends messages to the i nstrument cl us-
ter to turn the l amp on for about three seconds when
the i gni ti on swi tch i s turned to the On posi ti on as a
bul b test. After compl eti on of the bul b test, the SKI M
sends bus messages to keep the l amp off for a dura-
ti on of about one second. Then the SKI M sends mes-
sages to the i nstrument cl uster ci rcui try to turn the
l amp on or off based upon the resul ts of the SKI S
sel f-tests. I f the SKI S i ndi cator l amp comes on and
stays on after the bul b test, i t i ndi cates that the
SKI M has detected a system mal functi on and/or that
the SKI S has become i noperati ve.
I f the SKI M detects an i nval i d key when the i gni ti on
swi tch i s turned to the On posi ti on, i t sends messages to
the i nstrument cl uster to fl ash the SKI S i ndi cator l amp.
The SKI M can al so send messages to the i nstrument
cl uster to fl ash the l amp and to generate a si ngl e audi -
bl e chi me tone. These functi ons serve as an i ndi cati on
to the customer that the SKI S has been pl aced i n i ts
“Customer Learn” programmi ng mode. See Sentry Key
I mmobi l i zer System Transponder Programmi ng i n thi s
group for more i nformati on on the “Customer Learn”
programmi ng mode.
The SKI S i ndi cator l amp uses a repl aceabl e i ncandes-
cent bul b and bul b hol der on the i nstrument cl uster
el ectroni c ci rcui t board. Refer to Group 8E - I nstrument
Panel Systems for di agnosi s and servi ce of a faul ty
SKI S i ndi cator l amp. I f the SKI S i ndi cator l amp comes
on and stays on after the bul b test functi on, di agnosi s of
the SKI S shoul d be performed wi th a DRB scan tool
and the proper Di agnosti c Procedures manual .
DIAGNOSIS AND TESTING
SENTRY KEY IMMOBILIZER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Sentry Key Immobilizer System involves the use of
a DRB scan tool. Refer to the proper Diagnostic
Procedures manual for the procedures.
The Sentry Key I mmobi l i zer System (SKI S) and
the Chrysl er Col l i si on Detecti on (CCD) data bus net-
work shoul d be di agnosed usi ng a DRB scan tool .
The DRB wi l l al l ow confi rmati on that the CCD data
bus i s functi onal , that the Sentry Key I mmobi l i zer
Modul e (SKI M) i s pl aci ng the proper messages on the
CCD data bus, and that the Powertrai n Control Mod-
ul e (PCM) and the i nstrument cl uster are recei vi ng
the CCD data bus messages. Refer to the proper
Di agnosti c Procedures manual for the procedures.
Refer to 8W-39 - Vehi cl e Theft Securi ty System i n
Group 8W - Wi ri ng Di agrams for compl ete ci rcui t
descri pti ons and di agrams.
(1) Check the fuses i n the fusebl ock modul e. I f OK,
go to Step 2. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. Unpl ug the wi re harness connector at the
SKI M. Check for conti nui ty between the ground ci r-
cui t cavi ty of the SKI M wi re harness connector and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 3. I f not OK, repai r the open ci rcui t to ground
as requi red.
(3) Connect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
SKI M wi re harness connector. I f OK, go to Step 4. I f
not OK, repai r the open ci rcui t to the fuse i n the
fusebl ock modul e as requi red.
(4) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run/start) ci rcui t cavi ty of the SKI M wi re har-
ness connector. I f OK, use a DRB scan tool and the
proper Di agnosti c Procedures manual to compl ete the
di agnosi s of the SKI S. I f not OK, repai r the open ci rcui t
to the fuse i n the fusebl ock modul e as requi red.
TJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3
DESCRIPTION AND OPERATION (Continued)
SERVICE PROCEDURES
SENTRY KEY IMMOBILIZER SYSTEM
TRANSPONDER PROGRAMMING
Two programmed Sentry Key transponders are
i ncl uded wi th the Sentry Key I mmobi l i zer System
(SKI S) when i t i s shi pped from the factory. The Sentry
Key I mmobi l i zer Modul e (SKI M) can be programmed to
recogni ze up to si x addi ti onal transponders, for a total
of ei ght Sentry Keys. The fol l owi ng “Customer Learn”
programmi ng procedure for the programmi ng of addi -
ti onal transponders requi res access to at l east two of
the val i d Sentry Keys. I f two val i d Sentry Keys are not
avai l abl e, Sentry Key programmi ng wi l l requi re the use
of a DRB scan tool and the proper Di agnosti c Proce-
dures manual .
CUSTOMER LEARN
(1) Obtai n the addi ti onal Sentry Key transponder
bl ank(s) that are to be programmed for the vehi cl e. Cut
the addi ti onal Sentry Key transponder bl anks to match
the i gni ti on l ock cyl i nder mechani cal key codes.
(2) I nsert one of the two val i d Sentry Key tran-
sponders i nto the i gni ti on swi tch and turn the i gni -
ti on swi tch to the On posi ti on.
(3) After the i gni ti on swi tch has been i n the On posi -
ti on for about three seconds, but no more than fi fteen
seconds l ater, cycl e the i gni ti on swi tch back to the Off
posi ti on. Repl ace the fi rst val i d Sentry Key i n the i gni -
ti on l ock cyl i nder wi th the second val i d Sentry Key and
turn the i gni ti on swi tch back to the On posi ti on.
(4) About ten seconds after the compl eti on of Step
3, the SKI S i ndi cator l amp wi l l start to fl ash and a
si ngl e audi bl e chi me tone wi l l sound to i ndi cate that
the system has entered the “Customer Learn” pro-
grammi ng mode.
(5) Wi thi n about fi fty seconds of enteri ng the “Cus-
tomer Learn” programmi ng mode, turn the i gni ti on
swi tch to the Off posi ti on, repl ace the val i d Sentry
Key wi th a bl ank Sentry Key transponder, and turn
the i gni ti on swi tch back to the On posi ti on.
(6) About ten seconds after the compl eti on of Step
5, a si ngl e audi bl e chi me tone wi l l sound and the
SKI S i ndi cator l amp wi l l stop fl ashi ng and stay on
sol i d for about three seconds to i ndi cate that the
bl ank Sentry Key transponder has been successful l y
programmed. The SKI S wi l l i mmedi atel y return to
normal system operati on fol l owi ng exi t from the
“Customer Learn” programmi ng mode.
(7) Go back to Step 2 and repeat thi s process for
each addi ti onal Sentry Key transponder bl ank to be
programmed.
I f any of the above steps i s not compl eted i n the
proper sequence, or wi thi n the al l otted ti me, the SKI S
wi l l automati cal l y exi t the “Customer Learn” program-
mi ng mode. The SKI S wi l l al so automati cal l y exi t the
“Customer Learn” programmi ng mode i f i t sees a non-
bl ank Sentry Key transponder when i t shoul d see a
bl ank, i f i t has al ready programmed ei ght val i d Sentry
Keys, or i f the i gni ti on swi tch i s turned to the Off posi -
ti on for more than about fi fty seconds.
REMOVAL AND INSTALLATION
SENTRY KEY IMMOBILIZER MODULE
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO GROUP 8M - PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL COM-
PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Di sconnect and i sol ate the battery negati ve cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel . See Knee Bl ocker i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Remove the three screws that secure the l ower
steeri ng col umn shroud to the upper shroud (Fi g. 2).
Fig. 2 Steering Column Shrouds Remove/Install
1 – UPPER SHROUD
2 – SCREW (3)
3 – LOWER SHROUD
4 – STEERING WHEEL
8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS TJ
(4) I f the vehi cl e i s equi pped wi th a standard non-
ti l t steeri ng col umn, l oosen the two upper steeri ng
col umn mounti ng nuts. I f the vehi cl e i s equi pped
wi th the opti onal ti l t steeri ng col umn, move the ti l t
steeri ng col umn to the ful l y l owered posi ti on.
(5) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(6) Di sengage the steeri ng col umn wi re harness
retai ner from the tab on the top of the Sentry Key
I mmobi l i zer Modul e (SKI M) mounti ng bracket (Fi g. 3).
(7) Unpl ug the wi re harness connector from the
SKI M receptacl e.
(8) The SKI M mounti ng bracket features a cl i p for-
mati on that secures the SKI M to the i nboard l ower
fl ange of the steeri ng col umn jacket. Pul l downward
on the connector end of the SKI M mounti ng bracket
to rel ease thi s cl i p from the steeri ng col umn jacket.
(9) Rotate the SKI M and i ts mounti ng bracket
downwards and then to the si de away from the steer-
i ng col umn to sl i de the SKI M antenna ri ng from
around the i gni ti on swi tch l ock cyl i nder housi ng.
(10) Remove the SKI M from the vehi cl e.
(11) Reverse the removal procedures to i nstal l .
Ti ghten the non-ti l t steeri ng col umn mounti ng nuts
to 22 N·m (200 i n. l bs.) and the steeri ng col umn
shroud mounti ng screws to 2 N·m (18 i n. l bs.).
NOTE: If the SKIM is replaced with a new unit, a
DRBIIIா scan tool and the proper Diagnostic Proce-
dures manual MUST be used to initialize the new
SKIM and to program at least two Sentry Key
transponders.
Fig. 3 Sentry Key Immobilizer Module Remove/Install
1 – UPPER SHROUD
2 – STEERING COLUMN
3 – WIRE HARNESS CONNECTOR
4 – SENTRY KEY IMMOBILIZER MODULE
5 – IGNITION LOCK CYLINDER
6 – SCREW
7 – LOWER SHROUD
8 – STEERING WHEEL
TJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5
REMOVAL AND INSTALLATION (Continued)
CHIME/BUZZER WARNING SYSTEMS
TABLE OF CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 1
DRIVER DOOR J AMB SWITCH . . . . . . . . . . . . . . 1
DRIVER SEAT BELT SWITCH. . . . . . . . . . . . . . . . 2
KEY-IN IGNITION SWITCH. . . . . . . . . . . . . . . . . . 2
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
DRIVER DOOR J AMB SWITCH . . . . . . . . . . . . . . 2
DRIVER SEAT BELT SWITCH. . . . . . . . . . . . . . . . 2
KEY-IN IGNITION SWITCH. . . . . . . . . . . . . . . . . . 3
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 3
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
CHIME WARNING SYSTEM SWITCHES. . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
Thi s group covers the chi me warni ng system,
whi ch i s standard factory-i nstal l ed equi pment on thi s
model . The chi me warni ng system provi des an audi -
bl e warni ng to the dri ver under the fol l owi ng condi -
ti ons:
• Check gauges l amp i l l umi nati on
• Dri ver si de seat bel t i s not fastened wi th the
i gni ti on swi tch i n the On posi ti on
• Head or park l amps are turned on wi th the i gni -
ti on swi tch Off and the dri ver si de front door open
• Key i s i n the i gni ti on swi tch wi th the i gni ti on
swi tch Off and the dri ver si de front door open
• Low fuel warni ng l amp i l l umi nati on - l ess than
about one-ei ghth tank of fuel remai ni ng
• The opti onal Sentry Key I mmobi l i zer System
(SKI S) i s i n the “customer programmi ng” mode.
Fol l owi ng are general descri pti ons of the major
components i n the chi me warni ng system. Refer to
8W-40 I nstrument Cl uster or 8W-44 - I nteri or Li ght-
i ng i n Group 8W - Wi ri ng Di agrams for compl ete ci r-
cui t descri pti ons and di agrams.
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER
The i nstrument cl uster i s an el ectromechani cal
uni t that contai ns i ntegrated ci rcui try and i nternal
programmi ng to perform a vari ety of functi ons. The
i nstrument cl uster ci rcui try moni tors hard-wi red
swi tch i nputs, as wel l as message i nputs recei ved
from other vehi cl e el ectroni c modul es on the Chrysl er
Col l i si on Detecti on (CCD) data bus network.
The i nstrument cl uster uses these many i nputs
al ong wi th i ts i nternal programmi ng and an i ntegral
chi me tone generator to perform the functi ons of the
chi me warni ng modul e on thi s model . The i nstru-
ment cl uster ci rcui try al so has a sel f-di agnosti c capa-
bi l i ty. Refer to Group 8E - I nstrument Panel Systems
for more i nformati on on thi s feature.
Hard-wi red chi me warni ng system i nputs to the
i nstrument cl uster i ncl ude the fol l owi ng:
• Dri ver door jamb swi tch
• Dri ver seat bel t swi tch
• Headl amp swi tch
• Key-i n i gni ti on swi tch.
The onl y i nstrument cl uster di agnosi s found i n thi s
group consi sts of confi rmi ng the vi abi l i ty of the hard-
wi red chi me request i nputs to the i nstrument cl uster
ci rcui try. For di agnosi s of the CCD data bus and the
data bus message i nputs, a DRB scan tool and the
proper Di agnosti c Procedures manual are recom-
mended.
Refer to Group 8E - I nstrument Panel Systems for
the i nstrument cl uster servi ce procedures. The
i nstrument cl uster chi me warni ng ci rcui try and
chi me tone generator cannot be repai red and, i f
faul ty or damaged, the i nstrument cl uster assembl y
must be repl aced.
DRIVER DOOR JAMB SWITCH
The dri ver door jamb swi tch i s mounted to the
dri ver si de door hi nge pi l l ar. The swi tch cl oses a path
to ground for the i nstrument cl uster chi me warni ng
ci rcui try through the key-i n i gni ti on swi tch and/or
the headl amp swi tch when the dri ver door i s opened,
and opens the ground path when the dri ver door i s
cl osed.
The dri ver door jamb swi tch cannot be repai red
and, i f faul ty or damaged, i t must be repl aced. Refer
to Group 8L - Lamps for the servi ce procedures.
TJ CHIME/BUZZER WARNING SYSTEMS 8U - 1
DRIVER SEAT BELT SWITCH
The dri ver seat bel t swi tch i s i ntegral to the dri ver
seat bel t buckl e-hal f assembl y. The swi tch i s nor-
mal l y cl osed, provi di ng a ground path to the i nstru-
ment panel chi me warni ng ci rcui try. When the ti p-
hal f of the seat bel t i s i nserted i nto the seat bel t
buckl e, the swi tch opens the ground path.
The dri ver seat bel t swi tch cannot be repai red and,
i f faul ty or damaged, the enti re dri ver seat bel t buck-
l e-hal f uni t must be repl aced. Refer to Group 23 -
Body for the servi ce procedures.
KEY-IN IGNITION SWITCH
The key-i n i gni ti on swi tch i s i ntegral to the i gni -
ti on swi tch, whi ch i s mounted on the l eft si de of the
steeri ng col umn, opposi te the i gni ti on l ock cyl i nder.
I t cl oses a path to ground for the i nstrument cl uster
chi me warni ng ci rcui try when the i gni ti on key i s
i nserted i n the i gni ti on l ock cyl i nder and the dri ver
door jamb swi tch i s cl osed (dri ver door i s open). The
key-i n i gni ti on swi tch opens the ground path when
the key i s removed from the i gni ti on l ock cyl i nder.
The key-i n i gni ti on swi tch cannot be repai red and,
i f faul ty or damaged, the enti re i gni ti on swi tch must
be repl aced. Refer to Group 8D - I gni ti on Systems for
the servi ce procedures.
HEADLAMP SWITCH
The headl amp swi tch i s l ocated i n the i nstrument
panel , outboard of the steeri ng col umn. I t cl oses a
path to ground for the i nstrument cl uster chi me
warni ng ci rcui try when the park or head l amps are
on and the dri ver door jamb swi tch i s cl osed (dri ver
door i s open). The headl amp swi tch opens the ground
path when the headl amp swi tch i s turned off.
The headl amp swi tch cannot be repai red and, i f
faul ty or damaged, i t must be repl aced. Refer to
Group 8E - I nstrument Panel Systems for the servi ce
procedures.
DIAGNOSIS AND TESTING
DRIVER DOOR JAMB SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-40 - I nstrument Cl uster or 8W-44 - I nteri or
Li ghti ng i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Rotate the headl amp swi tch knob countercl ock-
wi se to ensure that the dome l amps are not swi tched
off. Open the dri ver door and note whether the i nte-
ri or l amps l i ght. They shoul d l i ght. I f OK, see the
di agnosi s for the Key-I n I gni ti on Swi tch or the Head-
l amp Swi tch i n thi s group. I f not OK, go to Step 2.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. Unpl ug the dri ver door jamb swi tch from i ts
wi re harness connector. Check for conti nui ty between
the door jamb swi tch output ci rcui t cavi ty of the
dri ver door jamb swi tch wi re harness connector and
a good ground. There shoul d be conti nui ty. I f OK, go
to Step 3. I f not OK, repai r the ci rcui t to ground as
requi red.
(3) Check for conti nui ty between the door jamb
swi tch output ci rcui t termi nal and the l eft front door
jamb swi tch sense termi nal of the door jamb swi tch.
There shoul d be conti nui ty wi th the swi tch pl unger
rel eased, and no conti nui ty wi th the swi tch pl unger
depressed. I f not OK, repl ace the faul ty swi tch.
DRIVER SEAT BELT SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-40 - I nstrument Cl uster or 8W-44 - I nteri or
Li ghti ng i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Unpl ug the dri ver seat bel t swi tch wi re har-
ness connector on the fl oor under the dri ver seat
near the seat bel t buckl e-hal f anchor. Check for con-
ti nui ty between the seat bel t swi tch sense ci rcui t and
the ground ci rcui t cavi ti es of the seat bel t hal f of the
dri ver seat bel t swi tch wi re harness connector. There
shoul d be conti nui ty wi th the seat bel t unbuckl ed,
and no conti nui ty wi th the seat bel t buckl ed. I f OK,
go to Step 2. I f not OK, repl ace the faul ty seat bel t
buckl e-hal f assembl y.
(2) Check for conti nui ty between the ground ci r-
cui t cavi ty i n the body hal f of the dri ver seat bel t
swi tch wi re harness connector and a good ground.
There shoul d be conti nui ty. I f OK, see the I nstru-
ment Cl uster di agnosi s i n thi s group. I f not OK,
repai r the ci rcui t to ground as requi red.
8U - 2 CHIME/BUZZER WARNING SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
KEY-IN IGNITION SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-40 - I nstrument Cl uster or 8W-44 - I nteri or
Li ghti ng i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the steeri ng col umn shrouds. Refer to
Group 8D - I gni ti on Systems for the procedures.
Unpl ug the key-i n i gni ti on swi tch wi re harness con-
nector from the i gni ti on swi tch.
(2) Check for conti nui ty between the key-i n swi tch
sense ci rcui t and the l eft front door jamb swi tch
sense ci rcui t termi nal s of the key-i n i gni ti on swi tch.
There shoul d be conti nui ty wi th the key i n the i gni -
ti on l ock cyl i nder, and no conti nui ty wi th the key
removed from the i gni ti on l ock cyl i nder. I f OK, go to
Step 3. I f not OK, repl ace the faul ty i gni ti on swi tch
assembl y.
(3) Check for conti nui ty between the l eft front door
jamb swi tch sense ci rcui t cavi ty of the key-i n i gni ti on
swi tch wi re harness connector and a good ground.
There shoul d be conti nui ty wi th the dri ver door open,
and no conti nui ty wi th the dri ver door cl osed. I f OK,
see the di agnosi s for I nstrument Cl uster i n thi s
group. I f not OK, repai r the ci rcui t to the dri ver door
jamb swi tch as requi red.
HEADLAMP SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-40 - I nstrument Cl uster or 8W-44 - I nteri or
Li ghti ng i n Group 8W - Wi ri ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the headl amp swi tch from the i nstru-
ment panel . Refer to Group 8E - I nstrument Panel
Systems for the procedures. Unpl ug the headl amp
swi tch wi re harness connectors. Check for conti nui ty
between the l eft front door jamb swi tch sense ci rcui t
cavi ty of the headl amp swi tch wi re harness connector
and a good ground. There shoul d be no conti nui ty
wi th the dri ver door cl osed, and conti nui ty wi th the
dri ver door open. I f OK, go to Step 2. I f not OK,
repai r the ci rcui t to the dri ver door jamb swi tch as
requi red.
(2) Check for conti nui ty between the key-i n swi tch
sense ci rcui t termi nal and the l eft front door jamb
swi tch sense termi nal of the headl amp swi tch. There
shoul d be no conti nui ty wi th the swi tch i n the Off
posi ti on, and conti nui ty wi th the swi tch i n the park
or head l amps On posi ti on. I f OK, see the di agnosi s
for the I nstrument Cl uster i n thi s group. I f not OK,
repl ace the faul ty headl amp swi tch.
INSTRUMENT CLUSTER
Before performi ng thi s test, compl ete the testi ng of
the hard-wi red chi me warni ng system swi tches as
descri bed i n thi s group. For ci rcui t descri pti ons and
di agrams, refer to 8W-40 - I nstrument Cl uster or
8W-44 - I nteri or Li ghti ng i n Group 8W - Wi ri ng Di a-
grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster from the
i nstrument panel . Refer to Group 8E - I nstrument
Panel Systems for the procedures.
(2) Unpl ug the headl amp swi tch and the key-i n
i gni ti on swi tch wi re harness connectors. Check for
conti nui ty between the key-i n swi tch sense ci rcui t
cavi ty of the ri ght i nstrument cl uster wi re harness
connector (connector B) and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 3. I f not
OK, repai r the short ci rcui t as requi red.
(3) Check for conti nui ty between the key-i n swi tch
sense ci rcui t cavi ti es of the ri ght i nstrument cl uster
wi re harness connector (connector B) and the head-
l amp swi tch wi re harness connector. There shoul d be
conti nui ty. I f OK, go to Step 4. I f not OK, repai r the
open ci rcui t as requi red.
(4) Unpl ug the dri ver seat bel t swi tch wi re har-
ness connector. Check for conti nui ty between the seat
bel t swi tch sense ci rcui t cavi ty of the ri ght i nstru-
ment cl uster wi re harness connector (connector B)
and a good ground. There shoul d be no conti nui ty. I f
TJ CHIME/BUZZER WARNING SYSTEMS 8U - 3
DIAGNOSIS AND TESTING (Continued)
OK, go to Step 5. I f not OK, repai r the short ci rcui t
as requi red.
(5) Check for conti nui ty between the seat bel t
swi tch sense ci rcui t cavi ti es of the ri ght i nstrument
cl uster wi re harness connector (connector B) and the
dri ver seat bel t swi tch wi re harness connector. There
shoul d be conti nui ty. I f OK, test the i nstrument cl us-
ter as descri bed i n Group 8E - I nstrument Panel Sys-
tems. I f not OK, repai r the open ci rcui t as requi red.
REMOVAL AND INSTALLATION
CHIME WARNING SYSTEM SWITCHES
Servi ce procedures for the vari ous hard-wi red
swi tches used i n the chi me warni ng system can be
found i n the proper group as fol l ows:
• Dri ver door jamb swi tch - refer to Group 8L -
Lamps
• Dri ver seat bel t swi tch - refer to Group 23 -
Body
• Headl amp swi tch - refer to Group 8E - I nstru-
ment Panel Systems
• Key-i n i gni ti on swi tch - refer to Group 8D - I gni -
ti on Systems.
8U - 4 CHIME/BUZZER WARNING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
WIRING DIAGRAMS
CONTENTS
page page
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1
ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . . 8W-35-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1
COMPONENT INDEX. . . . . . . . . . . . . . . . . . 8W-02-1
CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1
CONNECTOR/GROUND LOCATIONS . . . . . . 8W-90-1
FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . 8W-50-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1
FUSE/FUSE BLOCK. . . . . . . . . . . . . . . . . . . 8W-11-1
GENERAL INFORMATION . . . . . . . . . . . . . . 8W-01-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . 8W-40-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . 8W-95-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1
TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
TJ WIRING DIAGRAMS 8W - 1
8W-01 GENERAL INFORMATION
INDEX
page page
DESCRIPTION AND OPERATION
CIRCUIT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . 4
CIRCUIT INFORMATION . . . . . . . . . . . . . . . . . . . . 4
CONNECTOR INFORMATION . . . . . . . . . . . . . . . . 7
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . . 8
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
NOTES, CAUTIONS, and WARNINGS . . . . . . . . . . 7
SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . . 5
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 7
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TAKE OUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TERMINOLOGY. . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING
INTERMITTENT AND POOR CONNECTIONS. . . . . 9
TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING WIRING PROBLEMS . . . . . 10
SERVICE PROCEDURES
CONNECTOR AND TERMINAL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 13
CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 12
DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . . 14
TERMINAL REPLACEMENT. . . . . . . . . . . . . . . . . 14
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 12
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 11
TERMINAL/CONNECTOR REPAIR—THOMAS
AND BETTS CONNECTORS . . . . . . . . . . . . . . . 11
WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION AND OPERATION
INTRODUCTION
Chrysl er wi ri ng di agrams are desi gned to provi de
i nformati on regardi ng the vehi cl es wi ri ng content. I n
order to effecti vel y use Chrysl er wi ri ng di agrams to
di agnose and repai r a Chrysl er vehi cl e, i t i s i mpor-
tant to understand al l of thei r features and charac-
teri sti cs.
Di agrams are arranged such that the power (B+)
si de of the ci rcui t i s pl aced near the top of the page,
and the ground (B-) si de of the ci rcui t i s pl aced near
the bottom of the page.
Al l swi tches, components, and modul es are shown
i n the at rest posi ti on wi th the doors cl osed and the
key removed from the i gni ti on.
Components are shown two ways. A sol i d l i ne
around a component i ndi cates that the component i s
compl ete. A dashed l i ne around a component i ndi -
cates that the component bei ng shown i s not com-
pl ete. I ncompl ete components have a reference
number to i ndi cate the page where the component i s
shown compl ete.
I t i s i mportant to real i ze that no attempt i s made
on the di agrams to represent components and wi ri ng
as they appear on the vehi cl e. For exampl e, a short
pi ece of wi re i s treated the same as a l ong one. I n
addi ti on, swi tches and other components are shown
as si mpl y as possi bl e, wi th regard to functi on onl y.
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 1
The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
8W - 01 - 2 8W - 01 GENERAL INFORMATION TJ
DESCRIPTION AND OPERATION (Continued)
The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 3
DESCRIPTION AND OPERATION (Continued)
CIRCUIT INFORMATION
Each wi re shown i n the di agrams contai ns a code
whi ch i denti fi es the mai n ci rcui t, part of the mai n
ci rcui t, gage of wi re, and col or (Fi g. 1).
CIRCUIT FUNCTIONS
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i ts functi on. To i denti fy
whi ch ci rcui t code appl i es to a system, refer to the
Ci rcui t I denti fi cati on Code Chart. Thi s chart shows
the mai n ci rcui ts onl y and does not show the second-
ary codes that may appl y to some model s.
Fig. 1 Wire Code Identification
1 – COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER)
2 – GAUGE OF WIRE (18 GAUGE)
3 – PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 – MAIN CIRCUIT IDENTIFICATION
WIRE COLOR CODE CHART
COLOR CODE COLOR
STANDARD
TRACER
COLOR
BL BLUE WT
BK BLACK WT
BR BROWN WT
DB DARK BLUE WT
DG DARK GREEN WT
GY GRAY BK
LB LIGHT BLUE BK
LG LIGHT GREEN BK
OR ORANGE BK
PK PINK BK or WT
RD RED WT
TN TAN WT
VT VIOLET WT
WT WHITE BK
YL YELLOW BK
* WITH TRACER
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS (GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY FEED)
Q POWER OPTIONS (IGNITION FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
8W - 01 - 4 8W - 01 GENERAL INFORMATION TJ
DESCRIPTION AND OPERATION (Continued)
SECTION IDENTIFICATION
The wi ri ng di agrams are grouped i nto i ndi vi dual
secti ons. I f a component i s most l i kel y found i n a par-
ti cul ar group, i t wi l l be shown compl ete (al l wi res,
connectors, and pi ns) wi thi n that group. For exam-
pl e, the Auto Shutdown Rel ay i s most l i kel y to be
found i n Group 30, so i t i s shown there compl ete. I t
can, however, be shown parti al l y i n another group i f
i t contai ns some associ ated wi ri ng.
SYMBOLS
I nternati onal symbol s are used throughout the wi r-
i ng di agrams. These symbol s are consi stent wi th
those bei ng used around the worl d
GROUP TOPIC
8W-01 thru
8W-09
General Information and Diagram
Overview
8W-10 thru
8W-19
Main Sources of Power and Vehicle
Grounding
8W-20 thru
8W-29
Starting and Charging
8W-30 thru
8W-39
Powertrain/Drivetrain Systems
8W-40 thru
8W-49
Body Electrical items and A/C
8W-50 thru
8W-59
Exterior Lighting, Wipers, and Trailer
Tow
8W-60 thru
8W-69
Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-90 Connector Locations (including
grounds)
8W-95 Splice Locations
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 5
DESCRIPTION AND OPERATION (Continued)
Wiring Diagram Symbols
8W - 01 - 6 8W - 01 GENERAL INFORMATION TJ
DESCRIPTION AND OPERATION (Continued)
TERMINOLOGY
Thi s a l i st of terms wi th there defi ni ti ons used i n
the wi ri ng di agrams.
Bui l t-Up-Export . . . . . . . Vehi cl es Bui l t For Sal e I n
Markets Other Than North Ameri ca
Except-Bui l t-Up-Export . Vehi cl es Bui l t For Sal e I n
North Ameri ca
LHD . . . . . . . . . . . . . . . . Left Hand Dri ve Vehi cl es
RHD . . . . . . . . . . . . . . . Ri ght Hand Dri ve Vehi cl es
EATX . . . El ectroni c Automati c Transmi ssi on-Front
Wheel Dri ve
ATX . . Automati c Transmi ssi on-Front Wheel Dri ve
MTX . . . . Manual Transmi ssi on-Front Wheel Dri ve
A/T. . . . Automati c Transmi ssi on-Rear Wheel Dri ve
M/T . . . . . Manual Transmi ssi on-Rear Wheel Dri ve
SOHC . . . . . . . . . . . Si ngl e Over Head Cam Engi ne
DOHC . . . . . . . . . . . . Dual Over Head Cam Engi ne
CONNECTOR INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
I n-l i ne connectors are i denti fi ed by a number, as
fol l ows:
• I n-l i ne connectors l ocated on the engine com-
partment harness are C100 seri es numbers.
• Connectors l ocated on the instrument panel
harness are C200 seri es numbers.
• Connectors l ocated on the body harness are
C300 seri es numbers.
• J umper harness connectors are C400 seri es
numbers.
• Grounds and ground connectors are i denti -
fi ed wi th a “G” and fol l ow the same seri es number-
i ng as the i n-l i ne connector.
Component connectors are i denti fi ed by the compo-
nent name i nstead of a number. Mul ti pl e connectors
on a component use a C1, C2, etc. i denti fi er.
LOCATIONS
Secti on 8W-90 contai ns connector/ground l ocati on
i l l ustrati ons. The i l l ustrati ons contai n the connector
name (or number)/ground number and component
i denti fi cati on. Connector/ground l ocati on charts i n
Secti on 8W-90 reference the i l l ustrati on number for
components and connectors.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the Di a-
gram pages.
SPLICE LOCATIONS
Spl i ce Locati on charts i n Secti on 8W-70 show the
enti re spl i ce, and provi de references to other secti ons
the spl i ce serves.
Secti on 8W-95 contai ns i l l ustrati ons that show the
general l ocati on of the spl i ces i n each harness. The
i l l ustrati ons show the spl i ce by number, and provi de
a wri tten l ocati on.
NOTES, CAUTIONS, and WARNINGS
Throughout thi s group addi ti onal i mportant i nfor-
mati on i s presented i n three ways; Notes, Cauti ons,
and Warni ngs.
NOTES are used to hel p descri be how swi tches or
components operate to compl ete a parti cul ar ci rcui t.
They are al so used to i ndi cate di fferent condi ti ons
that may appear on the vehi cl e. For exampl e, an
up-to and after condi ti on.
CAUTIONS are used to i ndi cate i nformati on that
coul d prevent maki ng an error that may damage the
vehi cl e.
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 7
DESCRIPTION AND OPERATION (Continued)
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
TAKE OUTS
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component.
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 2) i s used to i ndi cate thi s. When han-
dl i ng any component wi th thi s symbol compl y wi th
the fol l owi ng procedures to reduce the possi bi l i ty of
el ectrostati c charge bui l d up on the body and i nad-
vertent di scharge i nto the component. I f i t i s not
known whether the part i s ESD sensi ti ve, assume
that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part from i ts protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i ts package,
ground the package to a known good ground on the
vehi cl e.
DIAGNOSIS AND TESTING
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
• Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
• Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in today’s vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-me-
gohm or greater impedance rating.
• Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: - Most of the electrical components used
in today’s vehicle are Solid State. When checking
resistance in these circuits use a meter with a
10-megohm or greater impedance rating. In addi-
tion, make sure the power is disconnected from the
circuit. Circuits that are powered up by the vehicle
electrical system can cause damage to the equip-
ment and provide false readings.
• Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 3). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
Fig. 2 Electrostatic Discharge Symbol
Fig. 3 Probing Tool
1 – SPECIAL TOOL 6801
2 – PROBING END
8W - 01 - 8 8W - 01 GENERAL INFORMATION TJ
DESCRIPTION AND OPERATION (Continued)
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y check the fol l owi ng i tems.
• Connectors are ful l y seated
• Spread termi nal s, or termi nal push out
• Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i n
posi ti on
• Di rt or corrosi on on the termi nal s. Any amount
of corrosi on or di rt coul d cause an i ntermi ttent prob-
l em
• Damaged connector/component casi ng exposi ng
the i tem to di rt and moi sture
• Wi re i nsul ati on that has rubbed through causi ng
a short to ground
• Some or al l of the wi ri ng strands broken i nsi de
of the i nsul ati on coveri ng.
• Wi ri ng broken i nsi de of the i nsul ati on
TROUBLESHOOTING TESTS
Before begi nni ng any tests on a vehi cl es el ectri cal
system use the Wi ri ng Di agrams and study the ci r-
cui t. Al so refer to the Troubl eshooti ng Wi ri ng Prob-
l ems i n thi s secti on.
TESTING FOR VOLTAGE POTENTIAL
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 4).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
TESTING FOR CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 5).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
TESTING FOR A SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the suspected fused ci rcui ts.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
Fig. 4 Testing for Voltage Potential
Fig. 5 Testing for Continuity
1 – FUSE REMOVED FROM CIRCUIT
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 9
DIAGNOSIS AND TESTING (Continued)
(4) Start connecti ng the i tems i n the fuse ci rcui t
one at a ti me. When the fuse bl ows the ci rcui t wi th
the short to ground has been i sol ated.
TESTING FOR A VOLTAGE DROP
(1) Connect the posi ti ve l ead of the vol tmeter to
the si de of the ci rcui t cl osest to the battery (Fi g. 6).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch or component.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em.
(6) Veri fy proper operati on. For thi s step check for
proper operati on of al l i tems on the repai red ci rcui t.
Refer to the wi ri ng di agrams.
SERVICE PROCEDURES
WIRING REPAIR
When repl aci ng or repai ri ng a wi re, i t i s i mportant
that the correct gage be used as shown i n the wi ri ng
di agrams. The wi res must al so be hel d securel y i n
pl ace to prevent damage to the i nsul ati on.
(1) Di sconnect battery negati ve cabl e
(2) Remove 1 i nch of i nsul ati on from each end of
the wi re.
(3) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Make sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(4) Spread the strands of the wi re apart on each
part of the exposed wi re (exampl e 1). (Fi g. 7)
(5) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on (exampl e
2) (Fi g. 7)
(6) Twi st the wi res together (exampl e 3) (Fi g. 7)
(7) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(8) Center the heat shri nk tubi ng over the joi nt,
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng.
(9) Secure the wi re to the exi sti ng ones to prevent
chafi ng or damage to the i nsul ati on
(10) Connect battery and test al l affected systems.
Fig. 6 Testing for Voltage Drop
Fig. 7 Wire Repair
1 – EXAMPLE 1
2 – EXAMPLE 2
3 – EXAMPLE 3
8W - 01 - 10 8W - 01 GENERAL INFORMATION TJ
DIAGNOSIS AND TESTING (Continued)
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Di sconnect battery.
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) I nsert the termi nal rel easi ng speci al tool 6742
i nto the termi nal end of the connector (Fi g. 8).
(4) Usi ng speci al tool 6742 rel ease the l ocki ng fi n-
gers on the termi nal (Fi g. 9).
(5) Pul l on the wi re to remove i t from the connec-
tor.
(6) Repai r or repl ace the connector or termi nal , as
necessary.
TERMINAL/CONNECTOR REPAIR— THOMAS
AND BETTS CONNECTORS
(1) Di sconnect battery.
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) Push i n the two l ock tabs on the si de of the
connector (Fi g. 10).
(4) I nsert the probe end of speci al tool 6934 i nto
the back of the connector cavi ty (Fi g. 11).
(5) Grasp the wi re and tool 6934 and sl owl y
remove the wi re and termi nal from the connector.
Fig. 8 Molex Connector Repair
1 – CONNECTOR
2 – SPECIAL TOOL 6742
Fig. 9 Using Special Tool 6742
1 – CONNECTOR
2 – SPECIAL TOOL 6742
Fig. 10 Thomas and Betts Connector Lock Release
Tabs
1 – LOCK TABS
Fig. 11 Removing Wire Terminal
1 – SPECIAL TOOL 6934
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)
(6) Repai r or repl ace the termi nal .
(7) I nstal l the wi re and termi nal i n the connector.
Ful l y seat the termi nal i n the connector.
(8) Push i n the si ngl e l ock tab on the si de of the
connector (Fi g. 12).
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS
(1) Di sconnect battery.
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) Push down on the yel l ow connector l ocki ng tab
to rel ease the termi nal s (Fi g. 13).
(4) Usi ng speci al tool 6932, push the termi nal to
remove i t from the connector (Fi g. 14).
(5) Repai r or repl ace the connector or termi nal as
necessary.
(6) When re-assembl i ng the connector, the l ocki ng
wedge must be pl aced i n the l ocked posi ti on to pre-
vent termi nal push out.
CONNECTOR REPLACEMENT
(1) Di sconnect battery.
(2) Di sconnect the connector that i s to be repai red
from i ts mati ng hal f/component
(3) Remove the connector l ocki ng wedge, i f
requi red (Fi g. 15)
Fig. 12 Single Lock Tab
1 – SINGLE LOCK TAB
Fig. 13 Augat Connector Repair
1 – LOCKING TAB
2 – CONNECTOR
Fig. 14 Using Special Tool 6932
1 – SPECIAL TOOL 6932
2 – CONNECTOR
Fig. 15 Connector Locking Wedge
1 – CONNECTOR
2 – CONNECTOR LOCKING WEDGE TAB
8W - 01 - 12 8W - 01 GENERAL INFORMATION TJ
SERVICE PROCEDURES (Continued)
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 16) (Fi g. 17).
(5) Reset the termi nal l ocki ng tang, i f i t has one.
(6) I nsert the removed wi re i n the same cavi ty on
the repai r connector.
(7) Repeat steps four through si x for each wi re i n
the connector, bei ng sure that al l wi res are i nserted
i nto the proper cavi ti es. For addi ti onal connector pi n-
out i denti fi cati on, refer to the wi ri ng di agrams.
(8) I nsert the connector l ocki ng wedge i nto the
repai red connector, i f requi red.
(9) Connect connector to i ts mati ng hal f/compo-
nent.
(10) Connect battery and test al l affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Di sconnect battery.
(2) Di sconnect the connector (that i s to be
repai red) from i ts mati ng hal f/component.
(3) Cut off the exi sti ng wi re connector di rectl y
behi nd the i nsul ator. Remove si x i nches of tape from
the harness.
(4) Stagger cut al l wi res on the harness si de at 1/2
i nch i nterval s (Fi g. 18).
(5) Remove 1 i nch of i nsul ati on from each wi re on
the harness si de.
(6) Stagger cut the matchi ng wi res on the repai r
connector assembl y i n the opposi te order as was done
on the harness si de of the repai r. Al l ow extra l ength
for sol dered connecti ons. Check that the overal l
l ength i s the same as the ori gi nal (Fi g. 18).
(7) Remove 1 i nch of i nsul ati on from each wi re.
(8) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Be sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(9) Spread the strands of the wi re apart on each
part of the exposed wi res.
(10) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on.
(11) Twi st the wi res together.
(12) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(13) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng
(14) Repeat steps 8 through 13 for each wi re.
(15) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
Fig. 16 Terminal Removal
1 – CONNECTOR
2 – FROM SPECIAL TOOL KIT 6680
Fig. 17 Terminal Removal Using Special Tool
1 – FROM SPECIAL TOOL KIT 6680
2 – CONNECTOR
Fig. 18 Stagger Cutting Wires
1 – REPAIR SIDE WIRES
2 – STAGER CUTS
3 – HARNESS WIRES
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 13
SERVICE PROCEDURES (Continued)
(16) Re-connect the repai red connector.
(17) Connect the battery, and test al l affected sys-
tems.
TERMINAL REPLACEMENT
(1) Di sconnect battery.
(2) Di sconnect the connector bei ng repai red from
i ts mati ng hal f. Remove connector l ocki ng wedge, i f
requi red (Fi g. 19).
(3) Remove connector l ocki ng wedge, i f requi red
(Fi g. 19).
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 20) (Fi g. 21).
(5) Cut the wi re 6 i nches from the back of the con-
nector.
(6) Remove 1 i nch of i nsul ati on from the wi re on
the harness si de.
(7) Sel ect a wi re from the termi nal repai r assem-
bl y that best matches the col or wi re bei ng repai red.
(8) Cut the repai r wi re to the proper l ength and
remove 1 i nch of i nsul ati on.
(9) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Make sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(10) Spread the strands of the wi re apart on each
part of the exposed wi res.
(11) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on.
(12) Twi st the wi res together.
(13) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(14) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng.
(15) I nsert the repai red wi re i nto the connector.
(16) I nstal l the connector l ocki ng wedge, i f
requi red, and reconnect the connector to i ts mati ng
hal f/component.
(17) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(18) Connect battery, and test al l affected systems.
DIODE REPLACEMENT
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 22).
Fig. 19 Connector Locking Wedge Tab (Typical)
1 – CONNECTOR
2 – CONNECTOR LOCKING WEDGE TAB
Fig. 20 Terminal Removal
1 – CONNECTOR
2 – FROM SPECIAL TOOL KIT 6680
Fig. 21 Terminal Removal Using Special Tool
1 – FROM SPECIAL TOOL KIT 6680
2 – CONNECTOR
8W - 01 - 14 8W - 01 GENERAL INFORMATION TJ
SERVICE PROCEDURES (Continued)
(4) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(5) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary refer to the
appropri ate wi ri ng di agram for current fl ow.
(6) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(7) Tape the di ode to the harness usi ng el ectri cal
tape maki ng, sure the di ode i s compl etel y seal ed
from the el ements.
(8) Re-connect the battery, and test affected sys-
tems.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 22 Diode Identification
1 – CURRENT FLOW
2 – BAND AROUND DIODE INDICATES CURRENT FLOW
3 – DIODE AS SHOWN IN THE DIAGRAMS
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 15
SERVICE PROCEDURES (Continued)
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . 8W-42
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . 8W-42
A/C- Heater Control . . . . . . . . . . . . . . . . . . . 8W-42
A/C Pressure Swi tches . . . . . . . . . . . . . . . 8W-30, 42
ABS Di ode . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35
ABS Pump Motor Rel ay . . . . . . . . . . . . . . . . 8W-35
ABS Pump Motor . . . . . . . . . . . . . . . . . . . . . 8W-35
ABS System Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-35
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . 8W-43
Ai rbag Squi bs . . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Automati c Shut Down Rel ay . . . . . . . . . . . . . 8W-30
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-51
Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20, 30
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . . 8W-42
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-51
Brake Shi ft I nterl ock Sol enoi d . . . . . . . . . . . 8W-31
Brake Warni ng I ndi cator Swi tch . . . . . . . . . . 8W-40
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . 8W-30
Center Hi gh Mounted Stop Lamp . . . . . . . . . 8W-51
Ci gar Li ghter/Accessory Rel ay . . . . . . . . . . . . 8W-41
Ci gar Li ghter/Power Outl et . . . . . . . . . . . . . . 8W-41
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . 8W-50, 51
Ci ty Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . 8W-30, 43
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . . 8W-40
Cl utch Pedal Posi ti on Swi tch Connector . . . . 8W-21
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . . . 8W-21
Combi nati on Fl asher . . . . . . . . . . . . . . . . . . . 8W-52
Control l er Anti -Lock Brake . . . . . . . . . . . . . . 8W-35
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-44
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . 8W-30
Data Li nk Connector . . . . . . . . . . . . . . . . . . . 8W-30
Dayti me Runni ng Lamp Modul e . . . . . . . . . . 8W-50
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Door Ajar Swi tches . . . . . . . . . . . . . . . . . . . . 8W-44
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . . 8W-30
Engi ne Cool ant Temperature Gauge . . . . . . . 8W-40
Engi ne Cool ant Temperature Sensor . . . . . . . 8W-30
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . . . 8W-30
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . 8W-21
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . 8W-21
Fog Lamp I l l umi nati on . . . . . . . . . . . . . . . . . 8W-51
Fog Lamp I ndi cator . . . . . . . . . . . . . . . . . . . . 8W-51
Fog Lamp Rel ays . . . . . . . . . . . . . . . . . . . . . . 8W-50
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-50
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Component Page
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11
Fuses (FB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11
Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Fusi bl e Li nk A11 . . . . . . . . . . . . . . . . . . . . . . 8W-10
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
G Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Headl amp Di mmer Swi tch . . . . . . . . . . . . . . 8W-50
Headl amp Level i ng Motors . . . . . . . . . . . . . . 8W-50
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . 8W-50
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-50
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-30, 41
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Hydraul i c Control Uni t . . . . . . . . . . . . . . . . . 8W-35
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
I ndi cators . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-40
I ntake Ai r Temperature Sensor . . . . . . . . . . . 8W-30
I nternal Del ay Rel ay . . . . . . . . . . . . . . . . . . . 8W-53
Key-I n Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-40, 44
Lamp Assembl i es . . . . . . . . . . . . . . . . . . . . . . 8W-51
Leak Detecti on Pump . . . . . . . . . . . . . . . . . . 8W-30
Li cense Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Mani fol d Absol ute Pressure Sensor . . . . . . . . 8W-30
Manual Transmi ssi on Jumper . . . . . . . . . 8W-21, 30
Odometer/Tri p Odometer . . . . . . . . . . . . . . . . 8W-40
Oi l Pressure Gauge . . . . . . . . . . . . . . . . . . . . 8W-40
Oxygen Sensor Downstream Heater Rel ay . . 8W-30
Oxygen Sensor Upstream Heater Rel ay . . . . 8W-30
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . 8W-40
Park/Neutral Posi ti on Swi tch . . . . . . . . . . 8W-21, 51
Park/Turn Si gnal Lamps . . . . . . . . . . . . . 8W-50, 52
Passenger Ai rbag On/Off Swi tch . . . . . . . . . . 8W-43
Power Di stri buti on Center . . . . . . . . . . . . . . . 8W-10
Power Steeri ng Pressure Swi tch . . . . . . . . . . 8W-30
Powertrai n Control Modul e . . . . . . . . . . . . . . 8W-30
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Radi o Antenna . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . 8W-51
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-51
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-51
TJ 8W - 02 COMPONENT INDEX 8W - 02 - 1
Component Page
Rear Washer Pump . . . . . . . . . . . . . . . . . . . . 8W-53
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . 8W-48
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . 8W-48
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . 8W-48
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8W-53
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . . 8W-53
Repeater Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-52
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-40
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . 8W-30
Si de Marker Lamps . . . . . . . . . . . . . . . . . 8W-50, 52
Sound Bar Dome Lamp . . . . . . . . . . . . . . . . . 8W-44
Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Speed Control Swi tch Pods . . . . . . . . . . . . . . 8W-30
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Spl i ce I nformati on . . . . . . . . . . . . . . . . . . . . . 8W-70
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Tai l /Stop Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-51
Component Page
Tai l /Stop/Turn Si gnal Lamps . . . . . . . . . . 8W-51, 52
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . 8W-30, 30
Torque Converter Cl utch Sol enoi d . . . . . . . . . 8W-31
Transfer Case Swi tch . . . . . . . . . . . . . . . . . . 8W-31
Tri p Odometer Reset Swi tch . . . . . . . . . . . . . 8W-40
Turn Si gnal Lamps . . . . . . . . . . . . . . . . . . . . 8W-52
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . 8W-51, 52
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-44
Vehi cl e Speed Control Servo . . . . . . . . . . . . . 8W-30
Vehi cl e Speed Sensor Si gnal . . . . . . . . . . . . . 8W-30
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-30
Vol t Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . 8W-35
Wi ndshi el d Washer Pump . . . . . . . . . . . . . . . 8W-53
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . . . . 8W-53
Wi ndshi el d Wi per Swi tch . . . . . . . . . . . . . . . 8W-53
8W - 02 - 2 8W - 02 COMPONENT INDEX TJ
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . 8W-10-17
A/C Compressor Cl utch Rel ay . . . . . . . . . . 8W-10-17
ABS Di ode . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
ABS Pump Motor . . . . . . . . . . . . . . . . . . . 8W-10-11
ABS Pump Motor Rel ay . . . . . . . . . . . . . . 8W-10-11
ABS System Rel ay . . . . . . . . . . . . . . . . . . 8W-10-11
Automati c Shut Down Rel ay . . . . . . . . . . . 8W-10-15
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-10-9
Brake Warni ng I ndi cator Swi tch . . . . . . . . 8W-10-13
Ci gar Li ghter/Accessory Rel ay . . . . . . . 8W-10-13, 14
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . 8W-10-12
Control l er Anti -Lock Brake . . . . . . . . . . . . 8W-10-11
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-10-18
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Engi ne Starter Motor . . . . . . . . . . . . . . 8W-10-7, 12
Engi ne Starter Motor Rel ay . . . . . . . . . . . 8W-10-12
Fog Lamp Rel ay No. 1 . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . 8W-10-16
Fuel I njector No. 2 . . . . . . . . . . . . . . . . . . 8W-10-16
Fuel I njector No. 3 . . . . . . . . . . . . . . . . . . 8W-10-16
Fuel I njector No. 4 . . . . . . . . . . . . . . . . . . 8W-10-16
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . 8W-10-16
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . 8W-10-16
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuse 1 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Fuse 1 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 9
Fuse 2 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 9
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 10
Fuse 5 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Fuse 6 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 11
Fuse 7 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 11
Fuse 8 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 12
Fuse 9 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Fuse 9 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 15
Fuse 10 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Fuse 10 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-7, 10
Fuse 11 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Fuse 11 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-7, 10
Fuse 12 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Fuse 13 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Fuse 14 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Fuse 14 (PDC) . . . . . . . . . . . . . . . . . 8W-10-8, 12, 13
Fuse 15 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Component Page
Fuse 15 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 14
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 15
Fuse 17 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9
Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 14
Fuse 18 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 17
Fuse 19 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 17
Fuse 20 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Fuse 21 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 17
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 17
Fuse 25 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 18
Fuse 26 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 15
Fuse 28 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-8, 11
Fuse Bl ock . . . . . . . . . . . . . . . 8W-10-9, 10, 12, 13, 14
Fusi bl e Li nk A11 . . . . . . . . . . . . . . . . . . . . 8W-10-7
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-10-10
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . 8W-10-17
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Hydraul i c Control Uni t . . . . . . . . . . . . . . . 8W-10-11
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . . . . 8W-10-16
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . 8W-10-12, 13
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-10-18
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-10-18
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Low Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Oxygen Sensor 1/1 Upstream . . . . . . . . 8W-10-14, 15
Oxygen Sensor 1/2 Downstream . . . . . 8W-10-14, 15
Oxygen Sensor 2/1 Upstream . . . . . . . . . . 8W-10-14
Oxygen Sensor 2/2 Downstream . . . . . . . . 8W-10-14
Oxygen Sensor Downstream
Heater Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-10-14
Oxygen Sensor Upstream Heater Rel ay . . 8W-10-14
Park Brake Swi tch . . . . . . . . . . . . . . . . . . 8W-10-13
Power Di stri buti on Center . . 8W-10-2, 7, 8, 9, 10, 11,
12, 13, 14, 15, 17, 18
Powertrai n Control Modul e . . . . . . . . . . . . 8W-10-15
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . 8W-10-9
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-10-9
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8W-10-18
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-10-17
Sound Bar Dome Lamp . . . . . . . . . . . . . . . 8W-10-18
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . 8W-10-10
Underhood Lamp . . . . . . . . . . . . . . . . . . . 8W-10-18
TJ 8W - 10 POWER DISTRIBUTION 8W - 10 - 1
8W-11 FUSE/FUSE BLOCK
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8W-11-9
A/C- Heater Control . . . . . . . . . . . . . . . . 8W-11-4, 7
ABS System Rel ay . . . . . . . . . . . . . . . . . . . 8W-11-7
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-11-6, 8
Automati c Shut Down Rel ay . . . . . . . . . . . . 8W-11-8
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-11-7
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-11-7
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-11-7
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-11-4
Brake Shi ft I nterl ock Sol enoi d . . . . . . . . . . 8W-11-8
Ci gar Li ghter/Accessory Rel ay . . . . . . . . . . 8W-11-11
Ci gar Li ghter/Power Outl et . . . . . . . . . . . . 8W-11-11
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . 8W-11-10
Cl utch Pedal Posi ti on Swi tch Connector . . 8W-11-10
Control l er Anti -Lock Brake . . . . . . . . . . . . . 8W-11-7
Dayti me Runni ng Lamp Modul e . . . . . . . . . 8W-11-9
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . 8W-11-5
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . 8W-11-9
Engi ne Starter Motor Rel ay . . . . . . . . . . . 8W-11-10
Fog Lamp Rel ay No. 1 . . . . . . . . . . . . . . . . 8W-11-5
Fog Lamp Rel ay No. 2 . . . . . . . . . . . . . . . . 8W-11-5
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . 8W-11-4
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . 8W-11-8
Fuse 1 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Fuse 2 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Fuse 3 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Fuse 4 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-5
Fuse 5 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-6
Fuse 6 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-6
Fuse 7 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-7
Fuse 8 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-7
Fuse 9 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-8
Fuse 10 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-8
Fuse 11 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-9
Fuse 12 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-8
Component Page
Fuse 13 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Fuse 14 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Fuse 15 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Fuse 16 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-11-11
Fuse 17 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Fuse 18 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-11-11
Fuse 19 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-11-11
Fuse 20 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Fuse Bl ock . . . . . . . . . 8W-11-2, 4, 5, 6, 7, 8, 9, 10, 11
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-5
Headl amp Di mmer Swi tch . . . . . . . . . . . . 8W-11-11
Headl amp Level i ng Swi tch . . . . . . . . . . . . 8W-11-11
Headl amp Swi tch . . . . . . . . . . . . . . . . . 8W-11-4, 11
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-11-4, 8
Left Headl amp Level i ng Motor . . . . . . . . . 8W-11-11
Oxygen Sensor Downstream Heater Rel ay . 8W-11-8
Oxygen Sensor Upstream Heater Rel ay . . . 8W-11-8
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . 8W-11-7
Passenger Ai rbag On/Off Swi tch . . . . . . . . . 8W-11-8
Passenger Door Ajar Swi tch . . . . . . . . . . . . 8W-11-5
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-11-8
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4, 10
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . 8W-11-5, 11
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . . 8W-11-4
Rear Wi ndow Defogger Rel ay . . . . . . . . 8W-11-7, 10
Rear Wi ndow Defogger Swi tch . . . . . . . . 8W-11-4, 10
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-11-6
Rear Wi per/Washer Swi tch . . . . . . . . . . . 8W-11-4, 6
Ri ght Headl amp Level i ng Motor . . . . . . . . 8W-11-11
Sentry Key I mmobi l i zer Modul e . . . . . . . 8W-11-4, 8
Torque Converter Cl utch Sol enoi d . . . . . . . 8W-11-9
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . 8W-11-10
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . . 8W-11-10
Wi ndshi el d Wi per Swi tch . . . . . . . . . . . . . 8W-11-10
TJ 8W - 11 FUSE/FUSE BLOCK 8W - 11 - 1
8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . 8W-15-12, 13, 14
A/C- Heater Control . . . . . . . . . . . . . . . . 8W-15-6, 7
ABS Pump Motor . . . . . . . . . . . . . . . . . . . . 8W-15-2
ABS Pump Motor Rel ay . . . . . . . . . . . . . . . 8W-15-2
ABS System Rel ay . . . . . . . . . . . . . . . . . . . 8W-15-2
Ai rbag Control Modul e . . . . . . . . . . . . . . . 8W-15-10
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Bl end Door Actuator . . . . . . . . . . . . . . . . 8W-15-6, 7
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . 8W-15-6, 7
Brake Lamp Swi tch . . . . . . . . . . . . . . . . 8W-15-8, 9
Center Hi gh Mounted Stop Lamp . . . . . . . 8W-15-10
Ci gar Li ghter/Accessory Rel ay . . . . . . . . 8W-15-8, 9
Ci gar Li ghter/Power Outl et . . . . . . . . . . . 8W-15-6, 7
Combi nati on Fl asher . . . . . . . . . . . . . . . . 8W-15-8, 9
Control l er Anti -Lock Brake . . . . . . . . . . . . . 8W-15-2
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-15-11
Dayti me Runni ng Lamp Modul e . . . . . . . . . 8W-15-2
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . 8W-15-8, 9
Engi ne Starter Motor Rel ay . . . . . . 8W-15-12, 13, 14
Fog Lamp Rel ay No. 1 . . . . . . . . . . . . . . . . 8W-15-8
Fog Lamp Rel ay No. 2 . . . . . . . . . . . . . . . . 8W-15-8
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . 8W-15-6
Fuel Pump Modul e . . . . . . . . . . . . . 8W-15-12, 13, 14
Fuse 4 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8, 9
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8, 9
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
G105 . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12, 13, 14
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8, 9
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Generator . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
Headl amp Level i ng Swi tch . . . . . . . . . . . 8W-15-6, 7
Headl amp Swi tch . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-15-3
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . 8W-15-8, 9
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-15-6, 7
Left Ci ty Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Left Front Park/Turn Si gnal Lamp . . . . . . . 8W-15-3
Left Front Turn Si gnal Lamp . . . . . . . . . . . 8W-15-3
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Left Headl amp Level i ng Motor . . . . . . . . . . 8W-15-3
Left Li cense Lamp . . . . . . . . . . . . . . . . . . 8W-15-10
Left Repeater Lamp . . . . . . . . . . . . . . . . . . 8W-15-3
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Manual Transmi ssi on Jumper . . . . 8W-15-12, 13, 14
Oxygen Sensor 1/1 Upstream . . . . . 8W-15-12, 13, 14
Oxygen Sensor 1/2 Downstream . . . 8W-15-12, 13, 14
Oxygen Sensor 2/1 Upstream . . . . . . . . . . 8W-15-13
Oxygen Sensor 2/2 Downstream . . . . . . . . 8W-15-13
Passenger Ai rbag On/Off Swi tch . . . . . . . . 8W-15-10
Passenger Door Ajar Swi tch . . . . . . . . . . 8W-15-8, 9
Power Steeri ng Pressure Swi tch . . . . . . . . 8W-15-14
Powertrai n Control Modul e . . . . 8W-15-11, 12, 13, 14
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-8, 9
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . 8W-15-8, 9
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . 8W-15-6, 7
Rear Washer Pump . . . . . . . . . . . . . . . . . . 8W-15-10
Rear Wi ndow Defogger . . . . . . . . . . . . . . . 8W-15-10
Rear Wi ndow Defogger Swi tch . . . . . . . . 8W-15-6, 7
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-15-10
Rear Wi per/Washer Swi tch . . . . . . . . . . . 8W-15-6, 7
Ri ght Ci ty Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-5
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Ri ght Front Park/Turn Si gnal Lamp . . . . . . 8W-15-4
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . 8W-15-5
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
Ri ght Headl amp Level i ng Motor . . . . . . . . . 8W-15-5
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . 8W-15-10
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . . 8W-15-5
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . 8W-15-10
Sentry Key I mmobi l i zer Modul e . . . . 8W-15-9, 10, 11
Transfer Case Swi tch . . . . . . . . . . . 8W-15-12, 13, 14
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-2
Vehi cl e Speed Control Servo . . . . . . . . . . . . 8W-15-2
Wi ndshi el d Washer Pump . . . . . . . . . . . . . . 8W-15-3
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . 8W-15-8, 9
Wi ndshi el d Wi per Swi tch . . . . . . . . . . . . 8W-15-8, 9
TJ 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1
8W-20 CHARGING SYSTEM
Component Page
Automati c Shut Down Rel ay . . . . . . . . . . . . 8W-20-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Battery Temperature Sensor . . . . . . . . . . . . 8W-20-3
Engi ne Starter Motor . . . . . . . . . . . . . . . . . 8W-20-2
Fuse 9 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Fuse 12 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Component Page
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Power Di stri buti on Center . . . . . . . . . . . . . 8W-20-2
Powertrai n Control Modul e . . . . . . . . . . . 8W-20-2, 3
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8W-20-2
TJ 8W - 20 CHARGING SYSTEM 8W - 20 - 1
8W-21 STARTING SYSTEM
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . . 8W-21-2
Cl utch Pedal Posi ti on Swi tch Connector . . . 8W-21-2
Engi ne Starter Motor . . . . . . . . . . . . . . . . . 8W-21-2
Engi ne Starter Motor Rel ay . . . . . . . . . . . . 8W-21-2
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Fuse 20 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Component Page
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Manual Transmi ssi on Jumper . . . . . . . . . . 8W-21-2
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . 8W-21-2
Power Di stri buti on Center . . . . . . . . . . . . . 8W-21-2
TJ 8W - 21 STARTING SYSTEM 8W - 21 - 1
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8W-30-3
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . 8W-30-16
A/C Low Pressure Swi tch . . . . . . . . . . . . . 8W-30-16
A/C- Heater Control . . . . . . . . . . . . . . . . . 8W-30-16
Ai rbag Control Modul e . . . . . . . . . . . . . . . 8W-30-18
Automati c Shut Down
Rel ay . . . . . . . . . . . . . . . . . . 8W-30-2, 4, 5, 6, 7, 12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11
Battery Temperature Sensor . . . . . . 8W-30-10, 11, 19
Brake Lamp Swi tch . . . . . . . . . . . . . . . 8W-30-16, 20
Brake Shi ft I nterl ock Sol enoi d . . . . . . . 8W-30-16, 20
Camshaft Posi ti on Sensor . . . . . . . . . . . . 8W-30-4, 5
Ci gar Li ghter/Accessory Rel ay . . . . . . . 8W-30-16, 20
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19
Control l er Anti -Lock Brake . . . . . . . . . . . . 8W-30-17
Crankshaft Posi ti on Sensor . . . . . . . . . . . 8W-30-4, 5
Data Li nk Connector . . . . . . . . . . . . . . 8W-30-17, 18
Dayti me Runni ng Lamp Modul e . . . . . 8W-30-10, 11
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . 8W-30-15
Engi ne Cool ant Temperature Sensor . . . . 8W-30-8, 9
Engi ne Oi l Pressure Sensor . . . . . 8W-30-8, 9, 10, 11
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . 8W-30-6, 7
Fuel I njector No. 2 . . . . . . . . . . . . . . . . . 8W-30-6, 7
Fuel I njector No. 3 . . . . . . . . . . . . . . . . . 8W-30-6, 7
Fuel I njector No. 4 . . . . . . . . . . . . . . . . . 8W-30-6, 7
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . . 8W-30-7
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . . 8W-30-7
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuse 1 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18
Fuse 9 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Fuse 11 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-30-15
Fuse 12 (FB) . . . . . . . . . . . . . . 8W-30-2, 3, 13, 14, 18
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-30-12
Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-30-13
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuse 25 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-30-17
Fuse 26 (PDC) . . . . . . . . . . . . . . . . . 8W-30-4, 5, 6, 7
Fuse Bl ock . . . . . . . . . . . . . 8W-30-2, 3, 13, 14, 15, 18
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20
Component Page
G105 . . . . . . . . . . . . 8W-30-2, 3, 12, 13, 14, 16, 17, 18
G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16, 18, 20
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18
Generator . . . . . . . . . . . . . . . . . . . . . . 8W-30-15, 16
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-30-18
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . 8W-30-15
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . . . . . 8W-30-5
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-30-18
I ntake Ai r Temperature Sensor . . . . . . . . 8W-30-8, 9
Leak Detecti on Pump . . . . . . . . . . . . . . . . 8W-30-15
Left Speed Control Swi tch Pod . . . . . . . . . 8W-30-19
Mani fol d Absol ute Pressure Sensor . . . . . 8W-30-8, 9
Manual Transmi ssi on Jumper . . . . . . . . . . 8W-30-16
Oxygen Sensor 1/1 Upstream . . . . . . . . 8W-30-12, 13
Oxygen Sensor 1/2 Downstream . . . . . 8W-30-12, 14
Oxygen Sensor 2/1 Upstream . . . . . . . . . . 8W-30-13
Oxygen Sensor 2/2 Downstream . . . . . . . . 8W-30-14
Oxygen Sensor Downstream Heater
Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13, 14
Oxygen Sensor Upstream Heater
Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13, 14
Park/Neutral Posi ti on Swi tch . . . . . . . . . . 8W-30-16
Power Di stri buti on
Center . . . . . . . 8W-30-2, 3, 4, 5, 6, 7, 12, 13, 17, 19
Power Steeri ng Pressure Swi tch . . . . . . . . 8W-30-16
Powertrai n Control Modul e . 8W-30-2, 3, 4, 5, 6, 7, 8,
9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19
Powertrai n Control Modul e . . . . . . . . . . . . 8W-30-20
Ri ght Speed Control Swi tch Pod . . . . . . . . 8W-30-19
Sentry Key I mmobi l i zer Modul e . . 8W-30-2, 3, 17, 18
Sound Bar Dome Lamp . . . . . . . . . . . . . . . 8W-30-17
Throttl e Posi ti on Sensor . . . . . . . . . . . 8W-30-10, 11
Torque Converter Cl utch Sol enoi d . . . . . . . 8W-30-15
Underhood Lamp . . . . . . . . . . . . . . . . . . . 8W-30-17
Vehi cl e Speed Control Servo . . . . . . . . . . . 8W-30-20
Vehi cl e Speed Sensor . . . . . . . . . . . . . . 8W-30-10, 11
Vehi cl e Speed Sensor Si gnal . . . . . . . . . . . 8W-30-11
TJ 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1
8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-31-2
Brake Shi ft I nterl ock Sol enoi d . . . . . . . . . . 8W-31-2
Ci gar Li ghter/Accessory Rel ay . . . . . . . . . . 8W-31-2
Fuse 10 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Fuse 11 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Component Page
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-31-2
Powertrai n Control Modul e . . . . . . . . . . . . 8W-31-2
Torque Converter Cl utch Sol enoi d . . . . . . . 8W-31-2
Transfer Case Swi tch . . . . . . . . . . . . . . . . . 8W-31-2
TJ 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
8W-35 ANTI-LOCK BRAKES
Component Page
ABS Di ode . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
ABS Pump Motor . . . . . . . . . . . . . . . . . . . . 8W-35-2
ABS Pump Motor Rel ay . . . . . . . . . . . . . . . 8W-35-2
ABS System Rel ay . . . . . . . . . . . . . . . . . . . 8W-35-2
ABS Warni ng I ndi cator . . . . . . . . . . . . . . . . 8W-35-3
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-35-5
Brake Shi ft I nterl ock Sol enoi d . . . . . . . . . . 8W-35-3
Control l er Anti -Lock Brake . . . . . 8W-35-2, 3, 4, 5, 6
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-35-5
Fuse 2 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 7 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 10 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Component Page
Fuse 28 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3, 5
G Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Hydraul i c Control Uni t . . . . . . . . . . . . . . . . 8W-35-4
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-35-3
Left Front Wheel Speed Sensor . . . . . . . . . 8W-35-6
Left Rear Wheel Speed Sensor . . . . . . . . . . 8W-35-6
Power Di stri buti on Center . . . . . . . . . . . . . 8W-35-2
Powertrai n Control Modul e . . . . . . . . . . . . 8W-35-5
Ri ght Front Wheel Speed Sensor . . . . . . . . 8W-35-6
Ri ght Rear Wheel Speed Sensor . . . . . . . . . 8W-35-6
TJ 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1
8W-40 INSTRUMENT CLUSTER
Component Page
ABS Di ode . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6
ABS Warni ng I ndi cator . . . . . . . . . . . . . . . . 8W-40-6
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-40-4
Ai rbag Warni ng I ndi cator . . . . . . . . . . . . . . 8W-40-4
Brake Shi ft I nterl ock Sol enoi d . . . . . . . . . . 8W-40-2
Brake Warni ng I ndi cator . . . . . . . . . . . . . . 8W-40-6
Brake Warni ng I ndi cator Swi tch . . . . . . . . 8W-40-6
Check Engi ne I ndi cator . . . . . . . . . . . . . . . 8W-40-4
Check Gauges I ndi cator . . . . . . . . . . . . . . . 8W-40-4
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . 8W-40-8
Control l er Anti -Lock Brake . . . . . . . . . . . . . 8W-40-6
Crui se Control I ndi cator . . . . . . . . . . . . . . . 8W-40-3
Data Li nk Connector . . . . . . . . . . . . 8W-40-3, 4, 6, 7
Dayti me Runni ng Lamp Modul e . . . . . . . . . 8W-40-9
Dome Lamp And Sound Bar Dome Lamp . . 8W-40-2
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . 8W-40-7
Engi ne Cool ant Temperature Gauge . . . . . . 8W-40-3
Engi ne Cool ant Temperature Sensor . . . . . 8W-40-3
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . 8W-40-3
Fog Lamp Rel ay No. 2 . . . . . . . . . . . . . . . . 8W-40-9
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . 8W-40-3
Fuse 3 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8
Fuse 4 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-7
Fuse 10 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Fuse 25 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 7, 8
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
G201 . . . . . . . . . . . . . . . . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6, 7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
Component Page
Headl amp Di mmer Swi tch . . . . . . . . . . . . . 8W-40-9
Headl amp Swi tch . . . . . . . . . . . . . . . . . . 8W-40-7, 8
Hi gh Beam I ndi cator . . . . . . . . . . . . . . . . . 8W-40-9
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-40-6
I nstrument Cl uster . . . . . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9
Key-I n Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-40-7
Left Turn Si gnal I ndi cator . . . . . . . . . . . . . 8W-40-9
Low Fuel I ndi cator . . . . . . . . . . . . . . . . . . . 8W-40-4
Odometer/Tri p Odometer . . . . . . . . . . . . . . 8W-40-4
Oi l Pressure Gauge . . . . . . . . . . . . . . . . . . . 8W-40-3
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . 8W-40-6
Passenger Door Ajar Swi tch . . . . . . . . . . . . 8W-40-7
Power Di stri buti on Center . . . . . . . . . . . . . 8W-40-2
Powertrai n Control Modul e . . . . . . . 8W-40-3, 4, 5, 7
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-40-8
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-40-8
Ri ght Turn Si gnal I ndi cator . . . . . . . . . . . . 8W-40-9
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-40-4
Seat Bel t Warni ng I ndi cator . . . . . . . . . . . . 8W-40-5
Sentry Key I mmobi l i zer Modul e I ndi cator . 8W-40-5
Sound Bar Dome Lamp . . . . . . . . . . . . . . . 8W-40-2
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Transfer Case Swi tch . . . . . . . . . . . . . . . . . 8W-40-5
Tri p Odometer Reset Swi tch . . . . . . . . . . . . 8W-40-4
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . 8W-40-9
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-40-2
Upshi ft I ndi cator . . . . . . . . . . . . . . . . . . . . 8W-40-5
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . 8W-40-3
Vol t Meter . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
TJ 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-41-2
Ci gar Li ghter/Accessory Rel ay . . . . . . . . . . 8W-41-2
Ci gar Li ghter/Power Outl et . . . . . . . . . . . . 8W-41-2
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 15 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 19 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Component Page
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Power Di stri buti on Center . . . . . . . . . . . 8W-41-2, 3
TJ 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . 8W-42-4
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8W-42-4
A/C Heater Control . . . . . . . . . . . . . . . . . . . 8W-42-4
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . 8W-42-4
A/C Low Pressure Swi tch . . . . . . . . . . . . . . 8W-42-4
A/C- Heater Control . . . . . . . . . . . . . . . . 8W-42-2, 3
Bl end Door Actuator . . . . . . . . . . . . . . . . 8W-42-2, 3
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . 8W-42-2, 3
Bl ower Motor Resi stor Bl ock . . . . . . . . . . 8W-42-2, 3
Fuse 1 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Component Page
Fuse 8 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Fuse 11 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-4
Fuse 21 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-42-4
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-4
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Power Di stri buti on Center . . . . . . . . . . 8W-42-2, 3, 4
Powertrai n Control Modul e . . . . . . . . . . . . 8W-42-4
TJ 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1
8W-43 AIRBAG SYSTEM
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-43-2, 3
Ai rbag Warni ng I ndi cator . . . . . . . . . . . . . . 8W-43-3
Brake Shi ft I nterl ock Sol enoi d . . . . . . . . . . 8W-43-3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-43-3
Dri ver Ai rbag Squi b . . . . . . . . . . . . . . . . . . 8W-43-2
Fuse 5 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Component Page
Fuse 9 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Fuse 10 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-43-3
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . . 8W-43-2
Passenger Ai rbag On/Off Swi tch . . . . . . . . . 8W-43-2
TJ 8W - 43 AIRBAG SYSTEM 8W - 43 - 1
8W-44 INTERIOR LIGHTING
Component Page
A/C- Heater Control . . . . . . . . . . . . . . . . . . 8W-44-5
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
Dome Lamp And Sound Bar Dome Lamp . . 8W-44-4
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . 8W-44-4
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . 8W-44-5
Fuse 3 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5, 6
Fuse 4 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Fuse 25 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 4
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-44-4, 5, 6
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4, 5
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4, 5
Headl amp Swi tch . . . . . . . . . . . . . . . . 8W-44-4, 5, 6
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-44-4, 6
Key-I n Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Left Courtesy Lamp . . . . . . . . . . . . . . . . . . 8W-44-4
Passenger Door Ajar Swi tch . . . . . . . . . . . . 8W-44-4
Power Di stri buti on Center . . . . . . . . . . . 8W-44-2, 4
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . 8W-44-5, 6
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . . 8W-44-5
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-44-5
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . 8W-44-5
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-44-4
Sound Bar Dome Lamp . . . . . . . . . . . . . . 8W-44-2, 4
Underhood Lamp . . . . . . . . . . . . . . . . . . 8W-44-3, 4
TJ 8W - 44 INTERIOR LIGHTING 8W - 44 - 1
8W-47 AUDIO SYSTEM
Component Page
Dome Lamp And Sound Bar Dome Lamp . . 8W-47-2
Fuse 3 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse 15 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse 25 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-47-2
Left Front Speaker . . . . . . . . . . . . . . . . . . . 8W-47-3
Left Rear Speaker . . . . . . . . . . . . . . . . . . . . 8W-47-3
Component Page
Power Di stri buti on Center . . . . . . . . . . . . . 8W-47-2
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
Radi o Antenna . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Ri ght Front Speaker . . . . . . . . . . . . . . . . . . 8W-47-3
Ri ght Rear Speaker . . . . . . . . . . . . . . . . . . 8W-47-3
Sound Bar Dome Lamp . . . . . . . . . . . . . . . 8W-47-2
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-47-2
TJ 8W - 47 AUDIO SYSTEM 8W - 47 - 1
8W-48 REAR WINDOW DEFOGGER
Component Page
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse 7 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse 17 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-48-2
Power Di stri buti on Center . . . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-48-2
TJ 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1
8W-50 FRONT LIGHTING
Component Page
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . 8W-50-2, 5
Dayti me Runni ng Lamp Modul e . . . . . . . 8W-50-2, 8
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . 8W-50-3
Fog Lamp Rel ay No. 1 . . . . . . . . . . . . . . . . 8W-50-7
Fog Lamp Rel ay No. 2 . . . . . . . . . . . 8W-50-2, 4, 6, 8
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . 8W-50-7
Fuse 3 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 6
Fuse 4 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Fuse 11 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8
Fuse 16 (FB) . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 5
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-50-7
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-50-5, 6, 8
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8
G102 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 4, 5, 7
G103 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 4, 5, 7
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 5, 7
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Headl amp Di mmer Swi tch . . . . . . . . 8W-50-2, 5, 6, 8
Headl amp Level i ng Swi tch . . . . . . . . . . . . . 8W-50-5
Headl amp Swi tch . . . . . . . . . . . 8W-50-2, 3, 4, 5, 6, 8
Component Page
I nstrument Cl uster . . . . . . . . . . . 8W-50-2, 3, 4, 6, 8
Key-I n Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Left Ci ty Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-50-7
Left Front Park/Turn Si gnal Lamp . . . . . . . 8W-50-4
Left Headl amp . . . . . . . . . . . . . . . . . . . . 8W-50-2, 8
Left Headl amp Level i ng Motor . . . . . . . . . . 8W-50-5
Left Si de Marker Lamp . . . . . . . . . . . . . . . 8W-50-4
Power Di stri buti on Center . . . . . . . . . . . . . 8W-50-7
Powertrai n Control Modul e . . . . . . . . . . . . 8W-50-8
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Ri ght Ci ty Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-7
Ri ght Front Park/Turn Si gnal Lamp . . . . . . 8W-50-4
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . 8W-50-2, 8
Ri ght Headl amp Level i ng Motor . . . . . . . . . 8W-50-5
Ri ght Si de Marker Lamp . . . . . . . . . . . . . . 8W-50-4
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . 8W-50-4
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . 8W-50-8
TJ 8W - 50 FRONT LIGHTING 8W - 50 - 1
8W-51 REAR LIGHTING
Component Page
Back-Up Lamp . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3
Back-Up Lamp Swi tch . . . . . . . . . . . . . . 8W-51-2, 3
Brake Lamp Swi tch . . . . . . . . . . . . . . . . 8W-51-4, 6
Brake Shi ft I nterl ock Sol enoi d . . . . . . . . . . 8W-51-6
Center Hi gh Mounted Stop Lamp . . . . . . 8W-51-4, 6
Ci gar Li ghter/Accessory Rel ay . . . . . . . . . . 8W-51-6
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
Control l er Anti -Lock Brake . . . . . . . . . . . 8W-51-4, 6
Fog Lamp I l l umi nati on . . . . . . . . . . . . . . 8W-51-7, 8
Fog Lamp I ndi cator . . . . . . . . . . . . . . . . . 8W-51-7, 8
Fuse 2 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4, 6
Fuse 3 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
Fuse 4 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
Fuse 7 (FB) . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3
Fuse 16 (FB) . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
Fuse Bl ock . . . . . . . . . . . . . . . . 8W-51-2, 3, 4, 6, 7, 8
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6, 7, 8
Component Page
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4, 7, 8
Headl amp Di mmer Swi tch . . . . . . . . . . . 8W-51-7, 8
Headl amp Swi tch . . . . . . . . . . . . . . . 8W-51-2, 3, 7, 8
Left Li cense Lamp . . . . . . . . . . . . . . . . . 8W-51-7, 8
Left Rear Lamp Assembl y . . . . . . 8W-51-2, 3, 4, 5, 6
Park/Neutral Posi ti on Swi tch . . . . . . . . . 8W-51-2, 3
Powertrai n Control Modul e . . . . . . . . . . . . 8W-51-6
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . 8W-51-7, 8
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . 8W-51-7, 8
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . 8W-51-7, 8
Ri ght Rear Lamp Assembl y . . . . . 8W-51-2, 3, 4, 5, 6
Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . 8W-51-3, 4
Tai l /Stop/Turn Si gnal Lamp . . . . . . . . . . 8W-51-2, 5
Turn Si gnal Lamp . . . . . . . . . . . . . . . . . . 8W-51-3, 5
Turn Si gnal /Hazard Swi tch . . . . . . . 8W-51-2, 3, 5, 6
Vehi cl e Speed Control Servo . . . . . . . . . . . . 8W-51-6
TJ 8W - 51 REAR LIGHTING 8W - 51 - 1
8W-52 TURN SIGNALS
Component Page
Combi nati on Fl asher . . . . . . . . . . . . . . . . . 8W-52-2
Fuse 11 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
Fuse 13 (FB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-52-3
Left Front Park/Turn Si gnal Lamp . . . . . . . 8W-52-3
Left Front Turn Si gnal Lamp . . . . . . . . . . . 8W-52-3
Left Rear Lamp Assembl y . . . . . . . . . . . . . . 8W-52-2
Component Page
Left Repeater Lamp . . . . . . . . . . . . . . . . . . 8W-52-3
Left Si de Marker Lamp . . . . . . . . . . . . . . . 8W-52-3
Power Di stri buti on Center . . . . . . . . . . . . . 8W-52-2
Ri ght Front Park/Turn Si gnal Lamp . . . . . . 8W-52-3
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . 8W-52-3
Ri ght Rear Lamp Assembl y . . . . . . . . . . . . 8W-52-2
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . . 8W-52-3
Ri ght Si de Marker Lamp . . . . . . . . . . . . . . 8W-52-3
Tai l /Stop/Turn Si gnal Lamp . . . . . . . . . . . . 8W-52-2
Turn Si gnal Lamp . . . . . . . . . . . . . . . . . . . . 8W-52-2
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . 8W-52-2, 3
TJ 8W - 52 TURN SIGNALS 8W - 52 - 1
8W-53 WIPERS
Component Page
Fuse 3 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
Fuse 6 (FB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
Fuse 14 (FB) . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3, 4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-53-4
Component Page
I nternal Del ay Rel ay . . . . . . . . . . . . . . . . . 8W-53-3
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
Rear Washer Pump . . . . . . . . . . . . . . . . . . . 8W-53-4
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-53-4
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . 8W-53-4
Wi ndshi el d Washer Pump . . . . . . . . . . . . 8W-53-2, 3
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . 8W-53-2, 3
Wi ndshi el d Wi per Swi tch . . . . . . . . . . . . 8W-53-2, 3
TJ 8W - 53 WIPERS 8W - 53 - 1
8W-70 SPLICE INFORMATION
Component Page
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-9
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-4
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-7
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-15
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 8
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5, -6, 7
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
S127 . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3, -5, -6, 7
S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
S129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-8
S132 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12, -13, 14
S133 . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3, -5, -6, 7
S134 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12, -13, 14
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10, 11
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12, 13
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Component Page
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
S147 . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3, -5, -6, 7
S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-11
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8, 9
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4, 6
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9
S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-11
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2
S400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
S401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-6
TJ 8W - 70 SPLICE INFORMATION 8W - 70 - 1
8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . 8W-80-4
A/C Heater Control . . . . . . . . . . . . . . . . . . . 8W-80-4
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . 8W-80-4
A/C Low Pressure Swi tch . . . . . . . . . . . . . . 8W-80-5
ABS Di ode . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-5
ABS Pump Motor . . . . . . . . . . . . . . . . . . . . 8W-80-5
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-80-5
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-80-5
Battery Temperature Sensor . . . . . . . . . . . . 8W-80-6
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-80-6
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-80-6
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-80-6
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . 8W-80-6
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-80-7
Brake Shi ft I nterl ock Sol enoi d . . . . . . . . . . 8W-80-7
Brake Warni ng I ndi cator Swi tch . . . . . . . . 8W-80-7
C103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7
C104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8
C107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9
C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9
C110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-10
C154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-10
C170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
C322 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13, 14
C323 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14, 15
Component Page
C325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
Camshaft Posi ti on Sensor . . . . . . . . . . . . . 8W-80-16
Ci gar Li ghter/Accessory Rel ay . . . . . . . . . 8W-80-17
Ci gar Li ghter/Power Outl et . . . . . . . . . . . . 8W-80-17
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . 8W-80-17
Combi nati on Fl asher . . . . . . . . . . . . . . . . . 8W-80-17
Control l er Anti -Lock Brake . . . . . . . . . . . . 8W-80-18
Crankshaft Posi ti on Sensor . . . . . . . . . . . . 8W-80-18
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-80-19
Dayti me Runni ng Lamp Modul e . . . . . . . . 8W-80-19
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . 8W-80-20
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . 8W-80-20
Engi ne Cool ant Temperature Sensor . . . . . 8W-80-20
Engi ne Oi l Pressure Sensor . . . . . . . . . . . 8W-80-20
Fog Lamp Rel ay No. 1 . . . . . . . . . . . . . . . 8W-80-21
Fog Lamp Rel ay No. 2 . . . . . . . . . . . . . . . 8W-80-21
Front Fog Lamp Swi tch . . . . . . . . . . . . . . 8W-80-21
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . 8W-80-21
Fuel I njector No. 2 . . . . . . . . . . . . . . . . . . 8W-80-22
Fuel I njector No. 3 . . . . . . . . . . . . . . . . . . 8W-80-22
Fuel I njector No. 4 . . . . . . . . . . . . . . . . 8W-80-22, 23
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . 8W-80-23
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . 8W-80-23
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-80-23
G Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
TJ 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1
Component Page
Headl amp Di mmer Swi tch . . . . . . . . . . . . 8W-80-24
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . . . . .
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-80-24
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . 8W-80-24
Hydraul i c Control Uni t . . . . . . . . . . . . . . . 8W-80-25
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . 8W-80-25
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . . . . 8W-80-25
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-80-25
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-80-26
I ntake Ai r Temperature Sensor . . . . . . . . . 8W-80-26
Key-I n Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
Leak Detecti on Pump . . . . . . . . . . . . . . . . 8W-80-27
Left Ci ty Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-27
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-80-27
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-27
Left Front Park/Turn Si gnal Lamp . . . . . . 8W-80-27
Left Front Speaker . . . . . . . . . . . . . . . . . . 8W-80-27
Left Front Turn Si gnal Lamp . . . . . . . . . . 8W-80-28
Left Front Wheel Speed Sensor . . . . . . . . . 8W-80-28
Left Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-80-28
Left Headl amp Level i ng Motor . . . . . . . . . 8W-80-28
Left Li cense Lamp . . . . . . . . . . . . . . . . . . 8W-80-28
Left Rear Lamp Assembl y . . . . . . . . . . . . . 8W-80-28
Left Rear Speaker . . . . . . . . . . . . . . . . . . . 8W-80-29
Left Rear Wheel Speed Sensor . . . . . . . . . 8W-80-29
Left Repeater Lamp . . . . . . . . . . . . . . . . . 8W-80-29
Component Page
Left Si de Marker Lamp . . . . . . . . . . . . . . . 8W-80-29
Low Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-80-29
Mani fol d Absol ute Pressure Sensor . . . . . . 8W-80-29
Oxygen Sensor 1/1 Upstream . . . . . . . . . . 8W-80-30
Oxygen Sensor 1/2 Downstream . . . . . . . . 8W-80-30
Oxygen Sensor 2/1 Upstream . . . . . . . . . . 8W-80-30
Oxygen Sensor 2/2 Downstream . . . . . . . . 8W-80-31
Park/Neutral Posi ti on Swi tch . . . . . . . . . . 8W-80-31
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . 8W-80-31
Passenger Ai rbag Di sconnect Bypass
Jumper . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
Passenger Ai rbag On/Off Swi tch . . . . . . . . 8W-80-32
Passenger Door Ajar Swi tch . . . . . . . . . . . 8W-80-32
Power Steeri ng Pressure Swi tch . . . . . . . . 8W-80-32
Powertrai n Control Modul es . . . . . . 8W-80-33, 34, 35
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35, 36
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-36
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . 8W-80-36
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . 8W-80-36
Rear Washer Pump . . . . . . . . . . . . . . . . . . 8W-80-37
Rear Wi ndow Defogger Swi tch . . . . . . . . . 8W-80-37
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-80-37
Rear Wi per/Washer Swi tch . . . . . . . . . . . . 8W-80-37
Ri ght Ci ty Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-38
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8W-80-38
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-38
8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS TJ
Component Page
Ri ght Front Park/Turn Si gnal Lamp . . . . . 8W-80-38
Ri ght Front Speaker . . . . . . . . . . . . . . . . . 8W-80-38
Ri ght Front Turn Si gnal Lamp . . . . . . . . . 8W-80-38
Ri ght Front Wheel Speed Sensor . . . . . . . 8W-80-39
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . 8W-80-39
Ri ght Headl amp Level i ng Motor . . . . . . . . 8W-80-39
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . 8W-80-39
Ri ght Rear Lamp Assemby . . . . . . . . . . . . 8W-80-39
Ri ght Rear Speaker . . . . . . . . . . . . . . . . . . 8W-80-39
Ri ght Rear Wheel Speed Sensor . . . . . . . . 8W-80-40
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . 8W-80-40
Ri ght Si de Marker Lamp . . . . . . . . . . . . . 8W-80-40
Seatbel t Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-80-40
Component Page
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8W-80-40
Sound Bar Dome Lamp . . . . . . . . . . . . . . . 8W-80-40
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . 8W-80-41
Torque Converter Cl utch Sol enoi d . . . . . . . 8W-80-41
Transfer Case Swi tch . . . . . . . . . . . . . . . . 8W-80-41
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . 8W-80-41
Underhood Lamp . . . . . . . . . . . . . . . . . . . 8W-80-41
Vehi cl e Speed Control Servo . . . . . . . . . . . 8W-80-42
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . 8W-80-42
Wi ndshi el d Washer Pump . . . . . . . . . . . . . 8W-80-42
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . . 8W-80-42
Wi ndshi el d Wi per Swi tch . . . . . . . . . . . . . 8W-80-42
TJ 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3
8W-90 CONNECTOR/GROUND LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng com-
ponent and connector l ocati ons i n the vehi cl e. A con-
nector i ndex i s provi ded. Use the wi ri ng di agrams i n
each secti on for connector number i denti fi cati on.
Refer to the i ndex for the proper fi gure number.
CONNECTOR/GROUND LOCATIONS
For i tems that are not shown i n thi s secti on a N/S
i s pl aced i n the Fi g. col umn.
Connector
Name/Number
Color Location Fig.
A/C
Compressor
Clutch
BK At A/C
Compressor
Clutch
12
A/C Heater
Control - C1
BK Rear of Blower
Motor Switch
18, 19
A/C Heater
Control - C2
BK Rear of Lamp 18, 19
A/C Heater
Control - C3
BK Rear of A/C
Heater Control
Switch
18, 19
A/C High
Pressure Switch
(2.5L)
BK On A/C
Compressor
N/S
A/C High
Pressure Switch
(4.0L)
BK T/O at A/C
Compressor
Clutch T/O or
Intake Air
Temperature
Sensor T/O
N/S
A/C Low
Pressure Switch
GY Near T/O for
Powertrain
Control Module
N/S
ABS Diode BK Near T/O for
Controller
Anti-Lock Brake
2
ABS Pump
Motor
BK Left Side of
Engine
Compartment
Near Grommet
6
Airbag Control
Module
YL Front of Floor
Pan Tunnel
16, 17,
20
Back-up Lamp
Switch (M/T)
BK Right Side of
Transmission
14
Battery
Temperature
Sensor
BK Under Battery
Tray
3, 4
Blend Door
Actuator
On HVAC
Harness
N/S
Connector
Name/Number
Color Location Fig.
Blower Motor On HVAC
Harness
N/S
Blower Motor
Relay
BK On HVAC
Harness
N/S
Blowe Motor
Resistor Block
On HVAC
Harness
N/S
Brake Lamp
Switch
GY Top of Brake
Pedal Bracket
16, 17
Brake Shift
Interlock
Solenoid
WT Near Steering
Column
21
Brake Warning
Indicator Switch
BK On Brake
Master Cylinder
2, 3
C103 (2.5L) BK Near T/O for
Fuel Injector
NO. 4
2, 3
C103 (4.0L) BK Near T/O for
Fuel Injector
NO. 6
2, 3
C104 (LHD) GY Rear of Engine 2
C104 (RHD) BK Rear of Engine 3
C106 (LHD) BK Left Kick Panel 2, 16
C106 (RHD) BK Right Kick
Panel
17
C107 (LHD) YL Left Kick Panel 2, 16
C107 (RHD) YL Right Kick
Panel
17
C108 (LHD) BL Left Kick Panel 2, 16
C108 (RHD) BL Right Kick
Panel
17
C110 BK Left Fender
Side Shield
3, 5
C154 BK Top Right Side
of Transmission
11, 14
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1
Connector
Name/Number
Color Location Fig.
C170 (LHD) LT
GY/
BK
Left Kick Panel 2, 18
C170 (RHD) LT
GY/
BK
Right Kick
Panel
19
C180 BK Engine
Compartment
Left Side
N/S
C202 (LHD) GY Left Kick Panel 16, 18
C202 (RHD) GY Right Kick
Panel
17, 19
C203 (LHD) GN Left Kick Panel 16, 18
C203 (RHD) GN Right Kick
Panel
17, 19
C204 (LHD) RD Left Kick Panel 16, 18
C204 (RHD) RD Right Kick
Panel
17, 19
C205 (LHD) BK Bottom Right of
Instrument
Panel
22
C205 (RHD) BK Bottom Left of
Instrument
Panel
19
C322 BK Left Kick Panel 16, 17,
23
C323 (LHD) RD Left Kick Panel 16, 23
C323 (RHD) LT GY Left Kick Panel 17, 24
C325 (4 Spkr
Sys)
WT/
BK
Left Side of
Sound Bar
23, 24
C326 (Hard
Top)
BK Left Rear
Quarter Panel
23, 24
C329 (LHD) BK Left Side of
Rear Bumper
25
C329 (RHD) BK Right Side of
Rear Bumper
26
C330 (4 Spkr
Sys)
WT/
BK
Left Side of
Sound Bar
23, 24
C331 (Hard
Top)
BK Left Rear
Quarter Panel
23, 24
Camshaft
Position Sensor
(2.5L)
GY Below
Distributor
11
Camshaft
Position Sensor
(4.0L)
GY T/O at
Generator T/O
N/S
Connector
Name/Number
Color Location Fig.
Cigar Lighter/
Accessory
Relay (LHD)
BK Bottom of
Instrument
Panel Near
Steering
Column
16, 23
Cigar Lighter/
Accessory
Relay (RHD)
BK Bottom of
Instrument
Panel Near
Steering
Column
N/S
Cigar Lighter/
Power Outlet
RD Rear of Cigar
Lighter
18, 19
Clockspring -
C1
YL Rear of
Clockspring
21
Clockspring -
C2
NAT Rear of
Clockspring
21
Clutch Pedal
Position Switch
(M/T)
BK Top of Clutch
Pedal Bracket
16, 17
Combination
Flasher
BK Bottom of
Instrument
Panel Near
Steering
Column
21
Controller
Anti-Lock Brake
- C1
GY Near Grommet
Rear Left Side
of Dash Panel
2
Controller
Anti-Lock Brake
- C2
GY Near Grommet
Rear Left Side
of Dash Panel
2
Crankshaft
Position Sensor
BK At Rear of
Intake Manifold
9, 13
Data Link
Connector
(LHD)
BK Bottom Left of
Instrument
Panel
18
Data Link
Connector
(RHD)
BK Bottom Right of
Instrument
Panel
19
Daytime
Running Lamp
Module (Except
Built-Up-Export)
BK Left Side of
Engine
Compartment
4
Driver Door Ajar
Switch
NAT At “A” Pillar 16, 17
Duty Cycle
Evap/Purge
solenoid
BK Left Fender
Side Shield
5
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
Engine Coolant
Temperature
Sensor
BK On Thermostat
Housing
9, 10
Engine Oil
Pressure
Sensor (2.5L)
BK Right Side of
Engine Block
11
Engine Oil
Pressure
Sensor (4.0L)
BK Right Side of
Engine Block
N/S
Fog Lamp
Relay NO.1
(Except
Built-Up-Export)
BK Near Fuse
Block T/O
16
Fog Lamp
Relay NO.2
(Except
Built-Up-Export)
BK Near Fuse
Block T/O
16
Front Fog Lamp
Switch (Except
Built-Up-Export)
BK At Switch 18
Fuel Injector
NO.1
BK At Injector 9, 10
Fuel Injector
NO.2
BK At Injector 9, 10
Fuel Injector
NO.3
BK At Injector 9, 10
Fuel Injector
NO.4
BK At Injector 9, 10
Fuel Injector
NO.5
BK At Injector 10
Fuel Injector
NO.6
BK At Injector 10
Fuel Pump
Module
BK Above Fuel
Tank
27
G100 Rear Center of
Engine
Compartment
2, 3
G101 Rear Center of
Engine
Compartment
2
G102 Left Radiator
Closure Panel
5
G103 Right Radiator
Closure Panel
1
G105 (2.5L) Right Rear of
Engine Block
12
G105 (4.0L) Right Rear of
Engine Block
N/S
Connector
Name/Number
Color Location Fig.
G106 Right Rear of
Engine Block
12
G107 Right Rear of
Engine Block
12
G200 (LHD) Left Rear of
Instrument
Panel
18
G200 (RHD) Right Rear of
Instrument
Panel
19
G201 (LHD) Left Rear of
Instrument
Panel
18
G201 (RHD) Right Rear of
Instrument
Panel
19
G202 (LHD) Right Rear of
Instrument
Panel
22
G202 (RHD) Left Rear of
Instrument
Panel
19
G203 (LHD) Right Rear of
Instrument
Panel
22
G203 (RHD) Left Rear of
Instrument
Panel
19
G300 (LHD) Left Kick Panel 16
G300 (RHD) Right Kick
Panel
17
G301 (LHD) Right Kick
Panel
16
G301 (RHD) Left Kick Panel 17
G302 (LHD) Left Kick Panel 16
G302 (RHD) Right Kick
Panel
17
G Switch BK Near T/O for
Controller
Anti-Lock Brake
20
Generator BK Rear of
Generator
12
Headlamp
Dimmer Switch
BK At Steering
Column Part of
Multifunction
Switch
21
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
Headlamp
Leveling Switch
(Built-Up-
Export)
WT At Switch 18, 19
Headlamp
Switch
BK Rear of Switch 18, 19
High Note Horn BK Left Front
Fender Side
Shield
5
Hydraulic
Control Unit
BK Left Side of
Engine
Compartment
6
Idle Air Control
Motor
BK Side of Throttle
Body
9, 10
Ignition Coil
(2.5L)
GY T/O near G105
T/O
N/S
Ignition Coil
Pack (4.0L)
BK Near T/O for
Crankshaft
Position Sensor
N/S
Ignition Switch GY Rear of Ignition
Switch
21
Instrument
Cluster - C1
GN Rear of Cluster 18, 19
Instrument
Cluster - C2
BL Rear of Cluster 18, 19
Intake Air
Temperature
Sensor
GY Rear of Intake
Manifold
9, 10
Key-In Switch GN At Key-In
Switch
21
Leak Detection
Pump (Except
Built-Up-Export)
BK Engine
Compartment
Left Side
N/S
Left City Lamp
(Built-Up-
Export)
BK At Lamp 5
Left Courtesy
Lamp
BK Left Side of
Instrument
Panel
18, 19
Left Fog Lamp
(Except
Built-Up-Export)
BK At Lamp N/S
Left Front
Park/Turn
Signal Lamp
(Except
Built-Up-Export)
BK At Lamp N/S
Connector
Name/Number
Color Location Fig.
Left Front
Speaker
BK At Speaker 18, 19
Left Front Turn
Signal Lamp
(Built-Up-
Export)
BK At Lamp N/S
Left Front
Wheel Speed
Sensor
BK Left Side of
Engine
Compartment
Near Hydraulic
Control Unit
6
Left Headlamp BK Rear of Lamp 5
Left Headlamp
Leveling Motor
(Built-Up-
Export)
BK Near Headlamp
at Motor
5
Left License
Lamp
(Built-Up-
Export)
GY At Lamp 25, 26
Left Rear Lamp
Assembly
BK At Lamp 25, 26
Left Rear
Speaker (Sound
Bar)
BK At Sound Bar N/S
Left Rear Wheel
Speed Sensor
BK Near Vehicle
Speed Sensor
T/O
27
Left Repeater
Lamp
(Built-Up-
Export)
GY At Lamp N/S
Left Side
Marker Lamp
(Except
Built-Up-Export)
GY At Lamp N/S
Low Note Horn
(Except
Built-Up-Export)
BK Left Front
Fender Side
Shield
5
Manifold
Absolute
Pressure
Sensor
BK Side of Throttle
Body
9, 10
Oxygen Sensor
1/1 Upstream
GY On Front
Exhaust Pipe
9, 15
Oxygen Sensor
1/2 Downstream
BK Rear of
Catalytic
Converter
15
8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
Oxygen Sensor
1/1 Upstream
(4.0L California/
European III)
GY Near T/O for
Engine Coolant
Temperature
Sensor
15
Oxygen Sensor
1/2 Downstream
(4.0L California/
European III)
BK Near T/O for
Oxygen Sensor
1/1 Front Bank
Up
15
Oxygen Sensor
2/1 Upstream
(4.0L California/
European III)
GY Near Idle Air
Control Motor
T/O
15
Oxygen Sensor
2/2 Downstream
(4.0L California/
European III)
GY T/O near
Ignition Coil
Pack T/O
15
Park/Neutral
Position Switch
(A/T)
Left Side of
Transmission
11
Passenger
Airbag
YL Rear of Airbag 16, 17,
19, 22
Passenger
Airbag
Disconnect
Bypass Jumper
YL Near Fuse
Block T/O
N/S
Passenger
Airbag On/Off
Switch - C1
LT GY Near Fuse
Block T/O
16, 17
Passenger
Airbag On/Off
Switch - C2
YL Near Fuse
Block T/O
16, 17
Passenger Door
Ajar Switch
BK Near T/O for
G301
16, 17
Power Steering
Pressure Switch
(2.5L)
BK Near Power
Steering Pump
9
Powertrain
Control Module
- C1 (LHD)
BK Right Rear of
Engine
Compartment
4
Powertrain
Control Module
- C1 (RHD)
BK Left Rear of
Engine
Compartment
3
Powertrain
Control Module
- C2 (LHD)
WT Right Rear of
Engine
Compartment
4
Powertrain
Control Module
- C2 (RHD)
WT Left Rear of
Engine
Compartment
3
Connector
Name/Number
Color Location Fig.
Powertrain
Control Module
- C3 (LHD)
GY Right Rear of
Engine
Compartment
4
Powertrain
Control Module
- C3 (RHD)
GY Left Rear of
Engine
Compartment
3
PRNDL Lamp BK Rear of Lamp 16, 17
Radio - C1 GY Rear of Radio 18, 19
Radio - C2 BK Rear of Radio 18, 19
Rear Fog Lamp
(Built-Up-
Export)
BK At Lamp 25, 26
Rear Fog Lamp
Relay
(Built-Up-
Export) (LHD)
LT GN Near Fuse
Block T/O
16
Rear Fog Lamp
Relay
(Built-Up-
Export) (RHD)
LT GN Near Fuse
Block T/O
17
Rear Fog Lamp
Switch
(Built-Up-
Export)
WT At Switch 18, 19
Rear Washer
Pump (Hard
Top)
BK Under Washer
Fluid Reservoir
5
Rear Window
Defogger Switch
(Hard Top)
GY Behind Rear
Window
Defogger
Switch
18, 19
Rear Wiper
Motor (Hard
Top)
BK At Rear Wiper
Motor
N/S
Rear Wiper/
Washer Switch
(Hard Top)
WT Behind Rear
Wiper/Washer
Switch
18, 19
Right City Lamp
(Built-Up-
Export)
BK At Lamp 1
Right Courtesy
Lamp
BK Right Side of
Instrument
Panel
19, 22
Right Fog Lamp
(Except
Built-Up-Export)
BK At Lamp 1
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
Right Front
Park/Turn
Signal Lamp
(Except
Built-Up-Export)
BK At Lamp 1
Right Front
Speaker
BK At Speaker 19, 22
Right Front Turn
Signal Lamp
(Built-Up-
Export)
BK At Lamp 1
Right Front
Wheel Speed
Sensor
BK Rear of Engine 13
Right Headlamp BK Rear of Lamp 1
Right Headlamp
Leveling Motor
(Built-Up-
Export)
BK Near Headlamp
at Motor
1
Right License
Lamp
(Built-Up-
Export)
GY At Lamp 25, 26
Right Rear
Lamp Assembly
BK At Lamp 24, 25
Right Rear
Speaker (Sound
Bar)
BK At Sound Bar N/S
Right Rear
Wheel Speed
Sensor
BK Near Vehicle
Speed Sensor
T/O
27
Right Repeater
Lamp
(Built-Up-
Export)
GY At Lamp 1
Right Side
Marker Lamp
(Except
Built-Up-Export)
GY At Lamp 1
Connector
Name/Number
Color Location Fig.
Seat Belt Switch
(Except LHD
Built-Up-Export)
BK Near Park
Brake Switch
T/O
23, 24
Sentry Key
Immobilizer
Module
BK At Immobilizer 16, 17
Sound Bar
Dome Lamp
BK At Sound Bar N/S
Throttle Position
Sensor
WT Side of Throttle
Body
9, 10
Torque
Converter
Clutch Solenoid
BK Left Side of
Transmission
14
Transfer Case
Switch
BK Left Side of
Transfer Case
14
Turn Signal/
Hazard Switch
BK At Steering
Column Part of
Multifunction
Switch
21
Underhood
Lamp
BK Under Hood 2, 3
Vehicle Speed
Control Servo
(LHD)
BK Left Side of
Engine
Compartment
N/S
Vehicle Speed
Control Servo
(RHD)
BK Right Side of
Engine
Compartment
N/S
Vehicle Speed
Sensor
BK Left Rear of
Transfer Case
14
Windshield
Washer Pump
BK Under Washer
Fluid Reservoir
5
Windshield
Wiper Motor
BK Center of Cowl
Panel
7, 8
Windshield
Wiper Switch
NAT At Steering
Column
21
8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
F
r
o
n
t
E
n
d
W
i
r
i
n
g
C
o
n
n
e
c
t
o
r
s
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
2
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
c
t
o
r
s

R
e
a
r
,
L
H
D
8W - 90 - 8 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
3
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
c
t
o
r
s

R
e
a
r
,
R
H
D
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
4
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
c
t
o
r
s

L
H
D
8W - 90 - 10 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
5
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
c
t
o
r
s

L
e
f
t
S
i
d
e
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11
DESCRIPTION AND OPERATION (Continued)
Fig. 6 ABS Hydraulic Control Unit
Fig. 7 Windshield Wiper Motor—LHD
8W - 90 - 12 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
Fig. 8 Windshield Wiper Motor—RHD
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
9
E
n
g
i
n
e
H
a
r
n
e
s
s
C
o
n
n
e
c
t
o
r
s

2
.
5
L
E
n
g
i
n
e
8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
0
E
n
g
i
n
e
H
a
r
n
e
s
s
C
o
n
n
e
c
t
o
r
s

4
.
0
L
E
n
g
i
n
e
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
1
E
n
g
i
n
e
a
n
d
A
u
t
o
m
a
t
i
c
T
r
a
n
s
m
i
s
s
i
o
n
C
o
n
n
e
c
t
o
r
s
8W - 90 - 16 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
2
E
n
g
i
n
e
a
n
d
T
r
a
n
s
m
i
s
s
i
o
n
C
o
n
n
e
c
t
o
r
s
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
3
C
r
a
n
k
s
h
a
f
t
P
o
s
i
t
i
o
n
S
e
n
s
o
r
a
n
d
R
i
g
h
t
F
r
o
n
t
W
h
e
e
l
S
p
e
e
d
S
e
n
s
o
r
8W - 90 - 18 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
4
T
r
a
n
s
m
i
s
s
i
o
n
a
n
d
T
r
a
n
s
f
e
r
C
a
s
e
C
o
n
n
e
c
t
o
r
s
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
5
O
x
y
g
e
n
S
e
n
s
o
r
C
o
n
n
e
c
t
o
r
s
8W - 90 - 20 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
6
D
a
s
h
P
a
n
e
l
C
o
n
n
e
c
t
o
r
s

L
H
D
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
7
D
a
s
h
P
a
n
e
l
C
o
n
n
e
c
t
o
r
s

R
H
D
8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
8
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
W
i
r
i
n
g
C
o
n
n
e
c
t
o
r
s

L
H
D
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 23
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
1
9
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
W
i
r
i
n
g
C
o
n
n
e
c
t
o
r
s

R
H
D
8W - 90 - 24 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
2
0
A
i
r
b
a
g
C
o
n
t
r
o
l
M
o
d
u
l
e
a
n
d
G
S
w
i
t
c
h
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 25
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
2
1
S
t
e
e
r
i
n
g
C
o
l
u
m
n
C
o
n
n
e
c
t
o
r
s
8W - 90 - 26 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
Fig. 22 Instrument Panel Connectors—Right Side, LHD
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 27
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
2
3
B
o
d
y
C
o
n
n
e
c
t
o
r
s

L
H
D
8W - 90 - 28 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
i
g
.
2
4
R
e
a
r
B
o
d
y
W
i
r
i
n
g
C
o
n
n
e
c
t
o
r
s

R
H
D
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 29
DESCRIPTION AND OPERATION (Continued)
Fig. 25 Rear Under Body Wiring Connectors—LHD
Fig. 26 Rear Under Body Wiring Connectors—RHD
8W - 90 - 30 8W - 90 CONNECTOR/GROUND LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
Fig. 27 Rear Engine Harness Connectors
TJ 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 31
DESCRIPTION AND OPERATION (Continued)
8W-95 SPLICE LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng the
general l ocati on of the spl i ces i n thi s vehi cl e. A spl i ce
i ndex i s provi ded. Use the wi ri ng di agrams i n each
secti on for spl i ce number i denti fi cati on. Refer to the
i ndex for proper spl i ce number.
SPLICE LOCATIONS
For spl i ces that are not shown i n the fi gures i n
thi s secti on, an N/S i s pl aced i n the Fi g. col umn.
Splice Number Location Fig.
S101 (LHD) Near T/O for Power
Distribution Center
2
S101 (RHD) Near T/O for Power
Distribution Center
3
S102 Near T/O for G100 or Daytime
Running Lamp Module
2, 3
S103 (LHD) Near T/O for G101 or
Powertrain Control Module -
C3
2
S103 (RHD) Near T/O for Battery
Temperature Sensor
3
S104 Near T/O for C110 2
S105 (LHD) Near T/O for C110 2
S105 (LHD)
(DRL)
Near T/O for ABS Pump Motor 2
S105 (RHD) Near T/O for C110 3
S106 Near T/O for Ground G100 2
S106 (DRL) Near T/O for Daytime Running
Lamp Module
2
S108 (LHD) Near T/O for Underhood Lamp 2
S108 (RHD) Near T/O for C110 3
S109 Near T/O for C103 and C104 2
S110 Near T/O for C103 and C104 2
S111 Near T/O for Battery
Temperature Sensor or Power
Distribution Center
2, 3
S112 In T/O for Controller Antilock
Brake - C2
2
S113 Near T/O for G100 2
S114 Near ABS Pump Motor T/O 2
S115 (Except
Built-Up-
Export)
Near T/O for Duty Cycle
Evap/Purge Solenoid
1
S116 (Except
Built-Up-
Export)
Near T/O for High Note Horn 1
Splice Number Location Fig.
S117 Near T/O for High Note Horn 1
S118 Near Left Headlamp T/O 1
S119 Left Side Radiator Closure
Panel
1
S121 (LHD) Near T/O for Powertrain
Control Module - C1
N/S
S121 (RHD) Near T/O for Powertrain
Control Module - C2
N/S
S122
(Built-Up-
Export)
Near Grommet for Left Front
Turn Signal Lamp
N/S
S122 (Except
Built-Up-
Export)
Near Grommet for Left Front
Park/Turn Signal Lamp
N/S
S123 (LHD) Near T/O for C104 6
S123 (RHD)
(2.5L)
Near T/O for A/C Low
Pressure Switch
7
S123 (RHD)
(4.0L)
Near T/O for Fuel Injector NO.
6
7
S124 (LHD)
(ABS)
Near T/O for G105 6
S124 (LHD)
(All 2.5L)
Near T/O for C104 6
S124 (LHD)
(Except ABS)
Near T/O for C154 6
S124 (RHD)
(2.5L)
Near T/O for C103 7
S124 (RHD)
(4.0L)
Near T/O for G105 7
S125
(Built-Up-
Export)
Near Grommet for Right Front
Turn Signal Lamp
N/S
S125 (Fog
Lamps)
(Except
Built-Up-
Export)
Near Grommet for Right Front
Park/Turn Signal Lamp and
Right Side Marker Lamp
N/S
S126 (LHD) Near T/O for C104 6
TJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 1
Splice Number Location Fig.
S126 (2.5L)
(RHD)
Near T/O for Fuel Injector NO.
4
7
S126 (4.0L)
(RHD)
Near T/O for Fuel Injector NO.
6
7
S127 (LHD) Near T/O for Idle Air Control
Motor
4
S127 (RHD)
(2.5L)
Between Fuel Injector NO. 2
and Fuel Injector NO. 3
5
S127 (RHD)
(4.0L)
Near T/O for Idle Air Control
Motor
5
S128 (LHD) Between Fuel Injector NO. 2
and Fuel Injector NO. 3
4
S128 (RHD)
(2.5L)
Near T/O for Fuel Injector NO.
1
5
S128 (RHD)
(4.0L)
Between Fuel Injector NO. 2
and Fuel Injector NO. 3
5
S129 (LHD) Near T/O for C104 6
S129 (RHD) Near T/O for C104 7
S130 (LHD)
(ABS) (All
2.5L)
Near T/O for C104 6
S130 (LHD)
(Except ABS)
(All California/
European III)
Near A/C Low Pressure Switch
T/O
6
S130 (RHD) Near T/O for C103 7
S131 (LHD) Near T/O for Power
Distribution Center
2
S131 (RHD) Near T/O for C110 3
S132 (LHD) Near T/O for G105 6
S132 (LHD)
(All 2.5L)
Near T/O for C154 6
S132 (RHD)
(2.5L)
Near T/O for C154 7
S132 (RHD)
(4.0L)
Near T/O for Crankshaft
Position Sensor
7
S133 (LHD) Near T/O for G105 6
S133 (RHD) Near T/O For C104 7
S134 (LHD)
(ABS) (All
2.5L)
Near T/O for C154 6
S134 (LHD)
(Except ABS)
(All California/
European III)
Near A/C Low Pressure Switch
T/O
6
S134 (RHD)
(2.5L)
Near T/O for C154 7
Splice Number Location Fig.
S134 (RHD)
(4.0L)
Near T/O for Crankshaft
Position Sensor
7
S135 (LHD)
(ABS) (All
2.5L)
Near T/O for Oxygen Sensor
1/2 Downstream
6
S135 (LHD)
(Except ABS)
(All California/
European III)
Near T/O for C104 6
S135 (RHD)
(2.5L)
Near T/O for Oxygen Sensor
1/2 Downstream
7
S136 In Battery Harness Near PDC N/S
S137 (LHD) Near T/O for Engine Coolant
Temperature Sensor
4
S137 (RHD) Near T/O for Engine Coolant
Temperature Sensor
5
S138
(Built-Up-
Export)
Near T/O for Right Headlamp
Leveling Motor
1
S139 Near T/O for Fuel Injector NO.
5
4
S140 (LHD) Near T/O for C104 N/S
S140 (RHD)
(4.0L)
In T/O for Oxygen Sensor 2/2
Right Bank Down
N/S
S141
(Built-Up-
Export)
Near T/O for Left Front Turn
Signal Lamp
N/S
S141 (Except
Built-Up-
Export)
Near T/O for Left Front
Park/Turn Signal Lamp
N/S
S142
(Built-Up-
Export)
Near Grommet for Right Front
Turn Signal Lamp
N/S
S142 (Fog
Lamps)
(Except
Built-Up-
Export)
Near T/O for Right Front
Park/Turn Signal Lamp
N/S
S142 (Except
Fog Lamps)
(Except
Built-Up-
Export)
Near Grommet for Right Front
Park/Turn Signal Lamp and
Right Side Marker Lamp
N/S
S143 Near T/O for Left Front
Park/Turn Signal Lamp
N/S
S144 Near T/O for Right Front
Park/Turn Signal Lamp
N/S
S144 (Fog
Lamps)
Near T/O for Right Fog Lamp N/S
8W - 95 - 2 8W - 95 SPLICE LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
Splice Number Location Fig.
S145 Near T/O for Crankshaft
Position Sensor
N/S
S146 Near T/O for Powertrain
Control Module - C3
2
S147 (LHD) Between T/O’s for Underhood
Lamp and C103, C104
2
S147 (RHD) Right Side of Engine
Compartment Near Grommet
3
S150
(Built-Up-
Export)
Near T/O for Right Headlamp
Leveling Motor
1
S151
(Built-Up-
Export)
Near T/O for Left Headlamp
Ground
1
S202 Center Rear of Instrument
Panel
10, 11
S204 Center Rear of Instrument
Panel
10, 11
S206 Center Rear of Instrument
Panel
10, 11
S207 Near Cigar Lighter T/O 10, 11
S301 (LHD) Near Grommet for Windshield
Wiper Motor
8
S301 (RHD) Near T/O for Passenger Airbag 9
S302 Near Grommet for Windshield
Wiper Motor
8, 9
S303 Near Grommet for Windshield
Wiper Motor
8, 9
S304 (LHD) Near Grommet for Windshield
Wiper Motor
8
S304 (RHD) Near T/O for 100 Way
Connector
9
S306 Near T/O for Airbag Control
Module
8, 9
S307 Near T/O for Airbag Control
Module
8, 9
Splice Number Location Fig.
S309 Front of Left Rear Wheel Well 12, 13
S310 Left Rear Quarter Panel, Near
Body Grommet
12, 13
S311 Near Left Rear Lamp
Assembly Connector
12, 13
S313 Front of Left Rear Wheel Well 12, 13
S314 Front of Left Rear Wheel Well 12, 13
S314
(Built-Up-
Export)
(Hardtop)
Top of Left Rear Wheel Well 12
S315 Near Right Rear Lamp
Assembly Connector
12, 13
S316 In T/O for Rear Fog Lamp 12, 13
S317 Near T/O for Left License
Lamp
12, 13
S320 (LHD) Near T/O for 100 way
Connector
8
S320 (RHD) Near Passenger Airbag T/O 9
S330 (LHD) In T/O for Fuse Block 8
S330 (RHD) Near Passenger Airbag T/O 9
S331 Near T/O for Airbag Control
Module
8, 9
S332 Near T/O for Cigar Lighter/
Accessory Relay
8, 9
S335 Near Left Rear Lamp
Assembly Connector
12
S400 Near T/O for Rear Window
Defogger Feed
N/S
S401 Near T/O for Rear Window
Defogger Feed
N/S
TJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 3
DESCRIPTION AND OPERATION (Continued)
F
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1
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8W - 95 - 4 8W - 95 SPLICE LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
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2
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TJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 5
DESCRIPTION AND OPERATION (Continued)
F
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3
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8W - 95 - 6 8W - 95 SPLICE LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
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4
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TJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 7
DESCRIPTION AND OPERATION (Continued)
F
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5
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W
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8W - 95 - 8 8W - 95 SPLICE LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
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6
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TJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 9
DESCRIPTION AND OPERATION (Continued)
F
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7
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W
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S
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R
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8W - 95 - 10 8W - 95 SPLICE LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
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8
D
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P
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W
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TJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 11
DESCRIPTION AND OPERATION (Continued)
F
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9
D
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P
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W
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8W - 95 - 12 8W - 95 SPLICE LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
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.
1
0
I
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s
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TJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 13
DESCRIPTION AND OPERATION (Continued)
F
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.
1
1
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s
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8W - 95 - 14 8W - 95 SPLICE LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
F
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1
2
B
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d
y
W
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S
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TJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 15
DESCRIPTION AND OPERATION (Continued)
F
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1
3
B
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y
W
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8W - 95 - 16 8W - 95 SPLICE LOCATIONS TJ
DESCRIPTION AND OPERATION (Continued)
ENGINE
TABLE OF CONTENTS
page page
2. 5L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4. 0L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.5L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . 2
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . 2
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . 5
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . 5
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PISTON AND CONNECTING ROD . . . . . . . . . . . . . 5
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROCKER ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC TAPPET. . . . . . . . . . . . . . . . . . . . . . . 7
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . 7
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 8
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . . . 8
SERVICE DIAGNOSIS—PERFORMANCE . . . . . . . 9
SERVICE DIAGNOSIS—MECHANICAL. . . . . . . . . 10
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . . 12
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 13
CYLINDER COMPRESSION PRESSURE TEST . . 13
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 14
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . 15
SERVICE PROCEDURES
VALVE TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PISTON—FITTING . . . . . . . . . . . . . . . . . . . . . . . . 16
PISTON RING—FITTING . . . . . . . . . . . . . . . . . . . 16
CONNECTING ROD BEARINGS—FITTING . . . . . 19
FITTING CRANKSHAFT MAIN BEARINGS . . . . . . 21
FORM-IN-PLACE GASKETS. . . . . . . . . . . . . . . . . 24
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . . 24
HONING CYLINDER BORES . . . . . . . . . . . . . . . . 25
MEASURING WITH PLASTIGAGE . . . . . . . . . . . . 25
REPAIR DAMAGED OR WORN THREADS. . . . . . 26
SERVICE ENGINE ASSEMBLY (SHORT
BLOCK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . . 27
ENGINE OIL SERVICE. . . . . . . . . . . . . . . . . . . . . 27
REMOVAL AND INSTALLATION
ENGINE MOUNTS—FRONT. . . . . . . . . . . . . . . . . 29
ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . . . 30
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 31
EXHAUST MANIFOLD—2.5L ENGINE . . . . . . . . . 34
INTAKE MANIFOLD—2.5L ENGINE . . . . . . . . . . . 34
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 36
ROCKER ARMS AND PUSH RODS . . . . . . . . . . . 36
VALVE SPRING AND SEAL . . . . . . . . . . . . . . . . . 37
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 38
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . . 40
VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . . 41
TIMING CASE COVER OIL SEAL . . . . . . . . . . . . . 41
TIMING CASE COVER. . . . . . . . . . . . . . . . . . . . . 42
TIMING CHAIN AND SPROCKETS. . . . . . . . . . . . 43
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CAMSHAFT PIN REPLACEMENT. . . . . . . . . . . . . 45
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . 47
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . 47
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
PISTON AND CONNECTING ROD . . . . . . . . . . . . 51
REAR MAIN OIL SEAL . . . . . . . . . . . . . . . . . . . . . 52
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 52
VALVE, GUIDE AND SEAL . . . . . . . . . . . . . . . . . . 53
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 54
CLEANING AND INSPECTION
ROCKER ARMS AND PUSH RODS . . . . . . . . . . . 55
TJ ENGINE 9 - 1
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . . 55
ENGINE CYLINDER HEAD. . . . . . . . . . . . . . . . . . 56
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 56
SPECIFICATIONS
ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . 57
SPECIFICATIONS—TORQUE. . . . . . . . . . . . . . . . 60
SPECIAL TOOLS
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION
DESCRIPTION
The 2.5 l i ter (150 CI D) four-cyl i nder engi ne i s an
i n-l i ne, l i ghtwei ght, overhead val ve engi ne.
Thi s engi ne i s desi gned for unl eaded fuel . The
engi ne cyl i nder head has dual quench-type combus-
ti on chambers that create turbul ence and fast burn-
i ng of the ai r/fuel mi xture. Thi s resul ts i n good fuel
economy.
The cyl i nders are numbered 1 through 4 from front
to rear. The fi ri ng order i s 1-3-4-2 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n fi ve mai n beari ngs and the camshaft rotates
wi thi n four beari ngs.
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.3 and No.4 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
• 1st Di gi t—The year (8 = 1998).
• 2nd & 3rd Di gi ts—The month (01 - 12).
• 4th & 5th Di gi ts—The engi ne type/fuel system/
compressi on rati o (HX = A 2.5 l i ter (150 CI D) 9.1:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
• 6th & 7th Di gi ts—The day of engi ne bui l d (01 -
31).
FOR EXAMPLE: Code * 801HX23 * i denti fi es a
2.5 l i ter (150 CI D) engi ne wi th a mul ti -poi nt fuel
i njecti on system, 9.1:1 compressi on rati o and bui l t on
January 23, 1998
LUBRICATION SYSTEM
DESCRIPTION
A gear—type posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng.
OPERATION
The pump draws oi l through the screen and i nl et
tube from the sump at the rear of the oi l pan. The oi l
i s dri ven between the dri ve and i dl er gears and
pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
Fig. 1 Engine Firing Order
Fig. 2 Build Date Code Location
1 – NO. 4 CYLINDER
2 – NO. 3 CYLINDER
3 – DAY
4 – MONTH
5 – YEAR
6 – MACHINED SURFACE
9 - 2 2. 5L ENGINE TJ
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan.
TJ 2. 5L ENGINE 9 - 3
DESCRIPTION AND OPERATION (Continued)
Oil Lubrication System—2.5L Engine
1 – CAM/CRANK MAIN GALLERY (5)
2 – TAPPET GALLERY
3 – TAPPET GALLERY
4 – CAMSHAFT BEARING
5 – NUMBER 1 CAMSHAFT BEARING JOURNAL
6 – CAMSHAFT SPROCKET
7 – TAPPET GALLERY
9 - 4 2. 5L ENGINE TJ
DESCRIPTION AND OPERATION (Continued)
CYLINDER BLOCK
DESCRIPTION
The cyl i nder bl ock i s a cast i ron i nl i ne four cyl i n-
der desi gn. The cyl i nder bl ock i s dri l l ed formi ng gal -
l eri es for both oi l and cool ant.
CYLINDER HEAD
DESCRIPTION
The cyl i nder head i s made of cast i ron contai ni ng
ei ght val ves made of chrome pl ated heat resi stant
steel , val ve stem seal s, spri ngs, retai ners and keep-
ers. The cyl i nder head, val ve seats and gui des can be
resurfaced for servi ce purposes.
The cyl i nder head uses dual quench-type desi gn
combusti on chambers whi ch cause turbul ence i n the
cyl i nders al l owi ng faster burni ng of the ai r/fuel mi x-
ture, resul ti ng i n better fuel economy.
The val ve gui des are i ntegral to the cyl i nder head,
They are not repl aceabl e. However, they are servi ce-
abl e.
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
PISTON AND CONNECTING ROD
DESCRIPTION
The pi stons are made of a hi gh strength al umi num
al l oy, the pi ston ski rts are coated wi th a sol i d l ubri -
cant (Mol ykote) to reduce fri cti on and provi de scuff
resi stance. The connecti ng rods are made of cast i ron.
Fig. 3 Cylinder Block—2.5L
1 – CYLINDER BLOCK
Fig. 4 Cylinder Head
1 – CYLINDER HEAD BOLTS
2 – CYLINDER HEAD GASKET
3 – CYLINDER HEAD
Fig. 5 Crankshaft—Typical
1 – MAIN BEARING JOURNALS
2 – COUNTER BALANCE WEIGHTS
TJ 2. 5L ENGINE 9 - 5
DESCRIPTION AND OPERATION (Continued)
CAMSHAFT
DESCRIPTION
The camshaft i s made of cast i ron wi th ei ght
machi ned l obes and four beari ng journal s.
OPERATION
When the camshaft rotates, the l obes actuate the
tappets and push rods forci ng upward on the rocker
arms whi ch appl i es downward force on the val ves.
ROCKER ARM
DESCRIPTION
The rocker arms are made of stamped steel and
have a operati onal rati o of 1.6:1.
OPERATION
When the push rods are forced upward by the cam-
shaft l obes the push rod presses upward on the
rocker arms, the rocker arms pi vot, forci ng down-
ward pressure on the val ves forci ng the val ves to
move downward and off from thei r seats.
VALVES
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Al l
val ves use three bead l ock keepers to retai n the val ve
spri ng and promote val ve rotati on (Fi g. 9).
Fig. 6 Piston and Connecting Rod Assembly
Fig. 7 Camshaft—Typical
1 – CAMSHAFT
2 – LOBES
3 – BEARING JOURNAL
Fig. 8 Rocker Arms—Typical
1 – CAPSCREWS
2 – BRIDGE
3 – PIVOT ASSEMBLY
4 – PUSH RODS
5 – ROCKER ARMS
9 - 6 2. 5L ENGINE TJ
DESCRIPTION AND OPERATION (Continued)
VALVE SPRING
DESCRIPTION
The val ve spri ngs are made of hi gh strength
chrome si l i con steel . The spri ngs are common for
both i ntake and exhaust val ves.
CYLINDER HEAD COVER
DESCRIPTION
The cyl i nder head cover i s made of di e cast al umi -
num and i ncorporates the Crankcase Venti l ati on
(CCV) Hoses and the oi l fi l l openi ng.
HYDRAULIC TAPPET
DESCRIPTION
Val ve l ash i s control l ed by hydraul i c tappets
l ocated i nsi de the cyl i nder bl ock, i n tappet bores
above the camshaft.
OIL PAN
DESCRIPTION
The oi l pan i s made of stamped steel . The oi l pan
gasket i s a one pi ece steel backbone si l i cone coated
gasket.
VALVE STEM SEAL
DESCRIPTION
The val ve stem seal s are made of rubber and i ncor-
porate a garter spri ng to mai ntai n consi stent l ubri ca-
ti on control (Fi g. 9).
Fig. 9 Valve and Keeper Configuration 2.5L Engine
1 – VALVE LOCKS (3–BEAD)
2 – RETAINER
3 – VALVE STEM OIL SEAL
4 – INTAKE VALVE
5 – EXHAUST VALVE
6 – VALVE SPRING
Fig. 10 Cylinder Head Cover
1 – AIR INLET FITTING
2 – CYLINDER HEAD COVER
3 – FIXED ORIFICE FITTING
Fig. 11 Oil Pan
1 – OIL PAN
2 – OIL PAN DRAIN PLUG
TJ 2. 5L ENGINE 9 - 7
DESCRIPTION AND OPERATION (Continued)
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s made of cast al umi num and
uses seven bol ts to mount to the cyl i nder head. Thi s
mounti ng styl e i mproves seal i ng and reduces the
chance of l eaks.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol d i s l og styl e and i s made of
hi gh si l i con mol ybdenum cast i ron. The exhaust man-
i fol d shares a common gasket wi th the i ntake mani -
fol d. The exhaust mani fol d al so i ncorporates a bal l
fl ange outl et for i mproved seal i ng and strai n free
connecti ons (Fi g. 12).
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS— INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
Refer to the Servi ce Di agnosi s—Performance chart
and the Servi ce Di agnosi s—Mechani cal chart for pos-
si bl e causes and correcti ons of mal functi ons. Refer to
Group 14, Fuel System for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
• Cyl i nder Compressi on Pressure Test.
• Cyl i nder Combusti on Pressure Leakage Test.
• Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s.
• I ntake Mani fol d Leakage Di agnosi s.
Fig. 12 Intake and Exhaust Manifold
9 - 8 2. 5L ENGINE TJ
DESCRIPTION AND OPERATION (Continued)
SERVICE DIAGNOSIS— PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to
Group 8A, Battery, for correct
procedures. Check charging system.
Refer to Group 8C, Charging
Systems, for correct procedures.
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to
Group 8B, Starting Systems, for
correct diagnostics/procedures
4. Siezed accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace siezed
component.
5. Engine internal mechanical
failure or hydro-static lock
5. Refer to Group 9, Engine, for
correct diagnostics/procedures
ENGINE CRANKS BUT WILL NOT
START
1. No spark 1. Check for spark. Refer to Group
8D, Ignition System, for correct
procedures.
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. Refer to Group
14, Fuel System, for correct
procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. Refer to Group 9,
Engine, for correct procedures.
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to group 8D, Ignition System
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer
to group 8D, Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
TJ 2. 5L ENGINE 9 - 9
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to Group 8D, ignition system)
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to Group 14 for
correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Worn or incorrectly gapped spark
plugs
3. Replace or clean and re-gap
spark plugs (Refer to group 8D,
Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed
5. Check for correct firing order or
replace spark plug cables. (Refer to
Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary
(Refer to group 8D, Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses. Replace if
necessary (Refer to Group 11,
Exhaust System & Intake Manifold)
8. EGR valve leaking or stuck open 8. Test and replace, if necessary
(Refer to group 25, Emission
Control Systems)
ENGINE MISSES ON
ACCELERATION
1. Worn or incorrectly gapped spark
plugs
1. Replace spark plugs or clean and
set gap. (Refer to group 8D, Ignition
System)
2. Spark plug cables defective or
crossed
2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(refer to group 8D, Ignition System)
SERVICE DIAGNOSIS— MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil
Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
9 - 10 2. 5L ENGINE TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces
9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive connecting rod
bearing clearance
Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive main bearing
clearance
4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
7. Loose flywheel or torque
converter
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
TJ 2. 5L ENGINE 9 - 11
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace worn gears or oil pump
assy
5. Thin or diluted oil 5. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged
8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or
cracked
9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets
1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded
plug. Replace cup style plug
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED
1. PCV System malfunction 1. Refer to group 25, Emission
Control System for correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
HYDRAULIC TAPPETS
LEAK-DOWN TEST
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 13).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
9 - 12 2. 5L ENGINE TJ
DIAGNOSIS AND TESTING (Continued)
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
CYLINDER COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sabl e the fuel system. (Refer to Group 14,
Fuel System for the correct procedure)
(5) Di sconnect the i gni ti on coi l .
(6) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(7) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
Refer to Engi ne Speci fi cati ons for the correct
engi ne compressi on pressures.
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS
A l eaki ng engi ne cyl i nder head gasket usual l y
resul ts i n l oss of power, l oss of cool ant and engi ne
mi sfi ri ng.
An engi ne cyl i nder head gasket l eak can be l ocated
between adjacent cyl i nders or between a cyl i nder and
the adjacent water jacket.
• An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders i s i ndi cated by a l oss of power
and/or engi ne mi sfi re.
• An engi ne cyl i nder head gasket l eaki ng between
a cyl i nder and an adjacent water jacket i s i ndi cated
by cool ant foami ng or overheati ng and l oss of cool ant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders; fol l ow the proce-
dures outl i ned i n Cyl i nder Compressi on Pressure
Fig. 13 Leak-Down Tester
1 – POINTER
2 – WEIGHTED ARM
3 – RAM
4 – CUP
5 – HANDLE
6 – PUSH ROD
TJ 2. 5L ENGINE 9 - 13
DIAGNOSIS AND TESTING (Continued)
Test. An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders wi l l resul t i n approxi matel y a
50-70% reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Remove the radi ator cap.
Start the engi ne and al l ow i t to warm up unti l the
engi ne thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
I f bubbl es are not vi si bl e, i nstal l a radi ator pres-
sure tester and pressuri ze the cool ant system.
I f a cyl i nder i s l eaki ng combusti on pressure i nto
the water jacket, the tester poi nter wi l l pul sate wi th
every combusti on stroke of the cyl i nder.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
• Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
• Leaks between adjacent cyl i nders or i nto water
jacket.
• Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(3) Remove the spark pl ugs.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turer’s i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturer’s i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to the Cyl i nder Combusti on Pressure Leak-
age Test Di agnosi s chart.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Remove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
ENGINE OIL LEAK INSPECTION
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
9 - 14 2. 5L ENGINE TJ
DIAGNOSIS AND TESTING (Continued)
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.
(4) If the oil leak source is not positively
identified at this time, proceed wi th the ai r l eak
detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(1) Di sconnect the battery.
(2) Rai se the vehi cl e.
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
ENGINE OIL PRESSURE
(1) Di sconnect connector and remove oi l pressure
sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292 or equi val ent. Start engi ne and record pres-
sure. Refer to Oi l Pressure i n Engi ne Speci fi cati ons
for the correct pressures.
SERVICE PROCEDURES
VALVE TIMING
• Di sconnect the spark pl ug wi res and remove the
spark pl ugs.
• Remove the engi ne cyl i nder head cover.
• Remove the capscrews, bri dge and pi vot assem-
bl y, and rocker arms from above the No.1 cyl i nder.
• Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
• Rotate the crankshaft unti l the No.4 pi ston i s at
top dead center (TDC) on the compressi on stroke.
• Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90°.
• I nstal l a di al i ndi cator on the end of the No.1
cyl i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
TJ 2. 5L ENGINE 9 - 15
DIAGNOSIS AND TESTING (Continued)
• Set the di al i ndi cator poi nter at zero.
• Set the di al i ndi cator poi nter at zero.
• Rotate the crankshaft cl ockwi se (vi ewed from
the front of the engi ne) unti l the di al i ndi cator
poi nter i ndi cates 0.305 mm (0.012 i nch) travel di s-
tance (l i ft).
• The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
• I f the ti mi ng notch i s more than 13 mm (1/2
i nch) away from the TDC mark i n ei ther di recti on,
the val ve ti mi ng i s i ncorrect.
• I f the val ve ti mi ng i s i ncorrect, the cause may be
a broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
PISTON— FITTING
BORE GAUGE METHOD
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm
(.0001 i n.) I NCREMENTS i s requi red. I f a bore
gauge i s not avai l abl e, do not use an i nsi de mi crome-
ter.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 15).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 14). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
PISTON RING— FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
Fig. 14 Moly Coated Piston
1 – MOLY COATED
2 – MOLY COATED
Fig. 15 Bore Gauge
1 – FRONT
2 – BORE GAUGE
3 – CYLINDER BORE
4 – 49.5 MM
(1–15/16 in)
9 - 16 2. 5L ENGINE TJ
SERVICE PROCEDURES (Continued)
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 16) (Fi g. 17). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 18).
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 19).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 20).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 20) (Fi g.
22).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Ring Gap Orientation
• Posi ti on the gaps on the pi ston as shown (Fi g.
23).
• Oi l spacer - Gap on center l i ne of pi ston ski rt.
PISTON SIZE CHART
CYLINDER BORE SIZE PISTON LETTER SIZE
98.438 - 98.448 mm
(3.8755 - 3.8759 in.)
A
98.448 - 98.458 mm
(3.8759 - 3.8763 in.)
B
98.458 - 98.468 mm
(3.8763 - 3.8767 in.)
C
98.468 - 98.478 mm
(3.8767 - 3.8771 in.)
D
98.478 - 98.488 mm
(3.8771 - 3.8775 in.)
E
98.488 - 98.498 mm
(3.8775 - 3.8779 in.)
F
Fig. 16 Piston Dimensions
Fig. 17 Ring Side Clearance Measurement
1 – FEELER GAUGE
RING SIDE CLEARANCE CHART
ITEM SPECIFICATION
Top Compression Ring 0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Second Compression
Ring
0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Oil Control Ring 0.06 - 0.21 mm
(0.0024 - 0.0083 in.)
TJ 2. 5L ENGINE 9 - 17
SERVICE PROCEDURES (Continued)
• Oi l rai l s - gap 180° apart on centerl i ne of pi ston
pi n bore.
• No. 2 Compressi on ri ng - Gap 180° from top oi l
rai l gap.
• No. 1 Compressi on ri ng - Gap 180° from No. 2
compressi on ri ng gap.
Fig. 18 Gap Measurement
1 – FEELER GAUGE
RING GAP MEASUREMENT CHART
ITEM SPECIFICATION
Top Compression Ring 0.229 - 0.610 mm
(0.0090 - 0.0240 in.)
Second Compression
Ring
0.483 - 0.965 mm
(0.0190 - 0.080 in.)
Oil Control Ring 0.254 - 1.500 mm
(0.010 - 0.060 in.)
Fig. 19 Top Compression ring identification
1 – TOP COMPRESSION RING
Fig. 20 Second Compression Ring Identification
1 – SECOND COMPRESSION RING
2 – CHAMFER
3 – ONE DOT
Fig. 21 Compression Ring Chamfer Location
1 – TOP COMPRESSION RING
2 – SECOND COMPRESSION RING
3 – PISTON
4 – CHAMFER
Fig. 22 Compression Ring Installation
1 – COMPRESSION RING
2 – RING EXPANDER RECOMMENDED
9 - 18 2. 5L ENGINE TJ
SERVICE PROCEDURES (Continued)
CONNECTING ROD BEARINGS— FITTING
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 24) (Fi g. 25). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 26). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
duri ng i nstal l ati on.
Fig. 23 Ring Gap Orientation
1 – TOP COMPRESSION RING
2 – BOTTOM COMPRESSION RING
3 – TOP OIL CONTROL RAIL
4 – OIL RAIL SPACER
5 – BOTTOM OIL CONTROL RAIL
6 – IMAGINARY LINE PARALLEL TO PISTON PIN
7 – IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
Fig. 24 Connecting Rod Bearing Inspection
1 – UPPER
2 – MATING EDGES
3 – GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 – WEAR PATTERN — ALWAYS GREATER ON UPPER
BEARING
5 – LOWER
Fig. 25 Locking Tab Inspection
1 – ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 26 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
TJ 2. 5L ENGINE 9 - 19
SERVICE PROCEDURES (Continued)
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
27). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 N·m (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to-journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 28). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance (refer to
Connecti ng Rod Beari ng Fi tti ng Chart).
Fig. 27 Rod and Piston Assembly Installation
Fig. 28 Measuring Bearing Clearance with
Plastigage
1 – PLASTIGAGE SCALE
2 – COMPRESSED PLASTIGAGE
9 - 20 2. 5L ENGINE TJ
SERVICE PROCEDURES (Continued)
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING CONNECTING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow 53.2257-53.2079 mm Yellow - Standard Yellow - Standard
(2.0955-2.0948 in.)
Orange 53.2079 - 53.1901 mm Yellow - Standard Blue - Undersize
(2.0948 - 2.0941 in.) 0.025 mm (0.001 in.)
0.0178 mm (0.0007 in.)
Undersize
Blue 53.1901 - 53.1724 mm Blue - Undersize Blue - Undersize
(2.0941 - 2.0934 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
0.0356 mm (0.0014 in.)
Undersize
Red 52.9717 - 52.9539 mm Red - Undersize Red - Undersize
(2.0855 - 2.0848 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
0.254 mm (0.010 in.)
Undersize
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 45 N·m (33 ft. l bs.) torque.
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 29).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 30). I n general the
l ower beari ng hal f wi l l have a heavi er wear pattern.
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 5 have an arrow to i ndi cate the for-
Fig. 29 Checking Connecting Rod Side Clearace—
Typical
TJ 2. 5L ENGINE 9 - 21
SERVICE PROCEDURES (Continued)
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark on the adjacent
cheek. The rear mai n journal , i s i denti fi ed by a col or-
coded pai nt mark on the crankshaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, pro-
ceed to Crankshaft Mai n Beari ng—I nstal l ati on.
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
N·m (80 ft. l bs.) torque.
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 31). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
Fig. 30 Main Bearing Wear Patterns
1 – UPPER INSERT
2 – NO WEAR IN THIS AREA
3 – LOW AREA IN BEARING LINING
4 – LOWER INSERT
BEARING INSERT PAIR CHART
INSERT CORRECT INCORRECT
UPPER STANDARD STANDARD
LOWER 0.025 mm
(0.001 in.)
UNDERSIZE
0.051 mm
(0.002 in.)
UNDERSIZE
Fig. 31 Measuring Bearing Clearance with
Plastigage
1 – PLASTIGAGE SCALE
2 – COMPRESSED PLASTIGAGE
9 - 22 2. 5L ENGINE TJ
SERVICE PROCEDURES (Continued)
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
ceed to Crankshaft Mai n Beari ng—I nstal l ati on.
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cated wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
I f journal s 1 through 5 di ameters are l ess than
63.4517 mm (2.4981 i nches), repl ace crankshaft or
gri nd crankshaft down to accept the appropri ate
undersi ze beari ng i nserts.
Once the proper cl earances have been obtai ned,
proceed to Crankshaft Mai n Beari ng—I nstal l ati on.
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock
(refer to Cyl i nder Bl ock - Di sassembl e).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90°
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
Once the proper cl earances have been obtai ned,
proceed to Crankshaft Mai n Beari ng—I nstal l ati on.
MAIN BEARING FITTING CHART
CRANKSHAFT JOURNALS CORRESPONDING CRANKSHAFT BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow
63.5025 - 63.4898 mm
Yellow - Standard Yellow - Standard
(2.5001 - 2.4996 in.)
Orange
63.4898 - 63.4771mm
Yellow - Standard
Blue- Undersize 0.025 mm
(0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue
63.4771 - 63.4644 mm
Blue- Undersize 0.025 mm
(0.001 in.)
Blue- Undersize 0.025 mm
(0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
Green
63.4644 - 63.4517 mm
Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize 0.051 mm
(0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
TJ 2. 5L ENGINE 9 - 23
SERVICE PROCEDURES (Continued)
CRANKSHAFT JOURNALS CORRESPONDING CRANKSHAFT BEARING INSERT
Red
63.2485 - 63.2358 mm
Red - Undersize 0.254 mm
(0.010 in.)
Red - Undersize 0.254 mm
(0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
FORM-IN-PLACE GASKETS
There are several pl aces where form-i n-pl ace gas-
kets are used on the engi ne. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when appl yi ng form-i n-pl ace gaskets.
Bead si ze, conti nui ty and l ocati on are of great i mpor-
tance. Too thi n a bead can resul t i n l eakage whi l e too
much can resul t i n spi l l -over. A conti nuous bead of
the proper wi dth i s essenti al to obtai n a l eak-free
joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne area (Mopar Si l i cone Rubber
Adhesi ve Seal ant and Mopar Gasket Maker). Each
have di fferent properti es and cannot be used i nter-
changeabl y.
MOPAR SILICONE RUBBER ADHESIVE SEALANT
Mopar Si l i cone Rubber Adhesi ve Seal ant, normal l y
bl ack i n col or, i s avai l abl e i n 3 ounce tubes. Moi sture
i n the ai r causes the seal ant materi al to cure. Thi s
materi al i s normal l y used on fl exi bl e metal fl anges.
I t has a shel f l i fe of a year and wi l l not properl y cure
i f over aged. Al ways i nspect the package for the expi -
rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normal l y red i n col or, i s
avai l abl e i n 6 cc tubes. Thi s anaerobi c type gasket
materi al cures i n the absence of ai r when squeezed
between smooth machi ned metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. DO NOT use
on fl exi bl e metal fl anges.
SURFACE PREPARATION
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et or other sui tabl e tool to break the seal
between the mati ng surfaces. A fl at gasket scraper
may al so be l i ghtl y tapped i nto the joi nt but care
must be taken not to damage the mati ng surfaces.
Scrape or wi re brush al l gasket surfaces to remove
al l l oose materi al . I nspect stamped parts to ensure
gasket rai l s are fl at. Fl atten rai l s wi th a hammer on
a fl at pl ate, i f requi red. Gasket surfaces must be free
of oi l and di rt. Make sure the ol d gasket materi al i s
removed from bl i nd attachi ng hol es.
GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care.
Mopar Si l i cone Rubber Adhesi ve Seal ant shoul d be
appl i ed i n a conti nuous bead approxi matel y 3 mm
(0.12 i nch) i n di ameter. Al l mounti ng hol es must be
ci rcl ed. For corner seal i ng, a 3 or 6 mm (1/8 or 1/4
i nch) drop i s pl aced i n the center of the gasket con-
tact area. Uncured seal ant may be removed wi th a
shop towel . Components shoul d be torqued i n pl ace
whi l e the seal ant i s sti l l wet to the touch (wi thi n 10
mi nutes). The use of a l ocati ng dowel i s recom-
mended duri ng assembl y to prevent smeari ng the
materi al off l ocati on.
Mopar Gasket Maker shoul d be appl i ed spari ngl y
to one gasket surface. The seal ant di ameter shoul d
be 1.00 mm (0.04 i nch) or l ess. Be certai n the mate-
ri al surrounds each mounti ng hol e. Excess materi al
can easi l y be wi ped off. Components shoul d be
torqued i n pl ace wi thi n 15 mi nutes. The use of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng the materi al off l ocati on.
ENGINE PERFORMANCE
I t i s i mportant that the vehi cl e i s operati ng to i ts
opti mum performance l evel to mai ntai n fuel economy
and the l owest emi ssi on l evel s. I f vehi cl e i s not oper-
ati ng to these standards, refer to Engi ne Di agnosi s
outl i ned i n thi s secti on. The fol l owi ng procedures can
assi st i n achi evi ng the proper engi ne di agnosi s.
(1) Test cranki ng amperage draw. Refer to El ectri -
cal Group 8B, Col d Cranki ng Test.
(2) Check i ntake mani fol d bol t torque; Refer to
Group 11, Exhaust System and I ntake Mani fol d.
(3) Perform cyl i nder compressi on test. Refer to
Cyl i nder Compressi on Pressure Test i n the Engi ne
Di agnosi s area of thi s secti on.
(4) Cl ean or repl ace spark pl ugs as necessary and
adjust gap as speci fi ed i n El ectri cal Group 8D.
Ti ghten to speci fi cati ons.
(5) Test resi stance of spark pl ug cabl es. Refer to
El ectri cal Group 8D, Spark Pl ug Cabl es.
(6) I nspect the pri mary wi res. Test coi l output vol t-
age and pri mary resi stance. Repl ace parts as neces-
sary. Refer to El ectri cal Group 8D, for speci fi cati ons.
(7) Test fuel pump for pressure. Refer to Group 14,
Fuel System Speci fi cati ons.
9 - 24 2. 5L ENGINE TJ
SERVICE PROCEDURES (Continued)
(8) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Lubri cati on and Mai ntenance, Group 0.
(9) I nspect crankcase venti l ati on system as out
l i ned i n Group 0, Lubri cati on and Mai ntenance. For
emi ssi on control s see Group 25, Emi ssi on Control s
for servi ce procedures.
(10) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823 equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round as wel l as removi ng l i ght
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). 20-60 strokes,
dependi ng on the bore condi ti on, wi l l be suffi ci ent to
provi de a sati sfactory surface. Usi ng honi ng oi l
C-3501-3880 or a l i ght honi ng oi l avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50° to 60°
for proper seati ng of ri ngs (Fi g. 32).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50° to 60°
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
MEASURING WITH PLASTIGAGE
CRANKSHAFT MAIN BEARING CLEARANCE
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage, or equi val ent. The fol l ow-
i ng i s the recommended procedures for the use of
Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) The total cl earance of the mai n beari ngs can
onl y be determi ned by removi ng the wei ght of the
crankshaft. Thi s can be accompl i shed by ei ther of two
methods:
METHOD - 1 (PREFERRED)
Shi m the beari ngs adjacent to the beari ng to be
checked. Thi s wi l l remove the cl earance between
upper beari ng shel l and the crankshaft. Pl ace a mi n-
i mum of 0.254 mm (0.010 i nch) shi m between the
beari ng shel l and the adjacent beari ng cap. Ti ghten
the bol ts to 18 N·m (13 ft. l bs.) torque.
• ALL ENGINES —When checki ng No.1 mai n
beari ng; shi m No.2 mai n beari ng.
• ALL ENGINES —When checki ng No.2 mai n
beari ng; shi m No.1 and No.3 mai n beari ng.
• ALL ENGINES —When checki ng No.3 mai n
beari ng; shi m No.2 and No.4 mai n beari ng.
• ALL ENGINES —When checki ng No.4 mai n
beari ng; shi m No.3 and No.5 mai n beari ng.
• 2.5L ENGINE —When checki ng No.5 mai n
beari ng; shi m No.4 mai n beari ng.
• 4.0L ENGINE —When checki ng No.5 mai n
beari ng; shi m No.4 and No.6 mai n beari ng.
• 4.0L ENGINE —When checki ng No.6 mai n
beari ng; shi m No.5 and No.7 mai n beari ng.
• 4.0L ENGINE —When checki ng No.7 mai n
beari ng; shi m No.6 mai n beari ng.
Fig. 32 Cylinder Bore Crosshatch Pattern
1 – CROSSHATCH PATTERN
2 – INTERSECT ANGLE
TJ 2. 5L ENGINE 9 - 25
SERVICE PROCEDURES (Continued)
NOTE: Remove all shims before assembling
engine.
METHOD - 2 (ALTERNATIVE)
The wei ght of the crankshaft i s supported by a jack
under the counterwei ght adjacent to the beari ng
bei ng checked.
(1) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 33). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n
that area. Ti ghten the beari ng cap bol ts of the bear-
i ng bei ng checked to requi red torque. (Refer to the
torque speci fi cati ons at the rear of the engi ne’s sec-
ti on). DO NOT rotate the crankshaft or the Plas-
tigage may be smeared, giving inaccurate
results.
(2) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 34). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(3) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
CONNECTING ROD BEARING CLEARANCE
Engi ne connecti ng rod beari ng cl earances can be
determi ned by use of Pl asti gage, or equi val ent. The
fol l owi ng i s the recommended procedures for the use
of Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 33). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n the
suspect area.
(3) The crankshaft must be turned unti l the con-
necti ng rod to be checked starts movi ng toward the
top of the engi ne. Onl y then shoul d the rod cap wi th
Pl asti gage i n pl ace be assembl ed. Ti ghten the rod cap
nuts to requi red torque. (Refer to the torque speci fi -
cati ons at the rear of the engi ne’s secti on). DO NOT
rotate the crankshaft or the Plastigage may be
smeared, giving inaccurate results.
(4) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 34). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(5) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
• Dri l l i ng out worn or damaged threads.
• Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
• I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A servi ce repl acement engi ne assembl y (short
bl ock) may be i nstal l ed whenever the ori gi nal cyl i n-
der bl ock i s defecti ve or damaged beyond repai r. I t
Fig. 33 Placement of Plastigage in Bearing Shell
1 – PLASTIGAGE
Fig. 34 Clearance Measurement
9 - 26 2. 5L ENGINE TJ
SERVICE PROCEDURES (Continued)
consi sts of the cyl i nder bl ock, crankshaft, pi ston and
rod assembl i es. I f needed, the camshaft must be pro-
cured separatel y and i nstal l ed before the engi ne i s
i nstal l ed i n the vehi cl e.
A short bl ock i s i denti fi ed wi th the l etter “S”
stamped on the same machi ned surface where the
bui l d date code i s stamped for compl ete engi ne
assembl i es.
I nstal l ati on i ncl udes the transfer of components
from the defecti ve or damaged ori gi nal engi ne. Fol -
l ow the appropri ate procedures for cl eani ng, i nspec-
ti on and torque ti ghteni ng.
HYDROSTATIC LOCK
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(refer to Group 14, Fuel System).
(2) Di sconnect the negati ve cabl e from the battery.
(3) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the pl ugs from the
engi ne.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (i .e. cool ant,
fuel , oi l , etc.).
(7) Make sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt engi ne oi l i nto the cyl i nders to l ubri cate
the wal l s. Thi s wi l l prevent damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 37 N·m (27 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
N·m (25 ft. l bs.) torque.
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l (refer to Group 0, Lubri ca-
ti on and Mai ntenance).
(15) Connect the negati ve cabl e to the battery.
(16) Start the engi ne and check for any l eaks.
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING 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 PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
I n gasol i ne engi nes. use an engi ne oi l that i s API
Servi ce Grade Certi fi ed (Fi g. 35).
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 35).
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 10W-30 speci fi es a mul ti pl e
vi scosi ty engi ne oi l .
When choosi ng an engi ne oi l , consi der the range of
temperatures the vehi cl e wi l l be operated i n before
the next oi l change. Sel ect an engi ne oi l that i s best
sui ted to your area’s parti cul ar ambi ent temperature
range and vari ati on (Fi g. 36).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
Fig. 35 Engine Oil Container Standard Notations
TJ 2. 5L ENGINE 9 - 27
SERVICE PROCEDURES (Continued)
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
The engi ne oi l l evel i ndi cator (Di psti ck) i s l ocated
at the ri ght rear of the 2.5L engi ne. I nspect engi ne
oi l l evel approxi matel y every 800 ki l ometers (500
mi l es). Unl ess the engi ne has exhi bi ted l oss of oi l
pressure, run the engi ne for about fi ve mi nutes
before checki ng oi l l evel . Checki ng engi ne oi l l evel on
a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck (Fi g. 37).
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, note oi l l evel readi ng (Fi g. 37).
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Al l Jeep engi nes are equi pped wi th a hi gh qual i ty
ful l -fl ow, throw-away type oi l fi l ter. Chrysl er Corpo-
rati on recommends a Mopar or equi val ent oi l fi l ter be
used.
OIL FILTER REMOVAL
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss (Fi g. 38).
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
Fig. 36 Temperature/Engine Oil Viscosity
Fig. 37 Engine Oil Dipstick—2.5L Engine
1 – DIPSTICK
2 – SAFE
3 – ADD
9 - 28 2. 5L ENGINE TJ
SERVICE PROCEDURES (Continued)
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface (Fi g. 39) of oi l and gri me.
OIL FILTER INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 39) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
REMOVAL AND INSTALLATION
ENGINE MOUNTS— FRONT
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Support the engi ne.
(4) Remove through bol t nut (Fi g. 40) (Fi g. 41). DO
NOT remove the through bol t.
(5) Remove the retai ni ng bol ts and nuts from the
support cushi ons.
(6) Remove the through bol t.
(7) Remove the engi ne mount i nsul ator.
INSTALLATION
(1) I f the engi ne support bracket was removed,
posi ti on the bracket onto the bl ock and i nstal l the
attachi ng bol ts. Ti ghten the bol ts to 50 N·m (37 ft.
l bs.) and the nuts to 34 N·m (25 ft. l bs.) torque.
(2) Pl ace the i nsul ator on the support bracket.
I nstal l the i nsul ator retai ni ng bol ts and nuts.
Fig. 38 Oil Filter—2.5L Engine
1 – OIL FILTER
Fig. 39 Oil Filter Sealing Surface—Typical
1 – SEALING SURFACE
2 – RUBBER GASKET
3 – OIL FILTER
Fig. 40 Left Front Mount—2.5L Engine
1 – BOLT (2)
2 – LEFT HAND ENGINE MOUNT ASSEMBLY
3 – BOLT (3)
4 – NUT (2)
5 – THROUGH BOLT
6 – LOCKNUT
7 – STUD
TJ 2. 5L ENGINE 9 - 29
SERVICE PROCEDURES (Continued)
Ti ghten the bol ts and nuts to 40 N·m (30 ft. l bs.)
torque.
(3) I nstal l the through bol t and the retai ni ng nut.
Ti ghten the through bol t nut to 48 N·m (35 ft. l bs.)
torque.
(4) Remove the engi ne support.
(5) Lower the vehi cl e.
(6) Connect negati ve cabl e to battery.
ENGINE MOUNT— REAR
A resi l i ent rubber cushi on supports the transmi s-
si on at the rear between the transmi ssi on extensi on
housi ng and the rear support crossmember or ski d
pl ate.
REMOVAL
ALL TRANSMISSIONS
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the ski d pl ate (Fi g. 42) (Fi g. 43).
(4) Remove the ski d pl ate bol ts and the ski d pl ate.
MANUAL TRANSMISSIONS
(1) Remove nuts hol di ng support cushi on to trans-
mi ssi on support bracket.
(2) Remove the support cushi on.
(3) Remove bol ts hol di ng transmi ssi on support
bracket to transmi ssi on.
(4) Remove the transmi ssi on support bracket.
AUTOMATIC TRANSMISSIONS
(1) Remove nuts hol di ng support cushi on to trans-
mi ssi on support bracket (Fi g. 43). Remove the sup-
port cushi on.
(2) Remove the bol ts hol di ng the transmi ssi on sup-
port bracket to transmi ssi on.
(3) Remove the transmi ssi on support bracket.
INSTALLATION
MANUAL TRANSMISSION:
(1) Posi ti on the transmi ssi on mount bracket to the
transmi ssi on and i nstal l the bol ts (Fi g. 42).
(2) Ti ghten the bol ts to 54 N·m (40 ft. l bs.) torque.
(3) Posi ti on the support cushi on to the transmi s-
si on mount bracket and i nstal l nuts (Fi g. 42).
(4) Ti ghten the nuts to 41 N·m (30 ft. l bs.) torque.
AUTOMATIC TRANSMISSION:
(1) Posi ti on the transmi ssi on mount bracket to the
transmi ssi on and i nstal l the bol ts. Ti ghten the bol ts
to 54 N·m (40 ft. l bs.) torque.
Fig. 41 Right Front Mount—2.5L Engine
1 – RIGHT HAND ENGINE MOUNT ASSEMBLY
2 – STUD (2)
3 – THROUGH BOLT
4 – LOCKNUT (2)
5 – BOLT (2)
Fig. 42 Rear Mount (Manual Transmission)
1 – CUSHION
2 – BRACKET
3 – SKID PLATE
9 - 30 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(2) Posi ti on the support cushi on to the transmi s-
si on mount bracket and i nstal l nuts. Ti ghten the
nuts to 41 N·m (30 ft. l bs.) torque (Fi g. 43).
(3) I f the support cushi on bracket was removed
from the ski d pl ate, posi ti on the bracket on the ski d
pl ate and i nstal l the nuts and bol ts. Ti ghten the nuts
to 28 N·m (21 ft. l bs.) torque.
ALL TRANSMISSIONS
(1) Posi ti on the ski d pl ate to the studs of the sup-
port cushi on and i nstal l the nuts (Fi g. 42) (Fi g. 43).
Ti ghten the nuts to 28 N·m (21 ft. l bs.) torque.
(2) I nstal l the ski d pl ate bol ts to the si l l and
ti ghten to 75 N·m (55 ft. l bs.) torque.
(3) Remove the transmi ssi on support.
(4) Lower the vehi cl e.
(5) Connect negati ve cabl e to battery.
ENGINE ASSEMBLY
REMOVAL
(1) Pl ace a protecti ve cl oth over the wi ndshi el d
frame. Rai se the hood and rest i t on the wi ndshi el d
frame.
(2) Di sconnect the battery negati ve cabl e.
(3) Remove the ai r cl eaner resonator and rel ated
duct work. (Fi g. 44)
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(4) Remove the radi ator drai n cock and radi ator
cap to drai n the cool ant. DO NOT waste usabl e cool -
ant. I f the sol uti on i s cl ean, drai n the cool ant i nto a
cl ean contai ner for reuse. Cl ose drai n cock when
drai ni ng i s compl ete.
(5) Di scharge A/C system and di sconnect compres-
sor sucti on/di scharge hose assembl y (i f A/C
equi pped). Refer to Group 24, Heati ng and Ai r Con-
di ti oni ng for correct procedures.
(6) Remove upper radi ator hose.
(7) Remove the vi scous fan/dri ve assembl y.
(8) Remove accessory dri ve bel t. (Refer to Group 7,
Cool i ng for the correct procedures.)
(9) Di sconnect the transmi ssi on cool er l i nes (i f
equi pped) from the radi ator.
(10) Di sconnect l ower radi ator hose at radi ator.
(11) Remove the fan shroud screws.
(12) Remove the radi ator attachi ng bol ts.
(13) Remove the radi ator and fan shroud.
(14) Di sconnect the wi res at the starter motor sol e-
noi d.
(15) Di sconnect the wi re connectors from the gen-
erator. Secure the harness out of the way.
(16) I f equi pped wi th A/C, di sconnect the compres-
sor cl utch connector and the A/C hi -pressure swi tch
connector.
(17) Di sconnect the i gni ti on coi l and di stri butor
wi re connectors.
(18) Di sconnect the oi l pressure sender wi re con-
nector.
(19) Di sconnect harness ground at the engi ne oi l
di psti ck tube mounti ng stud. Secure the harness out
of the way.
(20) Di sconnect the heater hoses from the thermo-
stat housi ng and water pump i nl et tube.
(21) Di sconnect CCV hoses from the cyl i nder head
cover and i ntake mani fol d (Fi g. 44).
(22) Di sconnect the accel erator, transmi ssi on l i ne
pressure (i f equi pped), and speed control (i f equi pped)
cabl es from the throttl e body.
(23) Remove cabl e(s) from the bracket and secure
out of the way.
(24) Di sconnect the body ground at the engi ne.
(25) Di sconnect the fol l owi ng connectors and
secure thei r harness out of the way:
• Power steeri ng pressure swi tch (i f equi pped)
• Cool ant temperature sensor at the thermostat
housi ng
• Four (4) fuel i njector connectors
• I ntake ai r temperature sensor
• I dl e ai r control motor
Fig. 43 Rear Mount (AutomaticTransmission)
1 – BRACKET
2 – CUSHION
3 – BRACKET
TJ 2. 5L ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)
• Throttl e posi ti on sensor
• MAP sensor
• Crankshaft posi ti on sensor
• Oxygen sensor
(26) Di sconnect the CCV, hvac suppl y, brake
booster suppl y, and cani ster purge hoses from the
i ntake mani fol d.
(27) Rel i eve fuel pressure. (Refer to Group 14, Fuel
Pressure Rel ease Procedure for correct procedure)
(28) Di sconnect the fuel suppl y l i ne at the fuel
rai l . (Refer to Group 14, Qui ck Connect Fi tti ngs for
correct procedure)
(29) I f equi pped wi th power steeri ng:
(a) Di sconnect the hoses from the fi tti ngs at the
steeri ng gear.
(b) Drai n the pump reservoi r.
(c) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn objects from enteri ng the
system.
(30) Li ft the vehi cl e and support i t wi th support
stands.
(31) Remove the oi l fi l ter.
(32) Remove the starter motor.
(33) Remove the engi ne support cushi on-to-bracket
through bol ts.
(34) Di sconnect the exhaust pi pe from the mani -
fol d.
Manual Transmission models: (Fi g. 46)
(35) Remove two (2) cl utch housi ng i nspecti on
cover bol ts and the two (2) cl utch housi ng i nspecti on
cover bol ts/nuts.
(36) Remove shi el d.
(37) Remove si x (6) cl utch housi ng to engi ne bl ock
bol ts.
Proceed to step Step 41
Automatic Transmission models: (Fi g. 45)
(38) Remove two (2) torque converter housi ng
i nspecti on cover bol ts and the two (2) torque conver-
tor housi ng i nspecti on cover bol ts/nuts.
(39) Remove four (4) torque converter to fl expl ate
bol ts.
(40) Remove si x (6) transmi ssi on to engi ne bl ock
bol ts.
(41) Drai n the engi ne oi l .
(42) Lower the vehi cl e.
(43) Attach a l i fti ng devi ce to the engi ne.
(44) Rai se the engi ne off the front supports.
(45) Pl ace a fl oor jack or support stand under the
fl ywheel /converter housi ng.
(46) Separate the engi ne from the transmi ssi on,
l i ft the engi ne out of the engi ne compartment and
i nstal l on an engi ne stand.
(47) I nstal l the oi l fi l ter to keep forei gn materi al
out of the engi ne.
INSTALLATION
(1) Remove the oi l fi l ter.
Fig. 44 Air Cleaner Resonator and Duct Work
1 – AIR TUBE
2 – CCV TUBE
3 – AIR INLET FITTING
4 – CCV TUBE
5 – FIXED ORIFICE FITTING
Fig. 45 Automatic Transmission to Engine—2.5L
1 – TORQUE CONVERTER
2 – TORQUE CONVERTER HOUSING
3 – COVER
4 – FLEXPLATE
9 - 32 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(2) Li ft the engi ne off the stand and l ower i t i nto
the engi ne compartment. For easi er i nstal l ati on, i t
may be useful to remove the engi ne support cushi ons
from the engi ne support brackets as an ai de for
al i gnment of the engi ne-to-transmi ssi on.
Manual Transmission models: (Fig. 46)
(3) Lower engi ne i nto compartment.
(4) I nsert the transmi ssi on shaft i nto the cl utch
spl i ne.
(5) Al i gn the fl ywheel housi ng wi th the engi ne.
(6) I nstal l and ti ghten the fl ywheel housi ng bol ts
to 38 N·m (28 ft. l bs.).
Proceed to Step 10
Automatic Transmission models: (Fig. 45)
(7) Al i gn converter housi ng wi th engi ne.
(8) I nstal l and ti ghten the converter housi ng bol ts
to 38 N·m (28 ft. l bs.).
(9) I nstal l and ti ghten the torque converter to fl ex-
pl ate bol ts to 68 N·m (50 ft. l bs.).
(10) Remove the fl oorjack or support stand from
beneath the fl ywheel /converter housi ng.
(11) Lower the engi ne and engi ne support cushi ons
onto the engi ne compartment brackets. Ensure that
the bol t hol es are al i gned. I nstal l the thru-bol ts and
nuts and ti ghten to 81 N·m (60 ft. l bs.).
(12) Remove the engi ne l i fti ng devi ce.
(13) Rai se the vehi cl e.
(14) I nstal l i nspecti on cover and ti ghten bol ts/nuts
to 16 N·m (138 i n. l bs.)
(15) Attach the exhaust pi pe to the mani fol d.
I nstal l and ti ghten the nuts to 31 N·m (23 ft. l bs.)
torque.
(16) I nstal l the starter motor and bol ts. Ti ghten
the bol ts to 45 N·m (33 ft. l bs.).
(17) I nstal l the oi l fi l ter.
(18) Lower the vehi cl e.
(19) I f equi pped wi th power steeri ng:
(a) Remove the protecti ve caps
(b) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 N·m (38 ft. l bs.)
torque.
(c) Fi l l the pump reservoi r wi th fl ui d.
(20) I nspect the fuel suppl y l i ne o-ri ngs and
repl ace i f necessary. I nstal l fuel suppl y l i ne to fuel
rai l . Push unti l a “cl i ck” i s heard. Veri fy the connec-
ti on by pul l i ng outward on l i ne. I nstal l l atch cl i p.
(21) Attach fuel suppl y l i ne bracket to i ntake man-
i fol d.
(22) Connect the brake booster, hvac, cani ster
purge, and CCV vacuum hoses to the i ntake mani -
fol d.
(23) Connect the fol l owi ng el ectri cal connectors:
• Power steeri ng pressure swi tch (i f equi pped)
• Cool ant temperature sensor at the thermostat
housi ng
• Four (4) fuel i njector connectors
• I ntake ai r temperature sensor
• I dl e ai r control motor
• Throttl e posi ti on sensor
• MAP sensor
• Crankshaft posi ti on sensor
• Oxygen sensor
(24) I nstal l the engi ne ground strap.
(25) Connect heater hoses to thermostat housi ng
and water pump i nl et tube.
(26) Connect accel erator cabl e, transmi ssi on l i ne
pressure cabl e (i f equi pped), and speed control cabl e
(i f equi pped) to bracket and throttl e body.
(27) I nstal l the fan shroud and radi ator. Ti ghten
fan shroud and radi ator fasteners to 8 N·m (75 i n.
l bs.).
(28) Connect transmi ssi on cool er l i nes (i f
equi pped). Ti ghten fi tti ngs to 15 N·m (135 i n. l bs.).
(29) I nstal l the vi scous fan/dri ve assembl y. Ti ghten
nuts to 27 N·m (20 ft. l bs.)
(30) I nstal l and tensi on the accessory dri ve bel t.
Refer to Group 7, Cool i ng System for correct proce-
dure/speci fi cati ons.
(31) I nstal l the radi ator hoses.
(32) Connect the fol l owi ng el ectri cal connectors:
• I gni ti on coi l
• Di stri butor
• Starter motor
• A/C compressor cl utch (i f equi pped)
• A/C Hi -pressure swi tch (i f equi pped)
• Generator
• Oi l pressure sender
• Harness ground at di psti ck tube bracket
Fig. 46 Manual Transmission to Engine—2.5L
1 – FLYWHEEL/CLUTCH
2 – CLUTCH HOUSING
3 – COVER
TJ 2. 5L ENGINE 9 - 33
REMOVAL AND INSTALLATION (Continued)
(33) Remove the cool ant temperature sendi ng uni t
to permi t ai r to escape from the bl ock. Fi l l the cool -
i ng system wi th cool ant. I nstal l the cool ant tempera-
ture sendi ng uni t when the system i s fi l l ed.
(34) Connect A/C sucti on/di scharge hose and
recharge A/C system. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for correct procedures.
(35) I nstal l ai r cl eaner resonator and duct work.
(36) Lower the hood and secure i n pl ace.
(37) Start the engi ne and i nspect for l eaks.
(38) Stop the engi ne and check al l fl ui d l evel s. Add
fl ui d, as requi red.
EXHAUST MANIFOLD— 2. 5L ENGINE
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Rai se the vehi cl e.
(3) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d.
(4) Lower the vehi cl e.
(5) Remove the i ntake mani fol d. (Refer to proce-
dure i n thi s secti on).
(6) Remove fasteners 2 through 5 and remove the
i ntake mani fol d (Fi g. 47).
(7) Remove fasteners 1, 6 and 7 and remove the
engi ne exhaust mani fol d (Fi g. 47).
INSTALLATION
(1) Cl ean the i ntake and engi ne exhaust mani fol ds
and cyl i nder head mati ng surfaces. DO NOT allow
foreign material to enter either the intake man-
ifold or the ports in the cylinder head.
(2) I nstal l a new i ntake mani fol d gasket over the
al i gnment dowel s on the cyl i nder head.
(3) I nstal l the engi ne exhaust mani fol d assembl y.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 47).
(4) Ti ghten bol t No. 1 to 41 N·m (30 ft. l bs.) torque
(Fi g. 47).
(5) I nstal l the i ntake mani fol d on the cyl i nder
head dowel s (Fi g. 47).
(6) I nstal l bol ts 2 through 5 (Fi g. 47). Ti ghten
these bol ts to 31 N·m (23 ft. l bs.) torque.
(7) I nstal l new engi ne exhaust mani fol d spacers
over the engi ne exhaust mani fol d mounti ng studs i n
the cyl i nder head (Fi g. 47).
(8) Ti ghten nuts 6 and 7 to 14 N·m (126 i n. l bs.)
torque (Fi g. 47).
(9) I nstal l al l components to the i ntake mani fol d.
(10) Rai se the vehi cl e.
(11) Connect the exhaust pi pe to the engi ne
exhaust mani fol d. Ti ghten the bol ts to 31 N·m (23 ft.
l bs.) torque.
(12) Lower the vehi cl e.
(13) Connect the battery negati ve cabl e.
(14) Start the engi ne and check for l eaks.
INTAKE MANIFOLD— 2. 5L ENGINE
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Remove the ai r i nl et hose and resonator from
the throttl e body and ai r cl eaner housi ng (Fi g. 48).
(3) Loosen the accessory dri ve bel t tensi on and
remove the bel t from the power steeri ng pump.
(Refer to Group 7, Cool i ng for correct procedure).
(4) Remove the power steeri ng pump and brackets
from the water pump and i ntake mani fol d. Support
power steeri ng pump and bracket wi th mechani cs
wi re attached to the radi ator upper crossmember.
(5) Perform the fuel pressure rel ease procedure.
(Refer to Group 14, Fuel System for correct proce-
dure)
(6) Di sconnect fuel suppl y tube from the fuel rai l .
(Refer to Group 14, Fuel System - Qui ck Connect Fi t-
ti ngs)
(7) Di sconnect the accel erator cabl e from the throt-
tl e body and cabl e bracket.
(8) Di sconnect the speed control and transmi ssi on
l i ne pressure cabl e from the throttl e body and cabl e
bracket (i f equi pped).
CAUTION: When disconnecting the speed control
connector at the throttle body, DO NOT pry the con-
nector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.
(9) Di sconnect the el ectri cal connectors. Pul l the
harnesses away from the mani fol d.
• The throttl e posi ti on sensor.
• The i dl e ai r control motor.
• The cool ant temperature sensor at the thermo-
stat housi ng.
Fig. 47 Intake/Engine Exhaust Manifold
Installation—2.5L Engine
9 - 34 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
• The mani fol d ai r temperature sensor at the
i ntake mani fol d.
• The fuel i njectors.
• The oxygen sensor.
(10) Di sconnect the crankcase venti l ati on (CCV)
vacuum hose and mani fol d absol ute pressure (MAP)
sensor vacuum hose connector at the i ntake mani -
fol d.
(11) Di sconnect HVAC suppl y vacuum hose from
i ntake mani fol d.
(12) Di sconnect CCV hose at the cyl i nder head
cover (Fi g. 48).
(13) Remove the mol ded vacuum harness.
(14) Di sconnect the vacuum brake booster hose at
the i ntake mani fol d.
(15) Remove bol ts 2 through 5 securi ng the i ntake
mani fol d to the cyl i nder head (Fi g. 49). LOOSEN
BUT DO NOT REMOVE exhaust mani fol d bol t No. 1
and nuts 6 and 7.
(16) Remove the i ntake mani fol d and gaskets.
Drai n the cool ant from the mani fol d.
INSTALLATION
(1) Cl ean the i ntake mani fol d and cyl i nder head
mati ng surfaces. DO NOT allow foreign material
to enter either the intake manifold or the ports
in the cylinder head.
(2) I nstal l the new i ntake mani fol d gasket over the
l ocati ng dowel s.
(3) Posi ti on the mani fol d i n pl ace and fi nger
ti ghten the mounti ng bol ts.
(4) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 49).
• Fastener No. 1—Ti ghten to 41 N·m (30 ft. l bs.)
torque.
• Fasteners Nos. 2 through 5—Ti ghten to 31 N·m
(23 ft. l bs.) torque.
• Fasteners Nos. 6 and 7—Ti ghten to 23 N·m (17
ft. l bs.) torque.
(5) Before connecting the fuel line to the fuel
rail inspect the fuel line O-rings and replace
them if necessary. Connect the fuel suppl y tube to
the fuel rai l i nl et. Push tube unti l a cl i ck i s heard.
(6) Pul l out on fuel suppl y l i ne to veri fy that i t i s
properl y connected. I nstal l l atch cl i p.
(7) Connect the mol ded vacuum hoses to the vac-
uum port on the i ntake mani fol d and the cyl i nder
head cover.
(8) Connect the el ectri cal connectors.
• The throttl e posi ti on sensor.
• The i dl e ai r control motor.
• The cool ant temperature sensor at the thermo-
stat housi ng.
• The mani fol d ai r temperature sensor at the
i ntake mani fol d.
• The fuel i njectors.
• The oxygen sensor.
(9) Connect the brake booster vacuum suppl y hose.
(10) Connect the CCV hose and MAP sensor vac-
uum hose connectors to the throttl e body.
(11) I nstal l the power steeri ng pump and bracket
assembl y to the water pump and i ntake mani fol d.
Torque power steeri ng pump bol ts to 28 N·m (21 ft.
l bs.). Torque bracket to water pump bol ts to 47 N·m
(35 ft. l bs.).
Fig. 48 Air Inlet/CCV System—2.5L Engine
1 – AIR TUBE
2 – CCV TUBE
3 – AIR INLET FITTING
4 – CCV TUBE
5 – FIXED ORIFICE FITTING
Fig. 49 Intake/Exhaust Manifold—2.5L Engine
TJ 2. 5L ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)
CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the
water pump to turn in the opposite direction result-
ing in engine overheating. Refer to Group 7, Cool-
ing System for the proper procedure.
(12) I nstal l and tensi on the accessory dri ve bel t.
(Refer to Group 7, Cool i ng System for the correct pro-
cedure)
(13) Connect the accel erator cabl e to the bracket
and the throttl e l ever.
(14) Connect the speed control and transmi ssi on
l i ne pressure cabl e (i f equi pped) to the bracket and
throttl e l ever.
(15) I nstal l the ai r i nl et hose and resonator to the
throttl e body and the ai r cl eaner.
(16) Connect the battery negati ve cabl e.
(17) Start the engi ne and check for l eaks.
CYLINDER HEAD COVER
A cured gasket i s part of the engi ne cyl i nder head
cover.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover (Fi g.
50).
(3) Remove the ai r i nl et hose and resonator from
the ai r cl eaner and throttl e body.
(4) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(5) Remove the engi ne cyl i nder head cover (Fi g.
50).
(6) Remove any ori gi nal seal er from the cover seal -
i ng surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
(7) Remove al l resi due from the seal i ng surface
usi ng a cl ean, dry cl oth.
INSTALLATION
(1) I nspect the engi ne cyl i nder head cover for
cracks. Repl ace the cover, i f cracked.
NOTE: The original dark grey gasket material
should NOT be removed. If sections of the gasket
material are missing or are compressed, replace the
engine cylinder head cover. However, sections with
minor damage such as small cracks, cuts or chips
may be repaired with a hand held applicator. The
new material must be smoothed over to maintain
gasket height. Allow the gasket material to cure
prior to engine cylinder head cover installation.
(2) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet the oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(3) I nstal l engi ne cyl i nder head cover. Ti ghten the
mounti ng bol ts to 13 N·m (115 i n. l bs.) torque.
(4) Connect the CCV hoses (Fi g. 50).
(5) Connect negati ve cabl e to battery.
(6) I nstal l the ai r i nl et hose and resonator.
ROCKER ARMS AND PUSH RODS
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
(1) Remove the engi ne cyl i nder head cover. (Refer
to procedure i n thi s secti on)
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 51). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 51). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
(6) Cl ean al l the components wi th cl eani ng sol -
vent.
(7) Use compressed ai r to bl ow out the oi l passages
i n the rocker arms and push rods.
Fig. 50 Engine Cylinder Head Cover
1 – AIR INLET FITTING
2 – AIR FILTER COVER
3 – FIXED ORIFICE FITTING
9 - 36 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or equi v-
al ent, l ubri cate the area of the rocker arm that the
pi vot contacts. I nstal l rocker arms, pi vots and bri dge
above each cyl i nder i n thei r ori gi nal posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 N·m (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover.
VALVE SPRING AND SEAL
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(1) Remove the engi ne cyl i nder head cover. Refer
to procedure i n thi s secti on.
(2) Remove cap screws, bri dge and pi vot assem-
bl i es and rocker arms for access to each val ve spri ng
to be removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) I nstal l a 14 mm (1/2 i nch) (thread si ze) ai r hose
adaptor i n the spark pl ug hol e.
(7) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(8) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 52).
(9) Remove val ve spri ng and retai ner (Fi g. 52).
(10) Remove val ve stem oi l seal s (Fi g. 52). Note
the val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(i ntake/bl ack i n col or) or EXH (exhaust/brown i n
col or). DO NOT mi x the seal s.
INSTALLATION
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
Fig. 51 Rocker Arm Assembly
1 – CAPSCREWS
2 – BRIDGE
3 – PIVOT ASSEMBLY
4 – PUSH RODS
5 – ROCKER ARMS
TJ 2. 5L ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge cap screws al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
cap screws to 28 N·m (21 ft. l bs.) torque.
(9) I nstal l the engi ne cyl i nder head cover.
CYLINDER HEAD
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant and di sconnect the hoses at
the engi ne thermostat housi ng. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean and i s bei ng
drai ned onl y to servi ce the engi ne or cool i ng system,
drai n the cool ant i nto a cl ean contai ner for reuse.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the engi ne cyl i nder head cover. (Refer
to procedure i n thi s secti on)
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms (Fi g. 53).
(6) Remove the push rods (Fi g. 53). Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the accessory dri ve bel t at the power
steeri ng pump bracket, i f equi pped or at the i dl er
pul l ey bracket (refer to Group 7, Cool i ng System for
the proper procedure).
(8) I f equi pped wi th ai r condi ti oni ng, perform the
fol l owi ng:
(a) Remove the bol ts from the A/C compressor
mounti ng bracket and set the compressor asi de.
(b) Remove the ai r condi ti oner compressor
bracket bol ts from the engi ne cyl i nder head.
(c) Loosen the through bol t at the bottom of the
bracket.
(9) I f equi pped, di sconnect the power steeri ng
pump bracket. Set the pump and bracket asi de. DO
NOT di sconnect the hoses.
Fig. 52 Valve and Valve Components
1 – VALVE LOCKS (3–BEAD)
2 – RETAINER
3 – VALVE STEM OIL SEAL
4 – INTAKE VALVE
5 – EXHAUST VALVE
6 – VALVE SPRING
Fig. 53 Rocker Arm Assembly
1 – CAPSCREWS
2 – BRIDGE
3 – PIVOT ASSEMBLY
4 – PUSH RODS
5 – ROCKER ARMS
9 - 38 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(10) Perform fuel pressure rel ease procedure
(Refer to Group 14, fuel systems for proper proce-
dures).
(11) Remove the l atch cl i p and di sconnect the fuel
suppl y hose.
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head (refer to Group
11, Exhaust System and I ntake Mani fol d for the
proper procedures).
(13) Number and di sconnect the i gni ti on wi res and
remove the spark pl ugs.
(14) Di sconnect the cool ant temperature sendi ng
uni t connector.
(15) Remove the engi ne cyl i nder head bol ts.
(16) Remove the engi ne cyl i nder head and gasket
(Fi g. 54).
(17) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i sn’t known i f they were used before, di scard the
bol ts.
(18) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
NOTE: If valves, springs, or seals are to be inspect-
ed/replaced at this time, refer to Valves and Valve
Springs later in this section for proper inspection
procedures.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Fabri cate two engi ne cyl i nder head al i gnment
dowel s from used head bol ts (Fi g. 55). Use the l ong-
est head bol t. Cut the head of the bol t off bel ow the
hex head. Then cut a sl ot i n the top of the dowel to
al l ow easi er removal wi th a screwdri ver.
(2) I nstal l one dowel i n bol t hol e No.10 and the
other dowel i n bol t hol e No.8 (Fi g. 56).
(3) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(4) Pl ace the engi ne cyl i nder head gasket (wi th the
numbers faci ng up) over the dowel s.
(5) Pl ace the engi ne cyl i nder head over the dowel s.
Fig. 54 Engine Cylinder Head Assembly
1 – BRIDGE
2 – PIVOT ASM.
3 – ROCKER ARM
4 – CYLINDER HEAD
5 – HEAD GASKET
6 – PUSH ROD
Fig. 55 Fabricate Alignment Dowels
1 – USED CYLINDER HEAD BOLT
2 – SLOT
Fig. 56 Alignment Dowel Locations
1 – ALIGNMENT DOWEL
2 – ALIGNMENT DOWEL
TJ 2. 5L ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(6) Coat the threads of bol t No.7, onl y, wi th Locti te
PST seal ant or equi val ent.
(7) I nstal l al l head bol ts, except No.8 and No.10.
(8) Remove the dowel s.
(9) I nstal l No.8 and No.10 head bol ts.
CAUTION: During the final tightening sequence,
bolt No.7 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt No.7.
(10) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
57) :
(a) Ti ghten al l bol ts i n sequence (1 through 10)
to 30 N·m (22 ft. l bs.) torque.
(b) Ti ghten al l bol ts i n sequence (1 through 10)
to 61 N·m (45 ft. l bs.) torque.
(c) Check al l bol ts to veri fy they are set to 61
N·m (45 ft. l bs.) torque.
(d) Ti ghten bol ts (i n sequence):
• Bol ts 1 through 6 to 149 N·m (110 ft. l bs.)
torque.
• Bol t 7 to 136 N·m (100 ft. l bs.) torque.
• Bol ts 8 through 10 to 149 N·m (110 ft. l bs.)
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(11) Connect the cool ant temperature sendi ng uni t
connector.
(12) I nstal l the spark pl ugs and ti ghten to 37 N·m
(27 ft. l bs.) torque. Connect the i gni ti on wi res.
(13) I nstal l the i ntake and exhaust mani fol ds
(refer to Group 11, Exhaust System and I ntake Man-
i fol d for the proper procedures).
(14) I nstal l the fuel suppl y l i ne. Push unti l a
“cl i ck” i s heard. Rei nstal l l atch cl i p.
(15) I f equi pped, attach the power steeri ng pump
and bracket.
(16) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed.
(17) I nstal l the engi ne cyl i nder head cover.
(18) Attach the ai r condi ti oni ng compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
Ti ghten the bol ts to 40 N·m (30 ft. l bs.) torque.
(19) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 N·m (20 ft. l bs.)
torque.
CAUTION: The accessory drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(20) I nstal l the accessory dri ve bel t and correctl y
tensi on the bel t (refer to Group 7, Cool i ng System for
the proper procedure).
(21) I nstal l the ai r cl eaner assembl y.
(22) Connect the hoses to the thermostat housi ng
and fi l l the cool i ng system to the speci fi ed l evel (refer
to Group 7, Cool i ng Systems for the proper proce-
dure).
(23) I nstal l the cool ant temperature sendi ng uni t
connector.
(24) Connect negati ve cabl e to battery.
(25) Connect the upper radi ator hose and heater
hose at the thermostat housi ng.
(26) Fi l l the cool i ng system. Check for l eaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(27) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the thermostat opens. Add cool ant, i f requi red.
HYDRAULIC TAPPETS
REMOVAL
Retai n al l the components i n the same order as
removed.
(1) Remove the engi ne cyl i nder head cover (refer to
procedure earl i er i n thi s secti on)
(2) Remove the bri dge and pi vot assembl i es and
rocker arms by removi ng the capscrews at each
Fig. 57 Engine cylinder head Bolt Tightening
Sequence
9 - 40 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
bri dge. Al ternatel y l oosen each capscrew, one turn at
a ti me, to avoi d damagi ng the bri dges.
(3) Remove the push rods.
(4) Remove the tappets through the push rod open-
i ngs i n the cyl i nder head wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 58).
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(4) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(5) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 N·m (21 ft. l bs.) torque.
(6) I nstal l the engi ne cyl i nder head cover.
VIBRATION DAMPER
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the serpenti ne dri ve bel t and fan
shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 59).
INSTALLATION
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n posi ti on, al i gn the keyway on the
vi brati on damper hub wi th the crankshaft key and
tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 N·m
(80 ft. l bs.) torque.
(4) I nstal l the serpenti ne dri ve bel t and ti ghten to
the speci fi ed tensi on (refer to Group 7, Cool i ng Sys-
tems for the proper speci fi cati ons and procedures).
(5) Connect negati ve cabl e to battery.
TIMING CASE COVER OIL SEAL
REMOVAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the serpenti ne dri ve bel t.
(3) Remove the vi brati on damper.
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
Fig. 58 Hydraulic Valve Tappet Removal/Installation
Tool
1 – HYDRAULIC VALVE TAPPET REMOVAL/INSTALLATION TOOL
Fig. 59 Vibration Damper Removal Tool 7697
1 – VIBRATION DAMPER REMOVAL TOOL
2 – WRENCH
TJ 2. 5L ENGINE 9 - 41
REMOVAL AND INSTALLATION (Continued)
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 60). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
(4) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 N·m (80 ft. l bs.)
torque.
(5) I nstal l the serpenti ne bel t and ti ghten to the
speci fi ed tensi on (refer to Group 7, Cool i ng Systems
for the proper speci fi cati ons and procedures).
(6) I nstal l the radi ator shroud.
(7) Connect negati ve cabl e to battery.
TIMING CASE COVER
REMOVAL
(1) Di sconnect battery negati ve cabl e.
(2) Remove accessory dri ve bel t (Refer to Group
07, Cool i ng System for proper procedure)
(3) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(4) Remove the fan and hub assembl y and remove
the fan shroud.
(5) Remove the A/C compressor (i f equi pped) and
generator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the vi brati on damper (Fi g. 61).
(7) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(8) Remove the ti mi ng case cover and gasket from
the engi ne.
(9) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 61).
INSTALLATION
(1) Cl ean the ti mi ng case cover, oi l pan and cyl i n-
der bl ock gasket surfaces.
(2) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(3) Posi ti on the gasket on the cyl i nder bl ock.
(4) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(5) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 62).
(6) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
(7) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
N·m (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 N·m (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover bol ts to 9.5 N·m (84 i n.
l bs.) torque.
(8) Remove the cover al i gnment tool .
(9) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
(10) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper, washer and
bol t. Lubri cate and ti ghten the bol t to 108 N·m (80 ft.
l bs.) torque.
Fig. 60 Timing Case Cover Oil Seal Installation
1 – SEAL INSTALLATION TOOL
2 – DRAW SCREW TOOL
Fig. 61 Timing Case Cover Components
1 – TIMING CASE COVER
2 – OIL SLINGER
3 – CRANKSHAFT OIL SEAL
4 – VIBRATION DAMPER PULLEY
9 - 42 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(11) I nstal l the A/C compressor (i f equi pped) and
generator bracket assembl y.
(12) I nstal l the engi ne fan and hub assembl y and
shroud.
(13) I nstal l the accessory dri ve bel t and ti ghten to
obtai n the speci fi ed tensi on.
(14) Connect negati ve cabl e to battery.
TIMING CHAIN AND SPROCKETS
The chai n dri ve system i s equi pped wi th a ti mi ng
chai n tensi oner whi ch reduces noi se and prol ongs
ti mi ng chai n l i fe. I n addi ti on, i t compensates for
wear and temperature changes on the val ve trai n for
proper engi ne operati on.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the fan and shroud.
(3) Remove the serpenti ne dri ve bel t.
(4) Remove the crankshaft vi brati on damper.
(5) Remove the ti mi ng case cover.
(6) Rotate crankshaft unti l the “0” ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 63).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the camshaft retai ni ng bol t and
remove the sprockets and chai n as an assembl y (Fi g.
64).
(9) To repl ace the ti mi ng chai n tensi oner, the oi l
pan must be removed.
INSTALLATION
(1) Turn the tensi oner l ever to the unl ocked (down)
posi ti on (Fi g. 65).
(2) Pul l the tensi oner bl ock toward the tensi oner
l ever to compress the spri ng. Hol d the bl ock and turn
the tensi oner l ever to the l ock posi ti on (Fi g. 65).
(3) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n the crankshaft keyway, i nstal l the
crankshaft, camshaft sprockets and ti mi ng chai n.
Ensure the ti mi ng marks on the sprockets are prop-
erl y al i gned (Fi g. 63).
(4) I nstal l the camshaft sprocket retai ni ng bol t
and washer. Ti ghten the bol t to 108 N·m (80 ft. l bs.)
torque.
(5) Turn the chai n tensi oner l ever to the unl ocked
(down) posi ti on (Fi g. 65).
(6) I nstal l the oi l sl i nger.
(7) Repl ace the oi l seal i n the ti mi ng case cover.
Fig. 62 Timing Case Cover Alignment and Seal
Installation Tool 6139
1 – TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
Fig. 63 Crankshaft—Camshaft Alignment
1 – TIMING MARKS
Fig. 64 Camshaft and Crankshaft Sprockets and
Chain
1 – CAMSHAFT SPROCKET
2 – CRANKSHAFT SPROCKET
3 – CHAIN
TJ 2. 5L ENGINE 9 - 43
REMOVAL AND INSTALLATION (Continued)
(8) I nstal l the ti mi ng case cover and gasket.
(9) Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper, washer and
bol t. Lubri cate and ti ghten the bol t to 108 N·m (80 ft.
l bs.) torque.
(10) I nstal l the fan and shroud.
(11) Connect negati ve cabl e to battery.
CAMSHAFT
REMOVAL
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n the cool i ng system. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto a
cl ean contai ner for reuse.
(3) Remove the radi ator or radi ator and condenser,
i f equi pped wi th A/C.
(4) Scri be a mark on the di stri butor housi ng i n
l i ne wi th the l i p of the rotor.
(5) Scri be a mark on the di stri butor housi ng near
the cl amp and conti nue the scri be mark on the cyl i n-
der bl ock i n l i ne wi th the di stri butor mark.
(6) For ease of i nstal l ati on, note the posi ti on of the
rotor and di stri butor housi ng i n rel ati on to adjacent
engi ne components.
(7) Remove the di stri butor and i gni ti on wi res.
(8) Remove the engi ne cyl i nder head cover.
(9) Remove the rocker arms, bri dges and pi vots.
(10) Remove the push rods.
(11) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder head.
(12) Remove the vi brati on damper.
(13) Remove the ti mi ng case cover.
(14) Remove the ti mi ng chai n and sprockets.
(15) Remove the camshaft (Fi g. 66).
INSTALLATION
(1) I nspect the cam l obes for wear.
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the ti mi ng case cover, exami ne the oi l pres-
sure rel i ef hol es i n the rear cam journal . The oi l
pressure rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent.
(7) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs (Fi g. 66).
(8) Turn the tensi oner l ever to the unl ocked (down)
posi ti on (Fi g. 67).
(9) Pul l the tensi oner bl ock toward the tensi oner
l ever to compress the spri ng. Hol d the bl ock and turn
the tensi oner l ever to the l ock posi ti on (Fi g. 67).
(10) I nstal l the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned.
(11) I nstal l the camshaft sprocket retai ni ng bol t
and washer. Ti ghten the bol t to 108 N·m (80 ft. l bs.)
torque.
(12) Rel ease the ti mi ng chai n tensi oner by movi ng
the l ever to the unl ock posi ti on (Fi g. 67).
(13) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 68). Refer to Ti mi ng Case Cover
I nstal l ati on.
Fig. 65 Loading Timing Chain Tensioner
1 – LOCK
2 – UNLOCK
3 – TENSIONER BLOCK
4 – TENSIONER LEVER
Fig. 66 Camshaft
1 – CAMSHAFT
2 – CRANKSHAFT
9 - 44 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(14) I nstal l the vi brati on damper.
(15) I nstal l the hydraul i c val ve tappets.
(16) I nstal l the push rods.
(17) I nstal l the rocker arms, bri dges and pi vots.
(18) I nstal l the engi ne cyl i nder head cover.
(19) Posi ti on the oi l pump gear. Refer to Di stri bu-
tor i n the Component Removal /I nstal l ati on secti on of
Group 8D, I gni ti on Systems.
(20) I nstal l the di stri butor and i gni ti on wi res.
Refer to Di stri butor i n the Component Removal /I n-
stal l ati on secti on of Group 8D, I gni ti on Systems.
(21) I nstal l the radi ator or radi ator and condenser,
i f equi pped wi th A/C.
(22) Fi l l the cool i ng system.
(23) Connect negati ve cabl e to battery.
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n the radi ator. DO NOT waste reusabl e
cool ant. Drai n the cool ant i nto a cl ean contai ner.
(3) Remove the fan and shroud.
(4) Remove the accessory dri ve bel t.
(5) Di sconnect the radi ator overfl ow tube, radi ator
hoses, automati c transmi ssi on fl ui d cool er pi pes (i f
equi pped).
(6) Remove the radi ator.
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
(7) I f equi pped wi th ai r condi ti oni ng, Remove the
A/C condenser attachi ng bol ts and move the con-
denser and recei ver/dri er assembl y up and out of the
way.
(8) Remove the crankshaft vi brati on damper.
(9) Remove the ti mi ng case cover. Cl ean the gasket
materi al from the cover.
(10) Rotate crankshaft unti l the crankshaft
sprocket ti mi ng mark i s cl osest to and on the center
l i ne wi th the camshaft sprocket ti mi ng mark (Fi g.
69).
(11) Remove camshaft sprocket retai ni ng bol t.
(12) Remove the crankshaft oi l sl i nger.
(13) Remove the sprockets and chai n as an assem-
bl y (Fi g. 70).
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(14) I nspect the damaged camshaft pi n.
(15) I f the pi n i s a spri ng-type pi n, remove the bro-
ken pi n by i nserti ng a sel f-tappi ng screw i nto the pi n
and careful l y pul l i ng the pi n from the camshaft.
(16) I f the pi n i s a dowel -type pi n, center-punch i t.
Ensure the exact center i s l ocated when center-
punchi ng the pi n.
Fig. 67 Loading Timing Chain Tensioner
1 – LOCK
2 – UNLOCK
3 – TENSIONER BLOCK
4 – TENSIONER LEVER
Fig. 68 Timing Case Cover
1 – TIMING CASE COVER
2 – CAMSHAFT
3 – CRANKSHAFT
TJ 2. 5L ENGINE 9 - 45
REMOVAL AND INSTALLATION (Continued)
CAUTION: Cover the opened oil pan area to pre-
vent metal chips from entering the pan.
(17) Dri l l i nto the pi n center wi th a 4 mm (5/32
i nch) dri l l bi t.
(18) I nsert a sel f-tappi ng screw i nto the dri l l ed pi n
and careful l y pul l the pi n from the camshaft.
INSTALLATION
(1) Cl ean the camshaft pi n hol e.
(2) Compress the center of the repl acement spri ng
pi n wi th vi se gri ps.
(3) Careful l y dri ve the pi n i nto the camshaft pi n
hol e unti l i t i s seated.
(4) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n wi th the ti mi ng marks
al i gned (Fi g. 69).
(5) I nstal l the crankshaft oi l sl i nger.
(6) Ti ghten the camshaft sprocket bol t to 108 N·m
(80 ft. l bs.) torque.
(7) Check the val ve ti mi ng.
(8) Coat both si des of the repl acement ti mi ng case
cover gasket wi th gasket seal er. Appl y a 3 mm (1/8
i nch) bead of Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent to the joi nt formed at the ti mi ng
case cover and cyl i nder bl ock.
(9) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(10) Pl ace Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng of
the cover (Fi g. 71).
(11) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
bol ts. I nstal l the oi l pan-to-ti mi ng case cover bol ts.
(12) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
N·m (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 N·m (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 14 N·m
(120 i n. l bs.) torque. Ti ghten the oi l pan-to-cover 5/16
i nch bol ts to 18 N·m (156 i n. l bs.) torque.
(13) Remove the cover al i gnment tool and i nstal l a
repl acement oi l seal i nto the cover.
(14) I nstal l the vi brati on damper on the crank-
shaft.
(15) Lubri cate and ti ghten the damper bol t to 108
N·m (80 ft. l bs.) torque.
(16) I f equi pped wi th ai r condi ti oni ng, i nstal l the
A/C condenser and recei ver/dri er assembl y.
Fig. 69 Timing Chain Alignment
1 – TIMING MARKS
Fig. 70 Camshaft and Crankshaft Sprocket and
Chain
1 – CAMSHAFT SPROCKET
2 – CRANKSHAFT SPROCKET
3 – CHAIN
Fig. 71 Timing Case Cover Alignment and Seal
Installation Tool 6139
1 – TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
9 - 46 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(17) I nstal l the accessroy dri ve bel t on the pul l eys
and ti ghten (refer to Group 7, Cool i ng System for the
speci fi cati ons and procedures).
(18) I nstal l the radi ator. Connect the radi ator
hoses and automati c transmi ssi on fl ui d cool er pi pes,
i f equi pped. Fi l l the cool i ng system.
(19) I nstal l the fan and shroud.
(20) Connect negati ve cabl e to battery.
CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated.
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available, such as recom-
mended tool 8544 Camshaft Bushing Remover
Installer.
Camshaft end pl ay i s mai ntai ned by the l oad
pl aced on the camshaft by the oi l pump and di stri b-
utor dri ve gear. The hel i cal cut of the gear hol ds the
camshaft sprocket thrust face agai nst the cyl i nder
bl ock face.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the spark pl ugs.
(3) Rai se the vehi cl e.
(4) Remove the oi l pan and oi l pump.
(5) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 72).
(6) Remove the l ower i nsert from the beari ng cap.
(7) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 73). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 73). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(8) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
Fig. 72 Removing Main Bearing Caps and Lower
Inserts
1 – CONNECTING ROD JOURNAL
2 – MAIN BEARING CAPS
Fig. 73 Removing Upper Inserts
1 – COTTER PIN
2 – FABRICATED TOOL
3 – BEARING INSERT
4 – TONGUE DEPRESSOR
TJ 2. 5L ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(5) Cl ean the rear mai n beari ng cap (No.5) mati ng
surfaces.
(6) Appl y Mopar௡ Gasket Maker, or equi val ent on
the rear beari ng cap (Fi g. 74). The bead shoul d be 3
mm (0.125 i n) thi ck. DO NOT appl y Mopar௡ Gasket
Maker, or equi val ent to the l i p of the seal .
(7) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(8) Ti ghten the bol ts of caps 1, 3, 4 and 5 to 54
N·m (40 ft. l bs.) torque. Now ti ghten these bol ts to 95
N·m (70 ft. l bs.) torque. Fi nal l y, ti ghten these bol ts to
108 N·m (80 ft. l bs.) torque.
(9) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.2 to 54 N·m (40 ft. l bs.) torque. Then ti ghten
to 95 N·m (70 ft. l bs.) torque and fi nal l y ti ghten to
108 N·m (80 ft. l bs.) torque.
(10) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(11) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 75). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(12) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock (refer to Cyl i nder
Bl ock - Assembl e).
(13) I nstal l the oi l pan.
(14) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
N·m (25 ft. l bs.) torque.
(15) I nstal l new rearmai n seal . Refer to Rear Mai n
Seal i n thi s secti on.
(16) Lower the vehi cl e.
Fig. 74 Location of Moparா Gasket Maker
1 – MOPARா GASKET MAKER (OR EQUIVALENT)
2 – 19 mm (.75 IN)
3 – 6 mm (0.025 IN)
Fig. 75 Crankshaft End Play Measurement
1 – DIAL INDICATOR
2 – CRANKSHAFT
9 - 48 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(17) I nstal l the spark pl ugs. Ti ghten the pl ugs to
37 N·m (27 ft. l bs.) torque.
(18) Fi l l the oi l pan wi th engi ne oi l to the safe
mark on the di psti ck l evel .
(19) Connect negati ve cabl e to battery.
OIL PAN
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Remove the engi ne starter motor.
(5) Remove the fl ywheel /torque converter housi ng
access cover.
(6) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(7) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(8) Remove the engi ne mount through bol ts.
(9) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(10) Remove transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
are attached to the oi l pan studs.
(11) Remove the oi l pan fasteners. Careful l y
remove the oi l pan and gasket.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1/4 x 1 1/2
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 76).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 77).
(4) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces).
(5) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(6) Posi ti on the oi l pan over the dowel s and onto
the gasket.
(7) I nstal l the 1/4 i nch oi l pan fasteners. Ti ghten
these fasteners to 9.5 N·m (84 i n. l bs.) torque. I nstal l
the 5/16 i nch oi l pan fasteners (Fi g. 79). Ti ghten
these fasteners to 15 N·m (132 i n. l bs.) torque.
(8) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan fasteners and ti ghten to 9.5 N·m (84 i n.
l bs.).
(9) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
Fig. 76 Fabrication of Alignment Dowels
1 – 1/4ЈЈ ϫ 1 1/2ЈЈ BOLT
2 – DOWEL
3 – SLOT
Fig. 77 Position of Dowels in Cylinder Block
1 – 5/16ЈЈ HOLES
2 – DOWEL HOLES
3 – CYLINDER BLOCK
4 – 5/16ЈЈ HOLES
Fig. 78 Oil Pan Sealer Locations
1 – SEALER LOCATIONS
TJ 2. 5L ENGINE 9 - 49
REMOVAL AND INSTALLATION (Continued)
(10) I nstal l the through bol ts and ti ghten the nuts.
(11) Lower the jack stand and remove the pi ece of
wood.
(12) I nstal l the fl ywheel and torque converter
housi ng access cover.
(13) I nstal l the engi ne starter motor.
(14) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(15) I nstal l transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
attach to the oi l pan studs.
(16) I nstal l the oi l pan drai n pl ug (Fi g. 79).
Ti ghten the pl ug to 34 N·m (25 ft. l bs.) torque.
(17) Lower the vehi cl e.
(18) Connect negati ve cabl e to battery.
(19) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(20) Start the engi ne and i nspect for l eaks.
OIL PUMP
The posi ti ve-di spl acement gear-type oi l pump i s
dri ven by the di stri butor shaft, whi ch i s dri ven by a
gear on the camshaft. Oi l i s si phoned i nto the pump
through an i nl et tube and strai ner assembl y that i s
pressed i nto the pump body.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
REMOVAL
(1) Drai n the engi ne oi l .
(2) Remove the oi l pan.
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
80).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 N·m
(17 ft. l bs.) torque.
(2) I nstal l the oi l pan and gasket.
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
Fig. 79 Position of 5/16 inch Oil Pan Bolts
1 – OIL PAN
2 – OIL PAN DRAIN PLUG
Fig. 80 Oil Pump Assembly
1 – OIL FILTER ADAPTOR
2 – BLOCK
3 – GASKET
4 – OIL INLET TUBE
5 – OIL PUMP
6 – STRAINER ASSEMBLY
7 – ATTACHING BOLTS
9 - 50 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
PISTON AND CONNECTING ROD
REMOVAL
(1) Remove the engi ne cyl i nder head cover.
(2) Remove the rocker arms, bri dges and pi vots.
(3) Remove the push rods.
(4) Remove the engi ne cyl i nder head.
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(6) Rai se the vehi cl e.
(7) Drai n the engi ne oi l .
(8) Remove the oi l pan and gasket.
(9) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 81).
(10) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(11) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 82).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed.
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts do not
scratch the crankshaft journals or cylinder walls.
Short pieces of rubber hose slipped over the con-
necting rod bolts will provide protection during
installation.
(5) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 83).
(6) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 83).
(7) Rai se the vehi cl e.
(8) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(9) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
Fig. 81 Stamped Connecting Rods and Caps
1 – CONNECTING ROD CAP
2 – CONNECTING ROD
Fig. 82 Removal of Connecting Rod and Piston
Assembly
1 – PISTON
2 – CONNECTING ROD
3 – CYLINDER BLOCK
TJ 2. 5L ENGINE 9 - 51
REMOVAL AND INSTALLATION (Continued)
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(10) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(11) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.
(13) I nstal l the oi l pan and gaskets as outl i ned i n
the i nstal l ati on procedure.
(14) Lower the vehi cl e.
(15) I nstal l the engi ne cyl i nder head, push rods,
rocker arms, bri dges, pi vots and engi ne cyl i nder head
cover.
(16) Fi l l the crankcase wi th engi ne oi l .
REAR MAIN OIL SEAL
REMOVAL
(1) Remove the fl ywheel or converter dri ve pl ate.
Di scard the ol d bol ts.
(2) Pry out the seal from around the crankshaft
fl ange, maki ng sure not to scratch or ni ck the crank-
shaft. (Fi g. 84).
INSTALLATION
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Coat the outer l i p of the repl acement rear mai n
beari ng seal wi th engi ne oi l .
(3) Careful l y posi ti on the seal i nto pl ace. Use rear
mai n Seal I nstal l er Tool 6271A to i nstal l the seal
fl ush wi th the cyl i nder bl ock.
CAUTION: The felt lip must be located inside the
flywheel mounting surface. If the lip is not posi-
tioned correctly the flywheel could tear the seal.
(4) I nstal l the fl ywheel or converter dri ve pl ate.
New bol ts MUST be used when i nstal l i ng the fl y-
wheel or converter pl ate. Ti ghten the new bol ts to 68
N·m (50 ft. l bs.) torque. Turn the bol ts an addi ti onal
60°.
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
DISASSEMBLY
(1) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(2) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s.
(3) Use an Arkansas smooth stone or a jewel ers
fi l e to remove any burrs on the top of the val ve stem,
especi al l y around the groove for the l ocks.
(4) Remove the val ves, and pl ace them i n a rack i n
the same order as removed.
Fig. 83 Rod and Piston Assembly Installation
Fig. 84 Replacement of Rear Crankshaft Oil Seal
1 – CRANKSHAFT
2 – CRANKSHAFT OIL SEAL
9 - 52 2. 5L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
ASSEMBLY
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems. I f the 0.381 mm (0.015 i nch) over-
si ze val ve stems are used, oversi ze oi l seal s are
requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
VALVE, GUIDE AND SEAL
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 85). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.)— (Fi g. 86).
VALVE STEM OIL SEAL REPLACEMENT
Val ve stem oi l seal s are i nstal l ed on each val ve
stem to prevent rocker arm l ubri cati ng oi l from
enteri ng the combusti on chamber through the val ve
gui de bores. One seal i s marked I NT (i ntake val ve)
and the other i s marked EXH (exhaust val ve).
Repl ace the oi l seal s whenever val ve servi ce i s per-
formed or i f the seal s have deteri orated.
VALVE GUIDES
The val ve gui des are an i ntegral part of the engi ne
cyl i nder head and are not repl aceabl e.
When the val ve stem gui de cl earance i s excessi ve,
the val ve gui de bores must be reamed oversi ze. Ser-
vi ce val ves wi th oversi ze stems are avai l abl e i n 0.076
Fig. 85 Valve Facing Margin
1 – 0.787 MM (1/32 INCH) VALVE MARGIN
2 – NO MARGIN
Fig. 86 Measurement of Valve Seat Runout
1 – DIAL INDICATOR
TJ 2. 5L ENGINE 9 - 53
DISASSEMBLY AND ASSEMBLY (Continued)
mm (0.003 i nch) and 0.381 mm (0.015 i nch) i ncre-
ments.
Correspondi ng oversi ze val ve stem seal s are al so
avai l abl e and must be used wi th val ves havi ng 0.381
mm (0.015 i nch) oversi ze stems, 0.076mm (.003i n.)
oversi ze stems do not requi re oversi ze seal s.
NOTE: If the valve guides are reamed oversize, the
valve seats must be ground to ensure that the valve
seat is concentric to the valve guide.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
Val ve stem-to-gui de cl earance may be measured by
ei ther of the fol l owi ng two methods.
PREFERRED METHOD:
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 87).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
ALTERNATIVE METHOD:
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 88).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a Uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 89).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
CYLINDER BLOCK
DISASSEMBLY
(1) Drai n the engi ne oi l . Remove and di scard the
oi l fi l ter.
Fig. 87 Measurement of Valve Guide Bore Diameter
1 – GAUGE
2 – 9.525 MM (3/8 INCH)
3 – VALVE STEM GUIDE
4 – CYLINDER HEAD
Fig. 88 Measurement of Lateral Movement Of Valve
Stem
1 – DIAL INDICATOR
9 - 54 2. 5L ENGINE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove the water pump from the cyl i nder
bl ock.
(3) Remove the di stri butor from the cyl i nder bl ock.
(4) Remove the vi brati on damper.
(5) Remove the ti mi ng case cover and l ay the cover
upsi de down.
(6) Posi ti on a dri ft punch i nto the sl ot i n the back
of the cover and tap the ol d seal out.
(7) Remove the ti mi ng chai n bumper.
(8) Remove the oi l sl i nger from crankshaft.
(9) Remove the camshaft retai ni ng bol t and
remove the sprockets and chai n as an assembl y.
(10) Remove the camshaft.
(11) Remove the oi l pan and gasket.
(12) Remove the ti mi ng chai n tensi oner.
(13) Remove the front and rear oi l gal l ey pl ugs.
(14) Remove the connecti ng rods and the pi stons.
Remove the connecti ng rod and pi ston assembl i es
through the top of the cyl i nder bores.
(15) Remove the crankshaft.
ASSEMBLY
(1) I nstal l the crankshaft.
(2) I nstal l the connecti ng rods and the pi stons
through the top of the cyl i nder bores.
(3) I nstal l the front and rear oi l gal l ey pl ugs.
(4) I nstal l the ti mi ng chai n tensi oner.
(5) I nstal l the camshaft.
(6) I nstal l the sprockets and chai n as an assembl y.
(7) I nstal l the oi l sl i nger to the crankshaft.
(8) I nstal l the ti mi ng chai n bumper.
(9) I nstal l the ti mi ng case cover seal .
(10) I nstal l the ti mi ng case cover.
(11) I nstal l the oi l pan gasket and oi l pan.
(12) I nstal l the vi brati on damper.
(13) I nstal l the water pump. Ti ghten the mounti ng
bol ts to 31 N·m (270 i n. l bs.) torque.
(14) Remove the di stri butor from the cyl i nder
bl ock.
(15) Lubri cate the oi l fi l ter seal wi th cl ean engi ne
oi l . Ti ghten oi l fi l ter to 18 N·m (13 ft. l bs.) torque.
(16) I nstal l the engi ne i nto the vehi cl e.
(17) Fi l l the engi ne wi th cl ean l ubri cati on oi l .
(18) Fi l l the cool i ng system.
CLEANING AND INSPECTION
ROCKER ARMS AND PUSH RODS
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
HYDRAULIC TAPPETS
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and defecti ve tap-
pets.
Fig. 89 Valve Spring Tester
1 – TORQUE WRENCH
2 – VALVE SPRING TESTER
TJ 2. 5L ENGINE 9 - 55
DISASSEMBLY AND ASSEMBLY (Continued)
ENGINE CYLINDER HEAD
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
exhaust mani fol d and engi ne cyl i nder head mati ng
surfaces. Remove al l gasket materi al and carbon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
CYLINDER BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
• The gal l ey at the oi l fi l ter adaptor hol e, the fi l ter
bypass hol e (Fi g. 90).
• The front and rear oi l gal l ey hol es (Fi g. 91) (Fi g.
92).
• The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Mopar௡ Thread Seal ant wi th Tefl on to the threads of
the front and rear oi l gal l ey pl ugs. Ti ghten the pl ugs
to 41 N·m (30 ft. l bs.) torque.
INSPECTION
I nspect the cyl i nder bores for si gns of scorri ng, pi t-
ti ng or cracks. I f the cyl i nder bores are scorred or
pi tted the cyl i nder bores wi l l requi re borei ng or hon-
i ng to cl ean them up. Refer to Honi ng Cyl i nder Bores
i n thi s Secti on. I f the cyl i nder bore(s) are cracked the
cyl i nder bl ock must be repl aced.
I nspect the cyl i nder bl ock to cyl i nder head mati ng
surface for fl atness and/or pi tti ng.
Fig. 90 Oil Filter Adaptor Hole
1 – FILTER BYPASS HOLE
2 – OIL FILTER ADAPTOR HOLE
Fig. 91 Front Oil Galley Hole
1 – FRONT OIL GALLEY HOLE
Fig. 92 Rear Oil Galley Hole
1 – REAR OIL GALLEY HOLE
9 - 56 2. 5L ENGINE TJ
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
ENGINE SPECIFICATIONS
ENGINE DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type In-line 4 Cylinder
Bore and Stroke 98.4 x 81.0 mm
(3.88 x 3.19 in.)
Displacement 2.5L (150 cu. in.)
Compression Ratio 9.1:1
Compression Pressure
Range
827 to 1,034 kPa
(120 to 150 psi)
Max. Variation Between
Cylinders
206 kPa (30 psi)
Firing Order 1–3–4–2
Lubrication Pressure Feed–Full Flow
Filtration
Cooling System Liquid Cooled–Forced
Circulation
Cylinder Block Cast Iron
Crankshaft Cast Nodular Iron
Cylinder Head Cast Iron
Camshaft Cast Iron
Pistons Aluminum Alloy
Cylinder Combustion
Cavity
Double Quench
Connecting Rods Cast Iron
CAMSHAFT
Hydraulic Tappet
Clearance
Zero Lash
Bearing Clearance 0.025 - 0.076 mm
(0.001 - 0.003 in.)
Bearing Journal Diameter
No. 1 51.54 - 51.56 mm
(2.029 - 2.030 in.)
No. 2 51.28 - 51.31 mm
(2.019 - 2.020 in.)
DESCRIPTION SPECIFICATION
No. 3 51.03 - 51.05 mm
(2.009 - 2.010 in.)
No. 4 50.78 - 50.80 mm
(1.999 - 2.000 in.)
Base Circle Runout
(Max)
0.03 mm
(0.001 in.)
Camshaft Lobe Lift
Exhaust 6.579 mm (0.259 in.)
Intake 6.477 mm (0.255 in.)
Camshaft Duration
Intake 253.3°
Exhaust 259°
VALVES
Valve Lift
Exhaust 10.528 mm (0.4145 in.)
Intake 10.350 mm (0.4075 in.)
Intake Valve Timing
Opens 15.4°(BTDC)
Closes 58°(ABDC)
Duration 253.3°
Exhaust Valve Timing
Opens 52.8°(BBDC)
Closes 26.2°(ATDC)
Duration 259°
Valve Overlap 41.6°
Valve Lenght (Overall)
Intake 124.435 - 125.070 mm
(4.899 - 4.924 in.)
Exhaust 125.120 - 125.755 mm
(4.927 - 4.952 in.)
Valve Stem Diameter 7.899 - 7.925 mm
(0.311 - 0.312 in.)
Stem to Guide Clearance 0.025 - 0.076 mm
(0.001 - 0.003 in.)
ValveFace Angle
Intake 46.5°
Exhaust 46.5°
TJ 2. 5L ENGINE 9 - 57
DESCRIPTION SPECIFICATION
Valve Head Diameter
Intake 48.387 - 48.641 mm
(1.905 - 1.915 in.)
Exhaust 37.973 - 38.227 mm
(1.495 - 1.505 in.)
Tip Refinishing (Max
Alowable)
0.25 mm (0.010 in.)
VALVE SPRINGS
Free Length (Approx.) 47.65 mm (1.876 in.)
Spring Load
Valve Closed 316 to 351 N @
41.656 mm
(71 to 79 Lbs. @
1.64 in.)
Valve Open 898.6 to 969.7 N @
30.89 mm
(202 to 218 Lbs. @
1.216 in.)
Inside Diameter (Top) 21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height 41.656 mm (1.640 in.)
CRANKSHAFT
End Play 0.038 to 0.165 mm
(0.0015 to 0.0065 in.)
Main Bearing Journal
Diameter
63.489 to 63.502 mm
(2.4996 to 2.5001 in.)
Main Bearing Journal
Width
No. 1 27.58 to 27.89 mm
(1.086 to 1.098 in.)
No. 2 32.28 to 32.33 mm
(1.271 to 1.273 in.)
No. 3-4-5 30.02 to 30.18 mm
(1.182 to 1.188 in.)
Main Bearing Clearance 0.03 to 0.06 mm
(0.001 to 0.0025 in.)
Main Bearing Clearance
(Preferred) 0.051 mm
(0.002 in.)
DESCRIPTION SPECIFICATION
Connecting Rod Journal
Diameter 53.17 to 53.23 mm
(2.0934 to 2.0955 in.)
Connecting Rod Journal
Width
27.18 to 27.33 mm
(1.070 to 1.076 in.)
Out of Round - Max 0.013 mm (0.0005 in.)
Taper - Max 0.013 mm (0.0005 in.)
CYLINDER BLOCK
Deck Height 236.73 mm (9.320 in.)
Deck Clearance 0.000 mm (0.000 in.)
Cylinder Bore Diameter—
Standard 98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
Cylinder Bore Diameter—
Taper (Max) 0.025 mm
(0.001 in.)
Out of Round (Max) 0.025 mm
(0.001 in.)
Tappet Bore Diameter 23.000 to 23.025 mm
(0.9055 to 0.9065 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness Max 0.20 mm for total length
(0.008 in. for total length)
Main Bearing Bore
Diameter
68.3514 to 68.3768 mm
(2.691 to 2.692 in.)
CONNECTING RODS
Total Weight (Less
Bearing)
663 to 671 grams
(23.39 to 23.67 oz.)
Length (Center to Center) 155.52 to 155.62 mm
(6.123 to 6.127 in.)
9 - 58 2. 5L ENGINE TJ
SPECIFICATIONS (Continued)
DESCRIPTION SPECIFICATION
Piston Pin Bore Diameter 23.59 to 23.62 mm
(0.9288 to 0.9298 in.)
Bore (Less Bearings) 56.08 to 56.09 mm
(2.2080 to 2.2085 in.)
Bearing Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Bearing Clearance
(Preferred)
0.044 to 0.050 mm
(0.0015 to 0.0020 in.)
Side Clearance 0.25 to 0.48 mm
(0.010 to 0.019 in.)
Twist (Max) 0.002 mm per mm
(0.002 in. per in.)
Bend (Max) 0.006 mm per mm
(0.006 in. per inch.)
CYLINDER HEAD
Combustion Chamber 49.9 to 52.9 cc
(3.04 to 3.23 cu. in.)
Valve Guide I. D.
(Integral)
7.95 to 7.97 mm
(0.313 to 0.314 in.)
Valve Seat Angle
Intake 44.5°
Exhaust 44.5°
Valve Seat Width 1.01 to 1.52 mm
(0.040 to 0.060 in.)
Valve Seat Runout 0.064 mm
(0.0025 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness (Max) 0.20 mm for total length
(0.008 in. for total length)
DESCRIPTION SPECIFICATION
ROCKER ARMS, PUSH RODS & TAPPETS
Rocker Arm Ratio 1.6:1
Push Rod Length (Blue) 241.300 to 241.808 mm
(9.500 to 9.520 in.)
Push Rod Diameter 7.92 to 8.00 mm
(0.312 to 0.315 in.)
Hydraulic Tappet
Diameter
22.962 to 22.974 mm
(0.904 to 0.9045 in.)
Tappet to Bore Clearance 0.025 to 0.063 mm
(0.001 to 0.0025 in.)
PISTON
Weight (Less Pin) 417 to 429 grams
(14.7 to 15.1 oz.)
Compression Height 40.61 to 40.72 mm
(1.599 to 1.603 in.)
Piston to Bore Clearance 0.018 to 0.038 mm
(0.0008 to 0.0015 in.)
Piston Ring Groove
Height
Compression Rings 1.530 to 1.555 mm
(0.0602 to 0.0612 in.)
Oil Control Ring 4.035 to 4.060 mm
(0.1589 to 0.1598 in.)
Piston Ring Groove
Diameter
Compression Ring #1 88.39 to 88.65 mm
(3.48 to 3.49 in.)
Compression Ring #2 87.63 to 87.88 mm
(89.66 to 89.92 in.)
Oil Control Ring 89.66 to 89.92 mm
(3.53 to 3.54 in.)
Piston Pin Bore Diameter 23.650 to 23.658 mm
(0.9312 to 0.9315 in.)
Piston Pin Diameter 23.637 to 23.640 mm
(0.9306 to 0.9307 in.)
Piston to Pin Clearance 0.0102 to 0.0208 mm
(0.0005 to 0.0009 in.)
TJ 2. 5L ENGINE 9 - 59
SPECIFICATIONS (Continued)
DESCRIPTION SPECIFICATION
PISTON RINGS
Ring Gap Clearance
Top Compression Ring 0.229 to 0.610 mm
(0.0090 to 0.0240 in.)
2nd Compression Ring 0.483 to 0.965 mm
(0.0190 to 0.0380 in.)
Oil Control Steel Rails 0.254 to 1.500 mm
(0.010 to 0.060 in.)
Ring Side Clearance
Compression Rings 0.042 to 0.084 mm
(0.0017 to 0.0033 in.)
Oil Control Rings 0.06 to 0.21 mm
(0.0024 to 0.0083 in.)
OIL PUMP AND OIL PRESSURE
Gear to Body Clearance
(Radial) 0.051 to 0.102 mm
(0.002 to 0.004 in.)
(Radial Preferred) 0.051 mm
(0.002 in.)
Gear End Clearance—
Plastigage 0.051 to 0.152 mm
(0.002 to 0.006 in.)
Plastigage Preferred 0.051 mm
(0.002 in.)
Feeler Gauge 0.1016 to 0.2032 mm
(0.004 to 0.008 in.)
Feeler Gauge Preferred 0.1778 mm
(0.007 in.)
Min. Pressure (600 rpm) 89.6 kPa
(13 psi)
Min. Pressure at Idle
(800 rpm)
172 to 241 kPa
(25 to 35 psi)
Min. Pressure at 1600
rpm and Higher 255 to 517 kPa
(37 to 75 psi)
Oil Pressure Relief 517 kPa
(75 psi)
SPECIFICATIONS— TORQUE
TORQUE CHART 2.5L ENGINE
DESCRIPTION N·m Ft.
Lbs.
In. Lbs
A/C Compressor Bracket 47 35 —
to Engine—Bolts
A/C Compressor Mounting
Bolts
28 — 250
Block Heater Nut 1.8 — 16
Camshaft Sprocket Bolt 108 80 —
Clutch Cover to Flywheel
Bolts
31 23 —
Connecting Rod Cap Nuts 45 33 —
Cylinder Block Drain Plugs 41 30 —
Cylinder Head Bolts #1–10 149 110 —
& #12–14
Cylinder Head Bolt #11 135 100 —
Cylinder Head Cover Bolts 13 — 115
Dipstick Tube Bracket to 19 — 168
Cylinder Block—Bolt
Distributor Hold-Down
Clamp Bolt
23 — 204
Engine Front Insulator
Bracket—
81 60 —
Bolts
Insulator Bracket—Nuts 47 35 —
Insulator—Through Bolt 81 60 —
Engine Rear Support
Cushion
22 — 192
/Crossmember—Nuts
Support Cushion/Bracket
Nuts
46 34 —
Transmission Support
Bracket—
43 32 —
Bolts
Transmission Support
Bracket
75 55 —
/Cushion—Bolt
Transmission Support
Adaptor
75 55 —
Bracket—Bolts
Exhaust Manifold/Pipe
Nuts
27 20 —
9 - 60 2. 5L ENGINE TJ
SPECIFICATIONS (Continued)
DESCRIPTION N·m Ft.
Lbs.
In. Lbs
Exhaust Manifold
Bolt #1 41 30 —
Bolts #2-5 31 23 —
Nuts 6 and 7 14 — 126
Flywheel/Converter
Housing Bolts
38 28 —
Flywheel to Crankshaft
Bolts
143 105 —
Front Cover to Block Bolts
1/4-20
7 — 60
Front Cover to Block
5/16-18
22 — 192
Generator Mounting—
Bolts
57 42 —
Generator Mounting 47 35 —
Bracket to Engine—Bolts
Main Bearing Cap Bolts 108 80 —
Oil Filter Adaptor Bolt 102 75 —
Oil Filter Connector 68 50 —
Oil Filter 18 13 —
Oil Galley Plug 41 30 —
Oil Pan 1/4-20 Bolts 9.5 — 84
Oil Pan 5/16-18 Bolts 15 — 132
Oil Pan Drain Plug 34 25 —
Oil Pressure Sending Unit 15 — 130
Oil Pump Short Attaching
Bolts
23 — 204
Oil Pump Long Attaching
Bolts
23 — 204
Oil Pump Cover Bolts 8 — 70
Rocker Arm—Bolts 28 21 —
Spark Plugs 37 27 —
Starter Motor Mounting
Bolts
45 33 —
Thermostat Housing Bolts 18 — 156
Throttle Body Bolts 10 — 90
Vibration Damper Bolt 108 80 —
Water Pump to Block Bolts 31 23 —
SPECIAL TOOLS
ENGINE
Fig. 93 Valve Spring Compressor Tool MD-998772A
Fig. 94 Hydraulic Valve Tappet Removal Tool
C-4129–A
Fig. 95 Vibration Damper Removal Tool 7697
Fig. 96 Timing Case Cover Alignment and Seal Tool
6139
TJ 2. 5L ENGINE 9 - 61
SPECIFICATIONS (Continued)
4.0L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . 63
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 65
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 66
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
PISTON AND CONNECTING ROD . . . . . . . . . . . . 66
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 67
VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . 68
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 68
HYDRAULIC TAPPET. . . . . . . . . . . . . . . . . . . . . . 68
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 68
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 69
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . . 69
SERVICE DIAGNOSIS—PERFORMANCE . . . . . . 70
SERVICE DIAGNOSIS—MECHANICAL. . . . . . . . . 71
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . . 73
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 74
CYLINDER COMPRESSION PRESSURE TEST . . 74
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 75
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 75
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . 76
SERVICE PROCEDURES
VALVE TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . 76
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . . . 77
PISTON RING—FITTING . . . . . . . . . . . . . . . . . . . 77
FITTING CONNECTING ROD BEARINGS. . . . . . . 80
FITTING CRANKSHAFT MAIN BEARINGS . . . . . . 82
FORM-IN-PLACE GASKETS. . . . . . . . . . . . . . . . . 86
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . . 86
HONING CYLINDER BORES . . . . . . . . . . . . . . . . 86
MEASURING WITH PLASTIGAGE . . . . . . . . . . . . 87
REPAIR DAMAGED OR WORN THREADS. . . . . . 88
SERVICE ENGINE ASSEMBLY (SHORT
BLOCK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . . 88
ENGINE OIL SERVICE. . . . . . . . . . . . . . . . . . . . . 89
REMOVAL AND INSTALLATION
ENGINE MOUNTS—FRONT. . . . . . . . . . . . . . . . . 91
ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . . . 91
ENGINE BENDING BRACES . . . . . . . . . . . . . . . . 92
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 93
INTAKE AND EXHAUST MANIFOLD. . . . . . . . . . . 96
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 97
ROCKER ARMS AND PUSH RODS . . . . . . . . . . . 98
VALVE STEM SEAL AND SPRING . . . . . . . . . . . . 98
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 99
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 101
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . 101
VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . 102
TIMING CASE COVER . . . . . . . . . . . . . . . . . . . . 102
TIMING CHAIN AND SPROCKETS . . . . . . . . . . . 103
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 106
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 106
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
PISTONS AND CONNECTING RODS . . . . . . . . . 110
CRANKSHAFT OIL SEALS—REAR . . . . . . . . . . . 111
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TIMING CASE COVER OIL SEAL . . . . . . . . . . . . 113
DISASSEMBLY AND ASSEMBLY
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 113
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . 115
CLEANING AND INSPECTION
INTAKE AND EXHAUST MANIFOLD . . . . . . . . . . 116
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . 116
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 116
ROCKER ARMS AND PUSH RODS . . . . . . . . . . 116
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . 116
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . 117
SPECIFICATIONS
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 118
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 121
SPECIAL TOOLS
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9 - 62 4. 0L ENGINE TJ
DESCRIPTION AND OPERATION
ENGINE
DESCRIPTION
The 4.0 Li ter (242 CI D) si x-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne. Thi s
engi ne i s desi gned for unl eaded fuel .
The engi ne cyl i nder head has dual quench-type
combusti on chambers that create turbul ence and fast
burni ng of the ai r/fuel mi xture. Thi s resul ts i n better
fuel economy.
The cyl i nders are numbered 1 through 6 from front
to rear. The fi ri ng order i s 1-5-3-6-2-4 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n seven mai n beari ngs. The camshaft rotates
wi thi n four beari ngs.
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.2 and No.3 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
• 1st Di gi t—The year (8 = 1998).
• 2nd & 3rd Di gi ts—The month (01 - 12).
• 4th & 5th Di gi ts—The engi ne type/fuel system/
compressi on rati o (MX = A 4.0 Li ter (242 CI D) 8.7:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
• 6th & 7th Di gi ts—The day of engi ne bui l d (01 -
31).
(1) FOR EXAMPLE: Code * 801MX12 * i denti -
fi es a 4.0 Li ter (242 CI D) engi ne wi th a mul ti -poi nt
fuel i njecti on system, 8.7:1 compressi on rati o and
bui l t on January 12, 1998.
LUBRICATION SYSTEM
DESCRIPTION
A gear—type posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng.
OPERATION
The pump draws oi l through the screen and i nl et
tube from the sump at the rear of the oi l pan. The oi l
i s dri ven between the dri ve and i dl er gears and
pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, camshaft posi ti on sensor dri ve gear, cyl -
i nder wal l s, and pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
Fig. 1 Engine Firing Order
Fig. 2 Build Date Code Location
1 – YEAR
2 – MONTH
3 – DAY
TJ 4. 0L ENGINE 9 - 63
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan.
9 - 64 4. 0L ENGINE TJ
DESCRIPTION AND OPERATION (Continued)
CYLINDER BLOCK
Oil Lubrication System—4.0L Engine
1 – CAM/CRANK MAIN GALLERY (7)
2 – TAPPET GALLERY
3 – TAPPET GALLERY
4 – CAMSHAFT BEARING
5 – NUMBER 1 CAMSHAFT BEARING JOURNAL
6 – CAMSHAFT SPROCKET
7 – TAPPET GALLERY
TJ 4. 0L ENGINE 9 - 65
DESCRIPTION AND OPERATION (Continued)
DESCRIPTION
The cyl i nder bl ock i s a cast i ron i nl i ne si x cyl i nder
desi gn. The cyl i nder bl ock i s dri l l ed formi ng gal l eri es
for both oi l and cool ant (Fi g. 3).
CYLINDER HEAD
DESCRIPTION
The cyl i nder head i s made of cast i ron contai ni ng
twel ve val ves made of chrome pl ated heat resi stant
steel , val ve stem seal s, spri ngs, retai ners and keep-
ers. The cyl i nder head and val ve seats can be resur-
faced for servi ce purposes.
The val ve gui des are i ntegral to the cyl i nder head,
They are not repl aceabl e. However, they are servi ce-
abl e.
The cyl i nder head uses dual quench-type desi gn
combusti on chambers whi ch cause turbul ence i n the
cyl i nders al l owi ng faster burni ng of the ai r/fuel mi x-
ture, resul ti ng i n better fuel economy (Fi g. 4).
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
The crankshaft i s a crosshaped four throw desi gn
wi th ei ght counterwei ghts for bal anci ng purposes.
The crankshaft i s supported by seven sel ect mai n
beari ngs wi th the number three servi ng as the thrust
washer l ocati on. The mai n journal s of the crankshaft
are cross dri l l ed to i mprove rod beari ng l ubri cati on.
The sel ect fi t mai n beari ng marki ngs are l ocated on
the crankshaft counter wei ghts. The crankshaft rear
oi l seal i s a two pi ece desi gn. The front oi l seal i s a
one pi ece desi gn retai ned i n the ti mi ng chai n cover
(Fi g. 5).
PISTON AND CONNECTING ROD
DESCRIPTION
The pi stons are made of a hi gh strength al umi num
al l oy wi th an anodi zed top ri ng groove and crown.
Pi ston ski rts are coated wi th a sol i d l ubri cant
(Mol ykote) to reduce fri cti on and provi de scuff resi s-
tance. The connecti ng rods are made of ducti l e i ron.
A pressed fi t pi ston pi n i s used to attach the pi ston
and connecti ng rod.
Fig. 3 4.0L Cylinder Block with Main Bearing Caps
and Cap Brace
1 – BLOCK
2 – MAIN BEARING CAP BRACE
Fig. 4 Cylinder Head 4.0L Engine
1 – CYLINDER HEAD BOLTS
2 – CYLINDER HEAD GASKET
3 – CYLINDER HEAD
Fig. 5 Crankshaft with Select Fit Marking Location
1 – 1/4” LETTERS
2 – (ROD)
3 – (MAIN)
9 - 66 4. 0L ENGINE TJ
DESCRIPTION AND OPERATION (Continued)
CAMSHAFT
DESCRIPTION
The camshaft i s made of gray cast i ron wi th twel ve
machi ned l obes and four beari ng journal s. When the
camshaft rotates the l obes actuate the tappets and
push rods, forci ng upward on the rocker arms whi ch
appl i es downward force on the val ves.
ROCKER ARM
DESCRIPTION
The rocker arms are made of stamped steel and
have a operati onal rati o of 1.6:1. When the push rods
are forced upward by the camshaft l obes the push
rod presses upward on the rocker arms, the rocker
arms pi vot, forci ng downward pressure on the val ves
forci ng the val ves to move downward and off from
thei r seats (Fi g. 8).
VALVES
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Al l
val ves use three bead l ocks to promote val ve rotati on
(Fi g. 9).
VALVE SPRING
DESCRIPTION
The val ve spri ngs are made of hi gh strength si l i con
chrome spri ng steel . The spri ngs are common for
both i ntake and exhaust val ves. (Fi g. 9).
Fig. 6 Piston and Connecting Rod Assembly
Fig. 7 Camshaft—Typical
1 – CAMSHAFT
2 – LOBES
3 – BEARING JOURNAL
Fig. 8 Rocker Arms 4.0L Engine
1 – CAPSCREWS
2 – BRIDGE
3 – PIVOT ASSEMBLY
4 – PUSH RODS
5 – ROCKER ARMS
TJ 4. 0L ENGINE 9 - 67
DESCRIPTION AND OPERATION (Continued)
VALVE STEM SEAL
DESCRIPTION
The val ve stem seal s are made of rubber and i ncor-
porate a garter spri ng to mai ntai n consi stent l ubri ca-
ti on control (Fi g. 9).
CYLINDER HEAD COVER
DESCRIPTION
The cyl i nder head cover (Fi g. 10) i s made of
stamped steel and i ncorporates the Crankcase Venti -
l ati on (CCV) Hoses and the oi l fi l l openi ng.
HYDRAULIC TAPPET
DESCRIPTION
Val ve l ash i s control l ed by hydraul i c tappets
l ocated i nsi de the cyl i nder bl ock, i n tappet bores
above the camshaft.
OIL PAN
DESCRIPTION
The oi l pan i s made of stamped steel . The oi l pan
gasket i s a one pi ece steel backbone si l i cone coated
gasket.
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s made of cast al umi num and
uses el even bol ts to mount to the cyl i nder head. Thi s
mounti ng styl e i mproves seal i ng and reduces the
chance of l eaks.
Fig. 9 Valve and Keeper Configuration 4.0L Engine
1 – VALVE LOCKS (3–BEAD)
2 – RETAINER
3 – VALVE STEM OIL SEAL
4 – INTAKE VALVE
5 – EXHAUST VALVE
6 – VALVE SPRING
Fig. 10 Cylinder Head Cover
Fig. 11 Oil Pan
1 – OIL PAN
2 – OIL PAN DRAIN PLUG
9 - 68 4. 0L ENGINE TJ
DESCRIPTION AND OPERATION (Continued)
EXHAUST MANIFOLD
DESCRIPTION
The two exhaust mani fol ds are l og styl e and are
made of hi gh si l i con mol ybdenum cast i ron. The
exhaust mani fol ds share a common gasket wi th the
i ntake mani fol d. The exhaust mani fol ds al so i ncorpo-
rate bal l fl ange outl ets for i mproved seal i ng and
strai n free connecti ons.
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS— INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
Refer to the Servi ce Di agnosi s—Performance chart
and the Servi ce Di agnosi s—Mechani cal chart for pos-
si bl e causes and correcti ons of mal functi ons. Refer to
Group 14, Fuel System for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
• Cyl i nder Compressi on Pressure Test.
• Cyl i nder Combusti on Pressure Leakage Test.
• Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s.
• I ntake Mani fol d Leakage Di agnosi s.
Fig. 12 Intake Manifold 4.0L Engine
Fig. 13 Exhaust Manifolds 4.0L Engine
TJ 4. 0L ENGINE 9 - 69
DESCRIPTION AND OPERATION (Continued)
SERVICE DIAGNOSIS— PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to
Group 8A, Battery, for correct
procedures. Check charging system.
Refer to Group 8C, Charging
Systems, for correct procedures.
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to
Group 8B, Starting Systems, for
correct diagnostics/procedures
4. Siezed accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace siezed
component.
5. Engine internal mechanical
failure or hydro-static lock
5. Refer to Group 9, Engine, for
correct diagnostics/procedures
ENGINE CRANKS BUT WILL NOT
START
1. No spark 1. Check for spark. Refer to Group
8D, Ignition System, for correct
procedures.
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. Refer to Group
14, Fuel System, for correct
procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. Refer to Group 9,
Engine, for correct procedures.
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to group 8D, Ignition System
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer
to group 8D, Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
9 - 70 4. 0L ENGINE TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to Group 8D, ignition system)
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to Group 14 for
correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Worn or incorrectly gapped spark
plugs
3. Replace or clean and re-gap
spark plugs (Refer to group 8D,
Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed
5. Check for correct firing order or
replace spark plug cables. (Refer to
Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary
(Refer to group 8D, Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses. Replace if
necessary (Refer to Group 11,
Exhaust System & Intake Manifold)
8. EGR valve leaking or stuck open 8. Test and replace, if necessary
(Refer to group 25, Emission
Control Systems)
ENGINE MISSES ON
ACCELERATION
1. Worn or incorrectly gapped spark
plugs
1. Replace spark plugs or clean and
set gap. (Refer to group 8D, Ignition
System)
2. Spark plug cables defective or
crossed
2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(refer to group 8D, Ignition System)
SERVICE DIAGNOSIS— MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil
Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
TJ 4. 0L ENGINE 9 - 71
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces
9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive connecting rod
bearing clearance
Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive main bearing
clearance
4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
7. Loose flywheel or torque
converter
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
9 - 72 4. 0L ENGINE TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace worn gears or oil pump
assy
5. Thin or diluted oil 5. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged
8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or
cracked
9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets
1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded
plug. Replace cup style plug
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED
1. PCV System malfunction 1. Refer to group 25, Emission
Control System for correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
HYDRAULIC TAPPETS
LEAK-DOWN TEST
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 14).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
TJ 4. 0L ENGINE 9 - 73
DIAGNOSIS AND TESTING (Continued)
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
CYLINDER COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sabl e the fuel system. (Refer to Group 14,
Fuel System for the correct procedure)
(5) Di sconnect the i gni ti on coi l .
(6) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(7) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
Refer to Engi ne Speci fi cati ons for the correct
engi ne compressi on pressures.
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS
A l eaki ng engi ne cyl i nder head gasket usual l y
resul ts i n l oss of power, l oss of cool ant and engi ne
mi sfi ri ng.
An engi ne cyl i nder head gasket l eak can be l ocated
between adjacent cyl i nders or between a cyl i nder and
the adjacent water jacket.
• An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders i s i ndi cated by a l oss of power
and/or engi ne mi sfi re.
• An engi ne cyl i nder head gasket l eaki ng between
a cyl i nder and an adjacent water jacket i s i ndi cated
by cool ant foami ng or overheati ng and l oss of cool ant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders; fol l ow the proce-
dures outl i ned i n Cyl i nder Compressi on Pressure
Fig. 14 Leak-Down Tester
1 – POINTER
2 – WEIGHTED ARM
3 – RAM
4 – CUP
5 – HANDLE
6 – PUSH ROD
9 - 74 4. 0L ENGINE TJ
DIAGNOSIS AND TESTING (Continued)
Test. An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders wi l l resul t i n approxi matel y a
50-70% reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Remove the radi ator cap.
Start the engi ne and al l ow i t to warm up unti l the
engi ne thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
I f bubbl es are not vi si bl e, i nstal l a radi ator pres-
sure tester and pressuri ze the cool ant system.
I f a cyl i nder i s l eaki ng combusti on pressure i nto
the water jacket, the tester poi nter wi l l pul sate wi th
every combusti on stroke of the cyl i nder.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
• Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
• Leaks between adjacent cyl i nders or i nto water
jacket.
• Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(3) Remove the spark pl ugs.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turer’s i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturer’s i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to the Cyl i nder Combusti on Pressure Leak-
age Test Di agnosi s chart.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Remove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
ENGINE OIL LEAK INSPECTION
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
TJ 4. 0L ENGINE 9 - 75
DIAGNOSIS AND TESTING (Continued)
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.
(4) If the oil leak source is not positively
identified at this time, proceed wi th the ai r l eak
detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(1) Di sconnect the battery.
(2) Rai se the vehi cl e.
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
ENGINE OIL PRESSURE
(1) Di sconnect connector and remove oi l pressure
sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292 or equi val ent. Start engi ne and record pres-
sure. Refer to Oi l Pressure i n Engi ne Speci fi cati ons
for the correct pressures.
SERVICE PROCEDURES
VALVE TIMING
Di sconnect the coi l rai l and remove from engi ne.
Remove spark pl ugs.
Remove the engi ne cyl i nder head cover.
Remove the capscrews, bri dge and pi vot assembl y,
and rocker arms from above the No.1 cyl i nder.
Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
Rotate the crankshaft unti l the No.6 pi ston i s at
top dead center (TDC) on the compressi on stroke.
Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90°.
I nstal l a di al i ndi cator on the end of the No.1 cyl -
i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
9 - 76 4. 0L ENGINE TJ
DIAGNOSIS AND TESTING (Continued)
Set the di al i ndi cator poi nter at zero.
Rotate the crankshaft cl ockwi se (vi ewed from the
front of the engi ne) unti l the di al i ndi cator poi nter
i ndi cates 0.305 mm (0.012 i nch) travel di stance (l i ft).
The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
I f the ti mi ng notch i s more than 13 mm (1/2 i nch)
away from the TDC mark i n ei ther di recti on, the
val ve ti mi ng i s i ncorrect.
I f the val ve ti mi ng i s i ncorrect, the cause may be a
broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
PISTON FITTING
BORE GAGE METHOD
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm
(.0001 i n.) I NCREMENTS i s requi red. I f a bore
gauge i s not avai l abl e, do not use an i nsi de mi crome-
ter.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 16).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 15). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
PISTON RING— FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
Fig. 15 Moly Coated Piston
1 – MOLY COATED
2 – MOLY COATED
Fig. 16 Bore Gauge
1 – FRONT
2 – BORE GAUGE
3 – CYLINDER BORE
4 – 49.5 MM
(1–15/16 in)
TJ 4. 0L ENGINE 9 - 77
SERVICE PROCEDURES (Continued)
(Fi g. 17) (Fi g. 18). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 19).
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 20).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 21).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 21) (Fi g.
23).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Ring Gap Orientation
• Posi ti on the gaps on the pi ston as shown (Fi g.
24).
• Oi l spacer - Gap on center l i ne of pi ston ski rt.
• Oi l rai l s - gap 180° apart on centerl i ne of pi ston
pi n bore.
PISTON SIZE CHART
CYLINDER BORE SIZE PISTON LETTER SIZE
98.438 - 98.448 mm
(3.8755 - 3.8759 in.)
A
98.448 - 98.458 mm
(3.8759 - 3.8763 in.)
B
98.458 - 98.468 mm
(3.8763 - 3.8767 in.)
C
98.468 - 98.478 mm
(3.8767 - 3.8771 in.)
D
98.478 - 98.488 mm
(3.8771 - 3.8775 in.)
E
98.488 - 98.498 mm
(3.8775 - 3.8779 in.)
F
Fig. 17 Piston Dimensions
Fig. 18 Ring Side Clearance Measurement
1 – FEELER GAUGE
RING SIDE CLEARANCE CHART
ITEM SPECIFICATION
Top Compression Ring 0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Second Compression
Ring
0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Oil Control Ring 0.06 - 0.21 mm
(0.0024 - 0.0083 in.)
9 - 78 4. 0L ENGINE TJ
SERVICE PROCEDURES (Continued)
• No. 2 Compressi on ri ng - Gap 180° from top oi l
rai l gap.
• No. 1 Compressi on ri ng - Gap 180° from No. 2
compressi on ri ng gap.
Fig. 19 Gap Measurement
1 – FEELER GAUGE
RING GAP MEASUREMENT CHART
ITEM SPECIFICATION
Top Compression Ring 0.229 - 0.610 mm
(0.0090 - 0.0240 in.)
Second Compression
Ring
0.483 - 0.965 mm
(0.0190 - 0.080 in.)
Oil Control Ring 0.254 - 1.500 mm
(0.010 - 0.060 in.)
Fig. 20 Top Compression ring identification
1 – TOP COMPRESSION RING
Fig. 21 Second Compression Ring Identification
1 – SECOND COMPRESSION RING
2 – CHAMFER
3 – ONE DOT
Fig. 22 Compression Ring Chamfer Location
1 – TOP COMPRESSION RING
2 – SECOND COMPRESSION RING
3 – PISTON
4 – CHAMFER
Fig. 23 Compression Ring Installation
1 – COMPRESSION RING
2 – RING EXPANDER RECOMMENDED
TJ 4. 0L ENGINE 9 - 79
SERVICE PROCEDURES (Continued)
FITTING CONNECTING ROD BEARINGS
INSPECTION
BEARINGS
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 25) (Fi g. 26). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 27). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
CONNECTING RODS
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
Fig. 24 Ring Gap Orientation
1 – TOP COMPRESSION RING
2 – BOTTOM COMPRESSION RING
3 – TOP OIL CONTROL RAIL
4 – OIL RAIL SPACER
5 – BOTTOM OIL CONTROL RAIL
6 – IMAGINARY LINE PARALLEL TO PISTON PIN
7 – IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
Fig. 25 Connecting Rod Bearing Inspection
1 – UPPER BEARING HALF
2 – MATING EDGES
3 – GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 – WEAR PATTERN — ALWAYS GREATER ON UPPER
BEARING
5 – LOWER BEARING HALF
Fig. 26 Locking Tab Inspection
1 – ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 27 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
9 - 80 4. 0L ENGINE TJ
SERVICE PROCEDURES (Continued)
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
duri ng i nstal l ati on.
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
28). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 N·m (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to- journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 29). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance (refer to
Connecti ng Rod Beari ng Fi tti ng Chart).
Fig. 28 Rod and Piston Assembly Installation
Fig. 29 Measuring Bearing Clearance with
Plastigage
1 – PLASTIGAGE SCALE
2 – COMPRESSED PLASTIGAGE
TJ 4. 0L ENGINE 9 - 81
SERVICE PROCEDURES (Continued)
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow
53.2257 - 53.2079 mm
Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
Orange
53.2079 - 53.1901 mm
Yellow - Standard
Blue - Undersize (2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
Blue
53.1901 - 53.1724 mm
Blue - Undersize Blue - Undersize (2.0941 - 2.0934 in.)
0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
Red
52.9717 - 52.9539 mm
Red - Undersize Red - Undersize (2.0855 - 2.0848 in.)
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 45 N·m (33 ft. l bs.) torque.
SIDE CLEARANCE MEASUREMENT
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 30).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 31). I n general the
l ower beari ng hal f wi l l have a heavi er wear pattern.
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 7 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
Fig. 30 Checking Connecting Rod Side Clearance—
Typical
9 - 82 4. 0L ENGINE TJ
SERVICE PROCEDURES (Continued)
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark (Fi g. 32) on the
adjacent cheek or counterwei ght towards the rear of
the crankshaft (fl ange end). The rear mai n journal , i s
i denti fi ed by a col or-coded pai nt mark on the crank-
shaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, pro-
ceed to Crankshaft Mai n Beari ng—I nstal l ati on.
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
N·m (80 ft. l bs.) torque.
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 33). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
ceed to Crankshaft Mai n Beari ng—I nstal l ati on.
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cate wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
Fig. 31 Main Bearing Wear Patterns
1 – UPPER INSERT
2 – NO WEAR IN THIS AREA
3 – LOW AREA IN BEARING LINING
4 – LOWER INSERT
TJ 4. 0L ENGINE 9 - 83
SERVICE PROCEDURES (Continued)
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
Repl ace the crankshaft or gri nd to accept the
appropri ate undersi ze beari ng i nserts i f:
• Journal di ameters 1 through 6 are l ess than
63.4517 mm (2.4981 i nches)
• Journal 7 di ameter i s l ess than 63.4365 mm
(2.4975 i nches).
Once the proper cl earances have been obtai ned,
proceed to Crankshaft Mai n Beari ng—I nstal l ati on.
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock
(refer to Cyl i nder Bl ock - Di sassembl e).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90°
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock (refer
to Cyl i nder Bl ock - Assembl e and Crankshaft Mai n
Beari ngs - I nstal l ati on).
Fig. 32 Crankshaft Journal Size Paint I. D. Location
1 – NO. 7 MAIN JOURNAL SIZE PAINT MARK
2 – NO. 6 CONNECTING ROD JOURNAL SIZE PAINT MARK
3 – NO. 1 CONNECTING ROD JOURNAL SIZE PAINT MARK
4 – NO. 1 MAIN JOURNAL SIZE PAINT MARK
BEARING INSERT PAIRS CHART
INSERT CORRECT INCORRECT
UPPER STANDARD STANDARD
LOWER 0.025 mm
(0.001 in.)
UNDERSIZE
0.051 mm
(0.002 in.)
UNDERSIZE
Fig. 33 Measuring Bearing Clearance with
Plastigage
1 – PLASTIGAGE SCALE
2 – COMPRESSED PLASTIGAGE
9 - 84 4. 0L ENGINE TJ
SERVICE PROCEDURES (Continued)
MAIN BEARING FITTING CHART
Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow
63.5025 -63.4898 mm
Yellow - Standard Yellow - Standard
(2.5001 - 2.4996 in.)
Orange
63.4898 - 63.4771 mm
Yellow - Standard
Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue
63.4771 - 63.4644 mm
Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
Green
63.4644 - 63.4517 mm
Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
Red
63.2485 - 63.2358 mm
Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
Crankshaft Journal #7 Only Corresponding Bearing Insert
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow
63.4873 - 63.4746 mm
Yellow - Standard Yellow - Standard
(2.4995 - 2.4990 in.)
Orange
63.4746 - 63.4619 mm
Yellow - Standard
Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue
63.4619 - 63.4492 mm
Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4985 - 2.4980 in.)
0.0254 mm (0.001 in.)
Undersize
Green
63.4492 - 63.4365 mm
Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4980 - 2.4975 in.)
0.0381 mm (0.0015 in.)
Undersize
Red
63.2333 - 63.2206 mm
Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4895 - 2.4890 in.)
0.254 mm (0.010 in.)
Undersize
TJ 4. 0L ENGINE 9 - 85
SERVICE PROCEDURES (Continued)
FORM-IN-PLACE GASKETS
There are several pl aces where form-i n-pl ace gas-
kets are used on the engi ne. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when appl yi ng form-i n-pl ace gaskets.
Bead si ze, conti nui ty and l ocati on are of great i mpor-
tance. Too thi n a bead can resul t i n l eakage whi l e too
much can resul t i n spi l l -over. A conti nuous bead of
the proper wi dth i s essenti al to obtai n a l eak-free
joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne area (Mopar Si l i cone Rubber
Adhesi ve Seal ant and Mopar Gasket Maker). Each
have di fferent properti es and cannot be used i nter-
changeabl y.
MOPAR SILICONE RUBBER ADHESIVE SEALANT
Mopar Si l i cone Rubber Adhesi ve Seal ant, normal l y
bl ack i n col or, i s avai l abl e i n 3 ounce tubes. Moi sture
i n the ai r causes the seal ant materi al to cure. Thi s
materi al i s normal l y used on fl exi bl e metal fl anges.
I t has a shel f l i fe of a year and wi l l not properl y cure
i f over aged. Al ways i nspect the package for the expi -
rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normal l y red i n col or, i s
avai l abl e i n 6 cc tubes. Thi s anaerobi c type gasket
materi al cures i n the absence of ai r when squeezed
between smooth machi ned metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. DO NOT use
on fl exi bl e metal fl anges.
SURFACE PREPARATION
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et or other sui tabl e tool to break the seal
between the mati ng surfaces. A fl at gasket scraper
may al so be l i ghtl y tapped i nto the joi nt but care
must be taken not to damage the mati ng surfaces.
Scrape or wi re brush al l gasket surfaces to remove
al l l oose materi al . I nspect stamped parts to ensure
gasket rai l s are fl at. Fl atten rai l s wi th a hammer on
a fl at pl ate, i f requi red. Gasket surfaces must be free
of oi l and di rt. Make sure the ol d gasket materi al i s
removed from bl i nd attachi ng hol es.
GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care.
Mopar Si l i cone Rubber Adhesi ve Seal ant shoul d be
appl i ed i n a conti nuous bead approxi matel y 3 mm
(0.12 i nch) i n di ameter. Al l mounti ng hol es must be
ci rcl ed. For corner seal i ng, a 3 or 6 mm (1/8 or 1/4
i nch) drop i s pl aced i n the center of the gasket con-
tact area. Uncured seal ant may be removed wi th a
shop towel . Components shoul d be torqued i n pl ace
whi l e the seal ant i s sti l l wet to the touch (wi thi n 10
mi nutes). The use of a l ocati ng dowel i s recom-
mended duri ng assembl y to prevent smeari ng the
materi al off l ocati on.
Mopar Gasket Maker shoul d be appl i ed spari ngl y
to one gasket surface. The seal ant di ameter shoul d
be 1.00 mm (0.04 i nch) or l ess. Be certai n the mate-
ri al surrounds each mounti ng hol e. Excess materi al
can easi l y be wi ped off. Components shoul d be
torqued i n pl ace wi thi n 15 mi nutes. The use of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng the materi al off l ocati on.
ENGINE PERFORMANCE
I t i s i mportant that the vehi cl e i s operati ng to i ts
opti mum performance l evel to mai ntai n fuel economy
and the l owest emi ssi on l evel s. I f vehi cl e i s not oper-
ati ng to these standards, refer to Engi ne Di agnosi s
outl i ned i n thi s secti on. The fol l owi ng procedures can
assi st i n achi evi ng the proper engi ne di agnosi s.
(1) Test cranki ng amperage draw. Refer to El ectri -
cal Group 8B, Col d Cranki ng Test.
(2) Check i ntake mani fol d bol t torque; Refer to
Group 11, Exhaust System and I ntake Mani fol d.
(3) Perform cyl i nder compressi on test. Refer to
Cyl i nder Compressi on Pressure Test i n the Engi ne
Di agnosi s area of thi s secti on.
(4) Cl ean or repl ace spark pl ugs as necessary and
adjust gap as speci fi ed i n El ectri cal Group 8D.
Ti ghten to speci fi cati ons.
(5) Test resi stance of spark pl ug cabl es. Refer to
El ectri cal Group 8D, Spark Pl ug Cabl es.
(6) I nspect the pri mary wi res. Test coi l output vol t-
age and pri mary resi stance. Repl ace parts as neces-
sary. Refer to El ectri cal Group 8D, for speci fi cati ons.
(7) Test fuel pump for pressure. Refer to Group 14,
Fuel System Speci fi cati ons.
(8) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Lubri cati on and Mai ntenance, Group 0.
(9) I nspect crankcase venti l ati on system as out
l i ned i n Group 0, Lubri cati on and Mai ntenance. For
emi ssi on control s see Group 25, Emi ssi on Control s
for servi ce procedures.
(10) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823 equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round as wel l as removi ng l i ght
9 - 86 4. 0L ENGINE TJ
SERVICE PROCEDURES (Continued)
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). 20-60 strokes,
dependi ng on the bore condi ti on, wi l l be suffi ci ent to
provi de a sati sfactory surface. Usi ng honi ng oi l
C-3501-3880 or a l i ght honi ng oi l avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50° to 60°
for proper seati ng of ri ngs (Fi g. 34).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50° to 60°
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
MEASURING WITH PLASTIGAGE
CRANKSHAFT MAIN BEARING CLEARANCE
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage, or equi val ent. The fol l ow-
i ng i s the recommended procedures for the use of
Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) The total cl earance of the mai n beari ngs can
onl y be determi ned by removi ng the wei ght of the
crankshaft. Thi s can be accompl i shed by ei ther of two
methods:
METHOD - 1 (PREFERRED)
Shi m the beari ngs adjacent to the beari ng to be
checked. Thi s wi l l remove the cl earance between
upper beari ng shel l and the crankshaft. Pl ace a mi n-
i mum of 0.254 mm (0.010 i nch) shi m between the
beari ng shel l and the adjacent beari ng cap. Ti ghten
the bol ts to 18 N·m (13 ft. l bs.) torque.
• ALL ENGINES —When checki ng No.1 mai n
beari ng; shi m No.2 mai n beari ng.
• ALL ENGINES —When checki ng No.2 mai n
beari ng; shi m No.1 and No.3 mai n beari ng.
• ALL ENGINES —When checki ng No.3 mai n
beari ng; shi m No.2 and No.4 mai n beari ng.
• ALL ENGINES —When checki ng No.4 mai n
beari ng; shi m No.3 and No.5 mai n beari ng.
• 2.5L ENGINE —When checki ng No.5 mai n
beari ng; shi m No.4 mai n beari ng.
• 4.0L ENGINE —When checki ng No.5 mai n
beari ng; shi m No.4 and No.6 mai n beari ng.
• 4.0L ENGINE —When checki ng No.6 mai n
beari ng; shi m No.5 and No.7 mai n beari ng.
• 4.0L ENGINE —When checki ng No.7 mai n
beari ng; shi m No.6 mai n beari ng.
NOTE: Remove all shims before assembling
engine.
METHOD - 2 (ALTERNATIVE)
The wei ght of the crankshaft i s supported by a jack
under the counterwei ght adjacent to the beari ng
bei ng checked.
(1) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 35). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n
that area. Ti ghten the beari ng cap bol ts of the bear-
i ng bei ng checked to requi red torque. (Refer to the
torque speci fi cati ons at the rear of the engi ne’s sec-
ti on). DO NOT rotate the crankshaft or the Plas-
tigage may be smeared, giving inaccurate
results.
Fig. 34 Cylinder Bore Crosshatch Pattern
1 – CROSSHATCH PATTERN
2 – INTERSECT ANGLE
TJ 4. 0L ENGINE 9 - 87
SERVICE PROCEDURES (Continued)
(2) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 36). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(3) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
CONNECTING ROD BEARING CLEARANCE
Engi ne connecti ng rod beari ng cl earances can be
determi ned by use of Pl asti gage, or equi val ent. The
fol l owi ng i s the recommended procedures for the use
of Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 35). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n the
suspect area.
(3) The crankshaft must be turned unti l the con-
necti ng rod to be checked starts movi ng toward the
top of the engi ne. Onl y then shoul d the rod cap wi th
Pl asti gage i n pl ace be assembl ed. Ti ghten the rod cap
nuts to requi red torque. (Refer to the torque speci fi -
cati ons at the rear of the engi ne’s secti on). DO NOT
rotate the crankshaft or the Plastigage may be
smeared, giving inaccurate results.
(4) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 36). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(5) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
• Dri l l i ng out worn or damaged threads.
• Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
• I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A servi ce repl acement engi ne assembl y (short
bl ock) may be i nstal l ed whenever the ori gi nal cyl i n-
der bl ock i s defecti ve or damaged beyond repai r. I t
consi sts of the cyl i nder bl ock, crankshaft, pi ston and
rod assembl i es. I f needed, the camshaft must be pro-
cured separatel y and i nstal l ed before the engi ne i s
i nstal l ed i n the vehi cl e.
A short bl ock i s i denti fi ed wi th the l etter “S”
stamped on the same machi ned surface where the
bui l d date code i s stamped for compl ete engi ne
assembl i es.
I nstal l ati on i ncl udes the transfer of components
from the defecti ve or damaged ori gi nal engi ne. Fol -
l ow the appropri ate procedures for cl eani ng, i nspec-
ti on and torque ti ghteni ng.
HYDROSTATIC LOCK
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
Fig. 35 Placement of Plastigage in Bearing Shell
1 – PLASTIGAGE
Fig. 36 Clearance Measurement
9 - 88 4. 0L ENGINE TJ
SERVICE PROCEDURES (Continued)
(1) Perform the Fuel Pressure Rel ease Procedure
(refer to Group 14, Fuel System).
(2) Di sconnect the negati ve cabl e from the battery.
(3) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the pl ugs from the
engi ne.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (i .e. cool ant,
fuel , oi l , etc.).
(7) Make sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt engi ne oi l i nto the cyl i nders to l ubri cate
the wal l s. Thi s wi l l prevent damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 37 N·m (27 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
N·m (25 ft. l bs.) torque.
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l (refer to Group 0, Lubri ca-
ti on and Mai ntenance).
(15) Connect the negati ve cabl e to the battery.
(16) Start the engi ne and check for any l eaks.
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING 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 PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
I n gasol i ne engi nes. use an engi ne oi l that i s API
Servi ce Grade Certi fi ed (Fi g. 37).
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 37).
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 10W-30 speci fi es a mul ti pl e
vi scosi ty engi ne oi l .
When choosi ng an engi ne oi l , consi der the range of
temperatures the vehi cl e wi l l be operated i n before
the next oi l change. Sel ect an engi ne oi l that i s best
sui ted to your area’s parti cul ar ambi ent temperature
range and vari ati on (Fi g. 38).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
The engi ne oi l l evel i ndi cator (Di psti ck) i s l ocated
at the ri ght rear of both 2.5L engi nes and 4.0L
Fig. 37 Engine Oil Container Standard Notations
Fig. 38 Temperature/Engine Oil Viscosity
TJ 4. 0L ENGINE 9 - 89
SERVICE PROCEDURES (Continued)
engi nes. I nspect engi ne oi l l evel approxi matel y every
800 ki l ometers (500 mi l es). Unl ess the engi ne has
exhi bi ted l oss of oi l pressure, run the engi ne for
about fi ve mi nutes before checki ng oi l l evel . Checki ng
engi ne oi l l evel on a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck (Fi g. 39).
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, note oi l l evel readi ng (Fi g. 39).
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Al l Jeep engi nes are equi pped wi th a hi gh qual i ty
ful l -fl ow, throw-away type oi l fi l ter. Chrysl er Corpo-
rati on recommends a Mopar or equi val ent oi l fi l ter be
used.
OIL FILTER REMOVAL
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss.
(4) When fi l ter separates from cyl i nder bl ock oi l
fi l ter boss, ti p gasket end upward to mi ni mi ze oi l
spi l l . Remove fi l ter from vehi cl e.
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface (Fi g. 40) of oi l and gri me.
OIL FILTER INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 40) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
Fig. 39 Engine Oil Dipstick—4.0L Engine Typical
1 – ENGINE OIL DIPSTICK
2 – ADD
3 – SAFE
4 – ENGINE OIL FILL CAP
5 – TRANSMISSION DIPSTICK
9 - 90 4. 0L ENGINE TJ
SERVICE PROCEDURES (Continued)
REMOVAL AND INSTALLATION
ENGINE MOUNTS— FRONT
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Support the engi ne.
(4) Remove the nut from the through bol t (Fi g. 41)
(Fi g. 42). DO NOT remove the through bol t.
(5) Remove the retai ni ng bol ts and nuts from the
i nsul ator.
(6) Remove the through bol t.
(7) Remove the i nsul ator.
INSTALLATION
(1) I f the engi ne support bracket was removed,
posi ti on the bracket onto the bl ock and i nstal l the
attachi ng bol ts (Fi g. 41) (Fi g. 42). Ti ghten the bol ts
to 50 N·m (37 ft. l bs.) torque.
(2) Pl ace the i nsul ator on the support bracket.
I nstal l the i nsul ator retai ni ng bol ts and nuts.
Ti ghten the bol ts and nuts to 40 N·m (30 ft. l bs)
torque.
(3) I nstal l the through bol t and the retai ni ng nut.
Ti ghten the through bol t nut to 48 N·m (35 ft. l bs.)
torque.
(4) Remove the engi ne support.
(5) Lower the vehi cl e.
(6) Connect negati ve cabl e to battery.
ENGINE MOUNT— REAR
A resi l i ent rubber cushi on bracket assembl y sup-
ports the transmi ssi on at the rear. Thi s bracket i s
attached to the crossmember.
Fig. 40 Oil Filter Sealing Surface—Typical
1 – SEALING SURFACE
2 – RUBBER GASKET
3 – OIL FILTER
Fig. 41 Left Front Engine Mount
1 – BOLT (2)
2 – THROUGH BOLT
3 – NUT (2)
4 – BOLT (3)
5 – LEFT HAND ENGINE MOUNT ASSEMBLY
Fig. 42 Right Front Engine Mount
1 – RIGHT HAND ENGINE MOUNT ASSEMBLY
2 – THROUGH BOLT
3 – BOLT (3)
TJ 4. 0L ENGINE 9 - 91
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the bol ts hol di ng the i sol ator mount
assembl y to the transmi ssi on (Fi g. 43) (Fi g. 44).
(4) Rai se the transmi ssi on SLI GHTLY.
(5) Remove the through bol t and nut. Remove the
rear i sol ator mount assembl y.
(6) I f necessary, remove the bol ts hol di ng the rear
mount bracket to the crossmember.
INSTALLATION
(1) Posi ti on the rear mount bracket assembl y onto
the crossmember and i nstal l the bol ts. Ti ghten the
bol ts to 46 N·m (34 ft. l bs.)
(2) Posi ti on i sol ator mount i nto mount bracket and
i nstal l through bol t and nut. DO NOT ti ghten the
bol t at thi s ti me.
(3) Lower the transmi ssi on.
(4) Remove the transmi ssi on support.
(5) I nstal l the mount fasteni ng bol ts and ti ghten to
54 N·m (40 ft. l bs.) torque.
(6) Ti ghten the through bol t nut to 50 N·m (37 ft.
l bs.).
(7) Lower the vehi cl e.
(8) Connect the negati ve cabl e to the battery.
ENGINE BENDING BRACES
REMOVAL
The engi ne bendi ng braces are used to add
strength to the powertrai n and to address some
mi nor NVH concerns.
NOTE: Before the engine or the transmission can
be removed the engine bending braces must be
removed.
(1) Rai se and support vehi cl e.
NOTE: Both left and right side bending braces are
removed the sameway. Only the right side is
shown.
NOTE: The exhaust does not require removal to
preform this procedure.
(2) Remove the exhaust hanger bracket retai ni ng
bol t.
(3) Remove l ocknut and transmi ssi on bendi ng
brace bar.
(4) Remove engi ne-to-bendi ng brace retai ni ng bol t,
bendi ng brace bar and cross bar.
Fig. 43 Rear Engine Mount—(4X2)
Fig. 44 Rear Engine Mount—(4X4)
ITEM DESCRIPTON TORQUE
1 NUT (Qty 1) 45 N·m (33 ft. lbs.)
2 BOLT (Qty 4) 46 N·m (34 ft. lbs.)
3 BOLT (Qty 2
Per Side)
68 N·m (50 ft. lbs.)
4 BOLT (Qty 2
Per Side)
46 N·m (34 ft. lbs.)
5 BOLT (Qty 4) 46 N·m (34 ft. lbs.)
9 - 92 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
NOTE: DO NOT tighten the retaining hardware until
all bending braces are in place.
(1) Posi ti on the cross brace i nto the engi ne-to-
transmi ssi on brace, then posi ti on the engi ne-to-trans-
mi ssi on brace and i nstal l retai ni ng bol t.
(2) Posi ti on the transmi ssi on bendi ng brace onto
through brace and i nstal l new l ocknut.
(3) Posi ti on exhaust hanger and transmi ssi on
brace, i nstal l retai ni ng bol t (Fi g. 46).
(4) Ti ghten engi ne-to-transmi ssi on brace retai ni ng
bol t (Fi g. 45) to 40 N·m (30 ft. l bs.).
(5) Ti ghten transmi ssi on brace retai ni ng bol ts (Fi g.
46) to 40 N·m (30 ft. l bs.), then ti ghten transmi ssi on
brace retai ni ng l ock nuts (Fi g. 46) to 108 N·m (80 ft.
l bs.).
ENGINE ASSEMBLY
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
(3) Remove the radi ator drai n cock and radi ator
cap to drai n the cool ant. DO NOT waste usabl e cool -
ant. I f the sol uti on i s cl ean, drai n the cool ant i nto a
cl ean contai ner for reuse.
(4) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 47).
(5) Remove the l ower radi ator hose.
(6) Remove upper radi ator support retai ni ng bol ts
and remove radi ator support.
(7) Remove the fan assembl y from the water
pump.
(8) Remove the fan shroud (Fi g. 47).
(9) Di sconnect the transmi ssi on fl ui d cool er l i nes
(automati c transmi ssi on).
(10) Di scharge the A/C system. (Refer to Group 24,
Heati ng and Ai r Condi ti oni ng)
(11) Remove the servi ce val ves and cap the com-
pressor ports.
(12) Remove the radi ator or radi ator/condenser (i f
equi pped wi th A/C).
(13) Di sconnect the heater hoses at the engi ne
thermostat housi ng and water pump (Fi g. 47).
(14) Di sconnect the accel erator cabl e, transmi ssi on
l i ne pressure cabl e and speed control cabl e (i f
equi pped) from the throttl e body (Fi g. 48).
(15) Remove cabl es from the bracket and secure
out of the way.
(16) Di sconnect the body ground at the engi ne.
(17) Di sconnect the fol l owi ng connectors and
secure thei r harness out of the way.
• Power steeri ng pressure swi tch
• Cool ant temperature sensor
• Si x (6) fuel i njector connectors
• I ntake ai r temperature sensor
• Throttl e posi ti on sensor
Fig. 45 Engine-to-Transmission Bending Braces
1 – ENGINE-TO-TRANSMISSION BENDING BRACE
2 – CROSS BRACE
3 – ENGINE-TO-TRANSMISSION BENDING BRACE RETAINING
BOLT
Fig. 46 Transmission Bending Braces and Exhaust
Hanger
1 – TRANSMISSION BENDING BRACE RETAINING BOLT
2 – ENGINE-TO-TRANSMISSION BENDING BRACE
3 – LOCKNUT
4 – TRANSMISSION BRACE
5 – EXHAUST HANGER
TJ 4. 0L ENGINE 9 - 93
REMOVAL AND INSTALLATION (Continued)
• Map sensor
• Crankshaft posi ti on sensor
• Oxygen sensor
• Camshaft posi ti on sensor
• Generator connector and B+ termi nal wi re
(18) Di sconnect the coi l rai l el ectri cal connecti ons
and the oi l pressure swi tch connector.
(19) Perform the fuel pressure rel ease procedure.
(Refer to Group 14, Fuel System for correct proce-
dure)
(20) Di sconnect the fuel suppl y l i ne at the i njector
rai l . (Refer to Group 14, Qui ck-Connect Fi tti ngs for
the correct procedure)
(21) Remove the fuel l i ne bracket from the i ntake
mani fol d.
(22) Remove the ai r cl eaner assembl y (Fi g. 49).
(23) Di sconnect the hoses from the fi tti ngs at the
steeri ng gear.
(24) Drai n the pump reservoi r.
(25) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn objects from enteri ng the sys-
tem.
(26) Rai se and support the vehi cl e.
(27) Di sconnect the wi res from the engi ne starter
motor sol enoi d.
(28) Remove the engi ne starter motor.
(29) Di sconnect the oxygen sensor from the
exhaust pi pe.
(30) Di sconnect the exhaust pi pe from the mani -
fol d.
(31) Remove the exhaust pi pe support.
(32) Remove the bendi ng brace. Refer to Engi ne
Bendi ng Brace i n thi s secti on for procedure.
(33) Remove the engi ne fl ywheel /converter housi ng
access cover.
(34) Mark the converter and dri ve pl ate l ocati on.
(35) Remove the converter-to-dri ve pl ate bol ts.
(36) Remove the upper engi ne fl ywheel /converter
housi ng bol ts and l oosen the bottom bol ts.
(37) Remove the engi ne mount cushi on-to-engi ne
compartment bracket bol ts.
(38) Lower the vehi cl e.
(39) Attach a l i fti ng devi ce to the engi ne.
(40) Rai se the engi ne off the front supports.
(41) Pl ace a support or fl oor jack under the con-
verter (or engi ne fl ywheel ) housi ng.
(42) Remove the remai ni ng converter (or engi ne
fl ywheel ) housi ng bol ts.
(43) Li ft the engi ne out of the engi ne compart-
ment.
Fig. 47 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Heater hoses
1 – UPPER RADIATOR HOSE
2 – HEATER HOSES
3 – FAN SHROUD
4 – COOLANT RECOVERY HOSE
Fig. 48 Accelerator Cable, Vehicle Speed Control
Cable, Automatic Transmission Control Cable &
Quick-Connect Fuel Lines
1 – ACCELERATOR CABLE
2 – SPEED CONTROL CABLE
3 – QUICK-CONNECT FUEL LINES
4 – AUTOMATIC TRANSMISSION CONTROL CABLE
9 - 94 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the engine
flywheel.
(1) Attach a l i fti ng devi ce to the engi ne and l ower
the engi ne i nto the engi ne compartment. For easi er
i nstal l ati on, i t may be necessary to remove the
engi ne mount bracket as an ai d i n al i gnment of the
engi ne to the transmi ssi on.
(2) Al i gn the transmi ssi on torque converter hous-
i ng wi th the engi ne.
(3) Loosel y i nstal l the converter housi ng l ower
bol ts and i nstal l the next hi gher bol t and nut on each
si de.
(4) Ti ghten al l 4 bol ts fi nger ti ght.
(5) I nstal l the engi ne mount brackets (i f removed).
(6) Lower the engi ne and engi ne mount brackets
onto the engi ne compartment cushi ons. I nstal l the
bol ts and fi nger ti ghten the nuts.
(7) Remove the engi ne l i fti ng devi ce.
(8) Rai se and support the vehi cl e.
(9) I nstal l the remai ni ng engi ne fl ywheel /converter
housi ng bol ts. Ti ghten al l bol ts to 38 N·m (28 ft. l bs.)
torque.
(10) I nstal l the converter-to-dri ve pl ate bol ts.
(11) Ensure the i nstal l ati on reference marks are
al i gned.
(12) I nstal l the engi ne fl ywheel /converter housi ng
access cover.
(13) I nstal l the exhaust pi pe support and ti ghten
the screw.
(14) I nstal l the engi ne bendi ng brace.
(15) Ti ghten the engi ne mount-to-bracket bol ts.
(16) Connect the vehi cl e speed sensor wi re connec-
ti ons and ti ghten the screws.
(17) Connect the exhaust pi pe to the mani fol d.
(18) I nstal l the engi ne starter motor and connect
the cabl e.
(19) Connect the wi res to the engi ne starter motor
sol enoi d.
(20) Lower the vehi cl e.
(21) Connect al l the vacuum hoses and wi re con-
nectors i denti fi ed duri ng engi ne removal .
(22) Remove protecti ve caps from the power steer-
i ng hoses.
(23) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 N·m (38 ft. l bs.)
torque.
(24) Fi l l the pump reservoi r wi th fl ui d.
(25) I nspect the fuel suppl y l i ne o-ri ng(s) and
repl ace i f necessary. Connect fuel suppl y l i ne to i njec-
ti or rai l and veri fy connecti on by pul l i ng outward on
the l i ne.
(26) I nstal l the fuel l i ne bracket to the i ntake
mani fol d.
(27) Connect the coi l rai l el ectri cal connectors and
oi l pressure swi tch connector.
(28) Connect the fol l owi ng el ectri cal connectors:
• Power steeri ng pressure swi tch
• Cool ant temperature sensor
• Si x (6) fuel i njector connectors
• I ntake ai r temperature sensor
• Throttl e posi ti on sensor
• Map sensor
• Crankshaft posi ti on sensor
• Oxygen sensor
• Camshaft posi ti on sensor
• Generator connector and B+ termi nal wi re
(29) Connect al l previ ousl y removed vacuum hoses.
(30) Connect the body ground strap.
(31) I nstal l the throttl e, transmi ssi on l i ne pres-
sure, and speed control cabl es to thei r mounti ng
bracket and connect them to the throttl e body.
(32) Connect the heater hoses at the engi ne ther-
mostat housi ng and water pump.
(33) I nstal l the fan assembl y to the water pump.
(34) Pl ace the fan shroud i n posi ti on over the fan.
(35) I nstal l the radi ator or radi ator/condenser.
(36) Connect the servi ce val ves to the A/C com-
pressor ports, i f equi pped wi th A/C.
Fig. 49 Air Cleaner Assembly & Power Steering
Pump
1 – POWER STEERING PUMP
2 – AIR CLEANER ASSEMBLY
TJ 4. 0L ENGINE 9 - 95
REMOVAL AND INSTALLATION (Continued)
(37) Charge the ai r condi ti oner system (refer to
Group 24, Heati ng and Ai r Condi ti oni ng).
(38) Connect the radi ator hoses and automati c
transmi ssi on fl ui d cool er pi pes, i f equi pped.
(39) I nstal l the fan shroud to the radi ator or radi -
ator/condenser (i f equi pped wi th A/C).
(40) I nstal l upper radi ator support.
(41) Connect the upper radi ator hose and ti ghten
the cl amp.
(42) Connect the l ower radi ator hose and ti ghten
the cl amp.
(43) Fi l l crankcase wi th engi ne oi l . (Refer to Group
0, Lubri cati on and Mai ntenance for correct capaci -
ti es.)
(44) Fi l l the cool i ng system wi th reusabl e cool ant
or new cool ant (refer to Group 7, Cool i ng System).
(45) Al i gn the hood to the scri be marks. I nstal l the
hood.
(46) I nstal l the ai r cl eaner assembl y.
(47) I nstal l the battery and connect the battery
cabl e.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(48) Start the engi ne, i nspect for l eaks and correct
the fl ui d l evel s, as necessary.
INTAKE AND EXHAUST MANIFOLD
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Di sconnect the battery negati ve cabl e.
(2) Remove ai r cl eaner i nl et hose from throttl e
body assembl y.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped) and the transmi ssi on l i ne pres-
sure cabl e.
(5) Di sconnect the fol l owi ng el ectri cal connecti ons
and secure thei r harness out of the way:
• Throttl e Posi ti on Sensor
• I dl e Ai r Control Motor
• Cool ant Temperature Sensor (at thermostat
housi ng)
• I ntake Ai r Temperature Sensor
• Oxygen Sensor
• Crank Posi ti on Sensor
• Si x (6) Fuel I njector Connectors
(6) Di sconnect the Map Sensor, HVAC, and Brake
Booster vacuum suppl y hoses at the i ntake mani fol d.
(7) Perform the fuel pressure rel ease procedure.
(Refer to Group 14, Fuel Systems for correct proce-
dure)
(8) Di sconnect and remove the fuel system suppl y
l i ne from the fuel rai l assembl y. (Refer to Group 14,
Qui ck Connect Fi tti ngs for correct procedures)
(9) Remove the accessory dri ve bel t (refer to Group
7, Cool i ng System). Loosen the tensi oner.
(10) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and set asi de.
(11) Rai se the vehi cl e.
(12) Di sconnect the exhaust pi pes from the engi ne
exhaust mani fol ds.
(13) Lower the vehi cl e.
(14) Remove the i ntake mani fol d and engi ne
exhaust mani fol ds.
INSTALLATION
I f the mani fol d i s bei ng repl aced, ensure al l the fi t-
ti ng, etc. are transferred to the repl acement mani -
fol d.
(1) I nstal l a new engi ne exhaust/i ntake mani fol d
gasket over the al i gnment dowel s on the cyl i nder
head.
(2) Posi ti on the engi ne exhaust mani fol ds to the
cyl i nder head. I nstal l fastener Number 3 and fi nger
ti ghten at thi s ti me (Fi g. 50).
(3) I nstal l i ntake mani fol d on the cyl i nder head
dowel s.
(4) I nstal l washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fi g. 50).
(5) I nstal l washer and fastener Numbers 6 and 7
(Fi g. 50).
(6) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 50).
• Fastener Numbers 1 through 5—Ti ghten to 33
N·m (24 ft. l bs.) torque.
• Fastener Numbers 6 and 7—Ti ghten to 14 N·m
(126 i n. l bs.) torque.
• Fastener Numbers 8 through 11—Ti ghten to 33
N·m (24 ft. l bs.) torque.
(7) I nstal l the power steeri ng pump and bracket to
the i ntake mani fol d. Ti ghten the bel t to speci fi cati on.
(Refer to Group 7, Cool i ng System for the correct pro-
cedures)
(8) I nstal l the fuel system suppl y l i ne to the fuel
rai l assembl y. Before connecting the fuel supply
line to the fuel rail inspect the O-rings and
replace if necessary. Refer to Group 14, Fuel
System for the correct procedure.
(9) Connect al l el ectri cal connecti ons on the i ntake
mani fol d.
(10) Connect the vacuum hoses previ ousl y
removed.
9 - 96 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(11) I nstal l throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped).
(12) I nstal l the transmi ssi on l i ne pressure cabl e (i f
equi pped). Refer to Group 21, Transmi ssi on for the
adjustment procedures.
(13) I nstal l ai r cl eaner assembl y.
(14) Connect ai r i nl et hose to the throttl e body
assembl y.
(15) Rai se the vehi cl e.
(16) Connect the exhaust pi pes to the engi ne
exhaust mani fol ds. Ti ghten the bol ts to 31 N·m (23
ft. l bs.)
(17) Lower the vehi cl e.
(18) Connect the battery negati ve cabl e.
(19) Start the engi ne and check for l eaks.
CYLINDER HEAD COVER
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
There are two cyl i nder head bol ts that have a pi n
to l ocate the cyl i nder head cover gasket, they are
l ocated at posi ti on 8 and 9 (Fi g. 52)
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover.
(3) Di sconnect the fresh ai r i nl et hose from the
engi ne cyl i nder head cover.
(4) Di sconnect the accel erator, transmi ssi on, and
speed (i f equi pped) control cabl es from the throttl e
body (Fi g. 51).
(5) Remove the three bol ts that fasten the control
cabl e bracket to the i ntake mani fol d.
(6) Remove control cabl es from cyl i nder head cover
cl i p.
(7) Posi ti on control cabl es and bracket away from
cyl i nder head cover secure wi th ti e straps.
(8) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(9) Remove the engi ne cyl i nder head cover and
gasket.
INSTALLATION
(1) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet and oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(2) I nstal l cyl i nder head cover and gasket. Ti ghten
the mounti ng bol ts to 10 N·m (85 i n. l bs.) torque.
(3) Connect the CCV hoses.
(4) I nstal l control cabl es and bracket on i ntake
mani fol d and ti ghten bol ts to 8.7 N·m (77 i n. l bs.)
torque.
(5) Connect control cabl es to throttl e body l i nkage.
(6) Snap control cabl es i nto cyl i nder head cover
cl i p.
(7) Connect negati ve cabl e to battery.
Fig. 50 Intake and Exhaust Manifolds—4.0L
Fig. 51 Engine Cylinder Head Cover
1 – TRANS CONTROL CABLE
2 – ACCELERATOR CABLE
3 – CONTROL CABLE BRACKET
4 – CYLINDER HEAD COVER
Fig. 52 Cylinder Head Cover Gasket Locator Pins at
#8 & #9
TJ 4. 0L ENGINE 9 - 97
REMOVAL AND INSTALLATION (Continued)
ROCKER ARMS AND PUSH RODS
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
(1) Remove the engi ne cyl i nder head cover.
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 53). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 53). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or equi v-
al ent, l ubri cate the area of the rocker arm that the
pi vot contacts. I nstal l rocker arms, pi vots and bri dge
above each cyl i nder i n thei r ori gi nal l y posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 N·m (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover.
VALVE STEM SEAL AND SPRING
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
I nspect the val ve stems, especi al l y the grooves for
ni cks, and hi gh spots. I f excessi ve ni cks or hi gh spots
are found the val ve or val ves shoul d be repl aced.
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(1) Remove the engi ne cyl i nder head cover.
(2) Remove capscrews, bri dge and pi vot assembl i es
and rocker arms for access to each val ve spri ng to be
removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 54).
(8) Remove val ve spri ng and retai ner (Fi g. 54).
(9) Remove val ve stem oi l seal s (Fi g. 54). Note the
val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(I ntake) or EXH (Exhaust). DO NOT mi x the seal s.
NOTE: If valves, valve springs or seals are to be
inspected / replaced at this time, refer to Valves and
Valve Springs in this section for proper inspection
procedures.
INSTALLATION
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
Fig. 53 Rocker Arm Assembly
1 – CAPSCREWS
2 – BRIDGE
3 – PIVOT ASSEMBLY
4 – PUSH RODS
5 – ROCKER ARMS
9 - 98 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge capscrews al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
capscrews to 28 N·m (21 ft. l bs.) torque.
(9) I nstal l the engi ne cyl i nder head cover.
CYLINDER HEAD
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant and di sconnect the hoses at
the engi ne thermostat housi ng and the water pump
i nl et. DO NOT waste reusabl e cool ant. I f the sol uti on
i s cl ean and i s bei ng drai ned onl y to servi ce the
engi ne or cool i ng system, drai n the cool ant i nto a
cl ean contai ner for reuse.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the engi ne cyl i nder head cover.
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms.
(6) Remove the push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order as removed.
(7) Loosen the accessory dri ve bel t at the power
steeri ng pump. (Refer to Group 7, Cool i ng System for
the correct procedure). Sl i p the bel t off of the power
steeri ng pul l ey.
(8) Remove the A/C compressor mounti ng bol ts
and secure the compressor to the si de.
(9) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and water pump. Set the
pump and bracket asi de. DO NOT di sconnect the
hoses.
(10) Perform the Fuel System Pressure Rel ease
procedure. (Refer to Group 14, Fuel System)
(11) Di sconnect the fuel suppl y l i ne at the fuel rai l .
(Refer to Group 14, Qui ck-Connect Fi tti ngs for the
correct procedures)
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head. (Refer to Group
11, Exhaust System and I ntake Mani fol d for the
proper procedures)
(13) Di sconnect the coi l rai l el ectri cal connectors
and remove the coi l rai l .
(14) Remove spark pl ugs.
(15) Di sconnect the temperature sendi ng uni t wi re
connector.
(16) Remove the engi ne cyl i nder head bol ts. Bol t
No.14 cannot be removed unti l the head i s moved for-
ward (Fi g. 55). Pul l bol t No.14 out as far as i t wi l l go
and then suspend the bol t i n thi s posi ti on (tape
around the bol t).
Fig. 54 Valve and Valve Components
1 – VALVE LOCKS (3–BEAD)
2 – RETAINER
3 – VALVE STEM OIL SEAL
4 – INTAKE VALVE
5 – EXHAUST VALVE
6 – VALVE SPRING
TJ 4. 0L ENGINE 9 - 99
REMOVAL AND INSTALLATION (Continued)
(17) Remove the engi ne cyl i nder head and gasket
(Fi g. 55).
(18) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i sn’t known i f they were used before, di scard the
bol ts.
(19) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
NOTE: If the valves, springs, or seals are to be
inspected/replaced at this time, refer to Valves and
Valve Springs in this section for proper inspection
procedures.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) Posi ti on the engi ne cyl i nder head gasket (wi th
the numbers faci ng up) usi ng the al i gnment dowel s
i n the cyl i nder bl ock, to posi ti on the gasket.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(3) Wi th bol t No.14 hel d i n pl ace (tape around
bol t), i nstal l the engi ne cyl i nder head over the same
dowel s used to l ocate the gasket. Remove the tape
from bol t No.14.
(4) Coat the threads of stud bol t No.11 wi th Loc-
ti te 592 seal ant, or equi val ent.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
56).
CAUTION: During the final tightening sequence,
bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.
(a) Ti ghten al l bol ts i n sequence (1 through 14)
to 30 N·m (22 ft. l bs.) torque.
(b) Ti ghten al l bol ts i n sequence (1 through 14)
to 61 N·m (45 ft. l bs.) torque.
(c) Check al l bol ts to veri fy they are set to 61
N·m (45 ft. l bs.) torque.
(d) Ti ghten bol ts i n sequence:
• Bol ts 1 through 10 to 149 N·m (110 ft. l bs.)
torque.
• Bol t 11 to 135 N·m (100 ft. l bs.) torque.
• Bol ts 12 through 14 to 149 N·m (110 ft. l bs.)
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(6) I nstal l the spark pl ugs and ti ghten to 37 N·m
(27 ft. l bs.) torque.
(7) Connect the temperature sendi ng uni t wi re
connector.
(8) I nstal l the i gni ti on coi l rai l and coi l rai l el ectri -
cal connectors.
(9) I nstal l the i ntake and engi ne exhaust mani -
fol ds (refer to procedures i n thi s secti on).
(10) I nstal l the fuel l i ne and the vacuum advance
hose.
(11) Attach the power steeri ng pump and bracket.
Fig. 55 Engine Cylinder Head Assembly
1 – CYLINDER HEAD BOLTS
2 – CYLINDER HEAD GASKET
3 – CYLINDER HEAD
CYLINDER HEAD BOLTS
POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
8,9 1/2 in.-13 BOLT WITH DOWEL
POINT
2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16 in.-14 STUD
END
All bolts are 12 point drives for rocker cover clearance
9 - 100 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(12) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed (refer to
Rocker Arms and Push Rods i n thi s secti on).
(13) I nstal l the engi ne cyl i nder head cover.
(14) Attach the ai r condi ti oner compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
Ti ghten the bol ts to 40 N·m (30 ft. l bs.) torque.
(15) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 N·m (20 ft. l bs.)
torque.
CAUTION: The serpentine drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(16) I nstal l the serpenti ne dri ve bel t. (refer to
Group 7, Cool i ng System for the proper procedure).
(17) I nstal l the ai r cl eaner and ducti ng.
(18) Connect the hoses to the engi ne thermostat
housi ng and fi l l the cool i ng system to the speci fi ed
l evel (refer to Group 7, Cool i ng Systems for the
proper procedure).
(19) The automati c transmi ssi on throttl e l i nkage
and cabl e must be adjusted after compl eti ng the
engi ne cyl i nder head i nstal l ati on (refer to Group 21,
Transmi ssi ons for the proper procedures).
(20) I nstal l the temperature sendi ng uni t and con-
nect the wi re connector.
(21) I f equi pped wi th ai r condi ti oni ng, i nstal l A/C
compressor and charge A/C system (refer to Group 24
Heati ng and Ai r Condi ti oni ng).
(22) Connect negati ve cabl e to battery.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(23) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the engi ne thermostat opens. Add cool ant, i f
requi red.
VALVES AND VALVE SPRINGS
Thi s procedure i s done wi th the engi ne cyl i nder
head removed from the bl ock.
REMOVAL
(1) Remove the engi ne cyl i nder head from the cyl -
i nder bl ock.
(2) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s.
(4) Use a smooth stone or a jewel ers fi l e to remove
any burrs on the top of the val ve stem, especi al l y
around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
the same order as removed.
INSTALLATION
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems. I f the 0.381 mm (0.015 i nch) over-
si ze val ve stems are used, oversi ze oi l seal s are
requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
(8) I nstal l the engi ne cyl i nder head.
HYDRAULIC TAPPETS
Retai n al l the components i n the same order as
removed.
REMOVAL
(1) Remove the engi ne cyl i nder head (Refer to cyl -
i nder head r&i i n thi s secti on).
(2) Remove the push rods.
(3) Remove the tappets through the push rod open-
i ngs i n the cyl i nder bl ock wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 57).
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
Fig. 56 Engine Cylinder Head Bolt Tightening
Sequence
TJ 4. 0L ENGINE 9 - 101
REMOVAL AND INSTALLATION (Continued)
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the cyl i nder head assy (Refer to cyl i nder
head r&i i n thi s secti on).
(4) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(5) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(6) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 N·m (21 ft. l bs.) torque.
(7) Pour the remai ni ng Mopar Engi ne Oi l Suppl e-
ment, or equi val ent over the enti re val ve actuati ng
assembl y. The Mopar Engi ne Oi l Suppl ement, or
equi val ent must remai n wi th the engi ne oi l for at
l east 1 609 km (1,000 mi l es). The oi l suppl ement
need not be drai ned unti l the next schedul ed oi l
change.
(8) I nstal l the engi ne cyl i nder head cover.
VIBRATION DAMPER
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the serpenti ne dri ve bel t and fan
shroud. Refer to Group 7, Cool i ng Systems for the
procedures.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 58).
INSTALLATION
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n posi ti on, al i gn the keyway on the
vi brati on damper hub wi th the crankshaft key and
tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 N·m
(80 ft. l bs.) torque.
(4) I nstal l the serpenti ne dri ve bel t. (Refer to
Group 7, Cool i ng Systems for the proper speci fi ca-
ti ons and procedures).
(5) Connect negati ve cabl e to battery.
TIMING CASE COVER
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the vi brati on damper.
(3) Remove the fan and hub assembl y and remove
the fan shroud.
(4) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(5) Remove the A/C compressor (i f equi pped) and
generator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(7) Remove the ti mi ng case cover and gasket from
the engi ne.
(8) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 59).
INSTALLATION
Cl ean the ti mi ng case cover, oi l pan and cyl i nder
bl ock gasket surfaces.
(1) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
Fig. 57 Hydraulic Valve Tappet Removal—
Installation Tool
1 – HYDRAULIC TAPPET REMOVAL TOOL
2 – CYLINDER BLOCK
Fig. 58 Vibration Damper Removal Tool 7697
1 – VIBRATION DAMPER REMOVAL TOOL
2 – WRENCH
9 - 102 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(2) Posi ti on the gasket on the cyl i nder bl ock.
(3) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(4) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 60).
(5) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
(6) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
N·m (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 N·m (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 9.5 N·m
(84 i n. l bs.) torque.
(7) Remove the cover al i gnment tool .
(8) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
(9) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 N·m (80 ft. l bs.)
torque.
(10) I nstal l the A/C compressor (i f equi pped) and
generator bracket assembl y.
(11) I nstal l the engi ne fan and hub assembl y and
shroud.
(12) I nstal l the serpenti ne dri ve bel t.
(13) Connect negati ve cabl e to battery.
TIMING CHAIN AND SPROCKETS
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the fan and shroud.
(3) Remove the serpenti ne dri ve bel t.
(4) Remove the crankshaft vi brati on damper.
(5) Remove the ti mi ng case cover.
(6) Rotate crankshaft unti l the “0” ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 61).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the camshaft sprocket bol t and washer
(Fi g. 62).
Fig. 59 Timing Case Cover Components
1 – TIMING CASE COVER
2 – OIL SLINGER
3 – CRANKSHAFT OIL SEAL
4 – VIBRATION DAMPER PULLEY
Fig. 60 Timing Case Cover Alignment and Seal
Installation Tool 6139
1 – TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
Fig. 61 Crankshaft—Camshaft Alignment
1 – CAMSHAFT SPROCKET
2 – TIMING MARKS
3 – CRANKSHAFT SPROCKET
TJ 4. 0L ENGINE 9 - 103
REMOVAL AND INSTALLATION (Continued)
(9) Remove the crankshaft sprocket, camshaft
sprocket and ti mi ng chai n as an assembl y.
(10) I nstal l ati on of the ti mi ng chai n wi th the ti m-
i ng marks on the crankshaft and camshaft sprockets
properl y al i gned ensures correct val ve ti mi ng. A worn
or stretched ti mi ng chai n wi l l adversel y affect val ve
ti mi ng. I f the ti mi ng chai n defl ects more than 12.7
mm (1/2 i nch) repl ace i t.
INSTALLATION
Assembl e the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned (Fi g. 61).
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n the keyway on the crankshaft, i nstal l
the assembl y on the crankshaft and camshaft.
(2) I nstal l the camshaft sprocket bol t and washer
(Fi g. 62). Ti ghten the bol t to 68 N·m (50 ft. l bs.)
torque.
(3) To veri fy correct i nstal l ati on of the ti mi ng
chai n, rotate the crankshaft 2 revol uti ons. The cam-
shaft and crankshaft sprocket ti mi ng mark shoul d
al i gn (Fi g. 61).
(4) I nstal l the crankshaft oi l sl i nger.
(5) Repl ace the oi l seal i n the ti mi ng case cover.
(6) I nstal l the ti mi ng case cover and gasket.
(7) Wi th the key i nstal l ed i n the crankshaft key-
way, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 N·m (80 ft. l bs.)
torque.
(8) I nstal l the serpenti ne dri ve bel t. (refer to
Group 7, Cool i ng System for the proper procedure).
(9) I nstal l the fan and hub assembl y. I nstal l the
shroud.
(10) Connect negati ve cabl e to battery.
CAMSHAFT
REMOVAL
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n the cool i ng system. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto a
cl ean contai ner for reuse.
(3) Remove the radi ator or radi ator and condenser,
i f equi pped wi th A/C (refer to Group 7, Cool i ng Sys-
tem for the proper procedure).
(4) Remove the engi ne cyl i nder head cover.
(5) Remove the rocker arms, bri dges and pi vots.
(6) Remove the push rods.
(7) Remove the engi ne cyl i nder head and gasket.
(8) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder bl ock.
(9) Remove the vi brati on damper.
(10) Remove the ti mi ng case cover.
(11) Rotate the crankshaft unti l the crankshaft
sprocket ti mi ng mark i s al i gned on centerl i ne wi th
the camshaft sprocket ti mi ng mark (Fi g. 64).
(12) Remove the ti mi ng chai n and sprockets.
(13) Remove the front bumper and/or gri l l e, as
requi red.
(14) Remove the two thrust pl ate retai ni ng screws,
thrust pl ate and camshaft (Fi g. 63).
INSTALLATION
(1) I nspect the cam l obes for wear.
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the thrust washer, exami ne the oi l pressure
rel i ef hol es i n the rear cam journal . The oi l pressure
rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent.
(7) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs (Fi g. 63).
(8) Posi ti on thrust pl ate and i nstal l retai ni ng
screws. Ti ghten screws to 24 N·m (18 ft. l bs.).
(9) I nstal l the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned.
(10) I nstal l the camshaft sprocket bol t/cup washer.
Ti ghten the bol t to 68 N·m (50 ft. l bs.).
Fig. 62 Camshaft Sprocket and Thrust Plate
1 – CAMSHAFT
2 – CAMSHAFT SPROCKET W/ INTEGRAL KEY
3 – BOLT & CUP WASHER
4 – THRUST PLATE
9 - 104 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(11) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 65). Refer to Ti mi ng Case Cover
I nstal l ati on.
(12) I nstal l the vi brati on damper (Fi g. 65).
(13) I nstal l the hydraul i c val ve tappets.
(14) I nstal l the cyl i nder head gasket wi th the
numbers faci ng up.
(15) I nstal l the cyl i nder head and head bol ts
(Refer to cyl i nder head R&I i n thi s secti on for torque
val ues and ti ghteni ng sequence).
(16) I nstal l the push rods.
(17) I nstal l the rocker arms and pi vot and bri dge
assembl i es. Ti ghten each of the capscrews for each
bri dge al ternatel y, one turn at a ti me, to avoi d dam-
agi ng the bri dge (Refer to Rocker Arms and Push
Rods i n thi s secti on).
(18) I nstal l the engi ne cyl i nder head cover.
(19) I nstal l the serpenti ne dri ve bel t. (refer to
Group 7, Cool i ng System for the proper procedure).
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with Mopar
Engine Oil Supplement, or equivalent. The Mopar
Engine Oil Supplement, or equivalent must remain
with the engine oil for at least 1609 km (1,000
miles). The oil supplement need not be drained until
the next scheduled oil change.
(20) I nstal l the radi ator, connect the hoses and fi l l
the cool i ng system to the speci fi ed l evel (refer to
Group 7, Cool i ng System for the proper procedure).
(21) Check the i gni ti on ti mi ng and adjust as nec-
essary.
(22) I nstal l the gri l l e and bumper, i f removed.
(23) Connect negati ve cabl e to battery.
Fig. 63 Camshaft
1 – CAMSHAFT
2 – CRANKSHAFT
Fig. 64 Crankshaft / Camshaft Sprocket Timing Mark
Alignment
1 – CAMSHAFT SPROCKET
2 – TIMING MARKS
3 – CRANKSHAFT SPROCKET
Fig. 65 Timing Case Cover Components
1 – TIMING CASE COVER
2 – OIL SLINGER
3 – CRANKSHAFT OIL SEAL
4 – VIBRATION DAMPER PULLEY
TJ 4. 0L ENGINE 9 - 105
REMOVAL AND INSTALLATION (Continued)
CAMSHAFT BEARINGS
REMOVAL
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated. Camshaft
end pl ay i s mai ntai ned by the thrust pl ate.
(1) Remove the camshaft. Refer to Camshaft i n
thi s secti on for procedure.
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available, such as recom-
mended tool 8544 Camshaft Bushing Remover
Installer.
(2) Usi ng Speci al tool , remove the camshaft bear-
i ngs.
INSTALLATION
(1) I nspect the camshaft beari ng journal s for
uneven wear pattern or fi ni sh.
(2) I nspect the camshaft l obes and di stri butor gear
for wear.
(3) I nspect the camshaft thrust pl ate for wear. I f
the pl ate shows excessi ve wear i nspect the camshaft
oi l pressure rel i ef hol es i n the rear cam jounral . The
rel i ef hol es must be cl ean and free of debri s.
CAUTION: Make sure outside diameter of number 1
bearing is clean. Make sure that the bearing is
properly installed in the engine block, align the oil
hole in the bearing with the oil gallery in the bear-
ing bore. Failure to do so will cause inadequate oil
supply for the sprockets and timing chain.
(4) Usi ng speci al tool , i nstal l new camshaft bear-
i ngs.
(5) Lubri cate the camshaft wi th Mopar௡ engi ne oi l
suppl ement, or equi val ent.
(6) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs
(7) Posi ti on the thrust pl ate and i nstal l the two
retai ni ng screws. Ti ghten screws to 24 N·m (18 ft.
l bs.).
(8) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n wi th the ti mi ng marks
al i gned. I nstal l the sprocket bol t.
(9) Ti ghten the camshaft sprocket bol t and washer
to 68 N·m (50 ft. l bs.).
(10) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft two ful l revol uti ons then
posi ti on the camshaft sprocket ti mi ng mark as shown
i n (Fi g. 66).
(11) I nstal l the ti mi ng chai n cover refer to the pro-
cedure i n thi s secti on.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the spark pl ugs.
(3) Rai se the vehi cl e.
(4) Remove the oi l pan and oi l pump.
(5) Remove mai n beari ng cap brace (Fi g. 67).
(6) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 68).
(7) Remove the l ower i nsert from the beari ng cap.
(8) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 69). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 69). After movi ng
Fig. 66 Crankshaft / Camshaft Chain Drive
Installation—Typical
1 – CAMSHAFT SPROCKET
2 – TIMING MARKS
3 – CRANKSHAFT SPROCKET
9 - 106 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(9) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) On the rear mai n cap, appl y Mopar௡ Gasket
Maker seal er on both si des of cyl i nder bl ock as
shown i n (Fi g. 70). The dab of seal er shoul d be 3 mm
(0.125 i n.) i n di ameter.
(5) Appl y Mopar௡ Gasket Maker on the rear bear-
i ng cap. The bead shoul d be 2.3 mm (0.09 i n.) i n
di ameter. DO NOT appl y seal er to the l i p of the seal .
(6) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(7) Ti ghten the bol ts of caps 1, 2, 4, 5, 6, and 7 to
54 N·m (40 ft. l bs.) torque. Now ti ghten these bol ts to
95 N·m (70 ft. l bs.) torque. Fi nal l y, ti ghten these
bol ts to 108 N·m (80 ft. l bs.) torque.
(8) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.3 to 54 N·m (40 ft. l bs.) torque. Then ti ghten
to 95 N·m (70 ft. l bs.) torque and fi nal l y ti ghten to
108 N·m (80 ft. l bs.) torque.
(9) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
Fig. 67 Main Bearing Caps and Brace.
1 – BLOCK
2 – MAIN BEARING CAP BRACE
Fig. 68 Removing Main Bearing Caps and Lower
Inserts
1 – CONNECTING ROD JOURNAL
2 – MAIN BEARING CAPS
Fig. 69 Removing Upper Inserts
1 – COTTER PIN
2 – BEARING INSERT
3 – TONGUE DEPRESSOR
TJ 4. 0L ENGINE 9 - 107
REMOVAL AND INSTALLATION (Continued)
(10) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 71). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(11) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock (refer to Cyl i nder
Bl ock - Assembl e).
(12) I nstal l mai n beari ng cap brace ti ghten nuts to
47 N·m (35 ft. l bs.) torque.
(13) I nstal l oi l pump assy. and ti ghten attachi ng
bol ts to 23 N·m (17 ft. l bs.)
(14) I nstal l the oi l pan.
(15) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
N·m (25 ft. l bs.) torque.
(16) Lower the vehi cl e.
(17) I nstal l the spark pl ugs. Ti ghten the pl ugs to
37 N·m (27 ft. l bs.) torque.
(18) Fi l l the oi l pan wi th engi ne oi l to the ful l
mark on the di psti ck l evel .
(19) Connect negati ve cabl e to battery.
OIL PAN
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the exhaust
mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(6) Remove the starter motor.
(7) Remove the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(8) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(9) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(10) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(11) Remove the engi ne mount through bol ts.
Fig. 70 Location of Sealer
1 – DOWEL
2 – SEALER LOCATIONS
3 – CYLINDER BLOCK
4 – HALFWAY BETWEEN
5 – REAR FACE OF CYLINDER BLOCK
6 – 3mm (0.125 in.)
Fig. 71 Crankshaft End Play Measurement
1 – DIAL INDICATOR
2 – CRANKSHAFT
9 - 108 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
(12) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(13) Remove transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
are attached to the oi l pan studs.
(14) Remove the oi l pan bol ts and studs. Careful l y
sl i de the oi l pan and gasket to the rear. I f equi pped
wi th an oi l l evel sensor, take care not to damage the
sensor.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1 1/2 x 1/4
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 72).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 73).
(4) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces) (Fi g. 74).
(5) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(6) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(7) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 N·m (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 75). Ti ghten these bol ts to 15
N·m (132 i n. l bs.) torque.
(8) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 N·m (84
i n. l bs.) torque.
(9) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(10) I nstal l the through bol ts and ti ghten the nuts.
Fig. 72 Fabrication of Alignment Dowels
1 – 1/4ЈЈ ϫ 1 1/2ЈЈ BOLT
2 – DOWEL
3 – SLOT
Fig. 73 Position of Dowels in Cylinder Block
1 – DOWEL HOLES
2 – CYLINDER BLOCK
3 – 5/16ЈЈ HOLES
4 – 5/16ЈЈ HOLES
Fig. 74 Oil Pan Sealer Location
1 – SEALER LOCATIONS
Fig. 75 Position of 5/16 inch Oil Pan Bolts
1 – OIL PAN
2 – OIL PAN DRAIN PLUG
TJ 4. 0L ENGINE 9 - 109
REMOVAL AND INSTALLATION (Continued)
(11) Lower the jack stand and remove the pi ece of
wood.
(12) I nstal l the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(13) I nstal l the engi ne starter motor.
(14) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(15) I nstal l transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
attach to the oi l pan studs.
(16) I nstal l the oi l pan drai n pl ug (Fi g. 75).
Ti ghten the pl ug to 34 N·m (25 ft. l bs.) torque.
(17) Lower the vehi cl e.
(18) Connect negati ve cabl e to battery.
(19) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(20) Start the engi ne and i nspect for l eaks.
PISTONS AND CONNECTING RODS
REMOVAL
(1) Remove the engi ne cyl i nder head cover.
(2) Remove the rocker arms, bri dges and pi vots.
(3) Remove the push rods.
(4) Remove the engi ne cyl i nder head.
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(6) Rai se the vehi cl e.
(7) Drai n the engi ne oi l .
(8) Remove the oi l pan and gasket.
(9) Remove mai n beari ng cap brace (Fi g. 76).
(10) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 77).
(11) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(12) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 78).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed.
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
Fig. 76 Main Bearings Caps and Brace
1 – BLOCK
2 – MAIN BEARING CAP BRACE
Fig. 77 Stamped Connecting Rods and Caps
1 – CONNECTING ROD CAP
2 – CONNECTING ROD
9 - 110 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 79).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 79).
(6) Rai se the vehi cl e.
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.
(11) I nstal l mai n beari ng cap brace (Fi g. 76).
Ti ghten nuts to 47 N·m (35 ft. l bs.).
(12) I nstal l the oi l pan and gaskets as outl i ned i n
the i nstal l ati on procedure.
(13) Lower the vehi cl e.
(14) I nstal l the engi ne cyl i nder head, push rods,
rocker arms, bri dges, pi vots and engi ne cyl i nder head
cover.
(15) Fi l l the crankcase wi th engi ne oi l .
CRANKSHAFT OIL SEALS— REAR
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
REMOVAL
(1) Remove transmi ssi on i nspecti on cover.
(2) Remove oi l pan. Refer to procedure i n thi s sec-
ti on
(3) Remove mai n beari ng cap brace.
(4) Remove rear mai n beari ng cap (No.7).
(5) Push upper seal out of the groove. Ensure that
the crankshaft and seal groove are not damaged.
Fig. 78 Removal of Connecting Rod and Piston
Assembly
1 – PISTON
2 – CONNECTING ROD
3 – BLOCK
Fig. 79 Rod and Piston Assembly Installation
TJ 4. 0L ENGINE 9 - 111
REMOVAL AND INSTALLATION (Continued)
(6) Remove l ower hal f of the seal from the beari ng
cap.
INSTALLATION
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Appl y a thi n coat of engi ne oi l .
(3) Coat l i p of the seal wi th engi ne oi l .
(4) Careful l y posi ti on the upper seal i nto the
groove i n the cyl i nder bl ock. The l i p of the seal faces
toward the front of the engi ne.
(5) Appl y Mopar௡ Gasket Maker seal er on both
si des of cyl i nder bl ock as shown i n (Fi g. 80). The dab
of seal er shoul d be 3 mm (0.125 i n.) i n di ameter.
(6) Appl y Mopar௡ Gasket Maker on the rear bear-
i ng cap (Fi g. 80). The bead shoul d be 2.3 mm (0.09
i n.) i n di ameter. DO NOT appl y seal er to the l i p of
the seal .
(7) Posi ti on the l ower seal i nto the beari ng cap
recess and seat i t fi rml y. Be sure the seal i s fl ush
wi th the cyl i nder bl ock pan rai l .
(8) Coat the outer curved surface of the l ower seal
wi th soap and the l i p of the seal wi th engi ne oi l .
(9) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(10) Ti ghten al l mai n beari ng bol ts to 108 N·m (80
ft. l bs.) torque.
(11) I nstal l the mai n beari ng cap brace. Ti ghten
nuts to 47 N·m (35 ft. l bs.).
(12) I nstal l the oi l pan gasket and oi l pan. Ti ghten
1/4 – 20 screws to 14 N·m (120 i n. l bs.). Ti ghten 5/16
– 18 screws to 18 N·m (156 i n. l bs.)
(13) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces) (Fi g. 81)
(14) I nstal l transmi ssi on i nspecti on cover.
OIL PUMP
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
REMOVAL
(1) Drai n the engi ne oi l .
(2) Remove the oi l pan.
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
82).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
Fig. 80 Location of Sealer
1 – DOWEL
2 – SEALER LOCATIONS
3 – CYLINDER BLOCK
4 – HALFWAY BETWEEN
5 – REAR FACE OF CYLINDER BLOCK
6 – 3mm (0.125 in.)
Fig. 81 Oil Pan Sealer Location
1 – SEALER LOCATIONS
9 - 112 4. 0L ENGINE TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 N·m
(17 ft. l bs.) torque.
(2) I nstal l the oi l pan.
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
TIMING CASE COVER OIL SEAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the serpenti ne dri ve bel t.
(3) Remove the vi brati on damper.
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 83). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
(4) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 N·m (80 ft. l bs.)
torque.
(5) I nstal l the serpenti ne bel t and ti ghten to the
speci fi ed tensi on (refer to Group 7, Cool i ng Systems
for the proper speci fi cati ons and procedures).
(6) I nstal l the radi ator shroud.
(7) Connect negati ve cabl e to battery.
DISASSEMBLY AND ASSEMBLY
VALVE SERVICE
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
Fig. 82 Oil Pump Assembly
1 – OIL FILTER ADAPTOR
2 – BLOCK
3 – GASKET
4 – OIL INLET TUBE
5 – OIL PUMP
6 – STRAINER ASSEMBLY
7 – ATTACHING BOLTS
Fig. 83 Timing Case Cover Oil Seal Installation
1 – SEAL INSTALLATION TOOL
2 – DRAW SCREW TOOL
TJ 4. 0L ENGINE 9 - 113
REMOVAL AND INSTALLATION (Continued)
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 84). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 85).
VALVE STEM OIL SEAL REPLACEMENT
Val ve stem oi l seal s are i nstal l ed on each val ve
stem to prevent rocker arm l ubri cati ng oi l from
enteri ng the combusti on chamber through the val ve
gui de bores. One seal i s marked I NT (i ntake val ve)
and the other i s marked EXH (exhaust val ve).
Repl ace the oi l seal s whenever val ve servi ce i s per-
formed or i f the seal s have deteri orated.
VALVE GUIDES
The val ve gui des are an i ntegral part of the engi ne
cyl i nder head and are not repl aceabl e.
When the val ve stem gui de cl earance i s excessi ve,
the val ve gui de bores must be reamed oversi ze. Ser-
vi ce val ves wi th oversi ze stems are avai l abl e i n 0.076
mm (0.003 i nch) and 0.381 mm (0.015 i nch) i ncre-
ments.
Correspondi ng oversi ze val ve stem seal s are al so
avai l abl e and must be used wi th val ves havi ng 0.381
mm (0.015 i nch) oversi ze stems.
NOTE: If the valve guides are reamed oversize, the
valve seats must be ground to ensure that the valve
seat is concentric to the valve guide.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
Val ve stem-to-gui de cl earance may be measured by
ei ther of the fol l owi ng two methods.
PREFERRED METHOD
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 86).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
Fig. 84 Valve Facing Margin
1 – VALVE MARGIN
2 – NO MARGIN
Fig. 85 Measurement of Valve Seat Runout
1 – DIAL INDICATOR
9 - 114 4. 0L ENGINE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
ALTERNATIVE METHOD
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 87).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 88).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
CYLINDER BLOCK
DISASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) Drai n the engi ne oi l . Remove and di scard the
oi l fi l ter.
(2) Remove the water pump from the cyl i nder
bl ock.
(3) Remove the vi brati on damper.
(4) Remove the ti mi ng case cover and l ay the cover
upsi de down.
(5) Posi ti on a dri ft punch i nto the sl ot i n the back
of the cover and tap the ol d seal out.
(6) Remove the oi l sl i nger from crankshaft.
(7) Remove the camshaft retai ni ng bol t and
remove the sprockets and chai n as an assembl y.
(8) Remove the camshaft.
(9) Remove the oi l pan and gasket.
(10) Remove the front and rear oi l gal l ey pl ugs.
(11) Remove the oi l pump.
Fig. 86 Measurement of Valve Guide Bore Diameter
1 – GAUGE
2 – 9.525 MM (3/8 INCH)
3 – VALVE STEM GUIDE
4 – CYLINDER HEAD
Fig. 87 Measurement of Lateral Movement of Valve
Stem
1 – DIAL INDICATOR
Fig. 88 Valve Spring Tester
1 – TORQUE WRENCH
2 – VALVE SPRING TESTER
TJ 4. 0L ENGINE 9 - 115
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Remove the connecti ng rods and the pi stons.
Remove the connecti ng rod and pi ston assembl i es
through the top of the cyl i nder bores.
(13) Remove the crankshaft.
ASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) I nstal l the crankshaft.
(2) I nstal l the connecti ng rods and the pi stons
through the top of the cyl i nder bores.
(3) I nstal l the oi l pump.
(4) I nstal l the oi l pan and gasket.
(5) I nstal l the camshaft.
(6) I nstal l the sprockets and chai n as an assembl y.
(7) I nstal l the oi l sl i nger from the crankshaft.
(8) I nstal l the ti mi ng case cover seal .
(9) I nstal l the ti mi ng case cover.
(10) I nstal l the vi brati on damper.
(11) I nstal l the water pump. Ti ghten the mounti ng
bol ts to 31 N·m (23 ft. l bs.) torque.
(12) Lubri cate the oi l fi l ter seal wi th cl ean engi ne
oi l . Ti ghten oi l fi l ter to 18 N·m (156 i n. l bs.) torque.
(13) I nstal l the engi ne i nto the vehi cl e.
(14) Fi l l the engi ne wi th cl ean l ubri cati on oi l (refer
to Group 0, Lubri cati on and Mai ntenance).
(15) Fi l l the cool i ng system.
CLEANING AND INSPECTION
INTAKE AND EXHAUST MANIFOLD
Cl ean the mati ng surfaces of the cyl i nder head and
the mani fol d i f the ori gi nal mani fol d i s to be
i nstal l ed.
CYLINDER HEAD
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
engi ne exhaust mani fol d and engi ne cyl i nder head
mati ng surfaces. Remove al l gasket materi al and car-
bon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
CYLINDER HEAD COVER
CLEANING
Remove any ori gi nal seal er from the cover seal i ng
surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
Remove al l resi due from the seal i ng surface usi ng
a cl ean, dry cl oth.
INSPECTION
I nspect the engi ne cyl i nder head cover for cracks.
Repl ace the cover, i f cracked.
The ori gi nal dark grey gasket materi al shoul d
NOT be removed. I f secti ons of the gasket materi al
are mi ssi ng or are compressed, repl ace the engi ne
cyl i nder head cover. However, secti ons wi th mi nor
damage such as smal l cracks, cuts or chi ps may be
repai red wi th a hand hel d appl i cator. The new mate-
ri al must be smoothed over to mai ntai n gasket
hei ght. Al l ow the gasket materi al to cure pri or to
engi ne cyl i nder head cover i nstal l ati on.
ROCKER ARMS AND PUSH RODS
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
HYDRAULIC TAPPETS
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
9 - 116 4. 0L ENGINE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and defecti ve tap-
pets.
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 89).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
CYLINDER BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
• The gal l ey at the oi l fi l ter adaptor hol e.
• The front and rear oi l gal l ey hol es.
• The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 N·m (25 ft. l bs.) torque.
INSPECTION
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter (Fi g. 90). To
correctl y sel ect the proper si ze pi ston, a cyl i nder bore
gauge, capabl e of readi ng i n 0.003 mm (.0001 i n.)
I NCREMENTS i s requi red. I f a bore gauge i s not
avai l abl e, do not use an i nsi de mi crometer.
Fig. 89 Leak-Down Tester
1 – POINTER
2 – WEIGHTED ARM
3 – RAM
4 – CUP
5 – HANDLE
6 – PUSH ROD
Fig. 90 Cylinder Bore Measurement
TJ 4. 0L ENGINE 9 - 117
CLEANING AND INSPECTION (Continued)
(2) Measure the i nsi de di ameter of the cyl i nder
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90° and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
must be bored and then honed to accept an oversi ze
pi ston. A sl i ght amount of taper al ways exi sts i n the
cyl i nder bore after the engi ne has been i n use for a
peri od of ti me.
SPECIFICATIONS
SPECIFICATIONS
4.0L ENGINE
DESCRIPTION SPECIFICATION
Engine Type In-line 6 Cylinder
Bore and Stroke 98.4 x 86.69 mm
(3.88 x 3.413 in.)
Displacement 4.0L (242 cu. in.)
Compression Ratio 8.8:1
Firing Order 1–5–3–6–2–4
Lubrication Pressure Feed–Full Flow
Filtration
Cooling System Liquid Cooled–Forced
Circulation
Cylinder Block Cast Iron
Crankshaft Cast Nodular Iron
Cylinder Head Cast Iron
Camshaft Cast Iron
DESCRIPTION SPECIFICATION
Pistons Aluminum Alloy
Combustion Chamber Dual-Quench
Connecting Rods Cast Malleable Iron
CAMSHAFT
Hydraulic Tappet
Clearance
Zero Lash
Bearing Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Bearing Journal Diameter
No. 1 51.54 to 51.56 mm
(2.029 to 2.030 in.)
No. 2 51.28 to 51.31 mm
(2.019 to 2.020 in.)
No. 3 51.03 to 51.05 mm
(2.009 to 2.010 in.)
No. 4 50.78 to 50.80 mm
(1.999 to 2.000 in.)
Base Circle Runout
(MAX)
0.03 mm
(0.001 in.)
Valve Lift
Intake 10.350 mm (0.4075 in.)
Exhaust 10.528 mm (0.4145 in.)
Valve Timing
Intake
Opens 12.4°BTDC
Closes 60.9°ABDC
Exhaust
Opens 49.8 BBDC
Closes 29.2°ATDC
Valve Overlap 41.6°
Intake Duration 253.3°
Exhaust Duration 259.°
9 - 118 4. 0L ENGINE TJ
CLEANING AND INSPECTION (Continued)
DESCRIPTION SPECIFICATION
CRANKSHAFT
End Play 0.038 to 0.165 mm
(0.0015 to 0.0065 in.)
Main Bearing Journal
Diameter
No. 1-6 63.489 to 63.502 mm
(2.4996 to 2.5001 in.)
No. 7 63.449 to 63.487 mm
(2.4980 to 2.4995 in.)
Main Bearing Journal
Width
No. 1 27.58 to 27.89 mm
(1.086 to 1.098 in.)
No. 3 32.28 to 32.33 mm
(1.271 to 1.273 in.)
No. 2-4-5-6-7 30.02 to 30.18 mm
(1.182 to 1.188 in.)
Main Bearing Clearance 0.03 to 0.06 mm
(0.001 to 0.0025 in.)
Preferred 0.051 mm (0.002 in.)
Connecting Rod Journal
Diameter 53.17 to 53.23 mm
(2.0934 to 2.0955 in.)
Connecting Rod Journal
Width
27.18 to 27.33 mm
(1.070 to 1.076 in.)
Out-of-Round (MAX) 0.013 mm (0.0005 in.)
Taper (MAX) 0.013 mm (0.0005 in.)
CYLINDER BLOCK
Deck Height 240.03 to 240.18 mm
(9.450 to 9.456 in.)
Deck Clearance (Below
Block)
0.546 mm (0.0215 in.)
Cylinder Bore Diameter
Standard 98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
Taper 0.025 mm (0.001 in.)
Out-ofRound 0.025 mm (0.001 in.)
DESCRIPTION SPECIFICATION
Tappet Bore Diameter 23.000 to 23.025 mm
(0.9055 to 0.9065 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness Max. 0.20 mm max. for total
length
(0.008 in. max. for total
length)
Main Bearing Bore
Diameter
68.3514 to 68.3768 mm
(2.691 to 2.692 in.)
CONNECTING ROD
Total Weight (Less
Bearing)
663 to 671 grams
(23.39 to 23.67 oz.)
Length (Center-to-Center) 155.52 to 155.62 mm
(6.123 to 6.127 in.)
Piston Pin Bore Diameter 23.59 to 23.62 mm
(0.9288 to 0.9298 in.)
Bore (Less Bearings) 56.08 to 56.09 mm
(2.2080 to 2.2085 in.)
Bearing Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Preferred 0.044 to 0.050 mm
(0.0015 to 0.0020 in.)
Side Clearance 0.25 to 0.48 mm
(0.010 to 0.019 in.)
Twist (Max.) 0.002 mm per mm
(0.002 in. per inch)
Bend (Max.) 0.002 mm per mm
(0.002 in. per inch.)
CYLINDER COMPRESSION PRESSURE
Pressure Range 827 to 1,034 kPa
(120 to 150 psi)
TJ 4. 0L ENGINE 9 - 119
SPECIFICATIONS (Continued)
DESCRIPTION SPECIFICATION
Max. Variation Between
Cylinders 206 kPa (30 psi)
CYLINDER HEAD
Combustion Chamber 55.22 to 58.22 cc
(3.37 to 3.55 cu. in.)
Valve Guide I. D.
(Integral)
7.95 to 7.97 mm
(0.313 to 0.314 in.)
Valve Stem-to-Guide 0.025 to 0.076 mm
Clearance (0.001 to 0.003 in.)
Valve Seat Angle
Intake 44.5°
Exhaust 44.5°
Valve Seat Width 1.02 to 1.52 mm
(0.040 to 0.060 in.)
Valve Seat Runout 0.064 mm (0.0025 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness Max. 0.20 mm - max. for total
length
(0.008 in. max. for total
length)
ROCKER ARMS, PUSH RODS & TAPPETS
Rocker Arm Ratio 1.6:1
Push Rod Length 244.856 to 245.364 mm
(Pink) (9.640 to 9.660 in.)
Push Rod Diameter 7.92 to 8.00 mm
(0.312 to 0.315 in.)
Hydraulic Tappet
Diameter
22.962 to 22.974 mm
(0.904 to 0.9045 in.)
Tappet-to-Bore Clearance 0.025 to 0.063 mm
(0.001 to 0.0025 in.)
DESCRIPTION SPECIFICATION
VALVES
Valve Length (Overall)
Intake 122.479 to 122.860 mm
(4.822 to 4.837 in.)
Exhaust 122.860 to 123.241 mm
(4.837 to 4.852 in.)
Valve Stem Diameter 7.899 to 7.925 mm
(0.311 to 0.312 in.)
Stem-to-Guide Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Valve Head Diameter
Intake 48.387 to 48.641 mm
(1.905 to 1.915 in.)
Exhaust 37.973 to 38.227 mm
(1.495 to 1.505 in.)
Valve Face Angle
Intake 46.5°
Exhaust 46.5°
Tip Refinishing (Max.
Allowable)
0.25 mm (0.010 in.)
VALVE SPRINGS
Free Length (Approx.) 47.65 mm (1.876 in.)
Spring Load
Valve Closed 316 to 351 N @ 41.656
mm
(71 to 79 lbf. @ 1.64 in.)
Valve Open 898.6 to 969.7 N @
30.89 mm
(202 to 218 lbf @ 1.216
in.)
Inside Diameter 21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height 41.656 mm (1.64 in.)
PISTONS
Weight (Less Pin) 417 to 429 grams
(14.7 to 15.1 oz.)
Piston Pin Bore
(Centerline
40.61 to 40.72 mm
9 - 120 4. 0L ENGINE TJ
SPECIFICATIONS (Continued)
DESCRIPTION SPECIFICATION
to Piston Top) (1.599 to 1.603 in.)
Piston-to-Bore Clearance 0.018 to 0.038 mm
(0.0008 to 0.0015 in.)
Ring Gap Clearance
Top Compression Ring 0.229 to 0.610 mm
(0.0090 to 0.0240 in.)
2nd Compression Ring 0.483 to 0.965 mm
(0.0190 to 0.0380 in.)
Oil Control Steel Rails 0.254 to 1.500 mm
(0.010 to 0.060 in.)
Ring Side Clearance
Compression Rings 0.042 to 0.084 mm
(0.0017 to 0.0033 in.)
Oil Control Rings 0.06 to 0.21 mm
(0.0024 to 0.0083 in.)
Piston Ring Groove
Height
Compression Rings 1.530 to 1.555 mm
(0.0602 to 0.0612 in.)
Oil Control Ring 4.035 to 4.060 mm
(0.1589 to 0.1598 in.)
Piston Ring Groove
Diameter
No.1 Compression Ring 88.39 to 88.65 mm
(3.48 to 3.49 in.)
No.2 Compression Ring 87.63 to 87.88 mm
(3.45 to 3.46 in.)
Oil Control Ring 89.66 to 89.92 mm
(3.53 to 3.54 in.)
Piston Pin Bore Diameter 23.650 to 23.658 mm
(0.9312 to 0.9315 in.)
Piston Pin Diameter 23.637 to 23.640 mm
(0.9306 to 0.9307 in.)
Piston-to-Pin Clearance 0.0102 to 0.0208 mm
(0.0005 to 0.0009 in.)
Piston-to-Pin Connecting
Rod (Press Fit) 8.9 kN (2000 lbf.)
DESCRIPTION SPECIFICATION
OIL PUMP
Gear-to-Body Clearance 0.051 to 0.102 mm
(Radial) (0.002 to 0.004 in.)
Gear-to-Body Clearance
(Radial) Preferred 0.051 mm (0.002 in.)
Gear End Clearance 0.051 to 0.152 mm
Plastigage (0.002 to 0.006 in.)
Gear End Clearance
Plastigage (Preferred) 0.051 mm (0.002 in.)
Gear End Clearance 0.1016 to 0.2032 mm
Feeler Gauge (0.004 to 0.008 in.)
Gear End Clearance
Feeler Gauge (Preferred) 0.1778 mm (0.007 in.)
Oil Pressure
At Idle Speed 89.6 kPa (13 psi)
At 1600 rpm & Higher 255 to 517 kPa
(37 to 75 psi)
Oil Pressure Relief 517 kPa (75 psi)
TORQUE SPECIFICATIONS
4.0L ENGINE
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
A/C Compressor—Bolts 28 — 250
Block Heater—Nut 2 — 16
Camshaft Sprocket—Bolt 68 50 —
Camshaft Thrust Plate to
Cylinder Block—Screws 24 18 —
Clutch Cover to Flywheel—
Bolts
54 40 —
Coil Bracket to Block—Bolts 22 — 192
Connecting Rod—Nuts 45 33 —
Cylinder Block—Drain Plugs 34 25 —
Cylinder Head—Bolts 135 100 —
Cylinder Head Cover—Bolts 10 — 85
Distributor Clamp—Bolts 23 — 204
TJ 4. 0L ENGINE 9 - 121
SPECIFICATIONS (Continued)
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
Engine Mounts—Front
Support Bracket Bolts 61 45 —
Support Cushion Bolts/Nuts 41 30 —
Support Cushion Bracket
Bolts
54 40 —
Support Cushion Bracket Stud
Nuts
41 30 —
Support Cushion Thru-Bolt 65 48 —
Engine Mounts—Rear
Crossmember to Sill Bolts—
(Automatic) 41 30 —
Insulator Stud Assembly—Nut 41 30 —
Support Cushion/
Crossmember—
Nuts 22 — 192
Support Cushion/Bracket—
Nuts
(Manual) 75 55 —
Transmission Support
Bracket—Bolt
(Manual) 46 34 —
Transmission Support Bracket/
Cushion—Bolt (4WD Auto) 75 55 —
Transmission Support Adaptor
Bracket—Bolts (2WD Auto) 75 55 —
Exhaust Manifold/Pipe—Nuts 27 20 —
Intake/Exhaust Manifold
Fasteners #1-5 33 24 —
Fasteners #6 and 7 14 — 126
Fasteners #8-11 33 24 —
Flywheel to Converter
Housing—Bolts
38 28 —
Flywheel to Crankshaft—Bolts 143 105 —
Front Cover to Block—Bolts
1/4-20 7 — 60
5/16-18 22 — 192
Fuel Rail—Bolts/Stud 12 — 108
Generator—Bolts 57 42 —
Generator Bracket to
Engine—Bolts
47 35 —
Main Bearing Cap—Bolts 108 80 —
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
Oil Filter 18 — 156
Oil Filter Connector to
Adaptor 47 35 —
Block 68 50 —
Adaptor Bolts 102 50 —
Oil Galley—Plug 41 30 —
Oil Pan—Bolts
1/4-20 9.5 — 84
5/16-18 15 — 132
Oil Pan—Drain Plug 34 25 —
Oil Pump
Mounting Bolts 23 — 204
Cover Bolts 8 — 70
Rocker Arm Assembly to
Cylinder
Head—Capscrews 30 21 —
Spark Plugs 37 27 —
Starter Motor—Mounting Bolts 45 33 —
Thermostat Housing—Bolts 18 — 156
Throttle Body—Bolts 10 — 90
Vibration Damper—Bolt 108 80 —
Water Pump to Block—Bolts 23 17 —
SPECIAL TOOLS
4. 0L ENGINE
Valve Spring Compressor Tool MD-998772A
9 - 122 4. 0L ENGINE TJ
SPECIFICATIONS (Continued)
Timing Case Cover Alignment and Seal installation
Tool 6139
Vibration Damper Removal Tool 7697
Hydraulic Valve Tappet Removal/Installation Tool
C-4129–A
TJ 4. 0L ENGINE 9 - 123
SPECIAL TOOLS (Continued)
EXHAUST SYSTEM
CONTENTS
page page
DESCRIPTION AND OPERATION
CATALYTIC CONVERTER. . . . . . . . . . . . . . . . . . . . 1
EXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . . . 5
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
CATALYTIC CONVERTER/EXHAUST
PIPE—EARLY BUILD. . . . . . . . . . . . . . . . . . . . . 6
CATALYTIC CONVERTER/EXHAUST
PIPE—LATE BUILD. . . . . . . . . . . . . . . . . . . . . . 6
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MUFFLER AND TAILPIPE ASSEMBLY—
EARLY BUILD . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MUFFLER AND TAILPIPE ASSEMBLY—LATE
BUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 10
DESCRIPTION AND OPERATION
EXHAUST SYSTEM
DESCRIPTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
The basi c exhaust system consi sts of exhaust man-
i fol d(s), exhaust pi pe wi th oxygen sensors, catal yti c
converter(s), heat shi el d(s), muffl er and tai l pi pe
The 2.5L and 4.0L Federal Emi ssi ons vhei cl es use
a si ngl e catal yti c converter, whi l e the Cal i forni a mod-
el s use addi ti onal mi ni catal yti c converters i nl i ne
wi th the exhaust pi pe bel ow the exhaust mani fol ds.
CATALYTIC CONVERTER
DESCRIPTION
Cal i forni a emi ssi ons vehi cl es i ncorporate two mi ni
catal yti c converters as wel l as the under fl oor cata-
l yti c converter, i nto the exhaust system. These cata-
l yti c converters are made of stai nl ess steel desi gned
to operate at extremel y hi gh temperatures. Federal
vehi cl es use a si ngl e under fl oor catal yti c converter
onl y (Fi g. 1) (Fi g. 2) (Fi g. 3).
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unl eaded gasol i ne must be used to avoi d contami -
nati ng the catal yst core.
TJ EXHAUST SYSTEM 11 - 1
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
Fig. 1 Exhaust System—4.0L Early Build Typical
1 – MINI CONVERTERS (2)
2 – CATALYTIC CONVERTER
3 – TAIL PIPE HANGER REAR MOUNT INSULATOR
4 – TAIL PIPE
5 – MUFFLER
6 – OXYGEN SENSORS (ALL)
7 – OXYGEN SENSORS (CALIFORNIA ONLY)
11 - 2 EXHAUST SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
Fig. 2 Exhaust System—2.5L Late Build Typical
1 – MINI CATALYTIC CONVERTER
2 – CATALYTIC CONVERTER
3 – TAILPIPE
4 – MUFFLER
5 – EXHAUST PIPE TO EXHAUST MANIFOLD FLANGE
TJ EXHAUST SYSTEM 11 - 3
DESCRIPTION AND OPERATION (Continued)
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
Fig. 3 Exhaust System—4.0L Late Build Typical
1 – MUFFLER TO CATALYTIC CONVERTER FLANGE
2 – TAILPIPE
3 – MUFFLER
4 – CATALYTIC CONVERTER
5 – EXHAUST PIPE TO CATALYTIC CONVERTER FLANGE
6 – MINI CATALYTIC CONVERTER
7 – EXHAUST PIPE
11 - 4 EXHAUST SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
EXHAUST HEAT SHIELDS
DESCRIPTION
Heat shi el ds are made of stamped/formed steel , or
metal foi l .
Exhaust heat shi el ds are needed to protect both
the vehi cl e and the envi ronment from the hi gh tem-
peratures devel oped by the catal yti c converter. The
catal yti c converter rel eases addi ti onal heat i nto the
exhaust system. Under severe operati ng condi ti ons,
the temperature i ncreases i n the area of the con-
verter. Such condi ti ons can exi st when the engi ne
mi sfi res or otherwi se does not operate at peak effi -
ci ency.
DIAGNOSIS AND TESTING
EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts to specified
torque at leaking joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.
7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
Fig. 4 Exhaust Heat Shield—Typical
1 – HEAT SHIELD
TJ EXHAUST SYSTEM 11 - 5
DESCRIPTION AND OPERATION (Continued)
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
REMOVAL AND INSTALLATION
CATALYTIC CONVERTER/EXHAUST PIPE—
EARLY BUILD
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Saturate the studs and nuts wi th a Mopar௡
rust penetrant. Al l ow 5 mi nutes for penetrati on (Fi g.
5).
(3) Remove the oxygen sensors from the exhaust
pi pe and the catal yti c converter (Fi g. 5).
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d.
(5) Support the transmi ssi on and remove the rear
crossmember.
(6) Remove the cl amp from the catal yti c converter
and muffl er connecti on.
(7) Heat the catal yti c converter and muffl er con-
necti on wi th an oxyacetyl ene torch unti l the metal
becomes cherry red.
(8) Whi l e the metal i s sti l l cherry red, twi st the
muffl er assembl y back and forth to separate i t from
the catal yti c converter.
INSTALLATION
(1) Assembl e catal yti c converter and muffl er
l oosel y to permi t proper al i gnment of al l parts.
(2) Use a new cl amp and ti ghten the nut to 48
N·m (35 ft. l bs.) torque.
(3) Connect the exhaust pi pe to the engi ne exhaust
mani fol d. Ti ghten the nuts to 31 N·m (23 ft. l bs.)
torque.
(4) I nstal l the rear crossmember. Ti ghten the
crossmember-to-si l l bol ts to 41 N·m (30 ft. l bs.)
torque. Remove the support from the transmi ssi on.
(5) Coat the oxygen sensors wi th anti -sei ze com-
pound. I nstal l the sensors and ti ghten the nut to 30
N·m (22 ft. l bs.) torque.
(6) Lower the vehi cl e.
(7) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
CATALYTIC CONVERTER/EXHAUST PIPE— LATE
BUILD
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
Fig. 5 Exhaust Pipe with Catalytic Converter
1 – EXHAUST PIPE MOUNTING BRACKET
2 – CATALYTIC CONVERTER
3 – NUT
4 – SEAL RING (4.0L ONLY)
11 - 6 EXHAUST SYSTEM TJ
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Saturate the studs and nuts wi th a Mopar௡
rust penetrant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the oxygen sensors from the exhaust
pi pe and the catal yti c converter.
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d (Fi g. 6) (Fi g. 7).
(5) Remove catal yti c converter to muffl er fl ange
retai ni ng nuts (Fi g. 6) (Fi g. 7).
(6) Sl i de exhaust pi pe foward unti l exhaust pi pe
hanger di sengages from transmi ssi on support.
Remove exhaust pi pe and catal yti c converter from
vehi cl e.
INSTALLATION
(1) Posi ti on exhaust pi pe and catal yti c converter
i nto vehi cl e.
(2) I nsert exhaust pi pe hanger i nto transmi ssi on
support (Fi g. 6) (Fi g. 7).
(3) I nstal l exhaust pi pe onto exhaust mani fol d DO
NOT ti ghten bol ts at thi s ti me.
(4) Posi ti on muffl er fl ange onto catal yti c converter
fl ange and i nstal l retai ni ng bol ts and nuts. DO NOT
ti ghten nuts at thi s ti me (Fi g. 6) (Fi g. 7).
(5) Make sure the exhaust system i s al i gned and
has the proper cl earance. The mi ni mum cl earance i s
25mm (1 i nch).
(6) Ti ghten muffl er to catal yti c converter fl ange
retai ni ng nuts to 28.5 N·m (21 ft. l bs.).
(7) Ti ghten exhaust pi pe to exhaust mani fol d
mounti ng bol ts to 31 N·m (23 ft. l bs.).
(8) I nstal l the oxygen sensors i n the exhaust pi pe
and catal yti c converter.
(9) Lower vehi cl e.
(10) Start engi ne check for l eaks.
MUFFLER AND TAILPIPE ASSEMBLY— EARLY
BUILD
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
Fig. 6 Exhaust Pipe and Catalytic Converter
Removal/Installation 2.5L Engine Late Build
1 – CATALYTIC CONVERTER
2 – TRANSMISSION SUPPORT
3 – EXHAUST HANGER
4 – EXHAUST PIPE
Fig. 7 Exhaust Pipe and Catalytic Converter
Removal/Installation 4.0L Engine Late Build
1 – CATALYTIC CONVERTER
2 – TRANSMISSION SUPPORT
3 – EXHAUST HANGER
4 – EXHAUST PIPE
TJ EXHAUST SYSTEM 11 - 7
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
REMOVAL
(1) Rai se the vehi cl e and support the rear of the
vehi cl e by the si de rai l s and al l ow the axl e to hang
free.
(2) Remove the cl amp from the catal yti c converter
and muffl er connecti on (Fi g. 8).
(3) Remove the tai l pi pe hangers from the i nsul a-
tors (Fi g. 9).
(4) Heat the catal yti c converter-to-muffl er connec-
ti on wi th an oxyacetyl ene torch unti l the metal
becomes cherry red.
(5) Whi l e the metal i s sti l l cherry red, twi st the
exhaust tai l pi pe/muffl er assembl y back and forth to
separate i t from the catal yti c converter.
• To separate an ori gi nal equi pment exhaust
tai l pi pe/muffl er combi nati on, cut the exhaust tai l pi pe
cl ose to the muffl er. Col l apse the part remai ni ng i n
the muffl er and remove.
• To remove a servi ce exhaust tai l pi pe/muffl er
combi nati on, appl y heat unti l the metal becomes
cherry red. Remove the exhaust tai l pi pe/muffl er
cl amp and twi st the exhaust tai l pi pe out of the muf-
fl er.
INSTALLATION
(1) Assembl e catal yti c converter and muffl er
l oosel y to permi t proper al i gnment of al l parts.
(2) I nstal l the exhaust tai l pi pe i nto the rear of the
muffl er.
(3) I nstal l the exhaust tai l pi pe/muffl er assembl y
on the rear exhaust tai l pi pe hanger. Make sure that
the exhaust tai l pi pe has suffi ci ent cl earance from the
fl oor pan.
(4) Ti ghten the nut on the muffl er-to-catal yti c con-
verter cl amp to 48 N·m (35 ft. l bs.) torque.
(5) I nsert rods i nto i sol ators.
(6) Lower the vehi cl e.
(7) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
MUFFLER AND TAILPIPE ASSEMBLY— LATE
BUILD
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
Fig. 8 Catalytic Converter to Muffler Connection
Early Build
1 – CATALYTIC CONVERTER
2 – CLAMP
3 – MUFFLER
Fig. 9 Muffler and Tailpipe Assembly Early Build
1 – ISOLATOR
2 – ISOLATOR
3 – TAIL PIPE HANGER
4 – MUFFLER HANGER
5 – MUFFLER AND TAILPIPE ASSEMBLY
6 – CLAMP
7 – CATALYTIC CONVERTER
11 - 8 EXHAUST SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
REMOVAL
(1) Rai se the vehi cl e and support the rear of the
vehi cl e by the si de rai l s and al l ow the axl e to hang
free.
(2) Remove the tai l pi pe hangers from the i nsul a-
tors (Fi g. 10).
(3) Remove muffl er to catal yti c converter fl ange
retai ni ng nuts (Fi g. 10).
(4) Remove muffl er and tai l pi pe assembl y from
vehi cl e.
Fig. 10 Muffler and Tailpipe Removal/Installation—Late Build
1 – TRANSMISSION SUPPORT
2 – TAILPIPE HANGER INSULATORS
3 – TAILPIPE HANGERS
4 – TAILPIPE
5 – MUFFLER
6 – MUFFLER TO CATALYTIC CONVERTER FLANGE
7 – NUTS
8 – CATALYTIC CONVERTER
TJ EXHAUST SYSTEM 11 - 9
REMOVAL AND INSTALLATION (Continued)
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
INSTALLATION
(1) Posi ti on muffl er and tai l pi pe assembl y i nto
vehi cl e.
(2) Posi ti on muffl er and catal yti c converter fl anges
togather and i nstal l nuts (Fi g. 10). DO NOT ti ghten
nuts at thi s ti me.
(3) I nstal l tai l pi pe hangers i nto the i nsul ators (Fi g.
10).
(4) Make sure the muffl er and tai l pi pe are cor-
rectl y posi ti oned and the proper al i gnment. The mi n-
i mum cl earance between components i s 25mm (1
i nch).
(5) Ti ghten muffl er to catal yti c converter fl ange
nuts to 28.5 N·m (21 ft. l bs.).
(6) Lower vehi cl e.
(7) Start engi ne check for l eaks.
HEAT SHIELDS
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the screws and/or nuts hol di ng the
heat shi el ds to the frame and/or fl oor pan (Fi g. 11)
(Fi g. 12).
(3) When removi ng muffl er heat shi el d, the muf-
fl er front support bracket must be removed fi rst.
(4) Sl i de the shi el ds out around the exhaust sys-
tem.
INSTALLATION
(1) Posi ti on the heat shi el ds to the fl oor pan or the
frame and i nstal l the screws and/or nuts.
(2) Ti ghten the nuts and/or screws to 45 N·m (33
ft. l bs.) (Fi g. 11).
(3) Lower the vehi cl e.
SPECIFICATIONS
TORQUE SPECIFICATIONS
Fig. 11 Muffler Rear Heat Shield Removal/
Installation
1 – REAR MUFFLER HEAT SHIELD
2 – NUT
3 – SELF TAPPING SCREW
Fig. 12 Muffler Middle Heat Shield Removal/
Installation
1 – MIDDLE MUFFLER HEAT SHIELD
2 – NUTS
3 – SELF TAPPING SCREWS
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
Crossmember to Sill—Bolts 41 30 —
Exhaust Pipe to Manifold—
Nuts
31 23 —
Muffler to Catalytic
Converter— Clamps
48 35 —
Muffler to Catalytic Converter
Flange—Nuts
Late Build 28.5 21 —
Catalytic Converter to Exhaust
Pipe Flange
—Nuts Late Build 28.5 21 —
Oxygen Sensors 30 22 —
Power Steering Pump/
Tensioner Bracket—
Bolts to Intake Manifold 28 21 —
Bolts to Water Pump 48 35 —
11 - 10 EXHAUST SYSTEM TJ
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-02-00 February, 2000
FRAME AND BUMPERS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . 1
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION
TABLE OF CONTENTS
page
DESCRIPTION AND OPERATION
FRAME DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
FRAME DESCRIPTION
The Jeep TJ frame i s the structural center of the
vehi cl e. I n addi ti on to supporti ng the body and pay-
l oad, the frame provi des a stati on for the engi ne. The
vehi cl e body i s attached to the frame wi th hol ddowns
(Fi g. 1). The torque speci fi cati on for the hol ddown
bol ts are: Radi ator to frame, ti ghten to 47 N·m ( 35
ft. l bs.) torque. Mai n fl oor to frame, ti ghten to 67
N·m ( 50 ft. l bs.) torque. Rear fl oor to frame, ti ghten
to 47 N·m ( 35 ft. l bs.) torque.
The frame i s constructed of mi l d-strength rectan-
gul ar tubi ng and crossmembers. The crossmembers
joi n the si derai l s and retai n them i n al i gnment i n
rel ati on to each other. Thi s provi des resi stance to
frame twi sts and strai ns.
BUMPERS
DESCRIPTION
Bumpers are used at the front and rear of the
vehi cl e. Bumpers are made up of a center secti on and
two extensi ons.
OPERATION
The bumpers are attached to the frame and pro-
vi de mounti ng poi nts for some opti onal accessori es
such as fog l i ghts and tow hooks.
TJ FRAME AND BUMPERS 13 - 1
Fig. 1 Body to Frame Holddowns
1 – UPPER BODY MOUNT RETAINER
2 – UPPER BODY MOUNT INSULATOR
3 – LOWER BODY MOUNT INSULATOR
4 – FRAME
5 – UPPER BODY MOUNT RETAINER
6 – UPPER BODY MOUNT INSULATOR
7 – LOWER BODY MOUNT INSULATOR
8 – FRAME
13 - 2 FRAME AND BUMPERS TJ
DESCRIPTION AND OPERATION (Continued)
BUMPERS
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
TOW HOOKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT BUMPER EXTENSION. . . . . . . . . . . . . . . . 3
FRONT BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR BUMPER EXTENSION. . . . . . . . . . . . . . . . . 4
REAR BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
TOW HOOKS
Some Jeep vehi cl es are equi pped wi th emergency
tow hooks. The tow hooks shoul d be used for EMER-
GENCY purposes onl y.
FRONT TOW HOOK REMOVAL
(1) Remove the torx bol ts that attach the tow hook
to the bumper (Fi g. 1).
(2) Separate the tow hook from the bumper.
FRONT TOW HOOK INSTALLATION
(1) Posi ti on the tow hook on the bumper.
(2) I nstal l the torx bol ts that attach the tow hook
to the bumper. Ti ghten the bol ts to 108 N·m (80 ft.
l bs.) torque.
REAR TOW HOOK REMOVAL
(1) Remove the fasteners that attach the rear tow
hook to the frame (Fi g. 2).
(2) Separate the tow hook from the frame.
REAR TOW HOOK INSTALLATION
(1) Posi ti on the tow hook on the frame.
(2) I nstal l the fasteners that attach the rear tow hook
to the frame. Ti ghten the bol ts to 67 N·m (50 ft.l bs.).
FRONT BUMPER EXTENSION
REMOVAL
(1) Remove the screws attachi ng the bumper
extensi on to the bumper (Fi g. 3).
(2) Separate the extensi on from the bumper.
INSTALLATION
(1) Posi ti on the extensi on on the bumper.
(2) I nstal l the screws attachi ng the bumper exten-
si on to the bumper.
Fig. 1 Front Tow Hook
1 – FRAME
2 – BUMPER
3 – TOW HOOK
Fig. 2 Rear Tow Hook
1 – FRAME
2 – REAR BUMPER
3 – TOW HOOK
4 – BOLT
5 – NUT
TJ FRAME AND BUMPERS 13 - 3
FRONT BUMPER
REMOVAL
(1) I f equi pped, di sconnect the fog l amp harness
connector.
(2) Remove the screws that attach the bumper to
the frame rai l (Fi g. 4).
(3) I f equi pped, remove the tow hook.
(4) Separate the bumper from the vehi cl e.
INSTALLATION
(1) Posi ti on the bumper on the vehi cl e.
(2) I f equi pped, i nstal l the tow hook.
(3) I nstal l the screws that attach the bumper to
the frame rai l . Ti ghten the screws to 104 N·m (77 ft.
l bs.) torque.
(4) I f equi pped, Connect the fog l amp harness con-
nector.
REAR BUMPER EXTENSION
REMOVAL
(1) Remove the screws attachi ng the bumper
extensi on to the bumper (Fi g. 5).
(2) Separate the extensi on from the bumper.
INSTALLATION
(1) Posi ti on the extensi on on the bumper.
(2) I nstal l the screws attachi ng the bumper exten-
si on to the bumper.
REAR BUMPER
REMOVAL
(1) Remove the bol t attachi ng the bumper to frame
rai l (Fi g. 5).
Fig. 3 Bumper Extension
1 – BUMPER EXTENSION
2 – FRONT BUMPER
Fig. 4 Front Bumper Components
1 – VALANCE
2 – BUMPER GUARD
3 – FRONT BUMPER
4 – BUMPER EXTENSION
5 – FRAME
Fig. 5 Rear Bumper Components
1 – BODY
2 – CROSSMEMBER
3 – FRAME
4 – REAR BUMPER
5 – REAR BUMPER
6 – BRACE
7 – REAR BUMPER EXTENSION
13 - 4 FRAME AND BUMPERS TJ
REMOVAL AND INSTALLATION (Continued)
(2) I f equi pped, separate the rear tow eye from the
bumper.
(3) Remove the nuts attachi ng the bumper to the
rear frame crossmember.
(4) Separate the bumper from the vehi cl e.
INSTALLATION
(1) Posi ti on the bumper on the vehi cl e.
(2) I nstal l the nuts attachi ng the bumper to the
rear frame crossmember. Ti ghten the nuts to 67 N·m
(50 ft.l bs.) torque.
(3) I f equi pped, posi ti on the rear tow eye on the
bumper.
(4) I nstal l the bol t attachi ng the bumper to frame
rai l . Ti ghten the bol ts to 67 N·m (50 ft.l bs.) torque.
TJ FRAME AND BUMPERS 13 - 5
REMOVAL AND INSTALLATION (Continued)
FRAME
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
FRAME SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL AND INSTALLATION
TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . . 7
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . 9
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 11
SERVICE PROCEDURES
FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE OR EXPLOSION CAN RESULT. WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE ACHIEVED
DURING INSTALLATION. IF NOT, DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
CLEAR OF CABLES OR CHAINS ON PULLING
EQUIPMENT DURING FRAME STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 3 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566°C (1050°F), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventi onal frame that i s bent
or twi sted can be strai ghtened by appl i cati on of heat.
The temperature must not exceed 566°C (1050°F).
The metal wi l l have a dul l red gl ow at the desi red
temperature. Excessi ve heat wi l l decrease the
strength of the metal and resul t i n a weakened
frame.
Wel di ng the joi nts around ri veted cross members
and frame si de rai l s i s not recommended.
A strai ghteni ng repai r process shoul d be l i mi ted to
frame members that are not severel y damaged. The
repl acement bol ts, nuts and ri vets that are used to
joi n the frame members shoul d conform to the same
speci fi cati ons as the ori gi nal bol ts, nuts and ri vets.
FRAME REPAIRS
DRILLING HOLES
Do not dri l l hol es i n the top and bottom of frame
rai l , metal fati gue can resul t causi ng frame fai l ure.
Hol es dri l l ed i n the si de of the frame rai l must be at
l east 38 mm (1.5 i n.) from the top and bottom
fl anges.
Addi ti onal dri l l hol es shoul d be l ocated away from
exi sti ng hol es.
WELDING
Use MI G, TI G or arc wel di ng equi pment to repai r
wel ded frame components.
Frame components that have been damaged shoul d
be i nspected for cracks before returni ng the vehi cl e
to use. I f cracks are found i n accessi bl e frame com-
ponents perform the fol l owi ng procedures.
(1) Dri l l a hol e at each end of the crack wi th a 3
mm (O.125 i n.) di ameter dri l l bi t.
(2) Usi ng a sui tabl e di e gri nder wi th 3 i nch cut off
wheel , V-groove the crack to al l ow 100% wel d pene-
trati on.
(3) Wel d the crack.
(4) I f necessary when a si de rai l i s repai red, gri nd
the wel d smooth and i nstal l a rei nforcement channel
(Fi g. 1) over the repai red area.
CAUTION: A reinforcement should never be used
on the front section of the frame. The frame section
forward of the suspension mounts contains energy
management holes (Fig. 2). Reinforcing this area
may effect energy management.
13 - 6 FRAME AND BUMPERS TJ
NOTE: If a reinforcement is required, it should
completely cover the repaired area. The reinforce-
ment should also overlap the top and bottom of the
frame by more than 50% of its width. Weld as indi-
cated (Fig. 1).
FRAME FASTENERS
Bol ts and nuts and can be used to repai r frames or
to i nstal l a rei nforcement secti on on the frame.
Coni cal -type washers are preferred over the spl i t-
ri ng type l ock washers. Normal l y, grade-5 bol ts are
adequate for frame repai r. Grade-3 bolts or softer
should not be used. Ti ghteni ng bol ts/nuts wi th the
correct torque, refer to the I ntroducti on Group at the
front of thi s manual for ti ghteni ng i nformati on.
REMOVAL AND INSTALLATION
TRANSFER CASE SKID PLATE
The transmi ssi on and transfer case crossmember i s
i ntegrated wi th the transfer case ski d pl ate.
REMOVAL
WARNING: THE TRANSFER CASE AND TRANSMIS-
SION ARE SUPPORTED BY THE TRANSFER CASE
SKID PLATE. BEFORE REMOVING THE TRANSFER
CASE SKID PLATE, ENSURE THAT THE TRANSMIS-
SION IS PROPERLY SUPPORTED.
(1) Rai se and support the vehi cl e.
(2) Pl ace a support under the transmi ssi on.
(3) Remove the nuts attachi ng the transmi ssi on
mount to the ski d pl ate (Fi g. 3) and (Fi g. 4).
(4) Remove the bol ts attachi ng the ski d pl ate to
the frame (Fi g. 5).
(5) Separate the ski d pl ate from the vehi cl e.
INSTALLATION
(1) Posi ti on the ski d pl ate on the vehi cl e.
(2) I nstal l the bol ts attachi ng the ski d pl ate to the
frame. Ti ghten the bol ts to 74 N·m ( 55 ft. l bs.)
torque.
Fig. 1 Frame Reinforcement
1 – FRAME CENTER LINE
2 – FRAME
3 – FRAME REPAIR REINFORCEMENT
Fig. 2 Energy Management Holes
1 – ENERGY MANAGEMENT HOLES
Fig. 3 Transmission Mount—Automatic
Transmission
1 – TRANSMISSION SUPPORT BRACKET
2 – AUTOMATIC TRANSMISSION
3 – SKID PLATE
4 – FRAME
5 – TRANSMISSION MOUNT SUPPORT BRACKET
6 – CUSHION
TJ FRAME AND BUMPERS 13 - 7
SERVICE PROCEDURES (Continued)
(3) I nstal l the nuts attachi ng the transmi ssi on
mount to the ski d pl ate. Ti ghten the nuts to 28 N·m
( 21 ft. l bs.) torque.
(4) Remove the support under the transmi ssi on.
(5) Remove the support from under the vehi cl e and
l ower the vehi cl e.
FUEL TANK SKID PLATE
REMOVAL
(1) Posi ti on a support under the fuel tank ski d
pl ate.
(2) Remove the protecti ve caps from the end of the
strap studs.
(3) Remove the nuts that attach the ski d pl ate to
the straps and to the crossmembers (Fi g. 6).
(4) Separate the fuel tank strap from the ski d
pl ate.
(5) Support the fuel tank and remove the ski d
pl ate from the vehi cl e.
INSTALLATION
(1) Attach the ski d pl ate to the fuel tank strap.
(2) Posi ti on and support the ski d pl ate under the
fuel tank.
(3) I nstal l the nuts to attach the ski d pl ate to the
straps and to the frame crossmembers. Ti ghten the
fuel tank strap nuts to 5 N·m (40 i n. l bs.) torque.
Ti ghten the ski d pl ate-to-crossmember nuts wi th 16
N·m (138 i n. l bs.) torque.
(4) I nstal l the protecti ve caps on the end of the
strap studs.
(5) Remove the support from under the ski d pl ate.
Fig. 4 Transmission Mount—Manual Transmission
1 – TRANSMISSION SUPPORT BRACKET
2 – MANUAL TRANSMISSION
3 – SKID PLATE
4 – FRAME
5 – CUSHION
Fig. 5 Transfer Case Skid Plate
1 – SKID PLATE
2 – BOLTS
3 – FRAME
Fig. 6 Fuel Tank Skid Plate
1 – STRAP
2 – FRAME
3 – SKID PLATE
4 – PROTECTIVE CAP
5 – FUEL TANK
13 - 8 FRAME AND BUMPERS TJ
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
FRAME DIMENSIONS
FRAME SIDE VIEW
TJ FRAME AND BUMPERS 13 - 9
FRAME TOP VIEW
13 - 10 FRAME AND BUMPERS TJ
SPECIFICATIONS (Continued)
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Front Bumper Screw . . . . . . . . 104 N·m (77 ft. l bs.)
Front Tow Hook Screw . . . . . . 108 N·m (80 ft. l bs.)
Fuel Tank Ski d Pl ate Nuts . . . 16 N·m (138 i n. l bs.)
Fuel Tank Strap Nuts . . . . . . . . 5 N·m (40 i n. l bs.)
Mai n Fl oor hol down Bol t . . . . . . 47 N·m (35 ft. l bs.)
Radi ator Hol down Bol t . . . . . . . 47 N·m (35 ft. l bs.)
Rear Bumper Bol t . . . . . . . . . . . 67 N·m (50 ft. l bs.)
Rear Bumper Nut . . . . . . . . . . . 67 N·m (50 ft. l bs.)
Rear Fl oor hol down Bol t . . . . . . 47 N·m (35 ft. l bs.)
Transfer Case Ski d Pl ate Bol ts . 74 N·m (55 ft. l bs.)
Transmi ssi on Mount Nuts . . . . . 28 N·m (21 ft. l bs.)
TJ FRAME AND BUMPERS 13 - 11
SPECIFICATIONS (Continued)
FRAME AND BUMPERS
TABLE OF CONTENTS
page
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BUMPERS
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
EMERGENCY TOE EYE. . . . . . . . . . . . . . . . . . . . . 1
FRONT BUMPER EXTENSIONS . . . . . . . . . . . . . . 1
FRONT LICENSE PLATE BRACKET. . . . . . . . . . . . 2
REAR LICENSE PLATE BRACKET. . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
EMERGENCY TOE EYE
REMOVAL
(1) Remove the emergency toe eye cover.
(2) Remove the emergency toe eye attachi ng bol ts
(Fi g. 1).
INSTALLATION
(1) Perform the removal procedure i n reverse order.
FRONT BUMPER EXTENSIONS
REMOVAL
(1) Remove the front bumper extensi on attachi ng
screws (Fi g. 2).
(2) Remove the front bumper extensi on.
Fig. 1 Emergency Toe Eye
1 – FRONT TOW EYELET
2 – EYELET MOUNTING SCREWS
3 – FRONT BUMPER
Fig. 2 Front Bumper Extension
1 – BUMPER EXTENSION FASTENERS
2 – FRONT BUMPER
3 – BUMPER EXTENSION
TJ FRAME AND BUMPERS 13 - 1
2000 JEEP WRANGLER
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
FRONT LICENSE PLATE BRACKET
REMOVAL
(1) Remove the front l i cense pl ate bracket attach-
i ng bol ts and bracket (Fi g. 3).
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
REAR LICENSE PLATE BRACKET
REMOVAL
(1) Remove the rear l i cense pl ate bracket attach-
i ng screws (Fi g. 4).
(2) Di sconnect the l i cense pl ate l amp el ectri cal
connectors.
INSTALLATION
(1) Perform the removal procedure i n reverse
order.
Fig. 3 Front License Plate Bracket
1 – FRONT LICENSE PLATE BRACKET
2 – FRONT BUMPER
Fig. 4 Rear License Plate Bracket
1 – REAR LICENSE PLATE MOUNTING SCREWS
2 – REAR LICENSE PLATE BRACKET
13 - 2 FRAME AND BUMPERS TJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP WRANGLER
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY SYSTEM. . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . 26
FUEL DELIVERY SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
PCM VIN REPROGRAMMING . . . . . . . . . . . . . . . . 1
FUEL DELIVERY SYSTEM. . . . . . . . . . . . . . . . . . . 1
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . . 2
FUEL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL GAUGE SENDING UNIT. . . . . . . . . . . . . . . . 3
FUEL FILTER/FUEL PRESSURE REGULATOR. . . . 3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL INJECTOR RAIL/FUEL DAMPER—2.5L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL RAIL/FUEL DAMPER—4.0L ENGINE. . . . . . . 5
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . . . 6
FUEL TUBES/LINES/HOSES AND CLAMPS . . . . . . 6
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST . . . . . . . . . . . . . . . 6
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . . . 7
FUEL PRESSURE LEAK DOWN TEST. . . . . . . . . . 7
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . . . . . 8
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 10
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . 10
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 10
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . 11
REMOVAL AND INSTALLATION
FUEL FILTER/FUEL PRESSURE REGULATOR. . . 14
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . 15
FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . . . 16
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 16
FUEL INJECTOR RAIL/FUEL DAMPER—2.5L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL INJECTOR RAIL/FUEL DAMPER—4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . . 22
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . 22
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . . 23
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . 23
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 23
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION AND OPERATION
PCM VIN REPROGRAMMING
OPERATION
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
FUEL DELIVERY SYSTEM
DESCRIPTION
The fuel del i very system consi sts of:
• the fuel pump modul e contai ni ng the el ectri c
fuel pump, fuel fi l ter/fuel pressure regul ator, fuel
gauge sendi ng uni t (fuel l evel sensor) and a separate
fuel fi l ter l ocated at bottom of pump modul e
TJ FUEL SYSTEM 14 - 1
• fuel tubes/l i nes/hoses
• qui ck-connect fi tti ngs
• fuel i njector rai l
• fuel i njectors
• fuel tank
• fuel tank fi l l er/vent tube assembl y
• fuel tank fi l l er tube cap
• rol l over val ve
• accel erator pedal
• throttl e cabl e
OPERATION
Fuel i s returned through the fuel pump modul e
and back i nto the fuel tank through the fuel fi l ter/
fuel pressure regul ator. A separate fuel return l i ne
from the engi ne to the tank i s not used.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock-
nut/gasket, and rol l over val ve (refer to Group 25,
Emi ssi on Control System for rol l over val ve i nforma-
ti on).
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum fuel fi l l er cap i s used. The fuel fi l l er tube
contai ns a fl ap door l ocated bel ow the fuel fi l l cap.
Al so to be consi dered part of the fuel system i s the
evaporati on control system. Thi s i s desi gned to
reduce the emi ssi on of fuel vapors i nto the atmo-
sphere. The descri pti on and functi on of the Evapora-
ti ve Control System i s found i n Group 25, Emi ssi on
Control Systems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump modul e on al l model s i s i nstal l ed
i nto the top of the fuel tank (Fi g. 1). The fuel pump
modul e contai ns the fol l owi ng components (Fi g. 1) or
(Fi g. 2):
• A combi nati on fuel fi l ter/fuel pressure regul ator
• A separate fuel pi ck-up fi l ter (strai ner)
• An el ectri c fuel pump
• A threaded l ocknut to retai n modul e to tank
• A gasket between tank fl ange and modul e
• Fuel gauge sendi ng uni t (fuel l evel sensor)
• Fuel suppl y tube (l i ne) connecti on
The fuel gauge sendi ng uni t, pi ck-up fi l ter and fuel
fi l ter/fuel pressure regul ator may be servi ced sepa-
ratel y. I f the el ectri cal fuel pump requi res servi ce,
the enti re fuel pump modul e must be repl aced.
Fig. 1 Fuel Tank/Fuel Pump Module (Top View)
1 – FUEL PUMP MODULE
2 – FUEL SUPPLY TUBE
3 – RETAINER CLAMP
4 – FUEL FILTER/FUEL PRESSURE REGULATOR
5 – LOCKNUT
6 – ROLLOVER VALVE
7 – TOP OF FUEL TANK
8 – ELECTRICAL CONNECTOR
9 – ROLLOVER VALVE
Fig. 2 Fuel Pump Module Components
1 – FUEL GAUGE FLOAT
2 – PICK-UP FILTER
3 – FUEL GAUGE SENDING UNIT
4 – FUEL FILTER/FUEL PRESSURE REGULATOR
5 – ELECTRIC FUEL PUMP
6 – PIGTAIL WIRING HARNESS
14 - 2 FUEL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
Refer to Fuel Pump, Fuel Fi l ter/Fuel Pressure Reg-
ul ator and Fuel Gauge Sendi ng Uni t.
FUEL PUMP
DESCRIPTION
The fuel pump i s l ocated i nsi de of the fuel pump
modul e. A 12 vol t, permanent magnet, el ectri c motor
powers the fuel pump.
OPERATION
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
Fuel i s drawn i n through a fi l ter at the bottom of
the modul e and pushed through the el ectri c motor
gearset to the pump outl et.
Check Valve Operation: The pump outl et con-
tai ns a one-way check val ve to prevent fuel fl ow back
i nto the tank and to mai ntai n fuel suppl y l i ne pres-
sure (engi ne warm) when pump i s not operati onal . I t
i s al so used to keep the fuel suppl y l i ne ful l of gaso-
l i ne when pump i s not operati onal . After the vehi cl e
has cool ed down, fuel pressure may drop to 0 psi
(col d fl ui d contracts), but l i qui d gasol i ne wi l l remai n
i n fuel suppl y l i ne between the check val ve and fuel
i njectors. Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition. Refer to the Fuel Pressure Leak
Down Test for more i nformati on.
FUEL GAUGE SENDING UNIT
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor track (card).
OPERATION
The fuel pump modul e has 4 di fferent ci rcui ts
(wi res). Two of these ci rcui ts are used for the fuel
gauge sendi ng uni t for fuel gauge operati on, and for
certai n OBD I I emi ssi on requi rements. The other 2
wi res are used for el ectri c fuel pump operati on.
For Fuel Gauge Operation: A constant i nput
vol tage source of about 12 vol ts (battery vol tage) i s
suppl i ed to the resi stor track on the fuel gauge send-
i ng uni t. Thi s i s fed di rectl y from the Powertrai n
Control Modul e (PCM). NOTE: For diagnostic pur-
poses, this 12V power source can only be veri-
fied with the circuit opened (fuel pump module
electrical connector unplugged). With the con-
nectors plugged, output voltages will vary from
about.6 volts at FULL, to about 8.6 volts at
EMPTY (about 8.6 volts at EMPTY for J eep
models, and about 7.0 volts at EMPTY for
Dodge Truck models). The resi stor track i s used to
vary the vol tage (resi stance) dependi ng on fuel tank
fl oat l evel . As fuel l evel i ncreases, the fl oat and arm
move up, whi ch decreases vol tage. As fuel l evel
decreases, the fl oat and arm move down, whi ch
i ncreases vol tage. The vari ed vol tage si gnal i s
returned back to the PCM through the sensor return
ci rcui t.
Both of the el ectri cal ci rcui ts between the fuel
gauge sendi ng uni t and the PCM are hard-wi red (not
mul ti -pl exed). After the vol tage si gnal i s sent from
the resi stor track, and back to the PCM, the PCM
wi l l i nterpret the resi stance (vol tage) data and send
a message across the mul ti -pl ex bus ci rcui ts to the
i nstrument panel cl uster. Here i t i s transl ated i nto
the appropri ate fuel gauge l evel readi ng. Refer to
I nstrument Panel for addi ti onal i nformati on.
For OBD II Emission Monitor Requirements:
The PCM wi l l moni tor the vol tage output sent from
the resi stor track on the sendi ng uni t to i ndi cate fuel
l evel . The purpose of thi s feature i s to prevent the
OBD I I system from recordi ng/setti ng fal se mi sfi re
and fuel system moni tor di agnosti c troubl e codes.
The feature i s acti vated i f the fuel l evel i n the tank
i s l ess than approxi matel y 15 percent of i ts rated
capaci ty. I f equi pped wi th a Leak Detecti on Pump
(EVAP system moni tor), thi s feature wi l l al so be acti -
vated i f the fuel l evel i n the tank i s more than
approxi matel y 85 percent of i ts rated capaci ty.
FUEL FILTER/FUEL PRESSURE REGULATOR
DESCRIPTION
The combi nati on fuel fi l ter and fuel pressure regu-
l ator i s l ocated on the top of fuel pump modul e (Fi g.
1).
OPERATION
A combi nati on fuel fi l ter and fuel pressure regul a-
tor i s used on al l engi nes. A separate frame mounted
fuel fi l ter i s not used wi th any engi ne.
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the Powertrai n Control
Modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 Ϯ 34 kPa
(49.2 Ϯ 5 psi ) at the fuel i njectors. I t contai ns a di a-
phragm, cal i brated spri ngs and a fuel return val ve.
The i nternal fuel fi l ter i s al so part of the assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump through an openi ng tube at the bot-
tom of fi l ter/regul ator (Fi g. 3).
The regul ator acts as a check val ve to mai ntai n
some fuel pressure when the engi ne i s not operati ng.
TJ FUEL SYSTEM 14 - 3
DESCRIPTION AND OPERATION (Continued)
Thi s wi l l hel p to start the engi ne. A second check
val ve i s l ocated at the outl et end of the el ectri c fuel
pump. Refer to Fuel Pump—Description and
Operation for more information. Also refer to
the Fuel Pressure Leak Down Test and the Fuel
Pump Pressure Tests.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 49 psi , an i nternal di aphragm cl oses
and excess fuel pressure i s routed back i nto the tank
through the pressure regul ator. A separate fuel
return l i ne i s not used wi th any engi ne.
FUEL TANK
DESCRIPTION
The fuel tank i s constructed of a pl asti c materi al .
I ts mai n functi ons are for fuel storage and for pl ace-
ment of the fuel pump modul e.
OPERATION
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
A rol l over val ve(s) i s mounted i nto the top of the
fuel tank (or pump modul e). Refer to Emi ssi on Con-
trol System for rol l over val ve i nformati on.
An evaporati on control system i s connected to the
rol l over val ve(s) to reduce emi ssi ons of fuel vapors
i nto the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng a Leak
Detecti on Pump (LDP). Refer to Emi ssi on Control
System for addi ti onal i nformati on.
FUEL INJECTORS
DESCRIPTION
An i ndi vi dual fuel i njector (Fi g. 4) i s used for each
i ndi vi dual cyl i nder.
OPERATION
The top (fuel entry) end of the i njector (Fi g. 4) i s
attached i nto an openi ng on the fuel rai l .
The fuel i njectors are el ectri cal sol enoi ds. The
i njector contai ns a pi ntl e that cl oses off an ori fi ce at
the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and needl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out
the ori fi ce. Because the fuel i s under hi gh pressure, a
fi ne spray i s devel oped i n the shape of a penci l
stream. The sprayi ng acti on atomi zes the fuel , add-
i ng i t to the ai r enteri ng the combusti on chamber.
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
Fig. 3 Fuel Filter/Fuel Pressure Regulator
1 – FUEL FILTER/FUEL PRESSURE REGULATOR
2 – TO FUEL INJECTORS
3 – FUEL SUPPLY TUBE
4 – O-RINGS
5 – FUEL INLET FROM PUMP
6 – FUEL RETURN TO TANK
Fig. 4 Fuel Injector—Typical
1 – FUEL INJECTOR
2 – NOZZLE
3 – TOP (FUEL ENTRY)
14 - 4 FUEL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage i s suppl i ed to the i njectors through
the ASD rel ay.
The PCM determi nes i njector pul se wi dth based on
vari ous i nputs.
FUEL INJECTOR RAIL/FUEL DAMPER— 2. 5L
ENGINE
DESCRIPTION
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne (Fi g. 5). On the 2.5L 4–cyl i n-
der engi ne, a fuel damper i s l ocated at the front of
the fuel rai l (Fi g. 5).
OPERATION
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n thi s
group for i nformati on.
The fuel rai l i s not repai rabl e.
FUEL RAIL/FUEL DAMPER— 4. 0L ENGINE
DESCRIPTION
The fuel rai l i s mounted to the i ntake mani fol d
(Fi g. 6). I t i s used to mount the fuel i njectors to the
engi ne. On the 4.0L 6–cyl i nder engi ne, a fuel
damper i s l ocated near the center of the fuel rai l
(Fi g. 6).
OPERATION
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Fig. 5 Fuel Injector Rail/Fuel Damper—2.5L Engine
1 – FUEL DAMPER
2 – FUEL INJECTOR
3 – NUMBERED TAG
4 – FUEL RAIL
5 – FUEL RAIL MOUNTING BOLTS/NUTS
6 – TEST PORT
7 – CABLE BRACKET
Fig. 6 Fuel Rail/Fuel Damper—4.0L Engine
1 – INJ. #1
2 – INJ. #2
3 – INJ. #3
4 – INJ. #4
5 – INJ. #5
6 – INJ. #6
7 – FUEL INJECTOR RAIL
8 – FUEL DAMPER
9 – PRESSURE TEST PORT CAP
10 – MOUNTING BOLTS (4)
11 – QUICK-CONNECT FITTING
TJ FUEL SYSTEM 14 - 5
DESCRIPTION AND OPERATION (Continued)
Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n thi s
group for i nformati on.
The fuel rai l i s not repai rabl e.
FUEL TANK FILLER TUBE CAP
DESCRIPTION
The pl asti c fuel tank fi l l er tube cap i s threaded
onto the end of the fuel fi l l tube. Certai n model s are
equi pped wi th a 1/4 turn cap.
OPERATION
The l oss of any fuel or vapor out of fuel fi l l er tube
i s prevented by the use of a pressure-vacuum fuel fi l l
cap. Rel i ef val ves i nsi de the cap wi l l rel ease fuel tank
pressure at predetermi ned pressures. Fuel tank vac-
uum wi l l al so be rel eased at predetermi ned val ues.
Thi s cap must be repl aced by a si mi l ar uni t i f
repl acement i s necessary. Thi s i s i n order for the sys-
tem to remai n effecti ve.
CAUTION: Remove fill cap before servicing any fuel
system component to relieve tank pressure. If
equipped with a California emissions package and a
Leak Detection Pump (LDP), the cap must be tight-
ened securely. If cap is left loose, a Diagnostic
Trouble Code (DTC) may be set.
FUEL TUBES/LINES/HOSES AND CLAMPS
DESCRIPTION
Al so refer to Qui ck-Connect Fi tti ngs.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
QUICK-CONNECT FITTINGS
DESCRIPTION
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Some are equi pped wi th
safety l atch cl i ps. Some may requi re the use of a spe-
ci al tool for di sconnecti on and removal . Refer to
Qui ck-Connect Fi tti ngs Removal /I nstal l ati on for more
i nformati on.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found el sewhere i n thi s
group.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (1–2 seconds) ri se to speci fi cati on.
Al l fuel systems are equi pped wi th a fuel tank
modul e mounted, combi nati on fuel fi l ter/fuel pressure
regul ator. The fuel pressure regul ator i s not con-
trol l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove protecti ve cap at fuel rai l test port.
Connect the 0–414 kPa (0-60 psi ) fuel pressure gauge
14 - 6 FUEL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
(from gauge set 5069) to test port pressure fi tti ng on
fuel rai l (Fi g. 7). The DRB III Scan Tool along
with the PEP module, the 500 psi pressure
transducer, and the transducer-to-test port
adapter may also be used in place of the fuel
pressure gauge.
(2) Start and warm engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa Ϯ 34
kPa (49.2 psi Ϯ 5 psi ) at i dl e.
(3) I f engi ne runs, but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, but speci fi cati ons for ei ther the Fuel Pump
Capaci ty, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, repl ace fuel pump
modul e assembl y. Refer to Fuel Pump Modul e
Removal /I nstal l ati on.
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for more i nformati on.
(5) I nstal l protecti ve cap to fuel rai l test port.
FUEL PUMP CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Rel ease fuel system pressure. Refer to Fuel
Pressure Rel ease Procedure.
(2) Di sconnect fuel suppl y l i ne at fuel rai l . Refer to
Qui ck-Connect Fi tti ngs. Some engi nes may requi re
ai r cl eaner housi ng removal before l i ne di sconnecti on.
(3) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16” fuel
l i nes and tool number 6631 i s used for 3/8” fuel l i nes.
(4) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose i nto di sconnected fuel suppl y l i ne.
I nsert other end of Adaptor Tool Hose i nto a gradu-
ated contai ner.
(5) Remove fuel fi l l cap.
(6) To acti vate fuel pump and pressuri ze system,
obtai n DRB scan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump wi l l del i ver at l east 1/4 l i ter
of fuel i n 7 seconds. Do not operate fuel pump for
l onger than 7 seconds wi th fuel l i ne di sconnected as
fuel pump modul e reservoi r may run empty.
(a) I f capaci ty i s l ower than speci fi cati on, but
fuel pump can be heard operati ng through fuel fi l l
cap openi ng, check for a ki nked/damaged fuel sup-
pl y l i ne somewhere between fuel rai l and fuel
pump modul e.
(b) I f l i ne i s not ki nked/damaged, and fuel pres-
sure i s OK, but capaci ty i s l ow, repl ace fuel fi l ter/
fuel pressure regul ator. The fi l ter/regul ator may be
servi ced separatel y on certai n appl i cati ons. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for addi ti onal i nformati on.
(c) I f both fuel pressure and capaci ty are l ow,
repl ace fuel pump modul e assembl y. Refer to Fuel
Pump Modul e Removal /I nstal l ati on.
FUEL PRESSURE LEAK DOWN TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Pressure Test and Fuel Pump Capaci ty Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (1–2 seconds) ri se to speci fi cati on.
Abnormal l y l ong peri ods of cranki ng to restart a
hot engi ne that has been shut down for a short
peri od of ti me may be caused by:
• Fuel pressure bl eedi ng past a fuel i njector(s).
• Fuel pressure bl eedi ng past the check val ve i n
the fuel pump modul e.
(1) Di sconnect the fuel i nl et l i ne at fuel rai l . Refer
to Fuel Tubes/Li nes/Hoses and Cl amps i n thi s secti on
of the group for procedures. On some engi nes, ai r
Fig. 7 Fuel Pressure Test Gauge (Typical Gauge
Installation at Test Port)
1 – SERVICE (TEST) PORT
2 – FUEL PRESSURE TEST GAUGE
3 – FUEL RAIL
TJ FUEL SYSTEM 14 - 7
DIAGNOSIS AND TESTING (Continued)
cl eaner housi ng removal may be necessary before
fuel l i ne di sconnecti on.
(2) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16” fuel
l i nes and tool number 6631 i s used for 3/8” fuel l i nes.
(3) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose between di sconnected fuel l i ne
and fuel rai l (Fi g. 8).
(4) Connect the 0-414 kPa (0-60 psi ) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropri ate Adaptor Tool . The DRB III Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engi ne and bri ng to normal operati ng
temperature.
(6) Observe test gauge. Normal operati ng pressure
shoul d be 339 kPa Ϯ 34 kPa (49.2 psi Ϯ 5 psi ).
(7) Shut engi ne off.
(8) Pressure shoul d not fal l bel ow 30 psi for five
minutes.
(9) I f pressure fal l s bel ow 30 psi , i t must be deter-
mi ned i f a fuel i njector, the check val ve wi thi n the
fuel pump modul e, or a fuel tube/l i ne i s l eaki ng.
(10) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(11) Shut engi ne off.
(12) Testing for fuel injector or fuel rail leak-
age: Cl amp off the rubber hose porti on of Adaptor
Tool between the fuel rai l and the test port “T” on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a fuel i njector or the fuel rai l i s l eaki ng.
(13) Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Cl amp off the rubber hose porti on of Adaptor Tool
between the vehi cl e fuel l i ne and test port “T” on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a l eak may be found at a fuel tube/l i ne. I f no
l eaks are found at fuel tubes or l i nes, one of the
check val ves i n ei ther the el ectri c fuel pump or fi l ter/
regul ator may be l eaki ng.
Note: A qui ck l oss of pressure usual l y i ndi cates a
defecti ve check val ve i n the fi l ter/regul ator. A sl ow
l oss of pressure usual l y i ndi cates a defecti ve check
val ve i n the el ectri c fuel pump.
The el ectri c fuel pump i s not servi ced separatel y.
Repl ace the fuel pump modul e assembl y. The fi l ter/
regul ator may be repl aced separatel y on certai n
appl i cati ons. Refer to Fuel Fi l ter/Fuel Pressure Reg-
ul ator Removal /I nstal l ati on for addi ti onal i nforma-
ti on.
FUEL PUMP AMPERAGE TEST
Thi s amperage (current draw) test i s to be done i n
conjuncti on wi th the Fuel Pump Pressure Test, Fuel
Pump Capaci ty Test and Fuel Pressure Leak Down
Test. Before performi ng the amperage test, be sure
the temperature of the fuel tank i s above 50° F (10°
C).
The DRB Scan Tool al ong wi th the DRB Low Cur-
rent Shunt (LCS) adapter (Fi g. 9) and i ts test l eads
wi l l be used to check fuel pump amperage speci fi ca-
ti ons.
(1) Be sure fuel tank contai ns fuel before starti ng
test. I f tank i s empty or near empty, amperage read-
i ngs wi l l be i ncorrect.
(2) Obtai n LCS adapter.
(3) Pl ug cabl e from LCS adapter i nto DRB scan
tool at SET 1 receptacl e.
(4) Pl ug DRB i nto vehi cl e 16–way connector (data
l i nk connector).
(5) Connect (-) and (+) test cabl e l eads i nto LCS
adapter receptacl es. Use 10 amp (10A +) receptacl e
and common (-) receptacl es.
(6) Gai n access to MAI N MENU on DRB screen.
(7) Press DVOM button on DRB.
Fig. 8 Connecting Adapter Tool—Typical
1 – VEHICLE FUEL LINE
2 – TEST PORT “T”
3 – SPECIAL TOOL 6923, 6631, 6541 OR 6539
4 – FUEL PRESSURE TEST GAUGE
5 – FUEL LINE CONNECTION AT RAIL
6 – FUEL RAIL
14 - 8 FUEL SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
(8) Usi ng l eft/ri ght arrow keys, hi ghl i ght CHAN-
NEL 1 functi on on DRB screen.
(9) Press ENTER three ti mes.
(10) Usi ng up/down arrow keys, hi ghl i ght RANGE
on DRB screen (screen wi l l defaul t to 2 amp scal e).
(11) Press ENTER to change 2 amp scal e to 10
amp scal e. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Di stri buti on Center
(PDC).
(13) Remove fuel pump rel ay from PDC. Refer to
l abel on PDC cover for rel ay l ocati on.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND FUEL
SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: TO PREVENT POSSIBLE DAMAGE TO
THE VEHICLE ELECTRICAL SYSTEM AND LCS
ADAPTER, THE TEST LEADS MUST BE CON-
NECTED INTO RELAY CAVITIES EXACTLY AS
SHOWN IN FOLLOWING STEPS.
Dependi ng upon vehi cl e model , year or engi ne con-
fi gurati on, three di fferent types of rel ays may be
used: Type-1, type-2 and type–3.
(14) I f equi pped wi th type–1 relay (Fi g. 10),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 10).
(15) I f equi pped wi th type–2 relay (Fi g. 11),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 11).
(16) I f equi pped wi th type–3 relay (Fi g. 12),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 3 and 5. For l ocati on of these cavi -
ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 12).
Fig. 9 Low Current Shunt Adapter
1 – LOW CURRENT SHUNT ADAPTER
2 – PLUG TO DRB
3 – TEST LEAD RECEPTACLES
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 10 Type–1 Relay
TJ FUEL SYSTEM 14 - 9
DIAGNOSIS AND TESTING (Continued)
(17) When LCS adapter test l eads are attached
i nto rel ay cavi ti es, fuel pump will be activated.
Determi ne fuel pump amperage on DRB screen.
Amperage shoul d be bel ow 10.0 amps. I f amperage i s
bel ow 10.0 amps, and speci fi cati ons for the Fuel
Pump Pressure, Fuel Pump Capaci ty and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ul e i s OK.
(18) I f amperage i s more than 10.0 amps, repl ace
fuel pump modul e assembl y. The el ectri c fuel pump
i s not servi ced separatel y.
(19) Di sconnect test l eads from rel ay cavi ti es
i mmedi atel y after testi ng.
FUEL GAUGE SENDING UNIT
The fuel gauge sendi ng uni t contai ns a vari abl e
resi stor (track). As the fl oat moves up or down, el ec-
tri cal resi stance wi l l change. Refer to I nstrument
Panel and Gauges for Fuel Gauge testi ng. To test the
gauge sendi ng uni t onl y, i t must be removed from
vehi cl e. The uni t i s part of the fuel pump modul e.
Refer to Fuel Pump Modul e Removal /I nstal l ati on for
procedures. Measure the resi stance across the send-
i ng uni t termi nal s. Wi th fl oat i n up posi ti on, resi s-
tance shoul d be 20 ohms (+/- 5%). Wi th fl oat i n down
posi ti on, resi stance shoul d be 270 ohms (+/- 5%).
FUEL INJECTOR TEST
To perform a compl ete test of the fuel i njectors and
thei r ci rcui try, use the DRB scan tool and refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual . To test the i njector onl y, refer to the fol l owi ng:
Di sconnect the fuel i njector wi re harness connector
from the i njector. The i njector i s equi pped wi th 2
el ectri cal termi nal s (pi ns). Pl ace an ohmmeter across
the termi nal s. Resi stance readi ng shoul d be approxi -
matel y 12 ohms Ϯ1.2 ohms at 20°C (68°F).
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fi l l cap.
(2) Remove fuel pump rel ay from Power Di stri bu-
ti on Center (PDC). For l ocati on of rel ay, refer to l abel
on undersi de of PDC cover.
(3) Start and run engi ne unti l i t stal l s.
(4) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(5) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unpl ug connector from any fuel i njector.
(7) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(8) Connect other end of jumper wi re to posi ti ve
si de of battery.
(9) Connect one end of a second jumper wi re to
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentari l y touch other end of jumper wi re
to negati ve termi nal of battery for no more than a
few seconds.
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 11 Type–2 Relay
TERMINAL LEGEND
NUMBER IDENTIFICATION
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
Fig. 12 Type–3 Relay
14 - 10 FUEL SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
(11) Pl ace a rag or towel bel ow fuel l i ne qui ck-con-
nect fi tti ng at fuel rai l .
(12) Di sconnect qui ck-connect fi tti ng at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs.
(13) Return fuel pump rel ay to PDC.
(14) One or more Di agnosti c Troubl e Codes (DTC’s)
may have been stored i n PCM memory due to fuel
pump rel ay removal . The DRB scan tool must be
used to erase a DTC.
QUICK-CONNECT FITTINGS
Al so refer to Fuel Tubes/Li nes/Hoses and Cl amps.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Safety l atch cl i ps are
used on certai n components/l i nes. Certai n fi tti ngs
may requi re use of a speci al tool for di sconnecti on.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure i n thi s group.
(2) Di sconnect negati ve battery cabl e from battery.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) Single-Tab Type Fitting: Thi s type of fi tti ng
i s equi pped wi th a si ngl e pul l tab (Fi g. 13). The tab
i s removabl e. After tab i s removed, qui ck-connect fi t-
ti ng can be separated from fuel system component.
(a) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 14). If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use screwdri ver to pry up pul l tab (Fi g. 14).
(c) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 15).
(5) Two-Tab Type Fitting: Thi s type of fi tti ng i s
equi pped wi th tabs l ocated on both si des of fi tti ng
(Fi g. 16). The tabs are suppl i ed for di sconnecti ng
qui ck-connect fi tti ng from component bei ng servi ced.
Fig. 13 Single-Tab Type Fitting
1 – PULL TAB
2 – QUICK-CONNECT FITTING
3 – PRESS HERE TO REMOVE PULL TAB
4 – INSERTED TUBE END
Fig. 14 Disconnecting Single-Tab Type Fitting
1 – PULL TAB
2 – SCREWDRIVER
3 – QUICK-CONNECT FITTING
TJ FUEL SYSTEM 14 - 11
SERVICE PROCEDURES (Continued)
(a) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 16) agai nst si des of
qui ck-connect fi tti ng wi th your fi ngers. Tool use i s
not requi red for removal and may damage pl asti c
retai ner.
(b) Pul l fi tti ng from fuel system component
bei ng servi ced.
(c) The pl asti c retai ner wi l l remai n on compo-
nent bei ng servi ced after fi tti ng i s di sconnected.
The o-ri ngs and spacer wi l l remai n i n qui ck-con-
nect fi tti ng connector body.
(6) Plastic Retainer Ring Type Fitting: Thi s
type of fi tti ng can be i denti fi ed by the use of a ful l -
round pl asti c retai ner ri ng (Fi g. 17) usual l y bl ack i n
col or.
Fig. 15 Removing Pull Tab
1 – FUEL TUBE OR FUEL SYSTEM COMPONENT
2 – PULL TAB
3 – QUICK-CONNECT FITTING
4 – FUEL TUBE STOP
Fig. 16 Typical Two-Tab Type Quick-Connect Fitting
1 – TAB(S)
2 – QUICK-CONNECT FITTING
Fig. 17 Plastic Retainer Ring Type Fitting
1 – FUEL TUBE
2 – QUICK CONNECT FITTING
3 – PUSH
4 – PLASTIC RETAINER
5 – PUSH
6 – PUSH
7 – PUSH
8 – PUSH
Fig. 18 Latch Clip—Type 1
1 – TETHER STRAP
2 – FUEL LINE
3 – SCREWDRIVER
4 – LATCH CLIP
5 – FUEL RAIL
14 - 12 FUEL SYSTEM TJ
SERVICE PROCEDURES (Continued)
(a) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 17). Wi th pl asti c ri ng
depressed, pul l fi tti ng from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
(c) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage.
Repl ace as necessary.
(7) Latch Clips: Dependi ng on vehi cl e model and
engi ne, 2 di fferent types of safety l atch cl i ps are used
(Fi g. 18) or (Fi g. 19). Type-1 i s tethered to fuel l i ne
and type-2 i s not. A speci al tool wi l l be necessary to
di sconnect fuel l i ne after l atch cl i p i s removed. The
l atch cl i p may be used on certai n fuel l i ne/fuel rai l
connecti on, or to joi n fuel l i nes together.
(a) Type 1: Pry up on l atch cl i p wi th a screw-
dri ver (Fi g. 18).
(b) Type 2: Separate and unl atch 2 smal l arms
on end of cl i p (Fi g. 19) and swi ng away from fuel
l i ne.
(c) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
(d) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne
(Fi g. 20). Use tool to rel ease l ocki ng fi ngers i n end
of l i ne.
(e) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
(f) After di sconnecti on, l ocki ng fi ngers wi l l
remai n wi thi n qui ck-connect fi tti ng at end of fuel
l i ne.
(8) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
CONNECTING
(1) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(2) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(3) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(4) Conti nue pushi ng unti l a cl i ck i s fel t.
(5) Si ngl e-tab type fi tti ng: Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
(6) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(7) Latch Cl i p Equi pped: I nstal l l atch cl i p (snaps
i nto posi ti on). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(8) Connect negati ve cabl e to battery.
(9) Start engi ne and check for l eaks.
Fig. 19 Latch Clip—Type 2
1 – LATCH CLIP
Fig. 20 Fuel Line Disconnection Using Special Tool
1 – SPECIAL FUEL LINE TOOL
2 – FUEL LINE
3 – FUEL RAIL
TJ FUEL SYSTEM 14 - 13
SERVICE PROCEDURES (Continued)
REMOVAL AND INSTALLATION
FUEL FILTER/FUEL PRESSURE REGULATOR
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s l ocated on the fuel pump modul e. The fuel
pump modul e i s l ocated on top of fuel tank.
The fi l ter/regul ator may be removed wi thout
removi ng fuel pump modul e al though fuel tank must
be removed.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Cl ean area around fi l ter/regul ator.
(3) Di sconnect fuel l i ne at fi l ter/regul ator. Refer to
Qui ck-Connect Fi tti ngs i n thi s group for procedures.
(4) Remove retai ner cl amp from top of fi l ter/regu-
l ator (Fi g. 21). Cl amp snaps to tabs on pump modul e.
Di scard ol d cl amp.
(5) Pry fi l ter/regul ator from top of pump modul e
wi th 2 screwdri vers. Uni t i s snapped i nto modul e.
(6) Di scard gasket bel ow fi l ter/regul ator (Fi g. 22).
(7) Before di scardi ng fi l ter/regul ator assembl y,
i nspect assembl y to veri fy that o-ri ngs (Fi g. 23) are
i ntact. I f the smal l est of the two o-ri ngs can not be
found on bottom of fi l ter/regul ator, i t may be neces-
sary to remove i t from the fuel i nl et passage i n fuel
pump modul e.
Fig. 21 Fuel Filter/Fuel Pressure Regulator
1 – RETAINER CLAMP
2 – FUEL FILTER/FUEL PRESSURE REGULATOR
3 – FUEL SUPPLY TUBE
4 – ALIGNMENT ARROW
Fig. 22 Fuel Filter/Fuel Pressure Regulator Gasket
1 – TOP OF MODULE
2 – GASKET
Fig. 23 Fuel Filter/Fuel Pressure Regulator O-Rings
1 – FUEL FILTER/FUEL PRESSURE REGULATOR
2 – TO FUEL INJECTORS
3 – FUEL SUPPLY TUBE
4 – O-RINGS
5 – FUEL INLET FROM PUMP
6 – FUEL RETURN TO TANK
7 – FUEL RETURN TO TANK
14 - 14 FUEL SYSTEM TJ
INSTALLATION
(1) Cl ean recessed area i n pump modul e where fi l -
ter/regul ator i s to be i nstal l ed.
(2) Obtai n new fi l ter/regul ator (two new o-ri ngs
shoul d al ready be i nstal l ed).
(3) Appl y a smal l amount of cl ean engi ne oi l to
o-ri ngs. Do not install o-rings separately into
fuel pump module. They will be damaged when
installing filter/regulator.
(4) I nstal l new gasket to top of fuel pump modul e.
(5) Press new fi l ter/regul ator i nto top of pump
modul e unti l i t snaps i nto posi ti on (a posi ti ve cl i ck
must be heard or fel t).
(6) The mol ded arrow (Fi g. 21) on top of fuel pump
modul e shoul d be poi nted towards front of vehi cl e (12
o’cl ock posi ti on).
(7) Rotate fi l ter/regul ator unti l fuel suppl y tube
(fi tti ng) i s poi nted to 10 o’cl ock posi ti on.
(8) I nstal l new retai ner cl amp (cl amp snaps over
top of fi l ter/regul ator and l ocks to fl anges on pump
modul e).
(9) Connect fuel l i ne at fi l ter/regul ator. Refer to
Qui ck-Connect Fi tti ngs i n thi s group for procedures.
(10) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL PUMP MODULE
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Drai n fuel tank and remove tank. Refer to the
Fuel Tank Removal /I nstal l ati on secti on of thi s group.
(2) Thoroughl y wash and cl ean area around pump
modul e to prevent contami nants from enteri ng tank.
(3) The pl asti c fuel pump modul e l ocknut i s
threaded onto fuel tank (Fi g. 24). I nstal l Speci al Tool
6856 to fuel pump modul e l ocknut and remove l ock-
nut (Fi g. 25). The fuel pump modul e wi l l spri ng up
when l ocknut i s removed.
(4) Remove modul e from fuel tank.
Fig. 24 Top View of Fuel Tank and Fuel Pump
Module
1 – FUEL PUMP MODULE
2 – FUEL SUPPLY TUBE
3 – RETAINER CLAMP
4 – FUEL FILTER/FUEL PRESSURE REGULATOR
5 – LOCKNUT
6 – ROLLOVER VALVE
7 – TOP OF FUEL TANK
8 – ELECTRICAL CONNECTOR
9 – ROLLOVER VALVE
Fig. 25 Locknut Removal/Installation—Typical
1 – SPECIAL TOOL 6856
2 – LOCKNUT
TJ FUEL SYSTEM 14 - 15
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the module gasket must be replaced.
(1) Thoroughl y cl ean l ocknut threads and mati ng
fuel tank threads. Use a soap/water sol uti on. Do not
use carburetor cl eaner to cl ean threads.
(2) Usi ng new gasket, posi ti on fuel pump modul e
i nto openi ng i n fuel tank.
(3) Appl y cl ean water to l ocknut threads.
(4) Posi ti on l ocknut over top of fuel pump modul e.
(5) Rotate modul e unti l arrow (Fi g. 21) i s poi nted
toward front of vehi cl e (12 o’cl ock posi ti on). Thi s step
must be done to prevent fl oat/fl oat rod assembl y from
contacti ng si des of fuel tank.
(6) I nstal l Speci al Tool 6856 to l ocknut.
(7) Ti ghten l ocknut to 74 N·m (55 ft. l bs.) torque.
(8) Rotate fuel fi l ter/fuel pressure regul ator unti l
i ts fi tti ng i s poi nted to 10 o’cl ock posi ti on.
(9) I nstal l fuel tank. Refer to Fuel Tank I nstal l a-
ti on i n thi s secti on.
FUEL PUMP INLET FILTER
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of fuel pump modul e (Fi g. 26). The fuel
pump modul e i s l ocated on top of fuel tank.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove fi l ter by pryi ng from bottom of modul e
wi th 2 screwdri vers. Fi l ter i s snapped to modul e.
(4) Cl ean bottom of pump modul e.
INSTALLATION
(1) Snap new fi l ter to bottom of modul e.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL GAUGE SENDING UNIT
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 27). The fuel pump modul e i s l ocated
wi thi n the fuel tank.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 28) to remove send-
i ng uni t from pump modul e.
INSTALLATION
(1) Posi ti on sendi ng uni t to pump modul e and
snap i nto pl ace.
(2) Connect el ectri cal connector to termi nal s.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
Fig. 26 Fuel Pump Inlet Filter
1 – FUEL PUMP MODULE
2 – FUEL PUMP INLET FILTER
Fig. 27 Fuel Gauge Sending Unit Location
1 – FUEL GAUGE FLOAT
2 – PICK-UP FILTER
3 – FUEL GAUGE SENDING UNIT
4 – FUEL FILTER/FUEL PRESSURE REGULATOR
5 – ELECTRIC FUEL PUMP
6 – PIGTAIL WIRING HARNESS
14 - 16 FUEL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL INJECTOR RAIL/FUEL DAMPER— 2. 5L
ENGINE
REMOVAL
The fuel damper i s not servi ced separatel y.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure as descri bed i n thi s Group.
(3) Di sconnect negati ve battery cabl e from battery.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Remove i njector harness el ectri cal connectors
at each i njector. Each i njector connector shoul d have
a numeri cal tag attached i denti fyi ng i ts correspond-
i ng cyl i nder (Fi g. 29). I f not, i denti fy each connector
before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs i n
thi s group for procedures.
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on i n thi s group
for procedures.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Group
8H, Speed Control System for procedures.
(9) Di sconnect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(10) Remove cabl e routi ng bracket (Fi g. 29) at
i ntake mani fol d.
(11) Remove nut securi ng crankshaft posi ti on sen-
sor pi gtai l harness to fuel rai l mounti ng stud.
Remove cl amp and harness from fuel rai l mounti ng
stud.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
29).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
INSTALLATION
(1) Cl ean each i njector bore at i ntake mani fol d.
(2) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
Fig. 28 Fuel Gauge Sending Unit Release Tab
1 – ELECTRICAL CONNECTOR
2 – FUEL GAUGE SENDING UNIT
3 – RELEASE TAB
4 – FUEL PUMP MODULE
Fig. 29 Fuel Rail Mounting—2.5L Engine
1 – FUEL DAMPER
2 – FUEL INJECTOR
3 – NUMBERED TAG
4 – FUEL RAIL
5 – FUEL RAIL MOUNTING BOLTS/NUTS
6 – TEST PORT
7 – CABLE BRACKET
TJ FUEL SYSTEM 14 - 17
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 Ϯ3 N·m (100 Ϯ25 i n. l bs.) torque.
(5) Posi ti on crankshaft posi ti on sensor pi gtai l wi re
harness cl amp and wi re harness to fuel rai l mount-
i ng stud. I nstal l nut securi ng harness to fuel rai l
mounti ng stud.
(6) Connect tagged i njector harness connectors to
appropri ate i njector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs i n thi s group for
procedures.
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(13) I nstal l ai r tube (or duct) at top of throttl e
body.
(14) I nstal l fuel tank cap.
(15) Connect negati ve battery cabl e to battery.
(16) Start engi ne and check for fuel l eaks.
FUEL INJECTOR RAIL/FUEL DAMPER— 4. 0L
ENGINE
REMOVAL
The fuel damper i s not servi ced separatel y.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure.
(3) Di sconnect negati ve battery cabl e from battery.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Di sconnect el ectri cal connectors at al l 6 fuel
i njectors. To remove connector refer to (Fi g. 30). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Group
8H, Speed Control System.
(9) Di sconnect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(10) Remove cabl e routi ng bracket at i ntake man-
i fol d.
(11) I f equi pped, remove wi ri ng harnesses at i njec-
ti on rai l studs by removi ng nuts.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
31).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
INSTALLATION
(1) Cl ean each i njector bore at i ntake mani fol d.
(2) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 Ϯ3 N·m (100 Ϯ25 i n. l bs.) torque.
(5) I f equi pped, connect wi ri ng harnesses to i njec-
ti on rai l studs.
Fig. 30 Remove/Install Fuel Injector Connector—
2.5L/4.0L Engine
14 - 18 FUEL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(6) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 30). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs..
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(13) I nstal l ai r tube (or duct) at top of throttl e
body.
(14) I nstal l fuel tank cap.
(15) Connect negati ve battery cabl e to battery.
(16) Start engi ne and check for fuel l eaks.
FUEL INJECTORS
REMOVAL
(1) Remove fuel rai l . Refer to Fuel I njector Rai l
Removal i n thi s secti on.
(2) Di sconnect cl i p(s) that retai n fuel i njector(s) to
fuel rai l (Fi g. 32).
INSTALLATION
(1) I nstal l fuel i njector(s) i nto fuel rai l assembl y
and i nstal l retai ni ng cl i p(s).
(2) I f same i njector(s) i s bei ng rei nstal l ed, i nstal l
new o-ri ng(s).
(3) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(4) I nstal l fuel rai l . Refer to Fuel Rai l I nstal l ati on.
(5) Start engi ne and check for fuel l eaks.
FUEL TANK
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. THIS PRESSURE MUST BE RELEASED
BEFORE SERVICING FUEL TANK.
Two di fferent procedures may be used to drai n fuel
tank (l oweri ng tank or usi ng DRB scan tool ).
The qui ckest drai ni ng procedure i nvol ves l oweri ng
the fuel tank.
As an al ternati ve procedure, the el ectri c fuel pump
may be acti vated al l owi ng tank to be drai ned at fuel
rai l connecti on. Refer to DRB scan tool for fuel pump
Fig. 31 Fuel Rail Mounting—4.0L Engine
1 – INJ. #1
2 – INJ. #2
3 – INJ. #3
4 – INJ. #4
5 – INJ. #5
6 – INJ. #6
7 – FUEL INJECTOR RAIL
8 – FUEL DAMPER
9 – PRESSURE TEST PORT CAP
10 – MOUNTING BOLTS (4)
11 – QUICK-CONNECT FITTING
Fig. 32 Fuel Injector Mounting
1 – INLET FITTING
2 – FUEL INJECTOR RAIL
3 – CLIP
4 – FUEL INJECTOR
TJ FUEL SYSTEM 14 - 19
REMOVAL AND INSTALLATION (Continued)
acti vati on procedures. Before di sconnecti ng fuel l i ne
at fuel rai l , rel ease fuel pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group for
procedures. Attach end of speci al test hose tool num-
ber 6541, 6539, 6631 or 6923 at fuel rai l di sconnec-
ti on (tool number wi l l depend on model and/or engi ne
appl i cati on). Posi ti on opposi te end of thi s hose tool to
an approved gasol i ne drai ni ng stati on. Acti vate fuel
pump and drai n tank unti l empty.
I f el ectri c fuel pump i s not operati ng, tank must be
l owered for fuel drai ni ng. Refer to fol l owi ng proce-
dures.
REMOVAL
On thi s model , the fuel tank i s mounted to vehi cl e
ski d pl ate. The ski d pl ate i s mounted to vehi cl e body.
(1) Remove fuel fi l l er cap.
(2) Perform the Fuel System Pressure Rel ease Pro-
cedure as descri bed el sewhere i n thi s group.
(3) Di sconnect negati ve battery cabl e.
(4) Remove 8 screws retai ni ng pl asti c fuel fi l l er
bezel to body (Fi g. 33). Remove fuel fi l l er bezel .
(5) To prevent contami nants from enteri ng tank,
temporari l y i nstal l fuel cap to fi l l hoses.
(6) Cut pl asti c ti e wrap securi ng rear axl e vent
hose to fuel fi l l er hoses.
(7) Di sconnect el ectri cal connector at front of fuel
tank (Fi g. 34).
(8) Di sconnect EVAP hose from EVAP l i ne at front
of fuel tank (Fi g. 34).
(9) Di sconnect qui ck-connect fi tti ng from fuel l i ne
at front of fuel tank (Fi g. 34). Refer to Qui ck-Connect
Fi tti ngs i n thi s group for procedures.
(10) The fuel tank and ski d pl ate are removed as
an assembl y. Central l y posi ti on a transmi ssi on jack
(or equi val ent l i fti ng devi ce) under ski d pl ate/fuel
tank assembl y. Secure tank assembl y to jack.
(11) Remove three ski d pl ate-to-body nuts at front
of tank (Fi g. 36). Remove one of the nuts through
access hol e on ski d pl ate (Fi g. 36).
(12) Remove four ski d pl ate-to-body nuts at rear of
tank (Fi g. 35). Do not loosen tank strap nuts
(Fig. 35).
(13) Lower the tank assembl y.
(14) I f fuel pump modul e i s to be removed, refer to
Fuel Pump Modul e Removal /I nstal l ati on.
(15) Di sconnect fuel fi l l er hoses at tank. Before
di sconnecti ng, mark and note the hose rotati onal
posi ti on i n rel ati on to tank fi tti ngs.
(16) Usi ng an approved portabl e gasol i ne si phon/
storage tank, drai n fuel from tank. To drai n fuel ,
posi ti on drai n hose i nto vent fi tti ng (smal l est of 2) on
si de of tank.
Fig. 33 Fuel Filler Hoses/Fuel Fill Cap
1 – FILLER HOSE CLAMPS (4)
2 – BEZEL
3 – BEZEL SCREWS (8)
4 – FUEL FILLER CAP
5 – FUEL FILLER HOSES
6 – FUEL TANK
14 - 20 FUEL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(17) To separate tank from ski d pl ate, remove two
protecti ve caps at tank strap studs (Fi g. 35) and
remove tank strap nuts.
(18) Remove both straps and remove tank from
ski d pl ate.
INSTALLATION
(1) Pl ace fuel tank i nto ski d pl ate. Wrap straps
around tank wi th strap studs i nserted through hol es
i n ski d pl ate. Ti ghten strap nuts to attai n 30 mm
(Ϯ2 mm) between bottom of nut to end of strap stud
(Fi g. 35). Do not over tighten nuts.
(2) I nstal l two protecti ve caps to tank strap studs.
(3) Connect fuel fi l l er hoses at tank. Ti ghten hose
cl amps.
(4) Rai se ski d pl ate/fuel tank assembl y i nto posi -
ti on on body whi l e gui di ng fi l l er hoses.
(5) I nstal l 7 ski d pl ate mounti ng nuts. Ti ghten to
16 N·m (141 i n. l bs.) torque.
(6) Remove tank jacki ng devi ce.
(7) Connect el ectri cal connector at front of fuel
tank.
(8) Connect EVAP hose to EVAP l i ne at front of
fuel tank.
(9) Connect qui ck-connect fi tti ng to fuel l i ne at
front of fuel tank. Refer to Qui ck-Connect Fi tti ngs i n
thi s group for procedures.
(10) Use a new pl asti c ti e wrap to secure rear axl e
vent hose to fuel fi l l er hoses.
(11) Posi ti on fuel fi l l er bezel to body. I nstal l 8
screws and ti ghten.
(12) Fi l l fuel tank. I nstal l fi l l er cap.
(13) Connect negati ve battery cabl e to battery.
(14) Start vehi cl e and i nspect for l eaks.
Fig. 34 Fuel Tank Connections
1 – L. R. SHOCK ABSORBER
2 – EVAP LINE (TO CANISTER)
3 – EVAP HOSE
4 – ELECTRICAL CONNECTOR
5 – QUICK-CONNECT FITTING
6 – FUEL LINE (TO ENGINE)
Fig. 35 Fuel Tank Mounting Nuts—Rear
1 – REAR SKID PLATE NUTS (4)
2 – SKID PLATE
3 – TANK STRAP STUD
4 – TANK STRAP NUT
5 – TANK STRAP NUTS (2)
6 – PROTECTIVE CAPS (2)
Fig. 36 Fuel Tank Mounting Nuts—Front
1 – FRONT SKID PLATE NUTS (3)
2 – SKID PLATE
3 – ACCESS HOLE
TJ FUEL SYSTEM 14 - 21
REMOVAL AND INSTALLATION (Continued)
FUEL TANK FILLER TUBE CAP
REMOVAL/INSTALLATION
I f repl acement of the 1/4 turn fuel tank fi l l er tube
cap i s necessary, i t must be repl aced wi th an i denti -
cal cap to be sure of correct system operati on.
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
ACCELERATOR PEDAL
REMOVAL
The accel erator pedal i s connected to the throttl e
body l i nkage by the throttl e cabl e. The cabl e i s pro-
tected by a pl asti c sheathi ng and i s connected to the
throttl e body l i nkage by a bal l socket. I t i s connected
to the upper part of the accel erator pedal arm by a
pl asti c retai ner (cl i p) (Fi g. 37). Thi s retai ner (cl i p)
snaps i nto the top of the accel erator pedal arm.
Retai ner tabs (bui l t i nto the cabl e sheathi ng) (Fi g.
37) fasten the cabl e to the dash panel .
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of accel erator pedal arm
(Fi g. 37). Pl asti c cabl e retai ner (cl i p) snaps i nto pedal
arm.
(2) Remove accel erator pedal mounti ng bracket
nuts.
(3) Remove accel erator pedal assembl y.
INSTALLATION
(1) Pl ace accel erator pedal assembl y over mount-
i ng studs protrudi ng from fl oor pan. Ti ghten mount-
i ng nuts to 8.5 N·m (75 i n. l bs.) torque.
(2) Sl i de throttl e cabl e i nto openi ng (sl ot) i n top of
pedal arm. An i ndex tab i s l ocated on pedal arm.
Rotate and push pl asti c cabl e retai ner (cl i p) i nto
accel erator pedal arm openi ng unti l i t snaps i nto
pl ace on i ndex tab.
(3) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
THROTTLE CABLE
REMOVAL
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of accel erator pedal arm
(Fi g. 37). Pl asti c cabl e retai ner (cl i p) snaps i nto pedal
arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, pi nch both si des of cabl e
housi ng retai ner tabs (Fi g. 37) at dash panel .
Remove cabl e housi ng from dash panel and pul l i nto
engi ne compartment.
(4) Remove cabl e from cl i p gui des on engi ne cyl i n-
der head (val ve) cover (Fi g. 38).
(5) Remove throttl e cabl e bal l socket at throttl e
body by pushi ng bal l socket towards rear of vehi cl e
(bal l snaps off of throttl e body pi n) (Fi g. 39).
(5)
(6) Remove throttl e cabl e from throttl e body
mounti ng bracket by compressi ng rel ease tabs (Fi g.
39) and pushi ng cabl e through hol e i n bracket.
(7) Remove throttl e cabl e from vehi cl e.
INSTALLATION
(1) Sl i de throttl e cabl e through hol e i n throttl e
body bracket unti l retai ner tabs l ock i nto bracket.
Connect cabl e bal l end to throttl e body l i nkage bal l
(snaps on).
(2) Snap cabl e i nto cl i p gui des on engi ne cyl i nder
head (val ve) cover.
Fig. 37 Accelerator Pedal Mounting
1 – CABLE RETAINER
2 – SLOT
3 – MOUNTING STUDS (2)
4 – PEDAL/BRACKET ASSEMBLY
5 – MOUNTING STUDS
6 – RETAINER TABS
7 – CABLE
8 – CABLE STOP
14 - 22 FUEL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(3) Push other end of cabl e through openi ng i n
dash panel unti l retai ni ng tabs l ock i nto panel .
(4) From i nsi de dri vers compartment, sl i de throttl e
cabl e core wi re i nto openi ng i n top of accel erator
pedal arm. An i ndex tab i s l ocated on pedal arm.
Rotate and push cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i n pl ace on i ndex tab.
(5) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
SPECIFICATIONS
FUEL TANK CAPACITY
FUEL SYSTEM PRESSURE
339 kPa Ϯ 34 kPa (49.2 psi Ϯ 2 psi ).
FUEL REQUIREMENTS
Your engi ne i s desi gned to meet al l emi ssi ons reg-
ul ati ons and provi de excel l ent fuel economy and per-
formance when usi ng hi gh qual i ty unl eaded gasol i ne
havi ng an octane rati ng of 87. The use of premi um
gasol i ne i s not recommended. The use of premi um
gasol i ne wi l l provi de no benefi t over hi gh qual i ty reg-
ul ar gasol i ne, and i n some ci rcumstances may resul t
i n poorer performance.
Li ght spark knock at l ow engi ne speeds i s not
harmful to your engi ne. However, conti nued heavy
spark knock at hi gh speeds can cause damage and
i mmedi ate servi ce i s requi red. Engi ne damage resul t-
i ng from operati on wi th a heavy spark knock may
not be covered by the new vehi cl e warranty.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng and hesi tati ons. I f you experi -
ence these symptoms, try another brand of gasol i ne
before consi deri ng servi ce for the vehi cl e.
Over 40 auto manufacturers worl d-wi de have
i ssued and endorsed consi stent gasol i ne speci fi cati ons
(the Worl dwi de Fuel Charter, WWFC) to defi ne fuel
properti es necessary to del i ver enhanced emi ssi ons,
performance and durabi l i ty for your vehi cl e. We rec-
ommend the use of gasol i nes that meet the WWFC
speci fi cati ons i f they are avai l abl e.
Fig. 38 Throttle Cable Routing
1 – THROTTLE CABLE
2 – GUIDE
Fig. 39 Throttle Cable at Throttle Body—Typical
1 – ACCELERATOR CABLE
2 – OFF
3 – OFF
4 – THROTTLE BODY BELLCRANK
5 – SPEED CONTROL CABLE
6 – RELEASE TABS
7 – BRACKET
Models Liters U. S. Gallons
All 72L 19
Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
TJ FUEL SYSTEM 14 - 23
REMOVAL AND INSTALLATION (Continued)
REFORMULATED GASOLINE
Many areas of the country requi re the use of
cl eaner burni ng gasol i ne referred to as “reformul at-
ed” gasol i ne. Reformul ated gasol i ne contai n oxygen-
ates, and are speci fi cal l y bl ended to reduce vehi cl e
emi ssi ons and i mprove ai r qual i ty.
We strongl y supports the use of reformul ated gas-
ol i ne. Properl y bl ended reformul ated gasol i ne wi l l
provi de excel l ent performance and durabi l i ty for the
engi ne and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppl i ers bl end unl eaded gasol i ne wi th
oxygenates such as 10% ethanol , MTBE, and ETBE.
Oxygenates are requi red i n some areas of the country
duri ng the wi nter months to reduce carbon monoxi de
emi ssi ons. Fuel s bl ended wi th these oxygenates may
be used i n your vehi cl e.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT i s a manganese-contai ni ng metal l i c addi ti ve
that i s bl ended i nto some gasol i ne to i ncrease octane.
Gasol i ne bl ended wi th MMT provi de no performance
advantage beyond gasol i ne of the same octane num-
ber wi thout MMT. Gasol i ne bl ended wi th MMT
reduce spark pl ug l i fe and reduce emi ssi on system
performance i n some vehi cl es. We recommend that
gasol i nes free of MMT be used i n your vehi cl e. The
MMT content of gasol i ne may not be i ndi cated on the
gasol i ne pump; therefore, you shoul d ask your gaso-
l i ne retai l er whether or not hi s/her gasol i ne contai ns
MMT.
I t i s even more i mportant to l ook for gasol i ne wi th-
out MMT i n Canada because MMT can be used at
l evel s hi gher than al l owed i n the Uni ted States.
MMT i s prohi bi ted i n Federal and Cal i forni a refor-
mul ated gasol i ne.
SULFUR IN GASOLINE
I f you l i ve i n the northeast Uni ted States, your
vehi cl e may have been desi gned to meet Cal i forni a
l ow emi ssi on standards wi th Cl eaner-Burni ng Cal i -
forni a reformul ated gasol i ne wi th l ow sul fur. I f such
fuel s are not avai l abl e i n states adopti ng Cal i forni a
emi ssi on standards, your vehi cl es wi l l operate sati s-
factori l y on fuel s meeti ng federal speci fi cati ons, but
emi ssi on control system performance may be
adversel y affected. Gasol i ne sol d outsi de of Cal i forni a
i s permi tted to have hi gher sul fur l evel s whi ch may
affect the performance of the vehi cl e’s catal yti c con-
verter. Thi s may cause the Mal functi on I ndi cator
Lamp (MI L), Check Engi ne or Servi ce Engi ne Soon
l i ght to i l l umi nate. We recommend that you try a di f-
ferent brand of unl eaded gasol i ne havi ng l ower sul fur
to determi ne i f the probl em i s fuel rel ated pri or to
returni ng your vehi cl e to an authori zed deal er for
servi ce.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
Al l gasol i ne sol d i n the Uni ted States and Canada
are requi red to contai n effecti ve detergent addi ti ves.
Use of addi ti onal detergents or other addi ti ves i s not
needed under normal condi ti ons.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle’s performance:
• The use of l eaded gas i s prohi bi ted by Federal
l aw. Usi ng l eaded gasol i ne can i mpai r engi ne perfor-
mance, damage the emi ssi on control system, and
coul d resul t i n l oss of warranty coverage.
• An out-of-tune engi ne, or certai n fuel or i gni ti on
mal functi ons, can cause the catal yti c converter to
overheat. I f you noti ce a pungent burni ng odor or
some l i ght smoke, your engi ne may be out of tune or
mal functi oni ng and may requi re i mmedi ate servi ce.
Contact your deal er for servi ce assi stance.
• When pul l i ng a heavy l oad or dri vi ng a ful l y
l oaded vehi cl e when the humi di ty i s l ow and the tem-
perature i s hi gh, use a premi um unl eaded fuel to
hel p prevent spark knock. I f spark knock persi sts,
l i ghten the l oad, or engi ne pi ston damage may resul t.
• The use of fuel addi ti ves whi ch are now bei ng
sol d as octane enhancers i s not recommended. Most
of these products contai n hi gh concentrati ons of
methanol . Fuel system damage or vehi cl e perfor-
mance probl ems resul ti ng from the use of such fuel s
or addi ti ves i s not the responsi bi l i ty of Dai ml er-
Chrysl er Corporati on and may not be covered under
the new vehi cl e warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
14 - 24 FUEL SYSTEM TJ
SPECIFICATIONS (Continued)
TORQUE CHART
DESCRIPTION TORQUE
Accel erator Pedal Bracket Mounti ng Nuts . 8.5 N·m
(75 i n. l bs.)
Fuel Hose Cl amps . . . . . . . . . . . 3 N·m (25 i n. l bs.)
Fuel Pump Modul e Locknut . . . 74 N·m (55 ft. l bs.)
Fuel Rai l Mounti ng Bol ts or Nuts . 11 N·m (100 i n.
l bs.)
Fuel Tank Ski dpl ate Bol ts . . . 16 N·m (141 i n. l bs.)
Fuel Tank Mounti ng Strap Bol ts . . Refer to manual
text
TJ FUEL SYSTEM 14 - 25
SPECIFICATIONS (Continued)
FUEL INJ ECTION SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWERTRAIN CONTROL MODULE (PCM) . . . . . 26
MODES OF OPERATION . . . . . . . . . . . . . . . . . . . 27
AUTOMATIC SHUTDOWN (ASD) RELAY
SENSE—PCM INPUT . . . . . . . . . . . . . . . . . . . . 30
BATTERY VOLTAGE—PCM INPUT. . . . . . . . . . . . 30
BRAKE SWITCH—PCM INPUT. . . . . . . . . . . . . . . 30
FIVE VOLT SENSOR SUPPLIES—PRIMARY
AND SECONDARY . . . . . . . . . . . . . . . . . . . . . . 30
FUEL LEVEL SENSOR—PCM INPUT . . . . . . . . . . 31
ENGINE COOLANT TEMPERATURE
SENSOR—PCM INPUT. . . . . . . . . . . . . . . . . . . 31
OXYGEN SENSOR—PCM INPUT. . . . . . . . . . . . . 31
IGNITION CIRCUIT SENSE—PCM INPUT . . . . . . 32
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR—PCM INPUT. . . . . . . . . . . . . . . . . . . 32
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR—PCM INPUT. . . . . . . . . . . . . . . . . . . 33
OIL PRESSURE SENSOR—PCM INPUT . . . . . . . 33
POWER GROUNDS . . . . . . . . . . . . . . . . . . . . . . . 34
POWER STEERING PRESSURE SWITCH—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SENSOR RETURN—PCM INPUT. . . . . . . . . . . . . 34
THROTTLE POSITION SENSOR (TPS)—PCM
INPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
VEHICLE SPEED AND DISTANCE SENSOR—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
AUTO SHUTDOWN (ASD) RELAY—PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS. . . . . . 35
DATA LINK CONNECTOR—PCM INPUT AND
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FUEL INJECTORS—PCM OUTPUT . . . . . . . . . . . 36
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . . . . . 36
IDLE AIR CONTROL (IAC) MOTOR—PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING
VISUAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . 37
ASD AND FUEL PUMP RELAYS. . . . . . . . . . . . . . 41
THROTTLE BODY MINIMUM AIR FLOW
CHECK PROCEDURE. . . . . . . . . . . . . . . . . . . . 42
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . . 43
FUEL PUMP RELAY. . . . . . . . . . . . . . . . . . . . . . . 44
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 44
THROTTLE POSITION SENSOR (TPS) . . . . . . . . 45
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . . 45
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
POWERTRAIN CONTROL MODULE (PCM) . . . . . 46
POWER STEERING PRESSURE SWITCH—
2.5L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OXYGEN SENSOR. . . . . . . . . . . . . . . . . . . . . . . . 47
AIR CLEANER ELEMENT. . . . . . . . . . . . . . . . . . . 49
ENGINE COOLANT TEMPERATURE SENSOR. . . 49
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . 50
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 51
SPECIAL TOOLS
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DESCRIPTION AND OPERATION
POWERTRAIN CONTROL MODULE (PCM)
DESCRIPTION
The PCM i s l ocated i n the engi ne compartment
(Fi g. 1). The PCM i s referred to as JTEC.
OPERATION
The PCM operates the fuel system. The PCM i s a
pre-programmed, tri pl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, speed con-
trol (i f equi pped), ai r condi ti oni ng compressor cl utch
engagement and i dl e speed. The PCM can adapt i ts
programmi ng to meet changi ng operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as PCM Outputs. The sensors
and swi tches that provi de i nputs to the PCM are con-
si dered PCM I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed, power
steeri ng pump pressure (2.5L onl y), and the brake
swi tch.
14 - 26 FUEL SYSTEM TJ
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: Powertrain Control Module (PCM) Inputs:
• A/C request (i f equi pped wi th factory A/C)
• A/C sel ect (i f equi pped wi th factory A/C)
• Auto shutdown (ASD) sense
• Battery temperature
• Battery vol tage
• Brake swi tch
• CCD bus (+) ci rcui ts
• CCD bus (-) ci rcui ts
• Camshaft posi ti on sensor si gnal
• Crankshaft posi ti on sensor
• Data l i nk connector for DRB scan tool
• Engi ne cool ant temperature sensor
• Fuel l evel
• Generator (battery vol tage) output
• I gni ti on ci rcui t sense (i gni ti on swi tch i n run
posi ti on)
• I ntake mani fol d ai r temperature sensor
• Leak detecti on pump (i f equi pped)
• Mani fol d Absol ute Pressure (MAP) sensor
• Oi l pressure sensor
• Oxygen sensors
• Park/neutral swi tch (auto. trans. onl y)
• Power ground
• Power steeri ng pressure swi tch (2.5L onl y)
• SCI recei ve (DRB scan tool 16–way connecti on)
• Sensor return
• Si gnal ground
• Speed control mul ti pl exed si ngl e wi re i nput
• Throttl e posi ti on sensor
• Vehi cl e speed sensor
NOTE: Powertrain Control Module (PCM) Outputs:
• A/C cl utch rel ay
• Auto Shutdown (ASD) rel ay
• CCD bus (+/-) ci rcui ts for: speedometer, vol tme-
ter, fuel gauge, oi l pressure gauge/l amp, engi ne temp.
gauge and speed control warn. l amp
• Duty cycl e EVAP cani ster purge sol enoi d
• Fi ve vol t sensor suppl y (pri mary)
• Fi ve vol t sensor suppl y (secondary)
• Fuel i njectors
• Fuel pump rel ay
• Generator fi el d dri ver (-)
• Generator fi el d source (+)
• I dl e Ai r Control (I AC) motor
• I gni ti on coi l
• Leak detecti on pump (i f equi pped)
• Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through CCD ci rcui ts.
• SCI transmi t (DRB scan tool 16–way connecti on)
• Speed control vacuum sol enoi d
• Speed control vent sol enoi d
• Tachometer (i f equi pped). Dri ven through CCD
ci rcui ts.
• Transmi ssi on convertor cl utch sol enoi d
MODES OF OPERATION
OPERATION
As i nput si gnal s to the Powertrai n Control Modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the PCM recei ves i nput
si gnal s and responds onl y accordi ng to preset PCM
programmi ng. I nput from the oxygen (O2S) sensors
i s not moni tored duri ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
Fig. 1 PCM Location
1 – PCM MOUNTING BOLTS (3)
2 – POWERTRAIN CONTROL MODULE (PCM)
3 – BATTERY
4 – (3) 32–WAY CONNECTOR
TJ FUEL SYSTEM 14 - 27
DESCRIPTION AND OPERATION (Continued)
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
• I gni ti on swi tch ON
• Engi ne start-up (crank)
• Engi ne warm-up
• I dl e
• Crui se
• Accel erati on
• Decel erati on
• Wi de open throttl e (WOT)
• I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
• The PCM pre-posi ti ons the I dl e Ai r Control
(I AC) motor.
• The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
• The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
• I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
• Throttl e posi ti on sensor (TPS) i s moni tored.
• The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
• The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
• The O2S sensor heater el ement i s energi zed vi a
the ASD rel ay. The O2S sensor i nput i s not used by
the PCM to cal i brate ai r-fuel rati o duri ng thi s mode
of operati on.
• The Up-shi ft I ndi cator Lamp i s i l l umi nated
(manual transmi ssi on onl y).
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The PCM recei ves i nputs from:
• Battery vol tage
• Engi ne cool ant temperature sensor
• Crankshaft posi ti on sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the PCM recei ves i nputs from:
• Battery vol tage
• Crankshaft posi ti on sensor
• Engi ne cool ant temperature sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
• Park/neutral swi tch (gear i ndi cator si gnal —auto.
trans. onl y)
• Ai r condi ti oni ng sel ect si gnal (i f equi pped)
• Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
• Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
• The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
• The PCM operates the A/C compressor cl utch
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l ow–pres-
sure A/C swi tches. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for addi ti onal i nformati on.
• When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
14 - 28 FUEL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the PCM)
recei ves i nputs from:
• Ai r condi ti oni ng sel ect si gnal (i f equi pped)
• Ai r condi ti oni ng request si gnal (i f equi pped)
• Battery vol tage
• Crankshaft posi ti on sensor
• Engi ne cool ant temperature sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
• Battery vol tage
• Park/neutral swi tch (gear i ndi cator si gnal —auto.
trans. onl y)
• Oxygen sensors
• Power steeri ng pressure swi tch (2.5L engi ne
onl y)
Based on these i nputs, the fol l owi ng occurs:
• Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
• The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
• The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
• The PCM operates the A/C compressor cl utch
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l ow–pres-
sure A/C swi tches. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for addi ti onal i nformati on.
On 2.5L 4–cyl i nder engi nes, a power steeri ng pres-
sure swi tch i s used to suppl y an i nput to the PCM
when steeri ng pump pressure i s hi gh. Thi s wi l l rai se
engi ne speed. Refer to Power Steeri ng Pressure
Swi tch i n thi s group for addi ti onal i nformati on. The
4.0L 6–cylinder engine does not use this switch.
CRUISE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At crui si ng speed, the PCM
recei ves i nputs from:
• Ai r condi ti oni ng sel ect si gnal (i f equi pped)
• Ai r condi ti oni ng request si gnal (i f equi pped)
• Battery vol tage
• Engi ne cool ant temperature sensor
• Crankshaft posi ti on sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
• Park/neutral swi tch (gear i ndi cator si gnal —auto.
trans. onl y)
• Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
• Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
• The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
• The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
• The PCM operates the A/C compressor cl utch
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
• The Up-shi ft I ndi cator Lamp i s operated (manu-
al transmi ssi on onl y).
ACCELERATION MODE
Thi s i s an Open Loop mode. The PCM recogni zes
an abrupt i ncrease i n throttl e posi ti on or MAP pres-
sure as a demand for i ncreased engi ne output and
vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased throttl e openi ng.
DECELERATION MODE
When the engi ne i s at operati ng temperature, thi s
i s an Open Loop mode. Duri ng hard decel erati on, the
PCM recei ves the fol l owi ng i nputs.
• Ai r condi ti oni ng sel ect si gnal (i f equi pped)
• Ai r condi ti oni ng request si gnal (i f equi pped)
• Battery vol tage
• Engi ne cool ant temperature sensor
• Crankshaft posi ti on sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
• Park/neutral swi tch (gear i ndi cator si gnal —auto.
trans. onl y)
• Vehi cl e speed sensor
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
TJ FUEL SYSTEM 14 - 29
DESCRIPTION AND OPERATION (Continued)
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the PCM recei ves the fol l owi ng
i nputs.
• Battery vol tage
• Crankshaft posi ti on sensor
• Engi ne cool ant temperature sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
• Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
• The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
• The Up-shi ft I ndi cator Lamp i s operated (manu-
al transmi ssi on onl y).
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
AUTOMATIC SHUTDOWN (ASD) RELAY
SENSE— PCM INPUT
DESCRIPTION
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated i n the engi ne com-
partment. Refer to l abel on PDC cover for rel ay l oca-
ti on.
OPERATION
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The rel ay i s used to
connect the oxygen sensor heater el ement, i gni ti on
coi l and fuel i njectors to 12 vol t + power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the powertrai n control modul e (PCM)
does not see 12 vol ts at thi s i nput when the ASD
shoul d be acti vated, i t wi l l set a di agnosti c troubl e
code (DTC).
BATTERY VOLTAGE— PCM INPUT
OPERATION
The battery vol tage i nput provi des power to the
Powertrai n Control Modul e (PCM). I t al so i nforms
the PCM what vol tage l evel i s suppl i ed to the i gni -
ti on coi l and fuel i njectors.
I f battery vol tage i s l ow, the PCM wi l l i ncrease
i njector pul se wi dth (peri od of ti me that the i njector
i s energi zed). Thi s i s done to compensate for the
reduced fl ow through i njector caused by the l owered
vol tage.
BRAKE SWITCH— PCM INPUT
OPERATION
When the brake l i ght swi tch i s acti vated, the Pow-
ertrai n Control Modul e (PCM) recei ves an i nput i ndi -
cati ng that the brakes are bei ng appl i ed. After
recei vi ng thi s i nput, the PCM mai ntai ns i dl e speed to
a schedul ed rpm through control of the I dl e Ai r Con-
trol (I AC) motor. The brake swi tch i nput i s al so used
to di sabl e vent and vacuum sol enoi d output si gnal s
to the speed control servo.
FIVE VOLT SENSOR SUPPLIES— PRIMARY
AND SECONDARY
DESCRIPTION
Two di fferent Powertrai n Control Modul e (PCM)
fi ve vol t suppl y ci rcui ts are used; pri mary and sec-
ondary.
OPERATION
These 2 ci rcui ts wi l l :
• suppl y the requi red 5 vol t power source to the
Crankshaft Posi ti on (CKP) sensor.
• suppl y the requi red 5 vol t power source to the
Camshaft Posi ti on (CMP) sensor.
• suppl y a reference vol tage for the Mani fol d Abso-
l ute Pressure (MAP) sensor.
• suppl y a reference vol tage for the Throttl e Posi -
ti on Sensor (TPS) sensor.
• suppl y the requi red 5 vol t power source to the
oi l pressure sensor.
• suppl y the requi red 5 vol t power source for the
Vehi cl e Speed Sensor (VSS) (i f equi pped).
• suppl y the 5 vol t power source to the transmi s-
si on pressure sensor (i f equi pped wi th an RE auto-
mati c transmi ssi on).
14 - 30 FUEL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
FUEL LEVEL SENSOR— PCM INPUT
DESCRIPTION
The fuel l evel sensor (fuel gauge sendi ng uni t) i s
l ocated on the fuel pump modul e.
OPERATION
Refer to Fuel Gauge Sendi ng Uni t i n the Fuel
Del i very secti on for i nformati on.
ENGINE COOLANT TEMPERATURE SENSOR—
PCM INPUT
DESCRIPTION
The Engi ne Cool ant Temperature (ECT) sensor i s
used to sense engi ne cool ant temperature. The sensor
protrudes i nto an engi ne water jacket.
The ECT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as engi ne cool ant
temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
At key-on, the Powertrai n Control Modul e (PCM)
sends out a regul ated 5 vol t si gnal to the ECT sensor.
The PCM then moni tors the si gnal as i t passes
through the ECT sensor to the sensor ground (sensor
return).
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
The PCM uses i nputs from the ECT sensor for the
fol l owi ng cal cul ati ons:
• for engi ne cool ant temperature gauge operati on
through CCD or PCI (J1850) communi cati ons
• I njector pul se-wi dth
• Spark-advance curves
• ASD rel ay shut-down ti mes
• I dl e Ai r Control (I AC) motor key-on steps
• Pul se-wi dth pri me-shot duri ng cranki ng
• O2 sensor cl osed l oop ti mes
• Purge sol enoi d on/off ti mes
• EGR sol enoi d on/off ti mes (i f equi pped)
• Leak Detecti on Pump operati on (i f equi pped)
• Radi ator fan rel ay on/off ti mes (i f equi pped)
• Target i dl e speed
OXYGEN SENSOR— PCM INPUT
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and
protrude i nto the vehi cl e exhaust system. Dependi ng
on the emi ssi on package, the vehi cl e may contai n
ei ther 2 or 4 sensors. On non-Cal i forni a emi ssi ons
packages, 2 sensors are used: upstream (referred to
as 1/1) and downstream (referred to as 1/2). On Cal -
i forni a emi ssi ons packages, 4 sensors are used: 2
upstream (referred to as 1/1 and 2/1) and 2 down-
stream (referred to as 1/2 and 2/2).
OPERATION
An O2 sensor i s a gal vani c battery that provi des
the PCM wi th a vol tage si gnal (0-1 vol t) i nversel y
proporti onal to the amount of oxygen i n the exhaust.
I n other words, i f the oxygen content i s l ow, the vol t-
age output i s hi gh; i f the oxygen content i s hi gh the
output vol tage i s l ow. The PCM uses thi s i nformati on
to adjust i njector pul se-wi dth to achi eve the
14.7–to–1 ai r/fuel rati o necessary for proper engi ne
operati on and to control emi ssi ons.
An O2 sensor must have a source of oxygen from
outsi de of the exhaust stream for compari son. Cur-
rent O2 sensors recei ve thei r fresh oxygen (outsi de
ai r) suppl y through the wi re harness. Thi s i s why i t
i s i mportant to never sol der an O2 sensor connector,
or pack the connector wi th grease.
Four wi res (ci rcui ts) are used on each O2 sensor: a
12–vol t feed ci rcui t for the sensor heati ng el ement; a
ground ci rcui t for the heater el ement; a l ow-noi se
sensor return ci rcui t to the PCM, and an i nput ci r-
cui t from the sensor back to the PCM to detect sen-
sor operati on.
Oxygen Sensor Heaters/Heater Relays: On a
certai n non-Cal i forni a emi ssi on package, the heaters
on both sensors are fed battery vol tage from the ASD
rel ay whi ch i s control l ed by the PCM. Refer to ASD
rel ay for more i nformati on. On another non-Cal i for-
ni a emi ssi on package, the heaters on both sensors
are fed battery vol tage from the two O2S heater
rel ays. The O2S rel ays are al so control l ed by the
PCM. On the Cal i forni a emi ssi on package, the heat-
ers on al l 4 sensors are fed battery vol tage from the
two O2S Heater Rel ays.
The O2 sensor uses a Posi ti ve Thermal Co-effi ci ent
(PTC) heater el ement. As temperature i ncreases,
resi stance i ncreases. At ambi ent temperatures
around 70°F, the resi stance of the heati ng el ement i s
approxi matel y 6 ohms. As the sensor’s temperature
i ncreases, resi stance i n the heater el ement i ncreases.
Thi s al l ows the heater to mai ntai n the opti mum
operati ng temperature of approxi matel y 930°-1100°F
(500°-600° C). Al though the sensors operate the
same, there are physi cal di fferences, due to the envi -
ronment that they operate i n, that keep them from
bei ng i nterchangeabl e.
Mai ntai ni ng correct sensor temperature at al l
ti mes al l ows the system to enter i nto cl osed l oop
operati on sooner. Al so, i t al l ows the system to remai n
i n cl osed l oop operati on duri ng peri ods of extended
i dl e.
TJ FUEL SYSTEM 14 - 31
DESCRIPTION AND OPERATION (Continued)
I n Cl osed Loop operati on, the PCM moni tors cer-
tai n O2 sensor i nput(s) al ong wi th other i nputs, and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2 sensor
i nput. The PCM adjusts i njector pul se wi dth based
on preprogrammed (fi xed) val ues and i nputs from
other sensors.
Upstream Sensor (Non-California Emissions):
The upstream O2S sensor (1/1 sensor) i s l ocated i n
the exhaust downpi pe before the catal yti c convertor.
I t provi des an i nput vol tage to the PCM. The i nput
tel l s the PCM the oxygen content of the exhaust gas.
The PCM uses thi s i nformati on to fi ne tune fuel
del i very to mai ntai n the correct oxygen content at
the downstream oxygen sensor. The PCM wi l l change
the ai r/fuel rati o unti l the upstream sensor i nputs a
vol tage that the PCM has determi ned wi l l make the
downstream sensor output (oxygen content) correct.
The upstream oxygen sensor al so provi des an i nput
to determi ne catal yst effi ci ency.
Downstream Sensor (Non-California Emis-
sions): The downstream heated oxygen sensor (1/2
sensor) i s l ocated near the outl et end of the catal yti c
convertor. The downstream sensor i s al so used to
determi ne the correct ai r fuel rati o. As the oxygen
content changes at the downstream the PCM cal cu-
l ates how much ai r fuel rati o change i s requi red. The
PCM then l ooks at the upstream oxygen sensor vol t-
age and changes fuel del i very unti l the upstream
sensor vol tage changes enough to correct the down-
stream sensor vol tage (oxygen content).
The downstream oxygen sensor al so provi des an
i nput to determi ne catal yst effi ci ency.
Upstream Sensors (California Emissions): Two
upstream sensors are used (1/1 and 2/1). The 1/1 sen-
sor i s the fi rst sensor to recei ve exhaust gases from
the #1 cyl i nder. Both of the upstream O2S sensors
are l ocated i n the exhaust mani fol d just before the
mi ni -catal yti c convertors. They provi de an i nput vol t-
age to the PCM. The i nput tel l s the PCM the oxygen
content of the exhaust gas. The PCM uses thi s i nfor-
mati on to fi ne tune fuel del i very to mai ntai n the cor-
rect oxygen content at the downstream oxygen
sensors. The PCM wi l l change the ai r/fuel rati o unti l
the upstream sensors i nput a vol tage that the PCM
has determi ned wi l l make the downstream sensors
output (oxygen content) correct.
The upstream oxygen sensors al so provi de an i nput
to determi ne mi ni -catal yst effi ci ency.
Downstream Sensors (California Emissions):
Two downstream sensors are used (1/2 and 2/2). The
downstream sensors are l ocated i n the exhaust down-
pi pes just after the mi ni -catal yti c convertors. The
downstream i s al so used to determi ne the correct ai r
fuel rati o. As the oxygen content changes at the
downstream the PCM cal cul ates how much ai r fuel
rati o change i s requi red. The PCM then l ooks at the
upstream oxygen sensor vol tage and changes fuel
del i very unti l the upstream sensor vol tage changes
enough to correct the downstream sensor vol tage
(oxygen content).
The downstream oxygen sensors al so provi de an
i nput to determi ne mi ni -catal yst effi ci ency.
IGNITION CIRCUIT SENSE— PCM INPUT
DESCRIPTION
Thi s ci rcui t ti es the i gni ti on swi tch to the Power-
trai n Control Modul e (PCM).
OPERATION
The i gni ti on ci rcui t sense i nput tel l s the PCM the
i gni ti on swi tch has energi zed the i gni ti on ci rcui t.
Battery vol tage i s al so suppl i ed to the PCM
through the i gni ti on swi tch when the i gni ti on i s i n
the RUN or START posi ti on. Thi s i s referred to as
the “i gni ti on sense” ci rcui t and i s used to “wake up”
the PCM. Vol tage on the i gni ti on i nput can be as l ow
as 6 vol ts and the PCM wi l l sti l l functi on. Vol tage i s
suppl i ed to thi s ci rcui t to power the PCM’s 8-vol t reg-
ul ator and to al l ow the PCM to perform fuel , i gni ti on
and emi ssi ons control functi ons. The battery vol tage
on thi s l i ne i s suppl i ed to the 8-vol t regul ator whi ch
then passes on a power-up suppl y to the 5-vol t regu-
l ator.
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR— PCM INPUT
DESCRIPTION
The 2–wi re I ntake Mani fol d Ai r Temperature (I AT)
sensor i s i nstal l ed i n the i ntake mani fol d wi th the
sensor el ement extendi ng i nto the ai r stream.
The I AT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as i ntake mani -
fol d temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
The I AT sensor provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM) i ndi cati ng the
densi ty of the ai r enteri ng the i ntake mani fol d based
upon i ntake mani fol d temperature. At key-on, a
5–vol t power ci rcui t i s suppl i ed to the sensor from
the PCM. The sensor i s grounded at the PCM
through a l ow-noi se, sensor-return ci rcui t.
The PCM uses thi s i nput to cal cul ate the fol l owi ng:
• I njector pul se-wi dth
• Adjustment of spark ti mi ng (to hel p prevent
spark knock wi th hi gh i ntake mani fol d ai r-charge
temperatures)
14 - 32 FUEL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
The resi stance val ues of the I AT sensor i s the same
as for the Engi ne Cool ant Temperature (ECT) sensor.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR— PCM INPUT
DESCRIPTION
The Mani fol d Absol ute Pressure (MAP) sensor i s
attached to the si de of the engi ne throttl e body wi th
2 screws. The sensor i s connected to the throttl e body
wi th a rubber L-shaped fi tti ng.
OPERATION
The MAP sensor i s used as an i nput to the Power-
trai n Control Modul e (PCM). I t contai ns a si l i con
based sensi ng uni t to provi de data on the mani fol d
vacuum that draws the ai r/fuel mi xture i nto the com-
busti on chamber. The PCM requi res thi s i nformati on
to determi ne i njector pul se wi dth and spark advance.
When mani fol d absol ute pressure (MAP) equal s
Barometri c pressure, the pul se wi dth wi l l be at max-
i mum.
A 5 vol t reference i s suppl i ed from the PCM and
returns a vol tage si gnal to the PCM that refl ects
mani fol d pressure. The zero pressure readi ng i s 0.5V
and ful l scal e i s 4.5V. For a pressure swi ng of 0–15
psi , the vol tage changes 4.0V. To operate the sensor,
i t i s suppl i ed a regul ated 4.8 to 5.1 vol ts. Ground i s
provi ded through the l ow-noi se, sensor return ci rcui t
at the PCM.
The MAP sensor i nput i s the number one contri b-
utor to fuel i njector pul se wi dth. The most i mportant
functi on of the MAP sensor i s to determi ne baromet-
ri c pressure. The PCM needs to know i f the vehi cl e i s
at sea l evel or at a hi gher al ti tude, because the ai r
densi ty changes wi th al ti tude. I t wi l l al so hel p to cor-
rect for varyi ng barometri c pressure. Barometri c
pressure and al ti tude have a di rect i nverse correl a-
ti on; as al ti tude goes up, barometri c goes down. At
key-on, the PCM powers up and l ooks at MAP vol t-
age, and based upon the vol tage i t sees, i t knows the
current barometri c pressure (rel ati ve to al ti tude).
Once the engi ne starts, the PCM l ooks at the vol tage
agai n, conti nuousl y every 12 mi l l i seconds, and com-
pares the current vol tage to what i t was at key-on.
The di fference between current vol tage and what i t
was at key-on, i s mani fol d vacuum.
Duri ng key-on (engi ne not runni ng) the sensor
reads (updates) barometri c pressure. A normal range
can be obtai ned by moni tori ng a known good sensor.
As the al ti tude i ncreases, the ai r becomes thi nner
(l ess oxygen). I f a vehi cl e i s started and dri ven to a
very di fferent al ti tude than where i t was at key-on,
the barometri c pressure needs to be updated. Any
ti me the PCM sees Wi de Open Throttl e (WOT), based
upon Throttl e Posi ti on Sensor (TPS) angl e and RPM,
i t wi l l update barometri c pressure i n the MAP mem-
ory cel l . Wi th peri odi c updates, the PCM can make
i ts cal cul ati ons more effecti vel y.
The PCM uses the MAP sensor i nput to ai d i n cal -
cul ati ng the fol l owi ng:
• Mani fol d pressure
• Barometri c pressure
• Engi ne l oad
• I njector pul se-wi dth
• Spark-advance programs
• Shi ft-poi nt strategi es (certai n automati c trans-
mi ssi ons onl y)
• I dl e speed
• Decel fuel shutoff
The MAP sensor si gnal i s provi ded from a si ngl e
pi ezoresi sti ve el ement l ocated i n the center of a di a-
phragm. The el ement and di aphragm are both made
of si l i cone. As mani fol d pressure changes, the di a-
phragm moves causi ng the el ement to defl ect, whi ch
stresses the si l i cone. When si l i cone i s exposed to
stress, i ts resi stance changes. As mani fol d vacuum
i ncreases, the MAP sensor i nput vol tage decreases
proporti onal l y. The sensor al so contai ns el ectroni cs
that condi ti on the si gnal and provi de temperature
compensati on.
The PCM recogni zes a decrease i n mani fol d pres-
sure by moni tori ng a decrease i n vol tage from the
readi ng stored i n the barometri c pressure memory
cel l . The MAP sensor i s a l i near sensor; meani ng as
pressure changes, vol tage changes proporti onatel y.
The range of vol tage output from the sensor i s usu-
al l y between 4.6 vol ts at sea l evel to as l ow as 0.3
vol ts at 26 i n. of Hg. Barometri c pressure i s the pres-
sure exerted by the atmosphere upon an object. At
sea l evel on a standard day, no storm, barometri c
pressure i s approxi matel y 29.92 i n Hg. For every 100
feet of al ti tude, barometri c pressure drops.10 i n. Hg.
I f a storm goes through i t can change barometri c
pressure from what shoul d be present for that al ti -
tude. You shoul d know what the average pressure
and correspondi ng barometri c pressure i s for your
area.
OIL PRESSURE SENSOR— PCM INPUT
DESCRIPTION
The 3–wi re, sol i d-state engi ne oi l pressure sensor
(sendi ng uni t) i s l ocated i n an engi ne oi l pressure
gal l ery.
OPERATION
The oi l pressure sensor uses three ci rcui ts. They
are:
• A 5–vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
TJ FUEL SYSTEM 14 - 33
DESCRIPTION AND OPERATION (Continued)
• A sensor ground through the PCM’s sensor
return
• A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
The oi l pressure sensor has a 3–wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5–vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
POWER GROUNDS
OPERATION
The Powertrai n Control Modul e (PCM) has 2 mai n
grounds. Both of these grounds are referred to as
power grounds. Al l of the hi gh-current, noi sy, el ectri -
cal devi ces are connected to these grounds as wel l as
al l of the sensor returns. The sensor return comes
i nto the sensor return ci rcui t, passes through noi se
suppressi on, and i s then connected to the power
ground.
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng PCM l oads:
• Generator fi el d wi ndi ng
• Fuel i njectors
• I gni ti on coi l (s)
• Certai n rel ays/sol enoi ds
• Certai n sensors
POWER STEERING PRESSURE SWITCH— PCM
INPUT
DESCRIPTION
A pressure sensi ng swi tch (Fi g. 2) i s i ncl uded i n
the power steeri ng system (mounted on the hi gh-
pressure l i ne). Thi s swi tch wi l l be used onl y on vehi -
cl es equi pped wi th a 2.5L engi ne and power steeri ng.
OPERATION
The power steeri ng pressure swi tch provi des an
i nput to the Powertrai n Control Modul e (PCM). Thi s
i nput i s provi ded duri ng peri ods of hi gh pump l oad
and l ow engi ne rpm; such as duri ng parki ng maneu-
vers. The PCM wi l l then i ncrease the i dl e speed
through the I dl e Ai r Control (I AC) motor. Thi s i s
done to prevent the engi ne from stal l i ng under the
i ncreased l oad.
When steeri ng pump pressure exceeds 3275 kPa Ϯ
690 kPa (475 psi Ϯ 100 psi ), the normal l y cl osed
swi tch wi l l open and the PCM wi l l i ncrease the
engi ne i dl e speed. Thi s wi l l prevent the engi ne from
stal l i ng.
When pump pressure drops to approxi matel y 1379
kPa (200 psi ), the swi tch ci rcui t wi l l re-cl ose and
engi ne i dl e speed wi l l return to i ts previ ous setti ng.
SENSOR RETURN— PCM INPUT
OPERATION
The Sensor Return ci rcui ts are i nternal to the Pow-
ertrai n Control Modul e (PCM).
Sensor Return provi des a l ow–noi se ground refer-
ence for al l engi ne control system sensors. Refer to
Power Grounds for more i nformati on.
THROTTLE POSITION SENSOR (TPS)— PCM
INPUT
DESCRIPTION
The 3–wi re Throttl e Posi ti on Sensor (TPS) i s
mounted on the throttl e body and i s connected to the
throttl e bl ade.
OPERATION
The TPS i s a 3–wi re vari abl e resi stor that provi des
the Powertrai n Control Modul e (PCM) wi th an i nput
si gnal (vol tage) that represents the throttl e bl ade
posi ti on of the throttl e body. The sensor i s connected
Fig. 2 Power Steering Pump Pressure Switch—2.5L
Engine
1 – POWER STEERING PRESSURE SWITCH
2 – ELECTRICAL CONNECTOR
3 – POWER STEERING PUMP
14 - 34 FUEL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
to the throttl e bl ade shaft. As the posi ti on of the
throttl e bl ade changes, the resi stance (output vol t-
age) of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from.26
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.49 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
The PCM needs to i denti fy the acti ons and posi ti on
of the throttl e bl ade at al l ti mes. Thi s i nformati on i s
needed to assi st i n performi ng the fol l owi ng cal cul a-
ti ons:
• I gni ti on ti mi ng advance
• Fuel i njecti on pul se-wi dth
• I dl e (l earned val ue or mi ni mum TPS)
• Off-i dl e (0.06 vol t)
• Wi de Open Throttl e (WOT) open l oop (2.608
vol ts above l earned i dl e vol tage)
• Decel erati on fuel l ean out
• Fuel cutoff duri ng cranki ng at WOT (2.608 vol ts
above l earned i dl e vol tage)
• A/C WOT cutoff (certai n automati c transmi s-
si ons onl y)
VEHICLE SPEED AND DISTANCE SENSOR—
PCM INPUT
DESCRIPTION
The 3–wi re Vehi cl e Speed Sensor (VSS) i s l ocated
on the speedometer pi ni on gear adapter. I f equi pped
wi th 4WD, thi s adapter i s l ocated on the extensi on
housi ng of the transfer case (dri vers si de). I f
equi pped wi th 2WD, thi s adapter i s l ocated on the
l eft si de of the transmi ssi on extensi on housi ng.
OPERATION
The VSS i s a 3–ci rcui t (3–wi re), magneti c, hal l -ef-
fect sensor.
The 3 ci rcui ts are:
• A 5–vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM).
• A ground i s provi ded for the sensor though a
l ow-noi se sensor return ci rcui t i n the PCM.
• An i nput to the PCM i s used to determi ne vehi -
cl e speed and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
Under decel erati on condi ti ons, the PCM adjusts
the I dl e Ai r Control (I AC) motor to mai ntai n a
desi red MAP val ue. Under i dl e condi ti ons, the PCM
adjusts the I AC motor to mai ntai n a desi red engi ne
speed.
AUTO SHUTDOWN (ASD) RELAY— PCM
OUTPUT
DESCRIPTION
The 5–pi n, 12–vol t, Automati c Shutdown (ASD)
rel ay i s l ocated i n the Power Di stri buti on Center
(PDC). Refer to l abel on PDC cover for rel ay l ocati on.
OPERATION
The ASD rel ay suppl i es battery vol tage (12+ vol ts)
to the fuel i njectors and i gni ti on coi l (s). Wi th certai n
emi ssi ons packages i t al so suppl i es 12–vol ts to the
oxygen sensor heati ng el ements.
The ground ci rcui t for the coi l wi thi n the ASD
rel ay i s control l ed by the Powertrai n Control Modul e
(PCM). The PCM operates the ASD rel ay by swi tch-
i ng i ts ground ci rcui t on and off.
The ASD rel ay wi l l be shut–down, meani ng the
12–vol t power suppl y to the ASD rel ay wi l l be de-ac-
ti vated by the PCM i f:
• the i gni ti on key i s l eft i n the ON posi ti on. Thi s
i s i f the engi ne has not been runni ng for approxi -
matel y 1.8 seconds.
• there i s a crankshaft posi ti on sensor si gnal to
the PCM that i s l ower than pre-determi ned val ues.
The PCM wi l l sense i f or when the ASD rel ay has
been acti vated through a “sense ci rcui t”. Refer to
Automati c Shut-Down (ASD) Rel ay Sense-PCM I nput
for addi ti onal i nformati on.
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS
OPERATION
The Powertrai n Control Modul e (PCM) sends cer-
tai n output si gnal s through the CCD bus ci rcui ts.
These si gnal s are used to control certai n i nstrument
panel l ocated i tems and to determi ne certai n i denti -
fi cati on numbers.
Refer to Group 8E, I nstrument Panel and Gauges
for addi ti onal i nformati on.
DATA LINK CONNECTOR— PCM INPUT AND
OUTPUT
DESCRIPTION
The data l i nk connector i s l ocated at the l ower
edge of the i nstrument panel near the steeri ng col -
umn.
TJ FUEL SYSTEM 14 - 35
DESCRIPTION AND OPERATION (Continued)
OPERATION
The 16–way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the Powertrai n Control Modul e (PCM).
FUEL INJECTORS— PCM OUTPUT
DESCRIPTION
The fuel i njectors are connected to the engi ne wi th
the fuel i njector rai l .
OPERATION
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the Powertrai n Control Modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage (12 vol ts +) i s suppl i ed to the i njec-
tors through the ASD rel ay. The ASD rel ay wi l l shut-
down the 12 vol t power source to the fuel i njectors i f
the PCM senses the i gni ti on i s on, but the engi ne i s
not runni ng. Thi s occurs after the engi ne has not
been runni ng for approxi matel y 1.8 seconds.
The PCM determi nes i njector on-ti me (pul se wi dth)
based on vari ous i nputs.
FUEL PUMP RELAY-PCM OUTPUT
DESCRIPTION
The 5–pi n, 12–vol t, fuel pump rel ay i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
l abel on the PDC cover for rel ay l ocati on.
OPERATION
The Powertrai n Control Modul e (PCM) energi zes
the el ectri c fuel pump through the fuel pump rel ay.
The fuel pump rel ay i s energi zed by fi rst appl yi ng
battery vol tage to i t when the i gni ti on key i s turned
ON, and then appl yi ng a ground si gnal to the rel ay
from the PCM.
Whenever the i gni ti on key i s turned ON, the el ec-
tri c fuel pump wi l l operate. But, the PCM wi l l shut-
down the ground ci rcui t to the fuel pump rel ay i n
approxi matel y 1–3 seconds unl ess the engi ne i s oper-
ati ng or the starter motor i s engaged.
IDLE AIR CONTROL (IAC) MOTOR— PCM
OUTPUT
DESCRIPTION
The I AC stepper motor i s mounted to the throttl e
body, and regul ates the amount of ai r bypassi ng the
control of the throttl e pl ate. As engi ne l oads and
ambi ent temperatures change, engi ne rpm changes. A
pi ntl e on the I AC stepper motor protrudes i nto a pas-
sage i n the throttl e body, control l i ng ai r fl ow through
the passage. The I AC i s control l ed by the Powertrai n
Control Modul e (PCM) to mai ntai n the target engi ne
i dl e speed.
OPERATION
At i dl e, engi ne speed can be i ncreased by retract-
i ng the I AC motor pi ntl e and al l owi ng more ai r to
pass through the port, or i t can be decreased by
restri cti ng the passage wi th the pi ntl e and di mi ni sh-
i ng the amount of ai r bypassi ng the throttl e pl ate.
The I AC i s cal l ed a stepper motor because i t i s
moved (rotated) i n steps, or i ncrements. Openi ng the
I AC opens an ai r passage around the throttl e bl ade
whi ch i ncreases RPM.
The PCM uses the I AC motor to control i dl e speed
(al ong wi th ti mi ng) and to reach a desi red MAP dur-
i ng decel (keep engi ne from stal l i ng).
The I AC motor has 4 wi res wi th 4 ci rcui ts. Two of
the wi res are for 12 vol ts and ground to suppl y el ec-
tri cal current to the motor wi ndi ngs to operate the
stepper motor i n one di recti on. The other 2 wi res are
al so for 12 vol ts and ground to suppl y el ectri cal cur-
rent to operate the stepper motor i n the opposi te
di recti on.
To make the I AC go i n the opposi te di recti on, the
PCM just reverses pol ari ty on both wi ndi ngs. I f onl y
1 wi re i s open, the I AC can onl y be moved 1 step
(i ncrement) i n ei ther di recti on. To keep the I AC
motor i n posi ti on when no movement i s needed, the
PCM wi l l energi ze both wi ndi ngs at the same ti me.
Thi s l ocks the I AC motor i n pl ace.
I n the I AC motor system, the PCM wi l l count
every step that the motor i s moved. Thi s al l ows the
PCM to determi ne the motor pi ntl e posi ti on. I f the
memory i s cl eared, the PCM no l onger knows the
posi ti on of the pi ntl e. So at the fi rst key ON, the
PCM dri ves the I AC motor cl osed, regardl ess of
where i t was before. Thi s zeros the counter. From
thi s poi nt the PCM wi l l back out the I AC motor and
keep track of i ts posi ti on agai n.
When engi ne rpm i s above i dl e speed, the I AC i s
used for the fol l owi ng:
• Off-i dl e dashpot (throttl e bl ade wi l l cl ose qui ckl y
but i dl e speed wi l l not stop qui ckl y)
• Decel erati on ai r fl ow control
14 - 36 FUEL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
• A/C compressor l oad control (al so opens the pas-
sage sl i ghtl y before the compressor i s engaged so
that the engi ne rpm does not di p down when the
compressor engages)
• Power steeri ng l oad control
The PCM can control pol ari ty of the ci rcui t to con-
trol di recti on of the stepper motor.
IAC Stepper Motor Program: The PCM i s al so
equi pped wi th a memory program that records the
number of steps the I AC stepper motor most recentl y
advanced to duri ng a certai n set of parameters. For
exampl e: The PCM was attempti ng to mai ntai n a
1000 rpm target duri ng a col d start-up cycl e. The l ast
recorded number of steps for that may have been
125. That val ue woul d be recorded i n the memory
cel l so that the next ti me the PCM recogni zes the
i denti cal condi ti ons, the PCM recal l s that 125 steps
were requi red to mai ntai n the target. Thi s program
al l ows for greater customer sati sfacti on due to
greater control of engi ne i dl e.
Another functi on of the memory program, whi ch
occurs when the power steeri ng swi tch (i f equi pped),
or the A/C request ci rcui t, requi res that the I AC step-
per motor control engi ne rpm, i s the recordi ng of the
l ast targeted steps i nto the memory cel l . The PCM
can anti ci pate A/C compressor l oads. Thi s i s accom-
pl i shed by del ayi ng compressor operati on for approx-
i matel y 0.5 seconds unti l the PCM moves the I AC
stepper motor to the recorded steps that were l oaded
i nto the memory cel l . Usi ng thi s program hel ps el i m-
i nate i dl e-qual i ty changes as l oads change. Fi nal l y,
the PCM i ncorporates a “No-LoadЉ engi ne speed l i m-
i ter of approxi matel y 1800 - 2000 rpm, when i t rec-
ogni zes that the TPS i s i ndi cati ng an i dl e si gnal and
I AC motor cannot mai ntai n engi ne i dl e.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the I AC motor through the PCM.
THROTTLE BODY
DESCRIPTION
The throttl e body i s l ocated on the i ntake mani fol d.
Fuel does not enter the i ntake mani fol d through the
throttl e body. Fuel i s sprayed i nto the mani fol d by
the fuel i njectors.
OPERATION
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body. The throttl e body
contai ns an ai r control passage control l ed by an I dl e
Ai r Control (I AC) motor. The ai r control passage i s
used to suppl y ai r for i dl e condi ti ons. A throttl e val ve
(pl ate) i s used to suppl y ai r for above i dl e condi ti ons.
Certai n sensors are attached to the throttl e body.
The accel erator pedal cabl e, speed control cabl e and
transmi ssi on control cabl e (when equi pped) are con-
nected to the throttl e body l i nkage arm.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the PCM.
DIAGNOSIS AND TESTING
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
hel p spot these faul ts and save unnecessary test and
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy that the three 32–way el ectri cal connec-
tors are ful l y i nserted i nto connector of Powertrai n
Control Modul e (PCM) (Fi g. 3).
(2) I nspect battery cabl e connecti ons. Be sure that
they are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ASD rel ay connec-
ti ons. I nspect starter motor rel ay connecti ons.
Fig. 3 Powertrain Control Module (PCM)
1 – PCM MOUNTING BOLTS (3)
2 – POWERTRAIN CONTROL MODULE (PCM)
3 – BATTERY
4 – (3) 32–WAY CONNECTOR
TJ FUEL SYSTEM 14 - 37
DESCRIPTION AND OPERATION (Continued)
I nspect rel ays for si gns of physi cal damage and cor-
rosi on. The rel ays are l ocated i n Power Di stri buti on
Center (PDC) (Fi g. 4). Refer to l abel on PDC cover
for rel ay l ocati on.
(4) 2.5L Engi ne: I nspect i gni ti on coi l pri mary con-
necti on. Veri fy coi l secondary cabl e i s fi rml y con-
nected to coi l (Fi g. 5).
(5) 4.0L Engi ne: I nspect i gni ti on coi l connecti on
(Fi g. 6).
(6) 2.5L Engi ne: Veri fy that di stri butor cap i s cor-
rectl y attached to di stri butor. Be sure that spark
pl ug cabl es are fi rml y connected to the di stri butor
cap and spark pl ugs are i n thei r correct fi ri ng order.
Be sure that coi l cabl e i s fi rml y connected to di stri b-
utor cap and coi l .
(7) Connect vehi cl e to an osci l l oscope and i nspect
spark events for foul ed or damaged spark pl ugs or
cabl es.
(8) Veri fy that generator output wi re, generator
connector and ground wi re are fi rml y connected to
the generator.
(9) I nspect system body grounds for l oose or di rty
connecti ons. Refer to Group 8, Wi ri ng for ground
l ocati ons.
(10) Veri fy Crankcase Venti l ati on (CCV) operati on.
Refer to Group 25, Emi ssi on Control System for addi -
ti onal i nformati on.
(11) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(12) Veri fy that hose connecti ons to al l ports of
vacuum fi tti ngs on i ntake mani fol d are ti ght and not
l eaki ng.
Fig. 4 Power Distribution Center (PDC)
1 – BATTERY
2 – POWER DISTRIBUTION CENTER (PDC)
Fig. 5 Ignition Coil—2.5L Engine
1 – IGNITION COIL
2 – ELECTRICAL CONNECTOR
3 – MOUNTING BOLTS
4 – SECONDARY CABLE
Fig. 6 Ignition Coil—4.0L Engine
1 – REAR OF VALVE COVER
2 – COIL RAIL
3 – SLIDE TAB
4 – RELEASE LOCK
5 – COIL CONNECTOR
14 - 38 FUEL SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
(13) I nspect accel erator cabl e and transmi ssi on
throttl e cabl e (i f equi pped). Check thei r connecti ons
to throttl e arm of throttl e body for any bi ndi ng or
restri cti ons.
(14) I f equi pped wi th vacuum brake booster, veri fy
that vacuum booster hose i s fi rml y connected to fi t-
ti ng on i ntake mani fol d. Al so check connecti on to
brake vacuum booster.
(15) I nspect ai r cl eaner i nl et and ai r cl eaner el e-
ment for di rt or restri cti ons.
(16) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(17) Veri fy i ntake mani fol d ai r temperature sensor
wi re connector i s fi rml y connected to harness connec-
tor (Fi g. 7) or (Fi g. 8).
(18) Veri fy MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 8). Al so veri fy
rubber L-shaped fi tti ng from MAP sensor to throttl e
body i s fi rml y connected (Fi g. 9).
(19) Veri fy that fuel i njector wi re harness connec-
tors are fi rml y connected to i njectors i n the correct
order. Each harness connector i s numeri cal l y tagged
wi th i njector number (I NJ 1, I NJ 2 etc.) of i ts corre-
spondi ng fuel i njector and cyl i nder number.
(20) Veri fy harness connectors are fi rml y con-
nected to I dl e Ai r Control (I AC) motor and Throttl e
Posi ti on Sensor (TPS) (Fi g. 8).
(21) Veri fy wi re harness connector i s fi rml y con-
nected to engi ne cool ant temperature sensor (Fi g.
10).
(22) Rai se and support vehi cl e.
(23) Veri fy that al l oxygen sensor wi re connectors
are fi rml y connected to sensors. I nspect sensors and
connectors for damage (Fi g. 11), (Fi g. 12), (Fi g. 13) or
(Fi g. 14).
(24) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(25) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(26) I f equi pped wi th automati c transmi ssi on, ver-
i fy that el ectri cal harness i s fi rml y connected to park/
neutral swi tch. Refer to Automati c Transmi ssi on
secti on of Group 21.
(27) Veri fy that el ectri cal harness connector i s
fi rml y connected to the vehi cl e speed sensor (Fi g. 15).
(28) Veri fy that fuel pump/gauge sender uni t wi re
connector i s fi rml y connected to harness connector.
(29) I nspect fuel hoses at fuel pump/gauge sender
uni t for cracks or l eaks.
Fig. 7 Intake Manifold Air Temp. Sensor Location—
2.5L Engine
1 – ELECTRICAL CONNECTOR
2 – INTAKE MANIFOLD TEMPERATURE SENSOR
3 – FUEL INJECTOR
Fig. 8 Sensor Locations—4.0L Engine
1 – MOUNTING BOLTS (4)
2 – THROTTLE BODY
3 – IAC MOTOR
4 – ELEC. CONN.
5 – TPS
6 – MAP SENSOR
7 – ELEC. CONN.
8 – IAT SENSOR
9 – ELEC. CONN.
TJ FUEL SYSTEM 14 - 39
DIAGNOSIS AND TESTING (Continued)
Fig. 9 Rubber L-Shaped Fitting—MAP Sensor-to-
Throttle Body
1 – THROTTLE BODY
2 – MAP SENSOR
3 – RUBBER FITTING
4 – MOUNTING SCREWS (2)
Fig. 10 Engine Coolant Temperature Sensor—
Typical
1 – THERMOSTAT HOUSING
2 – ENGINE COOLANT TEMPERATURE SENSOR
3 – ELECTRICAL CONNECTOR
Fig. 11 Oxygen Sensors—4.0L—Federal Emissions
1 – 1/2 O2S
2 – 1/1 02S
Fig. 12 Oxygen Sensors—4.0L—California
Emissions
1 – 1/2 O2S
2 – 1/1 O2S
3 – 2/1 O2S
4 – 2/2 O2S
14 - 40 FUEL SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
(30) I nspect transmi ssi on torque convertor housi ng
(automati c transmi ssi on) or cl utch housi ng (manual
transmi ssi on) for damage to ti mi ng ri ng on dri ve
pl ate/fl ywheel .
(31) Veri fy that battery cabl e and sol enoi d feed
wi re connecti ons to starter sol enoi d are ti ght and
cl ean. I nspect for chaffed wi res or wi res rubbi ng up
agai nst other components.
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered. Two di fferent
types of rel ays may be used, (Fi g. 16) or (Fi g. 17).
OPERATION
• Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
• The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
• Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
• When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
• When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Fig. 13 Front Oxygen Sensor—2.5L—Federal
Emissions
1 – 1/1 O2S
Fig. 14 Rear Oxygen Sensor—2.5L—Federal
Emissions
1 – 1/2 O2S
Fig. 15 Vehicle Speed Sensor—Typical—4WD
Shown
1 – SENSOR ELECTRICAL CONNECTOR
2 – SLIDE TAB
3 – 4WD TRANSFER CASE EXTENSION
4 – VEHICLE SPEED SENSOR
5 – RELEASE LOCK
TJ FUEL SYSTEM 14 - 41
DIAGNOSIS AND TESTING (Continued)
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
Ϯ5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to the Wi ri ng
Di agrams.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
The fol l owi ng test procedure has been devel oped to
check throttl e body cal i brati ons for correct i dl e condi -
ti ons. The procedure shoul d be used to di agnose the
throttl e body for condi ti ons that may cause i dl e prob-
l ems. This procedure should be used only after
normal diagnostic procedures have failed to
produce results that indicate a throttle body
related problem. Be sure to check for proper
operation of the idle air control motor before
performing this test.
A speci al fi xed ori fi ce tool (number 6714) (Fi g. 18)
must be used for the fol l owi ng test. Thi s tool has a
fi xed i nternal di ameter of 0.185”.
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 16 ASD and Fuel Pump Relay Terminals—
Type 1
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 17 ASD and Fuel Pump Relay Terminals—
Type 2
Fig. 18 6714 Fixed Orifice Tool
14 - 42 FUEL SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
(1) Start the engi ne and bri ng to operati ng tem-
perature. Be sure al l accessori es are off before per-
formi ng thi s test.
(2) Shut off engi ne and remove ai r duct at throttl e
body.
(3) 2.5L 4–Cylinder Engine: Near front/top of
val ve cover, di sconnect CCV tube at fi xed ori fi ce fi t-
ti ng (Fi g. 19). I nsert Speci al Tool 6714 i nto end of
di sconnected CCV tube (i nsert ei ther end of tool i nto
tube). Let tool and tube hang di sconnected at si de of
engi ne.
(4) 4.0L 6–Cylinder Engine: Di sconnect CCV
tube (Fi g. 20) at i ntake mani fol d fi tti ng. Attach a
short pi ece of rubber hose to speci al tool 6714 (i nsert
rubber hose to ei ther end of tool ). I nstal l rubber hose/
tool to i ntake mani fol d fi tti ng. Let CCV tube hang
di sconnected at si de of engi ne.
(5) Connect DRB scan tool to 16–way data l i nk
connector. Thi s connector i s l ocated at l ower edge of
i nstrument panel near steeri ng col umn. Refer to
appropri ate Powertrai n Di agnosti c Procedures ser-
vi ce manual for DRB operati on.
(6) Start engi ne and al l ow to warm up.
(7) Usi ng the DRB scan tool , scrol l through menus
as fol l ows: sel ect—Stand Al one DRB I I I , sel ect the
year 2000 Di agnosti cs, sel ect—Engi ne, sel ect—Sys-
tem Test, sel ect—Mi ni mum Ai r Fl ow.
(8) The DRB scan tool wi l l count down to stabi l i ze
i dl e rpm and di spl ay mi ni mum ai r fl ow i dl e rpm. The
i dl e rpm shoul d be between 500 and 900 rpm. I f i dl e
speed i s outsi de these speci fi cati ons, repl ace throttl e
body. Refer to Throttl e Body Removal /I nstal l ati on.
(9) Di sconnect DRB scan tool from vehi cl e.
(10) Remove ori fi ce tool and connect CCV tube to
engi ne.
(11) I nstal l ai r duct to throttl e body.
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN (ASD) RELAY
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 21). Refer to l abel on PDC cover
for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
Fig. 19 Install Orifice Tool 2.5L 4–Cylinder Engine
1 – AIR TUBE
2 – CCV TUBE
3 – AIR INLET FITTING
4 – CCV TUBE
5 – FIXED ORIFICE FITTING
Fig. 20 Install Orifice Tool 4.0L 6–Cylinder Engine
1 – AIR TUBE
2 – FIXED ORIFICE FITTING
3 – CCV TUBE
4 – AIR INLET FITTING
5 – CCV TUBE
TJ FUEL SYSTEM 14 - 43
DIAGNOSIS AND TESTING (Continued)
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
FUEL PUMP RELAY
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 21). Refer to l abel on PDC
cover for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
THROTTLE BODY
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the Powertrai n Control Modul e (PCM).
REMOVAL
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 22) or (Fi g.
23).
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(4) Remove four throttl e body mounti ng bol ts.
(5) Remove throttl e body from i ntake mani fol d.
(6) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
INSTALLATION
(1) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 11
N·m (100 i n. l bs.) torque.
(5) I nstal l control cabl es.
(6) I nstal l el ectri cal connectors.
(7) I nstal l ai r cl eaner at throttl e body.
Fig. 21 Power Distribution Center (PDC)
1 – BATTERY
2 – POWER DISTRIBUTION CENTER (PDC)
Fig. 22 Throttle Body and Sensor Locations—4.0L
Engine
1 – MOUNTING BOLTS (4)
2 – THROTTLE BODY
3 – IAC MOTOR
4 – ELEC. CONN.
5 – TPS
6 – MAP SENSOR
7 – ELEC. CONN.
8 – IAT SENSOR
9 – ELEC. CONN.
14 - 44 FUEL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
THROTTLE POSITION SENSOR (TPS)
The TPS i s mounted to the throttl e body (Fi g. 22)
or (Fi g. 23).
REMOVAL
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect TPS el ectri cal connector.
(3) Remove TPS mounti ng screws (Fi g. 24).
(4) Remove TPS.
INSTALLATION
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 25). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs).
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 N·m (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
(5) I nstal l ai r cl eaner tube to throttl e body.
IDLE AIR CONTROL (IAC) MOTOR
The I AC motor i s l ocated on the si de of the throttl e
body (Fi g. 22) or (Fi g. 23).
REMOVAL
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 26).
(4) Remove I AC motor from throttl e body.
INSTALLATION
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 N·m (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r cl eaner tube to throttl e body.
Fig. 23 Throttle Body and Sensor Locations—2.5L
Engine
1 – IDLE AIR CONTROL MOTOR
2 – IAT SENSOR
3 – THROTTLE BODY
4 – THROTTLE POSITION SENSOR
5 – MAP SENSOR
6 – IDLE AIR CONTROL PASSAGE INLET
7 – THROTTLE BODY MOUNTING BOLTS (4)
Fig. 24 TPS Mounting Screws
1 – MOUNTING SCREWS
2 – TPS
Fig. 25 Throttle Position Sensor—Installation
1 – TANGS
2 – THROTTLE SHAFT
3 – THROTTLE BODY
4 – TPS
TJ FUEL SYSTEM 14 - 45
REMOVAL AND INSTALLATION (Continued)
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR
The MAP sensor i s mounted to the si de of the
throttl e body (Fi g. 22) or (Fi g. 23). An L-shaped rub-
ber fi tti ng i s used to connect the MAP sensor to
throttl e body (Fi g. 27).
REMOVAL
(1) Remove ai r cl eaner i ntake tube at throttl e
body.
(2) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 27).
(3) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 27) from throttl e body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
INSTALLATION
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 N·m (25 i n. l bs.) torque.
(4) I nstal l ai r cl eaner i ntake tube.
POWERTRAIN CONTROL MODULE (PCM)
The PCM i s l ocated i n the engi ne compartment
(Fi g. 28).
REMOVAL
To avoi d possi bl e vol tage spi ke damage to the
PCM, i gni ti on key must be off, and negati ve battery
cabl e must be di sconnected before unpl uggi ng PCM
connectors.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Remove pl asti c shi el d from over 32–way con-
nectors. Shi el d snaps to connectors.
(3) Careful l y unpl ug three 32–way connectors (Fi g.
28) from PCM.
(4) Remove three PCM mounti ng bol ts and remove
PCM from vehi cl e.
Fig. 26 Mounting Bolts (Screws)—IAC Motor
1 – IDLE AIR CONTROL MOTOR
2 – MOUNTING SCREWS
Fig. 27 MAP Sensor Mounting
1 – THROTTLE BODY
2 – MAP SENSOR
3 – RUBBER FITTING
4 – MOUNTING SCREWS (2)
Fig. 28 PCM Location
1 – PCM MOUNTING BOLTS (3)
2 – POWERTRAIN CONTROL MODULE (PCM)
3 – BATTERY
4 – (3) 32–WAY CONNECTOR
14 - 46 FUEL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l PCM and mounti ng bol ts to vehi cl e.
(2) Ti ghten bol ts to 4 N·m (35 i n. l bs.).
(3) Check pi n connectors i n PCM and three
32–way connectors for corrosi on or damage. Al so
check pi n hei ghts i n connectors. Pi n hei ghts shoul d
al l be the same. Repai r as necessary before i nstal l i ng
32–way connectors.
(4) I nstal l three 32–way connectors.
(5) I nstal l pl asti c shi el d to 32–way connectors.
Shi el d snaps to connectors.
(6) I nstal l battery cabl e.
(7) Use the DRB scan tool to reprogram new PCM
wi th vehi cl es ori gi nal I denti fi cati on Number (VI N)
and ori gi nal vehi cl e mi l eage.
POWER STEERING PRESSURE SWITCH— 2. 5L
ENGINE
Thi s swi tch i s not used wi th 4.0L si x-cyl i nder
engi nes.
The power steeri ng pressure swi tch i s i nstal l ed i n
the power steeri ng hi gh-pressure hose (Fi g. 29).
REMOVAL
(1) Di sconnect el ectri cal connector from power
steeri ng pressure swi tch.
(2) Pl ace a smal l contai ner or shop towel beneath
swi tch to col l ect any excess fl ui d.
(3) Remove swi tch. Use back-up wrench on power
steeri ng l i ne to prevent l i ne bendi ng.
INSTALLATION
(1) I nstal l power steeri ng swi tch i nto power steer-
i ng l i ne.
(2) Ti ghten to 14–22 N·m (124–195 i n. l bs.) torque.
(3) Connect el ectri cal connector to swi tch.
(4) Check power steeri ng fl ui d and add as neces-
sary.
(5) Start engi ne and agai n check power steeri ng
fl ui d. Add fl ui d i f necessary.
OXYGEN SENSOR
REMOVAL
Never apply any type of grease to the oxygen
sensor electrical connector, or attempt any sol-
dering of the sensor wiring harness. For sensor
operation, it must have a comparison source of
oxygen from outside the exhaust system. This
fresh air is supplied to the sensor through its
pigtail wiring harness.
Refer to (Fi g. 30), (Fi g. 31), (Fi g. 32) or (Fi g. 33) for
O2S (oxygen sensor) l ocati on.
Fig. 29 Power Steering Pressure Switch
1 – POWER STEERING PRESSURE SWITCH
2 – ELECTRICAL CONNECTOR
3 – POWER STEERING PUMP Fig. 30 Oxygen Sensors—4.0L—Federal Emissions
1 – 1/2 O2S
2 – 1/1 O2S
TJ FUEL SYSTEM 14 - 47
REMOVAL AND INSTALLATION (Continued)
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Rai se and support vehi cl e.
(2) Di sconnect wi re connector from O2S sensor.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
(4) Cl ean threads i n exhaust pi pe usi ng appropri -
ate si ze tap.
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) I nstal l O2S sensor. Ti ghten to 30 N·m (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector.
(3) Lower vehi cl e.
Fig. 31 Oxygen Sensors—4.0L—California
Emissions
1 – 1/2 O2S
2 – 1/1 O2S
3 – 2/1 O2S
4 – 2/2 O2S
Fig. 32 Front Oxygen Sensor—2.5L—Federal
Emissions
1 – 1/1 O2S
Fig. 33 Rear Oxygen Sensor—2.5L—Federal
Emissions
1 – 1/2 O2S
14 - 48 FUEL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
AIR CLEANER ELEMENT
REMOVAL
(1) Loosen ai r tube cl amp at housi ng cover (Fi g.
34).
(2) Di sconnect ai r tube at cover.
(3) Pry back the cl i ps retai ni ng ai r cl eaner cover to
ai r cl eaner housi ng.
(4) Li ft cover up to expose ai r cl eaner el ement.
(5) Remove ai r cl eaner el ement.
(6) Cl ean i nsi de of ai r cl eaner housi ng and i ts
cover before i nstal l i ng new el ement.
INSTALLATION
(1) I nstal l ai r cl eaner el ement i nto housi ng.
(2) I nstal l housi ng cover to housi ng. Be sure cover
i s properl y seated to ai r cl eaner housi ng.
(3) Connect ai r tube at cover.
ENGINE COOLANT TEMPERATURE SENSOR
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
The cool ant temperature sensor i s i nstal l ed i n the
thermostat housi ng (Fi g. 35).
REMOVAL
(1) Parti al l y drai n cool i ng system unti l cool ant
l evel i s bel ow cyl i nder head. Observe the WARN-
INGS i n Group 7, Cool i ng.
(2) Di sconnect cool ant temperature sensor wi re
connector.
(3) Remove sensor from thermostat housi ng.
INSTALLATION
(1) Appl y seal ant to sensor threads (new repl ace-
ment sensors wi l l have seal ant al ready appl i ed).
(2) I nstal l cool ant temperature sensor i nto thermo-
stat housi ng. Ti ghten to 11 N·m (8 ft. l bs.) torque.
(3) Connect wi re connector.
(4) Fi l l cool i ng system. Refer to Group 7, Cool i ng
System.
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR
The i ntake mani fol d ai r temperature (I AT) sensor
i s i nstal l ed i nto i ntake mani fol d pl enum near throttl e
body (Fi g. 36) or (Fi g. 37).
REMOVAL
(1) Di sconnect el ectri cal connector from I AT sen-
sor.
(2) Remove sensor from i ntake mani fol d.
Fig. 34 Air Cleaner Element
1 – COVER
2 – CLAMP
3 – AIR TUBE
4 – HOUSING
5 – FILTER
Fig. 35 Engine Coolant Temperature Sensor—
Typical
1 – THERMOSTAT HOUSING
2 – ENGINE COOLANT TEMPERATURE SENSOR
3 – ELECTRICAL CONNECTOR
TJ FUEL SYSTEM 14 - 49
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l I AT sensor i nto i ntake mani fol d.
Ti ghten sensor to 28 N·m (20 ft. l bs.) torque.
(2) Connect el ectri cal connector to sensor.
VEHICLE SPEED SENSOR
The Vehi cl e Speed Sensor (VSS) i s l ocated on the
speedometer pi ni on gear adapter. I f equi pped wi th
4WD, thi s adapter i s l ocated on the transfer case
extensi on (l eft si de) (Fi g. 38). I f equi pped wi th 2WD,
thi s adapter i s l ocated on the extensi on housi ng of
the transmi ssi on (l eft si de).
REMOVAL
(1) Rai se and support vehi cl e.
(2) Di sconnect el ectri cal connector from sensor by
pushi ng sl i de tab (Fi g. 38). After sl i de tab has been
posi ti oned, push i n on secondary rel ease l ock (Fi g.
38) on si de of connector and pul l connector from sen-
sor.
(3) Remove sensor mounti ng bol t (Fi g. 39).
(4) Remove sensor (pul l strai ght out) from speed-
ometer pi ni on gear adapter (Fi g. 39). Do not remove
gear adapter from transmi ssi on.
Fig. 36 IAT Sensor Location—4.0L Engine
1 – MOUNTING BOLTS (4)
2 – THROTTLE BODY
3 – IAC MOTOR
4 – ELEC. CONN.
5 – TPS
6 – MAP SENSOR
7 – ELEC. CONN.
8 – IAT SENSOR
9 – ELEC. CONN.
Fig. 37 IAT Sensor Location—2.5L Engine
1 – ELECTRICAL CONNECTOR
2 – INTAKE MANIFOLD TEMPERATURE SENSOR
3 – FUEL INJECTOR
Fig. 38 VSS Location—4WD Shown
1 – SENSOR ELECTRICAL CONNECTOR
2 – SLIDE TAB
3 – 4WD TRANSFER CASE EXTENSION
4 – VEHICLE SPEED SENSOR
5 – RELEASE LOCK
14 - 50 FUEL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Cl ean i nsi de of speedometer pi ni on gear
adapter before i nstal l i ng speed sensor.
(2) I nstal l sensor i nto speedometer gear adapter
and i nstal l mounti ng bol t. Before tightening bolt,
verify speed sensor is fully seated (mounted
flush) to speedometer pinion gear adapter.
(3) Ti ghten sensor mounti ng bol t to 2.2 N·m (20 i n.
l bs.) torque.
(4) Connect el ectri cal connector to sensor.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Accel erator Pedal Bracket Mounti ng Nuts . 8.5 N·m
(75 i n. l bs.)
Engi ne Cool ant Temperature Sensor . . . . . . 11 N·m
(96 i n. l bs.)
Fuel Tank Mounti ng Nuts . . . Refer to manual text
Fuel Hose Cl amps . . . . . . . . . . . 1 N·m (10 i n. l bs.)
I AC Motor-To-Throttl e Body Bol ts . . . . . . . . 7 N·m
(60 i n. l bs.)
I ntake Mani fol d Ai r Temp. Sensor . . . . . . . 28 N·m
(20 ft. l bs.)
MAP Sensor Mounti ng Screws . . 3 N·m (25 i n. l bs.)
Oxygen Sensor . . . . . . . . . . . . . 30 N·m (22 ft. l bs.)
PCM Mounti ng Screws . . . . . . . . 4 N·m (35 i n. l bs.)
Power Steeri ng Pressure Swi tch . . . . . . 14–22 N·m
(124–195 i n. l bs.)
Throttl e Body Mounti ng Bol ts . . . . . . . . . . . 12 N·m
(108 i n. l bs.)
Throttl e Posi ti on Sensor Mounti ng Screws . . 7 N·m
(60 i n. l bs.)
Vehi cl e Speed Sensor Mounti ng Bol t . . . . . 2.2 N·m
(20 i n. l bs.)
Fig. 39 VSS Removal/Installation
1 – ELECTRICAL CONNECTOR
2 – SENSOR MOUNTING BOLT
3 – O-RING
4 – SPEEDOMETER PINION GEAR
5 – SPEEDOMETER PINION GEAR ADAPTER
6 – O-RING
7 – VEHICLE SPEED SENSOR
TJ FUEL SYSTEM 14 - 51
REMOVAL AND INSTALLATION (Continued)
SPECIAL TOOLS
FUEL SYSTEM
Spanner Wrench—6856
Adapters, Fuel Pressure Test—6539 and/or 6631
Fitting, Air Metering—6714
O2S (Oxygen Sensor) Remover/Installer—C-4907
Test Kit, Fuel Pressure—5069
Test Kit, Fuel Pressure—C-4799-B
Fuel Line Removal Tool—6782
14 - 52 FUEL SYSTEM TJ
FUEL SYSTEM
TABLE OF CONTENTS
page
DESCRIPTION AND OPERATION
FUEL REQUIREMENTS—LEADED FUEL
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
FUEL REQUIREMENTS— LEADED FUEL
VEHICLES
DESCRIPTION
Your vehi cl e i s desi gned to meet al l emi ssi on regu-
l ati ons and provi de excel l ent fuel economy when
usi ng hi gh qual i ty l eaded gasol i ne wi th a mi ni mum
octane rati ng of 91.
The vehi cl e wi l l operate on fuel s rangi ng from reg-
ul ar l eaded havi ng a mi ni mum research octane of 91
to super unl eaded wi th a mi ni mum research octane
of 98.
Li ght spark knock at l ow engi ne speeds i s not
harmful to your engi ne. However, conti nued heavy
spark knock at hi gh speeds can cause damage and
shoul d be reported to your deal er i mmedi atel y.
Engi ne damage resul ti ng from operati ng wi th a
heavy spark knock may not be covered by the new
vehi cl e warranty.
Besi des usi ng l eaded gasol i ne wi th the proper
octane rati ng, gasol i nes that contai n detergents, cor-
rosi on and stabi l i ty addi ti ves are recommended.
Usi ng gasol i nes that have these addi ti ves wi l l hel p
i mprove fuel economy, reduce emi ssi ons, and mai n-
tai n vehi cl e performance.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng and stumbl e. I f you experi ence
these probl ems, try another brand of gasol i ne before
consi deri ng servi ce for the vehi cl e.
TJ FUEL SYSTEM 14 - 1
2000 JEEP WRANGLER
2000 JEEP WRANGLER
STEERING
TABLE OF CONTENTS
page page
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . . 6
POWER STEERING GEAR. . . . . . . . . . . . . . . . . . . 11
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . 22
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . 25
POWER STEERING
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM DIAGNOSIS
CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER STEERING FLOW AND PRESSURE. . . . . 4
DESCRIPTION AND OPERATION
STEERING SYSTEM
DESCRIPTION
The power steeri ng system has a hydraul i c pump.
The pump i s a constant fl ow rate and di spl acement
vane-type pump. The pump reservoi r on the 4.0L
engi ne i s mounted to the pump body (Fi g. 1). The
2.5L engi ne has a remote pump reservoi r mounted to
the fan shroud (Fi g. 2).
The steeri ng gear used i s a vari abl e rati o reci rcu-
l ati ng bal l type gear. A ti l t and non-ti l t col umn pro-
vi de steeri ng i nput.
OPERATION
The gear acts as a rol l i ng thread between the
worm shaft and rack pi ston. The worm shaft i s sup-
ported by a thrust beari ng at the l ower end and a
beari ng assembl y at the upper end. When the worm
shaft i s turned from i nput from the steeri ng col umn
the rack pi ston moves. The rack pi ston teeth mesh
wi th the pi tman shaft. Turni ng the worm shaft turns
the pi tman shaft, whi ch turns the steeri ng l i nkage.
Fig. 1 Power Steering Gear & Pump – 4.0L
1 – 4.0 L PUMP
2 – RETURN HOSE
3 – STEERING GEAR
4 – PRESSURE HOSE
5 – RESERVOIR
TJ STEERING 19 - 1
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i t’s travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash panel
seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components/track bar.
2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other
components.
5. Reposition hose.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
Fig. 2 Power Steering Gear & Pump – 2.5L
1 – REMOTE RESERVOIR
2 – 2.5 L PUMP
3 – RETURN HOSES
4 – STEERING GEAR
5 – PRESSURE HOSE
19 - 2 STEERING TJ
DESCRIPTION AND OPERATION (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
4. Air in the system. 4. Perform pump initial operation.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose fitting. 2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering component. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of
adjustment.
7. Repair or replace gear.
8. Ball joints binding. 8. Inspect and repair as necessary.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR
MOMENTARY INCREASE IN
TURNING EFFORT
1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5. Pressure test and repair as necessary.
6. Internal gear leak. 6. Pressure and flow test, and repair as
necessary.
STEERING WHEEL
DOES NOT WANT TO RETURN
TO CENTER POSITION
1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust as necessary.
5. Ball joints binding. 5. Inspect and repair as necessary.
Some roads will cause a vehicle to drift, due to the crown in the road.
TJ STEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)
LOOSE STEERING AND VEHICLE LEADS/DRIFTS
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE PLAY IN STEERING
WHEEL
1. Worn or loose suspension or
steering components.
1. Repair as necessary.
2. Worn or loose wheel bearings. 2. Repair as necessary.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.
VEHICLE PULLS TO ONE SIDE
DURING BRAKING
1. Tire Pressure. 1. Adjust tire pressure.
2. Air in brake hydrauliics system. 2. Bleed brake system.
3. Worn brake components. 3. Repair as necessary.
VEHICLE LEADS OR DRIFTS
FROM STRAIGHT AHEAD
DIRECTION ON UNCROWNED
ROAD.
1. Tire pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Cross front tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align vehicle.
5. Weak or broken spring. 5. Replace spring.
6. Loose or worn steering/
suspension components.
6. Repair as necessary.
7. Cross caster out of spec. 7. Adjust or replace axle as
necessary.
POWER STEERING FLOW AND PRESSURE
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the gal l ons per mi nute (GPM) or
fl ow rate of the power steeri ng pump al ong wi th the
maxi mum rel i ef pressure. Perform test any ti me a
power steeri ng system probl em i s present. Thi s test
wi l l determi ne i f the power steeri ng pump or power
steeri ng gear i s not functi oni ng properl y. The fol l ow-
i ng pressure and fl ow test i s performed usi ng Power
Steeri ng Anal yzer Tool 6815 (Fi g. 3) and Adapter ki t
6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to Tube 6865.
(3) Connect Adapter 6826 to Power Steeri ng Ana-
l yzer test val ve end.
(4) Di sconnect the hi gh pressure hose from the
power steeri ng pump.
(5) Connect Tube 6865 to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to Adapter 6826.
(7) Open the test val ve compl etel y.
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge.
Fig. 3 Power Steering Analyzer
1 – TUBE
2 – ADAPTER FITTINGS
3 – ANALYZER
4 – GAUGE HOSE
19 - 4 STEERING TJ
DIAGNOSIS AND TESTING (Continued)
(9) Shut off the engi ne and check the fl ui d l evel ,
add fl ui d as necessary. Start engi ne agai n and l et
i dl e.
(10) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
(11) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. The readi ng shoul d be 2.4 - 2.8
GPM, i f the readi ng i s bel ow thi s speci fi cati on the
pump shoul d be repl aced.
CAUTION: This next step involves testing maxi-
mum pump pressure output and flow control valve
operation. Do not leave test valve closed for more
than three seconds as the pump could be damaged.
(12) Cl ose val ve ful l y three ti mes for three seconds
and record hi ghest pressure i ndi cated each ti me. All
three readings must be above pump relief pres-
sure specifications and within 345 kPa (50 psi)
of each other.
• Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
• Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
(13) Open the test val ve and turn the steeri ng
wheel to the extreme l eft and ri ght posi ti ons agai nst
the stops. Record the hi ghest pressure readi ng at
each posi ti on. Compare readi ngs to pump speci fi ca-
ti ons chart. I f pressure readi ngs are not wi thi n 50
psi . of each other, the gear i s l eaki ng i nternal l y and
must be repai red.
CAUTION: Do not force the pump to operate
against the stops for more than 2 to 4 seconds at a
time because, pump damage will result.
PUMP SPECIFICATIONS
ENGINE
RELIEF
PRESSURE Ϯ 50
FLOW RATE
(GPM)
2.5L
9653 kPa
(1400 psi)
1500 RPM 2.4 - 2.8
GPM
4.0L
9653 kPa
(1400 psi)
TJ STEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)
POWER STEERING PUMP
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 6
POWER STEERING PRESSURE LINE. . . . . . . . . . 6
POWER STEERING RETURN LINE . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING
PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
POWER STEERING PUMP - INITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL AND INSTALLATION
POWER STEERING PUMP – 4.0L . . . . . . . . . . . . . 7
POWER STEERING PUMP – 2.5L . . . . . . . . . . . . . 8
PUMP REMOTE RESERVOIR – 2.5L . . . . . . . . . . . 8
DISASSEMBLY AND ASSEMBLY
PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PUMP RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 10
DESCRIPTION AND OPERATION
POWER STEERING PUMP
DESCRIPTION
Hydraul i c pressure for the power steeri ng system
i s provi ded by a bel t dri ven power steeri ng pump
(Fi g. 1). The pump shaft has a pressed-on hi gh
strength pl asti c dri ve pul l ey that i s bel t dri ven by
the crankshaft pul l ey. The reservoi r i s attached to
the pump body wi th spri ng cl i ps on the 4.0L engi ne.
A remote pump reservoi r i s used on the 2.5L engi ne
mounted to the fan shroud. The power steeri ng pump
i s connected to the steeri ng gear by the pressure and
return hoses.
OPERATION
The power steeri ng pump i s a constant fl ow rate
and di spl acement, vane-type pump. The pump i nter-
nal parts operate submerged i n fl ui d. The fl ow con-
trol ori fi ce i s part of the hi gh pressure l i ne fi tti ng.
The pressure rel i ef val ve i nsi de the fl ow control val ve
l i mi ts the pump pressure.
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
POWER STEERING PRESSURE LINE
DESCRIPTION
The hose consi sts of two metal ends and rubber
center secti on that contai ns a tuni ng cabl e.
OPERATION
Power steeri ng pressure l i ne, i s used to transfer
hi gh pressure power steeri ng fl ui d, from the power
steeri ng pump to the power steeri ng gear.
Fig. 1 Pump With Integral Reservoir
1 – CAP
2 – FLUID RESERVOIR (TYPICAL)
3 – HIGH-PRESSURE FITTING
4 – DRIVE PULLEY
5 – PUMP BODY
6 – RESERVOIR CLIP
19 - 6 STEERING TJ
POWER STEERING RETURN LINE
DESCRIPTION
Power steeri ng return l i ne i s a hose whi ch i s
cl amped at the pump and the gear.
OPERATION
Power steeri ng return l i ne, i s used to transfer l ow
pressure power steeri ng fl ui d, from the power steer-
i ng gear to the power steeri ng pump.
DIAGNOSIS AND TESTING
PUMP LEAKAGE DIAGNOSIS
SERVICE PROCEDURES
POWER STEERING PUMP - INITIAL
OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal ambi ent temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
REMOVAL AND INSTALLATION
POWER STEERING PUMP – 4. 0L
REMOVAL
(1) Remove serpenti ne dri ve bel t, refer to Group 7
Cool i ng.
(2) Remove pressure and return hoses from pump
and drai n the pump.
(3) Loosen the pump bracket bol t at the engi ne
bl ock.
(4) Remove 3 pump mounti ng bol ts (Fi g. 2)
through pul l ey access hol es.
(5) Ti l t pump downward and remove from engi ne.
(6) Remove pul l ey from pump.
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) I nstal l pump on the engi ne mounti ng bracket.
(3) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 N·m (20 ft. l bs.).
(4) Ti ghten pump bracket bol t to 57 N·m (42 ft.
l bs.).
(5) I nstal l the pressure l i ne on the pump and
ti ghten to 28 N·m (21 ft. l bs.).
(6) I nstal l return hoses on pump.
(7) I nstal l dri ve bel t, refer to Group 7 Cool i ng.
(8) Add power steeri ng fl ui d, refer to Power Steer-
i ng Pump I ni ti al Operati on.
TJ STEERING 19 - 7
DESCRIPTION AND OPERATION (Continued)
POWER STEERING PUMP – 2. 5L
REMOVAL
(1) Remove serpenti ne dri ve bel t, refer to Group 7
Cool i ng.
(2) Remove pressure and return hoses from pump
and drai n the pump.
(3) Remove 3 pump mounti ng bol ts (Fi g. 3)
through pul l ey access hol es.
(4) Loosen the 3 pump bracket bol ts.
(5) Ti l t pump downward and remove from engi ne.
(6) Remove pul l ey from pump.
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) I nstal l pump on the engi ne mounti ng bracket.
(3) Ti ghten pump bracket bol ts to 47 N·m (35 ft.
l bs.).
(4) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 N·m (20 ft. l bs.).
(5) I nstal l the pressure l i ne on the pump and
ti ghten to 28 N·m (21 ft. l bs.).
(6) I nstal l return hoses on pump.
(7) I nstal l dri ve bel t, refer to Group 7 Cool i ng.
(8) Add power steeri ng fl ui d, refer to Power Steer-
i ng Pump I ni ti al Operati on.
PUMP REMOTE RESERVOIR – 2. 5L
REMOVAL
(1) Remove the pump return hoses from the reser-
voi r and drai n the reservoi r.
(2) Remove the push-i n fastener from the reservoi r
(Fi g. 4).
(3) Sl i de the reservoi r up out of the fan shroud
mount.
Fig. 2 Pump Mounting – 4.0L
1 – PUMP ASSEMBLY
2 – PUMP BRACKET
Fig. 3 Pump Mounting – 2.5L
1 – PUMP BRACKET
2 – PUMP ASSEMBLY 2.5L
Fig. 4 Pump Reservoir – 2.5L
1 – CAP
2 – FASTENER
3 – PUMP SUPPLY HOSE
4 – RETURN HOSE
5 – FAN SHROUD
6 – RESERVOIR
19 - 8 STEERING TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Sl i de reservoi r down onto the fan shroud
mount unti l i t cl i cks i n pl ace.
(2) I nstal l the push-i n fastener.
(3) I nstal l the hoses.
(4) Fi l l reservoi r to proper l evel , refer to Power
Steeri ng Pump I ni ti al Operati on.
DISASSEMBLY AND ASSEMBLY
PUMP PULLEY
DISASSEMBLY
(1) Remove pump assembl y.
(2) Remove pul l ey from pump wi th Pul l er C-4333
or equi val ent pul l er (Fi g. 5).
ASSEMBLY
NOTE: The pulley is marked front for installation.
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
or equi val ent i nstal l er (Fi g. 6). The pul l ey must be
fl ush wi th the end of the shaft. Ensure the tool and
pul l ey are al i gned wi th the pump shaft.
(3) I nstal l pump assembl y.
(4) Wi th Serpenti ne Bel t, run engi ne unti l warm (5
mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
PUMP RESERVOIR
DISASSEMBLY
(1) Remove power steeri ng pump.
(2) Cl ean exteri or of pump.
(3) Cl amp the pump body i n a soft jaw vi ce.
(4) Pry up tab and sl i de the retai ni ng cl i ps off (Fi g.
7).
NOTE: Use new retaining clips for installation.
Fig. 5 Pulley Removal
1 – POWER STEERING PUMP DRIVE PULLEY
2 – SPECIAL TOOL C-4333
Fig. 6 Pulley Installation
1 – POWER STEERING PUMP DRIVE PULLEY
2 – SPECIAL TOOL C-4063–B
Fig. 7 Pump Reservoir Clips
1 – RESERVOIR
2 – RETAINING CLIPS
TJ STEERING 19 - 9
REMOVAL AND INSTALLATION (Continued)
(5) Remove fl ui d reservoi r from pump body.
Remove and di scard O-ri ng seal .
ASSEMBLY
(1) Lubri cate new O-ri ng Seal wi th Mopar Power
Steeri ng Fl ui d or equi val ent.
(2) I nstal l O-ri ng seal i n housi ng.
(3) I nstal l reservoi r onto housi ng.
(4) Sl i de and tap i n new reservoi r retai ner cl i ps
unti l tab l ocks to housi ng.
(5) I nstal l power steeri ng pump.
(6) Add power steeri ng fl ui d, refer to Pump I ni ti al
Operati on.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Pump
Bracket to Pump . . . . . . . . . . 28 N·m (21 ft. l bs.)
Bracket to 4.0L Engi ne . . . . . 57 N·m (42 ft. l bs.)
Bracket to 2.5L Engi ne . . . . . 47 N·m (35 ft. l bs.)
Fl ow Control Val ve . . . . . . . . 75 N·m (55 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . 28 N·m (21 ft. l bs.)
SPECIAL TOOLS
POWER STEERING PUMP
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
Puller C-4333
Installer, Power Steering Pulley C-4063B
19 - 10 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
POWER STEERING GEAR
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWER STEERING GEAR. . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING
POWER STEERING GEAR LEAKAGE . . . . . . . . . 11
REMOVAL AND INSTALLATION
POWER STEERING GEAR. . . . . . . . . . . . . . . . . . 12
DISASSEMBLY AND ASSEMBLY
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . . . 12
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . . . 12
SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RACK PISTON AND WORM SHAFT . . . . . . . . . . . 16
ADJUSTMENTS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
POWER STEERING GEAR. . . . . . . . . . . . . . . . . . 21
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL TOOLS
POWER STEERING GEAR. . . . . . . . . . . . . . . . . . 21
DESCRIPTION AND OPERATION
POWER STEERING GEAR
DESCRIPTION
The power steeri ng gear i s a vari abl e rati o reci rcu-
l ati ng bal l type gear. The rati o i s 15:1 on center,
reduci ng to 13:1 at the end of travel .
OPERATION
The gear acts as a rol l i ng thread between the
worm shaft and rack pi ston. The worm shaft i s sup-
ported by a thrust beari ng at the l ower end and a
beari ng assembl y at the upper end. When the worm
shaft i s turned the rack pi ston moves. The rack pi s-
ton teeth mesh wi th the pi tman shaft. Turni ng the
worm shaft turns the pi tman shaft, whi ch turns the
steeri ng l i nkage.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the 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.
DIAGNOSIS AND TESTING
POWER STEERING GEAR LEAKAGE
TJ STEERING 19 - 11
REMOVAL AND INSTALLATION
POWER STEERING GEAR
REMOVAL
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on wi th the steeri ng wheel centered.
(2) Di sconnect and cap the fl ui d hoses/tubes from
power steeri ng pump.
(3) Remove the col umn coupl er shaft from the
gear.
(4) Remove pi tman arm from gear.
(5) Remove the steeri ng gear retai ni ng bol ts and
remove the gear (Fi g. 1).
(6) Remove power steeri ng hoses/tubes from steer-
i ng gear.
INSTALLATION
(1) I nstal l power steeri ng hoses/tubes to steeri ng
gear and ti ghten to 28 N·m (21 ft. l bs.).
(2) I nstal l steeri ng gear on the frame rai l and
ti ghten bol ts to 95 N·m (70 ft. l bs.)
(3) Al i gn the col umn coupl er shaft to steeri ng gear.
I nstal l a new coupl er pi nch bol t and ti ghten to 49
N·m (36 ft. l bs.).
(4) Al i gn and i nstal l the pi tman arm and ti ghten
nut to 251 N·m (185 ft. l bs.).
(5) I nstal l power steeri ng hoses/tubes to power
steeri ng pump.
(6) Fi l l power steeri ng system to proper l evel , refer
to Steeri ng Pump I ni ti al Operati on.
DISASSEMBLY AND ASSEMBLY
HOUSING END PLUG
DISASSEMBLY
(1) Unseat and remove retai ni ng ri ng from groove
wi th a punch through the hol e i n the end of the
housi ng (Fi g. 2).
(2) Sl owl y rotate stub shaft wi th 12 poi nt socket
COUNTER-CLOCKWI SE to force the end pl ug out
from housi ng.
CAUTION: Do not turn stub shaft any further than
necessary. The rack piston balls will drop out of the
rack piston circuit if the stub shaft is turned too far.
(3) Remove O-ri ng from the housi ng (Fi g. 3).
ASSEMBLY
(1) Lubri cate O-ri ng wi th power steeri ng fl ui d and
i nstal l i nto the housi ng.
(2) I nstal l end pl ug by tappi ng the pl ug l i ghtl y
wi th a pl asti c mal l et i nto the housi ng.
(3) I nstal l retai ni ng ri ng so one end of the ri ng
covers the housi ng access hol e (Fi g. 4).
PITMAN SHAFT/SEALS/BEARING
DISASSEMBLY
(1) Cl ean exposed end of pi tman shaft and housi ng
wi th a wi re brush.
(2) Remove prel oad adjuster nut (Fi g. 5).
Fig. 1 Steering Gear Mounting
1 – STEERING GEAR
2 – FRAME MOUNT
Fig. 2 End Plug Retaining Ring
1 – RETAINING RING
19 - 12 STEERING TJ
(3) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotati ng i t from the
stop 1/2 of the total amount of turns.
(5) Remove si de cover bol ts and remove si de cover,
gasket and pi tman shaft as an assembl y (Fi g. 5).
NOTE: The pitman shaft will not clear the housing
if it is not centered.
(6) Remove pi tman shaft from the si de cover.
(7) Remove dust seal from the housi ng wi th a seal
pi ck (Fi g. 6).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retai ni ng ri ng wi th snap ri ng pl i ers.
(9) Remove washer from the housi ng.
(10) Remove oi l seal from the housi ng wi th a seal
pi ck.
(11) Remove pi tman shaft beari ng from housi ng
wi th a beari ng dri ver and handl e (Fi g. 7).
ASSEMBLY
(1) I nstal l pi tman shaft beari ng i nto housi ng wi th
a beari ng dri ver and handl e.
(2) Coat the oi l seal and washer wi th special
grease suppl i ed wi th the new seal .
(3) I nstal l the oi l seal wi th a dri ver and handl e.
(4) I nstal l backup washer.
Fig. 3 End Plug Components
1 – HOUSING ASSEMBLY
2 – HOUSING END PLUG O-RING SEAL
3 – HOUSING END PLUG
4 – RETAINING RING
Fig. 4 Installing The Retaining Ring
1 – RING CAP
2 – PUNCH ACCESS HOLE
3 – RETAINER RING
Fig. 5 Side Cover and Pitman Shaft
1 – SIDE COVER BOLTS
2 – PRELOAD ADJUSTER NUT
3 – SIDE COVER
4 – GASKET SEAL
5 – PITMAN SHAFT
6 – HOUSING ASSEMBLY
TJ STEERING 19 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(5) I nstal l the retai ner ri ng wi th snap ri ng pl i ers.
(6) Coat the dust seal wi th special grease sup-
pl i ed wi th the new seal .
(7) I nstal l dust seal wi th a dri ver and handl e.
(8) I nstal l pi tman shaft to si de cover by screwi ng
shaft i n unti l i t ful l y seats to si de cover.
(9) I nstal l prel oad adjuster nut. Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(10) I nstal l gasket to si de cover and bend tabs
around edges of si de cover (Fi g. 5).
(11) I nstal l pi tman shaft assembl y and si de cover
to housi ng.
(12) I nstal l si de cover bol ts and ti ghten to 60 N·m
(44 ft. l bs.).
(13) Perform over-center rotati on torque adjust-
ment.
SPOOL VALVE
DISASSEMBLY
(1) Remove l ock nut (Fi g. 8).
(2) Remove adjuster nut wi th Spanner Wrench
C-4381.
(3) Remove thrust support assembl y out of the
housi ng (Fi g. 9).
(4) Pul l stub shaft and val ve assembl y from the
housi ng (Fi g. 10).
(5) Remove stub shaft from val ve assembl y by
l i ghtl y tappi ng shaft on a bl ock of wood to l oosen
shaft. Then di sengage stub shaft pi n from hol e i n
spool val ve and separate the val ve assembl y from
stub shaft (Fi g. 11).
(6) Remove spool val ve from val ve body by pul l i ng
and rotati ng the spool val ve from the val ve body (Fi g.
12).
(7) Remove spool val ve O-ri ng and val ve body
tefl on ri ngs and O-ri ngs underneath the tefl on ri ngs
(Fi g. 13).
Fig. 6 Pitman Shaft Seals & Bearing
1 – BEARING
2 – WASHER
3 – DUST SEAL
4 – RETAINER
5 – OIL SEAL
Fig. 7 Needle Bearing Removal
1 – REMOVER
2 – SIDE COVER AREA
Fig. 8 Lock Nut and Adjuster Nut
1 – ADJUSTER NUT
2 – STEERING GEAR
3 – LOCK NUT
4 – PUNCH
19 - 14 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(8) Remove the O-ri ng between the worm shaft
and the stub shaft.
ASSEMBLY
NOTE: Clean and dry all components, then lubri-
cate with power steering fluid.
(1) I nstal l spool val ve spool O-ri ng.
(2) I nstal l spool val ve i n val ve body by pushi ng
and rotati ng. Hol e i n spool val ve for stub shaft pi n
must be accessi bl e from opposi te end of val ve body.
(3) I nstal l stub shaft i n val ve spool and engage
l ocati ng pi n on stub shaft i nto spool val ve hol e (Fi g.
14).
NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoul-
der.
Fig. 9 Thrust Support Assembly
1 – STUB SHAFT
2 – HOUSING
3 – THRUST SUPPORT ASSEMBLY
Fig. 10 Valve Assembly With Stub Shaft
1 – GEAR
2 – THRUST SUPPORT
3 – LOCK NUT
4 – ADJUSTER NUT
5 – STUB SHAFT
6 – VALVE ASSEMBLY
Fig. 11 Stub Shaft
1 – STUB SHAFT
2 – VALVE BODY
3 – HOLE IN SPOOL
4 – SHAFT PIN
5 – 6mm (1/4”)
Fig. 12 Spool Valve
1 – SPOOL VALVE
2 – ROTATE VALVE TO REMOVE
3 – VALVE BODY
TJ STEERING 19 - 15
DISASSEMBLY AND ASSEMBLY (Continued)
(4) I nstal l O-ri ngs and tefl on ri ngs over the
O-ri ngs on val ve body.
(5) I nstal l O-ri ng i nto the back of the stub shaft
cap (Fi g. 15).
(6) I nstal l stub shaft and val ve assembl y i n the
housi ng. Li ne up worm shaft to sl ots i n the val ve
assembl y.
(7) I nstal l thrust support assembl y.
NOTE: The thrust support is serviced as an assem-
bly. If any component of the thrust support is dam-
aged the assembly must be replaced.
(8) I nstal l adjuster nut and l ock nut.
(9) Adjust Thrust Beari ng Prel oad and Over-Cen-
ter Rotati ng Torque.
RACK PISTON AND WORM SHAFT
DISASSEMBLY
(1) Remove housi ng end pl ug.
(2) Remove rack pi ston pl ug (Fi g. 16).
(3) Remove si de cover and pi tman shaft.
(4) Turn stub shaft COUNTERCLOCKWI SE unti l
the rack pi ston begi ns to come out of the housi ng.
(5) I nsert Arbor C-4175 i nto bore of rack pi ston
(Fi g. 17) and hol d tool ti ghtl y agai nst worm shaft.
(6) Turn the stub shaft wi th a 12 poi nt socket
COUNTERCLOCKWI SE, thi s wi l l force the rack pi s-
ton onto the tool and hol d the rack pi ston bal l s i n
pl ace.
(7) Remove the rack pi ston and tool together from
housi ng.
(8) Remove tool from rack pi ston.
(9) Remove rack pi ston bal l s.
(10) Remove cl amp bol ts, cl amp and bal l gui de
(Fi g. 18).
(11) Remove tefl on ri ng and O-ri ng from the rack
pi ston (Fi g. 19).
Fig. 13 Valve Seals
1 – O-RING SEALS
Fig. 14 Stub Shaft Installation
1 – NOTCH IN CAP
2 – VALVE BODY PIN
Fig. 15 Stub Shaft Cap O-Ring
1 – VALVE BODY
2 – STUB SHAFT CAP
3 – O-RING
19 - 16 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Remove the adjuster l ock nut and adjuster
nut from the stub shaft.
(13) Pul l the stub shaft wi th the spool val ve and
thrust support assembl y out of the housi ng.
(14) Remove the worm shaft from the housi ng
(Fi g. 20).
ASSEMBLY
NOTE: Clean and dry all components and lubricate
with power steering fluid.
(1) Check for scores, ni cks or burrs on the rack
pi ston fi ni shed surface. Sl i ght wear i s normal on the
worm gear surfaces.
Fig. 16 Rack Piston End Plug
1 – EXTENSION
2 – END PLUG
3 – RACK PISTON
4 – RATCHET
Fig. 17 Rack Piston with Arbor
1 – RACK PISTON
2 – SPECIAL TOOL C-4175
Fig. 18 Rack Piston
1 – CLAMP
2 – BALLS
3 – RACK PISTON
4 – BALL GUIDE
Fig. 19 Rack Piston Teflon Ring and O-Ring
1 – TEFLON SEAL
2 – BACK-UP O-RING MUST BE INSTALLED UNDER PISTON
RING
3 – RACK PISTON NUT
TJ STEERING 19 - 17
DISASSEMBLY AND ASSEMBLY (Continued)
(2) I nstal l O-ri ng and tefl on ri ng on the rack pi s-
ton.
(3) I nstal l worm shaft i n the rack pi ston and al i gn
worm shaft spi ral groove wi th rack pi ston bal l gui de
hol e (Fi g. 21).
CAUTION: The rack piston balls must be installed
alternately into the rack piston and ball guide. This
maintains worm shaft preload. There are 12 black
balls and 12 silver (Chrome) balls. The black balls
are smaller than the silver balls.
(4) Lubri cate and i nstal l rack pi ston bal l s through
return gui de hol e whi l e turni ng worm shaft COUN-
TERCLOCKWI SE (Fi g. 21).
(5) I nstal l remai ni ng bal l s i n gui de usi ng grease to
hol d the bal l s i n pl ace (Fi g. 22).
(6) I nstal l the gui de onto rack pi ston and i nstal l
cl amp and cl amp bol ts. Ti ghten bol ts to 4.8 N·m (43
i n. l bs.).
(7) I nsert Arbor C-4175 i nto bore of rack pi ston
and hol d tool ti ghtl y agai nst worm shaft.
(8) Turn the worm shaft COUNTERCLOCKWI SE
whi l e pushi ng on the arbor. Thi s wi l l force the rack
pi ston onto the arbor and hol d the rack pi ston bal l s
i n pl ace.
(9) I nstal l the races and thrust beari ng on the
worm shaft and i nstal l shaft i n the housi ng (Fi g. 20).
(10) I nstal l the stub shaft wi th spool val ve, thrust
support assembl y and adjuster nut i n the housi ng.
(11) I nstal l the rack pi ston and arbor tool i nto the
housi ng.
(12) Hol d arbor ti ghtl y agai nst worm shaft and
turn stub shaft CLOCKWI SE unti l rack pi ston i s
seated on worm shaft.
(13) I nstal l pi tman shaft and si de cover i n the
housi ng.
(14) I nstal l rack pi ston pl ug and ti ghten to 150
N·m (111 ft. l bs.).
(15) I nstal l housi ng end pl ug.
(16) Adjust worm shaft thrust beari ng prel oad and
over-center rotati ng torque.
Fig. 20 Worm Shaft
1 – GEAR HOUSING
2 – BEARING RACE
3 – WORM SHAFT
4 – BEARING
Fig. 21 Installing Balls in Rack Piston
1 – INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING
WORM COUNTER CLOCKWISE
2 – WORM FLANGE
Fig. 22 Balls in the Return Guide
1 – GUIDE
2 – PETROLEUM JELLY
3 – BALLS
19 - 18 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
ADJ USTMENTS
STEERING GEAR
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
WORM THRUST BEARING PRELOAD
(1) Mount the gear careful l y i nto a vi se.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Remove adjuster pl ug l ocknut (Fi g. 23).
(3) Rotate the stub shaft back and forth wi th a 12
poi nt socket to drai n the remai ni ng fl ui d.
(4) Turn the adjuster i n wi th Spanner Wrench
C-4381. Ti ghten the pl ug and thrust beari ng i n the
housi ng unti l fi rml y bottomed i n the housi ng about
34 N·m (25 ft. l bs.).
(5) Pl ace an i ndex mark on the housi ng even wi th
one of the hol es i n adjuster pl ug (Fi g. 24).
(6) Measure back (countercl ockwi se) 5.08 mm (0.20
i n) and mark housi ng (Fi g. 25).
(7) Rotate adjustment cap back (countercl ockwi se)
wi th spanner wrench unti l hol e i s al i gned wi th the
second mark (Fi g. 26).
(8) I nstal l and ti ghten l ocknut to 108 N·m (80 ft.
l bs.). Be sure adjustment cap does not turn whi l e
ti ghteni ng the l ocknut.
Fig. 23 Adjuster Lock Nut
1 – ADJUSTER NUT
2 – STEERING GEAR
3 – LOCK NUT
4 – PUNCH
Fig. 24 Alignment Marking On Housing
1 – INDEX
Fig. 25 Second Marking On Housing
1 – REFERENCE MARK
TJ STEERING 19 - 19
OVER-CENTER
NOTE: Before performing this procedure, the worm
bearing preload adjustment must be performed.
(1) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns.
(2) Starti ng at ei ther stop, turn the stub shaft
back 1/2 the total number of turns. Thi s i s the center
of the gear travel (Fi g. 27).
(3) Pl ace the torque wrench i n the verti cal posi ti on
on the stub shaft. Rotate the wrench 45 degrees each
si de of the center and record the hi ghest rotati onal
torque i n thi s range (Fi g. 28). Thi s i s the Over-Cen-
ter Rotati ng Torque.
NOTE: The stub shaft must rotate smoothly without
sticking or binding.
(4) Rotate the stud shaft between 90° and 180° to
the l eft of center and record the l eft off-center pre-
l oad. Repeat thi s to the ri ght of center and record the
ri ght off-center prel oad. The average of these two
recorded readi ngs i s the Prel oad Rotati ng Torque.
(5) The Over-Center Rotati ng Torque shoul d be
0.40-0.70 N·m (3-7 i n. l bs.) higher than the Prel oad
Rotati ng Torque.
(6) I f an adjustment to the Over-Center Rotati ng
Torque i s necessary, fi rst l oosen the adjuster l ock
nut. Then turn the pi tman shaft adjuster screw back
(COUNTERCLOCKWI SE) unti l ful l y extended, then
turn back i n (CLOCKWI SE) one ful l turn.
(7) Remeasure Over-Center Rotati ng Torque. I f
necessary turn the adjuster screw and repeat mea-
Fig. 26 Aligning To The Second Mark
1 – FIRST MARK
2 – SECOND MARK
3 – SPANNER WRENCH
Fig. 27 Steering Gear Centered
1 – ADJUSTMENT SCREW
2 – MASTER SPLINE
Fig. 28 Checking Over-center Rotation Torque
1 – CENTER
19 - 20 STEERING TJ
ADJ USTMENTS (Continued)
surement unti l correct Over-Center Rotati ng Torque
i s reached.
NOTE: To increase the Over-Center Rotating Torque
turn the screw CLOCKWISE.
(8) Prevent the adjuster screw from turni ng whi l e
ti ghteni ng adjuster l ock nut. Ti ghten the adjuster
l ock nut to 49 N·m (36 ft. l bs.).
SPECIFICATIONS
POWER STEERING GEAR
Steering Gear
Type . . . . . . . . . . . . . . . . . . . . Reci rcul ati ng Bal l
Gear Rati o . . . . . . . . . . . . . . . . . . . . . . 15 to 13:1
WormShaft Bearing
Prel oad . . . . . . . . . . 0.45–1.13 N·m (4–10 i n. l bs.)
Pitman Shaft Over-Center Drag
New Gear (under 400 mi l es) . . . . . 0.45–0.90 N·m
(4–8 i n. l bs.) + Worm Shaft Prel oad
Used Gear (over 400 mi l es) . . . . . . . 0.5–0.6 N·m
(4–5 i n. l bs.) + Worm Shaft Prel oad
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Gear
Adjustment Cap Locknut . . . 108 N·m (80 ft. l bs.)
Adjustment Screw Locknut . . 49 N·m (36 ft. l bs.)
Gear to Frame Bol ts . . . . . . . 95 N·m (70 ft. l bs.)
Pi tman Shaft Nut . . . . . . . 251 N·m (185 ft. l bs.)
Rack Pi ston Pl ug . . . . . . . . . 102 N·m (75 ft. l bs.)
Si de Cover Bol ts . . . . . . . . . . 60 N·m (44 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . 28 N·m (21 ft. l bs.)
Return Li ne . . . . . . . . . . . . . . 28 N·m (21 ft. l bs.)
SPECIAL TOOLS
POWER STEERING GEAR
Remover/Installer, Steering Plug C-4381
Remover, Pitman Arm C-4150A
Remover/Installer Steering Rack Piston C-4175
TJ STEERING 19 - 21
ADJ USTMENTS (Continued)
STEERING LINKAGE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE PROCEDURES
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL AND INSTALLATION
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PITMAN ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
STEERING DAMPENER. . . . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 24
SPECIAL TOOLS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION AND OPERATION
STEERING LINKAGE
DESCRIPTION
The steeri ng l i nkage consi sts of a pi tman arm,
drag l i nk, ti e rod, and steeri ng dampener (Fi g. 1).
Adjustment sl eeves are used on the ti e rod and drag
l i nk for toe and steeri ng wheel al i gnment.
SERVICE PROCEDURES
LUBRICATION
Peri odi c l ubri cati on of the steeri ng system compo-
nents i s requi red. Refer to Group 0, Lubri cati on And
Mai ntenance for the recommended mai ntenance
schedul e.
The fol l owi ng components must be l ubri cated:
• Ti e rod ends
• Drag l i nk
STEERING LINKAGE
The ti e rod end and bal l stud seal s shoul d be
i nspected duri ng al l oi l changes. I f a seal i s damaged,
i t shoul d be repl aced. Before i nstal l i ng a new seal ,
i nspect bal l stud at the throat openi ng. Check for
l ubri cant l oss, contami nati on, bal l stud wear or cor-
rosi on. I f these condi ti ons exi st, repl ace the ti e rod. A
repl acement seal can be i nstal l ed i f l ubri cant i s i n
good condi ti on. Otherwi se, a compl ete repl acement
bal l stud end shoul d be i nstal l ed.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the 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.
REMOVAL AND INSTALLATION
TIE ROD
REMOVAL
(1) Remove the cotter pi ns and nuts at the steer-
i ng knuckl e and drag l i nk (Fi g. 1).
(2) Remove the bal l studs wi th pul l er tool .
(3) I f necessary, l oosen the end cl amp bol ts and
remove the ti e rod ends from the tube.
Fig. 1 Steering Linkage
1 – COTTER PIN
2 – NUT
3 – DAMPENER
4 – PITMAN ARM
5 – WASHER
6 – TIE ROD
7 – DRAG LINK
19 - 22 STEERING TJ
INSTALLATION
(1) I f necessary, i nstal l the ti e rod ends i n the
tube. Posi ti on the ti e rod cl amp (Fi g. 2) and ti ghten
to 27 N·m (20 ft. l bs.).
(2) I nstal l the ti e rod on the drag l i nk and steeri ng
knuckl e.
(3) Ti ghten the bal l stud nut on the steeri ng
knuckl e to 47 N·m (35 ft. l bs.). Ti ghten the bal l stud
nut to drag l i nk to 47 N·m (35 ft. l bs.) torque. I nstal l
new cotter pi ns.
PITMAN ARM
REMOVAL
(1) Remove the cotter pi n and nut from the drag
l i nk at the pi tman arm.
(2) Remove the drag l i nk bal l stud from the pi t-
man arm wi th a pul l er.
(3) Remove the nut and washer from the steeri ng
gear shaft. Mark the pi tman shaft and pi tman arm
for i nstal l ati on reference. Remove the pi tman arm
from steeri ng gear wi th Pul l er C-4150A (Fi g. 3).
INSTALLATION
(1) Al i gn and i nstal l the pi tman arm on steeri ng
gear shaft.
(2) I nstal l the washer and nut on the shaft and
ti ghten the nut to 251 N·m (185 ft. l bs.).
(3) I nstal l drag l i nk bal l stud to pi tman arm.
I nstal l nut and ti ghten to 81 N·m (60 ft. l bs.). I nstal l
a new cotter pi n.
DRAG LINK
REMOVAL
(1) Remove the cotter pi ns and nuts at the steer-
i ng knuckl e and drag l i nk (Fi g. 1).
(2) Remove the steeri ng dampener bal l stud from
the drag l i nk wi th a pul l er tool .
(3) Remove the drag l i nk from the steeri ng
knuckl e wi th a pul l er tool . Remove the same for ti e
rod and pi tman arm.
(4) I f necessary, l oosen the end cl amp bol ts and
remove the ti e rod end from the l i nk.
INSTALLATION
(1) I nstal l the drag l i nk adjustment sl eeve and ti e
rod end. Posi ti on cl amp bol ts (Fi g. 2).
(2) Posi ti on the drag l i nk at the steeri ng l i nkage.
I nstal l the drag l i nk to the steeri ng knuckl e nut. Do
the same for the ti e rod and pi tman arm.
(3) Ti ghten the nut at the steeri ng knuckl e to 47
N·m (35 ft. l bs.). Ti ghten the pi tman nut to 81 N·m
(60 ft. l bs.) and ti e rod bal l stud nut to 47 N·m (35 ft.
l bs.). I nstal l new cotter pi ns and bend end 60°.
(4) I nstal l the steeri ng dampener onto the drag
l i nk and ti ghten the nut to 74 N·m (55 ft. l bs.).
I nstal l a new cotter pi n and bend end 60°.
Fig. 2 Tie Rod/Drag Link Clamp Bolt
1 – TIE ROD CLAMP
2 – DRAG LINK CLAMPS
Fig. 3 Pitman Arm Removal
1 – PITMAN ARM
2 – SPECIAL TOOL C-4150–A
3 – WRENCH
TJ STEERING 19 - 23
REMOVAL AND INSTALLATION (Continued)
STEERING DAMPENER
REMOVAL
(1) Pl ace the front wheel s i n a strai ght ahead posi -
ti on.
(2) Remove the steeri ng dampener retai ni ng nut
and bol t from the axl e bracket (Fi g. 1).
(3) Remove the cotter pi n and nut from the bal l
stud at the drag l i nk.
(4) Remove the steeri ng dampener bal l stud from
the drag l i nk usi ng C-3894-A pul l er.
INSTALLATION
(1) I nstal l the steeri ng dampener to the axl e
bracket and drag l i nk.
(2) I nstal l the steeri ng dampener bol t i n the axl e
bracket and ti ghten nut to 74 N·m (55 ft. l bs.).
(3) I nstal l the bal l stud nut at the drag l i nk and
ti ghten nut to 74 N·m (55 ft. l bs.). I nstal l a new cot-
ter pi n.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Pitman Arm
Shaft . . . . . . . . . . . . . . . . . 251 N·m (185 ft. l bs.)
Drag Link
Bal l Studs . . . . . . . . . . . . . . . 74 N·m (55 ft. l bs.)
Cl amp . . . . . . . . . . . . . . . . . . 49 N·m (36 ft. l bs.)
Tie Rod Ends
Bal l Studs . . . . . . . . . . . . . . . 74 N·m (55 ft. l bs.)
Cl amp . . . . . . . . . . . . . . . . . . 27 N·m (20 ft. l bs.)
Tie Rod
Bal l Stud . . . . . . . . . . . . . . . . 88 N·m (65 ft. l bs.)
Steering Damper
Frame . . . . . . . . . . . . . . . . . . 74 N·m (55 ft. l bs.)
Drag Li nk . . . . . . . . . . . . . . . 74 N·m (55 ft. l bs.)
SPECIAL TOOLS
STEERING LINKAGE
Puller C-3894–A
Remover Pitman C-4150A
19 - 24 STEERING TJ
REMOVAL AND INSTALLATION (Continued)
STEERING COLUMN
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION AND OPERATION
STEERING COLUMN
DESCRIPTION
The standard non-ti l t and ti l t steeri ng col umn has
been desi gned to be servi ced as an assembl y. The col -
umn i s connected to the steeri ng gear wi th an upper
and l ower shaft. The l ower shaft has a support bear-
i ng mounted to a bracket. The bracket mounts to the
frame rai l wi th two bol ts. These shafts and beari ng
are servi ceabl e. The key cyl i nder, swi tches, cl ock
spri ng, tri m shrouds and steeri ng wheel are servi ced
separatel y. On the non-ti l t col umn the upper mount-
i ng bracket i s al so servi ced separatel y.
SERVICE PRECAUTIONS
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to Group 8M and fol l ow al l WARNI NGS and
CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
REMOVAL AND INSTALLATION
STEERING COLUMN
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO GROUP 8M RESTRAINT SYS-
TEMS FOR SERVICE PROCEDURES. FAILURE TO
DO SO MAY RESULT IN ACCIDENTAL DEPLOY-
MENT OF THE AIRBAG AND POSSIBLE PERSONAL
INJURY.
CAUTION: Keep clock spring from turning during
removal and installation. Failure to do so may dam-
age the clock spring.
REMOVAL
(1) Posi ti on front wheel s straight ahead.
(2) Remove and i sol ate the negati ve ground cabl e
from the battery.
(3) Remove the ai rbag, refer to Group 8M
Restrai nt Systems for servi ce procedures.
NOTE: If equipped with cruise control, disconnect
clock spring harness from the cruise switch har-
ness on the steering wheel.
(4) Remove the steeri ng wheel wi th an appropri ate
pul l er (Fi g. 1).
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel before attempting to remove
the wheel. Failure to do so may damage the steer-
ing wheel.
(5) Turn i gni ti on cyl i nder to the on posi ti on and
remove cyl i nder by pressi ng rel ease through l ower
shroud access hol e (Fi g. 2).
(6) Remove knee bl ocker cover and knee bl ocker,
refer to Group 8E I nstrument Panel Systems.
(7) Remove screws from the l ower col umn shroud
(Fi g. 3) and remove the shroud.
TJ STEERING 19 - 25
(8) Remove the steeri ng coupl er bol t and col umn
mounti ng nuts (Fi g. 4) then l ower col umn off the
mounti ng studs.
(9) Remove upper col umn shroud (Fi g. 3).
(10) Di sconnect and remove the wi ri ng harness
from the col umn (Fi g. 5).
NOTE: If vehicle is equipped with automatic trans-
mission, remove shifter interlock cable. Refer to
Group 21 Transmission and Transfer Case for pro-
cedure.
(11) Remove col umn.
(12) Remove nut and bol t from the upper col umn
mounti ng bracket on non-ti l t col umn (Fi g. 6). Remove
the bracket from the col umn and note the mount-
ing location and orientation of the bracket.
(13) Remove cl ock spri ng (Fi g. 7), swi tches, (SKI M
i f equi pped) and i gni ti on key cyl i nder, refer to Group
8 El ectri cal for servi ce procedures.
INSTALLATION
(1) I nstal l upper col umn mounti ng bracket on non-
ti l t col umn. I nstal l the mounti ng bol t and ti ghten the
nut to 17 N·m (150 i n. l bs.).
(2) I nstal l swi tches, refer to Group 8 El ectri cal for
servi ce procedures.
Fig. 1 Steering Wheel
1 – PULLER
2 – STEERING WHEEL
Fig. 2 Key Cylinder Release Access Hole
1 – LOWER SHROUD
2 – RELEASE ACCESS HOLE
Fig. 3 Column Shrouds
1 – UPPER SHROUD
2 – LOWER SHROUD
Fig. 4 Steering Column Mounting
1 – STEERING COLUMN
2 – COUPLER
19 - 26 STEERING TJ
REMOVAL AND INSTALLATION (Continued)
(3) Al i gn and i nstal l col umn i nto the steeri ng cou-
pl er.
(4) I nstal l col umn harness and connect harness to
swi tches.
NOTE: If vehicle is equipped with automatic trans-
mission, install shifter interlock cable. Refer to
Group 21 Transmission and Transfer Case for
installation and adjustment.
(5) I nstal l upper col umn shrouds.
(6) I nstal l col umn onto the mounti ng studs.
(7) I nstal l mounti ng nuts and ti ghten to 23 N·m
(17 ft. l bs.).
(8) I nstal l steeri ng col umn coupl er bol t and ti ghten
to 49 N·m (36 ft. l bs.).
(9) Center the cl ock spri ng (i f necessary) and
i nstal l i t on the col umn, refer to Group 8 El ectri cal
for servi ce procedures.
(10) I nstal l l ower col umn shrouds and i nstal l
mounti ng screws.
(11) I nstal l i gni ti on cyl i nder.
(12) I nstal l knee bl ocker and knee bl ocker cover,
refer to Group 8E I nstrument Panel Systems.
(13) I nstal l steeri ng wheel and ti ghten nut to 54
N·m (40 ft. l bs.).
NOTE: If equipped with cruise control, connect
clock spring harness to cruise switch harness on
the steering wheel.
(14) I nstal l ai rbag, refer to Group 8M Restrai nt
Systems for servi ce procedures.
(15) I nstal l negati ve battery termi nal .
Fig. 5 Steering Column Harness
1 – COLUMN HARNESS
2 – STEERING COLUMN
Fig. 6 Non-Tilt Column
1 – NON-TILT COLUMN
2 – UPPER BRACKET
Fig. 7 Clock Spring
1 – CLOCKSPRING
2 – WIRE HARNESS
3 – TURN SIGNAL SWITCH LEVER
4 – STEERING COLUMN
5 – WIPER SWITCH LEVER
6 – LOCATING FINGERS
TJ STEERING 19 - 27
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Tilt Steering Column
Steeri ng Wheel Nut . . . . . . . . 54 N·m (40 ft. l bs.)
Mounti ng Nuts . . . . . . . . . . . 23 N·m (17 ft. l bs.)
Coupl er Bol t . . . . . . . . . . . . . . 49 N·m (36 ft. l bs.)
Non-Tilt Steering Column
Steeri ng Wheel Nut . . . . . . . . 54 N·m (40 ft. l bs.)
Mounti ng Nuts . . . . . . . . . . . 23 N·m (17 ft. l bs.)
Coupl er Bol t . . . . . . . . . . . . . . 49 N·m (36 ft. l bs.)
Upper Bracket Nut . . . . . . . 17 N·m (150 i n. l bs.)
19 - 28 STEERING TJ
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . . 1
NV3550 MANUAL TRANSMISSION . . . . . . . . . . . 40
AUTOMATIC TRANSMISSION— 30/32RH. . . . . . . 80
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . 210
AX5 MANUAL TRANSMISSION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . . 1
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL. . . . . . . . . . . . . . . . . . . . 3
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION NOISE. . . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT BEARING RETAINER SEAL. . . . . . . . . . . . 6
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . . . 6
DISASSEMBLY AND ASSEMBLY
ADAPTER/EXTENSION HOUSING AND
FRONT BEARING RETAINER . . . . . . . . . . . . . . . 7
SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 15
COUNTERSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . 28
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 29
SEMI-SYNCHRONIZED REVERSE IDLER
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CLEANING AND INSPECTION
AX5 MANUAL TRANSMISSION COMPONENTS . . 35
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIAL TOOLS
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DESCRIPTION AND OPERATION
AX5 MANUAL TRANSMISSION
DESCRIPTION
The AX5 i s a fi ve speed manual transmi ssi on wi th
fi fth gear bei ng the overdri ve range. An adapter
housi ng i s used to attach the transmi ssi on to the
transfer case on 4-wheel dri ve appl i cati ons. A stan-
dard styl e extensi on housi ng i s used for the 2-wheel
dri ve appl i cati ons. The shi ft mechani sm i s i ntegral to
the transmi ssi on assembl y and mounted i n the shi ft
tower porti on of the adapter/extensi on housi ng (Fi g.
1).
GEAR RATIOS
Gear rati os for the AX5 manual transmi ssi on are
as fol l ows:
• Fi rst gear: 3.93:1
• Second gear: 2.33:1
• Thi rd gear: 1.45:1
• Fourth gear: 1.00:1
• Fi fth gear: 0.85:1
• Reverse gear: 4.74:1
TRANSMISSION IDENTIFICATION
The AX5 i denti fi cati on code i s on the bottom sur-
face of the transmi ssi on case near the fi l l pl ug (Fi g.
2). The fi rst number i s year of manufacture. The sec-
ond and thi rd numbers i ndi cate month of manufac-
ture. The next seri es of numbers i s the transmi ssi on
seri al number.
OPERATION
The manual transmi ssi on recei ves power through
the cl utch assembl y from the engi ne. The cl utch di sc
i s spl i ned to the transmi ssi on i nput shaft and i s
turned at engi ne speed at al l ti mes that the cl utch i s
engaged. The i nput shaft i s connected to the trans-
mi ssi on countershaft through the mesh of fourth
speed gear on the i nput shaft and the fourth counter-
TJ TRANSMISSION AND TRANSFER CASE 21 - 1
shaft gear. At thi s poi nt, al l the transmi ssi on gears
are spi nni ng.
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. Thi s move-
ment moves the i nternal transmi ssi on shi ft compo-
nents to begi n the shi ft sequence. As the shi ft l ever
moves the sel ected shi ft rai l , the shi ft fork attached
to that rai l begi ns to move. The fork i s posi ti oned i n
a groove i n the outer ci rcumference of the synchro-
ni zer sl eeve. As the shi ft fork moves the synchroni zer
sl eeve, the synchroni zer begi ns to speed-up or sl ow
down the sel ected gear (dependi ng on whether we are
up-shi fti ng or down-shi fti ng). The synchroni zer does
thi s by havi ng the synchroni zer hub spl i ned to the
mai nshaft, or the countershaft i n some cases, and
movi ng the bl ocker ri ng i nto contact wi th the gear’s
fri cti on cone. As the bl ocker ri ng and fri cti on cone
come together, the gear speed i s brought up or down
to the speed of the synchroni zer. As the two speeds
match, the spl i nes on the i nsi de of the synchroni zer
sl eeve become al i gned wi th the teeth on the bl ocker
ri ng and the fri cti on cone and eventual l y wi l l sl i de
over the teeth, l ocki ng the gear to the mai nshaft, or
countershaft, through the synchroni zer.
LUBRICANT
DESCRIPTION
Recommended l ubri cant for AX5 transmi ssi ons i s
Mopar௡ 75W–90, API Grade GL–3 gear l ubri cant, or
equi val ent.
Correct l ubri cant l evel i s from the bottom edge, to
no more than 6 mm (1/4 i n.) bel ow the bottom edge of
the fi l l pl ug hol e.
The fi l l pl ug i s on the passenger si de of the
adapter housi ng (Fi g. 3). The drai n pl ug i s on the
bottom of the case.
Approxi mate dry fi l l l ubri cant capaci ty i s:
• 3.3 l i ters (3.49 quarts) for 4–wheel dri ve appl i ca-
ti ons.
Fig. 1 AX5 Manual Transmission
Fig. 2 Transmission Identification
1 – I. D. CODE ON CASE NEAR DRAIN PLUG
21 - 2 AX5 MANUAL TRANSMISSION TJ
DESCRIPTION AND OPERATION (Continued)
• 3.5 l i ters (3.70 quarts) for 2–wheel dri ve appl i ca-
ti ons.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the gear
case, i ntermedi ate pl ate and adaptor or extensi on
housi ng, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l probabl y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a non–recommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng the di sc to sl i p, grab, and/or chatter.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper, or contami nated l ubri cants. The con-
sequence of usi ng non–recommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd, and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Component damage, i ncorrect cl utch adjustment,
or a damaged cl utch pressure pl ate or di sc are addi -
ti onal probabl e causes of i ncreased shi ft effort. I ncor-
rect adjustment or a worn/damaged pressure pl ate or
di sc can cause i ncorrect rel ease. I f the cl utch probl em
i s advanced, gear cl ash duri ng shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear cl ash
when shi fti ng i nto any forward gear. I n some new or
rebui l t transmi ssi ons, new synchro ri ngs may tend to
sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n most
cases, thi s condi ti on wi l l decl i ne as the ri ngs wear–
i n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe, hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper, or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l ead to gear breakage.
REMOVAL AND INSTALLATION
TRANSMISSION
REMOVAL
(1) Shi ft transmi ssi on i nto fi rst or thi rd gear.
(2) Rai se and support vehi cl e on sui tabl e safety
stands.
(3) Support engi ne wi th adjustabl e jack stand.
Posi ti on wood bl ock between jack and oi l pan to
avoi d damagi ng pan.
(4) Remove crossmember/ski d pl ate.
(5) Di sconnect necessary exhaust system compo-
nents.
(6) Remove sl ave cyl i nder (Fi g. 4) from cl utch
housi ng.
(7) Mark rear propel l er shaft and rear axl e yokes
for i nstal l ati on al i gnment (Fi g. 5).
(8) Mark front propel l er shaft, axl e, and transfer
case yokes for i nstal l ati on al i gnment.
(9) Remove propel l er shaft(s).
(10) Uncl i p wi re harnesses from transmi ssi on and
transfer case.
Fig. 3 Fill Plug Location
1 – FILL PLUG LOCATION
TJ AX5 MANUAL TRANSMISSION 21 - 3
DESCRIPTION AND OPERATION (Continued)
(11) Di sconnect transfer case vent hose.
(12) Di sengage any wi re connectors attached to
transmi ssi on or transfer case components.
(13) Support transfer case wi th transmi ssi on jack.
(14) Secure transfer case to jack wi th safety
chai ns.
(15) Di sconnect transfer case shi ft l i nkage at
transfer case.
(16) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(17) Remove transfer case.
(18) Remove crankshaft posi ti on sensor (Fi g. 6).
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.
(19) Support transmi ssi on wi th transmi ssi on jack.
(20) Secure transmi ssi on to jack wi th safety
chai ns.
(21) Di sconnect rear cushi on and bracket from
transmi ssi on.
(22) Di sconnect transmi ssi on shi ft l ever as fol l ows:
(a) Lower transmi ssi on approxi matel y 7–8 cm (3
i n.) for access to shi ft l ever.
(b) Reach up and around transmi ssi on case and
unseat shi ft l ever dust boot from transmi ssi on shi ft
tower (Fi g. 7). Move boot upward on shi ft l ever for
access to retai ner that secures l ever i n shi ft tower.
(c) Reach up and around transmi ssi on case and
press shi ft l ever retai ner downward wi th fi nger
pressure. Turn retai ner countercl ockwi se to rel ease
i t.
(d) Li ft l ever and retai ner out of shi ft tower (Fi g.
7). Do not remove the shi ft l ever from the fl oor con-
sol e shi fter boots. Leave the l ever i n pl ace for
transmi ssi on i nstal l ati on.
(23) Remove cl utch housi ng brace rod.
(24) Remove cl utch housi ng-to-engi ne bol ts.
(25) Pul l transmi ssi on jack rearward unti l i nput
shaft cl ears cl utch. Then sl i de transmi ssi on out from
under vehi cl e.
(26) Remove cl utch rel ease beari ng, rel ease fork,
and retai ner cl i p.
Fig. 4 Slave Cylinder—Typical
1 – CLUTCH SLAVE CYLINDER
Fig. 5 Marking Propeller Shaft And Axle Yokes
1 – REFERENCE MARKS
Fig. 6 Crankshaft Position Sensor —2.5 and 4.0L
Engine
1 – ENGINE SPEED SENSOR
2 – GROMMET
3 – MOUNTING BOLT(S)
4 – LEFT REAR OF ENGINE
5 – TRANSMISSION
21 - 4 AX5 MANUAL TRANSMISSION TJ
REMOVAL AND INSTALLATION (Continued)
(27) Remove cl utch housi ng from transmi ssi on
(Fi g. 8).
INSTALLATION
(1) I nstal l cl utch housi ng on transmi ssi on. Ti ghten
housi ng bol ts to 46 N·m (34 ft. l bs.) torque (Fi g. 8).
(2) Lubri cate contact surfaces of rel ease fork pi vot
bal l stud and rel ease fork wi th hi gh temp grease.
(3) I nstal l rel ease beari ng, fork, and retai ner cl i p.
(4) Posi ti on and secure transmi ssi on on transmi s-
si on jack.
(5) Li ghtl y l ubri cate pi l ot beari ng and transmi s-
si on i nput shaft spl i nes wi th Mopar௡ hi gh temp
grease.
(6) Rai se transmi ssi on and al i gn transmi ssi on
i nput shaft and cl utch di sc spl i nes. Then sl i de trans-
mi ssi on i nto pl ace.
(7) I nstal l and ti ghten cl utch housi ng-to-engi ne
bol ts to the appropri ate torque: Be sure the hous-
ing is properly seated on engine block before
tightening bolts.
• Ti ghten 3/8” di ameter bol ts to 37 N·m (27
ft.l bs.).
• Ti ghten 7/16” di ameter bol ts to 58 N·m (43
ft.l bs.).
• Ti ghten M12 bol ts to 75 N·m (55 ft.l bs.).
(8) I nstal l cl utch housi ng brace rod.
(9) Lower transmi ssi on approxi matel y 7–8 cm (3
i n.) for access to shi ft tower. Be sure transmi ssi on i s
i n fi rst or thi rd gear.
(10) Reach up and around transmi ssi on and i nsert
shi ft l ever i n shi ft tower. Press l ever retai ner down-
ward and turn i t cl ockwi se to l ock i t i n pl ace. Then
i nstal l l ever dust boot on shi ft tower.
(11) I nstal l fasteners to hol d rear cushi on and
bracket to transmi ssi on. Then ti ghten transmi ssi on-
to-rear support bol ts/nuts to 54 N·m (40 ft. l bs.)
torque.
(12) I nstal l rear crossmember. Ti ghten crossmem-
ber-to-frame bol ts to 41 N·m (31 ft. l bs.) torque.
(13) Remove support stands from engi ne and
transmi ssi on.
(14) I nstal l and connect crankshaft posi ti on sensor.
(15) Posi ti on transfer case on transmi ssi on jack.
(16) Secure transfer case to jack wi th safety
chai ns.
(17) Rai se transfer case and al i gn transfer case
i nput shaft to the transmi ssi on output shaft.
(18) Sl i de transfer case forward unti l case i s
seated on transmi ssi on.
(19) I nstal l nuts to attach transfer case to trans-
mi ssi on. Ti ghten transfer case-to-transmi ssi on nuts
to 35 N·m (26 ft. l bs.) torque.
(20) Connect transfer case shi ft l i nkage at transfer
case.
(21) Connect transfer case vent hose.
(22) Secure wi re harnesses i n cl i ps/ti e straps on
transmi ssi on and transfer case.
Fig. 7 Removing/Installing Shift Lever
1 – SHIFT LEVER RETAINER
2 – DUST BOOT
3 – SHIFT TOWER
Fig. 8 Clutch Housing
1 – HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.)
2 – CLUTCH HOUSING
3 – TRANSMISSION
TJ AX5 MANUAL TRANSMISSION 21 - 5
REMOVAL AND INSTALLATION (Continued)
(23) Engage wi re connectors attached to al l neces-
sary transmi ssi on or transfer case components.
(24) I nstal l rear propel l er shaft sl i p yoke to trans-
mi ssi on or transfer case output shaft.
(25) Al i gn marks on rear propel l er shaft and rear
axl e yokes (Fi g. 9).
(26) I nstal l and ti ghten propel l er shaft U–joi nt
cl amp bol ts to 19 N·m (170 i n. l bs.) torque.
(27) Al i gn marks on front propel l er shaft, axl e,
and transfer case yokes.
(28) I nstal l and ti ghten propel l er shaft U–joi nt
cl amp bol ts to 19 N·m (170 i n. l bs.) torque.
(29) I nstal l sl ave cyl i nder i n cl utch housi ng.
(30) I nstal l ski d pl ate, i f equi pped. Ti ghten bol ts to
42 N·m (31 ft. l bs.) torque. Ti ghten stud nuts to 17
N·m (150 i n. l bs.) torque.
(31) Fi l l transmi ssi on and transfer case, i f
equi pped, wi th recommended l ubri cants. Refer to the
Lubri cant secti on of the appropri ate component for
correct fl ui d.
(32) Lower vehi cl e.
FRONT BEARING RETAINER SEAL
REMOVAL
(1) Remove rel ease beari ng and l ever from the
transmi ssi on.
(2) Remove the bol ts hol di ng the front beari ng
retai ner to the transmi ssi on case.
(3) Remove the front beari ng retai ner from the
transmi ssi on case.
(4) Usi ng a sui tabl e pry tool , remove the front
beari ng retai ner seal .
INSTALLATION
(1) Usi ng Tool Handl e C-4171 and Seal I nstal l er
8211, i nstal l new seal i n to the front beari ng retai ner
(Fi g. 10).
(2) Remove any resi dual gasket materi al from the
seal i ng surfaces of the beari ng retai ner and the
transmi ssi on case.
(3) I nstal l new front beari ng retai ner gasket to the
front beari ng retai ner.
(4) I nstal l the front beari ng retai ner onto the
transmi ssi on case.
(5) I nstal l the bol ts to hol d the beari ng retai ner
onto the transmi ssi on case.
(6) Ti ghten the bol ts to 17 N·m (12 ft. l bs.).
(7) I nstal l rel ease beari ng and l ever onto the
transmi ssi on.
ADAPTER HOUSING SEAL
REMOVAL
(1) Hoi st and support vehi cl e.
(2) Remove transfer case.
(3) Usi ng a sui tabl e pry tool , or a sl i de hammer
mounted screw, remove the adapter housi ng seal
(Fi g. 11).
INSTALLATION
(1) Cl ean seal bore of adapter housi ng of any
resi dual seal er materi al from ori gi nal seal .
Fig. 9 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks
1 – REFERENCE MARKS
Fig. 10 Install Front Bearing Retainer Seal
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL 8211 (AX5) OR 8209 (AX15)
21 - 6 AX5 MANUAL TRANSMISSION TJ
REMOVAL AND INSTALLATION (Continued)
(2) Usi ng Tool Handl e C-4171 and Seal I nstal l er
8208, i nstal l new seal so that the seal i s l ocated 0 Ϯ
0.2 mm (0 Ϯ 0.008 i n.) to the seal bore face of
adapter housi ng (Fi g. 12).
(3) I nstal l transfer case.
(4) Check and add fl ui d to transmi ssi on as neces-
sary. Refer to the Recommended Lubri cant secti on for
proper fl ui d requi rements.
(5) Lower vehi cl e.
DISASSEMBLY AND ASSEMBLY
ADAPTER/EXTENSION HOUSING AND FRONT
BEARING RETAINER
DISASSEMBLY
(1) Drai n transmi ssi on l ubri cant, i f necessary.
(2) Remove rel ease beari ng and l ever.
(3) Remove cl utch housi ng bol ts and remove hous-
i ng (Fi g. 15).
(4) Remove vehi cl e speed sensor and speedometer
adapter, i f necessary.
(5) Remove bol ts hol di ng shi ft tower to transmi s-
si on case.
(6) Remove shi ft tower from transmi ssi on case
(Fi g. 13).
(7) Remove shi ft tower gasket from shi ft tower or
transmi ssi on case (Fi g. 14).
Fig. 11 Remove Adapter Housing Seal
1 – ADAPTER HOUSING OIL SEAL
Fig. 12 Install Adapter Housing Seal
1 – SPECIAL TOOL 8208
2 – ADAPTER HOUSING
3 – SPECIAL TOOL C-4171
Fig. 13 Remove Shift Tower
1 – SHIFT TOWER
2 – ADAPTER/EXTENSION HOUSING
Fig. 14 Remove Shift Tower Gasket
1 – SHIFT TOWER
2 – GASKET
TJ AX5 MANUAL TRANSMISSION 21 - 7
REMOVAL AND INSTALLATION (Continued)
(8) Remove detent bal l pl ug (Fi g. 16).
(9) Remove detent spri ng and bal l wi th penci l
magnet (Fi g. 17), (Fi g. 18).
(10) Remove shi ft arm retai ner bol t (Fi g. 19).
(11) Remove shi ft arm restri ctor pi ns (Fi g. 20).
NOTE: The restrictor pins are not interchangeable
and are color coded. Note which color restrictor pin
is removed from each side of the transmission and
be sure to install it into the same location.
(12) Remove shi ft l ever shaft pl ug (Fi g. 21).
(13) Remove shi fter shaft wi th l arge magnet (Fi g.
22).
Fig. 15 Clutch Housing
1 – HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.)
2 – CLUTCH HOUSING
3 – TRANSMISSION
Fig. 16 Remove Detent Ball Plug
1 – TORX BIT
2 – DETENT BALL PLUG
Fig. 17 Remove Detent Spring
1 – PENCIL MAGNET
2 – DETENT BALL SPRING
Fig. 18 Remove Detent Ball
1 – PENCIL MAGNET
2 – SHIFT DETENT BALL
21 - 8 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(14) Remove the shi ft arm from the adapter hous-
i ng.
(15) Remove adapter/extensi on housi ng bol ts.
(16) Loosen adapter/extensi on housi ng by tappi ng
i t l oose wi th pl asti c mal l et (Fi g. 23).
(17) Remove adapter/extensi on housi ng (Fi g. 24).
(18) On 4x2 transmi ssi ons;
(a) Remove speedometer gear retai ni ng snap-
ri ng from output shaft.
(b) Remove speedometer gear from output shaft
and remove speedometer gear l ock bal l from output
shaft.
(c) Remove speedometer dri ve gear l ocati ng
snap-ri ng (Fi g. 25).
(19) Remove the bol ts hol di ng the front beari ng
retai ner to the transmi ssi on case.
(20) Remove the beari ng retai ner from transmi s-
si on case (Fi g. 26).
(21) Remove i nput shaft beari ng snap-ri ng (Fi g.
27).
(22) Remove countershaft front beari ng snap-ri ng.
Fig. 19 Shift Arm Retainer Bolt Removal
1 – RETAINER BOLT
2 – SHIFT ARM
Fig. 20 Shift Arm Restrictor Pins
1 – RESTRICTOR PINS
Fig. 21 Removing Shift Lever Shaft Plug
1 – SHIFT LEVER SHAFT PLUG
Fig. 22 Remove Shifter Shaft
1 – SHIFT ARM SHAFT
2 – LARGE MAGNET
TJ AX5 MANUAL TRANSMISSION 21 - 9
DISASSEMBLY AND ASSEMBLY (Continued)
(23) Separate i ntermedi ate pl ate and transmi ssi on
case by tappi ng them l oose wi th pl asti c mal l et (Fi g.
28).
(24) Separate the i ntermedi ate pl ate from the
transmi ssi on case (Fi g. 29).
ASSEMBLY
(1) Remove any resi dual seal er from transmi ssi on
case, i ntermedi ate pl ate, and adapter/extensi on hous-
i ng.
(2) Appl y a 1/8 to 3/16 i nch wi de bead of Threeb-
ond௡ Li qui d Gasket TB1281, P/N 83504038, as
shown, maki ng sure to keep seal er bead to i nsi de of
bol t hol es (Fi g. 30).
(3) Al i gn geartrai n and shi ft rai l s wi th mati ng
hol es i n transmi ssi on case and i nstal l transmi ssi on
case to the i ntermedi ate pl ate (Fi g. 31). Veri fy that
the transmi ssi on case i s seated on the i ntermedi ate
pl ate l ocati ng pi ns.
Fig. 23 Loosen Adapter/Extension Housing
1 – INTERMEDIATE PLATE
2 – ADAPTER HOUSING
3 – RUBBER FACED MALLET
Fig. 24 Remove Adapter/Extension Housing–Typical
1 – ADAPTER HOUSING
2 – INTERMEDIATE PLATE
Fig. 25 Speedometer Drive Gear Assembly
1 – SNAP RING
2 – LOCK BALL
3 – SNAP RING
4 – OUTPUT SHAFT GROOVES
5 – SPEEDOMETER GEAR
Fig. 26 Remove Front Bearing Retainer
1 – FRONT BEARING RETAINER
21 - 10 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(4) I nstal l new front beari ng snap ri ngs (Fi g. 32).
(5) I nstal l front beari ng retai ner gasket to front
beari ng retai ner.
(6) I nstal l the front beari ng retai ner (Fi g. 33) and
ti ghten bol ts to 17 N·m (12 ft. l bs.).
(7) On 4x2 transmi ssi ons;
(a) I nstal l speedometer dri ve gear l ocati ng snap-
ri ng (Fi g. 34).
(b) I nstal l speedometer gear l ock bal l i n output
shaft and i nstal l speedometer gear onto output
shaft.
(c) I nstal l speedometer gear retai ni ng snap-ri ng
onto output shaft.
Fig. 27 Remove Input Shaft Bearing Snap-ring
1 – SNAP RING PLIERS
2 – INPUT SHAFT
3 – INPUT SHAFT BEARING SNAP RING
Fig. 28 Separate Intermediate Plate and
Transmission Case
1 – INTERMEDIATE PLATE
2 – RUBBER MALLET
3 – GEAR CASE
Fig. 29 Remove Intermediate Plate from
Transmission Case
1 – GEAR CASE
2 – INTERMEDIATE PLATE
Fig. 30 Apply Sealer to Transmission Gear Case
1 – SEALER BEAD (1/8” - 3/16” WIDE)
2 – GEAR CASE
TJ AX5 MANUAL TRANSMISSION 21 - 11
DISASSEMBLY AND ASSEMBLY (Continued)
(8) Appl y a 1/8 to 3/16 i nch wi de bead of Threeb-
ond௡ Li qui d Gasket TB1281, P/N 83504038, to seal -
i ng surface of adapter/extensi on housi ng, maki ng
sure to keep seal er bead to i nsi de of bol t hol es.
(9) I nstal l adapter or extensi on housi ng on i nter-
medi ate pl ate (Fi g. 35). Ti ghten housi ng bol ts to 34
N·m (25 ft. l bs.) torque.
(10) Posi ti on shi ft arm i n shi fter tower openi ng of
adapter or extensi on housi ng (Fi g. 36). Be sure that
the shi fter arm i s engaged i nto the shi ft rai l s.
(11) Start shi fter arm shaft i n hol e i n back of
adapter or extensi on housi ng. Al i gn shi ft arm and
shi fter arm shaft and i nsert shi fter arm shaft
through the shi fter arm and i nto the forward porti on
of the adapter or extensi on housi ng (Fi g. 37).
Fig. 31 Install Transmission Gear Case to the
Intermediate Plate
1 – GEAR CASE
2 – INTERMEDIATE PLATE
Fig. 32 Install Front Bearing Snap-rings
1 – FRONT BEARING SNAP RINGS
Fig. 33 Install Front Bearing Retainer
1 – FRONT BEARING RETAINER
Fig. 34 Speedometer Drive Gear Assembly
1 – SNAP RING
2 – LOCK BALL
3 – SNAP RING
4 – OUTPUT SHAFT GROOVES
5 – SPEEDOMETER GEAR
21 - 12 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Rotate the shi fter arm shaft unti l the hol e i n
the shi ft arm i s al i gned wi th the hol e i n the shaft.
(13) I nstal l the shi ft arm retai ner bol t and ti ghten
to 38 N·m (28 ft. l bs.) (Fi g. 38).
(14) I nstal l and ti ghten shi fter arm shaft pl ug to
18 N·m (13 ft. l bs.) torque (Fi g. 39).
Fig. 35 Install Adapter/Extension Housing–Typical
1 – ADAPTER HOUSING
2 – INTERMEDIATE PLATE
Fig. 36 Position Shift Arm in Adapter or Extension
Housing
1 – SHIFT ARM
Fig. 37 Install Shifter Arm Shaft
1 – SHIFT ARM
2 – ADAPTER OR EXTENSION HOUSING
Fig. 38 Install Shift Arm Retainer Bolt
1 – RETAINER BOLT
2 – SHIFT ARM
TJ AX5 MANUAL TRANSMISSION 21 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(15) I nstal l shi ft restri ctor pi ns i n shi ft tower and
ti ghten to 27 N·m (20 ft. l bs.) (Fi g. 40).
NOTE: The restrictor pins are not interchangeable
and are color coded. Be sure to install the pin into
the same location from which it was removed.
(16) I nstal l shi ft detent bal l i n detent openi ng of
case (Fi g. 41).
(17) I nstal l detent spri ng i n case (Fi g. 42).
(18) I nstal l detent pl ug and ti ghten to 19 N·m (14
ft. l bs.) (Fi g. 43).
(19) I nstal l shi ft tower gasket onto shi ft tower.
(20) I nstal l the shi ft tower oi l defl ector and gasket
onto the adapter or extensi on housi ng.
(21) I nstal l shi ft tower onto transmi ssi on case
(Fi g. 44).
(22) I nstal l bol ts to hol d shi ft tower to transmi s-
si on case. Ti ghten tower bol ts to 18 N·m (13 ft. l bs.)
torque.
(23) I nstal l new metal o-ri ng onto the backup l amp
swi tch.
(24) I nstal l backup l amp swi tch (Fi g. 45). Ti ghten
swi tch to 44 N·m (32.5 ft. l bs.) torque.
Fig. 39 Shifter Arm Shaft Plug Installation
1 – SHAFT PLUG
Fig. 40 Install Shifter Restrictor Pins
1 – RESTRICTOR PINS
Fig. 41 Install Detent Ball
1 – PENCIL MAGNET
2 – SHIFT DETENT BALL
Fig. 42 Install Detent Spring
1 – PENCIL MAGNET
2 – DETENT BALL SPRING
21 - 14 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(25) I nstal l new seal i n adapter/extensi on housi ng.
(26) I nstal l vehi cl e speed sensor, i f necessary.
(27) I nstal l cl utch housi ng, rel ease beari ng, rel ease
fork and retai ner cl i p.
SHIFT MECHANISM AND GEARTRAIN
DISASSEMBLY
(1) I nstal l sui tabl e bol ts and washers i n i ntermedi -
ate pl ate (Fi g. 46). Then cl amp pl ate and gear assem-
bl y i n vi se. Use enough washers to prevent bol ts
from touchi ng. Al so be sure vi se jaws are cl amped on
bol t heads.
(2) Remove countershaft fi fth gear retai ni ng snap-
ri ng (Fi g. 47).
(3) Remove bol t hol di ng fi fth gear shi ft fork to
shi ft rai l (Fi g. 48).
Fig. 43 Install Detent Ball Plug
1 – TORX BIT
2 – DETENT BALL PLUG
Fig. 44 Install Shift Tower
1 – SHIFT TOWER
2 – ADAPTER/EXTENSION HOUSING
Fig. 45 Install Backup Lamp Switch
1 – SHIFT TOWER
2 – BACKUP LAMP SWITCH
Fig. 46 Positioning Intermediate Plate In Vise
1 – INTERMEDIATE PLATE
2 – BOLTS
TJ AX5 MANUAL TRANSMISSION 21 - 15
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Remove fi fth gear bl ocker ri ng from counter-
shaft assembl y wi th Pul l er L-4407 (Fi g. 49).
(5) Remove fi fth gear synchro ri ng (Fi g. 50).
(6) Remove the countershaft fi fth gear assembl y
from countershaft (Fi g. 51).
(7) Remove fi fth gear thrust ri ng from counter-
shaft (Fi g. 52).
(8) Remove fi fth gear thrust ri ng l ock bal l from
countershaft (Fi g. 53).
NOTE: There are many lock balls, check balls,
interlock balls, and interlock pins used in various
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.
Fig. 47 Remove Fifth Gear Snap-ring
1 – FIFTH GEAR SNAP RING (SELECT FIT)
Fig. 48 Remove Shift Fork Retainer Bolt
1 – SHIFT FORK RETAINER BOLT
2 – FIFTH GEAR SHIFT RAIL
3 – FIFTH GEAR SHIFT FORK
Fig. 49 Remove Fifth Gear Blocker Ring
1 – FIFTH GEAR BLOCKER RING
Fig. 50 Remove Fifth Gear Synchro Ring
1 – FIFTH GEAR SYNCHRO RING
21 - 16 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(9) Remove bol t hol di ng reverse i dl er gear shaft
l ock pl ate to the i ntermedi ate pl ate.
(10) Remove reverse i dl er gear shaft and reverse
i dl er gear assembl y (Fi g. 54).
NOTE: Be sure to retrieve the pin and compression
spring from the reverse idler shaft.
(11) Remove bol ts hol di ng output shaft rear bear-
i ng retai ner to the i ntermedi ate pl ate and remove
retai ner (Fi g. 55).
(12) Remove bol ts hol di ng 1–2 and 3–4 shi ft forks
to the shi ft rai l s (Fi g. 56) and di scard bol ts.
(13) Remove bol ts hol di ng reverse shi ft arm
bracket to i ntermedi ate pl ate (Fi g. 57).
Fig. 51 Remove Fifth Gear and Synchro Assembly
1 – FIFTH GEAR SYNCHRO SLEEVE ASSEMBLY
2 – COUNTER FIFTH GEAR
Fig. 52 Remove Fifth Gear Thrust Ring
1 – LOCK BALL NOTCH
2 – FIFTH GEAR THRUST RING
Fig. 53 Remove Fifth Gear Thrust Ring Lock Ball
1 – PENCIL MAGNET
2 – CLUSTER GEAR
3 – LOCK BALL RECESS
4 – THRUST RING LOCK BALL
Fig. 54 Remove Reverse Idler Shaft
1 – REVERSE IDLER SHAFT
TJ AX5 MANUAL TRANSMISSION 21 - 17
DISASSEMBLY AND ASSEMBLY (Continued)
(14) Remove snap-ri ng hol di ng output shaft rear
beari ng i nto the i ntermedi ate pl ate (Fi g. 58).
(15) Remove countershaft rear beari ng snap-ri ng.
(16) Wi th ai d of an assi stant, support the mai n-
shaft and countershaft. Tap on the rear of the mai n-
shaft and countershaft wi th a sui tabl e pl asti c mal l et.
Thi s wi l l rel ease the countershaft from the counter-
shaft rear beari ng and the mai nshaft rear beari ng
from the i ntermedi ate pl ate. The countershaft wi l l
rel ease from the countershaft beari ng fi rst and can
be removed by movi ng the countershaft rearward and
downward (Fi g. 59).
(17) Remove the mai nshaft by movi ng the mai n-
shaft forward unti l the mai nshaft rear beari ng i s
cl ear of the i ntermedi ate pl ate and then rotati ng the
mai nshaft downward out of the shi ft forks (Fi g. 60).
(18) Remove the 3–4 shi ft fork from the 3–4 shi ft
rai l (Fi g. 61).
(19) Remove the snap-ri ng from near the end of
the 1–2 shi ft rai l to al l ow the removal of the 1–2
shi ft fork.
(20) Remove the 1–2 shi ft fork from the 1–2 and
the 3–4 shi ft rai l s (Fi g. 62).
Fig. 55 Remove Output Shaft Rear Bearing Retainer
1 – OUTPUT SHAFT REAR BEARING RETAINER
Fig. 56 Remove Shift Fork To Shift Rail Bolts
1 – 1–2 SHIFT FORK
2 – 3–4 SHIFT FORK
Fig. 57 Remove Reverse Shift Arm Bracket Bolts
1 – REVERSE SHIFT ARM BOLTS
Fig. 58 Remove Output Shaft Rear Bearing
Snap-ring
1 – OUTPUT SHAFT REAR BEARING SNAP-RING
2 – COUNTERSHAFT REAR BEARING SNAP-RING
21 - 18 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(21) Remove threaded pl ugs from i ntermedi ate
pl ate. Then remove l ock bal l and spri ng from pl ug
hol es wi th penci l magnet (Fi g. 63). Note that the bot-
tom spri ng i s shorter i n l ength than the other two
spri ngs.
(22) Remove the i ntermedi ate pl ate from the vi se,
rotate the pl ate 180°, and rei nstal l the pl ate i n the
vi se usi ng the same bol t and washer mounti ng set-
up.
CAUTION: The interlock balls and pins are different
sizes and shapes. Be sure to correctly identify
which position an item is removed from to ensure
that it is reinstalled in the same location.
Fig. 59 Remove Countershaft and Countershaft
Rear Bearing
1 – INPUT SHAFT
2 – INTERMEDIATE PLATE
3 – OUTPUT SHAFT
4 – COUNTERSHAFT
5 – COUNTERSHAFT REAR BEARING
Fig. 60 Remove Mainshaft
1 – SHIFT FORKS
2 – MAINSHAFT
Fig. 61 Remove 3–4 Shift Fork
1 – 3–4 SHIFT FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 SHIFT RAIL
4 – 1–2 SHIFT FORK
Fig. 62 Remove 1–2 Shift Fork
1 – 1–2 SHIFT FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 SHIFT RAIL
TJ AX5 MANUAL TRANSMISSION 21 - 19
DISASSEMBLY AND ASSEMBLY (Continued)
(23) Remove fi fth gear shi ft rai l (Fi g. 64).
(24) Remove fi fth gear check bal l (Fi g. 65) and
i nterl ock pi n.
(25) Remove reverse shi ft head and rai l assembl y
(Fi g. 66).
(26) Remove snap-ri ng hol di ng reverse shi ft rai l
i nto i ntermedi ate pl ate.
(27) Remove reverse shi ft rai l and reverse shi ft
fork and arm assembl y from i ntermedi ate pl ate (Fi g.
67).
(28) Remove i nterl ock pi n from reverse shi ft rai l
(Fi g. 68).
(29) Remove reverse el ongated check bal l (Fi g. 69).
(30) Remove snap-ri ng on 3–4 shi ft rai l .
(31) Remove 1–2 shi ft rai l from i ntermedi ate pl ate.
(32) Remove i nterl ock pi n from 1–2 shi ft rai l (Fi g.
70).
Fig. 63 Remove Lock Ball And Spring
1 – THREADED PLUGS
2 – LOCK BALL
3 – SPRING
4 – PENCIL MAGNET
Fig. 64 Remove Fifth Gear Shift Rail
1 – INTERMEDIATE PLATE
2 – FIFTH GEAR SHIFT RAIL
Fig. 65 Remove Fifth Gear Check Ball
1 – FIFTH GEAR CHECK BALL
Fig. 66 Remove Reverse Shift Head And Rail
Assembly
1 – REVERSE SHIFT HEAD AND RAIL ASSEMBLY
21 - 20 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(33) Remove 1–2 shi ft rai l el ongated check bal l
from i ntermedi ate pl ate (Fi g. 71).
(34) Remove 3–4 shi ft rai l from i ntermedi ate pl ate.
ASSEMBLY
Refer to (Fi g. 72) whi l e assembl i ng and i nstal l i ng
the shi ft rai l components. Al so, veri fy that al l shi ft
rai l components are i n thei r neutral posi ti on when
i nstal l i ng the check bal l s and i nterl ock pi ns.
Fig. 67 Remove Reverse Shift Rail
1 – REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY
Fig. 68 Remove Interlock Pin From Reverse Shift
Rail
1 – REVERSE SHIFT RAIL
2 – INTERLOCK PIN
Fig. 69 Remove Reverse Check Ball
1 – REVERSE CHECK BALL
Fig. 70 Remove 1–2 Shift Rail Interlock Pin
1 – INTERLOCK PIN
2 – 1–2 SHIFT RAIL
TJ AX5 MANUAL TRANSMISSION 21 - 21
DISASSEMBLY AND ASSEMBLY (Continued)
(1) I nstal l the 3–4 shi ft rai l i nto the i ntermedi ate
pl ate.
(2) I nstal l the 1–2 el ongated check bal l i nto the
i ntermedi ate pl ate (Fi g. 73).
(3) I nstal l the i nterl ock pi n i nto the 1–2 shi ft rai l
(Fi g. 74).
(4) I nstal l the 1–2 shi ft rai l i nto the i ntermedi ate
pl ate.
(5) I nstal l snap-ri ng onto 3–4 shi ft rai l .
(6) I nstal l the reverse check bal l i nto the i nterme-
di ate pl ate (Fi g. 75).
(7) I nstal l the i nterl ock pi n i nto the reverse shi ft
rai l (Fi g. 76).
(8) Assembl e the reverse arm bracket to the
reverse fork (Fi g. 77).
(9) I nstal l reverse shi ft rai l i nto i ntermedi ate pl ate
and posi ti on reverse arm bracket to i ntermedi ate
pl ate (Fi g. 78).
(10) I nstal l snap-ri ng onto reverse shi ft rai l (Fi g.
79).
(11) I nstal l reverse shi ft head and rai l assembl y
i nto the i ntermedi ate pl ate.
Fig. 71 Remove 1–2 Check Ball
1 – 1–2 CHECK BALL
2 – 3–4 SHIFT RAIL
Fig. 72 Shift Rail Components
1 – 3–4 FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 FORK
4 – INTERMEDIATE PLATE
5 – FIFTH GEAR FORK
6 – FIFTH GEAR SHIFT RAIL
7 – 1–2 SHIFT RAIL
8 – REVERSE SHIFT RAIL
21 - 22 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(12) I nstal l the fi fth gear i nterl ock bal l and check
bal l (Fi g. 80).
(13) I nstal l fi fth gear shi ft rai l (Fi g. 81).
Fig. 73 Install 1–2 Check Ball
1 – 1–2 CHECK BALL
2 – 3–4 SHIFT RAIL
Fig. 74 Install 1–2 Shift Rail Interlock Pin
1 – INTERLOCK PIN
2 – 1–2 SHIFT RAIL
Fig. 75 Install Reverse Check Ball
1 – REVERSE CHECK BALL
Fig. 76 Install Reverse Interlock Pin
1 – REVERSE SHIFT RAIL
2 – INTERLOCK PIN
TJ AX5 MANUAL TRANSMISSION 21 - 23
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 77 Install Reverse Arm Bracket to Fork
1 – REVERSE SHIFT FORK
2 – REVERSE ARM BRACKET
Fig. 78 Install Reverse Shift Rail
1 – REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY
Fig. 79 Install Reverse Snap-ring
1 – SNAP RING
2 – REVERSE SHIFT RAIL
Fig. 80 Install Fifth Gear Check Ball
1 – FIFTH GEAR CHECK BALL
21 - 24 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(14) Remove the i ntermedi ate pl ate from the vi se,
rotate the pl ate 180°, and rei nstal l the pl ate i n the
vi se usi ng the same bol t and washer mounti ng set-
up.
(15) I nstal l the shi ft rai l detent bal l s i n the i nter-
medi ate pl ate.
(16) I nstal l the shi ft rai l detent spri ngs i n the
i ntermedi ate pl ate. Note that the bottom detent
spri ng i s shorter than the others.
(17) I nstal l the shi ft rai l detent pl ugs i n the i nter-
medi ate pl ate.
(18) I nstal l the 1–2 shi ft fork onto the 1–2 and 3–4
shi ft rai l s (Fi g. 82).
(19) I nstal l the snap-ri ng onto the 1–2 shi ft rai l .
(20) I nstal l the 3–4 shi ft fork onto the 3–4 shi ft
rai l (Fi g. 83).
(21) I nstal l mai nshaft i nto the i ntermedi ate pl ate
by gui di ng the output shaft through openi ng i n i nter-
medi ate pl ate unti l the shi ft forks are al i gned wi th
the appropri ate synchroni zer sl eeves. The mai nshaft
rear beari ng wi l l be started i n the i ntermedi ate pl ate
but not ful l y dri ven i n at thi s poi nt.
(22) Whi l e an assi stant supports the mai nshaft,
al i gn rear of countershaft wi th i nner race of counter-
shaft rear beari ng.
(23) Rai se countershaft upward unti l gears mesh
wi th the mati ng gears on the mai nshaft.
(24) Usi ng a sui tabl e rubber mal l et, tap on the
i nput shaft and the front of the countershaft equal l y
to i nstal l the mai nshaft rear beari ng i nto the i nter-
medi ate pl ate and the rear of the countershaft i nto
the rear countershaft beari ng. I t may be necessary to
occasi onal l y hol d the countershaft i nto the i ntermedi -
ate pl ate and tap the countershaft rear beari ng onto
the countershaft and i nto the i ntermedi ate pl ate.
(25) I nstal l snap-ri ngs onto the rear mai nshaft and
countershaft beari ngs.
(26) I nstal l the bol ts to hol d the reverse shi ft arm
bracket to the i ntermedi ate pl ate.
(27) I nstal l new bol ts to hol d the shi ft forks to the
shi ft rai l s (Fi g. 84).
(28) Posi ti on the mai nshaft rear beari ng retai ner
over the output shaft and onto the i ntermedi ate
pl ate.
Fig. 81 Install Fifth Gear Shift Rail
1 – INTERMEDIATE PLATE
2 – FIFTH GEAR SHIFT RAIL
Fig. 82 Install 1–2 Shift Fork
1 – 1–2 SHIFT FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 SHIFT RAIL
Fig. 83 Install 3–4 Shift Fork
1 – 3–4 SHIFT FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 SHIFT RAIL
4 – 1–2 SHIFT FORK
TJ AX5 MANUAL TRANSMISSION 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)
(29) I nstal l new bol ts to hol d the beari ng retai ner
to the i ntermedi ate pl ate.
(30) Move the reverse shi ft arm i nto the reverse
gear posi ti on. The reverse gear posi ti on i s wi th the
arm moved away from the i ntermedi ate pl ate (Fi g.
85).
(31) I nstal l the reverse i dl er gear assembl y i nto
posi ti on on the mai nshaft and reverse shi ft arm.
(32) I nstal l the compressi on spri ng and pi n i nto
the reverse i dl er gear shaft (Fi g. 86).
(33) I nstal l the reverse i dl er shaft through the
i ntermedi ate pl ate and reverse i dl er gear assembl y
(Fi g. 87) unti l the i dl er shaft pi n contacts the gear
assembl y. Make sure that the notched cut-out i n the
i dl er shaft i s to the rear of the transmi ssi on.
(34) Al i gn the pi n wi th the al i gnment notch i n the
reverse i dl er gear assembl y (Fi g. 88). The al i gnment
notch i n the reverse i dl er gear race/hub i s a smal l
rel i ef cut above one of the mai n l ongi tudi nal sl ots. Be
sure that the pi n i s al i gned wi th the proper sl ot, the
opposi te sl ot has an oi l drai n hol e whi ch the pi n wi l l
drop i nto. The assembl y wi l l then be l ocked onto the
shaft and wi l l need to be di sassembl ed i n order to be
removed.
(35) Depress compressi on spri ng and pi n i n
reverse i dl er gear shaft (Fi g. 89).
(36) I nstal l the reverse i dl er gear shaft the
remai nder of the way through the reverse i dl er gear
assembl y.
(37) Posi ti on the reverse i dl er gear shaft l ock pl ate
onto the i ntermedi ate pl ate.
(38) I nstal l a new bol t to hol d the i dl er gear shaft
l ock pl ate to the i ntermedi ate pl ate.
Fig. 84 Install Shift Fork Bolts
1 – 1–2 SHIFT FORK
2 – 3–4 SHIFT FORK
Fig. 85 Reverse Shift Arm Position
1 – REVERSE SHIFT ARM
2 – INTERMEDIATE PLATE
Fig. 86 Install Compression Spring And Pin
1 – REVERSE IDLER GEAR SHAFT
2 – PIN
3 – COMPRESSION SPRING
Fig. 87 Install Reverse Idler Shaft
1 – REVERSE IDLER SHAFT
21 - 26 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(39) I nstal l the fi fth gear thrust ri ng l ock bal l to
the countershaft (Fi g. 90).
(40) I nstal l the fi fth gear thrust ri ng onto the
countershaft and over the l ock bal l (Fi g. 91).
(41) I nstal l fi fth gear shi ft fork to the countershaft
fi fth gear assembl y.
(42) I nstal l the countershaft fi fth gear beari ngs
i nto the countershaft fi fth gear assembl y.
(43) Posi ti on the countershaft fi fth gear assembl y
on the countershaft. Ensure that the fi fth gear fork i s
i nstal l ed onto the fi fth gear shi ft rai l .
(44) I nstal l the fi fth gear synchro ri ng.
(45) Posi ti on the fi fth gear bl ocker ri ng onto the
countershaft.
(46) Usi ng a sui tabl e mal l et and spacer, tap the
fi fth gear bl ocker ri ng onto the countershaft.
(47) I nstal l new bol t to hol d fi fth gear shi ft fork to
the fi fth gear shi ft rai l (Fi g. 92).
(48) Measure countershaft fi fth gear thrust cl ear-
ance.
(49) Sel ect a snap-ri ng so that the thrust cl earance
i s 0.10–0.30 mm (0.004–0.010 i n.).
(50) I nstal l snap-ri ng to hol d fi fth gear bl ocker
ri ng onto countershaft.
(51) Remove i ntermedi ate pl ate from vi se and
remove bol ts and washers from i ntermedi ate.
Fig. 88 Align Idler Shaft Pin
1 – REVERSE IDLER GEAR ASSEMBLY
2 – ALIGNMENT NOTCH
Fig. 89 Depress Pin In Reverse Idler Gear Shaft
1 – DEPRESS PIN
Fig. 90 Install Fifth Gear Thrust Ring Lock Ball
1 – PENCIL MAGNET
2 – CLUSTER GEAR
3 – LOCK BALL RECESS
4 – THRUST RING LOCK BALL
Fig. 91 Install Fifth Gear Thrust Ring
1 – LOCK BALL NOTCH
2 – FIFTH GEAR THRUST RING
TJ AX5 MANUAL TRANSMISSION 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)
COUNTERSHAFT
DISASSEMBLY
(1) Remove sel ect fi t snap-ri ng hol di ng the coun-
tershaft front beari ng onto the countershaft (Fi g. 93).
(2) Usi ng Beari ng Spl i tter P-334, a sui tabl e spacer
on center of countershaft, and a shop press, remove
the countershaft front beari ng from the countershaft.
ASSEMBLY
(1) Remove any ni cks or burrs on countershaft hub
wi th fi ne emery or crocus cl oth.
(2) Posi ti on countershaft front beari ng on end of
countershaft.
(3) Usi ng Speci al Tool 8109 and a shop press,
press beari ng onto countershaft.
(4) Sel ect the thi ckest snap-ri ng that wi l l fi t i nto
the snap-ri ng groove of the countershaft (Fi g. 93).
(5) I nstal l snap-ri ng to hol d countershaft front
beari ng onto countershaft.
INPUT SHAFT
DISASSEMBLY
(1) Veri fy that the 3–4 synchroni zer i s i n the neu-
tral posi ti on.
(2) Separate i nput shaft from output shaft (Fi g.
94). Note that the output shaft pi l ot beari ng i s an
uncaged rol l er type beari ng.
(3) Remove the output shaft pi l ot beari ng rol l ers
from the i nput shaft and the output shaft.
(4) Remove the fourth gear synchroni zer ri ng from
the i nput shaft (Fi g. 95).
Fig. 92 Install Fifth Gear Retainer Bolt
1 – SHIFT FORK RETAINER BOLT
2 – FIFTH GEAR SHIFT RAIL
3 – FIFTH GEAR SHIFT FORK
I. D. MARK SNAP RING THICKNESS MM (IN.)
1 2.05 - 2.10 (0.0807 - 0.0827)
2 2.10 - 2.15 (0.0827 - 0.0846)
3 2.15 - 2.20 (0.0846 - 0.0866)
4 2.20 - 2.25 (0.0866 - 0.0886)
5 2.25 - 2.30 (0.0886 - 0.0906)
6 2.30 - 2.35 (0.0906 - 0.0925)
Fig. 93 Countershaft Front Bearing Snap-ring
Fig. 94 Separate Input and Output Shafts
1 – INPUT SHAFT ASSEMBLY
2 – OUTPUT SHAFT AND GEAR ASSEMBLY
21 - 28 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Remove the sel ect fi t snap-ri ng hol di ng the
i nput shaft beari ng onto the i nput shaft.
(6) Usi ng Beari ng Spl i tter P-334 and a shop press,
remove the beari ng from the i nput shaft.
ASSEMBLY
(1) Posi ti on i nput shaft beari ng onto i nput shaft.
(2) Usi ng Dri ver L-4507, dri ve beari ng onto i nput
shaft.
(3) Sel ect the thi ckest snap-ri ng that wi l l fi t i nto
the snap-ri ng groove of the i nput shaft (Fi g. 96).
(4) Lubri cate output shaft pi l ot beari ng bore of
i nput shaft wi th petrol eum jel l y.
(5) I nstal l output shaft pi l ot beari ng rol l ers i n
i nput shaft bore (Fi g. 97). Ensure to use suffi ci ent
petrol eum jel l y to hol d rol l ers i n posi ti on.
(6) I nstal l the fourth gear synchroni zer ri ng onto
the i nput shaft.
(7) I nstal l i nput shaft to output shaft. Use care
when mati ng the two shafts not to di spl ace any out-
put shaft pi l ot beari ng rol l ers.
OUTPUT SHAFT
DISASSEMBLY
(1) Remove i nput shaft and output shaft pi l ot
beari ng rol l ers from output shaft.
(2) Measure and note thrust cl earance of output
shaft gears (Fi g. 98). Cl earance shoul d be 0.10 – 0.25
mm (0.004 – 0.010 i n.).
(3) Remove output shaft fi fth gear snap ri ng wi th
two screwdri vers (Fi g. 99).
Fig. 95 Input Shaft Components
1 – BEARING
2 – SYNCHRO RING
3 – INPUT SHAFT
4 – BEARING SNAP RING
I. D. Mark Snap Ring Thickness mm (in.)
0 2.05-2.10 (0.0807-0.0827)
1 2.10-2.15 (0.0827-0.0846)
2 2.15-2.20 (0.0846-0.0866)
3 2.20-2.25 (0.0866-0.0886)
4 2.25-2.30 (0.0886-0.0906)
5 2.30-2.35 (0.0906-0.0925)
Fig. 96 Select Input Shaft Bearing Snap-ring
TJ AX5 MANUAL TRANSMISSION 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Usi ng Beari ng Spl i tter P-334 or sui tabl e press
pl ates posi ti oned under fi rst gear, press fi fth gear,
rear beari ng, fi rst gear, and fi rst gear beari ng i nner
race off output shaft (Fi g. 100).
(5) Remove fi rst gear needl e rol l er beari ng from
output shaft.
(6) Remove fi rst gear beari ng i nner race l ock bal l
wi th penci l magnet (Fi g. 101).
(7) Remove fi rst gear synchroni zer ri ng.
Fig. 97 Install Output Shaft Pilot Bearing Rollers
1 – INPUT SHAFT
2 – BEARING ROLLERS
Fig. 98 Check Output Shaft Gear Thrust Clearance
Fig. 99 Remove Fifth Gear Snap-ring
1 – SNAP RING
Fig. 100 Remove Fifth Gear, First Gear Bearing, And
Race
1 – PRESS RAM
2 – OUTPUT SHAFT
3 – FIRST-FIFTH GEAR-BEARING ASSEMBLY
21 - 30 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(8) Usi ng Beari ng Spl i tter P-334 or sui tabl e press
pl ates posi ti oned under second gear, press 1–2 syn-
chroni zer, reverse gear, and second gear from output
shaft (Fi g. 102).
(9) Remove second gear needl e rol l er beari ng from
the output shaft or second gear.
(10) Remove sel ect fi t snap-ri ng hol di ng the 3–4
synchroni zer onto the output shaft (Fi g. 103).
(11) Usi ng Beari ng Spl i tter P-334 or sui tabl e press
pl ates posi ti oned under thi rd gear, press the 3–4 syn-
chroni zer and thi rd gear from output shaft (Fi g. 104).
(12) Remove thi rd gear needl e rol l er beari ng from
output shaft or gear.
ASSEMBLY
TRANSMISSION ASSEMBLY INFORMATION
Lubri cate the transmi ssi on components wi th
Mopar௡ 75W–90, GL 3 gear l ubri cant duri ng assem-
bl y. Use petrol eum jel l y to l ubri cate seal l i ps and/or
hol d parts i n pl ace duri ng i nstal l ati on.
Refer to (Fi g. 105) duri ng assembl y for AX5 gear
assembl y i denti fi cati on.
(1) Lubri cate transmi ssi on components wi th speci -
fi ed gear l ubri cant.
(2) I f necessary, assembl e 1–2 and 3–4 synchro-
ni zer hubs, sl eeves, spri ngs and key i nserts (Fi g.
106).
(3) I nstal l thi rd gear needl e beari ng onto the out-
put shaft.
Fig. 101 Remove First Gear Bearing Inner Race
Lock Ball
1 – LOCK BALL
2 – PENCIL MAGNET
Fig. 102 Remove Second Gear, Reverse Gear, And
1–2 Synchronizer
1 – PRESS RAM
2 – SECOND GEAR
3 – 1–2 SYNCHRONIZER HUB
Fig. 103 Remove 3–4 Synchronizer Snap Ring
1 – 3–4 SYNCHRONIZER SNAP RING
TJ AX5 MANUAL TRANSMISSION 21 - 31
DISASSEMBLY AND ASSEMBLY (Continued)
(4) I nstal l thi rd gear over beari ng and onto output
shaft fl ange.
(5) I nstal l thi rd gear synchroni zer ri ng to thi rd
gear.
(6) Posi ti on the 3–4 synchroni zer onto the output
shaft.
(7) Usi ng Adapter 6747-1A and a shop press, press
the 3–4 synchroni zer onto the output shaft.
(8) Sel ect the thi ckest snap-ri ng that wi l l fi t i nto
the snap-ri ng groove of the output shaft (Fi g. 107).
(9) I nstal l snap-ri ng to hol d 3–4 synchroni zer onto
output shaft.
(10) Veri fy thi rd gear thrust cl earance wi th feel er
gauge (Fi g. 108). Cl earance shoul d be 0.10 – 0.25 mm
(0.004 – 0.010 i n.). I f cl earance i s out of speci fi cati on,
refer to Cl eani ng and I nspecti on secti on wi thi n thi s
group.
(11) I nstal l second gear needl e beari ng onto output
shaft.
(12) I nstal l second gear over beari ng and onto out-
put shaft fl ange.
(13) I nstal l second gear synchroni zer ri ng onto sec-
ond gear.
(14) Posi ti on 1–2 synchroni zer assembl y onto
spl i nes of output shaft.
(15) Usi ng Dri ver MD-998805, Adapter 6747-1A,
and a shop press, press the 1–2 synchroni zer onto
the output shaft.
(16) I nstal l fi rst gear synchroni zer ri ng i nto 1–2
synchroni zer.
Fig. 104 Remove 3–4 Synchronizer And Third Gear
1 – 3–4 SYNCHRONIZER
2 – THIRD GEAR
Fig. 105 Geartrain Components
1 – SNAP RING
2 – FIFTH GEAR
3 – COUNTER GEAR
4 – BEARING
5 – LOCK BALL
6 – SYNCHRO HUB/SLEEVE
7 – SNAP RING
8 – SPACER
9 – COUNTER 5TH GEAR
10 – SYNCHRO RING
11 – 5TH SPLINE GEAR
12 – SNAP RING
Fig. 106 Synchronizer Identification
1 – SLEEVES
2 – HUBS
21 - 32 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(17) I nstal l fi rst gear beari ng i nner race l ock bal l
i n output shaft (Fi g. 109).
(18) I nstal l fi rst gear needl e beari ng onto output
shaft (Fi g. 110).
(19) I nstal l fi rst gear onto output shaft and over
beari ng.
(20) I nstal l fi rst gear beari ng i nner race onto out-
put shaft and i nsi de fi rst gear beari ng. Rotate bear-
i ng race unti l race i nstal l s over l ock bal l .
(21) Posi ti on output shaft rear beari ng onto output
shaft. Ensure that the snap ri ng groove i n beari ng
outer race i s toward rear of output shaft.
(22) Usi ng Dri ver L-4507 and sui tabl e mal l et,
dri ve beari ng onto output shaft.
(23) I nstal l snap-ri ng onto output shaft rear bear-
i ng outer race.
I. D. Mark Snap Ring Thickness mm (in.)
C-1 1.75-1.80 (0.0689-0.0709)
D 1.80-1.85 (0.0709-0.0728)
D-1 1.85-1.90 (0.0728-0.0748)
E 1.90-1.95 (0.0748-0.0768)
E-1 1.95-2.00 (0.0768-0.0787)
F 2.00-2.05 (0.0788-0.0807)
F-1 2.05-2.10 (0.0807-0.0827)
Fig. 107 Select 3–4 Synchronizer Snap-ring
Fig. 108 Check Third Gear Clearance
1 – FEELER GAUGE
2 – THIRD GEAR
Fig. 109 Install First Gear Bearing Inner Race Lock
Ball
1 – FIRST GEAR LOCK BALL
Fig. 110 First Gear Components
1 – REAR BEARING
2 – INNER RACE
3 – FIRST GEAR
4 – NEEDLE BEARING
5 – FIRST GEAR LOCK BALL
TJ AX5 MANUAL TRANSMISSION 21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)
(24) Check fi rst–second gear thrust cl earance (Fi g.
111). Standard cl earance i s 0.10 – 0.25 mm (0.004 –
0.010 i n.). I f cl earance i s out of speci fi cati on, refer to
Cl eani ng and I nspecti on secti on wi thi n thi s group.
(25) Posi ti on fi fth gear onto output shaft wi th the
gear’s short shoul der toward the rear of shaft.
Ensure that the gear and output shaft spl i nes are
al i gned.
(26) Usi ng Adapter 6747-1A, Dri ver L-4507, and a
shop press, press fi fth gear onto output shaft.
(27) Sel ect the thi ckest snap-ri ng that wi l l fi t i nto
the snap-ri ng groove of the output shaft (Fi g. 112).
(28) I nstal l snap-ri ng to hol d fi fth gear onto output
shaft.
SEMI-SYNCHRONIZED REVERSE IDLER GEAR
DISASSEMBLY
(1) Remove snap-ri ng hol di ng the reverse i dl er
gear onto the reverse i dl er gear hub/race (Fi g. 113).
(2) Remove the pl ate washer from the reverse i dl er
gear hub/race (Fi g. 114).
(3) Remove the reverse i dl er gear from the reverse
i dl er gear hub/race (Fi g. 115).
(4) Remove the reverse i dl er gear synchroni zer
ri ng from the reverse i dl er gear hub/race (Fi g. 116).
ASSEMBLY
(1) I nstal l the reverse i dl er gear synchroni zer ri ng
onto the reverse i dl er gear hub/race. Appl y a fi l m of
75W-90 GL-3 transmi ssi on oi l to the contact surface
of the synchroni zer ri ng pri or to assembl y.
(2) I nstal l the reverse i dl er gear onto the reverse
i dl er gear hub/race. Appl y a fi l m of 75W-90 GL-3
transmi ssi on oi l to the reverse i dl er gear bushi ng
pri or to assembl y. Veri fy that the teeth on the syn-
chroni zer ri ng are properl y engaged i nto the recesses
of the reverse i dl er gear.
Fig. 111 Check First–Second Gear Thrust Clearance
I. D. Mark Snap Ring Thickness mm (in.)
A 2.67-2.72 (0.1051-0.1071)
B 2.73-2.78 (0.1075-0.1094)
C 2.79-2.84 (0.1098-0.1118)
D 2.85-2.90 (0.1122-0.1142)
E 2.91-2.96 (0.1146-0.1165)
F 2.97-3.02 (0.1169-0.1189)
G 3.03-3.08 (0.1193-0.1213)
H 3.09-3.14 (0.1217-0.1236)
J 3.15-3.20 (0.1240-0.1260)
K 3.21-3.26 (0.1264-0.1283)
L 3.27-3.32 (0.1287-0.1307)
Fig. 112 Select/Install Fifth Gear Snap Ring
21 - 34 AX5 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(3) I nstal l the pl ate washer over the reverse i dl er
gear hub/race and onto the reverse i dl er gear.
(4) I nstal l the snap-ri ng to hol d the reerse i dl er
gear onto the reverse i dl er hub/race.
CLEANING AND INSPECTION
AX5 MANUAL TRANSMISSION COMPONENTS
GENERAL INFORMATION
Cl ean the transmi ssi on components i n sol vent. Dry
the cases, gears, shi ft mechani sm and shafts wi th
compressed ai r. Dry the beari ngs wi th cl ean, dry
shop towel s onl y. Never use compressed ai r on the
beari ngs. Thi s coul d cause severe damage to the
beari ng rol l er and race surfaces.
I f output shaft or i nner race fl ange thi ckness i s
wi thi n speci fi cati on but any gear thrust cl earance i s
out of speci fi cati on, repl ace the necessary gear and
gear needl e beari ng as an assembl y.
GEAR CASE, ADAPTER/EXTENSION HOUSING,
INTERMEDIATE PLATE
Cl ean the case, housi ng, and i ntermedi ate pl ate
wi th sol vent and dry wi th compressed ai r. Repl ace
the case i f cracked, porous, or i f any of the beari ng
and gear bores are damaged.
I nspect the threads i n the case, housi ng, and pl ate.
Mi nor thread damage can be repai red wi th steel
thread i nserts, i f necessary. Do not attempt to repai r
any threads whi ch show evi dence of cracks around
the threaded hol e.
Fig. 113 Remove Reverse Idler Gear Snap-ring
1 – REVERSE IDLER GEAR
2 – SNAP-RING
3 – REVERSE IDLER GEAR HUB
4 – PLATE WASHER
Fig. 114 Remove Reverse Idler Gear Plate Washer
1 – REVERSE IDLER GEAR
2 – PLATE WASHER
Fig. 115 Remove Reverse Idler Gear
1 – REVERSE SYNCHRONIZER RING
2 – REVERSE IDLER GEAR HUB
3 – REVERSE IDLER GEAR
Fig. 116 Remove Reverse Idler Gear Synchronizer
Ring
1 – REVERSE SYNCHRONIZER RING
2 – REVERSE IDLER GEAR HUB
TJ AX5 MANUAL TRANSMISSION 21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)
OUTPUT SHAFT
Check thi ckness of the output shaft and i nner
beari ng race fl anges wi th a mi crometer or verni er
cal i pers (Fi g. 117).
• Mi ni mum thi ckness for shaft fl ange i s 4.80 mm
(0.189 i n.)
• Mi ni mum thi ckness for fi rst gear beari ng i nner
race fl ange i s 3.99 mm (0.157 i n.)
Measure di ameter of the output shaft journal sur-
faces wi th a mi crometer. Repl ace the shaft i f ei ther of
these surfaces are worn beyond speci fi ed l i mi ts.
• Second gear surface mi ni mum di ameter i s
37.964 mm (1.495 i n.)
• Thi rd gear surface mi ni mum di ameter i s 34.984
mm (1.377 i n.)
Measure di ameter of the fi rst gear beari ng i nner
race. Mi ni mum di ameter i s 38.985 mm (1.535 i n.).
Measure output shaft runout wi th a di al i ndi cator
(Fi g. 118). Runout shoul d not exceed 0.05 mm (0.002
i n.).
Repl ace output shaft or fi rst gear i nner beari ng
race i f measurement of any surface i s out of speci fi -
cati on. Do not attempt to repai r out of speci fi cati on
components.
COUNTERSHAFT
I nspect the countershaft gear teeth. Repl ace the
countershaft i f any teeth are worn or damaged.
I nspect the beari ng surfaces and repl ace shaft i f any
surface shows damage or wear.
Check condi ti on of the countershaft front beari ng.
Repl ace the beari ng i f worn, noi sy, or damaged.
GEAR AND SYNCHRONIZER
I nstal l the needl e beari ng and i nner race i n the
fi rst gear. Then check oi l cl earance between the gear
and i nner race (Fi g. 119). Cl earance shoul d be 0.009
– 0.032 mm (0.0004 – 0.0013 i n.).
I nstal l the needl e beari ngs and the second, thi rd
and counter fi fth gears on the output shaft. Then
check oi l cl earance between the gears and shaft wi th
a di al i ndi cator (Fi g. 120). Oi l cl earance for al l three
gears i s 0.009 – 0.0013 mm (0.0004 – 0.0013 i n.).
Check synchroni zer ri ng wear (Fi g. 121). I nsert
each ri ng i n matchi ng gear. Measure cl earance
between each ri ng and gear wi th feel er gauge.
Repl ace ri ng i f cl earance exceeds 2.0 mm (0.078 i n.).
Check shi ft fork–to–synchroni zer hub cl earance
wi th a feel er gauge (Fi g. 122). Repl ace the fork i f
cl earance exceeds 1.0 mm (0.039 i n.).
(1) I nspect al l mai nshaft gear teeth. Repl ace any
gear whi ch shows any worn or damaged teeth.
Fig. 117 Check Shaft And Bearing Race Flange
Thickness
1 – OUTPUT SHAFT FLANGE
2 – INNER RACE FLANGE
Fig. 118 Check Output Shaft Runout
1 – OUTPUT SHAFT JOURNAL
21 - 36 AX5 MANUAL TRANSMISSION TJ
CLEANING AND INSPECTION (Continued)
Fig. 119 Check Gear–To–Race Clearance
1 – GEAR
2 – INNER RACE
Fig. 120 Check Gear–To–Shaft Oil Clearance
1 – GEAR BEING CHECKED
2 – OUTPUT SHAFT
Fig. 121 Check Synchronizer Ring Wear
1 – FEELER GAUGE
2 – SYNCHRONIZER RING
Fig. 122 Check Fork–To–Hub Clearance
1 – SHIFT FORK
2 – FEELER GAUGE
3 – SYNCHRONIZER SLEEVE
TJ AX5 MANUAL TRANSMISSION 21 - 37
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ugs, Access . . . . . . . . . . . . . . . 19 N·m (14 ft.l bs.)
Bol ts, Adapter Housi ng . . . . . . . 34 N·m (25 ft.l bs.)
Swi tch, Back-up Li ght . . . . . . . 44 N·m (32.5 ft.l bs.)
Pl ugs, Drai n and Fi l l . . . . . . . . 44 N·m (32.5 ft.l bs.)
Bol ts, Front Beari ng Retai ner . . 17 N·m (12 ft.l bs.)
Pl ugs, I nterl ock and Detent . . . . 19 N·m (14 ft.l bs.)
Screws, Propel l er Shaft Cl amp . . . . . . . 16–23 N·m
(140–200 i n.l bs.)
Bol ts, Rear Mount to Transmi ssi on . . . . 33–60 N·m
(24–44 ft.l bs.)
Nut, Rear Mount Cl evi s . 54–75 N·m (40–55 ft.l bs.)
Nuts, Rear Mount to Crossmember . . . . 41–68 N·m
(30–50 ft.l bs.)
Pi ns, Restri ctor . . . . . . . . . . . . 27.4 N·m (20 ft.l bs.)
Bol ts, Reverse Shi ft Arm Bracket . . . . . . . . 18 N·m
(13 ft.l bs.)
Screw, Shi ft Arm Set . . . . . . . . . 38 N·m (28 ft.l bs.)
Screws, Shi ft Fork Set . . . . . . . . 20 N·m (15 ft.l bs.)
Nut, Shi ft Knob . . . . . . . . 20–34 N·m (15–25 ft.l bs.)
Screws, Shi fter Fl oor Cover . . . . . . . . . . . . 2–3 N·m
(17–30 i n.l bs.)
Bol ts, Shi ft Tower . . . . . . . . . . . . 18 N·m (13 ft.l bs.)
Nuts, Transfer Case Mounti ng . . . . . . . 30–41 N·m
(22–30 ft.l bs.)
SPECIAL TOOLS
AX5
C-3339 Dial Indicator Set
C-3995-A Installer, Extension Housing Seal
C-4171 Handle, Universal Tool
8211 Installer, Seal
8212 Installer, Seal
8208 Installer, Seal
P-334 Splitter, Bearing
21 - 38 AX5 MANUAL TRANSMISSION TJ
8109 Cup, Installer
L-4507 Tube, Driver
6747–1A Adapter, Fixture
MD-998805 Installer, Seal
TJ AX5 MANUAL TRANSMISSION 21 - 39
SPECIAL TOOLS (Continued)
NV3550 MANUAL TRANSMISSION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
NV3550 MANUAL TRANSMISSION. . . . . . . . . . . . 40
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL. . . . . . . . . . . . . . . . . . . 42
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . 42
TRANSMISSION NOISE. . . . . . . . . . . . . . . . . . . . 42
REMOVAL AND INSTALLATION
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 42
SHIFT TOWER. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DISASSEMBLY AND ASSEMBLY
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 45
CLEANING AND INSPECTION
TRANSMISSION COMPONENTS . . . . . . . . . . . . . 75
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SPECIAL TOOLS
NV3550 MANUAL TRANSMISSION. . . . . . . . . . . . 77
DESCRIPTION AND OPERATION
NV3550 MANUAL TRANSMISSION
DESCRIPTION
The NV3550 i s a medi um-duty, 5-speed, constant
mesh, ful l y synchroni zed manual transmi ssi on. Fi fth
gear i s an overdri ve range wi th a rati o of 0.78:1. The
NV3550 i s avai l abl e i n two and four–wheel dri ve con-
fi gurati ons.
The transmi ssi on gear case consi sts of two al umi -
num housi ngs. The cl utch housi ng i s a removabl e
component. I t i s not an i ntegral part of the transmi s-
si on front housi ng.
A combi nati on of rol l er and bal l beari ngs are used
to support the transmi ssi on shafts i n the two hous-
i ngs. The transmi ssi on gears al l rotate on caged type
needl e beari ngs. A rol l er beari ng i s used between the
i nput and output shaft.
The NV3550 has a si ngl e shaft shi ft mechani sm
wi th three shi ft forks al l mounted on the shaft. The
shaft i s supported i n the front and rear housi ngs by
bushi ngs and one l i near bal l beari ng. I nternal shi ft
components consi st of the forks, shaft, shi ft l ever
socket, and detent components (Fi g. 1).
GEAR RATIOS
Gear rati os for the NV3550 are as fol l ows:
RANGE RATIO
FIRST 4.01:1
SECOND 2.32:1
THIRD = 1.40:1
FOURTH = 1:1
FIFTH = 0.78:1
REVERSE = 3.55:1
IDENTIFICATION
The NV3550 i denti fi cati on and part number bar
code tags (Fi g. 2) are l ocated on the top of the trans-
mi ssi on, forward of the shi ft tower.
OPERATION
The manual transmi ssi on recei ves power through
the cl utch assembl y from the engi ne. The cl utch di sc
i s spl i ned to the transmi ssi on i nput shaft and i s
turned at engi ne speed at al l ti mes that the cl utch i s
engaged. The i nput shaft i s connected to the trans-
mi ssi on countershaft through the mesh of fourth
speed gear on the i nput shaft and the fourth counter-
shaft gear. At thi s poi nt, al l the transmi ssi on gears
are spi nni ng.
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. Thi s move-
ment moves the i nternal transmi ssi on shi ft compo-
nents to begi n the shi ft sequence. As the shi ft l ever
moves the sel ected shi ft rai l , the shi ft fork attached
to that rai l begi ns to move. The fork i s posi ti oned i n
a groove i n the outer ci rcumference of the synchro-
ni zer sl eeve. As the shi ft fork moves the synchroni zer
sl eeve, the synchroni zer begi ns to speed-up or sl ow
down the sel ected gear (dependi ng on whether we are
up-shi fti ng or down-shi fti ng). The synchroni zer does
thi s by havi ng the synchroni zer hub spl i ned to the
mai nshaft, or the countershaft i n some cases, and
movi ng the bl ocker ri ng i nto contact wi th the gear’s
fri cti on cone. As the bl ocker ri ng and fri cti on cone
come together, the gear speed i s brought up or down
to the speed of the synchroni zer. As the two speeds
match, the spl i nes on the i nsi de of the synchroni zer
sl eeve become al i gned wi th the teeth on the bl ocker
ri ng and the fri cti on cone and eventual l y wi l l sl i de
over the teeth, l ocki ng the gear to the mai nshaft, or
countershaft, through the synchroni zer.
21 - 40 NV3550 MANUAL TRANSMISSION TJ
LUBRICANT
DESCRIPTION
Requi red l ubri cant for the NV3550 i s Mopar௡ Man-
ual Transmi ssi on Lubri cant, P/N 4761526. Thi s i s the
only l ubri cant to be used i n NV3550 transmi ssi ons.
No other l ubri cants are acceptabl e, or recommended.
The correct transmi ssi on l ubri cant l evel i s to the
bottom edge of the fi l l pl ug hol e (Fi g. 3).
The transmi ssi on must be l evel to obtai n an accu-
rate l ubri cant l evel check. A dri ve–on type of hoi st i s
recommended for thi s purpose.
Lubri cant capaci ty of the NV3500 i s approxi matel y
2.28 l i ters (4.8 pi nts). Thi s represents the approxi -
mate quanti ty needed to refi l l the transmi ssi on after
a l ubri cant change or overhaul .
DRAIN AND FILL PLUG LOCATIONS
The NV3550 fi l l pl ug i s l ocated i n the front hous-
i ng. The drai n pl ug i s at the bottom rear of the hous-
i ng (Fi g. 3).
Fig. 1 NV3550 Shift Mechanism
1 – 3–4 FORK
2 – SHIFT SHAFT LEVER AND BUSHING
3 – 1–2 FORK
4 – FIFTH-REVERSE FORK
5 – SHIFT SHAFT
6 – REAR HOUSING
7 – ROLL PIN
8 – SHIFT LEVER SOCKET
9 – SHAFT RAIL DETENTS
10 – FRONT HOUSING
11 – SHIFT SHAFT
Fig. 2 NV3550 Identification
1 – PART NUMBER TAG
2 – IDENTIFICATION TAG
3 – FRONT OF REAR HOUSING
TJ NV3550 MANUAL TRANSMISSION 21 - 41
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the
housi ngs, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at component mati ng surfaces wi l l probabl y
be the resul t of i nadequate seal er, gaps i n the seal er,
i ncorrect bol t ti ghteni ng, or use of a non–recom-
mended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther a l oose or damaged, front beari ng retai ner or
retai ner seal . Lubri cant may al so dri p from the
transmi ssi on cl utch housi ng after extended opera-
ti on. I f the l eak i s severe, i t wi l l contami nate the
cl utch di sc causi ng sl i p, grab and chatter.
Transmi ssi ons fi l l ed from ai r or el ectri cal l y pow-
ered l ubri cant contai ners can be under fi l l ed. Al ways
check the l ubri cant l evel after fi l l i ng to avoi d an
under fi l l condi ti on.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel ; use a dri ve–on hoi st to
ensure thi s. Al so al l ow the l ubri cant to settl e for a
mi nute or so before checki ng. These recommenda-
ti ons wi l l ensure an accurate check and avoi d an
under-or-overfi l l condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper or contami nated l ubri cants, transmi s-
si on component damage, cl utch l i nkage mal functi on,
or by a damaged cl utch pressure pl ate or di sc.
Substanti al l ubri cant l eaks can resul t i n gear, shi ft
component, synchro and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of a probl em are usual l y hard shi fti ng and
noi se.
I ncorrect or contami nated l ubri cants can al so con-
tri bute to hard shi fti ng. The consequence of usi ng
non–recommended l ubri cants i s noi se, excessi ve
wear, i nternal bi nd and hard shi fti ng.
I mproper cl utch rel ease i s a frequent cause of hard
shi fti ng. I ncorrect adjustment or a worn, damaged
pressure pl ate or di sc can cause i ncorrect rel ease. I f
the cl utch probl em i s advanced, gear cl ash duri ng
shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear
cl ash when shi fti ng i nto any forward gear. I n some
new or rebui l t transmi ssi ons, new synchro ri ngs may
tend to sti ck sl i ghtl y causi ng sti ff and/or noi sy shi fts.
I n most cases, thi s condi ti on wi l l decl i ne as the ri ngs
wear i n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears can generate a
mi l d whi ne that may onl y be audi bl e at extreme
speeds.
Severe, obvi ousl y audi bl e transmi ssi on noi se i s
general l y the resul t of a l ubri cant probl em. I nsuffi -
ci ent, i mproper, or contami nated l ubri cant can pro-
mote rapi d wear of gears, synchros, shi ft rai l s, forks
and beari ngs. The overheati ng caused by a l ubri cant
probl em, can al so l ead to gear breakage.
REMOVAL AND INSTALLATION
TRANSMISSION
REMOVAL
(1) Shi ft transmi ssi on i nto fi rst or thi rd gear.
(2) Remove the fl oor consol e and shi ft boot as nec-
essary to access the bottom of the shi ft l ever at the
shi ft tower attachment.
Fig. 3 Drain and Fill Plug Locations
1 – DRAIN PLUG
2 – FILL PLUG
21 - 42 NV3550 MANUAL TRANSMISSION TJ
DESCRIPTION AND OPERATION (Continued)
(3) I nstal l nuts on two M6X1.0 bol ts and thread
the bol ts i nto the threaded hol es at the base of the
shi ft l ever.
(4) Ti ghten the nuts equal l y unti l the shi ft l ever
l oosens on the shi ft tower stub shaft.
(5) Remove the shi ft l ever from the shi ft tower.
(6) Rai se and support vehi cl e on sui tabl e safety
stands.
(7) Support engi ne wi th adjustabl e jack stand.
Posi ti on wood bl ock between jack and oi l pan to
avoi d damagi ng pan.
(8) Remove crossmember/ski d pl ate.
(9) Di sconnect necessary exhaust system compo-
nents.
(10) Remove sl ave cyl i nder (Fi g. 4) from cl utch
housi ng.
(11) Mark rear propel l er shaft and rear axl e yokes
for i nstal l ati on al i gnment (Fi g. 5).
(12) Mark front propel l er shaft, axl e, and transfer
case yokes for i nstal l ati on al i gnment.
(13) Remove propel l er shaft(s).
(14) Uncl i p wi re harnesses from transmi ssi on and
transfer case.
(15) Di sconnect transfer case vent hose.
(16) Di sengage any wi re connectors attached to
transmi ssi on or transfer case components.
(17) Support transfer case wi th transmi ssi on jack.
(18) Secure transfer case to jack wi th safety
chai ns.
(19) Di sconnect transfer case shi ft l i nkage at
transfer case.
(20) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(21) Remove transfer case.
(22) Remove crankshaft posi ti on sensor (Fi g. 6).
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.
(23) Support transmi ssi on wi th transmi ssi on jack.
(24) Secure transmi ssi on to jack wi th safety
chai ns.
(25) Di sconnect rear cushi on and bracket from
transmi ssi on.
(26) Remove cl utch housi ng-to-engi ne bol ts.
Fig. 4 Slave Cylinder
1 – CLUTCH SLAVE CYLINDER
Fig. 5 Marking Propeller Shaft And Axle Yokes
1 – REFERENCE MARKS
Fig. 6 Crankshaft Position Sensor —2.5 and 4.0L
Engine
1 – ENGINE SPEED SENSOR
2 – GROMMET
3 – MOUNTING BOLT(S)
4 – LEFT REAR OF ENGINE
5 – TRANSMISSION
TJ NV3550 MANUAL TRANSMISSION 21 - 43
REMOVAL AND INSTALLATION (Continued)
(27) Pul l transmi ssi on jack rearward unti l i nput
shaft cl ears cl utch. Then sl i de transmi ssi on out from
under vehi cl e.
(28) Remove cl utch rel ease beari ng, rel ease fork,
and retai ner cl i p.
(29) Remove cl utch housi ng from transmi ssi on
(Fi g. 7).
INSTALLATION
(1) I nstal l cl utch housi ng on transmi ssi on. Ti ghten
housi ng bol ts to 46 N·m (34 ft. l bs.) torque (Fi g. 7).
(2) Lubri cate contact surfaces of rel ease fork pi vot
bal l stud and rel ease fork wi th hi gh temp grease.
(3) I nstal l rel ease beari ng, fork, and retai ner cl i p.
(4) Posi ti on and secure transmi ssi on on transmi s-
si on jack.
(5) Li ghtl y l ubri cate pi l ot beari ng and transmi s-
si on i nput shaft spl i nes wi th Mopar௡ hi gh temp
grease.
(6) Rai se transmi ssi on and al i gn transmi ssi on
i nput shaft and cl utch di sc spl i nes. Then sl i de trans-
mi ssi on i nto pl ace.
(7) I nstal l and ti ghten cl utch housi ng-to-engi ne
bol ts to the appropri ate torque: Be sure the hous-
ing is properly seated on engine block before
tightening bolts.
• Ti ghten 3/8” di ameter bol ts to 37 N·m (27
ft.l bs.).
• Ti ghten 7/16” di ameter bol ts to 58 N·m (43
ft.l bs.).
• Ti ghten M12 bol ts to 75 N·m (55 ft.l bs.).
(8) Be sure transmi ssi on i s i n fi rst or thi rd gear.
(9) I nstal l fasteners to hol d rear cushi on and
bracket to transmi ssi on. Then ti ghten transmi ssi on-
to-rear support bol ts/nuts to 54 N·m (40 ft. l bs.)
torque.
(10) I nstal l rear crossmember. Ti ghten crossmem-
ber-to-frame bol ts to 41 N·m (31 ft. l bs.) torque.
(11) Remove support stands from engi ne and
transmi ssi on.
(12) I nstal l and connect crankshaft posi ti on sensor.
(13) Posi ti on transfer case on transmi ssi on jack.
(14) Secure transfer case to jack wi th safety
chai ns.
(15) Rai se transfer case and al i gn transfer case
i nput shaft to the transmi ssi on output shaft.
(16) Sl i de transfer case forward unti l case i s
seated on transmi ssi on.
(17) I nstal l nuts to attach transfer case to trans-
mi ssi on. Ti ghten transfer case-to-transmi ssi on nuts
to 35 N·m (26 ft. l bs.) torque.
(18) Connect transfer case shi ft l i nkage at transfer
case.
(19) Connect transfer case vent hose.
(20) Secure wi re harnesses i n cl i ps/ti e straps on
transmi ssi on and transfer case.
(21) Engage wi re connectors attached to al l neces-
sary transmi ssi on or transfer case components.
(22) I nstal l rear propel l er shaft sl i p yoke to trans-
mi ssi on or transfer case output shaft.
(23) Al i gn marks on rear propel l er shaft and rear
axl e yokes (Fi g. 8).
Fig. 7 Clutch Housing
1 – HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.)
2 – CLUTCH HOUSING
3 – TRANSMISSION
Fig. 8 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks
1 – REFERENCE MARKS
21 - 44 NV3550 MANUAL TRANSMISSION TJ
REMOVAL AND INSTALLATION (Continued)
(24) I nstal l and ti ghten propel l er shaft U–joi nt
cl amp bol ts to 19 N·m (170 i n. l bs.) torque.
(25) Al i gn marks on front propel l er shaft, axl e,
and transfer case yokes.
(26) I nstal l and ti ghten propel l er shaft U–joi nt
cl amp bol ts to 19 N·m (170 i n. l bs.) torque.
(27) I nstal l sl ave cyl i nder i n cl utch housi ng.
(28) I nstal l ski d pl ate, i f equi pped. Ti ghten bol ts to
42 N·m (31 ft. l bs.) torque. Ti ghten stud nuts to 17
N·m (150 i n. l bs.) torque.
(29) Fi l l transmi ssi on and transfer case, i f
equi pped, wi th recommended l ubri cants. Refer to the
Lubri cant secti on of the appropri ate component for
correct fl ui d.
(30) Lower vehi cl e.
(31) I nstal l nuts on two M6X1.0 bol ts and thread
the bol ts i nto the threaded hol es at the base of the
shi ft l ever.
(32) Ti ghten the nuts equal l y unti l the shi ft l ever
wi l l sl i de over the shi ft tower stub shaft.
(33) I nstal l the fl oor consol e and shi ft boot.
SHIFT TOWER
REMOVAL
(1) Shi ft transmi ssi on i nto Neutral .
(2) Unscrew and remove the shi ft l ever extensi on
from the shi ft
(3) Remove any fl oor consol e components neces-
sary to access the transmi ssi on shi ft tower.
(4) Remove the bol ts hol di ng the shi ft tower to the
i sol ator pl ate and transmi ssi on gear case.
(5) Remove the shi ft tower (Fi g. 9) from the trans-
mi ssi on.
INSTALLATION
(1) Shi ft transmi ssi on i nto thi rd gear.
(2) Cl ean the mati ng surfaces of shi ft tower and
transmi ssi on gear case wi th sui tabl e wax and grease
remover.
(3) I nstal l the shi ft tower onto the transmi ssi on
case. No seal ant i s necessary between the shi ft tower
and transmi ssi on case.
(4) I nstal l the bol ts to hol d the shi ft tower to the
i sol ator pl ate and the transmi ssi on gear case.
Ti ghten the shi ft tower bol ts to 8.5 N·m (6.3 ft. l bs.).
(5) I nstal l the shi ft l ever extensi on and any fl oor
consol e components previ ousl y removed.
DISASSEMBLY AND ASSEMBLY
TRANSMISSION
DISASSEMBLY
FRONT HOUSING
(1) I f necessary, temporari l y rei nstal l shi ft l ever
assembl y. Shi ft transmi ssi on i nto Neutral .
(2) I f l ubri cant was not drai ned out of transmi s-
si on duri ng removal , remove drai n pl ug and drai n
l ubri cant i nto contai ner at thi s ti me.
(3) I nspect drai n pl ug magnet for debri s.
(4) Remove backup l i ght swi tch (Fi g. 10). Swi tch i s
l ocated on dri ver si de of rear housi ng.
(5) I f necessary, remove shi ft tower bol ts and
remove tower and l ever assembl y (Fi g. 11).
(6) Remove shi ft shaft l ock bol t (Fi g. 12). Bol t i s
l ocated at top of front housi ng just forward of shi ft
tower. Bol t i s a shoul der bol t that secures the shi ft
shaft bushi ng and l ever.
(7) Use Remover 8117 and sui tabl e sl i de hammer
to remove shi ft shaft detent pl ug.
(8) Remove shi ft shaft detent pl unger and spri ng
(Fi g. 13). Use penci l magnet to remove spri ng then
pl unger, i f necessary.
Fig. 9 Remove Shift Tower
1 – SHIFT TOWER AND LEVER ASSEMBLY
2 – SHIFT SOCKET
3 – SEAL
Fig. 10 Installing Backup Light Switch
1 – BACKUP LIGHT SWITCH
TJ NV3550 MANUAL TRANSMISSION 21 - 45
REMOVAL AND INSTALLATION (Continued)
(9) Remove bol ts attachi ng i nput shaft beari ng
retai ner to front housi ng (Fi g. 14).
(10) Remove i nput shaft beari ng retai ner. Use pry
tool to careful l y l i ft retai ner and break seal er bead
(Fi g. 15).
(11) Remove beari ng retai ner from i nput shaft
(Fi g. 16).
(12) Remove snap ri ng that secures i nput shaft i n
front beari ng (Fi g. 17).
(13) Remove bol ts that attach front housi ng to rear
housi ng.
Fig. 11 Shift Tower Removal
1 – SHIFT TOWER AND LEVER ASSEMBLY
2 – SHIFT SOCKET
3 – SEAL
Fig. 12 Shift Shaft Lock Bolt Removal
1 – SHIFT SHAFT LOCK BOLT
2 – SHAFT SOCKET
Fig. 13 Detent Plunger And Spring Removal
1 – FRONT HOUSING
2 – PLUG
3 – SPRING
4 – PLUNGER
Fig. 14 Input Shaft Bearing Retainer Bolt Removal—
Typical
1 – INPUT SHAFT BEARING RETAINER
2 – RETAINER BOLTS
21 - 46 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(14) Separate front housi ng from rear housi ng
(Fi g. 18). Use pl asti c mal l et to tap front housi ng off
al i gnment dowel s.
(15) Remove and i nspect i nput shaft beari ng.
I nspect countershaft front beari ng race (Fi g. 19).
(16) Note posi ti on of i nput shaft, shi ft shaft and
forks, and geartrai n components i n housi ng (Fi g. 20).
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER SEGMENT
(1) Unseat the rol l pi n that secures the shi ft
socket tot he shi ft shaft wi th Speci al Tool 6858 as fol -
l ows:
Fig. 15 Loosening Bearing Retainer Sealer
Bead—Typical
1 – PRY TOOL
2 – INPUT SHAFT BEARING RETAINER
Fig. 16 Input Shaft Bearing Retainer Removal—
Typical
1 – SHAFT BEARING
2 – BEARING RETAINER
3 – INPUT SHAFT
Fig. 17 Input Shaft Snap Ring Removal—Typical
1 – INPUT SHAFT SNAP RING
2 – OIL FEED
Fig. 18 Front Housing Removal
1 – FRONT HOUSING
2 – REAR HOUSING
3 – DOWELS (2)
4 – PLASTIC MALLET
Fig. 19 Input Shaft Bearing and Countershaft Front
Bearing Race Location
1 – INPUT SHAFT BEARING
2 – FRONT HOUSING
3 – COUNTERSHAFT FRONT BEARING
TJ NV3550 MANUAL TRANSMISSION 21 - 47
DISASSEMBLY AND ASSEMBLY (Continued)
(a) Posi ti on Tool 6858 on the shi ft shaft. Center
the tool over the rol l pi n and veri fy that the tool
l egs are fi rml y seated on the shi ft socket (Fi g. 21).
(b) Ti l t the socket toward the si de of the case.
Thi s posi ti ons the rol l pi n at a sl i ght angl e to avoi d
trappi ng the pi n between the gear teeth.
(c) Ti ghten the tool punch to press the rol l pi n
downward and out of the shi ft socket (Fi g. 21). The
rol l pi n does not have to be compl etel y removed
from the shi ft socket. The rol l pi n must onl y be
cl ear of the shi ft shaft. Be careful not to push the
pi n i nto the geartrai n.
(2) Usi ng a hammer and sui tabl e punch, dri ve out
rol l pi n that secures shi ft bushi ng and l ever to shi ft
shaft (Fi g. 22).
NOTE: Be sure to use the proper size punch to
avoid bending the shift shaft.
(3) Pul l shi ft shaft strai ght out of rear housi ng,
shi ft socket, fi fth-reverse fork, and 1-2 fork (Fi g. 23).
(4) Remove shi ft socket from rear housi ng (Fi g.
24).
(5) Remove l ever and bushi ng (Fi g. 25).
Fig. 20 Geartrain And Shift Component
Identification
1 – SHIFT SHAFT
2 – BUSHING
3 – REAR HOUSING
4 – REVERSE IDLER AND SUPPORT
5 – OUTPUT SHAFT AND GEARS
6 – COUNTERSHAFT
7 – 1–2 FORK
8 – INPUT SHAFT
9 – 3–4 FORK
Fig. 21 Removing the Shift Socket Roll Pin
1 – SPECIAL TOOL
6858
2 – SHIFT SOCKET
Fig. 22 Removing Shift Shaft Lever And Bushing
Roll Pin
1 – PIN PUNCH
2 – BUSHING AND LEVER
3 – SHIFT SHAFT
21 - 48 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Remove 3-4 fork. Rotate 3-4 fork around syn-
chro sl eeve unti l fork cl ears shi ft arms on 1-2 and
fi fth-reverse forks. Then remove 3-4 fork (Fi g. 26).
(7) Remove the reverse i dl er shaft support bol t
(front bol t) (Fi g. 27).
(8) Loosen rear reverse i dl er shaft bol t (rear bol t)
(Fi g. 27).
(9) Remove reverse i dl er shaft support segment by
sl i di ng i t strai ght out of housi ng.
(10) Support geartrai n and rear housi ng on Assem-
bl y Fi xture Tool 6747 as fol l ows:
(a) Adjust hei ght of reverse i dl er pedestal rod
unti l the reverse i dl e shaft bottoms i n Cup 8115.
(b) Posi ti on Adapters 6747-1A and 6747-2A on
Assembl y Fi xture 6747.
(c) Sl i de fi xture tool onto i nput shaft, counter-
shaft and i dl er gear (Fi g. 28).
Fig. 23 Shifter Shaft
1 – SHIFTER SHAFT
2 – SHIFTER SHAFT DETENT
3 – 3–4 SHIFT FORK
Fig. 24 Shift Socket And Roll Pin
1 – SHAFT BORE
2 – ROLL PIN
3 – SHIFT SOCKET
Fig. 25 Removing Shift Shaft Lever And Bushing
1 – SHAFT LEVER AND BUSHING
2 – 3–4 FORK
Fig. 26 Removing 3-4 Shift Fork
1 – 3–4 FORK
2 – 1–2 AND 5TH-REVERSE FORK ARMS
3 – 3–4 SYNCHRO SLEEVE
Fig. 27 Reverse Idler Shaft/Support Bolts
1 – SUPPORT BOLT
2 – SHAFT BOLT
TJ NV3550 MANUAL TRANSMISSION 21 - 49
DISASSEMBLY AND ASSEMBLY (Continued)
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-04-01 April, 2001
(d) Stand geartrai n and rear housi ng upri ght on
fi xture (Fi g. 29). Have hel per hol d fi xture tool i n
pl ace whi l e housi ng and geartrai n i s bei ng rotated
i nto upri ght posi ti on.
(11) Remove rear bol t hol di ng reverse i dl er shaft
i n housi ng.
REAR ADAPTER HOUSING REMOVAL
(1) Locate di mpl es i n face of rear seal (Fi g. 30).
Use a sui tabl e sl i de hammer mounted screw to
remove seal by i nserti ng screw i nto seal at di mpl e
l ocati ons (Fi g. 31).
(2) Remove rear beari ng snap ri ng from output
shaft wi th heavy duty snap ri ng pl i ers (Fi g. 32).
(3) Li ft rear adapter housi ng upward and off
geartrai n (Fi g. 33).
(4) Remove beari ng retai ner bol ts and remove rear
beari ng retai ner and rear beari ng (Fi g. 34). Use ham-
mer handl e to push or tap beari ng out of housi ng i f
needed.
(5) Exami ne condi ti on of beari ng bore, counter-
shaft rear beari ng race and i dl er shaft notch i n rear
Fig. 28 Installing Assembly Fixture On Geartrain
1 – SPECIAL TOOL 6747
2 – SPECIAL TOOL 6747–1A
3 – SPECIAL TOOL 8115
4 – REVERSE IDLER PEDESTAL
5 – SPECIAL TOOL 6747–2A
Fig. 29 Geartrain And Housing Mounted On Fixture
Tool
1 – INPUT SHAFT
2 – COUNTERSHAFT
3 – SPECIAL TOOL 6747
Fig. 30 Location Of Dimples In Seal Face
1 – LOCATION OF DIMPLES
2 – SEAL FACE
Fig. 31 Rear Seal Removal
1 – SLIDE HAMMER
2 – REMOVER TOOL
3 – REAR SEAL
21 - 50 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
housi ng. Repl ace housi ng i f race, bore or notch are
worn or damaged.
GEARTRAIN DISASSEMBLY FROM FIXTURE
(1) Remove reverse i dl er gear assembl y from
assembl y fi xture cup.
(2) Remove 1-2 and fi fth-reverse forks from syn-
chro sl eeves.
(3) Sl i de countershaft out of fi xture tool .
(4) Remove output shaft beari ng retai ner from
rear surface of fi fth gear (retai ner wi l l drop onto gear
after bol ts are removed).
(5) Li ft and remove output shaft and gears off
i nput shaft.
(6) Li ft and remove i nput shaft, pi l ot beari ng and
fourth gear synchro ri ng from assembl y fi xture tool .
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are dif-
ferent and must not be intermixed. It is recom-
mended that each synchronizer unit be removed as
an assembly to avoid intermixing parts. It is also
recommended that each synchro hub and sleeve be
marked with a scriber or paint for correct assembly
reference.
(1) Remove snap ri ng that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembl y, thi rd gear syn-
chro ri ng, and thi rd gear wi th shop press and
Remover Tool 1130. Posi ti on Tool 1130 between sec-
ond and thi rd gears.
(3) Remove thi rd gear needl e beari ng (Fi g. 35).
(4) Remove retai ni ng ri ng that secures two-pi ece
thrust washer on shaft (Fi g. 36). Use smal l pry tool
to remove retai ni ng ri ng.
(5) Remove two-pi ece thrust washer (Fi g. 37). Note
posi ti on of washer l ocati ng l ugs i n shaft notches for
i nstal l ati on reference.
(6) Remove second gear and needl e beari ng (Fi g.
38).
Fig. 32 Rear Bearing Snap Ring Removal
1 – HEAVY DUTY SNAP RING PLIERS
2 – REAR BEARING SNAP RING
3 – OUTPUT SHAFT
Fig. 33 Rear Adapter Housing Removal
1 – REAR ADAPTER HOUSING
2 – OUTPUT SHAFT
Fig. 34 Rear Adapter Housing Components
1 – BEARING RETAINER
2 – RETAINER BOLTS (3)
3 – IDLER SHAFT NOTCH
4 – COUNTERSHAFT REAR BEARING RACE
5 – REAR BEARING
TJ NV3550 MANUAL TRANSMISSION 21 - 51
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Remove second gear synchro ri ng, synchro fri c-
ti on cone, and synchro cone (Fi g. 39).
(8) Remove i nterm ri ng.
(9) Remove 1-2 synchro hub snap ri ng.
(10) Remove 1-2 synchro hub and sl eeve and fi rst
gear from output shaft wi th shop press and Remover
Tool 1130 (Fi g. 40). Posi ti on Tool 1130 between fi rst
and reverse gears.
(11) Remove fi rst gear needl e beari ng (Fi g. 41).
(12) Remove output shaft beari ng snap ri ng (Fi g.
42).
(13) On 2-wheel dri ve model s, remove output shaft
beari ng.
(14) Remove fi fth gear (Fi g. 43).
Fig. 35 Third Gear Needle Bearing Removal
1 – THIRD GEAR NEEDLE BEARING
Fig. 36 Thrust Washer Retaining Ring Removal
1 – PRY TOOL
2 – THRUST WASHER RETAINING RING
Fig. 37 Two-Piece Thrust Washer Removal
1 – SECOND GEAR
2 – THRUST WASHER (2–PIECE)
3 – WASHER LOCATING LUG
Fig. 38 Second Gear And Needle Bearing Removal
1 – SECOND GEAR
2 – SECOND GEAR NEEDLE BEARING
21 - 52 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(15) Remove fi fth gear needl e beari ng. Spread
beari ng apart just enough to cl ear shoul der on output
shaft (Fi g. 44).
(16) Remove fi fth-reverse synchro hub snap ri ng
(Fi g. 45).
(17) Remove fi fth-reverse synchro hub and sl eeve
wi th shop press (Fi g. 46).
(18) Remove reverse gear and needl e beari ng (Fi g.
47).
Fig. 39 Second Gear Synchro Ring And Cones
Removal
1 – 1–2 SYNCHRO HUB AND SLEEVE
2 – INTERM RING
3 – SYNCHRO FRICTION CONE
4 – SYNCHRO CONE
5 – SYNCHRO RING
Fig. 40 Hub And Sleeve Removal—1-2 Synchro
1 – 1–2 SYNCHRO HUB AND SLEEVE
2 – SPECIAL TOOL
1130
Fig. 41 First Gear Needle Bearing Removal
1 – FIRST GEAR NEEDLE BEARING
Fig. 42 Output Shaft Bearing Snap Ring Removal
1 – OUTPUT SHAFT BEARING
2 – BEARING SNAP RING
3 – SNAP RING PLIERS
Fig. 43 Fifth Gear Removal
1 – FIFTH GEAR AND SYNCHRO RING
TJ NV3550 MANUAL TRANSMISSION 21 - 53
DISASSEMBLY AND ASSEMBLY (Continued)
REVERSE IDLER DISASSEMBLY
(1) Remove i dl er gear snap ri ngs (Fi g. 48).
(2) Remove thrust washer, wave washer, thrust
pl ate and i dl er gear from shaft.
(3) Remove i dl er gear needl e beari ng from shaft.
ASSEMBLY
Gaskets are not used i n the NV3550 transmi ssi on.
Seal ers are used at al l case joi nts. Recommended
seal ers are Mopar௡ Gasket Maker for al l case joi nts
and Mopar௡ si l i cone seal er, or equi val ent, for the
i nput shaft beari ng retai ner. Appl y these products as
i ndi cated i n the assembl y procedures.
NOTE: It is very important that the transmission
shift components be in Neutral position during
assembly. This is necessary to prevent damaging
synchro and shift components when the housings
are installed.
The 3-4, 1-2 and fi fth-reverse synchro hub snap
ri ngs can be fi tted sel ecti vel y. New snap ri ngs are
avai l abl e i n 0.05 mm (0.0019 i n.) thi ckness i ncre-
Fig. 44 Fifth Gear Needle Bearing Removal
1 – FIFTH GEAR NEEDLE BEARING (SPREAD BEARING TO
CLEAR SHOULDER ON SHAFT)
Fig. 45 Fifth-Reverse Synchro Hub Snap Ring
Removal
1 – FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 – SYNCHRO HUB SNAP RING
3 – SNAP RING PLIERS
Fig. 46 Fifth-Reverse Synchro Hub And Sleeve
Removal
1 – PRESS
2 – FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 – REVERSE GEAR
4 – OUTPUT SHAFT
Fig. 47 Reverse Gear And Needle Bearing Removal
1 – REVERSE GEAR AND NEEDLE BEARING
21 - 54 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
ments. Use the thi ckest snap ri ng that wi l l fi t i n
each snap ri ng groove.
SYNCHRONIZER
The easi est method of assembl i ng each synchro i s
to i nstal l the spri ngs, struts and detent bal l s one at a
ti me as fol l ows:
(1) Sl i de the sl eeve part way onto the hub. Leave
enough room to i nstal l the spri ng i n the hub and the
strut i n the hub groove.
(2) I nstal l the fi rst spri ng i n the hub. Then i nstal l
a strut over the spri ng. Be sure the spri ng i s seated
i n the spri ng bore i n the strut.
(3) Sl i de the sl eeve onto the hub just far enough to
hol d the fi rst strut and spri ng i n pl ace.
(4) Pl ace the detent bal l i n the top of the strut.
Then careful l y work the sl eeve over the bal l to hol d
i t i n pl ace. A smal l fl at bl ade screwdri ver can be used
to press the bal l i nto pl ace whi l e movi ng the sl eeve
over i t.
(5) Repeat the procedure for the remai ni ng
spri ngs, struts and bal l s. Tape, or a rubber band can
be used to temporari l y secure each strut and bal l as
they are i nstal l ed.
(6) Veri fy synchro assembl y. Be sure the three
spri ngs, struts and detent bal l s are al l i n pl ace (Fi g.
49).
OUTPUT SHAFT
(1) Lubri cate shaft, gears and beari ngs wi th rec-
ommended l ubri cant duri ng assembl y. Petrol eum
jel l y can be used to hol d parts i n pl ace.
(2) Check beari ng surfaces of output shaft for
ni cks or scratches. Smooth surfaces wi th 320/400 gri t
emery cl oth i f necessary. Appl y oi l to emery cl oth and
shaft surface before pol i shi ng.
(3) I nspect and repl ace any synchro ri ng that
exhi bi ts wear or damage. Compl etel y i mmerse each
synchro ri ng i n l ubri cant before i nstal l ati on.
Fig. 48 Reverse Idler Components
1 – SNAP RING
2 – FLAT WASHER
3 – WAVE WASHER
4 – THRUST WASHER
5 – REVERSE IDLER GEAR
6 – IDLER GEAR BEARING
7 – IDLER SHAFT
8 – THRUST WASHER
9 – SNAP RING
10 – THRUST WASHER LOCK BALLS
Fig. 49 Assembled View Of Synchro Components
1 – SLEEVE
2 – HUB SHOULDER
3 – SPRING (3)
4 – STRUT (3)
5 – DETENT BALL (3)
6 – HUB
TJ NV3550 MANUAL TRANSMISSION 21 - 55
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Lubri cate and i nstal l reverse gear needl e bear-
i ng on shaft (Fi g. 50). Sl i de beari ng up agai nst shoul -
der on output shaft.
(5) I nstal l reverse gear over needl e beari ng (Fi g.
51).
(6) I nstal l sol i d brass synchro ri ng on reverse gear
(Fi g. 52).
(7) Assembl e fi fth-reverse synchro hub, sl eeve,
struts, spri ngs and detent bal l s, i f not previ ousl y
done.
CAUTION: The fifth-reverse synchro hub and
sleeve can be installed backwards if care is not
exercised. One side of the hub has shoulders
around the hub bore. Make sure this side of the hub
is facing the front of the shaft. In addition, one side
of the sleeve is tapered. Be sure the sleeve is
installed so the tapered side will be facing the front
of the shaft.
(8) Start fi fth-reverse synchro assembl y on output
shaft spl i nes by hand. Then seat synchro onto shaft
wi th shop press and Remover 6310-1 (Fi g. 53).
(9) I nstal l new fi fth-reverse hub snap ri ng (Fi g.
54) as fol l ows:
(a) Snap ri ngs are avai l abl e i n thi cknesses from
2.00 mm to 2.20 mm (0.078 to 0.086 i n.).
(b) I nstal l thi ckest snap ri ng that wi l l fi t i n
shaft groove.
(c) Veri fy that snap ri ng i s compl etel y seated i n
groove before proceedi ng.
Fig. 50 Reverse Gear Bearing Installation
1 – REVERSE GEAR BEARING
2 – SHOULDER
Fig. 51 Reverse Gear Installation
1 – REVERSE GEAR
Fig. 52 Reverse Gear Synchro Ring Installation
1 – REVERSE GEAR
2 – SYNCHRO RING (SOLID BRASS)
Fig. 53 Fifth-Reverse Synchro Assembly Installation
1 – SPACER
2 – PRESS RAM
3 – REVERSE GEAR
4 – FIFTH-REVERSE SYNCHRO ASSEMBLY
5 – SPECIAL TOOL
6310–1
6 – PRESS BLOCKS
7 – OUTPUT SHAFT
21 - 56 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(10) I nstal l fi fth gear synchro ri ng i n synchro hub
and sl eeve (Fi g. 55).
(11) I nstal l fi fth gear beari ng. Spread beari ng onl y
enough to cl ear shoul der on output shaft (Fi g. 56). Be
sure beari ng i s properl y seated after i nstal l ati on.
(12) I nstal l fi fth gear on shaft and onto beari ng
(Fi g. 57).
(13) I nvert output shaft and set the shaft i n
Remover 6310-1 so that fi fth gear i s seated on the
tool (Fi g. 58).
(14) I nstal l fi rst gear beari ng on output shaft (Fi g.
58). Be sure beari ng i s seated on shaft shoul der and
i s properl y joi ned.
(15) I nstal l fi rst gear on shaft and over beari ng
(Fi g. 59). Make sure beari ng synchro cone i s faci ng
up as shown.
(16) I nstal l fi rst gear synchro ri ng (Fi g. 60).
(17) Assembl e 1-2 synchro hub sl eeve, spri ngs,
struts and detent bal l s.
CAUTION: The 1-2 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the synchro sleeve is marked First Gear
Side. Be sure this side of the sleeve will face first
gear after installation.
Fig. 54 Installing Fifth-Reverse Synchro Hub Snap
Ring
1 – FIFTH-REVERSE SYNCHRO ASSEMBLY
2 – SNAP RING
3 – PRESS BED
4 – PRESS BLOCKS
Fig. 55 Installing Fifth Gear Synchro Ring
1 – FIFTH-SPEED SYNCHRO RING
2 – FIFTH-REVERSE SYNCHRO ASSEMBLY
Fig. 56 Installing Fifth Gear Bearing
1 – SHAFT SHOULDER
2 – FIFTH GEAR BEARING
Fig. 57 Fifth Gear Installation
1 – FIFTH GEAR
2 – BEARING
TJ NV3550 MANUAL TRANSMISSION 21 - 57
DISASSEMBLY AND ASSEMBLY (Continued)
(18) Start 1-2 synchro assembl y on shaft by hand
(Fi g. 61). Be sure synchro sl eeve i s properl y posi -
ti oned. Si de marked fi rst si de must be faci ng fi rst
gear.
(19) Press 1-2 synchro onto output shaft usi ng
sui tabl e si ze pi pe tool and shop press (Fi g. 62).
CAUTION: Take time to align the synchro ring and
sleeve as hub the is being pressed onto the shaft.
The synchro ring can be cracked if it becomes mis-
aligned.
(20) I nstal l i nterm ri ng.
(21) I nstal l new 1-2 synchro hub snap ri ng (Fi g.
63) as fol l ows:
(a) Snap ri ngs are avai l abl e i n thi cknesses from
1.80 mm to 2.00 mm (0.070 to 0.078 i n.).
(b) I nstal l thi ckest snap ri ng that wi l l fi t i n
shaft groove.
(c) Veri fy that snap ri ng i s compl etel y seated i n
groove before proceedi ng.
Fig. 58 First Gear Bearing Installation
1 – FIRST GEAR BEARING
2 – SHAFT SHOULDER
3 – SPECIAL TOOL 6310–1
4 – PRESS BLOCKS
Fig. 59 First Gear Installation
1 – FIRST GEAR
2 – SPECIAL TOOL 6310–1
3 – BEARING
Fig. 60 First Gear Synchro Ring Installation
1 – FIRST GEAR SYNCHRO RING
2 – SPECIAL TOOL 6310–1
3 – FIRST GEAR
Fig. 61 Starting 1-2 Synchro On Shaft
1 – 1–2 SYNCHRO ASSEMBLY
2 – SPECIAL TOOL 6310–1
3 – BE SURE THIS IS “FIRST GEAR SIDE” OF SYNCHRO
SLEEVE
21 - 58 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(22) I nstal l second gear synchro ri ng i n 1-2 syn-
chro hub and sl eeve (Fi g. 64). Be sure synchro ri ng i s
properl y seated i n sl eeve.
(23) I nstal l synchro fri cti on cone and synchro cone
i n synchro ri ng.
(24) I nstal l second gear needl e beari ng on shaft
(Fi g. 65).
(25) I nstal l second gear onto shaft and beari ng
(Fi g. 66). Make sure that second gear i s ful l y seated
on synchro components.
(26) I nstal l two-pi ece thrust washer (Fi g. 67). Be
sure washer hal ves are seated i n shaft groove and
that washer l ugs are seated i n shaft l ug bores. Al so,
ensure that the i .d. grooves and marki ngs noted dur-
i ng removal are faci ng the correct di recti on.
Fig. 62 Pressing 1-2 Synchro Assembly Onto Output
Shaft
1 – SUITABLE SIZE PIPE TOOL
2 – SYNCHRO RING
3 – SPECIAL TOOL 6310–1
4 – 1–2 SYNCHRO ASSEMBLY
5 – PRESS RAM
Fig. 63 Installing 1-2 Synchro Hub Snap Ring
1 – 1–2 SYNCHRO
2 – SPECIAL TOOL 6310–1
3 – SYNCHRO SNAP RING
Fig. 64 Second Gear Synchro Ring Installation
1 – SECOND GEAR SYNCHRO RING
2 – 1–2 SYNCHRO
3 – SPECIAL TOOL 6310–1
Fig. 65 Second Gear Bearing Installation
1 – SECOND GEAR BEARING
2 – SPECIAL TOOL
6310–1
TJ NV3550 MANUAL TRANSMISSION 21 - 59
DISASSEMBLY AND ASSEMBLY (Continued)
(27) Start retai ni ng ri ng around two-pi ece thrust
washer (Fi g. 68). Make sure that the l ocati ng di mpl e
i s between the thrust washer hal ves.
(28) Seat thrust washer retai ni ng ri ng wi th pl asti c
mal l et (Fi g. 69).
(29) I nstal l thi rd gear needl e beari ng on shaft (Fi g.
70).
(30) I nstal l thi rd gear on shaft and beari ng (Fi g.
71).
(31) I nstal l thi rd speed synchro ri ng on thi rd gear
(Fi g. 72).
Fig. 66 Second Gear Installation
1 – SPECIAL TOOL 6310–1
2 – 1–2 SYNCHRO ASSEMBLY
3 – BEARING
4 – SECOND GEAR
Fig. 67 Installing Two-Piece Thrust Washer
1 – WASHER GROOVE IN SHAFT
2 – LUG BORE
3 – THRUST WASHER LUGS
4 – LUG BORE
5 – LUG
6 – WASHER HALF
Fig. 68 Starting Retaining Ring Over Two-Piece
Thrust Washer
1 – THRUST WASHER RETAINING RING
2 – THRUST WASHER HALVES
3 – SECOND GEAR
4 – LOCATING DIMPLE
Fig. 69 Seating Thrust Washer Retaining Ring
1 – PLASTIC MALLET
2 – THRUST WASHER RETAINING RING
21 - 60 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(32) Assembl e 3-4 synchro hub, sl eeve, spri ngs,
struts and detent bal l s.
CAUTION: The 3-4 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the sleeve has grooves in it. Be sure this
side of sleeve is also facing the front of the shaft.
(33) Start 3-4 synchro hub on output shaft spl i nes
by hand (Fi g. 73).
(34) Press 3-4 synchro assembl y onto output shaft
wi th shop press and sui tabl e si ze pi pe tool (Fi g. 74).
Make sure that the tool presses on hub as cl ose to
output shaft as possi bl e but does not contact the
shaft spl i nes.
(35) I nstal l 3-4 synchro hub snap ri ng (Fi g. 75) as
fol l ows:
(a) Snap ri ngs are avai l abl e i n thi cknesses from
2.00 mm to 2.30 mm (0.078 to 0.090 i n.).
(b) I nstal l thi ckest snap ri ng that wi l l fi t i n
shaft groove. Use heavy duty snap ri ng pl i ers to
i nstal l new ri ng.
(c) Veri fy that snap ri ng i s compl etel y seated i n
groove before proceedi ng.
(36) I nstal l output shaft beari ng.
(37) I nstal l output shaft beari ng snap ri ng (Fi g.
76). Use heavy duty snap ri ng pl i ers and spread snap
ri ng onl y enough to i nstal l i t. Be sure snap ri ng i s
compl etel y seated i n shaft groove before proceedi ng.
(38) Veri fy correct posi ti on of synchro sl eeves
before proceedi ng wi th assembl y operati ons (Fi g. 77).
Grooved si de of 3-4 sl eeve shoul d be faci ng forward.
Fi rst gear si de of 1-2 sl eeve shoul d be faci ng fi rst
gear. Tapered si de of fi fth-reverse sl eeve shoul d be
faci ng forward.
Fig. 70 Third Gear Bearing Installation
1 – THIRD GEAR BEARING
Fig. 71 Installing Third Gear
1 – THIRD GEAR
2 – BEARING
Fig. 72 Third Speed Synchro Ring Installation
1 – THIRD SPEED SYNCHRO RING
2 – THIRD GEAR
Fig. 73 Starting 3-4 Synchro Hub On Output Shaft
1 – GROOVED SIDE OF SLEEVE (TO FRONT)
2 – 3–4 SYNCHRO ASSEMBLY
TJ NV3550 MANUAL TRANSMISSION 21 - 61
DISASSEMBLY AND ASSEMBLY (Continued)
REVERSE IDLER ASSEMBLY
(1) Lubri cate i dl er components wi th gear l ube.
(2) Sl i de i dl er gear beari ng on shaft (Fi g. 78).
Beari ng fi ts ei ther way on shaft.
(3) Sl i de gear onto shaft. Si de of gear wi th recess
goes to rear (Fi g. 78).
(4) Pl ace fi rst l ock bal l i n di mpl e at rear end of
i dl er shaft (Fi g. 78). Petrol eum jel l y can be used to
hol d bal l i n pl ace i f desi red.
(5) Sl i de thrust rear thrust washer onto shaft and
over l ock bal l (Fi g. 79).
(6) I nstal l snap ri ng i n groove at rear of shaft (Fi g.
79).
(7) I nstal l l ock bal l i n di mpl e at front of shaft.
Hol d bal l i n pl ace wi th petrol eum jel l y i f desi red.
(8) I nstal l front thrust washer on shaft and sl i de
washer up agai nst gear and over l ock bal l (Fi g. 80).
(9) I nstal l wave washer, fl at washer and remai n-
i ng snap ri ng on i dl er shaft (Fi g. 80). Be sure snap
ri ng i s ful l y seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/BEARINGS
(1) I nspect shi ft shaft bushi ng and beari ng for
damage.
(2) I f necessary, the shi ft shaft bushi ng can be
repl aced as fol l ows:
Fig. 74 Pressing 3-4 Synchro Assembly On Output
Shaft
1 – PRESS RAM
2 – PIPE TOOL
3 – 3–4 SYNCHRO
4 – THIRD SPEED SYNCHRO RING
Fig. 75 Installing 3-4 Synchro Hub Snap Ring
1 – 3–4 SYNCHRO HUB SNAP RING
2 – HEAVY DUTY SNAP RING PLIERS
Fig. 76 Installing Output Shaft Bearing Snap Ring
1 – BEARING SNAP RING
2 – HEAVY DUTY SNAP RING PLIERS
21 - 62 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(a) Locate a bol t that wi l l thread i nto the bush-
i ng wi thout great effort.
(b) Thread the bol t i nto the bushi ng, al l owi ng
the bol t to make i ts own threads i n the bushi ng.
Fig. 77 Correct Synchro Sleeve Position
1 – DOUBLE GROOVE FORWARD
2 – GROOVE FORWARD
3 – FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 – TAPER FORWARD
5 – GROOVE FORWARD
6 – 5TH-REV SYNCHRO SLEEVE
7 – 1–2 SYNCHRO SLEEVE
8 – 3–4 SYNCHRO SLEEVE
Fig. 78 Idler Gear And Bearing Installation
1 – IDLER GEAR
2 – BEARING
3 – LOCK BALL
4 – REAR OF SHAFT
Fig. 79 Idler Gear Rear Thrust Washer Installation
1 – LOCK BALL
2 – SNAP RING GROOVE
3 – THRUST WASHER
TJ NV3550 MANUAL TRANSMISSION 21 - 63
DISASSEMBLY AND ASSEMBLY (Continued)
(c) Attach a sl i de hammer or sui tabl e pul l er to
the bol t and remove bushi ng.
(d) Use the short end of I nstal l er 8119 to i nstal l
the new bushi ng.
(e) The bushi ng i s correctl y i nstal l ed i f the bush-
i ng i s fl ush wi th the transmi ssi on case.
(3) I f necessary, the shi ft shaft beari ng can be
repl aced as fol l ows:
(a) Locate a bol t that wi l l thread i nto the bear-
i ng wi thout great effort.
(b) Thread the bol t i nto the beari ng as much as
possi bl e.
(c) Attach a sl i de hammer or sui tabl e pul l er to
the bol t and remove the beari ng.
(d) Use the short end of I nstal l er 8119 to i nstal l
the new beari ng.
(e) The beari ng i s correctl y i nstal l ed i f the bear-
i ng i s fl ush wi th the transmi ssi on case.
(4) I nspect detent pl unger bushi ngs for damage.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(5) I f necessary, the detent pl unger bushi ngs can
be repl aced as fol l ows:
(a) Usi ng the l ong end of I nstal l er 8119, dri ve
the detent bushi ngs through the outer case and
i nto the shi ft shaft bore.
(b) Remove the bushi ngs from the shi ft shaft
bore.
(c) I nstal l a new detent pl unger bushi ng on the
l ong end of I nstal l er 8118.
(d) Start the bushi ng i n the detent pl unger bore
i n the case.
(e) Dri ve the bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
(f) I nstal l a new detent pl unger bushi ng on the
short end of I nstal l er 8118.
(g) Start the bushi ng i n the detent pl unger bore
i n the case.
(h) Dri ve the bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
GEARTRAIN ASSEMBLY
(1) I nstal l Adapter 6747-1A on i nput shaft hub of
fi xture tool (Fi g. 81). Then i nstal l Adapter 6747-2A
on front beari ng hub of countershaft. Adapter
6747-2A has a rai sed shoul der on one si de. Be sure
the shoul der i s seated agai nst the countershaft.
Fig. 80 Idler Gear And Shaft Assembly
1 – REAR OF SHAFT
2 – GEAR
3 – THRUST WASHER AND BALL
4 – WAVE WASHER
5 – FLAT WASHER
6 – FRONT OF SHAFT
7 – SNAP RING
8 – SNAP RING
Fig. 81 Preparing Assembly Fixture For Geartrain
Build-up
1 – SPECIAL TOOL 6747–2A (INSTALL ON COUNTERSHAFT
FRONT HUB)
2 – SPECIAL TOOL 8115
3 – SPECIAL TOOL 6747–1A
4 – SPECIAL TOOL 6747
21 - 64 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(2) I nstal l i nput shaft i n fi xture tool . Make sure
Adapter Tool 6747-1A i s posi ti oned under shaft as
shown (Fi g. 82).
(3) I nstal l pi l ot beari ng i n i nput shaft (Fi g. 82).
NOTE: There is a correct and an incorrect way to
install the pilot bearing into the input shaft. The
side of the pilot bearing with the small diameter
goes toward the input shaft.
(4) I nstal l fourth gear synchro ri ng on i nput shaft
(Fi g. 83).
(5) Adjust hei ght of i dl er gear pedestal on assem-
bl y fi xture (Fi g. 84). Start wi th a basi c hei ght of 18.4
cm (7-1/4 i n.). Fi nal adjustment can be made after
gear i s posi ti oned on pedestal .
(6) I nstal l assembl ed output shaft and geartrai n i n
i nput shaft (Fi g. 85). Careful l y rotate output shaft
unti l the 3–4 synchro ri ng seats i n synchro hub and
sl eeve.
Fig. 82 Installing Pilot Bearing In Input Shaft
1 – PILOT BEARING
2 – INPUT SHAFT
Fig. 83 Installing Fourth Gear Synchro Ring On
Input Shaft
1 – FOURTH GEAR SYNCHRO RING
2 – INPUT SHAFT
Fig. 84 Idler Pedestal Basic Height Adjustment
1 – REVERSE IDLER PEDESTAL
Fig. 85 Output Shaft And Geartrain Installed In Input
Shaft
1 – OUTPUT SHAFT AND GEARTRAIN
2 – INPUT SHAFT
3 – SPECIAL TOOL 6747
TJ NV3550 MANUAL TRANSMISSION 21 - 65
DISASSEMBLY AND ASSEMBLY (Continued)
(7) I nstal l Adapter 6747-2A on front beari ng hub of
countershaft, i f not previ ousl y done. The adapter has
a shoul der on one si de. The shoul der goes toward the
countershaft.
(8) Sl i de countershaft (and adapter) i nto fi xture
sl ot. Veri fy that countershaft and output shaft gears
are ful l y meshed wi th the mai nshaft gears before
proceedi ng (Fi g. 86).
(9) Check al i gnment of countershaft and output
shaft gear teeth. Note that gears may not al i gn per-
fectl y. A di fference i n hei ght of 1.57 to 3.18 mm (1/16
to 1/8 i n.) wi l l probabl y exi st. Thi s di fference wi l l not
i nterfere wi th assembl y. However, i f the di fference i s
greater than thi s, the countershaft adapter tool i s
probabl y upsi de down. Remove countershaft, reverse
adapter tool , rei nstal l countershaft and check al i gn-
ment agai n.
(10) Posi ti on reverse i dl er i n support cup of assem-
bl y fi xture (Fi g. 87). Be sure i dl er gear i s properl y
meshed and al i gned wi th shaft gear teeth and that
bol t hol es are faci ng out and not toward geartrai n.
Adjust pedestal up or down i f necessary. Al so be sure
that short end of i dl er shaft i s faci ng up as shown.
(11) On 2-wheel dri ve transmi ssi on, thread one
Pi l ot Stud 8120 i n center or passenger si de hol e of
output shaft beari ng retai ner. Then posi ti on retai ner
on fi fth gear as shown (Fi g. 88).
Fig. 86 Countershaft Installed On Fixture Tool
1 – OUTPUT SHAFT AND GEARTRAIN
2 – COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
Fig. 87 Reverse Idler Assembly Positioned On
Assembly Fixture Pedestal
1 – OUTPUT SHAFT AND GEARTRAIN
2 – COUNTERSHAFT
3 – REVERSE IDLER ASSEMBLY
4 – TOOL PEDESTAL
Fig. 88 Positioning Output Shaft Bearing Retainer
For Rear Housing Installation
1 – SPECIAL TOOL
8120
2 – OUTPUT SHAFT BEARING RETAINER
21 - 66 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Assembl e 1-2 and fi fth reverse-shi ft forks (Fi g.
89). Arm of fi fth-reverse fork goes through sl ot i n 1-2
fork.
(13) I nstal l assembl ed shi ft forks i n synchro
sl eeves (Fi g. 90). Be sure forks are properl y seated i n
sl eeves.
ADAPTER HOUSING
(1) I nstal l rear beari ng i n adapter housi ng. Use
wood hammer handl e or wood dowel to tap beari ng
i nto pl ace.
(2) Posi ti on rear beari ng retai ner i n adapter hous-
i ng (Fi g. 91).
(3) Appl y Mopar௡ Gasket Maker, or equi val ent, to
threads, bol t shanks and under hex heads of beari ng
retai ner bol ts (Fi g. 94).
(4) Appl y l i beral quanti ty of petrol eum jel l y to
countershaft rear beari ng and beari ng race.
(5) I nstal l countershaft rear beari ng i n beari ng
race (Fi g. 92).
CAUTION: The countershaft bearings can be
installed backwards if care is not exercised. Be
sure the large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 93).
(6) Appl y extra petrol eum jel l y to hol d counter-
shaft rear beari ng i n pl ace when housi ng i s i nstal l ed.
Fig. 89 Assembling 1-2 And Fifth-Reverse Shift
Forks
1 – INSERT ARM THROUGH 1–2 FORK
2 – 1–2 FORK
3 – FIFTH-REVERSE FORK
Fig. 90 Shift Forks Installed In Synchro Sleeves
1 – SYNCHRO SLEEVES
2 – FORK ARMS
3 – SHIFT FORKS
Fig. 91 Preparing Adapter Housing For Installation
1 – BEARING RETAINER
2 – RETAINER BOLTS (3)
3 – IDLER SHAFT NOTCH
4 – COUNTERSHAFT REAR BEARING RACE
5 – REAR BEARING
TJ NV3550 MANUAL TRANSMISSION 21 - 67
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Appl y l i ght coat of petrol eum jel l y to shi ft shaft
bushi ng/beari ng i n adapter housi ng (Fi g. 93).
(8) I nstal l adapter housi ng on geartrai n.
(9) I nstal l rear beari ng snap ri ng on output shaft
(Fi g. 94).
(10) Lubri cate l i p of new rear seal (Fi g. 95) wi th
Mopar௡ Door Ease, or transmi ssi on fl ui d.
(11) I nstal l new rear seal i n adapter housi ng bore
wi th I nstal l er C-3860-A. Be sure seal i s ful l y seated
i n housi ng bore (Fi g. 95).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT
SOCKET
(1) Before proceedi ng, veri fy that al l synchro
sl eeves are i n Neutral posi ti on (centered on hub).
Move sl eeves i nto neutral i f necessary.
CAUTION: The transmission synchros must all be
in Neutral position for proper reassembly. Other-
wise, the housings, shift forks and gears can be
damaged during installation of the two housings.
(2) I nstal l 3-4 shi ft fork i n synchro sl eeve (Fi g. 96).
Veri fy that groove i n fork arm i s al i gned wi th grooves
i n 1-2 and fi fth-reverse fork arms as shown.
Fig. 92 Lubricating the Countershaft Rear Bearing
1 – COUNTERSHAFT REAR BEARING
2 – REAR BEARING RACE
3 – REAR HOUSING
4 – PETROLEUM JELLY (APPLY TO BEARING AND RACE)
Fig. 93 Countershaft Rear Bearing Installation
1 – SHIFT SHAFT BUSHING/BEARING
2 – COUNTERSHAFT REAR BEARING (SEATED IN RACE)
Fig. 94 Installing Rear Bearing Snap Ring
1 – HEAVY DUTY SNAP RING PLIERS
2 – REAR BEARING SNAP RING
3 – OUTPUT SHAFT
Fig. 95 Rear Seal Installation
1 – REAR SEAL
2 – SEAL LIP
3 – OUTPUT SHAFT
21 - 68 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Sl i de shi ft shaft through 3-4 shi ft fork (Fi g.
97). Be sure shaft detent notches are to the rear.
(4) Assembl e shi ft shaft shi ft l ever and bushi ng
(Fi g. 98). Be sure sl ot i n bushi ng i s faci ng up and rol l
pi n hol e for l ever i s al i gned wi th hol e i n shaft.
(5) I nstal l assembl ed l ever and bushi ng on shi ft
shaft (Fi g. 99).
(6) Sl i de shi ft shaft through 1-2 and fi fth-reverse
fork and i nto shi ft l ever openi ng i n rear housi ng (Fi g.
100).
(7) Al i gn shi ft socket wi th shaft and sl i de shaft
through socket and i nto shi ft shaft beari ng i n rear
housi ng (Fi g. 101).
(8) Rotate shi ft shaft so detent notches i n shaft are
faci ng the TOP of the transmi ssi on housi ng.
CAUTION: Correct positioning of the shift shaft
detent notch is important. Both of the shaft roll pins
can be installed even when the shaft is 180° off. If
this occurs, the transmission will have to be disas-
sembled again to correct shaft alignment.
(9) Sel ect correct new rol l pi n for shi ft shaft l ever
(Fi g. 102). Shaft l ever rol l pi n i s approxi matel y 22
mm (7/8 i n.) l ong. Shi ft socket rol l pi n i s approxi -
matel y 33 mm (1-1/4 i n.) l ong.
(10) Al i gn rol l pi n hol es i n shi ft shaft, l ever and
bushi ng. Then start rol l pi n i nto shaft l ever by hand
(Fi g. 103).
(11) Seat shaft l ever rol l pi n wi th pi n punch (Fi g.
104).
Fig. 96 Installing 3-4 Shift Fork
1 – 3–4 FORK
2 – ALIGN GROOVES IN FORK ARMS
Fig. 97 Shifter Shaft
1 – SHIFTER SHAFT
2 – SHIFTER SHAFT DETENT
3 – 3–4 SHIFT FORK
Fig. 98 Assembling Shift Shaft Lever And Bushing
1 – SHAFT LEVER
2 – LEVER BUSHING
3 – BUSHING LOCK PIN SLOT
Fig. 99 Installing Shift Shaft Lever And Bushing
1 – SHIFT SHAFT
2 – SHAFT LEVER AND BUSHING
3 – 3–4 FORK
TJ NV3550 MANUAL TRANSMISSION 21 - 69
DISASSEMBLY AND ASSEMBLY (Continued)
2000 TJ Service Manual
Publication No. 81-370-0048
TSB 26-04-01 April, 2001
CAUTION: The shaft lever roll pin must be flush
with the surface of the lever. The lever bushing will
bind on the roll pin if the pin is not seated flush.
(12) Before proceedi ng, veri fy that l ock pi n sl ot i n
l ever bushi ng i s posi ti oned as shown (Fi g. 104).
(13) Al i gn rol l pi n hol es i n shi ft socket and shi ft
shaft. Then start rol l pi n i nto shi ft shaft by hand
(Fi g. 105).
(14) Seat rol l pi n i n shi ft socket wi th pi n punch.
Rol l pi n must be fl ush wi th socket after i nstal l ati on
(Fi g. 106).
(15) Veri fy that notches i n shi ft fork arms are
al i gned. Real i gn arms i f necessary.
Fig. 100 Inserting Shaft Into Lever Opening In
Housing
1 – SHIFT SHAFT
Fig. 101 Shift Socket Installation
1 – SHIFT SOCKET
2 – SHIFT SHAFT
Fig. 102 Roll Pin Identification—Shaft Lever And
Shift Socket
1 – SHAFT LEVER ROLL PIN
2 – SHIFT SOCKET ROLL PIN
Fig. 103 Starting Roll Pin In Shift Shaft Lever
1 – SHAFT LEVER ROLL PIN (
7
⁄8” LONG)
2 – LEVER AND BUSHING
Fig. 104 Correct Seating Of Shift Shaft Lever Roll
Pin
1 – BUSHING LOCK PIN SLOT
2 – SEAT ROLL PIN FLUSH WITH LEVER
21 - 70 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER
(1) I f previ ousl y removed, i nstal l i nput shaft bear-
i ng i n front housi ng bore (Fi g. 107). I nstal l snap ri ng
and use pl asti c mal l et to seat beari ng. Beari ng goes
i n from front si de of housi ng onl y.
(2) Appl y l i beral quanti ty of petrol eum jel l y to
countershaft front beari ng. Then i nsert beari ng i n
front housi ng race (Fi g. 107). Large di ameter si de of
beari ng cage goes toward countershaft (Fi g. 108).
Smal l di ameter si de goes toward beari ng race i n
housi ng.
(3) Reach i nto countershaft front beari ng wi th fi n-
ger, and push each beari ng rol l er outward agai nst
race. Then appl y extra petrol eum jel l y to hol d rol l ers
i n pl ace. Thi s avoi ds havi ng rol l ers becomi ng di s-
pl aced duri ng housi ng i nstal l ati on. Thi s wi l l resul t i n
mi sal i gnment between beari ng and countershaft
beari ng hub.
Fig. 105 Starting Roll Pin In Shift Socket
1 – ROLL PIN
2 – SHIFT SOCKET
3 – SHIFT SHAFT
Fig. 106 Seating Shift Socket Roll Pin
1 – PIN PUNCH
2 – SHIFT SOCKET
3 – SEAT ROLL PIN FLUSH
4 – SHIFT SOCKET
Fig. 107 Input Shaft Bearing And Countershaft Front
Bearing
1 – INPUT SHAFT BEARING
2 – COUNTERSHAFT FRONT BEARING
3 – SHIFT SHAFT BUSHING
Fig. 108 Lubricating/Positioning Countershaft Front
Bearing
1 – BEARING RACE
2 – PETROLEUM JELLY
3 – COUNTERSHAFT FRONT BEARING
TJ NV3550 MANUAL TRANSMISSION 21 - 71
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Appl y smal l amount of petrol eum jel l y to shi ft
shaft bushi ng i n front housi ng.
(5) Appl y 1/8 i n. wi de bead of Mopar௡ Gasket
Maker, or equi val ent, to mati ng surfaces of front and
rear housi ngs (Fi g. 109).
(6) Have hel per hol d rear housi ng and geartrai n i n
upri ght posi ti on. Then i nstal l front housi ng on rear
housi ng and geartrai n.
(7) Work front housi ng downward onto geartrai n
unti l seated on rear housi ng.
CAUTION: If the front housing will not seat on the
rear housing, either the shift components are not in
Neutral, or one or more components are mis-
aligned. Do not force the front housing into place.
This will only result in damaged components.
(8) Tap rear housi ng al i gnment dowel s back i nto
pl ace wi th hammer and pi n punch. Both dowel s
shoul d be fl ush fi t i n each housi ng. Have hel per hol d
transmi ssi on upri ght whi l e dowel s are tapped back
i nto pl ace.
(9) Pl ace transmi ssi on i n hori zontal posi ti on.
(10) Appl y Mopar௡ Gasket Maker, or equi val ent, to
housi ng attachi ng bol ts. Appl y seal er materi al seal er
to undersi de of bol t heads and to bol t shanks and
threads (Fi g. 110).
(11) I nstal l and start housi ng attachi ng bol ts by
hand (Fi g. 110). Then ti ghten bol ts to 34 N·m (25 ft.
l bs.) torque.
(12) I nstal l shi ft shaft bushi ng l ock bol t (Fi g. 111).
Appl y Mopar௡ Gasket Maker, or equi val ent, to bol t
threads, shank and undersi de of bol t head before
i nstal l ati on.
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift
shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubri cate then i nstal l shi ft shaft detent
pl unger i n housi ng bore (Fi g. 112). Lubri cate pl unger
wi th petrol eum jel l y or gear l ubri cant. Be sure
plunger is fully seated in detent notch in shift
shaft.
(14) I nstal l detent spri ng i nsi de pl unger (Fi g. 112).
(15) I nstal l detent pl ug as fol l ows:
(a) I nstal l detent pl ug i n end of I nstal l er 8123.
Fig. 109 Applying Sealer To Front/Rear Housings
1 – HOUSING FLANGE SURFACE
2 – MOPAR GASKET MAKER (OR LOCTITE 518)
Fig. 110 Installing Housing Attaching Bolts
1 – HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
Fig. 111 Installing Shift Shaft Bushing Lock Bolt
1 – SHIFT SHAFT LOCK BOLT
2 – SHAFT SOCKET
21 - 72 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(b) Posi ti on pl ug on detent spri ng and compress
spri ng unti l detent pl ug pi l ots i n detent pl unger
bore.
(c) Dri ve detent pl ug i nto transmi ssi on case
unti l pl ug seats.
(16) I nstal l backup l i ght swi tch (Fi g. 113).
(17) I nstal l i nput shaft snap ri ng (Fi g. 114).
(18) I nstal l new oi l seal i n front beari ng retai ner
wi th I nstal l er Tool 6448 (Fi g. 115).
(19) Appl y bead of Mopar௡ si l i cone seal er, or
equi val ent, to fl ange surface of front beari ng retai ner
(Fi g. 116).
(20) Al i gn and i nstal l front beari ng retai ner over
i nput shaft and onto housi ng mounti ng surface (Fi g.
117). Al though retai ner i s one-way fi t on housi ng, be
sure bol t hol es are al i gned before seati ng retai ner.
NOTE: Be sure that no sealer gets into the oil feed
hole in the transmission case or bearing retainer.
Fig. 112 Installing Shift Shaft Detent Plunger,
Spring, and Plug
1 – FRONT HOUSING
2 – PLUG
3 – SPRING
4 – PLUNGER
Fig. 113 Installing Backup Light Switch
1 – BACKUP LIGHT SWITCH
Fig. 114 Installing Input Shaft Snap Ring—Typical
1 – INPUT SHAFT SNAP RING
Fig. 115 Installing Oil Seal In Front Bearing Retainer
1 – SPECIAL TOOL 6448
2 – FRONT BEARING RETAINER
Fig. 116 Applying Sealer To Bearing Retainer And
Housing—Typical
1 – APPLY SEALER BEAD
2 – INPUT SHAFT BEARING RETAINER
TJ NV3550 MANUAL TRANSMISSION 21 - 73
DISASSEMBLY AND ASSEMBLY (Continued)
(21) I nstal l and ti ghten beari ng retai ner bol ts to
7-10 N·m (5-7 ft. l bs.) torque (Fi g. 118).
SHIFT TOWER AND LEVER ASSEMBLY
(1) Appl y petrol eum jel l y to bal l end of shi ft l ever
and i nteri or of shi ft socket.
(2) Shi ft the transmi ssi on i nto thi rd gear.
(3) Al i gn and i nstal l shi ft tower and l ever assem-
bl y (Fi g. 119). Be sure shi ft bal l i s seated i n socket
and the offset i n the tower i s toward the passenger
si de of the vehi cl e before i nstal l i ng tower bol ts.
(4) I nstal l shi ft tower bol ts (Fi g. 120). Ti ghten
bol ts to 8.5 N·m (75.2 i n. l bs.) torque.
(5) Fi l l transmi ssi on to bottom edge of fi l l pl ug
hol e wi th Mopar௡ Transmi ssi on Lubri cant, P/N
4761526.
(6) I nstal l and ti ghten fi l l pl ug to 34 N·m (25 ft.
l bs.) torque.
(7) Check transmi ssi on vent. Be sure vent i s open
and not restri cted.
Fig. 117 Installing Input Shaft Bearing Retainer—
Typical
1 – INPUT SHAFT
2 – OIL FEED
3 – BEARING RETAINER
Fig. 118 Installing Input Shaft Bearing Retainer
Bolts—Typical
1 – INPUT SHAFT BEARING RETAINER
2 – RETAINER BOLTS
Fig. 119 Shift Tower Installation
1 – SHIFT TOWER AND LEVER ASSEMBLY
2 – SHIFT SOCKET
3 – SEAL
Fig. 120 Shift Tower Bolt Installation
1 – SHIFT TOWER AND LEVER ASSEMBLY
21 - 74 NV3550 MANUAL TRANSMISSION TJ
DISASSEMBLY AND ASSEMBLY (Continued)
CLEANING AND INSPECTION
TRANSMISSION COMPONENTS
Cl ean the gears, shafts, shi ft components and
transmi ssi on housi ngs wi th a standard parts cl ean-
i ng sol vent. Do not use aci d or corrosi ve base sol -
vents. Dry al l parts except beari ngs wi th compressed
ai r.
Cl ean the shaft beari ngs wi th a mi l d sol vent such
as Mopar௡ degreasi ng sol vent, Gunk, or si mi l ar sol -
vents. Do not dry the beari ngs wi th compressed ai r.
Al l ow the beari ngs to ei ther ai r dry, or wi pe them dry
wi th cl ean shop towel s.
SHIFT LEVER ASSEMBLY
The shi ft l ever assembl y i s not servi ceabl e. Repl ace
the l ever and shi ft tower as an assembl y i f the tower,
l ever, l ever bal l , or i nternal components are worn, or
damaged.
SHIFT SHAFT AND FORKS
I nspect the shi ft fork i nterl ock arms and synchro
sl eeve contact surfaces (Fi g. 121). Repl ace any fork
exhi bi ti ng wear or damage i n these areas. Do not
attempt to sal vage shi ft forks.
Check condi ti on of the shi ft shaft detent pl unger
and spri ng. The pl unger shoul d be smooth and free of
ni cks, or scores. The pl unger spri ng shoul d be
strai ght and not col l apsed, or di storted. Mi nor
scratches, or ni cks on the pl unger can be smoothed
wi th 320/400 gri t emery soaked i n oi l . Repl ace the
pl unger and spri ng i f i n doubt about condi ti on. Check
condi ti on of detent pl unger bushi ngs. Repl ace i f dam-
aged.
I nspect the shi ft shaft, shi ft shaft bushi ng and
beari ng, the shaft l ever, and the l ever bushi ng that
fi ts over the l ever. Repl ace the shaft i f bent, cracked,
or severel y scored. Mi nor burrs, ni cks, or scratches
can be smoothed off wi th 320/400 gri t emery cl oth
fol l owed by pol i shi ng wi th crocus cl oth. Repl ace the
shi ft shaft bushi ng or beari ng i f damaged.
Repl ace the shaft l ever and bushi ng i f ei ther part
i s deformed, or worn. Do not attempt to sal vage these
parts as shi ft fork bi ndi ng wi l l occur. Repl ace the rol l
pi n that secures the l ever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
I nspect the housi ngs careful l y. Look for cracks,
stri pped threads, scored mati ng surfaces, damaged
beari ng bores, or worn dowel pi n hol es. Mi nor ni cks
on mati ng surfaces can be dressed off wi th a fi ne fi l e,
or emery cl oth. Damaged threads can be renewed by
ei ther re-tappi ng or i nstal l i ng Hel i coi l i nserts.
Fig. 121 Shift Forks And Shaft
1 – SHIFT SHAFT
2 – SHAFT LEVER
3 – SHAFT LEVER BUSHING
4 – 3–4 SHIFT FORK
5 – 1–2 SHIFT FORK
6 – FIFTH-REVERSE SHIFT FORK
TJ NV3550 MANUAL TRANSMISSION 21 - 75
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. Be advised that
these components are NOT serviceable items. The
front housing will have to be replaced if the coun-
tershaft bearing race is loose, worn, or damaged.
The rear housing will have to be replaced if the
countershaft rear bearing race is loose, worn, or
damaged.
I nspect the i nput shaft beari ng retai ner. Be sure
the rel ease beari ng sl i de surface of the retai ner i s i n
good condi ti on. Mi nor ni cks on the surface can be
smoothed off wi th 320/420 gri t emery cl oth and fi nal
pol i shed wi th oi l coated crocus cl oth. Repl ace the
retai ner seal i f necessary.
I nspect the output shaft beari ng retai ner. Be sure
the U-shaped retai ner i s fl at and free of di storti on.
Repl ace the retai ner i f the threads are damaged, or i f
the retai ner i s bent, or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft beari ngs and races are machi ne
l apped duri ng manufacture to form matched sets.
The beari ngs and races shoul d not be i nterchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, it will be necessary to
replace the front or rear housing as necessary. A
new countershaft bearing will be supplied with each
new housing for service use.
The countershaft beari ngs can be i nstal l ed back-
wards i f care i s not exerci sed. The beari ng rol l er cage
i s a di fferent di ameter on each si de. Be sure the
beari ng i s i nstal l ed so the l arge di ameter si de of the
cage i s faci ng the countershaft gear (Fi g. 122). The
smal l di ameter si de goes i n the beari ng race.
REVERSE IDLER COMPONENTS
I nspect the i dl er gear, beari ng, shaft, thrust
washer, wave washer and thrust pl ate. Repl ace the
beari ng i f any of the needl e beari ng rol l ers are worn,
chi pped, cracked, fl at-spotted, or bri nnel l ed. Al so
repl ace the beari ng i f the pl asti c beari ng cage i s
damaged or di storted.
Repl ace the thrust washer, wave washer, or thrust
pl ate i f cracked, chi pped, or worn. Repl ace the i dl er
gear i f the teeth are chi pped, cracked or worn thi n.
Repl ace the shaft i f worn, scored, or the bol t threads
are damaged beyond repai r. Repl ace the support seg-
ment i f cracked, or chi pped and repl ace the i dl er
attachi ng bol ts i f the threads are damaged.
Shift Socket
I nspect the shi ft socket for wear or damage.
repl ace the socket i f the rol l pi n, or shi ft shaft bores
are damaged. Mi nor ni cks i n the shi ft l ever bal l seat
i n the socket can be smoothed down wi th 400 gri t
emery or wet/dry paper. Repl ace the socket i f the bal l
seat i s worn, or cracked. Do not reuse the ori gi nal
shi ft socket rol l pi n. I nstal l a new pi n duri ng reas-
sembl y. The socket rol l pi n i s approxi matel y i s
approxi matel y 33 mm (1-1/4 i n.) l ong.
Output Shaft And Geartrain
I nspect al l of the gears for worn, cracked, chi pped,
or broken teeth. Al so check condi ti on of the beari ng
bore i n each gear. The bores shoul d be smooth and
free of surface damage. Di scol orati on of the gear
bores i s a normal occurrence and i s not a reason for
repl acement. Repl ace gears onl y when tooth damage
has occurred, or i f the bores are bri nnel l ed or
severel y scored.
I nspect the shaft spl i nes and beari ngs surfaces.
Mi nor ni cks on the beari ng surfaces can be smoothed
wi th 320/420 gri t emery and fi nal pol i shed wi th cro-
cus cl oth. Repl ace the shaft i f the spl i nes are dam-
aged or beari ng surfaces are deepl y scored, worn, or
bri nnel l ed.
Fig. 122 Correct Countershaft Bearing Installation
1 – COUNTERSHAFT
2 – BEARING CAGE
21 - 76 NV3550 MANUAL TRANSMISSION TJ
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
NV3550 MANUAL TRANSMISSION
Description Torque
Cl utch Housi ng Bol ts . . . 54–61 N·m (40–45 ft. l bs.)
Crossmember-To-Frame Bol ts . . . . . . . . 61–75 N·m
(44–55 ft. l bs.)
Crossmember-To-I nsul ator Nuts . . . . . . 54–61 N·m
(40–45 ft. l bs.)
Drai n/Fi l l Pl ug . . . . . . . . . 9–27 N·m (14–20 ft. l bs.)
Front-To-Rear Housi ng Bol ts . . . . . . . . . 30–35 N·m
(22–26 ft. l bs.)
Front Beari ng Retai ner Bol ts . . . . . . . . . 7–10 N·m
(5–7 ft. l bs.)
I dl er Shaft Bol ts . . . . . . 19–25 N·m (14–18 ft. l bs.)
Rear Beari ng Retai ner Bol ts . . . . . . . . . 30–35 N·m
(22–26 ft. l bs.)
Shi ft Tower Bol ts . . . . . . . . . 7–10 N·m (5–7 ft. l bs.)
Sl ave Cyl i nder Attachi ng Nuts . . . . . . . . . . 23 N·m
(200 i n. l bs.)
Transfer Case Attachi ng Nuts . . 47 N·m (35 ft. l bs.)
U-Joi nt Cl amp Bol ts . . . . . . . . 19 N·m (170 i n. l bs.)
Remover, Seal—C-3985-B
Installer, Seal—C-3972-A
Remover, Bushing—6957
Installer, Bushing—6951
Handle—C-4171
Remover—8117
TJ NV3550 MANUAL TRANSMISSION 21 - 77
Remover/Installer, NV3550 Shift Rail Roll Pin—6858
Fixture, NV3550—6747
Adapter, Fixture—6747-1A
Adapter, Fixture—6747-2A
Cup, Fixture—8115
Splitter, Bearing—1130
Tube—6310-1
Installer—8118
Remover/Installer—8119
Stud, Alignment—8120
21 - 78 NV3550 MANUAL TRANSMISSION TJ
SPECIAL TOOLS (Continued)
Installer, Seal—C-3860-A
Installer—8123
Installer, Bearing Cone—6448
TJ NV3550 MANUAL TRANSMISSION 21 - 79
SPECIAL TOOLS (Continued)
AUTOMATIC TRANSMISSION—30/32RH
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
30/32RH AUTOMATIC TRANSMISSION . . . . . . . . 81
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . 87
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
VALVE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
ACCUMULATOR. . . . . . . . . . . . . . . . . . . . . . . . . 108
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 110
REAR CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . 111
OVERRUNNING CLUTCH. . . . . . . . . . . . . . . . . . 113
PLANETARY GEARSET . . . . . . . . . . . . . . . . . . . 113
BANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
SERVOS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
GOVERNOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 117
CONVERTER DRAINBACK VALVE . . . . . . . . . . . 117
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . 117
DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION DIAGNOSIS. . . . . 118
EFFECTS OF INCORRECT FLUID LEVEL . . . . . 119
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 119
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 119
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . . . 119
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 120
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 120
THROTTLE VALVE CABLE. . . . . . . . . . . . . . . . . 120
ROAD TESTING. . . . . . . . . . . . . . . . . . . . . . . . . 120
ANALYZING ROAD TEST . . . . . . . . . . . . . . . . . . 121
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 121
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION . . . . . . . . . . . . . . . . . . . . . 123
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 124
DIAGNOSIS CHARTS. . . . . . . . . . . . . . . . . . . . . 125
SERVICE PROCEDURES
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . . 133
FLUID AND FILTER REPLACEMENT . . . . . . . . . 133
TRANSMISSION FILL PROCEDURE. . . . . . . . . . 134
CONVERTER DRAINBACK CHECK VALVE
SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 135
FLUSHING COOLERS AND TUBES . . . . . . . . . . 135
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 136
REMOVAL AND INSTALLATION
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 136
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 139
ADAPTER HOUSING . . . . . . . . . . . . . . . . . . . . . 139
SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . . 140
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 141
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 141
BRAKE TRANSMISSION SHIFT INTERLOCK . . . 142
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
OUTPUT SHAFT REAR BEARING . . . . . . . . . . . 144
GOVERNOR AND PARK GEAR . . . . . . . . . . . . . 144
PARK LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
DISASSEMBLY AND ASSEMBLY
GOVERNOR AND PARK GEAR . . . . . . . . . . . . . 146
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 156
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
FRONT SERVO PISTON . . . . . . . . . . . . . . . . . . 168
REAR SERVO PISTON. . . . . . . . . . . . . . . . . . . . 169
OIL PUMP AND REACTION SHAFT SUPPORT. . 169
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 173
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 175
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . . 178
CLEANING AND INSPECTION
GOVERNOR AND PARK GEAR . . . . . . . . . . . . . 184
EXTENSION HOUSING AND PARK LOCK . . . . . 185
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 188
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM/OVERDRIVE PISTON RETAINER . . . . . 188
FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . . . . 188
REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . 188
OIL PUMP AND REACTION SHAFT SUPPORT. . 188
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 189
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 190
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . . 190
ADJUSTMENTS
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 191
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE ADJUSTMENT. . . . . . . . . . . . . . . . . . . 191
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 192
FRONT BAND ADJUSTMENT. . . . . . . . . . . . . . . 193
REAR BAND ADJUSTMENT . . . . . . . . . . . . . . . . 193
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . 194
SPECIFICATIONS
30/32RH AUTOMATIC TRANSMISSION . . . . . . . 205
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
SPECIAL TOOLS
30/32RH TRANSMISSIONS . . . . . . . . . . . . . . . . 206
21 - 80 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION
30/32RH AUTOMATIC TRANSMISSION
DESCRIPTION
The 30RH automati c transmi ssi on i s used wi th the
2.5L engi ne. The 32RH automati c transmi ssi on (Fi g.
1) i s used wi th the 4.0L engi ne. The 30/32RH are
three speed transmi ssi ons wi th a l ock-up cl utch i n
the torque converter. The transmi ssi ons contai n a
front and rear cl utch whi ch functi on as the i nput
dri vi ng components. They al so contai n the ki ckdown
(front) and the l ow/reverse (rear) bands whi ch, al ong
wi th the overrunni ng cl utch, serve as the hol di ng
components. The dri vi ng and hol di ng components
combi ne to sel ect the necessary pl anetary gear com-
ponents, i n the front and rear pl anetary gear set,
transfer the engi ne power from the i nput shaft
through to the output shaft. The transmi ssi ons con-
tai n a governor that i s mounted on the output shaft
and suppl i es pressure to the val ve body based on the
output shaft speed. The val ve body i s mounted to the
l ower si de of the transmi ssi on and contai ns the
val ves to control pressure regul ati on, fl ui d fl ow con-
trol , and cl utch/band appl i cati on. The oi l pump i s
mounted at the front of the transmi ssi on and i s
dri ven by the torque converter hub. The pump sup-
pl i es the oi l pressure necessary for cl utch/band actu-
ati on and transmi ssi on l ubri cati on. The 30/32RH
transmi ssi on i s cool ed by an i ntegral fl ui d cool er
i nsi de the radi ator.
TRANSMISSION IDENTIFICATION
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan gas-
ket surface (Fi g. 2). Refer to thi s i nformati on when
orderi ng repl acement parts.
TRANSMISSION GEAR RATIOS
Forward gear rati os are:
• 2.74:1 (fi rst gear)
• 1.54:1 (second gear)
• 1.00:1 (thi rd gear)
OPERATION
The appl i cati on of each dri vi ng or hol di ng compo-
nent i s control l ed by the val ve body based upon the
manual l ever posi ti on and governor pressure. The
governor pressure i s a vari abl e pressure i nput to the
val ve body and i s one of the si gnal s that a shi ft i s
necessary. Fi rst through thi rd gear are obtai ned by
sel ecti vel y appl yi ng and rel easi ng the di fferent
cl utches and bands. Engi ne power i s thereby routed
to the vari ous pl anetary gear assembl i es whi ch com-
bi ne wi th the overrunni ng cl utch assembl y to gener-
ate the di fferent gear rati os. The torque converter
cl utch i s hydraul i cal l y appl i ed and i s rel eased when
fl ui d i s vented from the hydraul i c ci rcui t by the
torque converter control (TCC) sol enoi d on the val ve
body. The torque converter cl utch i s control l ed by the
Powertrai n Control Modul e (PCM). The torque con-
verter cl utch engages i n thi rd gear when the vehi cl e
i s crui si ng on a l evel pl ane after the vehi cl e has
warmed up. The torque converter cl utch wi l l di sen-
gage momentari l y when an i ncrease i n engi ne l oad i s
sensed by the PCM, such as when the vehi cl e begi ns
to go uphi l l or the throttl e pressure i s i ncreased. The
torque converter cl utch feature i ncreases fuel econ-
omy and reduces the transmi ssi on fl ui d temperature.
PARK POWERFLOW
As the engi ne i s runni ng and the crankshaft i s
rotati ng, the fl expl ate and torque converter, whi ch
are al so bol ted to i t, are al l rotati ng i n a cl ockwi se
di recti on as vi ewed from the front of the engi ne. The
notched hub of the torque converter i s connected to
the oi l pump’s i nternal gear, suppl yi ng the transmi s-
si on wi th oi l pressure. As the converter turns, i t
turns the i nput shaft i n a cl ockwi se di recti on. As the
i nput shaft i s rotati ng, the front cl utch hub–rear
cl utch retai ner and al l thei r associ ated parts are al so
rotati ng, al l bei ng di rectl y connected to the i nput
shaft. The power fl ow from the engi ne through the
front–cl utch–hub and rear–cl utch–retai ner stops at
the rear–cl utch–retai ner. Therefore, no power fl ow to
the output shaft, occurs because no cl utches are
appl i ed. The onl y mechani sm i n use at thi s ti me i s
the parki ng sprag (Fi g. 3), whi ch l ocks the parki ng
gear on the output shaft to the transmi ssi on case.
NEUTRAL POWERFLOW
Wi th the gear sel ector i n the neutral posi ti on (Fi g.
4), the power fl ow of the transmi ssi on i s essenti al l y
the same as i n the park posi ti on. The onl y opera-
ti onal di fference i s that the parki ng sprag has been
di sengaged, unl ocki ng the output shaft from the
transmi ssi on case and al l owi ng i t to move freel y.
REVERSE POWERFLOW
When the gear sel ector i s moved i nto the reverse
posi ti on (Fi g. 5), the front cl utch and the rear band
are appl i ed. Wi th the appl i cati on of the front cl utch,
engi ne torque i s appl i ed to the sun gear, turni ng i t i n
a cl ockwi se di recti on. The cl ockwi se rotati on of the
sun gear causes the rear pl anet pi ni ons to rotate
agai nst engi ne rotati on i n a countercl ockwi se di rec-
ti on. The rear band i s hol di ng the l ow reverse drum,
whi ch i s spl i ned to the rear carri er. Si nce the rear
carri er i s bei ng hel d, the torque from the pl anet pi n-
i ons i s transferred to the rear annul us gear, whi ch i s
spl i ned to the output shaft. The output shaft i n turn
rotates wi th the annul us gear i n a countercl ockwi se
di recti on gi vi ng a reverse gear output. The enti re
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 81
Fig. 1 30/32 RH Automatic Transmission
21 - 82 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
transmi ssi on of torque i s appl i ed to the rear pl ane-
tary gearset onl y. Al though there i s torque i nput to
the front gearset through the sun gear, no other
member of the gearset i s bei ng hel d. Duri ng the
enti re reverse stage of operati on, the front pl anetary
gears are i n an i dl i ng condi ti on.
FIRST GEAR POWERFLOW
When the gearshi ft l ever i s moved i nto the dri ve
posi ti on the transmi ssi on goes i nto fi rst gear (Fi g. 6).
As soon as the transmi ssi on i s shi fted from park or
neutral to dri ve, the rear cl utch appl i es, appl yi ng the
rear cl utch pack to the front annul us gear. Engi ne
torque i s now appl i ed to the front annul us gear turn-
i ng i t i n a cl ockwi se di recti on. Wi th the front annul us
gear turni ng i n a cl ockwi se di recti on, i t causes the
front pl anets to turn i n a cl ockwi se di recti on. The
rotati on of the front pl anets cause the sun to revol ve
i n a countercl ockwi se di recti on. The sun gear now
transfers i ts countercl ockwi se rotati on to the rear
pl anets whi ch rotate back i n a cl ockwi se di recti on.
Wi th the rear annul us gear stati onary, the rear
pl anet rotati on on the annul us gear causes the rear
pl anet carri er to revol ve i n a countercl ockwi se di rec-
ti on. The rear pl anet carri er i s spl i ned i nto the l ow–
reverse drum, and the l ow reverse drum i s spl i ned to
the i nner race of the over–runni ng cl utch. Wi th the
over–runni ng cl utch l ocked, the pl anet carri er i s
hel d, and the resul ti ng torque provi ded by the pl anet
pi ni ons i s transferred to the rear annul us gear. The
rear annul us gear i s spl i ned to the output shaft and
rotated al ong wi th i t (cl ockwi se) i n an underdri ve
gear reducti on mode.
SECOND GEAR POWERFLOW
I n dri ve–second (Fi g. 7), the same el ements are
appl i ed as i n manual –second. Therefore, the power
fl ow wi l l be the same, and both gears wi l l be di s-
cussed as one i n the same. I n dri ve–second, the
transmi ssi on has proceeded from fi rst gear to i ts
Fig. 2 Transmission Part Number And Serial
Number Location
1 – PART NUMBER
2 – BUILD DATE
3 – SERIAL NUMBER
Fig. 3 Park Powerflow
1 – LEVER ENGAGED FOR PARK
2 – PARK SPRAG
3 – OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 – LEVER DISENGAGED FOR NEUTRAL
2 – PARK SPRAG
3 – OUTPUT SHAFT
4 – CAM
5 – LEVER
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 83
DESCRIPTION AND OPERATION (Continued)
shi ft poi nt, and i s shi fti ng from fi rst gear to second.
The second gear shi ft i s obtai ned by keepi ng the rear
cl utch appl i ed and appl yi ng the front (ki ckdown)
band. The front band hol ds the front cl utch retai ner
that i s l ocked to the sun gear dri vi ng shel l . Wi th the
rear cl utch sti l l appl i ed, the i nput i s sti l l on the front
annul us gear turni ng i t cl ockwi se at engi ne speed.
Now that the front band i s hol di ng the sun gear sta-
ti onary, the annul us rotati on causes the front pl anets
to rotate i n a cl ockwi se di recti on. The front carri er i s
then al so made to rotate i n a cl ockwi se di recti on but
at a reduced speed. Thi s wi l l transmi t the torque to
the output shaft, whi ch i s di rectl y connected to the
front pl anet carri er. The rear pl anetary annul us gear
wi l l al so be turni ng because i t i s di rectl y spl i ned to
the output shaft. Al l power fl ow has occurred i n the
front pl anetary gear set duri ng the dri ve–second
stage of operati on, and now the over–runni ng cl utch,
i n the rear of the transmi ssi on, i s di sengaged and
freewheel i ng on i ts hub.
DIRECT DRIVE POWERFLOW
The vehi cl e has accel erated and reached the shi ft
poi nt for the 2–3 upshi ft i nto di rect dri ve (Fi g. 8).
When the shi ft takes pl ace, the front band i s
rel eased, and the front cl utch i s appl i ed. The rear
cl utch stays appl i ed as i t has been i n al l the forward
gears. Wi th the front cl utch now appl i ed, engi ne
torque i s now on the front cl utch retai ner, whi ch i s
l ocked to the sun gear dri vi ng shel l . Thi s means that
the sun gear i s now turni ng i n engi ne rotati on (cl ock-
wi se) and at engi ne speed. The rear cl utch i s sti l l
appl i ed so engi ne torque i s al so sti l l on the front
annul us gear. I f two members of the same pl anetary
set are dri ven, di rect dri ve resul ts. Therefore, when
two members are rotati ng at the same speed and i n
the same di recti on, i t i s the same as bei ng l ocked up.
The rear pl anetary set i s al so l ocked up, gi ven the
sun gear i s sti l l the i nput, and the rear annul us gear
must turn wi th the output shaft. Both gears are
turni ng i n the same di recti on and at the same speed.
The front and rear pl anet pi ni ons do not turn at al l
i n di rect dri ve. The onl y rotati on i s the i nput from
the engi ne to the connected parts, whi ch are acti ng
as one common uni t, to the output shaft.
FLUID
NOTE: Refer to the maintenance schedules in
Group 0, Lubrication and Maintenance for the rec-
ommended maintenance (fluid/filter change) inter-
vals for this transmission.
Fig. 5 Reverse Powerflow
1 – FRONT CLUTCH ENGAGED
2 – OUTPUT SHAFT
3 – LOW/REVERSE BAND APPLIED
4 – INPUT SHAFT
5 – OUTPUT SHAFT
6 – INPUT SHAFT
7 – FRONT CLUTCH ENGAGED
8 – LOW/REVERSE BAND APPLIED
21 - 84 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
Fig. 6 First Gear Powerflow
1 – OUTPUT SHAFT
2 – OVER-RUNNING CLUTCH HOLDING
3 – REAR CLUTCH APPLIED
4 – OUTPUT SHAFT
5 – OVER-RUNNING CLUTCH HOLDING
6 – INPUT SHAFT
7 – REAR CLUTCH APPLIED
8 – INPUT SHAFT
Fig. 7 Second Gear Powerflow
1 – KICKDOWN BAND APPLIED
2 – OUTPUT SHAFT
3 – REAR CLUTCH ENGAGED
4 – OUTPUT SHAFT
5 – OVER-RUNNING CLUTCH FREE-WHEELING
6 – INPUT SHAFT
7 – REAR CLUTCH APPLIED
8 – KICKDOWN BAND APPLIED
9 – INPUT SHAFT
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 85
DESCRIPTION AND OPERATION (Continued)
NOTE: Refer to Service Procedures in this group
for fluid level checking procedures.
DESCRIPTION
Mopar௡ ATF Pl us 3, Type 7176, automati c trans-
mi ssi on fl ui d i s the recommended fl ui d for Dai ml er-
Chrysl er automati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar௡ ATF Pl us 3, Type 7176, automati c trans-
mi ssi on fl ui d when new i s red i n col or. The ATF i s
dyed red so i t can be i denti fi ed from other fl ui ds used
i n the vehi cl e such as engi ne oi l or anti freeze. The
red col or i s not permanent and i s not an i ndi cator of
fl ui d condi ti on. As the vehi cl e i s dri ven, the ATF wi l l
begi n to l ook darker i n col or and may eventual l y
become brown. This is normal. A dark brown/bl ack
fl ui d accompani ed wi th a burnt odor and/or deteri o-
rati on i n shi ft qual i ty may i ndi cate fl ui d deteri ora-
ti on or transmi ssi on component fai l ure.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous “speci al ” addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on “seal ers” shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
OPERATION
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
Fig. 8 Direct Drive Powerflow
1 – FRONT CLUTCH APPLIED
2 – OVER-RUNNING CLUTCH FREE-WHEELING
3 – OUTPUT SHAFT
4 – REAR CLUTCH APPLIED
5 – OUTPUT SHAFT
6 – INPUT SHAFT
7 – OVER-RUNNING CLUTCH FREE-WHEELING
8 – REAR CLUTCH APPLIED
9 – FRONT CLUTCH APPLIED
10 – INPUT SHAFT
21 - 86 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 9) i s a hydraul i c devi ce
that coupl es the engi ne crankshaft to the transmi s-
si on. The torque converter consi sts of an outer shel l
wi th an i nternal turbi ne, a stator, an overrunni ng
cl utch, an i mpel l er and an el ectroni cal l y appl i ed con-
verter cl utch. The converter cl utch provi des reduced
engi ne speed and greater fuel economy when
engaged. Cl utch engagement al so provi des reduced
transmi ssi on fl ui d temperatures. The converter
cl utch engages i n thi rd gear. The torque converter
hub dri ves the transmi ssi on oi l (fl ui d) pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.
IMPELLER
The i mpel l er (Fi g. 10) i s an i ntegral part of the
converter housi ng. The i mpel l er consi sts of curved
bl ades pl aced radi al l y al ong the i nsi de of the housi ng
on the transmi ssi on si de of the converter. As the con-
verter housi ng i s rotated by the engi ne, so i s the
i mpel l er, because they are one and the same and are
the dri vi ng member of the system.
TURBINE
The turbi ne (Fi g. 11) i s the output, or dri ven, mem-
ber of the converter. The turbi ne i s mounted wi thi n
the housi ng opposi te the i mpel l er, but i s not attached
to the housi ng. The i nput shaft i s i nserted through
the center of the i mpel l er and spl i ned i nto the tur-
bi ne. The desi gn of the turbi ne i s si mi l ar to the
i mpel l er, except the bl ades of the turbi ne are curved
i n the opposi te di recti on.
Fig. 9 Torque Converter Assembly
1 – TURBINE
2 – IMPELLER
3 – HUB
4 – STATOR
5 – CONVERTER CLUTCH DISC
6 – DRIVE PLATE
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 87
DESCRIPTION AND OPERATION (Continued)
Fig. 10 Impeller
1 – ENGINE FLEXPLATE
2 – OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
3 – IMPELLER VANES AND COVER ARE INTEGRAL
4 – ENGINE ROTATION
5 – ENGINE ROTATION
21 - 88 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
STATOR
The stator assembl y (Fi g. 12) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator i s l ocated between the i mpel l er and
turbi ne wi thi n the torque converter case (Fi g. 13).
The stator contai ns an over-runni ng cl utch, whi ch
al l ows the stator to rotate onl y i n a cl ockwi se di rec-
ti on. When the stator i s l ocked agai nst the over-run-
ni ng cl utch, the torque mul ti pl i cati on feature of the
torque converter i s operati onal .
Fig. 11 Turbine
1 – TURBINE VANE
2 – ENGINE ROTATION
3 – INPUT SHAFT
4 – PORTION OF TORQUE CONVERTER COVER
5 – ENGINE ROTATION
6 – OIL FLOW WITHIN TURBINE SECTION
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 89
DESCRIPTION AND OPERATION (Continued)
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fi g. 14) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shock–free power transfer, i t
i s natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel -
l er and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston was added to the turbi ne, and a fri cti on mate-
ri al was added to the i nsi de of the front cover to pro-
vi de thi s mechani cal l ock-up.
OPERATION
The converter i mpel l er (Fi g. 15) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi ne’s bl ades i t con-
ti nues i n a “hi nderi ng” di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n such a
di recti on that i t woul d tend to sl ow i t down.
Fig. 12 Stator Components
1 – CAM (OUTER RACE)
2 – ROLLER
3 – SPRING
4 – INNER RACE
Fig. 13 Stator Location
1 – STATOR
2 – IMPELLER
3 – FLUID FLOW
4 – TURBINE
Fig. 14 Torque Converter Clutch (TCC)
1 – IMPELLER FRONT COVER
2 – THRUST WASHER ASSEMBLY
3 – IMPELLER
4 – STATOR
5 – TURBINE
6 – FRICTION DISC
21 - 90 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
stator’s over-runni ng cl utch to i ts shaft (Fi g. 16).
Under stal l condi ti ons (the turbi ne i s stati onary), the
oi l l eavi ng the turbi ne bl ades stri kes the face of the
stator bl ades and tri es to rotate them i n a counter-
cl ockwi se di recti on. When thi s happens the over–run-
ni ng cl utch of the stator l ocks and hol ds the stator
from rotati ng. Wi th the stator l ocked, the oi l stri kes
the stator bl ades and i s redi rected i nto a “hel pi ng”
di recti on before i t enters the i mpel l er. Thi s ci rcul a-
ti on of oi l from i mpel l er to turbi ne, turbi ne to stator,
and stator to i mpel l er, can produce a maxi mum
torque mul ti pl i cati on of about 2.4:1. As the turbi ne
begi ns to match the speed of the i mpel l er, the fl ui d
that was hi tti ng the stator i n such as way as to
cause i t to l ock–up i s no l onger doi ng so. I n thi s con-
di ti on of operati on, the stator begi ns to free wheel
and the converter acts as a fl ui d coupl i ng.
TORQUE CONVERTER CLUTCH (TCC)
I n a standard torque converter, the i mpel l er and
turbi ne are rotati ng at about the same speed and the
stator i s freewheel i ng, provi di ng no torque mul ti pl i -
cati on. By appl yi ng the turbi ne’s pi ston to the front
cover’s fri cti on materi al , a total converter engage-
ment can be obtai ned. The resul t of thi s engagement
i s a di rect 1:1 mechani cal l i nk between the engi ne
and the transmi ssi on.
The engagement and di sengagement of the TCC
are automati c and control l ed by the Powertrai n Con-
Fig. 15 Torque Converter Fluid Operation
1 – APPLY PRESSURE
2 – THE PISTON MOVES SLIGHTLY FORWARD
3 – RELEASE PRESSURE
4 – THE PISTON MOVES SLIGHTLY REARWARD
Fig. 16 Stator Operation
1 – DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 – FRONT OF ENGINE
3 – INCREASED ANGLE AS OIL STRIKES VANES
4 – DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 91
DESCRIPTION AND OPERATION (Continued)
trol Modul e (PCM). The engagement cannot be acti -
vated i n the l ower gears because i t el i mi nates the
torque mul ti pl i cati on effect of the torque converter
necessary for accel erati on. I nputs that determi ne
cl utch engagement are: cool ant temperature, vehi cl e
speed and throttl e posi ti on. The torque converter
cl utch i s engaged by the cl utch sol enoi d on the val ve
body. The cl utch wi l l engage at approxi matel y 56
km/h (35 mph) wi th l i ght throttl e, after the shi ft to
thi rd gear.
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 17) i s l ocated i n the pump hous-
i ng i nsi de the bel l housi ng of the transmi ssi on case.
The oi l pump consi sts of an i nner and outer gear, a
housi ng, and a cover that al so serves as the reacti on
shaft support.
OPERATION
As the torque converter rotates, the converter hub
rotates the i nner and outer gears. As the gears
rotate, the cl earance between the gear teeth
i ncreases i n the crescent area, and creates a sucti on
at the i nl et si de of the pump. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
cl earance between the gear teeth i n the crescent area
decreases, i t forces pressuri zed fl ui d i nto the pump
outl et and to the val ve body.
VALVE BODY
DESCRIPTION
The val ve body consi sts of a cast al umi num val ve
body, a separator pl ate, and transfer pl ate. The val ve
body contai ns val ves and check bal l s that control
fl ui d del i very to the torque converter cl utch, bands,
and fri cti onal cl utches. The val ve body contai ns the
fol l owi ng components (Fi g. 18) and (Fi g. 19):
• Regul ator val ve
• Regul ator val ve throttl e pressure pl ug
• Li ne pressure pl ug and sl eeve
• Ki ckdown val ve
• Ki ckdown l i mi t val ve
• 1–2 shi ft val ve
• 1–2 control val ve
• 2–3 shi ft val ve
• 2–3 governor pl ug
• Throttl e val ve
• Throttl e pressure pl ug
• Swi tch val ve
• Manual val ve
• Converter cl utch control val ve
• Fai l -safe val ve
• Shuttl e val ve
• Shuttl e val ve throttl e pl ug
• 9 check bal l s
By adjusti ng the spri ng pressure acti ng on the reg-
ul ator val ve, transmi ssi on l i ne pressure can be
adjusted.
Fig. 17 Oil Pump Assembly
1 – OIL SEAL
2 – OIL PUMP BODY
3 – VENT
4 – REACTION SHAFT SUPPORT
5 – INNER ROTOR
6 – OUTER ROTOR
7 – “O” RING
21 - 92 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
NOTE: Refer to the Hydraulic Schematics for a
visual aid in determining valve location, operation
and design.
REGULATOR VALVE
The pressure regul ator val ve i s needed to control
the hydraul i c pressure wi thi n the system and reduce
the amount of heat produced i n the fl ui d. The pres-
sure regul ator val ve i s l ocated i n the val ve body near
the manual val ve. The pressure regul ator val ve trai n
control s the maxi mum pressure i n the l i nes by
meteri ng the dumpi ng of fl ui d back i nto the sump.
Regul ated pressure i s referred to as “l i ne pressure.”
The regul ator val ve (Fi g. 20) has a spri ng on one
end that pushes the val ve to the l eft. Thi s cl oses a
dump (vent) that i s used to l ower pressure. The cl os-
i ng of the dump wi l l cause the oi l pressure to
i ncrease. Oi l pressure on the opposi te end of the
val ve pushes the val ve to the ri ght, openi ng the
dump and l oweri ng oi l pressure. The resul t i s spri ng
pressure worki ng agai nst oi l pressure to mai ntai n
the oi l at speci fi c pressures. Wi th the engi ne run-
ni ng, fl ui d fl ows from the pump to the pressure reg-
ul ator val ve, manual val ve, and the i nterconnected
ci rcui ts. As fl ui d i s sent through passages to the reg-
ul ator val ve, the pressure pushes the val ve to the
ri ght agai nst the l arge spri ng. I t i s al so sent to the
reacti on areas on the l eft si de of the throttl e pressure
pl ug and the l i ne pressure pl ug. Wi th the gear sel ec-
Fig. 18 Valve Body Assembly
1 – GOVERNOR PLUG END PLATE
2 – SHUTTLE VALVE
3 – 1–2 GOVERNOR PLUG
4 – VALVE BODY
5 – REGULATOR VALVE THROTTLE PRESSURE PLUG
6 – SLEEVE
7 – LINE PRESSURE PLUG
8 – RETAINER
9 – 1–2 SHIFT VALVE
10 – 1–2 SHIFT CONTROL VALVE
11 – KICKDOWN LIMIT VALVE
12 – END PLATE
13 – THROTTLE PRESSURE PLUG
14 – KICKDOWN LIMIT VALVE BODY
15 – E-RING
16 – 2–3 SHIFT VALVE
17 – GUIDES
18 – 2–3 GOVERNOR PLUG
19 – PRIMARY SPRING
20 – SHUTTLE VALVE THROTTLE PLUG
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 93
DESCRIPTION AND OPERATION (Continued)
tor i n the park posi ti on, fl ui d reci rcul ates through
the regul ator and manual val ves back to the sump.
Meanwhi l e, the torque converter i s fi l l ed sl owl y. I n
al l other gear posi ti ons (Fi g. 21), fl ui d fl ows between
two ri ght si de l ands to the swi tch val ve and torque
converter. At l ow pump speeds, the fl ow i s control l ed
by the pressure val ve groove to reduce pressure to
the torque converter. After the torque converter and
swi tch val ve fi l l wi th fl ui d, the swi tch val ve becomes
the control l i ng meteri ng devi ce for torque converter
pressure. The regul ator val ve then begi ns to control
the l i ne pressure for the other transmi ssi on ci rcui ts.
The bal ance of the fl ui d pressure pushi ng the val ve
to the ri ght and the spri ng pressure pushi ng to the
l eft determi nes the si ze of the meteri ng passage at
l and #2 (l and #1 bei ng at the far ri ght of the val ve i n
the di agram). As fl ui d l eaks past the l and, i t moves
i nto a groove connected to the fi l ter or sump. As the
l and meters the fl ui d to the sump, i t causes the pres-
sure to reduce and the spri ng decreases the si ze of
the meteri ng passage. When the si ze of the meteri ng
passage i s reduced, the pressure ri ses agai n and the
si ze of the l and i s i ncreased agai n. Pressure i s regu-
l ated by thi s constant bal ance of hydraul i c and
spri ng pressure.
The meteri ng at l and #2 establ i shes the l i ne pres-
sure throughout the transmi ssi on. I t i s vari ed accord-
i ng to changes i n throttl e posi ti on, engi ne speed, and
transmi ssi on condi ti on wi thi n a range of 57–94 psi
(except i n reverse) (Fi g. 22). The regul ated l i ne pres-
sure i n reverse (Fi g. 23) i s hel d at much hi gher pres-
Fig. 19 Valve Body Assembly
1 – ADJUSTER BRACKET
2 – LINE PRESSURE ADJUSTER
3 – PRESSURE REGULATOR VALVE
4 – SWITCH VALVE
5 – VALVE BODY
6 – TRANSFER PLATE
7 – THROTTLE VALVE
8 – SLEEVE
9 – KICKDOWN VALVE
10 – THROTTLE PRESSURE ADJUSTER
Fig. 20 Regulator Valve in Park Position
21 - 94 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
sures than i n the other gear posi ti ons: 145–280 psi .
The hi gher pressure for reverse i s achi eved by the
manual val ve bl ocki ng the suppl y of l i ne pressure to
the reacti on area l eft of l and #4. Wi th thi s pressure
bl ocked, there i s l ess area for pressure to act on to
bal ance the force of the spri ng on the ri ght. Thi s
al l ows l i ne pressure to push the val ve trai n to the
ri ght, reduci ng the amount of fl ui d returned to the
pump’s i nl et, i ncreasi ng l i ne pressure.
Fig. 21 Regulator Valve in Neutral Position
1 – MANUAL VALVE
2 – TO SHIFT VALVE
3 – FROM THROTTLE VALVE
4 – REGULATOR VALVE
5 – THROTTLE PRESSURE PLUG
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 95
DESCRIPTION AND OPERATION (Continued)
Fig. 22 Regulator Valve in Drive Position
21 - 96 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
KICKDOWN VALVE
When the throttl e val ve i s as far over to the l eft as
i t can go, the maxi mum l i ne pressure possi bl e wi l l
enter the throttl e pressure ci rcui t. I n thi s case, throt-
tl e pressure wi l l equal l i ne pressure. Wi th the ki ck-
down val ve (Fi g. 24) pushed i nto the bore as far as i t
wi l l go, fl ui d i ni ti al l y fl ows through the annul ar
groove of the 2–3 shi ft val ve (whi ch wi l l be i n the
di rect dri ve posi ti on to the ri ght).
After passi ng the annul ar groove, the fl ui d i s
routed to the spri ng end of the 2–3 shi ft val ve. Fl ui d
pressure reacti ng on the area of l and #1 overcomes
governor pressure, downshi fti ng the 2–3 shi ft val ve
i nto the ki ckdown, or second gear stage of operati on.
The val ve i s hel d i n the ki ckdown posi ti on by throttl e
pressure routed from a seated check bal l (#2). Agai n,
i f vehi cl e speed i s l ow enough, throttl e pressure wi l l
al so push the 1–2 shi ft val ve l eft to seat i ts governor
pl ug, and downshi ft to dri ve breakaway.
KICKDOWN LIMIT VALVE
The purpose of the l i mi t val ve i s to prevent a 3–2
downshi ft at hi gher speeds when a part–throttl e
downshi ft i s not desi rabl e. At these hi gher speeds
onl y a ful l throttl e 3–2 downshi ft wi l l occur. At l ow
road speeds (Fi g. 25) the l i mi t val ve does not come
i nto pl ay and does not affect the downshi fts. As the
vehi cl e’s speed i ncreases (Fi g. 26), the governor pres-
sure al so i ncreases. The i ncreased governor pressure
acts on the reacti on area of the bottom l and of the
l i mi t val ve overcomi ng the spri ng force tryi ng to
push the val ve toward the bottom of i ts bore. Thi s
pushes the val ve upward agai nst the spri ng and bot-
toms the val ve agai nst the top of the housi ng. Wi th
the val ve bottomed agai nst the housi ng, the throttl e
pressure suppl i ed to the val ve wi l l be cl osed off by
the bottom l and of the l i mi t val ve. When the suppl y
of throttl e pressure has been shut off, the 3–2 part
throttl e downshi ft pl ug becomes i noperati ve, because
no pressure i s acti ng on i ts reacti on area.
Fig. 23 Regulator Valve in Reverse Position
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 97
DESCRIPTION AND OPERATION (Continued)
Fig. 24 Kickdown Valve
1 – GOVERNOR PLUG
2 – 2–3 SHIFT VALVE
3 – KICKDOWN VALVE
4 – THROTTLE VALVE
5 – MAXIMUM THROTTLE PRESSURE
6 – THROTTLE VALVE
7 – MANUAL VALVE
8 – 1–2 SHIFT VALVE
9 – GOVERNOR PLUG
21 - 98 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
Fig. 25 Kickdown Limit Valve-Low Speeds
Fig. 26 Kickdown Limit Valve-High Speeds
1 – GOVERNOR PRESSURE CLOSES LIMIT VALVE
2 – THROTTLE PRESSURE
3 – LIMIT VALVE
4 – 2–3 SHIFT VALVE
5 – GOVERNOR PLUG
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 99
DESCRIPTION AND OPERATION (Continued)
1–2 SHIFT VALVE
The 1–2 shi ft val ve assembl y (Fi g. 27), or mecha-
ni sm, consi sts of: the 1–2 shi ft val ve, governor pl ug,
and a spri ng on the end of the val ve. After the man-
ual val ve has been pl aced i nto a forward gear range,
l i ne pressure i s di rected to the 1–2 shi ft val ve. As the
throttl e i s depressed, throttl e pressure i s appl i ed to
the ri ght si de of the 1–2 shi ft val ve assembl y. Wi th
throttl e pressure appl i ed to the ri ght si de of the
val ve, there i s now both spri ng pressure and throttl e
pressure acti ng on the val ve, hol di ng i t agai nst the
governor pl ug. As the vehi cl e begi ns to move and
bui l d speed, governor pressure i s created and i s
appl i ed to the l eft of the val ve at the governor pl ug.
When governor pressure bui l ds to a poi nt where i t
can overcome the combi ned force of the spri ng and
throttl e pressure on the other si de of the val ve, the
val ve wi l l begi n to move over to the ri ght. As the
val ve moves to the ri ght, the mi ddl e l and of the val ve
wi l l cl ose off the ci rcui t suppl yi ng the throttl e pres-
sure to the ri ght si de of the val ve. When the throttl e
pressure i s cl osed off, the val ve wi l l move even far-
ther to the ri ght, al l owi ng l i ne pressure to enter
another ci rcui t and energi ze the front servo, appl yi ng
the front band (Fi g. 28).
The governor pl ug serves a dual purpose: [0001]
• I t al l ows the shi ft val ves to move ei ther l eft or
ri ght, al l owi ng both upshi fts and downshi fts.
• When i n a manual sel ecti on posi ti on, i t wi l l be
hydraul i cal l y “bl ocked” i nto posi ti on so no upshi ft can
occur.
The physi cal bl ocki ng of the upshi ft whi l e i n the
manual “1” posi ti on i s accompl i shed by the di recti ng
of l i ne pressure between both l ands of the governor
pl ug. The l i ne pressure reacts agai nst the l arger l and
of the pl ug, pushi ng the pl ug back agai nst the end
pl ate overcomi ng governor pressure. Wi th the combi -
nati on of the l i ne pressure and spri ng pressure, the
val ve cannot move, preventi ng any upshi ft.
1–2 SHIFT CONTROL VALVE
I t contai ns a val ve wi th four l ands and a spri ng. I t
i s used as both a “rel ay” and “bal anced” val ve.
The val ve has two speci fi c operati ons (Fi g. 29):
Fig. 27 1–2 Shift Valve-Before Shift
1 – TO FRONT SERVO AND 2–3 SHIFT VALVE
2 – THROTTLE PRESSURE
3 – LINE PRESSURE
4 – LINE PRESSURE PASSAGE FOR MANUAL LOW POSITION
21 - 100 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
Fig. 28 1–2 Shift Valve-After Shift
1 – TO FRONT SERVO AND 2–3 SHIFT VALVE
2 – THROTTLE PRESSURE
3 – LINE PRESSURE
4 – LINE PRESSURE PASSAGE FOR MANUAL LOW POSITION
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 101
DESCRIPTION AND OPERATION (Continued)
• Ai d i n qual i ty of the 1–2 upshi ft.
• Ai d i n the qual i ty and ti mi ng of the 3–2 ki ck-
down ranges.
When the manual val ve i s set to the Dri ve posi ti on
and the transmi ssi on i s i n the fi rst or second gear
range, 1–2 shi ft control or “modul ated throttl e pres-
sure” i s suppl i ed to the mi ddl e of the accumul ator
pi ston by the 1–2 shi ft control val ve. Duri ng the 1–2
upshi ft, thi s pressure i s used to control the ki ckdown
servo appl y pressure that i s needed to appl y the ki ck-
down and accumul ator pi stons. Thus, the 1–2 shi ft
poi nt i s “cushi oned” and the qual i ty i s i mproved.
Duri ng a WOT ki ckdown, ki ckdown pressure i s
appl i ed between the ki ckdown val ve and the 1–2
shi ft control val ve. Thi s addi ti onal pressure i s
di rected to the 1–2 shi ft control ’s spri ng cavi ty, add-
i ng to the spri ng l oad on the val ve. The resul t of thi s
i ncreased “modul ated” throttl e pressure i s a fi rmer
WOT upshi ft.
SHUTTLE VALVE
The assembl y i s contai ned i n a bore i n the val ve
body above the shi ft val ves. When the manual val ve
i s posi ti oned i n the Dri ve range, throttl e pressure
acts on the throttl e pl ug of the shuttl e val ve (Fi g. 29)
to move i t agai nst a spri ng, i ncreasi ng the spri ng
force on the shuttl e val ve. Duri ng a part or ful l throt-
tl e 1–2 upshi ft, the throttl e pl ug i s bottomed by
throttl e pressure, hol di ng the shuttl e val ve to the
ri ght agai nst governor pressure, and openi ng a
by–pass ci rcui t. The shuttl e val ve control s the qual -
i ty of the ki ckdown shi ft by restri cti ng the rate of
fl ui d di scharge from the front cl utch and servo
rel ease ci rcui ts. Duri ng a 3–2 ki ckdown, fl ui d di s-
charges through the shuttl e by–pass ci rcui t. When
Fig. 29 1–2 Shift Control Valve
1 – THROTTLE PLUG
2 – SHUTTLE VALVE
3 – 1–2 SHIFT CONTROL VALVE
21 - 102 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
the shuttl e val ve cl oses the by–pass ci rcui t, fl ui d di s-
charge i s restri cted and control l ed for the appl i cati on
of the front band. Duri ng a 2–3 “l i ft foot” upshi ft, the
shuttl e val ve by–passes the restri cti on to al l ow ful l
fl ui d fl ow through the by–pass groove for a faster
rel ease of the band.
2–3 SHIFT VALVE
The 2–3 shi ft val ve mechani sm (Fi g. 30) consi sts of
the 2–3 shi ft val ve, governor pl ug and spri ng, and a
throttl e pl ug. After the 1–2 shi ft val ve has compl eted
i ts operati on and appl i ed the front band, l i ne pres-
sure i s di rected to the 2–3 shi ft val ve through the
connecti ng passages from the 1–2 shi ft val ve. The
l i ne pressure wi l l then dead–end at l and #2 unti l the
2–3 val ve i s ready to make i ts shi ft. Now that the
vehi cl e i s i n moti on and under accel erati on, there i s
throttl e pressure bei ng appl i ed to the spri ng si de of
the val ve and between l ands #3 and #4.
As vehi cl e speed i ncreases, governor pressure
i ncreases proporti onatel y, unti l i t becomes great
enough to overcome the combi ned throttl e and spri ng
pressure on the ri ght si de of the val ve. When thi s
happens, the governor pl ug i s forced agai nst the shi ft
val ve movi ng i t to the ri ght. The shi ft val ve causes
l and #4 to cl ose the passage suppl yi ng throttl e pres-
sure to the 2–3 shi ft val ve. Wi thout throttl e pressure
present i n the ci rcui t now, the governor pl ug wi l l
push the val ve over far enough to bottom the val ve i n
i ts bore. Thi s al l ows l and #2 to di rect l i ne pressure to
the front cl utch.
After the shi ft (Fi g. 31), l i ne pressure i s di rected to
the l and between the shi ft val ve and the governor
pl ug, and to the rel ease si de of the ki ckdown servo.
Thi s rel eases the front band and appl i es the front
cl utch, shi fti ng i nto thi rd gear or di rect dri ve. The
rear cl utch remai ns appl i ed, as i t has been i n the
other gears. Duri ng a manual “1” or manual “2” gear
sel ecti on, l i ne pressure i s sent between the two l ands
of the 2–3 governor pl ug. Thi s l i ne pressure at the
governor pl ug l ocks the shi ft val ve i nto the second
gear posi ti on, preventi ng an upshi ft i nto di rect dri ve.
The theory for the bl ocki ng of the val ve i s the same
as that of the 1–2 shi ft val ve.
Fig. 30 2–3 Shift Valve-Before Shift
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 103
DESCRIPTION AND OPERATION (Continued)
THROTTLE VALVE
I n al l gear posi ti ons the throttl e val ve (Fi g. 32) i s
bei ng suppl i ed wi th l i ne pressure. The throttl e val ve
meters and reduces the l i ne pressure that now
becomes throttl e pressure. The throttl e val ve i s
moved by a spri ng and the ki ckdown val ve, whi ch i s
mechani cal l y connected to the throttl e. The l arger
the throttl e openi ng, the hi gher the throttl e pressure
(to a maxi mum of l i ne pressure). The smal l er the
throttl e openi ng, the l ower the throttl e pressure (to a
mi ni mum of zero at i dl e). As engi ne speed i ncreases,
the i ncrease i n pump speed i ncreases pump output.
The i ncrease i n pressure and vol ume must be regu-
l ated to mai ntai n the bal ance wi thi n the transmi s-
si on. To do thi s, throttl e pressure i s routed to the
reacti on area on the ri ght si de of the throttl e pres-
sure pl ug (i n the regul ator val ve).
The hi gher engi ne speed and l i ne pressure woul d
open the vent too far and reduce l i ne pressure too
much. Throttl e pressure, whi ch i ncreases wi th engi ne
speed (throttl e openi ng), i s used to oppose the move-
ment of the pressure val ve to hel p control the meter-
i ng passage at the vent. The throttl e pressure i s
combi ned wi th spri ng pressure to reduce the force of
the throttl e pressure pl ug on the pressure val ve. The
l arger spri ng at the ri ght cl oses the regul ator val ve
passage and mai ntai ns or i ncreases l i ne pressure.
The i ncreased l i ne pressure works agai nst the reac-
ti on area of the l i ne pressure pl ug and the reacti on
area l eft of l and #3 si mul taneousl y moves the regu-
l ator val ve trai n to the ri ght and control s the meter-
i ng passage.
Fig. 31 2–3 Shift Valve-After Shift
21 - 104 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
The ki ckdown val ve, al ong wi th the throttl e val ve,
serve to del ay upshi fts unti l the correct vehi cl e and
engi ne speed have been reached. I t al so control s
downshi fts upon dri ver demand, or i ncreased engi ne
l oad. I f these val ves were not i n pl ace, the shi ft
poi nts woul d be at the same speed for al l throttl e
posi ti ons. The ki ckdown val ve i s actuated by a cam
connected to the throttl e. Thi s i s accompl i shed
through ei ther a l i nkage or a cabl e. The cam forces
the ki ckdown val ve toward the throttl e val ve com-
pressi ng the spri ng between them and movi ng the
throttl e val ve. As the throttl e val ve l and starts to
uncover i ts port, l i ne pressure i s “metered” out i nto
the ci rcui ts and vi ewed as throttl e pressure. Thi s
i ncreased throttl e pressure i s metered out i nto the
ci rcui ts i t i s appl i ed to: the 1–2 and 2–3 shi ft val ves.
When the throttl e pressure i s hi gh enough, a 3–2
downshi ft wi l l occur. I f the vehi cl e speed i s l ow
enough, a 2–1 downshi ft wi l l occur.
SWITCH VALVE
When the transmi ssi on i s i n Dri ve Second just
before the TCC appl i cati on occurs (Fi g. 33), the pres-
sure regul ator val ve i s suppl yi ng torque converter
pressure to the swi tch val ve. The swi tch val ve di rects
thi s pressure through the transmi ssi on i nput shaft,
i nto the converter, through the converter, back out
between the i nput shaft and the reacti on shaft, and
back up to the swi tch val ve. From the swi tch val ve,
the fl ui d pressure i s di rected to the transmi ssi on
cool er, and l ubri cati on pressure returns from the
cool er to l ubri cate di fferent porti ons of the transmi s-
si on.
Once the TCC control val ve has moved to the l eft
(Fi g. 34), l i ne pressure i s di rected to the fai l –safe
val ve, and then to the ti p of the swi tch val ve, forci ng
the val ve downward. The swi tch val ve now vents oi l
from the front of the pi ston i n the torque converter,
and suppl i es l i ne pressure to the (rear) appl y si de of
the torque converter pi ston. Thi s pressure di fferen-
ti al causes the pi ston to appl y agai nst the fri cti on
materi al , cutti ng off any further fl ow of l i ne pressure
oi l . After the swi tch val ve i s shuttl ed downward
al l owi ng l i ne pressure to engage the TCC, torque
converter pressure i s di rected past the swi tch val ve
i nto the transmi ssi on cool er and l ubri cati on ci rcui ts.
Fig. 32 Throttle Valve
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 105
DESCRIPTION AND OPERATION (Continued)
Fig. 33 Switch Valve-Torque Converter Unlocked
21 - 106 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
CONVERTER CLUTCH CONTROL VALVE
The torque converter cl utch (TCC) control val ve
control s the back (ON) si de of the torque converter
cl utch. When the PCM energi zes the TCC sol enoi d to
engage the converter cl utch pi ston, pressure i s
appl i ed to the TCC control val ve whi ch moves to the
l eft and appl i es pressure to the fai l –safe val ve.
FAIL-SAFE VALVE
The pressure comi ng from the TCC control val ve
dead–ends at the fai l –safe val ve unti l governor pres-
sure on the ri ght si de of the val ve i ncreases. The
pressure must be hi gh enough to overcome the throt-
tl e and spri ng pressure on the l eft si de of the val ve
and push the val ve to the l eft. The pressure wi l l then
fl ow to the swi tch val ve.
MANUAL VALVE
The manual val ve (Fi g. 35) i s a rel ay val ve. The
purpose of the manual val ve i s to di rect fl ui d to the
correct ci rcui t needed for a speci fi c gear or dri vi ng
range. The manual val ve, as the name i mpl i es, i s
manual l y operated by the dri ver wi th a l ever l ocated
on the si de of the val ve body. The val ve i s connected
mechani cal l y by ei ther a cabl e or l i nkage to the gear-
shi ft mechani sm. The val ve i s hel d i n each of i ts
posi ti ons by a spri ng–l oaded rol l er or bal l that
engages the “roostercomb” of the manual val ve.
Fig. 34 Switch Valve-Torque Converter Locked
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 107
DESCRIPTION AND OPERATION (Continued)
ACCUMULATOR
DESCRIPTION
The accumul ator (Fi g. 36) i s a hydraul i c devi ce
that has the sol e purpose of cushi oni ng the appl i ca-
ti on of a band or cl utch. The accumul ator consi sts of
a dual –l and pi ston and a spri ng l ocated i n a bore i n
the transmi ssi on case.
OPERATION
Li ne pressure i s di rected between the l ands of the
pi ston (Fi g. 37), bottomi ng i t agai nst the accumul ator
pl ate. The accumul ator stays i n thi s posi ti on after
the transmi ssi on i s pl aced i nto a Dri ve posi ti on.
When the 1–2 upshi ft occurs (Fi g. 38), l i ne pressure
i s di rected to the l arge end of the pi ston and then to
the ki ckdown servo. As the l i ne pressure reaches the
accumul ator, the combi nati on of spri ng pressure and
l i ne pressure forces the pi ston away from the accu-
mul ator pl ate. Thi s causes a bal anced pressure si tu-
ati on, whi ch resul ts i n a cushi oned band appl i cati on.
After the ki ckdown servo has become i mmovabl e, l i ne
pressure wi l l fi ni sh pushi ng the accumul ator up i nto
i ts bore. When the l arge end of the accumul ator pi s-
ton i s seated i n i ts bore, the band or cl utch i s ful l y
appl i ed.
NOTE: The accumulator is shown in the inverted
position for illustrative purposes.
Fig. 35 Manual Valve
1 – 1–2 GOVERNOR PLUG
2 – 2–3 GOVERNOR PLUG
3 – GOVERNOR REAR CLUTCH ACCUMULATOR
4 – THROTTLE VALVE
5 – LAND #1
6 – PUMP
7 – PRESSURE REGULATOR
8 – LAND #2
Fig. 36 Accumulator
1 – ACCUMULATOR PISTON
2 – PISTON SPRING
21 - 108 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
PISTONS
DESCRIPTION
There are several si zes and types of pi stons used i n
an automati c transmi ssi on. Some pi stons are used to
appl y cl utches, whi l e others are used to appl y bands.
They al l have i n common the fact that they are round or
ci rcul ar i n shape, l ocated wi thi n a smooth wal l ed cyl i n-
der, whi ch i s cl osed at one end and converts fl ui d pres-
sure i nto mechani cal movement. The fl ui d pressure
exerted on the pi ston i s contai ned wi thi n the system
through the use of pi ston ri ngs or seal s.
OPERATION
The pri nci pal whi ch makes thi s operati on possi bl e i s
known as Pascal ’s Law. Pascal ’s Law can be stated as:
“Pressure on a confi ned fl ui d i s transmi tted equal l y i n
al l di recti ons and acts wi th equal force on equal areas.”
PRESSURE
Pressure (Fi g. 39) i s nothi ng more than force (l bs.)
di vi ded by area (i n or ft.), or force per uni t area.
Gi ven a 100 l b. bl ock and an area of 100 sq. i n. on
the fl oor, the pressure exerted by the bl ock i s: 100
l bs. 100 i n or 1 pound per square i nch, or PSI as i t i s
commonl y referred to.
PRESSURE ON A CONFINED FLUID
Pressure i s exerted on a confi ned fl ui d (Fi g. 40) by
appl yi ng a force to some gi ven area i n contact wi th the
fl ui d. A good exampl e of thi s i s a cyl i nder fi l l ed wi th
fl ui d and equi pped wi th a pi ston that i s cl osel y fi tted to
the cyl i nder wal l . I f a force i s appl i ed to the pi ston,
pressure wi l l be devel oped i n the fl ui d. Of course, no
pressure wi l l be created i f the fl ui d i s not confi ned. I t
wi l l si mpl y “l eak” past the pi ston. There must be a
resi stance to fl ow i n order to create pressure. Pi ston
seal i ng i s extremel y i mportant i n hydraul i c operati on.
Several ki nds of seal s are used to accompl i sh thi s
wi thi n a transmi ssi on. These i ncl ude but are not l i mi ted
to O–ri ngs, D–ri ngs, l i p seal s, seal i ng ri ngs, or
extremel y cl ose tol erances between the pi ston and the
Fig. 37 Accumulator in Neutral and Drive Positions
Fig. 38 Accumulator in Second Gear Position
1 – BOTTOM IN BORE
2 – SHUTTLE VALVE
Fig. 39 Force and Pressure Relationship
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 109
DESCRIPTION AND OPERATION (Continued)
cyl i nder wal l . The force exerted i s downward (gravi ty),
however, the pri nci pl e remai ns the same no matter
whi ch di recti on i s taken. The pressure created i n the
fl ui d i s equal to the force appl i ed, di vi ded by the pi ston
area. I f the force i s 100 l bs., and the pi ston area i s 10
sq. i n., then the pressure created equal s 10 PSI .
Another i nterpretati on of Pascal ’s Law i s that regard-
l ess of contai ner shape or si ze, the pressure wi l l be
mai ntai ned throughout, as l ong as the fl ui d i s confi ned.
I n other words, the pressure i n the fl ui d i s the same
everywhere wi thi n the contai ner.
FORCE MULTIPLICATION
Usi ng the 10 PSI exampl e used i n the i l l ustrati on
(Fi g. 41), a force of 1000 l bs. can be moved wi th a
force of onl y 100 l bs. The secret of force mul ti pl i ca-
ti on i n hydraul i c systems i s the total fl ui d contact
area empl oyed. The i l l ustrati on, (Fi g. 41), shows an
area that i s ten ti mes l arger than the ori gi nal area.
The pressure created wi th the smal l er 100 l b. i nput
i s 10 PSI . The concept “pressure i s the same every-
where” means that the pressure underneath the
l arger pi ston i s al so 10 PSI . Pressure i s equal to the
force appl i ed di vi ded by the contact area. Therefore,
by means of si mpl e al gebra, the output force may be
found. Thi s concept i s extremel y i mportant, as i t i s
al so used i n the desi gn and operati on of al l shi ft
val ves and l i mi ti ng val ves i n the val ve body, as wel l
as the pi stons, of the transmi ssi on, whi ch acti vate
the cl utches and bands. I t i s nothi ng more than
usi ng a di fference of area to create a di fference i n
pressure to move an object.
PISTON TRAVEL
The rel ati onshi p between hydraul i c l ever and a
mechani cal l ever i s the same. Wi th a mechani cal
l ever i t’s a wei ght–to–di stance output rather than a
pressure–to–area output. Usi ng the same forces and
areas as i n the previ ous exampl e, the smal l er pi ston
(Fi g. 42) has to move ten ti mes the di stance requi red
to move the l arger pi ston one i nch. Therefore, for
every i nch the l arger pi ston moves, the smal l er pi s-
ton moves ten i nches. Thi s pri nci pl e i s true i n other
i nstances al so. A common garage fl oor jack i s a good
exampl e. To rai se a car wei ghi ng 2000 l bs., an effort
of onl y 100 l bs. may be requi red. For every i nch the
car moves upward, the i nput pi ston at the jack han-
dl e must move 20 i nches downward.
FRONT CLUTCH
DESCRIPTION
The front cl utch assembl y (Fi g. 43) i s composed of
the front cl utch retai ner, pressure pl ate, four cl utch
pl ates, four dri vi ng di scs, pi ston, pi ston return
spri ng, return spri ng retai ner, and snap ri ngs. The
Fig. 40 Pressure on a Confined Fluid
Fig. 41 Force Multiplication
Fig. 42 Piston Travel
21 - 110 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
front cl utch i s the forwardmost component i n the
transmi ssi on geartrai n and i s di rectl y behi nd the oi l
pump and i s consi dered a dri vi ng component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To appl y the cl utch, pressure i s appl i ed between
the cl utch retai ner and pi ston. The fl ui d pressure i s
provi ded by the oi l pump, transferred through the
control val ves and passageways, and enters the
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved snap ri ng i s
used to cushi on the appl i cati on of the cl utch pack. I n
some transmi ssi ons, the snap ri ng i s sel ecti ve and
used to adjust cl utch pack cl earance.
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and one–way bal l –check–val ve l ocated i n the
cl utch retai ner. The check–val ve i s needed to el i mi -
nate the possi bi l i ty of pl ate drag caused by centri fu-
gal force acti ng on the resi dual fl ui d trapped i n the
cl utch pi ston retai ner.
REAR CLUTCH
DESCRIPTION
The rear cl utch assembl y (Fi g. 44) i s composed of
the rear cl utch retai ner, pressure pl ate, three cl utch
pl ates, four dri vi ng di scs, pi ston, Bel l evi l l e spri ng,
Fig. 43 Front Clutch
1 – RETAINER HUB SEAL
2 – CLUTCH PISTON
3 – PISTON SPRING
4 – SPRING RETAINER SNAP RING
5 – CLUTCH DISCS
6 – PRESSURE PLATE
7 – SNAP RING (WAVED)
8 – CLUTCH PLATES
9 – SPRING RETAINER
10 – PISTON SEAL
11 – FRONT CLUTCH RETAINER
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 111
DESCRIPTION AND OPERATION (Continued)
and snap ri ngs. The Bel l evi l l e spri ng acts as a l ever
to mul ti pl y the force appl i ed on to i t by the appl y pi s-
ton. The i ncreased appl y force on the rear cl utch
pack, i n compari son to the front cl utch pack, i s
needed to hol d agai nst the greater torque l oad
i mposed onto the rear pack. The rear cl utch i s
di rectl y behi nd the front cl utch and i s consi dered a
dri vi ng component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To appl y the cl utch, pressure i s appl i ed between
the cl utch retai ner and pi ston. The fl ui d pressure i s
provi ded by the oi l pump, transferred through the
control val ves and passageways, and enters the
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved snap ri ng i s
used to cushi on the appl i cati on of the cl utch pack. I n
some transmi ssi ons, the snap ri ng i s sel ecti ve and
used to adjust cl utch pack cl earance.
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
Fig. 44 Rear Clutch
1 – PISTON SPRING
2 – REAR CLUTCH PISTON
3 – CLUTCH PISTON SEALS
4 – OUTPUT SHAFT THRUST WASHER (METAL)
5 – INPUT SHAFT SNAP RING
6 – REAR CLUTCH RETAINER
7 – INPUT SHAFT
8 – REAR CLUTCH THRUST WASHER (FIBER)
9 – SHAFT FRONT SEAL RING (TEFLON)
10 – SHAFT REAR SEAL RING (METAL)
11 – CLUTCH PACK SNAP RING (SELECTIVE)
12 – RETAINER SEAL RING
13 – CLUTCH PLATES (3)
14 – TOP PRESSURE PLATE
15 – CLUTCH DISCS (4)
16 – BOTTOM PRESSURE PLATE
17 – WAVE SPRING
21 - 112 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and one–way bal l –check–val ve l ocated i n the
cl utch retai ner. The check–val ve i s needed to el i mi -
nate the possi bi l i ty of pl ate drag caused by centri fu-
gal force acti ng on the resi dual fl ui d trapped i n the
cl utch pi ston retai ner.
OVERRUNNING CLUTCH
DESCRIPTION
The overrunni ng cl utch (Fi g. 45) consi sts of an
i nner race, an outer race (or cam), rol l ers and
spri ngs, and the spri ng retai ner. The number of rol l -
ers and spri ngs depends on what transmi ssi on and
whi ch overrunni ng cl utch i s bei ng deal t wi th.
OPERATION
As the i nner race i s rotated i n a cl ockwi se di recti on
(as vi ewed from the front of the transmi ssi on), the
race causes the rol l ers to rol l toward the spri ngs,
causi ng them to compress agai nst thei r retai ner. The
compressi on of the spri ngs i ncreases the cl earance
between the rol l ers and cam. Thi s i ncreased cl ear-
ance between the rol l ers and cam resul ts i n a free-
wheel i ng condi ti on. When the i nner race attempts to
rotate countercl ockwi se, the acti on causes the rol l ers
to rol l i n the same di recti on as the race, ai ded by the
pushi ng of the spri ngs. As the rol l ers try to move i n
the same di recti on as the i nner race, they are
wedged between the i nner and outer races due to the
desi gn of the cam. I n thi s condi ti on, the cl utch i s
l ocked and acts as one uni t.
PLANETARY GEARSET
DESCRIPTION
The pl anetary gearsets (Fi g. 46) are desi gnated as
the front and rear pl anetary gear assembl i es and
l ocated i n such order. A si mpl e pl anetary gearset con-
si sts of three mai n members:
• The sun gear whi ch i s at the center of the sys-
tem.
• The pl anet carri er wi th pl anet pi ni on gears
whi ch are free to rotate on thei r own shafts and are
i n mesh wi th the sun gear.
• The annul us gear, whi ch rotates around and i s
i n mesh wi th the pl anet pi ni on gears.
NOTE: The number of pinion gears does not affect
the gear ratio, only the duty rating.
OPERATION
Wi th any gi ven pl anetary gearset, several condi -
ti ons must be met for power to be abl e to fl ow:
• One member must be hel d.
• Another member must be dri ven or used as an
i nput.
• The thi rd member may be used as an output for
power fl ow.
• For di rect dri ve to occur, two gear members i n
the front pl anetary gearset must be dri ven.
NOTE: Gear ratios are dependent on the number of
teeth on the annulus and sun gears.
Fig. 45 Overrunning Clutch
1 – OUTER RACE (CAM)
2 – ROLLER
3 – SPRING
4 – SPRING RETAINER
5 – INNER RACE (HUB)
Fig. 46 Planetary Gearset
1 – ANNULUS GEAR
2 – SUN GEAR
3 – PLANET CARRIER
4 – PLANET PINIONS (4)
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 113
DESCRIPTION AND OPERATION (Continued)
BANDS
DESCRIPTION
KICKDOWN (FRONT) BAND
The ki ckdown, or “front”, band (Fi g. 47) hol ds the
common sun gear of the pl anetary gear sets. The
front (ki ckdown) band i s made of steel , and faced on
i ts i nner ci rcumference wi th a fri cti on–type l i ni ng.
One end of the band i s anchored to the transmi ssi on
case, and the other i s acted on wi th a pushi ng force
by a servo pi ston. The front band i s a si ngl e–wrap
desi gn (the band does not compl etel y encompass/
wrap the drum that i t hol ds).
LOW/REVERSE (REAR) BAND
The l ow/reverse band, or “rear”, band (Fi g. 48) i s
si mi l ar i n appearance and operati on to the front
band. The rear band of the 32RH i s sl i ghtl y di fferent
i n that i t does not use a l i nk bar, but i s acted di rectl y
on by the appl y l ever. Thi s i s referred to as a doubl e–
wrap band desi gn (the drum i s compl etel y encom-
passed/wrapped by the band). The doubl e–wrap band
provi des a greater hol di ng power i n compari son to
the si ngl e–wrap desi gn.
OPERATION
KICKDOWN (FRONT) BAND
The ki ckdown band hol ds the common sun gear of
the pl anetary gear sets by appl yi ng and hol di ng the
front cl utch retai ner, whi ch i s spl i ned to the sun gear
dri vi ng shel l , and i n turn spl i ned di rectl y to the sun
gear. The appl i cati on of the band by the servo i s typ-
i cal l y done by an appl y l ever and l i nk bar.
LOW/REVERSE (REAR) BAND
The rear band hol ds the rear pl anet carri er sta-
ti onary by bei ng mounted around and appl i ed to the
l ow/reverse drum.
SERVOS
DESCRIPTION
KICKDOWN (FRONT) SERVO
The ki ckdown servo (Fi g. 49) consi sts of a two–l and
pi ston wi th an i nner pi ston, a pi ston rod and gui de,
and a return spri ng. The dual –l and pi ston uses seal
ri ngs on i ts outer di ameters and an O–ri ng for the
i nner pi ston.
LOW/REVERSE (REAR) SERVO
The rear (l ow/reverse) servo consi sts of a si ngl e
stage or di ameter pi ston and a spri ng l oaded pl ug.
The spri ng i s used to cushi on the appl i cati on of the
rear (l ow/reverse) band.
Fig. 47 Front Band
1 – FRONT BAND
2 – TRANSMISSION HOUSING
Fig. 48 Rear Band
1 – PLANETARY GEARTRAIN
2 – REAR BAND
3 – LEVER
4 – SERVO
5 – ADJUSTER
21 - 114 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
KICKDOWN (FRONT) SERVO
The appl i cati on of the pi ston i s accompl i shed by
appl yi ng pressure between the two l ands of the pi s-
ton. The pressure acts agai nst the l arger l ower l and
to push the pi ston downward, al l owi ng the pi ston rod
to extend though i ts gui de agai nst the appl y l ever.
Rel ease of the servo at the 2–3 upshi ft i s accom-
pl i shed by a combi nati on of spri ng and l i ne pressure,
acti ng on the bottom of the l arger l and of the pi ston.
The smal l pi ston i s used to cushi on the appl i cati on of
the band by bl eedi ng oi l through a smal l ori fi ce i n
the l arger pi ston. The rel ease ti mi ng of the ki ckdown
servo i s very i mportant to obtai n a smooth but fi rm
shi ft. The rel ease has to be very qui ck, just as the
front cl utch appl i cati on i s taki ng pl ace. Otherwi se,
engi ne runaway or a shi ft hesi tati on wi l l occur. To
accompl i sh thi s, the band retai ns i ts hol di ng capaci ty
unti l the front cl utch i s appl i ed, gi vi ng a smal l
amount of overl ap between them.
LOW/REVERSE (REAR) SERVO
Whi l e i n the de-energi zed state (no pressure
appl i ed), the pi ston i s hel d up i n i ts bore by the pi s-
ton spri ng. The pl ug i s hel d down i n i ts bore, i n the
pi ston, by the pl ug spri ng. When pressure i s appl i ed
to the top of the pi ston, the pl ug i s forced down i n i ts
bore, taki ng up any cl earance. As the pi ston moves, i t
causes the pl ug spri ng to compress, and the pi ston
moves down over the pl ug. The pi ston conti nues to
move down unti l i t hi ts the shoul der of the pl ug and
ful l y appl i es the band. The peri od of ti me from the
i ni ti al appl i cati on, unti l the pi ston i s agai nst the
shoul der of the pl ug, represents a reduced shocki ng
of the band that cushi ons the shi ft.
GOVERNOR
DESCRIPTION
The governor (Fi g. 50) val ve body i s attached to
the output shaft of the transmi ssi on.
OPERATION
The governor meters hydraul i c pressure (Fi g. 51),
and thi s metered pressure i s used to si gnal the
transmi ssi on when i t i s ti me for a shi ft to occur. I t
does thi s by bal anci ng governor pressure on one si de
of a shi ft val ve, and throttl e pressure on the other.
When governor pressure i ncreases far enough to
overcome the throttl e pressure on the val ve, a shi ft
occurs.
Wi th the gearshi ft sel ector i n a forward dri vi ng
range, l i ne pressure fl ows from the manual val ve and
down to the governor val ve. When the output shaft
starts to rotate wi th vehi cl e moti on (Fi g. 52), the gov-
ernor wei ght assembl y wi l l start to move outward
due to centri fugal force. As the wei ght i s moved out-
ward, i t wi l l pul l the val ve wi th i t unti l the l and of
the val ve uncovers the l i ne pressure port. As the port
begi ns to become uncovered, governor pressure i s
metered. As the vehi cl e’s speed conti nues to i ncrease
(Fi g. 53), the wei ght assembl y wi l l be at a poi nt at
whi ch governor pressure i s acti ng on the l eft si de of
the reacti on area of the val ve. Thi s produces suffi -
ci ent force to compress the spri ng and al l ow the
outer wei ght to move out agai nst the outer governor
body retai ni ng ri ng. At a very hi gh speed, the gover-
nor val ve wi l l be opened as far as possi bl e. I n thi s
condi ti on, i t i s possi bl e for governor pressure to meet,
but not to exceed, l i ne pressure. General l y governor
pressure ranges from 0–100 psi from i dl e to maxi -
mum speed, and ri ses proporti onal l y wi th the
i ncrease i n output shaft speed. Governor pressure
and throttl e pressure are acti ng upon the shi ft val ves
to determi ne when a shi ft wi l l occur. Governor pres-
sure i s a di rect i ndi cati on of road speed, and throttl e
pressure i s an i ndi cati on of engi ne l oad. When both
parameters have been met by the throttl e and gover-
nor pressures, an upshi ft or downshi ft wi l l occur.
Fig. 49 Front Servo
1 – VENT
2 – INNER PISTON
3 – PISTON
4 – SPRING
5 – RELEASE PRESSURE
6 – APPLY PRESSURE
7 – PISTON ROD
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 115
DESCRIPTION AND OPERATION (Continued)
Fig. 50 Governor
1 – SEAL RING (PLAIN END)
2 – SEAL RING (HOOK END)
3 – PARK GEAR
4 – GOVERNOR BODY
5 – GOVERNOR VALVE
6 – VALVE SHAFT
7 – E-CLIPS (2)
8 – FILTER
9 – SNAP RING (THIN)
10 – SNAP RING (THICK)
11 – SNAP RING
12 – RETAINER WASHER
13 – GOVERNOR WEIGHT ASSEMBLY
14 – GOVERNOR BODY BOLTS (4)
15 – WASHER
21 - 116 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
GEARSHIFT MECHANISM
DESCRIPTION
The shi ft mechani sm i s cabl e operated and pro-
vi des si x shi ft posi ti ons. The shi ft i ndi cator i s l ocated
on the consol e next to the gear shi ft. The shi ft posi -
ti ons are:
• Park (P)
• Reverse (R)
• Neutral (N)
• Dri ve (D)
• Manual Second (2)
• Manual Low (1)
OPERATION
Manual l ow (1) range provi des fi rst gear onl y. Over
run braki ng i s al so provi ded i n thi s range. Manual
second (2) range provi des fi rst and second gear onl y.
Dri ve range provi des fi rst, second, and thi rd gear
ranges.
CONVERTER DRAINBACK VALVE
DESCRIPTION
The drai nback val ve i s l ocated i n the transmi ssi on
cool er outl et (pressure) l i ne.
OPERATION
The val ve prevents fl ui d from drai ni ng from the
converter i nto the cool er and l i nes when the vehi cl e
i s shut down for l engthy peri ods. Producti on val ves
have a hose ni ppl e at one end, whi l e the opposi te end
i s threaded for a fl are fi tti ng. Al l val ves have an
arrow (or si mi l ar mark) to i ndi cate di recti on of fl ow
through the val ve.
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
DESCRIPTION
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 54).
OPERATION
The system l ocks the shi fter i nto the PARK posi -
ti on. The I nterl ock system i s engaged whenever the
i gni ti on swi tch i s i n the LOCK or ACCESSORY posi -
ti on. An addi ti onal el ectri cal l y acti vated feature wi l l
prevent shi fti ng out of the PARK posi ti on unl ess the
brake pedal i s depressed at l east one-hal f an i nch. A
magneti c hol di ng devi ce i n l i ne wi th the park/brake
i nterl ock cabl e i s energi zed when the i gni ti on i s i n
the RUN posi ti on. When the key i s i n the RUN posi -
Fig. 51 Governor—No Output Shaft Rotation
1 – GOVERNOR PRESSURE
2 – LINE PRESSURE
3 – OUTPUT SHAFT
4 – GOVERNOR
5 – VENT
Fig. 52 Governor—Moderate Output Shaft Rotation
Fig. 53 Governor—High Output Shaft Rotation
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 117
DESCRIPTION AND OPERATION (Continued)
ti on and the brake pedal i s depressed, the shi fter i s
unl ocked and wi l l move i nto any posi ti on. The i nter-
l ock system al so prevents the i gni ti on swi tch from
bei ng turned to the LOCK or ACCESSORY posi ti on
(Fi g. 55) unl ess the shi fter i s ful l y l ocked i nto the
PARK posi ti on.
DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION DIAGNOSIS
Automati c transmi ssi on probl ems can be a resul t of
poor engi ne performance, i ncorrect fl ui d l evel , i ncor-
rect l i nkage or cabl e adjustment, band or hydraul i c
control pressure adjustments, hydraul i c system mal -
functi ons or el ectri cal /mechani cal component mal -
functi ons. Begi n di agnosi s by checki ng the easi l y
accessi bl e i tems such as: fl ui d l evel and condi ti on,
l i nkage adjustments and el ectri cal connecti ons. A
road test wi l l determi ne i f further di agnosi s i s neces-
sary.
Fig. 54 Ignition Interlock Cable Routing
1 – SHIFT MECHANISM
2 – LOCK-TAB
3 – IGNITION LOCK INTERLOCK
4 – STEERING COLUMN
5 – SOLENOID
6 – WIRE CONNECTOR
7 – LEVER
8 – MOUNT BRACKET
9 – SHIFT CABLE
10 – AUTOMATIC TRANSMISSION
11 – TIE STRAP
12 – PARK/BRAKE INTERLOCK CABLE
Fig. 55 Ignition Key Cylinder Actuation
1 – SLIDER LOCKED
2 – CAM RETURN SPRING
3 – INTERLOCK CABLE
4 – CAM
5 – SLIDER
21 - 118 AUTOMATIC TRANSMISSION— 30/32RH TJ
DESCRIPTION AND OPERATION (Continued)
EFFECTS OF INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve, cl utch and servo operati on. Foami ng al so
causes fl ui d expansi on whi ch can resul t i n fl ui d over-
fl ow from the transmi ssi on vent or fi l l tube. Fl ui d
overfl ow can easi l y be mi staken for a l eak i f i nspec-
ti on i s not careful .
CAUSES OF BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
(1) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(2) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
FLUID CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
• addi ng i ncorrect fl ui d
• fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
• engi ne cool ant enteri ng the fl ui d
• i nternal fai l ure that generates debri s
• overheat that generates sl udge (fl ui d break-
down)
• fai l ure to reverse fl ush cool er and l i nes after
repai r
• fai l ure to repl ace contami nated converter after
repai r
The use of non recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on for some ti me, an overhaul
may al so be necessary; especi al l y i f shi ft probl ems
had devel oped.
The transmi ssi on cool er and l i nes shoul d be
reverse fl ushed whenever a mal functi on generates
sl udge and/or debri s. The torque converter shoul d
al so be repl aced at the same ti me.
Fai l ure to fl ush the cool er and l i nes wi l l resul t i n
recontami nati on. Fl ushi ng appl i es to auxi l i ary cool -
ers as wel l . The torque converter shoul d al so be
repl aced whenever a fai l ure generates sl udge and
debri s. Thi s i s necessary because normal converter
fl ushi ng procedures wi l l not remove al l contami -
nants.
PRELIMINARY DIAGNOSIS
Two basi c procedures are requi red. One procedure
for vehi cl es that are dri vabl e and an al ternate proce-
dure for di sabl ed vehi cl es (wi l l not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(2) Check fl ui d l evel and condi ti on.
(3) Adjust throttl e and gearshi ft l i nkage i f com-
pl ai nt was based on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform stal l test i f compl ai nt i s based on sl ug-
gi sh accel erati on. Or, i f abnormal throttl e openi ng i s
needed to mai ntai n normal speeds wi th a properl y
tuned engi ne.
(6) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(7) Perform ai r-pressure test to check cl utch-band
operati on.
VEHICLE IS DISABLED
(1) Check fl ui d l evel and condi ti on.
(2) Check for broken or di sconnected gearshi ft or
throttl e l i nkage.
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 119
DIAGNOSIS AND TESTING (Continued)
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri ve pl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
PARK/NEUTRAL POSITION SWITCH
The center termi nal of the park/neutral posi ti on
swi tch i s the starter-ci rcui t termi nal . I t provi des the
ground for the starter sol enoi d ci rcui t through the
sel ector l ever i n PARK and NEUTRAL posi ti ons onl y.
The outer termi nal s on the swi tch are for the backup
l amp ci rcui t.
SWITCH TEST
To test the swi tch, remove the wi ri ng connector.
Test for conti nui ty between the center termi nal and
the transmi ssi on case. Conti nui ty shoul d exi st onl y
when the transmi ssi on i s i n PARK or NEUTRAL.
Shi ft the transmi ssi on i nto REVERSE and test
conti nui ty at the swi tch outer termi nal s. Conti nui ty
shoul d exi st onl y when the transmi ssi on i s i n
REVERSE. Conti nui ty shoul d not exi st between the
outer termi nal s and the case.
Check gearshi ft l i nkage adjustment before repl ac-
i ng a swi tch that tests faul ty.
GEARSHIFT CABLE
(1) The fl oor shi fter l ever and gate posi ti ons
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
l ever i n PARK or NEUTRAL gate posi ti ons onl y.
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti on—Appl y forward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(b) PARK posi ti on—Appl y rearward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(c) NEUTRAL posi ti on—Normal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti on—Engi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from neutral to reverse.
THROTTLE VALVE CABLE
Transmi ssi on throttl e val ve cabl e adjustment i s
extremel y i mportant to proper operati on. Thi s adjust-
ment posi ti ons the throttl e val ve, whi ch control s shi ft
speed, qual i ty, and part-throttl e downshi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve. Refer to the Adjust-
ments secti on for the proper adjustment procedure.
ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that di agnosti c troubl e
codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, band or overrunni ng cl utch probl ems. I f the
condi ti on i s advanced, an overhaul wi l l be necessary
to restore normal operati on.
A sl i ppi ng cl utch or band can often be determi ned
by compari ng whi ch i nternal uni ts are appl i ed i n the
vari ous gear ranges. The Cl utch and Band Appl i ca-
ti on chart provi des a basi s for anal yzi ng road test
resul ts.
Fig. 56 Clutch And Band Application
21 - 120 AUTOMATIC TRANSMISSION— 30/32RH TJ
DIAGNOSIS AND TESTING (Continued)
ANALYZING ROAD TEST
Refer to the Cl utch and Band Appl i cati on chart
and note whi ch el ements are i n use i n the vari ous
gear ranges.
Veri fy that the rear cl utch i s appl i ed i n al l forward
ranges (D, 2, 1). The transmi ssi on overrunni ng cl utch
i s appl i ed i n fi rst gear (D, 2 and 1 ranges) onl y. The
rear band i s appl i ed i n 1 and R range onl y.
Veri fy that the overdri ve cl utch i s appl i ed onl y i n
fourth gear and the overdri ve di rect cl utch and over-
runni ng cl utch are appl i ed i n al l ranges except fourth
gear. For exampl e: I f sl i ppage occurs i n fi rst gear i n
D and 2 range but not i n 1 range, the transmi ssi on
overrunni ng cl utch i s faul ty. Si mi l arl y, i f sl i ppage
occurs i n any two forward gears, the rear cl utch i s
sl i ppi ng.
Appl yi ng the same method of anal ysi s, veri fy that
the front and rear cl utches are appl i ed si mul ta-
neousl y onl y i n D range thi rd gear. I f the transmi s-
si on sl i ps i n thi rd gear, ei ther the front cl utch or the
rear cl utch i s sl i ppi ng.
I f sl i ppage occurs duri ng the thi rd gear and the
di rect cl utch were to fai l , the transmi ssi on woul d l ose
both reverse gear and overrun braki ng i n 2 posi ti on
(manual second gear). I f the transmi ssi on sl i ps i n
any other forward gears, the transmi ssi on rear cl utch
i s probabl y sl i ppi ng.
Thi s process of el i mi nati on can be used to i denti fy
a sl i ppi ng uni t and check operati on. Proper use of
the Cl utch and Band Appl i cati on Chart i s the key.
Al though road test anal ysi s wi l l hel p determi ne the
sl i ppi ng uni t, the actual cause of a mal functi on usu-
al l y cannot be determi ned unti l hydraul i c and ai r
pressure tests are performed. Practi cal l y any condi -
ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Unl ess a mal functi on i s obvi ous, such as no dri ve
i n D range fi rst gear, do not di sassembl e the trans-
mi ssi on. Perform the hydraul i c and ai r pressure tests
to hel p determi ne the probabl e cause.
HYDRAULIC PRESSURE TEST
Hydraul i c test pressures range from a l ow of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port i n reverse.
An accurate tachometer and two test gauges are
requi red for the pressure test. Test Gauge C-3292
has a 100 psi range and i s used at the accumul ator,
governor, and front servo pressure ports. Test Gauge
C-3293-SP has a 300 psi range and i s used at the
rear servo port and overdri ve test ports where pres-
sures are hi gher. I n cases where two test gauges are
requi red, the 300 psi gauge can be used at any of the
other test ports.
Pressure Test Port Locations
Pressure test ports l ocati ons are provi ded at the
accumul ator, front servo, and rear servo, governor
passage, and overdri ve cl utch pressure passage (Fi g.
57), (Fi g. 58) and (Fi g. 59).
Li ne pressure i s checked at the accumul ator port
on the ri ght si de of the case. The front servo pressure
port i s at the ri ght si de of the case just behi nd the
fi l l er tube openi ng.
Connect a tachometer to the engi ne. Posi ti on the
tachometer so i t can be observed from under the
vehi cl e. Rai se the vehi cl e on a hoi st that wi l l al l ow
the wheel s to rotate freel y.
PRESSURE TEST PROCEDURE
Test One - Transmission In 1 Range
Thi s test checks pump output, pressure regul ati on,
and condi ti on of the rear cl utch and servo ci rcui t.
Test Gauges C-3292 and C-3293-SP are requi red for
thi s test. Gauge C-3292 has a 100 psi range. Gauge
C-3293-SP has a 300 psi range.
(1) Connect 100 psi Gauge C-3292 to accumul ator
port.
Fig. 57 Pressure Test Ports At Side Of Case
1 – REAR SERVO PORT
2 – LINE PRESSURE PORT
3 – FRONT SERVO PORT
Fig. 58 Pressure Test Ports At Rear Of Case—2WD
1 – GOVERNOR PRESSURE PORT
2 – REAR SERVO PRESSURE PORT
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 121
DIAGNOSIS AND TESTING (Continued)
(2) Connect 300 psi Gauge C-3293-SP to rear servo
port (Fi g. 57) and (Fi g. 58).
(3) Di sconnect throttl e and gearshi ft rods from
manual and throttl e l evers.
(4) Start and run engi ne at 1000 rpm.
(5) Move shi ft l ever (on manual l ever shaft) al l the
way forward i nto 1 range.
(6) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and note pressures on
both gauges.
(7) Li ne pressure at accumul ator port shoul d be
54-60 psi (372-414 kPa) wi th throttl e l ever forward
and gradual l y i ncrease to 90-96 psi (621-662 kPa) as
l ever i s moved rearward.
(8) Rear servo pressure shoul d be same as l i ne
pressure wi thi n 3 psi (20.68 kPa).
Test Two - Transmission In 2 Range
Thi s test checks pump output and pressure regul a-
ti on. Use 100 psi Test Gauge C-3292 for thi s test.
(1) Connect test gauge to accumul ator pressure
port (Fi g. 57) and (Fi g. 58).
(2) Start and run engi ne at 1000 rpm.
(3) Move shi ft l ever on val ve body manual l ever
shaft, one detent rearward from ful l forward posi ti on.
Thi s i s 2 range.
(4) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and read pressure at
both gauges.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease to 90-96 psi (621-662 kPa) as l ever i s moved
rearward.
Test Three - Transmission In D Range
Thi s test checks pressure regul ati on and condi ti on
of the cl utch ci rcui ts. Use both pressure Test Gauges
C-3292 and C-3293-SP for thi s test.
(1) Connect test gauges to accumul ator and front
servo ports (Fi g. 57) and (Fi g. 58). Use ei ther test
gauge at the two ports.
(2) Start and run engi ne at 1600 rpm for thi s test.
(3) Move sel ector l ever to D range. Thi s i s two
detents rearward from ful l forward posi ti on.
(4) Read pressures on both gauges as transmi ssi on
throttl e l ever i s moved from ful l forward to ful l rear-
ward posi ti on.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease as l ever i s moved rearward.
(6) Front servo i s pressuri zed onl y i n D range and
shoul d be same as l i ne pressure wi thi n 3 psi (21 kPa)
up to downshi ft poi nt.
Test Four - Transmission In Reverse
Thi s test checks pump output, pressure regul ati on
and the front cl utch and rear servo ci rcui ts. Use 300
psi Test Gauge C-3293-SP for thi s test.
(1) Connect 300 psi gauge to rear servo port (Fi g.
57) and (Fi g. 58).
(2) Start and run engi ne at 1600 rpm for test.
(3) Move val ve body sel ector l ever four detents
rearward from the ful l forward posi ti on. Thi s i s
Reverse range.
(4) Move throttl e l ever al l way forward then al l
way rearward and note gauge readi ngs.
(5) Pressure shoul d be 145 - 175 psi (1000-1207
kPa) wi th l ever forward and i ncrease to 230 - 280 psi
(1586-1931 kPa) as l ever i s moved rearward.
Test Five - Governor Pressure
Thi s test checks governor operati on by measuri ng
governor pressure response to changes i n engi ne
speed. I t i s usual l y not necessary to check governor
operati on unl ess shi ft speeds are i ncorrect or i f the
transmi ssi on wi l l not downshi ft.
(1) Connect 100 psi Test Gauge C-3292 to governor
pressure port (Fi g. 57) and (Fi g. 58).
(2) Move shi ft l ever to D range.
(3) Start and run engi ne at curb i dl e speed and
note pressure. At i dl e and wi th vehi cl e stopped, pres-
sure shoul d be zero to 1.5 psi maxi mum. I f pressure
exceeds thi s fi gure, governor val ve or wei ghts are
sti cki ng open.
(4) Sl owl y i ncrease engi ne speed and observe
speedometer and pressure test gauge. Governor pres-
sure shoul d i ncrease i n proporti on to vehi cl e speed.
(5) Pressure ri se shoul d be smooth and drop back
to 0 to 1.5 psi when wheel s stop rotati ng.
(6) Compare resul ts of pressure tests wi th anal ysi s
charts (Fi g. 60).
Fig. 59 Pressure Test Ports At Rear Of Case—4WD
1 – ADAPTER HOUSING
2 – GOVERNOR PRESSURE PORT PLUG
21 - 122 AUTOMATIC TRANSMISSION— 30/32RH TJ
DIAGNOSIS AND TESTING (Continued)
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on front/rear cl utch and band operati on. The test
can be conducted wi th the transmi ssi on ei ther i n the
vehi cl e or on the work bench, as a fi nal check, after
overhaul .
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
servo and cl utch appl y passages are shown (Fi g. 61).
Front Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through front cl utch appl y pas-
sage. Pi ston movement can be fel t and a soft thump
heard as the cl utch appl i es.
Rear Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through rear cl utch appl y passage.
Pi ston movement can be fel t and a soft thump heard
as the cl utch appl i es.
Front Servo Apply Air Test
Appl y ai r pressure to the front servo appl y pas-
sage. The servo rod shoul d extend and cause the
band to ti ghten around the drum. Spri ng pressure
shoul d rel ease the servo when ai r pressure i s
removed.
Rear Servo Air Test
Appl y ai r pressure to the rear servo appl y passage.
The servo rod shoul d extend and cause the band to
ti ghten around the drum. Spri ng pressure shoul d
rel ease the servo when ai r pressure i s removed.
TEST CONDITION INDICATION
Line pressure OK during
any one test
Pump and regulator valve
OK
Line pressure OK in R
but low in D, 2, 1
Leakage in rear clutch
area (servo, clutch seals,
governor support seal
rings on park gear)
Pressure OK in 1, 2 but
low in D3 and R
Leakage in front clutch
area (servo, clutch seals,
retainer bore, pump seal
rings)
Pressure OK in 2 but low
in R and 1
Leakage in rear servo
Front servo pressure in 2 Leakage in servo (broken
servo ring or cracked
servo piston)
Pressure low in all
positions
Clogged filter, stuck
pressure regulator valve,
worn or defective pump
Governor pressure too
high at idle speed
Governor valve sticking
open
Governor pressure low at
all mph figures
Governor valve sticking
closed
Lubrication pressure low
at all throttle positions
Clogged drainback valve,
oil cooler or lines, seal
rings leaking, output shaft
plugged with devris, worn
bushings in pump or
clutch retainer
Fig. 60 Pressure Test Analysis
Fig. 61 Air Pressure Test Passages
1 – REAR SERVO APPLY
2 – FRONT SERVO APPLY
3 – PUMP SUCTION
4 – FRONT CLUTCH APPLY
5 – FRONT SERVO RELEASE
6 – LINE PRESSURE TO ACCUMULATOR
7 – PUMP PRESSURE
8 – TO CONVERTER
9 – REAR CLUTCH APPLY
10 – FROM CONVERTER
11 – TO COOLER
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 123
DIAGNOSIS AND TESTING (Continued)
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Pump seal l eaks tend to move al ong the
dri ve hub and onto the rear of the converter. Pump
O-ri ng or pump body l eaks fol l ow the same path as a
seal l eak (Fi g. 62). Pump vent or pump attachi ng bol t
l eaks are general l y deposi ted on the i nsi de of the
converter housi ng and not on the converter i tsel f
(Fi g. 62). Pump seal or gasket l eaks usual l y travel
down the i nsi de of the converter housi ng. Front band
l ever pi n pl ug l eaks are general l y deposi ted on the
housi ng and not on the converter.
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
(1) Leaks at the wel d joi nt around the outsi de
di ameter wel d (Fi g. 63).
(2) Leaks at the converter hub wel d (Fi g. 63).
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Ti ghten front band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
front/rear cl utches from comi ng out when oi l pump i s
removed.
(3) Remove oi l pump and remove pump seal .
I nspect pump housi ng drai nback and vent hol es for
obstructi ons. Cl ear hol es wi th sol vent and wi re.
(4) I nspect pump bushi ng and converter hub. I f
bushi ng i s scored, repl ace i t. I f converter hub i s
scored, ei ther pol i sh i t wi th crocus cl oth or repl ace
converter.
(5) I nstal l new pump seal , O-ri ng, and gasket.
Repl ace oi l pump i f cracked, porous or damaged i n
any way. Be sure to l oosen the front band before
i nstal l i ng the oi l pump, damage to the oi l pump seal
may occur i f the band i s sti l l ti ghtened to the front
cl utch retai ner.
(6) Loosen ki ckdown l ever pi n access pl ug three
turns. Appl y Locti te 592, or Permatex No. 2 to pl ug
threads and ti ghten pl ug to 17 N·m (150 i n. l bs.)
torque.
(7) Adjust front band.
(8) Lubri cate pump seal and converter hub wi th
transmi ssi on fl ui d or petrol eum jel l y and i nstal l con-
verter.
(9) I nstal l transmi ssi on and converter housi ng
dust shi el d.
(10) Lower vehi cl e.
Fig. 62 Converter Housing Leak Paths
1 – PUMP SEAL
2 – PUMP VENT
3 – PUMP BOLT
4 – PUMP GASKET
5 – CONVERTER HOUSING
6 – CONVERTER
7 – REAR MAIN SEAL LEAK
Fig. 63 Converter Leak Points—Typical
1 – OUTSIDE DIAMETER WELD
2 – TORQUE CONVERTER HUB WELD
3 – STARTER RING GEAR
4 – LUG
21 - 124 AUTOMATIC TRANSMISSION— 30/32RH TJ
DIAGNOSIS AND TESTING (Continued)
DIAGNOSIS CHARTS
The di agnosi s charts provi de addi ti onal reference
when di agnosi ng a transmi ssi on faul t. The charts
provi de general i nformati on on a vari ety of transmi s-
si on, overdri ve uni t and converter cl utch faul t condi -
ti ons.
The hydraul i c fl ow charts, i n the Schemati cs and
Di agrams secti on of thi s group, outl i ne fl ui d fl ow and
hydraul i c ci rcui try. Ci rcui t operati on i s provi ded for
neutral , thi rd, fourth and reverse gear ranges. Nor-
mal worki ng pressures are al so suppl i ed for each of
the gear ranges.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
HARSH ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE
1. Fluid Level Low 1. Add Fluid
2. Throttle Linkage Misadjusted 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts Loose 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Misadjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component Damaged.
10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch (if equipped)
Faulty.
11. Replace converter and flush cooler and
line before installing new converter.
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 125
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
DELAYED ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE
1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Misadjusted. 3. Adjust linkage and repair linkage if worn
or damaged.
4. Rear Band Misadjusted. 4. Adjust band.
5. Valve Body Filter Plugged. 5. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
6. Oil Pump Gears Worn/Damaged. 6. Remove transmission and replace oil
pump.
7. Hydraulic Pressure Incorrect. 7. Perform pressure test, remove
transmission and repair as needed.
8. Reaction Shaft Seal Rings
Worn/Broken.
8. Remove transmission, remove oil pump
and replace seal rings.
9. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
9. Remove and disassemble transmission
and repair as necessary.
10. Governor Valve Stuck. 10. Remove and inspect governor
components. Replace worn or damaged
parts.
11. Regulator Valve Stuck. 11. Clean.
12. Cooler Plugged. 12. Flush transmission cooler and inspect
convertor drainback valve.
NO DRIVE RANGE
(REVERSE OK)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.
5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/
Damaged.
6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
21 - 126 AUTOMATIC TRANSMISSION— 30/32RH TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.
3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check press and inspect valve body.
Replace valve body (as assembly) if any
valve or bore is damaged. Clean and
reassemble correctly if all parts are in good
condition.
7. Transmission Internal Component
Damaged.
7. Remove and disassemble transmission.
Repair or replace failed components as
needed. Remove and disassemble
transmission. Repair or replace failed
components as needed.
8. Park Sprag not Releasing 8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Check Stall Speed, Worn/Damaged/
Stuck. Inspect and replace as required.
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 127
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)
1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.
2. Throttle Linkage Misadjusted. 2. Adjust linkage as described in service
section.
3. Throttle Linkage Binding. 3. Check cable for binding. Check for return
to closed throttle at transmission.
4. Gearshift Linkage/Cable
Misadjusted.
4. Adjust linkage/cable as described in
service section.
5. Fluid Filter Clogged. 5. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.
6. Governor Valve Sticking. 6. Inspect, clean or repair.
7. Governor Seal Rings Worn/
Damaged.
7. Inspect/replace.
8. Clutch or Servo Failure. 8. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
9. Front Band Misadjusted. 9. Adjust band.
10. Pump Suction Passage Leak. 10. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
NO REVERSE (D RANGES
OK)
1. Gearshift Linkage/Cable
Misadjusted/Damaged.
1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Inspect and replace as necessary.
3. Rear Band Misadjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Front Clutch Burnt. 6. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)
1. Governor Valve, Shaft, Weights or
Body Damaged/Stuck.
1. Remove governor assembly and clean or
repair as necessary.
2. Valve Body Malfunction. 2. Stuck 1-2 shift valve or governor plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW
1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.
2. Governor Valve Sticking. 2. Remove, clean and inspect. Replace
faulty parts.
21 - 128 AUTOMATIC TRANSMISSION— 30/32RH TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)
1. Governor Valve Sticking. 1. Remove governor, clean, inspect and
repair as required.
2. Valve Body Malfunction. 2. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
3. Front Servo Piston Cocked in
Bore.
3. Inspect servo and repair as required.
4. Front Band Linkage Malfunction 4. Inspect linkage and look for bind in
linkage.
NO KICKDOWN OR
NORMAL DOWNSHIFT
1. Throttle Linkage Misadjusted. 1. Adjust linkage.
2. Accelerator Pedal Travel
Restricted.
2. Floor mat under pedal, accelerator cable
worn or brackets bent.
3. Governor/Valve Body Hydraulic
Pressures Too High or Too Low Due
to Sticking Governor, Valve Body
Malfunction or Incorrect Hydraulic
Control Pressure Adjustments.
3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
4. Valve Body Malfunction. 4. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
5. Valve Body Malfunction. 5. Sticking 1-2, 2-3 shift valves, or governor
plugs.
STUCK IN LOW GEAR
(WILL NOT UPSHIFT)
1. Throttle Linkage Misadjusted/
Stuck.
1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage and repair linkage if worn
or damaged.
3. Governor/Valve Body, Governor
Valve Stuck Closed; Loose Output
Shaft Support or Governor Housing
Bolts, Leaking Seal Rings or Valve
Body Problem (i.e., Stuck 1- 2 Shift
Valve/Gov. Plug).
3. Check line and governor pressures to
determine cause. Correct as required.
4. Front Band Out of Adjustment. 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches
and bands. Repair faulty component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Misadjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped
Welded.
2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
determine cause and repair as required.
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 129
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Misassembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Misassembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.
4. Pump Passages Leaking 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage.
3. Rear Band Misadjusted. 3. Adjust band.
4. Rear Band Worn. 4. Replace as required.
5. Hydraulic Pressure Too Low. 5. Perform hydraulic pressure tests to
determine cause.
6. Rear Servo Leaking. 6. Air pressure check clutch-servo operation
and repair as required.
7. Band Linkage Binding. 7. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.
3. Throttle Linkage Misadjusted. 3. Adjust linkage.
4. Gearshift Linkage Misadjusted. 4. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking
Governor, Leaking Seal Rings,
Clutch Seals Leaking, Servo Leaks,
Clogged Filter or Cooler Lines
6. Perform hydraulic and air pressure tests
to determine cause.
7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.
7. Air pressure check clutch-servo operation
and repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR “D”
ONLY, BUT NOT IN 1
POSITION
Overrunning Clutch Faulty. Replace overrunning clutch.
21 - 130 AUTOMATIC TRANSMISSION— 30/32RH TJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
GROWLING, GRATING OR
SCRAPING NOISES
1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.
3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.
5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.
6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands
Misadjusted.
8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Misadjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.
5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.
WHINE/NOISE RELATED
TO ENGINE SPEED
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2 OR 2-3
SHIFTS
Lockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 131
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NO START IN PARK OR
NEUTRAL
1. Gearshift Linkage/Cable
Misadjusted.
1. Adjust linkage/cable.
2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Neutral Switch Faulty. 3. Refer to service section for test and
replacement procedure.
4. Neutral Switch Connect Faulty. 4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
5. Inspect lever assembly and replace if
damaged.
NO REVERSE (OR SLIPS
IN REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch
pack.
2. Rear Band Misadjusted. 2. Adjust band.
3. Front Clutch Malfunctioned/Burnt. 3. Air pressure test clutch operation.
Remove and rebuild if necessary.
OIL LEAKS (ITEMS
LISTED REPRESENT
POSSIBLE LEAK POINTS
AND SHOULD ALL BE
CHECKED.
1. Speedometer Adapter Leaks. 1. Replace both adapter seals.
2. Fluid Lines and Fittings Loose/
Leaks/Damaged.
2. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
3. Filler Tube (where tube enters
case) Leaks/Damaged.
3. Replace O-ring seal. Inspect tube for
cracks in tube.
4. Pressure Port Plug Loose
Loose/Damaged.
4. Tighten to correct torque. Replace plug
or reseal if leak persists.
5. Pan Gasket Leaks. 5. Tighten pan screws to 150 inch pounds.
If leaks persist, replace gasket. Do no over
tighten screws.
6. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
6. Replace shaft seal.
7. Rear Bearing Access Plate Leaks. 7. Replace gasket. Tighten screws.
8. Gasket Damaged or Bolts are
Loose.
8. Replace bolts or gasket or tighten both.
9. Adapter/Extension Gasket
Damaged Leaks/Damaged.
9. Replace gasket.
10. Neutral Switch Leaks/Damaged. 10. Replace switch and gasket.
11. Converter Housing Area Leaks. 11. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.
12. Pump Seal Leaks/Worn/
Damaged.
12. Replace seal.
13. Torque Converter Weld
Leak/Cracked Hub.
13. Replace converter.
14. Case Porosity Leaks. 14. Replace case.
21 - 132 AUTOMATIC TRANSMISSION— 30/32RH TJ
DIAGNOSIS AND TESTING (Continued)
SERVICE PROCEDURES
FLUID LEVEL CHECK
Transmi ssi on fl ui d l evel shoul d be checked monthl y
under normal operati on. I f the vehi cl e i s used for
trai l er towi ng or si mi l ar heavy l oad haul i ng, check
fl ui d l evel and condi ti on weekl y. Fl ui d l evel i s
checked wi th the engi ne runni ng at curb i dl e speed,
the transmi ssi on i n NEUTRAL and the transmi ssi on
fl ui d at normal operati ng temperature.
FLUID LEVEL CHECK PROCEDURE
(1) Transmi ssi on fl ui d must be at normal operat-
i ng temperature for accurate fl ui d l evel check. Dri ve
vehi cl e i f necessary to bri ng fl ui d temperature up to
normal hot operati ng temperature of 82°C (180°F).
(2) Posi ti on vehi cl e on l evel surface.
(3) Start and run engi ne at curb i dl e speed.
(4) Appl y parki ng brakes.
(5) Shi ft transmi ssi on momentari l y i nto al l gear
ranges. Then shi ft transmi ssi on back to Neutral .
(6) Cl ean top of fi l l er tube and di psti ck to keep
di rt from enteri ng tube.
(7) Remove di psti ck (Fi g. 64) and check fl ui d l evel
as fol l ows:
(a) Correct acceptabl e l evel i s i n crosshatch area.
(b) Correct maxi mum l evel i s to MAX arrow
mark.
(c) I ncorrect l evel i s at or bel ow MI N l i ne.
(d) I f fl ui d i s l ow, add onl y enough Mopar௡ ATF
Pl us 3 to restore correct l evel . Do not overfi l l .
CAUTION: Do not overfill the transmission. Overfill-
ing may cause leakage out the pump vent which
can be mistaken for a pump seal leak. Overfilling
will also cause fluid aeration and foaming as the
excess fluid is picked up and churned by the gear
train. This will significantly reduce fluid life.
FLUID AND FILTER REPLACEMENT
Refer to the Mai ntenance Schedul es i n Group 0,
Lubri cati on and Mai ntenance, for proper servi ce
i nterval s. The servi ce fl ui d fi l l after a fi l ter change i s
approxi matel y 3.8 l i ters (4.0 quarts).
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Remove the transmi ssi on/ski p pl ate as neces-
sary to access the transmi ssi on oi l pan.
(3) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(4) Remove bol ts hol di ng front and si des of pan to
transmi ssi on (Fi g. 65).
(5) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
(6) Sl owl y separate front of pan away from trans-
mi ssi on al l owi ng the fl ui d to drai n i nto drai n pan.
(7) Hol d up pan and remove remai ni ng bol ts hol d-
i ng pan to transmi ssi on.
(8) Whi l e hol di ng pan l evel , l ower pan away from
transmi ssi on.
(9) Pour remai ni ng fl ui d i n pan i nto drai n pan.
(10) Remove screws hol di ng fi l ter to val ve body
(Fi g. 66).
(11) Separate fi l ter from val ve body and pour fl ui d
i n fi l ter i nto drai n pan.
(12) Di spose used trans fl ui d and fi l ter properl y.
INSPECTION
I nspect bottom of pan and magnet for excessi ve
amounts of metal or fi ber contami nati on. A l i ght
coati ng of cl utch or band materi al on the bottom of
the pan does not i ndi cate a probl em unl ess accompa-
ni ed by sl i ppi ng condi ti on or shi ft l ag. I f fl ui d and
Fig. 64 Dipstick Fluid Level Marks—Typical
1 – DIPSTICK
2 – MAXIMUM CORRECT FLUID LEVEL
3 – ACCEPTABLE FLUID LEVEL
Fig. 65 Transmission Pan–Typical
1 – GASKET
2 – PAN
3 – TRANSMISSION
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 133
pan are contami nated wi th excessi ve amounts or
debri s, refer to the di agnosi s secti on of thi s group.
Check the adjustment of the front and rear bands,
adjust i f necessary. Refer to Adjustment secti on of
thi s group for proper procedure.
CLEANING
(1) Usi ng a sui tabl e sol vent, cl ean pan and mag-
net.
(2) Usi ng a sui tabl e gasket scraper, cl ean gasket
materi al from gasket surface of transmi ssi on case
and the gasket fl ange around the pan.
INSTALLATION
(1) Pl ace repl acement fi l ter i n posi ti on on val ve
body.
(2) I nstal l screws to hol d fi l ter to val ve body (Fi g.
66). Ti ghten screws to 4 N·m (35 i n. l bs.) torque.
(3) Pl ace new gasket i n posi ti on on pan. and
i nstal l pan on transmi ssi on.
(4) Pl ace pan i n posi ti on on transmi ssi on.
(5) I nstal l screws to hol d pan to transmi ssi on (Fi g.
65). Ti ghten bol ts to 17 N·m (150 i n. l bs.) torque.
(6) I nstal l the transmi ssi on/ski p pl ate.
(7) Lower vehi cl e and fi l l transmi ssi on wi th
Mopar௡ ATF Pl us 3, type 7176 fl ui d.
TRANSMISSION FILL PROCEDURE
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar௡ ATF
Pl us 3 to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 3
pints (1-1/2 quarts) of ATF Pl us 3 to transmi s-
si on.
(b) I f transmi ssi on was compl etel y overhaul ed,
torque converter was repl aced or drai ned, and
cool er was fl ushed, add 12 pints (6 quarts) of ATF
Pl us 3 to transmi ssi on.
(3) Appl y parki ng brakes.
(4) Start and run engi ne at normal curb i dl e
speed.
(5) Appl y servi ce brakes, shi ft transmi ssi on
through al l gear ranges then back to NEUTRAL, set
parki ng brake, and l eave engi ne runni ng at curb i dl e
speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick. Check to see i f the oi l l evel
i s equal on both si des of the di psti ck. I f one si de i s
noti cabl y hi gher than the other, the di psti ck has
pi cked up some oi l from the di psti ck tube. Al l ow the
oi l to drai n down the di psti ck tube and re-check.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow
mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
CONVERTER DRAINBACK CHECK VALVE
SERVICE
The converter drai nback check val ve i s l ocated i n
the cool er outl et (pressure) l i ne near the radi ator
tank. The val ve prevents fl ui d drai nback when the
vehi cl e i s parked for l engthy peri ods. The val ve check
bal l i s spri ng l oaded and has an openi ng pressure of
approxi matel y 2 psi .
The val ve i s servi ced as an assembl y; i t i s not
repai rabl e. Do not cl ean the val ve i f restri cted, or
contami nated by sl udge, or debri s. I f the val ve fai l s,
or i f a transmi ssi on mal functi on occurs that gener-
ates si gni fi cant amounts of sl udge and/or cl utch par-
ti cl es and metal shavi ngs, the val ve must be
repl aced.
The val ve must be removed whenever the cool er
and l i nes are reverse fl ushed. The val ve can be fl ow
tested when necessary. The procedure i s exactl y the
same as for fl ow testi ng a cool er.
Fig. 66 Transmission Filter–Typical
1 – FILTER
2 – TRANSMISSION
21 - 134 AUTOMATIC TRANSMISSION— 30/32RH TJ
SERVICE PROCEDURES (Continued)
I f the val ve i s restri cted, i nstal l ed backwards, or i n
the wrong l i ne, i t wi l l cause an overheati ng condi ti on
and possi bl e transmi ssi on fai l ure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.
OIL PUMP VOLUME CHECK
Measuri ng the oi l pump output vol ume wi l l deter-
mi ne i f suffi ci ent oi l fl ow to the transmi ssi on oi l
cool er exi sts, and whether or not an i nternal trans-
mi ssi on fai l ure i s present.
Veri fy that the transmi ssi on fl ui d i s at the proper
l evel . Refer to the Fl ui d Level Check procedure i n
thi s secti on. I f necessary, fi l l the transmi ssi on to the
proper l evel wi th Mopar௡ ATF+3, type 7176, Auto-
mati c Transmi ssi on Fl ui d.
(1) Di sconnect the To cooler l i ne at the cool er
i nl et and pl ace a col l ecti ng contai ner under the di s-
connected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
(3) I f one quart of transmi ssi on fl ui d i s col l ected i n
the contai ner i n 20 seconds or l ess, oi l pump fl ow vol -
ume i s wi thi n acceptabl e l i mi ts. I f fl ui d fl ow i s i nter-
mi ttent, or i t takes more than 20 seconds to col l ect
one quart of fl ui d, refer to the Hydraul i c Pressure
tests i n thi s secti on for further di agnosi s.
(4) Re-connect the To cooler l i ne to the transmi s-
si on cool er i nl et.
(5) Refi l l the transmi ssi on to proper l evel .
FLUSHING COOLERS AND TUBES
When a transmi ssi on fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The torque
converter must al so be repl aced. Thi s wi l l i nsure that
metal parti cl es or sl udged oi l are not l ater trans-
ferred back i nto the recondi ti oned (or repl aced) trans-
mi ssi on.
The onl y recommended procedure for fl ushi ng cool -
ers and l i nes i s to use Tool 6906A Cool er Fl usher.
CAUTION: The transmission oil cooler requires a
two stage flushing procedure due to an internally
mounted thermostat. Failure to follow the procedure
can result in severe transmission damage.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover pl ate fi l l er pl ug on Tool 6906A.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906A.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Remove the transmi ssi on oi l cool er from the
vehi cl e. Refer to the Group 7, Cool i ng System, for the
proper procedures.
(8) Remove the transmi ssi on oi l cool er thermostat.
Refer to the Group 7, Cool i ng System, for the proper
procedures.
(9) Re-i nstal l the thermostat cover onto the oi l
cool er and i nstal l the snap ri ng.
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 135
SERVICE PROCEDURES (Continued)
(10) Re-connect the oi l cool er to the transmi ssi on
cool er l i nes.
(11) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
(13) Remove the thermostat cover from the oi l
cool er.
(14) I nstal l Speci al Tool Cool er Pl ug 8414 i nto the
transmi ssi on oi l cool er.
(15) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes.
NOTE: This flushes the main oil cooler core pas-
sages only.
(16) Turn pump OFF.
(17) Remove the thermostat cover from the oi l
cool er.
(18) Remove Speci al Tool Cool er Pl ug 8414 from
the transmi ssi on oi l cool er.
(19) I nstal l a new thermostat spri ng, thermostat,
cover, and snap-ri ng i nto the transmi ssi on oi l cool er.
(20) I nstal l the transmi ssi on oi l cool er onto the
vehi cl e.
(21) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(22) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(23) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar௡ ATF Pl us 3, type 7176 automati c
transmi ssi on fl ui d.
(24) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(25) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts
of dri l l i ng out the worn-out damaged threads. Then
tap the hol e wi th a speci al Hel i -Coi l tap, or equi va-
l ent, and i nstal l i ng a Hel i -Coi l i nsert, or equi val ent,
i nto the hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
REMOVAL AND INSTALLATION
TRANSMISSION
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal.
REMOVAL
(1) Di sconnect battery negati ve cabl e.
(2) Di sconnect and l ower or remove necessary
exhaust components.
(3) Remove engi ne-to-transmi ssi on bendi ng braces.
(4) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(5) Remove starter motor.
(6) Di sconnect and remove crankshaft posi ti on sen-
sor. Retai n sensor attachi ng bol ts.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is left in place. To avoid damage,
remove the sensor before removing the transmis-
sion.
(7) Remove torque converter access cover.
(8) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan.
(9) Remove ski d pl ate for access.
(10) Remove fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube seal . Remove the
Fig. 67 Crankshaft Position Sensor—2.5L Engine
1 – EXHAUST DOWN PIPE
2 – TRANSMISSION HOUSING
3 – CRANKSHAFT POSITION SENSOR
21 - 136 AUTOMATIC TRANSMISSION— 30/32RH TJ
SERVICE PROCEDURES (Continued)
bol t attachi ng transfer case vent tube to converter
housi ng.
(11) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(12) Mark propel l er shaft and axl e yokes for
assembl y al i gnment. Then di sconnect and remove
propel l er shafts.
(13) Di sconnect wi res from park/neutral posi ti on
swi tch and vehi cl e speed sensor.
(14) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever.
(15) Di sconnect throttl e val ve cabl e from transmi s-
si on bracket and throttl e val ve l ever.
(16) Di sconnect shi ft rod from transfer case shi ft
l ever or remove shi ft l ever from transfer case.
(17) Support rear of engi ne wi th safety stand or
jack.
(18) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(19) Remove bol ts securi ng rear support and cush-
i on to transmi ssi on and crossmember. Rai se trans-
mi ssi on sl i ghtl y, sl i de exhaust hanger arm from
bracket and remove rear support.
(20) Remove bol ts attachi ng crossmember to frame
and remove crossmember.
(21) Di sconnect transfer case vent hose. Then di s-
connect vacuum swi tch harness.
(22) Remove transfer case.
(23) Remove al l converter housi ng bol ts.
(24) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(25) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(26) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
(27) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
INSTALLATION
(1) Check torque converter hub and hub dri ve
notches for sharp edges burrs, scratches, or ni cks.
Pol i sh the hub and notches wi th 320/400 gri t paper
and crocus cl oth i f necessary. The hub must be
smooth to avoi d damagi ng pump seal at i nstal l ati on.
(2) Lubri cate converter dri ve hub and oi l pump
seal l i p wi th transmi ssi on fl ui d.
(3) Al i gn converter and oi l pump.
(4) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(5) Check converter seati ng wi th steel scal e and
strai ghtedge (Fi g. 69). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(6) Temporari l y secure converter wi th C-cl amp.
(7) Li ghtl y grease crankshaft fl ange hol e.
(8) Posi ti on transmi ssi on on jack and secure i t
wi th safety chai ns.
Fig. 68 Crankshaft Position Sensor—4.0L Engine
1 – CRANKSHAFT POSITION SENSOR
2 – TRANSMISSION BELLHOUSING
3 – MOUNTING BOLT
Fig. 69 Typical Method Of Checking Converter
Seating
1 – SCALE
2 – STRAIGHTEDGE
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 137
REMOVAL AND INSTALLATION (Continued)
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
(11) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
(12) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft.
(13) I nstal l and ti ghten bol ts that attach transmi s-
si on converter housi ng to engi ne bl ock (Fi g. 70).
CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tighten-
ing any bolts.
(14) I nstal l torque converter attachi ng bol ts.
Ti ghten bol ts to fol l owi ng torque.
• 54 N·m (40 ft. l bs.) wi th 9.5 i n. 3-l ug converter
• 74 N·m (55 ft. l bs.) wi th 9.5 i n. 4-l ug converter
• 74 N·m (55 ft. l bs.) wi th 10.0 i n. 4-l ug converter
• 31 N·m (270 i n. l bs.) wi th 10.75 i n. 4-l ug con-
verter
(15) I nstal l crankshaft posi ti on sensor.
(16) I nstal l transmi ssi on fi l l tube and seal . I nstal l
new fi l l tube seal i n transmi ssi on before i nstal l ati on.
(17) Connect transmi ssi on cool er l i nes to transmi s-
si on.
(18) I nstal l transfer case onto transmi ssi on.
(19) I nstal l rear crossmember and attach trans-
mi ssi on rear support to crossmember.
(20) Remove engi ne support fi xture.
(21) Remove transmi ssi on jack.
(22) Connect vehi cl e speed sensor wi res.
(23) Connect wi res to park/neutral posi ti on swi tch.
(24) I nstal l crankshaft posi ti on sensor.
(25) I nstal l converter housi ng access cover.
(26) I nstal l exhaust pi pes and support brackets, i f
removed.
(27) I nstal l starter motor and cool er l i ne bracket.
(28) I nstal l new pl asti c retai ner grommet on any
shi ft l i nkage rod or l ever that was di sconnected.
Grommets shoul d not be reused. Use pry tool to
remove rod from grommet and cut away ol d grom-
met. Use pl i ers to snap new grommet i nto l ever and
to snap rod i nto grommet at assembl y.
(29) Connect gearshi ft and l i nkage and throttl e
cabl e.
(30) Connect transfer case shi ft l i nkage.
(31) Adjust gearshi ft l i nkage and throttl e val ve
cabl e i f necessary.
(32) Al i gn and connect propel l er shaft(s).
Fig. 70 Transmission Attachment
BOLT SET-TO SERVE
TORQUE
A
B
C
D
35 N•m (26 ft-lbs)
33 N•m (24 ft-lbs)
57 N•m (42 ft-lbs)
16 N•m (138 in-lbs)
21 - 138 AUTOMATIC TRANSMISSION— 30/32RH TJ
REMOVAL AND INSTALLATION (Continued)
(33) I nstal l ski d pl ate, rear cushi on and bracket, i f
removed.
(34) Fi l l transfer case to bottom edge of fi l l pl ug
hol e.
(35) Lower vehi cl e and fi l l transmi ssi on to correct
l evel wi th Mopar௡ ATF Pl us 3, type 7176 fl ui d.
TORQUE CONVERTER
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
(1) Lubri cate converter hub and oi l pump seal l i p
wi th transmi ssi on fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
strai ghtedge (Fi g. 71). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
ADAPTER HOUSING
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Support transmi ssi on wi th a sui tabl e l i fti ng
devi ce.
(3) Remove transmi ssi on ski d pl ate. Refer to
Group 13, Frame and Bumpers, for proper procedure.
(4) Remove propel l er shafts. Refer to Group 3, Di f-
ferenti al and Dri vel i ne, for proper procedure.
(5) Remove transfer case.
(6) Remove bol ts hol di ng adapter housi ng to trans-
mi ssi on case (Fi g. 72).
(7) Separate adapter housi ng from transmi ssi on.
(8) Sl i de adapter housi ng rearward and off output
shaft (Fi g. 72).
INSTALLATION
Cl ear gasket materi al from seal i ng surfaces on
adapter housi ng and rear of transmi ssi on. Repl ace
output shaft beari ng, i f necessary.
(1) I nstal l new rear seal i n adapter housi ng. Use
Tool Handl e C-4171 and Seal I nstal l er C-3860-A to
i nstal l seal .
(2) Pl ace adapter housi ng gasket i n posi ti on on
rear of transmi ssi on.
(3) Sl i de adapter housi ng forward and over output
shaft (Fi g. 72).
(4) Gui de park shaft i nto park sprag and push
adapter housi ng forward unti l rod passes through
Fig. 71 Checking Torque Converter Seating
1 – SCALE
2 – STRAIGHTEDGE
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 139
REMOVAL AND INSTALLATION (Continued)
openi ng behi nd sprag. I t may be necessary to use a
wi re to hol d sprag to the si de for rod to pass through.
(5) I nstal l bol ts to hol d adapter housi ng to rear of
transmi ssi on.
(6) I nstal l transfer case.
(7) I nstal l propel l er shafts.
(8) I nstal l rear transmi ssi on mount and ski d pl ate.
(9) Lower vehi cl e and veri fy transmi ssi on fl ui d
l evel . Add fl ui d as necessary.
SPEEDOMETER ADAPTER
Rear axl e gear rati o and ti re si ze determi ne speed-
ometer pi ni on requi rements.
REMOVAL
(1) Rai se vehi cl e.
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 73).
(4) Remove speed sensor and speedometer adapter
as assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 73).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar௡ el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or pi ns are l oose,
severel y corroded, or damaged.
INSTALLATION
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean for
proper adapter al i gnment and speedometer operati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter i f necessary (Fi g. 73).
Fig. 73 Speedometer Pinion Adapter Components
1 – SENSOR O-RING
2 – SPEEDOMETER ADAPTER
3 – ADAPTER O-RING
4 – SPEEDOMETER PINION
5 – ADAPTER CLAMP
6 – VEHICLE SPEED SENSOR
ITEM TORQUE
A 2-3 N·m (15-27 in. lbs.)
B 10-12 N·m (90-110 in. lbs.)
Fig. 72 Adapter Housing
1 – TRANSMISSION
2 – GASKET
3 – ADAPTER HOUSING
21 - 140 AUTOMATIC TRANSMISSION— 30/32RH TJ
REMOVAL AND INSTALLATION (Continued)
(3) Lubri cate sensor and adapter O-ri ngs wi th
transmi ssi on fl ui d.
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 N·m
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 74).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 o’cl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 N·m (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel , i f necessary.
PARK/NEUTRAL POSITION SWITCH
REMOVAL
(1) Rai se vehi cl e and posi ti on drai n pan under
swi tch.
(2) Di sconnect swi tch wi res.
(3) Remove swi tch from case.
INSTALLATION
(1) Move shi ft l ever to Park and Neutral posi ti ons.
Veri fy that swi tch operati ng l ever fi ngers are cen-
tered i n swi tch openi ng i n case (Fi g. 75).
(2) I nstal l new seal on swi tch and i nstal l swi tch i n
case. Ti ghten swi tch to 34 N·m (25 ft. l bs.) torque.
(3) Test conti nui ty of new swi tch wi th 12V test
l amp.
(4) Connect swi tch wi res and l ower vehi cl e.
(5) Top off transmi ssi on fl ui d l evel .
GEARSHIFT CABLE
REMOVAL
(1) Shi ft transmi ssi on i nto Park.
(2) Remove shi ft l ever bezel and necessary consol e
parts for access to shi ft l ever assembl y.
(3) Di sconnect cabl e at shi ft l ever and feed cabl e
through dash panel openi ng to undersi de of vehi cl e.
(4) Rai se vehi cl e.
(5) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng
bracket. Then remove ol d cabl e from vehi cl e.
INSTALLATION
(1) Route cabl e through hol e i n dash panel . Ful l y
seat cabl e grommet i nto dash panel .
(2) Pl ace the auto transmi ssi on manual shi ft con-
trol l ever i n “Park” detent (rearmost) posi ti on and
rotate prop shaft to ensure transmi ssi on i s i n park.
(3) Connect shi ft cabl e to shi fter mechani sm by
snappi ng cabl e retai ni ng ears i nto shi fter bracket
and press cabl e end fi tti ng onto l ever bal l stud.
(4) Pl ace the fl oor shi fter l ever i n park posi ti on.
Ensure that the pawl i s seated wi thi n the confi nes of
the adjustment gauge cl i p.
Fig. 74 Index Numbers On Speedometer Pinion
Adapter
1 – SPEEDOMETER ADAPTER
2 – INDEX NUMBER LOCATION
Fig. 75 Park/Neutral Position Switch
1 – NEUTRAL CONTACT
2 – MANUAL LEVER AND SWITCH PLUNGER IN REVERSE
POSITION
3 – PARK CONTACT
4 – SWITCH
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 141
REMOVAL AND INSTALLATION (Continued)
(5) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng ears are engaged and connect cabl e end
fi tti ng onto the manual control l ever bal l stud.
(6) Lock shi ft cabl e i nto posi ti on by pushi ng
upward on the adjusti ng l ock button.
(7) Remove and di scard the shi ft cabl e adjustment
gauge cl i p from the park gate of the shi fter.
BRAKE TRANSMISSION SHIFT INTERLOCK
REMOVAL
(1) Remove l ower steeri ng col umn cover. Refer to
Group 8E, I nstrument Panel and Gauges, for proper
procedure.
(2) Remove l ower steeri ng col umn shroud. Refer to
Group 19, Steeri ng, for proper procedure.
(3) Remove ti e strap near the sol enoi d retai ni ng
the brake transmi ssi on i nterl ock cabl e to the steeri ng
col umn.
(4) Di sengage wi re connector from sol enoi d.
(5) Wi th the i gni ti on removed or i n the unl ocked
posi ti on, di sengage l ock tab hol di ng cabl e end to
steeri ng col umn (Fi g. 76).
(6) Pul l cabl e end from steeri ng col umn.
(7) Remove the fl oor consol e and rel ated tri m.
Refer to Group 23, Body, for proper procedure.
(8) Di sconnect the cabl e eyel et from the bel l crank
(Fi g. 77).
(9) Di sconnect and remove the cabl e from the shi ft
bracket.
INSTALLATION
(1) Route repl acement cabl e behi nd i nstrument
panel and under fl oor consol e area to shi ft mecha-
ni sm (Fi g. 77).
(2) I nsert cabl e end i nto openi ng i n steeri ng col -
umn hub under i gni ti on l ock. Push cabl e i nward
unti l l ock tab engages.
(3) Connect the cabl e end eyel et onto shi fter
bel l crank pi n.
(4) Pl ace gear sel ector i n PARK.
(5) Push the spri ng-l oaded cabl e adjuster forward
and snap cabl e i nto bracket.
(6) Adjust the brake transmi ssi on shi fter i nterl ock
cabl e. Refer to the Adjustment porti on of thi s secti on
for proper procedures.
(7) Veri fy that the cabl e adjuster l ock cl amp i s
pushed downward to the l ocked posi ti on.
(8) Test the park-l ock cabl e operati on.
(9) I nstal l the fl oor consol e and rel ated tri m.
(10) I nstal l ti e strap to hol d cabl e to base of steer-
i ng col umn.
(11) I nstal l l ower steeri ng col umn shroud and i gni -
ti on l ock.
(12) I nstal l l ower steeri ng col umn cover.
VALVE BODY
REMOVAL
(1) Rai se vehi cl e.
(2) Remove oi l pan and drai n fl ui d.
(3) Loosen cl amp bol ts and remove throttl e and
manual val ve l evers from manual l ever shaft.
(4) Remove park/neutral posi ti on swi tch.
(5) Remove fi l ter from val ve body.
(6) Depress retai ni ng cl i p and pul l sol enoi d wi re
from case connector (Fi g. 78).
(7) Remove val ve body attachi ng screws.
(8) Lower val ve body enough to remove accumul a-
tor pi ston and pi ston spri ng (Fi g. 79).
(9) Pul l val ve body forward to di sengage park rod.
(10) Push manual l ever shaft and sol enoi d case
connector out of transmi ssi on case.
(11) Lower val ve body, rotate i t away from case,
pul l park l ock rod out of sprag, and remove val ve
body (Fi g. 80).
INSTALLATION
(1) Veri fy that park/neutral posi ti on swi tch i s NOT
i nstal l ed. Val ve body cannot be i nstal l ed wi th swi tch
i n pl ace. Remove swi tch i f necessary.
(2) I nstal l new seal s on accumul ator pi ston i f nec-
essary, and i nstal l pi ston i n case. Use smal l amount
of petrol eum jel l y to hol d pi ston i n pl ace.
(3) Pl ace val ve body manual l ever i n l ow (1 posi -
ti on) to ease i nserti ng park rod i nto sprag.
(4) Use screwdri ver to push park sprag i nto
engagement wi th park gear. Thi s makes cl earance for
knob on l ock rod to move past sprag when val ve body
i s i nstal l ed. Rotate output shaft to veri fy sprag
engagement.
Fig. 76 Brake/Park Interlock Cable
1 – IGNITION LOCK
2 – LOCK TAB
3 – CABLE END
21 - 142 AUTOMATIC TRANSMISSION— 30/32RH TJ
REMOVAL AND INSTALLATION (Continued)
(5) Posi ti on accumul ator spri ng between accumul a-
tor pi ston and val ve body.
Fig. 77 Cable and Shifter
1 – SHIFT MECHANISM
2 – LOCK-TAB
3 – IGNITION LOCK INTERLOCK
4 – STEERING COLUMN
5 – SOLENOID
6 – WIRE CONNECTOR
7 – LEVER
8 – MOUNT BRACKET
9 – SHIFT CABLE
10 – AUTOMATIC TRANSMISSION
11 – TIE STRAP
12 – PARK/BRAKE INTERLOCK CABLE
Fig. 78 Solenoid Wire Connector
1 – PUSH CLIP IN
2 – PULL
3 – CONVERTER CLUTCH SOLENOID CONNECTOR
Fig. 79 Accumulator Piston And Springs
1 – ACCUMULATOR PISTON
2 – OUTER SPRING
3 – PISTON SEAL RINGS
4 – INNER SPRING (32RH)
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 143
REMOVAL AND INSTALLATION (Continued)
(6) Posi ti on val ve body on transmi ssi on and work
knob on park l ock rod past sprag. Be sure accumul a-
tor pi ston and spri ng remai n i n posi ti on.
(7) Hol d val ve body i n posi ti on and i nstal l val ve
body screws fi nger ti ght.
(8) I nstal l park/neutral posi ti on swi tch.
(9) Ti ghten val ve body screws al ternatel y and
evenl y to 11 N·m (100 i n. l bs.) torque.
(10) I nstal l new fl ui d fi l ter on val ve body. I nstal l
and ti ghten fi l ter screws to 4 N·m (35 i n. l bs.) torque.
(11) Connect sol enoi d wi re to case connector.
(12) I nstal l manual and throttl e l evers on throttl e
l ever shaft. Ti ghten l ever cl amp screws and check for
free operati on. Shaft and l evers must operate freel y
wi thout any bi nd.
(13) I nstal l oi l pan and new gasket. Ti ghten pan
bol ts to 17 N·m (150 i n. l bs.) torque. I nstal l gasket
dry; do not use seal er.
(14) Connect park/neutral posi ti on swi tch and con-
verter cl utch sol enoi d wi res.
(15) I nstal l speedometer pi ni on gear, adapter and
speed sensor.
(16) Lower vehi cl e.
(17) Fi l l transmi ssi on wi th Mopar௡ ATF Pl us 3,
Type 7176 fl ui d.
(18) Adjust gearshi ft and throttl e cabl e i f neces-
sary.
OUTPUT SHAFT REAR BEARING
REMOVAL
(1) Remove extensi on housi ng.
(2) Remove snap ri ng that retai ns rear beari ng on
output shaft (Fi g. 81).
(3) Remove beari ng from output shaft.
INSTALLATION
(1) I nstal l beari ng on output shaft. Be sure retai n-
i ng ri ng groove i n outer ci rcumference of beari ng i s
toward the governor.
(2) I nstal l rear beari ng retai ni ng snap ri ng (Fi g.
81).
(3) I nstal l extensi on housi ng.
GOVERNOR AND PARK GEAR
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Mark propel l er shaft and axl e yoke for assem-
bl y reference. Then di sconnect and remove shaft.
(3) Di sconnect parki ng brake cabl e at equal i zer
and di sconnect exhaust components as necessary.
(4) Support transmi ssi on on a sui tabl e l i fti ng
devi ce.
(5) Remove ski d pl ate and rear transmi ssi on
mount.
(6) Remove extensi on housi ng.
(7) Loosen but do not remove bol ts that hol d gov-
ernor body to park gear.
(8) Rotate transmi ssi on output shaft unti l gover-
nor wei ght assembl y i s accessi bl e.
(9) Remove E-cl i p at end of governor val ve shaft
(Fi g. 82).
(10) Remove governor val ve and shaft from gover-
nor body (Fi g. 82).
(11) Remove snap ri ngs and spacer that retai n
governor body and park gear assembl y on output
shaft (Fi g. 83).
Fig. 80 Valve Body
1 – VALVE BODY
2 – CONVERTER CLUTCH MODULE
3 – SOLENOID
4 – PARK ROD
5 – CONVERTER CLUTCH SOLENOID CONNECTOR
6 – MANUAL VALVE
7 – MANUAL LEVER
Fig. 81 Output Shaft Rear Bearing—Typical
1 – BEARING SNAP RING GROOVE
2 – PARK LOCK CONTROL ROD
3 – REAR SNAP RING
21 - 144 AUTOMATIC TRANSMISSION— 30/32RH TJ
REMOVAL AND INSTALLATION (Continued)
(12) Remove bol ts hol di ng governor body to park
gear (Fi g. 84).
(13) Separate governor from park gear.
(14) Pul l park gear from rear support.
INSTALLATION
(1) I nstal l park gear i nto rear support so crown on
curved boss i s i n l i ne wi th hol e through output shaft.
(2) I nstal l governor fi l ter i n park gear.
(3) Sl i p governor body over output shaft and al i gn
port to fi l ter.
(4) I nstal l bol ts to hol d governor body to park gear.
Ti ghten bol ts to 11 N·m (95 i n. l bs.) torque (Fi g. 84).
(5) I nstal l governor body-park gear snap ri ngs and
washer on output shaft as fol l ows:
(a) I nstal l thi n snap ri ng fi rst. Then i nstal l
thrust washer second, and thi ck snap ri ng l ast
(Fi g. 83).
(b) Veri fy correct posi ti on of snap ri ngs. Be sure
flat side of each snap ring is toward governor
body.
(6) I nsert governor val ve and shaft through gover-
nor and i nstal l E-cl i p (Fi g. 82).
(7) I nstal l extensi on housi ng and gasket on trans-
mi ssi on. Ti ghten housi ng bol ts to 32 N·m (24 ft. l bs.).
(8) I nstal l rear transmi ssi on mount and ski d pl ate.
(9) I nstal l speed sensor and speedometer compo-
nents and connect speed sensor wi res.
(10) Connect exhaust components and brake cabl e,
i f removed.
(11) I nstal l propel l er shaft.
(12) Remove supports and l ower vehi cl e.
(13) Check transmi ssi on fl ui d l evel . Add fl ui d i f
necessary.
PARK LOCK
REMOVAL
(1) Rai se vehi cl e and remove propel l er shaft.
(2) Remove extensi on housi ng.
(3) Sl i de sprag shaft out of extensi on housi ng and
remove sprag and spri ng (Fi g. 85).
(4) Remove snap ri ng and sl i de reacti on pl ug and
pi n assembl y out of housi ng.
Fig. 82 Governor Valve
1 – E-CLIP
2 – PARK GEAR
3 – CURVER BOSS
4 – GOVERNOR VALVE
5 – GOVERNOR
Fig. 83 Snap Rings And Spacer
1 – GOVERNOR BODY
2 – THIN SNAP RING
3 – THRUST WASHER
4 – THICK SNAP RING
Fig. 84 Governor Body
1 – GOVERNOR/PARK GEAR ASSEMBLY
2 – GOVERNOR VALVE SHAFT BORE
3 – REAR SUPPORT
4 – OUTPUT SHAFT SPLINES
5 – SEAL RINGS
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 145
REMOVAL AND INSTALLATION (Continued)
(5) I f park rod requi res servi ce, i t wi l l be necessary
to remove val ve body.
INSTALLATION
(1) I nspect sprag shaft for scores and free move-
ment i n housi ng and sprag. I nspect sprag and control
rod spri ngs for di storti on and l oss of tensi on. repl ace
worn, damaged parts as necessary.
(2) I nspect square l ug on sprag for broken edges.
Check l ugs on park gear for damage. I nspect knob on
end of control rod for wear grooves, or bei ng sei zed
on rod. Repl ace rod i f bent, i f knob i s worn/grooved,
or i t has sei zed on rod. Repl ace park gear i f l ugs are
damaged. Repl ace the park l ock rod i f i t i s suspected
that the rod i s not the correct l ength.
(3) I nstal l reacti on pl ug and pi n assembl y i n hous-
i ng and secure wi th new snap ri ng (Fi g. 85).
(4) Posi ti on sprag and spri ng i n housi ng and i nsert
sprag shaft. Be sure square l ug on sprag i s toward
park gear. Al so be sure spri ng i s posi ti oned so i t
moves sprag away from gear.
(5) I nstal l extensi on housi ng.
(6) I nstal l propel l er shaft and l ower vehi cl e.
(7) Check transmi ssi on fl ui d l evel . Add fl ui d i f nec-
essary.
DISASSEMBLY AND ASSEMBLY
GOVERNOR AND PARK GEAR
DISASSEMBLY
(1) Remove governor body from transmi ssi on.
(2) Cl ean and i nspect governor fi l ter (Fi g. 86).
(3) Remove snap ri ng and washer that secure gov-
ernor wei ght assembl y i n body (Fi g. 87).
(4) Remove governor wei ght assembl y from gover-
nor body bore.
(5) Sl i de i ntermedi ate and i nner wei ght from outer
wei ght.
(6) Posi ti on i ntermedi ate wei ght on sui tabl e si ze
socket (Fi g. 88).
(7) Push i nner wei ght downward wi th nut dri ver.
Then remove i nner wei ght snap ri ng wi th Mi l l er
Pl i er Tool 6823 (Fi g. 88).
(8) Remove i nner wei ght and spri ng from i nterme-
di ate wei ght.
Fig. 85 Park Lock
1 – EXTENSION HOUSING
2 – SPRAG
3 – 8ЈЈ
4 – SHAFT
5 – E-CLIP
6 – SPRING
7 – CONTROL ROD
8 – SNAP RING
9 – PLUG AND PIN
10 – SPRING
Fig. 86 Governor Filter
1 – GOVERNOR FILTER
2 – PARK GEAR
21 - 146 AUTOMATIC TRANSMISSION— 30/32RH TJ
REMOVAL AND INSTALLATION (Continued)
ASSEMBLY
CAUTION: Exercise care when installing the rings.
They are easily broken if overspread or twisted dur-
ing installation.
I f i t was necessary to remove the park gear,
i nspect the seal ri ngs and bore i n rear support.
I nstal l new seal ri ngs on park gear hub onl y i f ori g-
i nal ri ngs are damaged, or worn. I nstal l ri ng wi th
i nterl ock ends fi rst and ri ng wi th pl ai n ends l ast.
Sl i p each ri ng on hub and seat them i n grooves. Ver-
i fy that rear ri ng ends are securel y i nterl ocked before
proceedi ng. I f the bore i n rear support i s damaged,
repl ace the rear support.
(1) Lubri cate governor components wi th Mopar௡
ATF Pl us 3, Type 7176 transmi ssi on fl ui d before
assembl y.
(2) Cl ean and i nspect governor wei ghts and bores
for scori ng or wear. Repl ace the governor body and
wei ghts i f damaged. Refer to Cl eani ng and I nspecti on
secti on of thi s group for proper procedure.
(3) I nsert spri ng i nto i ntermedi ate wei ght.
(4) I nsert i nner wei ght i nto i ntermedi ate wei ght and
i nstal l snap-ri ng (Fi g. 89). Veri fy snap-ri ng i s ful l y
seated i n groove i n i ntermedi ate wei ght (Fi g. 88).
(5) Assembl e governor wei ghts i nto governor body
(Fi g. 87).
(6) I nstal l washer and snap ri ng to hol d wei ghts i n
governor body.
(7) I nstal l governor body i n transmi ssi on
VALVE BODY
DISASSEMBLY
Posi ti on the val ve body on a cl ean work surface to
avoi d contami nati on.
Fig. 87 Snap Ring, Washer, and Outer Weight
1 – SNAP-RING
2 – E-CLIP
3 – PARK GEAR
4 – GOVERNOR VALVE
5 – SHAFT
6 – GOVERNOR
7 – OUTER WEIGHT
8 – INTERMEDIATE WEIGHT
9 – WASHER
Fig. 88 Inner Weight Snap Ring
1 – NUT DRIVER
2 – SUITABLE SIZE SOCKET
3 – INTERMEDIATE WEIGHT
4 – INNER WEIGHT SNAP RING
5 – SPECIAL TOOL 6823
Fig. 89 Intermediate and Inner Governor Weights
1 – INTERMEDIATE WEIGHT
2 – INNER WEIGHT
3 – SNAP-RING
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 147
DISASSEMBLY AND ASSEMBLY (Continued)
CAUTION: Do not clamp any part of the valve body
assembly (Fig. 90) in a vise. This practice will distort
the valve body and transfer plate resulting in valve
bind. Slide valves and plugs out carefully. Do not
use force at any time. The valves and valve body will
be damaged if force is used. Also tag or mark the
valve body springs for reference as they are
removed. Do not allow them to become intermixed.
(1) Remove screws attachi ng adjusti ng screw
bracket to val ve body and transfer pl ate. Hol d
bracket fi rml y agai nst spri ng force whi l e removi ng
l ast screw.
(2) Remove adjusti ng screw bracket, l i ne pressure
adjusti ng screw (Fi g. 91).
(3) Remove swi tch val ve and spri ng, pressure reg-
ul ator val ve and spri ng, ki ckdown val ve and spri ng,
and throttl e val ve from val ve body (Fi g. 91).
(4) Secure detent bal l and spri ng i n housi ng wi th
Retai ner Tool 6583 (Fi g. 92).
(5) Remove manual shaft E-cl i p, washer, and seal
(Fi g. 93).
(6) Pul l manual shaft and park rod assembl y upward
out of val ve body and off throttl e l ever (Fi g. 93).
(7) Remove manual val ve from val ve body (Fi g. 94)
(8) Remove Retai ner Tool 6583. Then remove and
retai n detent bal l and spri ng (Fi g. 93).
(9) Remove throttl e l ever (Fi g. 93).
(10) Remove park rod E-cl i p and separate rod from
manual l ever (Fi g. 95).
(11) Remove converter cl utch sol enoi d from separa-
tor pl ate (Fi g. 96). A T25 torx bi t i s requi red to
remove sol enoi d attachi ng screw.
(12) Remove screws attachi ng converter cl utch
modul e to val ve body and remove modul e and con-
necti ng tube (Fi g. 97).
(13) Remove screws attachi ng end cover pl ate to
torque converter modul e (Fi g. 98).
(14) Remove converter cl utch val ve, fai l safe val ve,
and spri ngs (Fi g. 98)
Fig. 90 Valve Body Assembly
1 – VALVE BODY
2 – CONVERTER CLUTCH MODULE
3 – SOLENOID
4 – PARK ROD
5 – CONVERTER CLUTCH SOLENOID CONNECTOR
6 – MANUAL VALVE
7 – MANUAL LEVER
Fig. 91 Adjusting Screw Bracket, Springs, Valve
Removal
1 – ADJUSTER BRACKET
2 – LINE PRESSURE ADJUSTER
3 – PRESSURE REGULATOR VALVE
4 – SWITCH VALVE
5 – VALVE BODY
6 – TRANSFER PLATE
7 – THROTTLE VALVE
8 – SLEEVE
9 – KICKDOWN VALVE
10 – THROTTLE PRESSURE ADJUSTER
Fig. 92 Securing Detent Ball And Spring With
Retainer Tool
1 – SPECIAL TOOL 6583
2 – DETENT BALL AND SPRING HOUSING
21 - 148 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(15) Turn val ve body over so transfer pl ate i s fac-
i ng upward (Fi g. 99). Wi th val ve body i n thi s posi -
ti on, val ve body check bal l s wi l l remai n i n pl ace and
not fal l out when transfer pl ate i s removed.
(16) Remove screws attachi ng transfer pl ate to
val ve body (Fi g. 99).
(17) Remove transfer pl ate and separator pl ate
from val ve body (Fi g. 99). Note posi ti on of fi l ter and
cl utch sol enoi d for reference. Remove val ve body
check bal l s.
(18) Posi ti on transfer pl ate on bench so separator
pl ate, and fi l ter are faci ng up. Thi s wi l l avoi d havi ng
rear cl utch and rear servo check bal l s fal l out when
pl ates are separated.
Fig. 93 Manual And Throttle Levers
1 – PARK ROD
2 – E-RING
3 – WASHER
4 – MANUAL LEVER
5 – MANUAL VALVE
6 – SPRING
7 – DETENT BALL
8 – VALVE BODY
Fig. 94 Manual Valve
1 – MANUAL VALVE
2 – VALVE BODY
Fig. 95 Park Rod
1 – MANUAL LEVER
2 – E-CLIP
3 – PARK ROD
Fig. 96 Converter Clutch Solenoid
1 – VALVE BODY
2 – TORQUE CONVERTER CLUTCH SOLENOID
Fig. 97 Clutch Module And Connecting Tube
1 – MODULE AND CONNECTING TUBE
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 149
DISASSEMBLY AND ASSEMBLY (Continued)
(19) Remove screws attachi ng separator pl ate to
transfer pl ate (Fi g. 100).
(20) Note posi ti on of fi l ter, rear cl utch servo and
rear servo check bal l s for assembl y reference (Fi g.
100) and (Fi g. 101).
(21) Remove shuttl e val ve end pl ate (Fi g. 102).
(22) Remove shuttl e val ve E-cl i p and remove sec-
ondary spri ng and spri ng gui des from end of val ve
(Fi g. 103).
(23) Remove governor pl ug end pl ate (Fi g. 104).
(24) Remove 1-2 and 2-3 shi ft val ve governor pl ugs
from val ve body (Fi g. 104).
(25) Remove shuttl e val ve throttl e pl ug, pri mary
spri ng and shuttl e val ve from val ve body (Fi g. 104).
(26) Remove screws attachi ng ki ckdown l i mi t
val ve body to val ve body (Fi g. 104).
(27) Remove 1-2 shi ft control val ve and spri ng
from val ve body (Fi g. 104).
(28) Remove 2-3 shi ft val ve and spri ng from val ve
body (Fi g. 104).
(29) Remove 1-2 shi ft val ve and spri ng from val ve
body (Fi g. 104).
(30) Remove throttl e pressure pl ug from ki ckdown
l i mi t val ve body (Fi g. 104).
(31) Remove retai ner from end of ki ckdown l i mi t
val ve body (Fi g. 104).
(32) Remove ki ckdown l i mi t val ve and spri ng from
ki ckdown l i mi t val ve body (Fi g. 104).
Fig. 98 Converter Clutch and Fail Safe Valves
1 – COVER PLATE
2 – CONVERTER CLUTCH VALVE
3 – TORQUE CONVERTER CLUTCH MODULE
4 – MODULE CONNECTING TUBE
5 – FAIL-SAFE VALVE
Fig. 99 Valve Body Transfer Plate Screws
1 – TRANSFER PLATE
2 – VALVE BODY
3 – SEPARATOR PLATE
Fig. 100 Transfer And Separator Plates
1 – SEPARATOR PLATE
2 – FILTER
3 – TRANSFER PLATE
Fig. 101 Rear Servo and Rear Clutch Check Balls
1 – REAR SERVO CHECK BALL
2 – TRANSFER PLATE
3 – REAR CLUTCH CHECK BALL
21 - 150 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(33) Remove regul ator val ve end pl ate from val ve
body (Fi g. 104).
(34) Remove regul ator val ve l i ne pressure pl ug,
pressure pl ug sl eeve, regul ator val ve throttl e pres-
sure pl ug and spri ng (Fi g. 104).
ASSEMBLY
Cl ean and i nspect al l val ve body components for
damage or wear. Refer to the Cl eani ng and I nspec-
ti on secti on of thi s group for proper procedure.
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves,
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the valve body resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
(1) Lubri cate val ve body bores, val ves and pl ugs
wi th Mopar௡ ATF Pl us 3, Type 7176, transmi ssi on
fl ui d.
(2) I nstal l regul ator val ve l i ne pressure pl ug, pres-
sure pl ug sl eeve, regul ator val ve throttl e pressure
pl ug, and spri ng i nto val ve body (Fi g. 104). Veri fy
val ve components sl i de freel y.
(3) I nstal l regul ator val ve end pl ate on val ve body
(Fi g. 104).
(4) I nstal l ki ckdown l i mi t val ve and spri ng i n ki ck-
down l i mi t val ve body (Fi g. 104). Veri fy val ve compo-
nents sl i de freel y.
(5) Compress spri ng i nto ki ckdown l i mi t val ve
body.
(6) I nstal l retai ner i n grooves at end of ki ckdown
l i mi t val ve body (Fi g. 104).
(7) I nstal l throttl e pressure pl ug i n ki ckdown l i mi t
val ve body (Fi g. 104).
(8) I nstal l 1-2 shi ft val ve and spri ng i nto val ve
body (Fi g. 104).
(9) I nstal l 2-3 shi ft val ve and spri ng i nto val ve
body (Fi g. 104).
(10) I nstal l 1-2 shi ft control val ve and spri ng i nto
val ve body (Fi g. 104).
(11) Veri fy val ve components sl i de freel y.
(12) Pl ace ki ckdown l i mi t val ve body and end pl ate
i n posi ti on on val ve body and compress spri ngs (Fi g.
104).
(13) I nstal l screws to attach ki ckdown l i mi t val ve
body to val ve body (Fi g. 104).
(14) I nstal l shuttl e val ve throttl e pl ug, pri mary
spri ng and shuttl e val ve i nto val ve body (Fi g. 104).
Veri fy val ve components sl i de freel y.
(15) I nstal l 1-2 and 2-3 shi ft val ve governor pl ugs
i nto val ve body (Fi g. 104). Veri fy val ve components
sl i de freel y.
(16) Pl ace governor pl ug end pl ate i n posi ti on on
val ve body and compress spri ng.
(17) I nstal l screws to attach governor pl ug end
pl ate to val ve body (Fi g. 104).
Fig. 102 Shuttle Valve End Plate
1 – VALVE BODY
2 – SHUTTLE VALVE END PLATE
Fig. 103 Shuttle Valve E-Clip And Secondary Spring
1 – E-CLIP
2 – SECONDARY SPRING AND GUIDES
3 – SHUTTLE VALVE
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 151
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 104 Control Valves, Shift Valves, And Governor Plugs
1 – GOVERNOR PLUG END PLATE
2 – SHUTTLE VALVE
3 – 1–2 GOVERNOR PLUG
4 – VALVE BODY
5 – REGULATOR VALVE THROTTLE PRESSURE PLUG
6 – SLEEVE
7 – LINE PRESSURE PLUG
8 – RETAINER
9 – 1–2 SHIFT VALVE
10 – 1–2 SHIFT CONTROL VALVE
11 – KICKDOWN LIMIT VALVE
12 – END PLATE
13 – THROTTLE PRESSURE PLUG
14 – KICKDOWN LIMIT VALVE BODY
15 – E-RING
16 – 2–3 SHIFT VALVE
17 – GUIDES
18 – 2–3 GOVERNOR PLUG
19 – PRIMARY SPRING
20 – SHUTTLE VALVE THROTTLE PLUG
21 - 152 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(18) Assembl e shuttl e val ve spri ng and gui des
(Fi g. 104). Pl ace spri ng and gui des i n posi ti on on
shuttl e val ve stem.
(19) Compress spri ng and i nstal l E-cl i p i n groove
on shuttl e val ve stem (Fi g. 105).
(20) Pl ace shuttl e val ve end pl ate i n posi ti on on
val ve body (Fi g. 106).
(21) I nstal l screws to attach shuttl e val ve end
pl ate to val ve body (Fi g. 106).
(22) I nstal l rear cl utch servo and rear servo check
bal l s i n proper cavi ti es i n transfer pl ate (Fi g. 107).
(23) I nsert fi l ter i nto openi ng i n separator pl ate
(Fi g. 108).
(24) Pl ace separator pl ate i n posi ti on on transfer
pl ate and i nstal l screws to attach separator pl ate to
transfer pl ate (Fi g. 108).
(25) Pl ace one 11/32 i n. check bal l and si x 1/4 i n.
check bal l s i n the proper cavi ti es i n the val ve body
(Fi g. 109).
(26) Pl ace transfer pl ate i n posi ti on on val ve body
(Fi g. 110).
(27) I nstal l screws to attach transfer pl ate to val ve
body (Fi g. 110).
(28) Turn val ve body over to expose the separator
pl ate.
(29) I nsert converter cl utch val ve and spri ng i nto
converter cl utch val ve modul e (Fi g. 111). Veri fy val ve
components sl i de freel y.
Fig. 105 Shuttle Valve E-Clip And Secondary Spring
1 – E-CLIP
2 – SECONDARY SPRING AND GUIDES
3 – SHUTTLE VALVE
Fig. 106 Shuttle Valve End Plate
1 – VALVE BODY
2 – SHUTTLE VALVE END PLATE
Fig. 107 Rear Servo and Rear Clutch Check Balls
1 – REAR SERVO CHECK BALL
2 – TRANSFER PLATE
3 – REAR CLUTCH CHECK BALL
Fig. 108 Transfer And Separator Plates
1 – SEPARATOR PLATE
2 – FILTER
3 – TRANSFER PLATE
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 153
DISASSEMBLY AND ASSEMBLY (Continued)
(30) I nsert spri ng and fai l -safe val ve i nto converter
cl utch val ve modul e (Fi g. 111). Veri fy val ve compo-
nents sl i de freel y.
(31) Pl ace cover pl ate i n posi ti on on converter
cl utch val ve modul e (Fi g. 111).
(32) I nstal l screws to attach cover to converter
cl utch val ve modul e (Fi g. 111).
(33) I nsert connecti ng tube i nto converter cl utch
val ve modul e (Fi g. 111).
(34) I nsert connecti ng tube i nto val ve body open-
i ng (Fi g. 112).
(35) Pl ace converter cl utch val ve modul e i n posi -
ti on on separator pl ate. I nstal l screws to attach con-
verter cl utch modul e to val ve body (Fi g. 112).
(36) I f necessary, i nstal l a new O-ri ng on converter
cl utch sol enoi d (Fi g. 113).
(37) I nsert converter cl utch sol enoi d i nto transfer
pl ate (Fi g. 113).
(38) I nstal l screw to attach sol enoi d to transfer
pl ate (Fi g. 113).
(39) I f necessary, i nsert park rod end i nto manual
l ever and i nstal l E-cl i p (Fi g. 114).
Fig. 109 Correct Position Of Valve Body Check Balls
1 – 1/4ЈЈ CHECK BALLS (6)
2 – 11/32ЈЈ CHECK BALL (1)
Fig. 110 Valve Body Transfer Plate Screws
1 – TRANSFER PLATE
2 – VALVE BODY
3 – SEPARATOR PLATE
Fig. 111 Converter Clutch Valve Module
1 – COVER PLATE
2 – CONVERTER CLUTCH VALVE
3 – TORQUE CONVERTER CLUTCH MODULE
4 – MODULE CONNECTING TUBE
5 – FAIL-SAFE VALVE
21 - 154 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(40) I nsert detent spri ng and bal l i nto openi ng i n
val ve body and i nstal l Retai ner Tool 6583 (Fi g. 115).
(41) I nstal l manual val ve i nto val ve body (Fi g.
116).
(42) I nsert throttl e l ever through transfer pl ate
si de of val ve body and upward (Fi g. 117).
(43) I nsert throttl e l ever i nto groove i n manual
val ve (Fi g. 118).
(44) I nstal l seal , washer, and E-cl i p to retai n man-
ual shaft to val ve body (Fi g. 117).
(45) I nstal l swi tch val ve and spri ng, pressure reg-
ul ator val ve and spri ng, ki ckdown val ve and spri ng,
and throttl e val ve i nto val ve body (Fi g. 119).
(46) Pl ace adjusti ng screw bracket and l i ne pres-
sure adjusti ng screw i n posi ti on on val ve body and
compress spri ngs (Fi g. 91).
(47) I nstal l screws to attach adjuster bracket to
val ve body.
Fig. 112 Clutch Module And Connecting Tube
1 – MODULE AND CONNECTING TUBE
Fig. 113 Converter Clutch Solenoid
1 – VALVE BODY
2 – TORQUE CONVERTER CLUTCH SOLENOID
Fig. 114 Park Rod
1 – MANUAL LEVER
2 – E-CLIP
3 – PARK ROD
Fig. 115 Securing Detent Ball And Spring With
Retainer Tool
1 – SPECIAL TOOL 6583
2 – DETENT BALL AND SPRING HOUSING
Fig. 116 Manual Valve
1 – MANUAL VALVE
2 – VALVE BODY
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 155
DISASSEMBLY AND ASSEMBLY (Continued)
TRANSMISSION
DISASSEMBLY
(1) Remove transmi ssi on from vehi cl e.
(2) I nstal l a sui tabl e tai l shaft housi ng pl ug to
avoi d contami nati ng i nternal components wi th cl ean-
i ng sol vents.
(3) Cl ean exteri or of transmi ssi on wi th sui tabl e
sol vent or pressure washer.
(4) Remove torque converter from transmi ssi on.
(5) Remove throttl e and shi ft l evers from val ve
body manual shaft and throttl e l ever shaft.
(6) Mount transmi ssi on i n repai r stand C-3750-B
or si mi l ar type stand (Fi g. 120).
(7) Remove extensi on housi ng.
(8) Remove fl ui d pan.
(9) Remove park/neutral posi ti on swi tch and seal
(Fi g. 121).
(10) Remove val ve body.
(11) Remove accumul ator spri ng and pi ston (Fi g.
122).
NOTE: The 32RH is equipped with an additional
spring under the accumulator piston.
(12) Loosen front band adjusti ng screw l ock nut
(Fi g. 123) 4-5 turns. Then ti ghten band adjusti ng
screw unti l band i s ti ght around front cl utch. Thi s
Fig. 117 Manual And Throttle Levers
1 – PARK ROD
2 – E-RING
3 – WASHER
4 – MANUAL LEVER
5 – MANUAL VALVE
6 – SPRING
7 – DETENT BALL
8 – VALVE BODY
Fig. 118 Manual Valve And Throttle Lever Alignment
1 – THROTTLE LEVER
2 – MANUAL LEVER VALVE ARM
3 – MANUAL VALVE
4 – KICKDOWN VALVE
Fig. 119 Adjusting Screw Bracket, Springs, and
Valves
1 – ADJUSTER BRACKET
2 – LINE PRESSURE ADJUSTER
3 – PRESSURE REGULATOR VALVE
4 – SWITCH VALVE
5 – VALVE BODY
6 – TRANSFER PLATE
7 – THROTTLE VALVE
8 – SLEEVE
9 – KICKDOWN VALVE
10 – THROTTLE PRESSURE ADJUSTER
21 - 156 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
prevents front/rear cl utches from comi ng out wi th
pump and possi bl y damagi ng cl utch or pump compo-
nents.
(13) Remove oi l pump bol ts.
(14) Thread bol ts of Sl i de Hammer Tool s C-3752
i nto threaded hol es i n pump body fl ange (Fi g. 124).
(15) Bump sl i de hammer wei ghts outward to
remove pump and reacti on shaft support assembl y
from case (Fi g. 124).
(16) Loosen front band adjusti ng screw unti l band
i s compl etel y l oose (Fi g. 123).
(17) Squeeze front band together and remove band
strut (Fi g. 125).
Fig. 120 Repair Stand
1 – TRANSMISSION
2 – STAND
Fig. 121 Park/Neutral Position Switch
1 – NEUTRAL SWITCH
2 – SOLENOID CONNECTOR
Fig. 122 Accumulator Piston And Spring
1 – ACCUMULATOR PISTON
2 – PISTON SPRING
Fig. 123 Front Band Adjusting Screw Lock Nut
1 – LOCK-NUT
2 – FRONT BAND ADJUSTER
Fig. 124 Oil Pump/Reaction Shaft Support
1 – OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY
2 – SLIDE HAMMER TOOLS C-3752
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 157
DISASSEMBLY AND ASSEMBLY (Continued)
(18) Remove front and rear cl utch uni ts as an
assembl y. Grasp i nput shaft, hol d cl utch uni ts
together and remove them from case (Fi g. 126).
(19) Li ft front cl utch off rear cl utch (Fi g. 127). Set
cl utch uni ts asi de for overhaul .
(20) Remove output shaft thrust washer from out-
put shaft (or from rear cl utch hub) (Fi g. 128).
(21) Remove output shaft thrust pl ate and washer
from output shaft hub (Fi g. 128).
(22) Remove front band from case (Fi g. 129).
(23) Remove extensi on housi ng from transmi ssi on
case.
(24) Remove governor body and park gear from
output shaft.
(25) Remove output shaft and pl anetary geartrai n
as assembl y (Fi g. 130). Support geartrai n wi th both
hands duri ng removal . Do not al l ow machi ned sur-
faces on output shaft to become ni cked or scratched.
Fig. 125 Front Band Strut
1 – BAND LEVER
2 – BAND STRUT
3 – FRONT BAND
Fig. 126 Front/Rear Clutch Assemblies
1 – FRONT BAND
2 – FRONT CLUTCH AND DRUM
3 – TRANSMISSION HOUSING
4 – REAR CLUTCH
Fig. 127 Separating Front Clutch From Rear Clutch
1 – FRONT CLUTCH
2 – REAR CLUTCH
21 - 158 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(26) Loosen rear band adjusti ng screw 4-5 turns
(Fi g. 131).
(27) Remove snap ri ng that secures l ow-reverse
drum to rear support hub, however do not remove
drum (Fi g. 132).
(28) Remove bol ts attachi ng rear support to trans-
mi ssi on case and pul l support from l ow-reverse drum
(Fi g. 133).
(29) Remove bol ts attachi ng overrunni ng cl utch
cam and l ow-reverse drum to transmi ssi on case (Fi g.
134).
Fig. 128 Output Shaft Thrust Plate and Washer
1 – OUTPUT SHAFT
2 – THRUST PLATE
3 – THRUST WASHER
Fig. 129 Front Band
1 – FRONT BAND
2 – TRANSMISSION HOUSING
Fig. 130 Planetary Geartrain
1 – SLOTS
2 – LOW-REVERSE DRUM
3 – PLANETARY GEARTRAIN
4 – TRANSMISSION HOUSING
5 – LUGS
Fig. 131 Rear Band Adjuster Location
1 – PLANETARY GEARTRAIN
2 – REAR BAND
3 – LEVER
4 – SERVO
5 – ADJUSTER
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 159
DISASSEMBLY AND ASSEMBLY (Continued)
REAR BAND—32RH.
(30) Remove rear band. The 32RH transmi ssi on i s
equi pped wi th a doubl e-wrap band that does not
requi re a l i nk bar.
(a) Remove l ow-reverse drum and overrunni ng
cl utch as assembl y. Sl i de drum and cl utch through
rear band and out of case (Fi g. 135). Set drum and
cl utch assembl y asi de for cl eani ng and i nspecti on.
(b) Remove rear band from case (Fi g. 135).
REAR BAND—30RH
(31) Remove rear band. The 30RH transmi ssi on i s
equi pped wi th a si ngl e-wrap band wi th a l i nk bar.
(a) Usi ng snap-ri ng pl i er, pul l rear band anchor
pi n (l ocated on the servo si de of the rear support)
from transmi ssi on case.
(b) Remove rear band and l i nk from transmi s-
si on (Fi g. 136).
(c) Separate rear band from l i nk (Fi g. 137).
(32) I f necessary remove front and rear band servo
l evers. Al l transmi ssi on components can be servi ced
wi thout removi ng the l evers.
(a) Usi ng a 1/4 i nch dri ve extensi on remove
front band reacti on pi n access pl ug (Fi g. 138).
Fig. 132 Low-Reverse Drum Snap Ring
1 – REAR BAND
2 – REAR SUPPORT HUB
3 – LOW-REVERSE DRUM SNAP RING
4 – LOW-REVERSE DRUM
Fig. 133 Rear Support
1 – OIL PAN FACE
2 – TRANSMISSION HOUSING
3 – REAR SUPPORT
Fig. 134 Overrunning Clutch Cam Bolt Locations
1 – OVERRUNNING CLUTCH CAM BOLTS
Fig. 135 Low- Reverse Band and Drum—32RH
1 – REAR BAND
2 – LUGS
3 – LOW-REVERSE DRUM
4 – REAR BAND ANCHOR PIN
21 - 160 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(b) Remove front band reacti on pi n wi th penci l
magnet. Pi n i s accessi bl e from converter housi ng
si de of case (Fi g. 139).
(c) Remove front band l ever (Fi g. 140).
(d) Usi ng snap-ri ng pl i er, pul l rear band l ever
pi vot from transmi ssi on case (Fi g. 141).
(e) Separate rear band servo l ever from trans-
mi ssi on.
(33) Compress front servo rod gui de about 1/8 i n.
wi th l arge C-cl amp and Tool C-4470, or Spri ng Com-
pressor Tool C-3422-B (Fi g. 142).
Fig. 136 Rear Band and Link—30RH
1 – LINK
2 – REAR BAND
Fig. 137 Rear Band and Link—30RH
1 – NOTCHED SIDE OF LINK GOES TOWARD BAND
Fig. 138 Front Band Reaction Pin Access Plug
1 – 1/4ЈЈ DRIVE EXTENSION
2 – FRONT BAND REACTION PIN ACCESS PLUG
Fig. 139 Front Band Reaction Pin
1 – PENCIL MAGNET
2 – FRONT BAND REACTION PIN
Fig. 140 Front Band Lever
1 – FRONT BAND LEVER
Fig. 141 Rear Band Servo Lever Pin
1 – PARALLEL JAW SNAP RING PLIERS
2 – REAR BAND LEVER PIVOT PIN
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 161
DISASSEMBLY AND ASSEMBLY (Continued)
(34) Remove front servo rod gui de snap ri ng (Fi g.
142). Exercise caution when removing snap
ring. Servo bore can be scratched or nicked if
care is not exercised.
(35) Remove compressor tool s and remove front
servo rod gui de, spri ng and servo pi ston.
(36) Compress rear servo spri ng retai ner about
1/16 i n. wi th C-cl amp and Tool C-4470 or SP-5560
(Fi g. 143). Val ve Spri ng Compressor C-3422-B can
al so be used to compress spri ng retai ner.
(37) Remove rear servo spri ng retai ner snap ri ng.
Then remove compressor tool s and remove rear servo
spri ng and pi ston.
ASSEMBLY
(1) I nstal l rear servo pi ston, spri ng and spri ng
retai ner. Compress rear servo spri ng and retai ner
wi th Compressor Tool C-3422-B (Fi g. 143) or a l arge
C-cl amp.
(2) I nstal l front servo pi ston, spri ng, and rod
gui de. Compress front servo rod gui de wi th Val ve
Spri ng Compressor C-3422-B and i nstal l servo snap
ri ng (Fi g. 142).
REAR BAND—32RH
(3) I nstal l rear band
(a) I nsert rear band through pan openi ng i n
transmi ssi on case. Si ngl e l ug toward pan face.
(b) Pl ace si ngl e l ug under adjuster screw and
two l ugs over anchor pi n i n transmi ssi on case (Fi g.
135).
REAR BAND—30RH
(4) I nstal l rear band.
(a) Assembl e l i nk bar to band. Notched si de of
l i nk toward band (Fi g. 141).
(b) I nsert rear band through pan openi ng i n
transmi ssi on case.
(c) I nsert hook on band onto adjuster l ever.
(d) Al i gn hol es i n l i nk bar wi th hol e i n transmi s-
si on case outboard of rear support openi ng (Fi g.
140).
(e) I nsert anchor pi n i nto case through l i nk bar.
(5) Exami ne bol t hol es i n overrunni ng cl utch cam.
Note that one hol e i s not threaded (Fi g. 144). Thi s
hol e must al i gn wi th bl ank area i n cl utch cam bol t
ci rcl e.
NOTE: The bolt holes in cam are slightly counter-
sunk on one side. This side of cam faces rearward
(toward rear support).
(6) Lubri cate overrunni ng cl utch rol l ers, spri ngs
and cam wi th Mopar௡ ATF Pl us 3, type 7176, trans-
mi ssi on fl ui d.
(7) Posi ti on overrunni ng cl utch on a cl ean, fl at
work surface wi th countersunk hol es downward.
(8) Pl ace rear of l ow-reverse drum over overrun-
ni ng cl utch and al i gn cl utch rol l ers to hub of drum.
(9) Whi l e sl i ghtl y pi voti ng l ow-reverse drum, push
hub of drum i nto overrunni ng cl utch. Veri fy that
countersunk hol es are faci ng outward. Cam should
be able to rotate in the drum clockwise only.
(10) I nsert a sui tabl e awl through the rear support
mounti ng hol e cl osest to the pan seal i ng face. The
awl shoul d be next to the wi de space area at the
back of transmi ssi on case.
Fig. 142 Compressing Front Servo
1 – SPRING COMPRESSOR TOOL C-3422–B
2 – ROD GUIDE SNAP RING
Fig. 143 Compressing Rear Servo Spring
1 – LARGE C-CLAMP
2 – TOOL C-4470 OR SP5560
3 – SERVO SPRING RETAINER
21 - 162 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(11) I nsert l ow-reverse drum and overrunni ng
cl utch i nto front of transmi ssi on case and i nto rear
band.
(12) I nsert awl ti p i nto the threaded hol e next to
the non-threaded hol e i n the overrunni ng cl utch cam.
Veri fy that non-threaded hol e i s al i gned wi th wi de
space area on transmi ssi on case.
(13) Push l ow-reverse drum rearward to cl ose gap
between cam and case.
(14) I nstal l overrunni ng cl utch cam bol ts. Clutch
cam bolts are shorter than rear support bolts.
Ti ghten cam bol ts to 17 N·m (150 i n. l bs. or 13 ft.
l bs.) torque.
(15) Hol d l ow-reverse drum i n posi ti on so rear sup-
port wi l l not push i t out of overrunni ng cl utch.
(16) I nsert rear support i nto openi ng at rear of
transmi ssi on case (Fi g. 145).
(17) Al i gn support wi th the embossed arrow i n the
di recti on of the pan face.
(18) I nstal l and ti ghten rear support bol ts to 17
N·m (150 i n. l bs.) torque.
(19) I nstal l snap ri ng to retai n l ow-reverse drum
to hub of rear support (Fi g. 146).
(20) Lubri cate output shaft, rear support bore and
l ow-reverse drum hub wi th transmi ssi on fl ui d.
(21) I nstal l assembl ed output shaft and pl anetary
geartrai n i n case (Fi g. 147).
(22) Al i gn dri ve l ugs on rear pl anetary gear wi th
sl ots i n l ow-reverse drum (Fi g. 147). Then seat pl an-
etary assembl y i n drum.
(23) I nstal l governor on output shaft.
(24) Turn and secure transmi ssi on so that front
openi ng i s upward.
(25) Assembl e front and rear cl utches together.
(a) Check i nput shaft seal ri ngs (Fi g. 148). Veri fy
that di agonal -cut ends of Tefl on௢ seal ri ng are
properl y joi ned and ends of metal ri ng are correctl y
hooked together. Al so be sure ri ngs are i nstal l ed i n
sequence shown.
(b) Al i gn teeth on cl utch di scs i n l i ne.
(c) I nsert i nput shaft on rear cl utch i nto center
of front cl utch (Fi g. 149).
(d) Engage teeth on rear cl utch hub i nto teeth
on cl utch (Fi g. 151). Rotate front cl utch retai ner
back and forth unti l compl etel y seated on rear
cl utch.
Fig. 144 Clutch Cam Alignment
1 – TRANSMISSION CASE
2 – OVERRUNNING CLUTCH
3 – NON-THREADER HOLE
4 – WIDE SPACE AREA
Fig. 145 Rear Support
1 – OIL PAN FACE
2 – TRANSMISSION HOUSING
3 – REAR SUPPORT
Fig. 146 Low-Reverse Drum Snap Ring
1 – REAR BAND
2 – REAR SUPPORT HUB
3 – LOW-REVERSE DRUM SNAP RING
4 – LOW-REVERSE DRUM
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 163
DISASSEMBLY AND ASSEMBLY (Continued)
(26) I nstal l output shaft thrust pl ate on shaft hub
i n pl anetary geartrai n dri vi ng shel l (Fi g. 150). Use
petrol eum jel l y to hol d thrust pl ate i n pl ace.
(27) Check rear cl utch thrust washer. Use addi -
ti onal petrol eum jel l y to hol d washer i n pl ace i f nec-
essary.
(28) Coat output shaft thrust washer wi th petro-
l eum jel l y. I nstal l washer i n rear cl utch hub (Fi g.
152). Use enough petrol eum jel l y to hol d washer i n
pl ace. Be sure grooved side of washer faces
rearward (toward output shaft) as shown. Also
note that washer only fits one way in clutch
hub.
(29) Al i gn dri ve teeth on rear cl utch di scs wi th
smal l screwdri ver (Fi g. 153). Thi s wi l l make i nstal l a-
ti on i nto front of pl anetary geartrai n easi er.
Fig. 147 Output Shaft And Planetary Geartrain
1 – SLOTS
2 – LOW-REVERSE DRUM
3 – PLANETARY GEARTRAIN
4 – TRANSMISSION HOUSING
5 – LUGS
Fig. 148 Input Shaft Seal Ring Location
1 – INPUT SHAFT
2 – TEFLON SEAL RING
3 – METAL SEAL RING
4 – REAR CLUTCH RETAINER
Fig. 149 Front and Rear Clutches
1 – REAR CLUTCH
2 – INPUT SHAFT
3 – FRONT CLUTCH
Fig. 150 Output Shaft Thrust Plate
1 – OUTPUT SHAFT HUB
2 – OUTPUT SHAFT THRUST PLATE
21 - 164 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(30) I nsert front band i nto openi ng at front of
transmi ssi on case (Fi g. 154).
(31) I nstal l front and rear cl utch uni ts as assembl y
(Fi g. 155). Al i gn rear cl utch wi th front annul us gear
and i nstal l assembl y i n dri vi ng shel l . Be sure out-
put shaft thrust washer and thrust plate are
not displaced during installation.
(32) Careful l y work assembl ed cl utches back and
forth to engage and seat rear cl utch di scs on front
annul us gear. Veri fy that front cl utch dri ve l ugs are
ful l y engaged i n sl ots of dri vi ng shel l after i nstal l a-
ti on.
(33) Engage front band on adjusti ng screw and
hol d band i n pl ace.
(34) I nstal l strut between band l ever and front
band (Fi g. 156).
Fig. 151 Assembling Front And Rear Clutch Units
1 – TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 – REAR CLUTCH ASSEMBLY
Fig. 152 Output Shaft Thrust Washer
1 – REAR CLUTCH HUB
2 – OUTPUT SHAFT THRUST WASHER
3 – OUTPUT SHAFT
Fig. 153 Aligning Rear Clutch Disc Lugs
1 – REAR CLUTCH DISCS
2 – USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC
TEETH
Fig. 154 Front Band
1 – FRONT BAND
2 – TRANSMISSION HOUSING
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 165
DISASSEMBLY AND ASSEMBLY (Continued)
(35) Ti ghten front band adjusti ng screw unti l band
just gri ps cl utch retai ner. Veri fy that front/rear
cl utches are sti l l seated before conti nui ng.
(36) Veri fy that reacti on shaft support hub seal
ri ngs are hooked together (Fi g. 157).
(37) Coat front cl utch thrust washer wi th petro-
l eum jel l y to hol d i t i n pl ace. Then i nstal l washer
over reacti on shaft hub and seat i t on pump (Fi g.
158).
CAUTION: The thrust washer bore (I. D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.
(38) Thread two Pi l ot Stud Tool s C-3288-B i nto
bol t hol es i n oi l pump fl ange (Fi g. 159).
(39) Al i gn and i nstal l oi l pump gasket (Fi g. 159).
(40) Lubri cate oi l pump seal s wi th Mopar௡ Door-
Ease, or Ru-Gl yde, Door Eze, or ATF Pl us 3.
(41) I nstal l oi l pump (Fi g. 160). Al i gn and posi ti on
pump on pi l ot studs. Sl i de pump down studs and
work i t i nto front cl utch hub and case by hand. Then
i nstal l two or three pump bol ts to hol d pump i n
pl ace.
(42) Remove pi l ot stud tool s and i nstal l remai ni ng
oi l pump bol ts. Ti ghten bol ts al ternatel y i n di agonal
pattern to 20 N·m (15 ft. l bs.).
Fig. 155 Installing Front/Rear Clutch
1 – FRONT BAND
2 – FRONT CLUTCH AND DRUM
3 – TRANSMISSION HOUSING
4 – REAR CLUTCH
Fig. 156 Front Band Linkage Installation
1 – BAND LEVER
2 – BAND STRUT
3 – FRONT BAND
Fig. 157 Reaction Shaft Support Seal Rings
1 – REACTION SHAFT SUPPORT HUB
2 – FRONT CLUTCH THRUST WASHER
3 – SEAL RINGS
Fig. 158 Front Clutch Thrust Washer Installation
1 – THRUST WASHER
2 – CHAMFERED SIDE OF WASHER BORE GOES TOWARD
PUMP
21 - 166 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(43) Measure i nput shaft end pl ay (Fi g. 161).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or output shaft thrust
washer and/or thrust plate are worn and need to be
changed.
(a) Attach Adapter 8266–7 to Handl e 8266–8.
(b) Attach di al i ndi cator (C-3339) to Handl e
8266–8.
(c) I nstal l the assembl ed tool onto the i nput
shaft of the transmi ssi on and ti ghten the retai ni ng
screw on Adapter 8266–7 to secure i t to the i nput
shaft.
(d) Posi ti on the di al i ndi cator pl unger agai nst a
fl at spot on the oi l pump and zero the di al i ndi ca-
tor.
(e) Move i nput shaft i n and out and record read-
i ng. End pl ay shoul d be 0.56 - 2.31 mm (0.022 -
0.091 i n.).
(44) Posi ti on transmi ssi on on work surface wi th
pan face upward.
(45) I nstal l val ve body.
(46) Adjust front and rear bands.
(47) I nstal l fl ui d fi l ter and pan.
(48) I nstal l rear extensi on housi ng.
(49) I nstal l torque converter.
OVERRUNNING CLUTCH/LOW-REVERSE DRUM
DISASSEMBLY
(1) I f the cl utch assembl y came out wi th the l ow-
reverse drum, thread two cl utch cam bol ts i nto the
cam. Then l i ft the cam out of the drum wi th the bol ts
(Fi g. 162). Rotate the cam back and forth to ease
removal i f necessary.
(2) Remove the cl utch rol l er and spri ng assembl y
from the overrunni ng cl utch race.
Fig. 159 Installing Pilot Studs And Oil Pump Gasket
1 – OIL PUMP GASKET
2 – PILOT STUD TOOLS C-3288–B
Fig. 160 Installing Oil Pump And Reaction Shaft
Support
1 – OIL PUMP
2 – PILOT STUD TOOL
3 – PILOT STUD TOOL
Fig. 161 Checking Input Shaft End Play
1 – TOOL 8266–8
2 – TOOL 8266–7
3 – TOOL C-3339
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 167
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Assembl e cl utch rol l ers and spri ngs i n retai ner
i f necessary (Fi g. 163).
(2) I nstal l overrunni ng cl utch rol l er, spri ng and
retai ner assembl y i n cl utch cam (Fi g. 164).
(3) Temporari l y assembl e and check overrunni ng
cl utch operati on as fol l ows:
(a) Assembl e cam and cl utch.
(b) I nstal l cl utch assembl y on l ow-reverse drum
wi th twi sti ng moti on (Fi g. 165).
(c) I nstal l drum-cl utch assembl y i n case and
i nstal l cl utch cam bol ts.
(d) I nstal l rear support and support attachi ng
bol ts.
(e) Check l ow-reverse drum rotati on. Drum
should rotate freely in clockwise direction
and lock when turned in counterclockwise
direction (as viewed from front of case).
FRONT SERVO PISTON
DISASSEMBLY
(1) Remove seal ri ng from rod gui de (Fi g. 167).
(2) Remove smal l snap ri ng from servo pi ston rod.
Then remove pi ston rod, spri ng and washer from pi s-
ton.
(3) Remove and di scard servo component O-ri ng
and seal ri ngs.
ASSEMBLY
(1) Lubri cate new O-ri ng and seal ri ngs wi th
petrol eum jel l y and i nstal l them on pi ston, gui de and
rod.
(2) I nstal l rod i n pi ston. I nstal l spri ng and washer
on rod. Compress spri ng and i nstal l snap ri ng (Fi g.
167).
(3) Set servo components asi de for i nstal l ati on dur-
i ng transmi ssi on reassembl y.
Fig. 162 Removing Overrunning Clutch From
Low-Reverse Drum
1 – CAM BOLTS
2 – LOW-REVERSE DRUM
3 – OVERRUNNING CLUTCH AND CAM
Fig. 163 Overrunning Clutch Rollers, Springs,
Retainer
1 – RETAINER
2 – SPRING
3 – ROLLER
Fig. 164 Assembling Overrunning Clutch And Cam
1 – CLUTCH CAM
2 – CLUTCH ROLL ASSEMBLY
21 - 168 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
REAR SERVO PISTON
DISASSEMBLY
(1) Remove smal l snap ri ng and remove pl ug and
spri ng from servo pi ston (Fi g. 168).
(2) Remove and di scard servo pi ston seal ri ng.
ASSEMBLY
(1) Lubri cate pi ston and gui de seal s wi th petro-
l eum jel l y. Lubri cate other servo parts wi th Mopar௡
ATF Pl us 3, Type 7176, transmi ssi on fl ui d.
(2) I nstal l new seal ri ng on servo pi ston.
(3) Assembl e pi ston, pl ug, spri ng and new snap
ri ng.
(4) Lubri cate pi ston seal l i p wi th petrol eum jel l y.
OIL PUMP AND REACTION SHAFT SUPPORT
DISASSEMBLY
(1) Remove seal ri ng from housi ng and reacti on
shaft support (Fi g. 169).
(2) Mark pump housi ng and support assembl y for
al i gnment reference.
(3) Remove bol ts attachi ng pump body to support
(Fi g. 170).
(4) Separate support from pump housi ng (Fi g.
171).
(5) Remove i nner and outer gears from reacti on
shaft support (Fi g. 172).
Fig. 165 Temporary Assembly Of Clutch And Drum
To Check Operation
1 – LOW-REVERSE DRUM
2 – CLUTCH RACE (ON HUB OF DRUM)
3 – OVERRUNNING CLUTCH
Fig. 166 Assembled Overrunning Clutch
1 – LOW-REVERSE DRUM
2 – OVERRUNNING CLUTCH CAM
3 – ROLLER AND SPRING ASSEMBLY
4 – CLUTCH RACE
5 – HUB OF LOW-REVERSE DRUM
Fig. 167 Front Servo
1 – PISTON RINGS
2 – O-RING
3 – SNAP-RING
4 – SEAL RING
5 – PISTON ROD GUIDE
6 – SNAP-RING
7 – SERVO SPRING
8 – PISTON ROD
9 – SERVO PISTON
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 169
DISASSEMBLY AND ASSEMBLY (Continued)
(6) I f pump seal was not removed duri ng transmi s-
si on di sassembl y, remove seal wi th punch and ham-
mer.
(7) Remove front cl utch thrust washer from sup-
port hub (Fi g. 173).
OIL PUMP BUSHING REPLACEMENT
(1) Remove pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng Remover SP-3551 from Tool Set
C-3887-J (Fi g. 174).
(2) I nstal l new pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng I nstal l er SP-5117 (Fi g. 174).
Bushi ng shoul d be fl ush wi th pump housi ng bore.
(3) Stake new pump bushi ng i n two pl aces wi th
bl unt punch (Fi g. 175). Remove burrs from stake
poi nts wi th kni fe bl ade afterward.
Fig. 168 Rear Servo Components
1 – SNAP RING
2 – PISTON SEAL
3 – PISTON PLUG
4 – SPRING RETAINER
5 – SNAP RING
6 – PISTON SPRING
7 – CUSHION SPRING
8 – PISTON
Fig. 169 Removing Pump Seal Ring
1 – PUMP HOUSING SEAL RING
Fig. 170 Pump Support Bolts
1 – REACTION SHAFT SUPPORT
2 – PUMP
Fig. 171 Separating Pump Housing From Reaction
Shaft Support
1 – REACTION SHAFT SUPPORT
2 – PUMP HOUSING
Fig. 172 Pump Gear Removal
1 – REACTION SHAFT SUPPORT
2 – INNER GEAR
3 – OUTER GEAR
21 - 170 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assembl e Bushi ng Remover Tool s SP-1191,
3633 and 5324 (Fi g. 176). Do not clamp any part
of reaction shaft or support in vise.
(2) Hol d Cup Tool SP-3633 fi rml y agai nst reacti on
shaft and thread remover SP-5324 i nto bushi ng as
far as possi bl e by hand. Then thread remover tool 3-4
addi ti onal turns i nto bushi ng wi th a wrench.
(3) Turn remover tool hex nut down agai nst
remover cup to pul l bushi ng from shaft. Cl ean al l
chi ps from shaft after bushi ng removal .
(4) Li ghtl y gri p ol d bushi ng i n vi se or wi th pl i ers
and back remover tool out of bushi ng.
(5) Assembl e Bushi ng I nstal l er Tool s C-4171 and
SP-5325 (Fi g. 176).
(6) Sl i de new bushi ng onto I nstal l er Tool SP-5325.
(7) Posi ti on reacti on shaft support upri ght on a
cl ean smooth surface.
(8) Al i gn bushi ng i n bore. Then tap bushi ng i nto
pl ace unti l Bushi ng I nstal l er SP-5325 bottoms.
(9) Cl ean reacti on shaft support thoroughl y after
i nstal l i ng bushi ng.
ASSEMBLY
(1) Lubri cate gear bore i n pump housi ng wi th
transmi ssi on fl ui d.
(2) Lubri cate pump gears wi th transmi ssi on fl ui d.
(3) Support pump housi ng on wood bl ocks (Fi g.
177).
(4) I nstal l outer gear i n pump housi ng (Fi g. 177).
Gear can be i nstal l ed ei ther way (i t i s not a one-way
fi t).
(5) I nstal l pump i nner gear (Fi g. 178).
CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter (I.
D.) is chamfered. Be sure the chamfered side faces
forward (to front of pump).
Fig. 173 Support Hub Thrust Washer
1 – BUSHING
2 – REACTION SHAFT SUPPORT
3 – THRUST WASHER
4 – HUB
Fig. 174 Removing Oil Pump Bushing
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL SP-3551
3 – BUSHING
4 – SPECIAL TOOL SP-5117
5 – BUSHING
6 – SPECIAL TOOL C-4171
7 – PUMP HOUSING
Fig. 175 Staking Oil Pump Bushing
1 – NARROW BLADE
2 – BLUNT PUNCH
3 – TWO STAKES
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 171
DISASSEMBLY AND ASSEMBLY (Continued)
(6) I nstal l new thrust washer on hub of reacti on
shaft support. Lubri cate washer wi th transmi ssi on
fl ui d or petrol eum jel l y.
(7) I f reacti on shaft seal ri ngs are bei ng repl aced,
i nstal l new seal ri ngs on support hub (Fi g. 179).
Lubri cate seal ri ngs wi th transmi ssi on fl ui d or petro-
l eum jel l y after i nstal l ati on. Squeeze each ri ng unti l
ri ng ends are securel y hooked together.
CAUTION: The reaction shaft support seal rings
will break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.
(8) I nstal l reacti on shaft support on pump housi ng
(Fi g. 180).
(9) Al i gn reacti on support on pump housi ng. Use
al i gnment marks made at di sassembl y. Or, rotate
support unti l bol t hol es i n support and pump housi ng
are al l al i gned (hol es are offset for one-way fi t).
(10) I nstal l al l bol ts that attach support to pump
housi ng. Then ti ghten bol ts fi nger ti ght.
(11) Ti ghten support-to-pump bol ts to requi red
torque as fol l ows:
(a) Reverse pump assembl y and i nstal l i t i n
transmi ssi on case. Posi ti on pump so bol ts are fac-
i ng out and are accessi bl e.
(b) Secure pump assembl y i n case wi th 2 or 3
bol ts, or wi th pi l ot studs.
Fig. 176 Replacing Reaction Shaft Support Bushing
1 – SPECIAL TOOL SP-1191
2 – SPECIAL TOOL SP-3633
3 – SPECIAL TOOL C-4171
4 – SPECIAL TOOL SP-5325
5 – REACTION SHAFT
6 – SPECIAL TOOL SP-5324
7 – BUSHING
Fig. 177 Supporting Pump And Installing Outer Gear
1 – OUTER GEAR
2 – PUMP HOUSING
3 – WOOD BLOCKS
Fig. 178 Pump Inner Gear Installation
1 – OUTER GEAR
2 – INNER GEAR
Fig. 179 Hub Seal Ring Position
1 – SEAL RINGS
2 – SUPPORT HUB
21 - 172 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(c) Ti ghten support-to-pump bol ts to 20 N·m (15
ft. l bs.).
(d) Remove pump assembl y from transmi ssi on
case.
(12) I nstal l new oi l seal i n pump wi th Speci al Tool
C-4193 and Tool Handl e C-4171 (Fi g. 181). Be sure
seal l i p faces i nward.
(13) I nstal l new seal ri ng around pump housi ng.
Be sure seal i s properl y seated i n groove.
(14) Lubri cate l i p of pump oi l seal and O-ri ng seal
wi th transmi ssi on fl ui d.
FRONT CLUTCH
DISASSEMBLY
(1) Remove waved snap ri ng and remove pressure
pl ate, cl utch pl ates and cl utch di scs (Fi g. 182).
(2) Compress cl utch pi ston spri ng wi th Compressor
Tool C-3575-A (Fi g. 183). Be sure l egs of tool are
seated squarel y on spri ng retai ner before compress-
i ng spri ng.
(3) Remove retai ner snap ri ng and remove com-
pressor tool .
(4) Remove spri ng retai ner and cl utch spri ng. Note
posi ti on of retai ner on spri ng for assembl y reference.
(5) Remove cl utch pi ston from cl utch retai ner.
Remove pi ston by rotati ng i t up and out of retai ner.
(6) Remove seal s from cl utch pi ston and cl utch
retai ner hub. Di scard both seal s as they are not reus-
abl e.
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal s on pi ston and i n hub of
retai ner. Be sure l i p of each seal faces i nteri or of
cl utch retai ner.
(3) Lubri cate l i ps of pi ston and retai ner seal s wi th
l i beral quanti ty of Mopar௡ Door Ease, or Ru-Gl yde.
Then l ubri cate retai ner hub, bore and pi ston wi th
l i ght coat of transmi ssi on fl ui d.
(4) I nstal l cl utch pi ston i n retai ner (Fi g. 184). Use
twi sti ng moti on to seat pi ston i n bottom of retai ner. A
thi n stri p of pl asti c (about 0.020” thi ck), can be used
to gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(5) Posi ti on spri ng i n cl utch pi ston (Fi g. 185).
(6) Posi ti on spri ng retai ner on top of pi ston spri ng
(Fi g. 186). Make sure retainer is properly
installed. Small raised tabs should be facing
upward. Semicircular lugs on underside of
retainer are for positioning retainer in spring.
Fig. 180 Assembling Reaction Shaft Support And
Pump Housing
1 – PUMP HOUSING
2 – REACTION SHAFT SUPPORT
Fig. 181 Pump Oil Seal Installation
1 – PUMP BODY
2 – PUMP SEAL
3 – SPECIAL TOOL C-4193
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 173
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 182 Front Clutch Components
1 – RETAINER HUB SEAL
2 – CLUTCH PISTON
3 – PISTON SPRING
4 – SPRING RETAINER SNAP RING
5 – CLUTCH DISCS
6 – PRESSURE PLATE
7 – SNAP RING (WAVED)
8 – CLUTCH PLATES
9 – SPRING RETAINER
10 – PISTON SEAL
11 – FRONT CLUTCH RETAINER
Fig. 183 Compressing Front Clutch Piston Spring
1 – FRONT CLUTCH SPRING
2 – COMPRESSOR TOOL C-3575–A
3 – RETAINER SNAP RING
4 – SPRING RETAINER
Fig. 184 Front Clutch Piston Installation
1 – CLUTCH PISTON
2 – FRONT CLUTCH RETAINER
21 - 174 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Compress pi ston spri ng and retai ner wi th Com-
pressor Tool C-3575-A (Fi g. 183). Then i nstal l new
snap ri ng to secure spri ng retai ner and spri ng.
(8) I nstal l cl utch pl ates and di scs (Fi g. 182).
I nstal l steel pl ate then di sc unti l al l pl ates and di scs
are i nstal l ed. The front cl utch uses 4 cl utch di scs.
(9) I nstal l pressure pl ate and waved snap ri ng
(Fi g. 182).
(10) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pl ate cl earance (Fi g. 187).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 187).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and compress the waved snap-ri ng. Thi s
wi l l assure that the snap-ri ng i s at the top of the
groove.
(c) Rel ease the pressure pl ate and zero the di al
i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
waved snap-ri ng and record the di al i ndi cator read-
i ng.
Cl earance shoul d be 1.70 to 3.40 mm (0.067 to
0.134 i n.). I f cl earance i s i ncorrect, cl utch di scs,
pl ates pressure pl ates and snap ri ng may have to be
changed.
REAR CLUTCH
DISASSEMBLY
(1) Remove thrust washer from forward si de of
cl utch retai ner.
(2) Remove i nput shaft front/rear seal ri ngs.
(3) Remove sel ecti ve cl utch pack snap ri ng (Fi g.
188).
(4) Remove top pressure pl ate, cl utch di scs, steel
pl ates, bottom pressure pl ate and wave snap ri ng
and wave spri ng (Fi g. 188).
(5) Remove cl utch pi ston wi th rotati ng moti on.
(6) Remove and di scard pi ston seal s.
(7) Remove i nput shaft snap-ri ng (Fi g. 189). I t
may be necessary to press the i nput shaft i n sl i ghtl y
to rel i eve tensi on on the snap-ri ng
(8) Press i nput shaft out of retai ner wi th shop
press and sui tabl e si ze press tool . Use a sui tabl y
si zed press tool to support the retai ner as cl ose to the
i nput shaft as possi bl e.
Fig. 185 Clutch Piston Spring Installation
1 – RETAINER
2 – CLUTCH SPRING
3 – PISTON
Fig. 186 Correct Spring Retainer Installed Position
1 – SMALL TABS ON RETAINER FACE UPWARD
Fig. 187 Measuring Front Clutch Pack Clearance
1 – DIAL INDICATOR
2 – WAVED SNAP-RING
3 – FRONT CLUTCH
4 – POINTER
5 – GAUGE BAR
6 – PRESSURE PLATE
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 175
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal ri ngs on cl utch retai ner hub
and i nput shaft i f necessary (Fi g. 190).
(a) Be sure cl utch hub seal ri ng i s ful l y seated i n
groove and i s not twi sted.
(3) Lubri cate spl i ned end of i nput shaft and cl utch
retai ner wi th transmi ssi on fl ui d. Then press i nput
shaft i nto retai ner. Use a sui tabl y si zed press tool to
support retai ner as cl ose to i nput shaft as possi bl e.
(4) I nstal l i nput shaft snap-ri ng (Fi g. 189).
(5) I nvert retai ner and press i nput shaft i n oppo-
si te di recti on unti l snap-ri ng i s seated.
(6) I nstal l new seal s on cl utch pi ston. Be sure l i p
of each seal faces i nteri or of cl utch retai ner.
(7) Lubri cate l i p of pi ston seal s wi th generous
quanti ty of Mopar௡ Door Ease. Then l ubri cate
retai ner hub and bore wi th l i ght coat of transmi ssi on
fl ui d.
(8) I nstal l cl utch pi ston i n retai ner. Use twi sti ng
moti on to seat pi ston i n bottom of retai ner. A thi n
stri p of pl asti c (about 0.020” thi ck), can be used to
gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) I nstal l pi ston spri ng i n retai ner and on top of
pi ston (Fi g. 193). Concave si de of spri ng faces down-
ward (toward pi ston).
(10) I nstal l wave spri ng i n retai ner (Fi g. 193). Be
sure spri ng i s compl etel y seated i n retai ner groove.
Fig. 188 Rear Clutch Components
1 – PISTON SPRING
2 – REAR CLUTCH PISTON
3 – CLUTCH PISTON SEALS
4 – OUTPUT SHAFT THRUST WASHER (METAL)
5 – INPUT SHAFT SNAP RING
6 – REAR CLUTCH RETAINER
7 – INPUT SHAFT
8 – REAR CLUTCH THRUST WASHER (FIBER)
9 – CLUTCH PACK SNAP RING (SELECTIVE)
10 – TOP PRESSURE PLATE
11 – CLUTCH DISCS (4)
12 – BOTTOM PRESSURE PLATE
13 – WAVE SPRING
14 – CLUTCH PLATES (3)
15 – RETAINER SEAL RING
16 – SHAFT REAR SEAL RING (PLASTIC)
17 – SHAFT FRONT SEAL RING (TEFLON)
21 - 176 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 189 Removing/Installing Input Shaft Snap-Ring
1 – REAR CLUTCH RETAINER
2 – INPUT SHAFT SNAP RING
3 – SNAP RING PLIERS
Fig. 190 Rear Clutch Retainer And Input Shaft Seal
Ring Installation
1 – REAR CLUTCH RETAINER HUB SEAL RING
2 – INPUT SHAFT SEAL RINGS
Fig. 191 Input Shaft Seal Ring Identification
1 – PLASTIC REAR SEAL RING
2 – TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER
SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)
Fig. 192 Pressing Input Shaft Into Rear Clutch
Retainer
1 – INPUT SHAFT
2 – REAR CLUTCH RETAINER
3 – PRESS RAM
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 177
DISASSEMBLY AND ASSEMBLY (Continued)
(11) I nstal l bottom pressure pl ate (Fi g. 188).
Ri dged si de of pl ate faces downward (toward pi ston)
and fl at si de toward cl utch pack.
(12) I nstal l fi rst cl utch di sc i n retai ner on top of
bottom pressure pl ate. Then i nstal l a cl utch pl ate fol -
l owed by a cl utch di sc unti l enti re cl utch pack i s
i nstal l ed (4 di scs and 3 pl ates are requi red) (Fi g.
188).
(13) I nstal l top pressure pl ate.
(14) I nstal l sel ecti ve snap ri ng. Be sure snap ri ng
i s ful l y seated i n retai ner groove.
(15) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pack cl earance (Fi g. 194).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 194).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and rel ease i t.
(c) Zero the di al i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
snap-ri ng and record the di al i ndi cator readi ng.
Cl earance shoul d be 0.64 - 1.14 mm (0.025 - 0.045
i n.). I f cl earance i s i ncorrect, steel pl ates, di scs, sel ec-
ti ve snap ri ng and pressure pl ates may have to be
changed.
The sel ecti ve snap ri ng thi cknesses are:
• .107–.109 i n.
• .098–.100 i n.
• .095–.097 i n.
• .083–.085 i n.
• .076–.078 i n.
• .071–.073 i n.
• .060–.062 i n.
(16) Coat rear cl utch thrust washer wi th petro-
l eum jel l y and i nstal l washer over i nput shaft and
i nto cl utch retai ner (Fi g. 195). Use enough petrol eum
jel l y to hol d washer i n pl ace.
PLANETARY GEARTRAIN/OUTPUT SHAFT
DISASSEMBLY
(1) Remove pl anetary snap ri ng (Fi g. 196).
(2) Remove front annul us and pl anetary assembl y
from dri vi ng shel l (Fi g. 196).
(3) Remove snap ri ng that retai ns front pl anetary
gear i n annul us gear (Fi g. 197).
Fig. 193 Piston Spring/Wave Spring Position
1 – REAR CLUTCH RETAINER
2 – PISTON SPRING
3 – WAVE SPRING
4 – CLUTCH PISTON Fig. 194 Checking Rear Clutch Pack Clearance
1 – DIAL INDICATOR
2 – PRESSURE PLATE
3 – SNAP RING
4 – STAND
5 – REAR CLUTCH
6 – GAUGE BAR
Fig. 195 Installing Rear Clutch Thrust Washer
1 – REAR CLUTCH RETAINER
2 – REAR CLUTCH THRUST WASHER
21 - 178 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Remove tabbed thrust washer and tabbed
thrust pl ate from hub of front annul us (Fi g. 198).
(5) Separate front annul us and pl anetary gears
(Fi g. 198).
(6) Remove front pl anetary gear front thrust
washer from annul us gear hub.
(7) Separate and remove dri vi ng shel l , rear pl ane-
tary and rear annul us from output shaft (Fi g. 199).
(8) Remove front pl anetary rear thrust washer
from dri vi ng shel l .
(9) Remove tabbed thrust washers from rear pl an-
etary gear.
(10) Remove l ock ri ng that retai ns sun gear i n
dri vi ng shel l . Then remove sun gear, spacer and
thrust pl ates.
Fig. 196 Front Annulus And Planetary Assembly
Removal
1 – DRIVING SHELL
2 – FRONT ANNULUS AND PLANETARY ASSEMBLY
3 – PLANETARY SNAP RING
Fig. 197 Front Planetary Snap Ring Removal
1 – FRONT ANNULUS GEAR
2 – PLANETARY SNAP RING
Fig. 198 Front Planetary And Annulus Gear
Disassembly
1 – FRONT ANNULUS
2 – THRUST WASHER
3 – THRUST PLATE
4 – FRONT THRUST WASHER
5 – FRONT PLANETARY
Fig. 199 Removing Driving Shell, Rear Planetary
And Rear Annulus
1 – REAR ANNULUS
2 – REAR PLANETARY
3 – DRIVING SHELL
4 – OUTPUT SHAFT
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 179
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Lubri cate output shaft and pl anetary compo-
nents wi th transmi ssi on fl ui d. Use petrol eum jel l y to
l ubri cate and hol d thrust washers and pl ates i n posi -
ti on.
(2) Assembl e rear annul us gear and support i f di s-
assembl ed. Be sure support snap ri ng i s seated and
that shoul der-si de of support faces rearward (Fi g.
200).
(3) I nstal l rear thrust washer on rear pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace. Al so be sure al l four washer tabs are properl y
engaged i n gear sl ots.
(4) I nstal l rear annul us over and onto rear pl ane-
tary gear (Fi g. 200).
(5) I nstal l assembl ed rear pl anetary and annul us
gear on output shaft (Fi g. 201). Veri fy that assembl y
i s ful l y seated on shaft.
(6) I nstal l front thrust washer on rear pl anetary
gear (Fi g. 202). Use enough petrol eum jel l y to hol d
washer on gear. Be sure al l four washer tabs are
seated i n sl ots.
(7) I nstal l spacer on sun gear (Fi g. 203).
(8) I nstal l thrust pl ate on sun gear (Fi g. 204). Note
that dri vi ng shel l thrust pl ates are i nterchangeabl e.
Use ei ther pl ate on sun gear and at front/rear of
shel l .
Fig. 200 Assembling Rear Annulus And Planetary
Gear
1 – REAR ANNULUS GEAR
2 – TABBED THRUST WASHER
3 – REAR PLANETARY
Fig. 201 Installing Rear Annulus And Planetary On
Output Shaft
1 – REAR ANNULUS AND PLANETARY GEAR ASSEMBLY
2 – OUTPUT SHAFT
Fig. 202 Installing Rear Planetary Front Thrust
Washer
1 – FRONT TABBED THRUST WASHER
2 – REAR PLANETARY GEAR
21 - 180 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(9) Hol d sun gear i n pl ace and i nstal l thrust pl ate
over sun gear at rear of dri vi ng shel l (Fi g. 205).
(10) Posi ti on wood bl ock on bench and support sun
gear on bl ock (Fi g. 206). Thi s makes i t easi er to al i gn
and i nstal l sun gear l ock ri ng. Keep wood bl ock
handy as i t wi l l al so be used for geartrai n end pl ay
check.
(11) Al i gn rear thrust pl ate on dri vi ng shel l and
i nstal l sun gear l ock ri ng. Be sure ri ng i s ful l y seated
i n sun gear ri ng groove (Fi g. 207).
(12) I nstal l assembl ed dri vi ng shel l and sun gear
on output shaft (Fi g. 208).
(13) I nstal l rear thrust washer on front pl anetary
gear (Fi g. 209). Use enough petrol eum jel l y to hol d
washer i n pl ace and be sure al l four washer tabs are
seated.
Fig. 203 Installing Spacer On Sun Gear
1 – SUN GEAR
2 – SUN GEAR SPACER
Fig. 204 Installing Driving Shell Front Thrust Plate
On Sun Gear
1 – SPACER
2 – SUN GEAR
3 – THRUST PLATE
Fig. 205 Installing Driving Shell Rear Thrust Plate
1 – DRIVING SHELL
2 – SUN GEAR
3 – REAR THRUST PLATE
Fig. 206 Supporting Sun Gear On Wood Block
1 – SUN GEAR
2 – DRIVING SHELL
3 – WOOD BLOCK
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 181
DISASSEMBLY AND ASSEMBLY (Continued)
(14) I nstal l front pl anetary gear on output shaft
and i n dri vi ng shel l (Fi g. 210).
(15) I nstal l front thrust washer on front pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace and be sure al l four washer tabs are seated.
(16) Assembl e front annul us gear and support, i f
necessary. Be sure support snap ri ng i s seated.
(17) I nstal l front annul us on front pl anetary (Fi g.
210).
(18) Posi ti on thrust pl ate on front annul us gear
support (Fi g. 211). Note that plate has two tabs
on it. These tabs fit in notches of annulus hub.
(19) I nstal l thrust washer i n front annul us (Fi g.
212). Align flat on washer with flat on planetary
hub. Also be sure washer tab is facing up.
(20) I nstal l front annul us snap ri ng (Fi g. 213). Use
snap ri ng pl i ers to avoi d di storti ng ri ng duri ng
i nstal l ati on. Al so be sure ri ng i s ful l y seated.
(21) I nstal l pl anetary sel ecti ve snap ri ng wi th
snap ri ng pl i ers (Fi g. 214). Be sure ri ng i s ful l y
seated.
(22) Turn pl anetary geartrai n assembl y over so
dri vi ng shel l i s faci ng workbench. Then support
geartrai n on wood bl ock posi ti oned under forward
end of output shaft. Thi s al l ows geartrai n compo-
nents to move forward for accurate end pl ay check.
(23) Check pl anetary geartrai n end pl ay wi th
feel er gauge (Fi g. 215). Gauge goes between shoul der
on output shaft and end of rear annul us support.
(24) Geartrai n end pl ay shoul d be 0.12 to 1.22 mm
(0.005 to 0.048 i n.). I f end pl ay i s i ncorrect, snap ri ng
(or thrust washers) may have to be repl aced. Snap
ri ng i s avai l abl e i n three di fferent thi cknesses for
adjustment purposes.
Fig. 207 Installing Sun Gear Lock Ring
1 – LOCK RING GROOVE
2 – SUN GEAR LOCK RING
3 – DRIVING SHELL
4 – REAR THRUST PLATE
Fig. 208 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
1 – SUN GEAR/DRIVING SHELL ASSEMBLY
2 – OUTPUT SHAFT
Fig. 209 Installing Rear Thrust Washer On Front
Planetary Gear
1 – FRONT PLANETARY GEAR
2 – REAR TABBED THRUST WASHER
21 - 182 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 210 Installing Front Planetary And Annulus Gears
1 – FRONT PLANETARY GEAR
2 – FRONT THRUST WASHER
3 – FRONT ANNULUS GEAR
Fig. 211 Positioning Thrust Plate On Front Annulus
Support
1 – FRONT ANNULUS
2 – THRUST PLATE
Fig. 212 Installing Front Annulus Thrust Washer
1 – WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB
2 – FRONT ANNULUS THRUST WASHER
3 – TAB FACES FRONT
Fig. 213 Installing Front Annulus Snap Ring
1 – SNAP RING PLIERS
2 – FRONT ANNULUS SNAP RING
Fig. 214 Installing Planetary Selective Snap Ring
1 – SELECTIVE SNAP RING
2 – SNAP RING PLIERS
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 183
DISASSEMBLY AND ASSEMBLY (Continued)
CLEANING AND INSPECTION
GOVERNOR AND PARK GEAR
Thoroughl y cl ean al l the governor parts i n a sui t-
abl e cl eani ng sol uti on but do not use any type of
causti c cl eani ng agents.
The governor wei ght components (Fi g. 216) and the
governor val ve (Fi g. 217), must sl i de freel y i n thei r
bores when cl ean and dry. Mi nor surface scratches
and burrs can be smoothed wi th crocus cl oth.
The al umi num governor val ve and outer wei ght
have a hard coati ng on them. Check condi ti on of thi s
coati ng careful l y. Do not reuse ei ther part i f the coat-
i ng i s damaged.
I nspect the governor wei ght spri ng for di storti on.
Repl ace the spri ng, i f di storted, col l apsed, or broken.
Cl ean the fi l ter i n sol vent and dry i t wi th compressed
ai r. Repl ace the fi l ter, i f damaged. I nspect the park
gear for chi pped or worn gear teeth or damaged ri ng
grooves. Repl ace the gear, i f damaged.
Check the teeth on the park gear for wear or dam-
age. Repl ace the gear i f necessary. I nspect the metal
seal ri ngs on the park gear hub. Repl ace the ri ngs
onl y i f severel y worn, or broken.
Fig. 216 Governor Weights
1 – INTERMEDIATE WEIGHT
2 – SNAP RING
3 – INNER WEIGHT
4 – INNER WEIGHT SPRING
5 – OUTER WEIGHT
Fig. 215 Checking Planetary Geartrain End Play
1 – OUTPUT SHAFT
2 – REAR ANNULUS GEAR
3 – FEELER GAUGE
21 - 184 AUTOMATIC TRANSMISSION— 30/32RH TJ
DISASSEMBLY AND ASSEMBLY (Continued)
EXTENSION HOUSING AND PARK LOCK
Cl ean the housi ng and park l ock components i n
sol vent and dry them wi th compressed ai r.
Exami ne the park l ock components i n the housi ng.
I f repl acement i s necessary, remove the shaft wi th
paral l el jaw snap ri ng pl i ers (Fi g. 218) and remove
the sprag and spri ng. Then remove the spri ng cl i p
and reacti on pl ug (Fi g. 219). Compress the reac-
tion plug spring clip only enough to remove
and install it. Do not distort the clip during
removal or installation.
Be sure a repl acement sprag i s i nstal l ed so the
sprag l ocki ng l ug wi l l face the park gear (Fi g. 220).
Al so be sure the spri ng i s correctl y posi ti oned as
shown (Fi g. 220). The sprag may not retract i f the
spri ng i s i mproperl y i nstal l ed.
VALVE BODY
Servi ceabl e val ve body components are:
• park l ock rod and E-cl i p
• swi tch val ve and spri ng
• pressure adjusti ng screw bracket
• throttl e val ve l ever
• manual l ever
• manual l ever shaft seal , washer, E-cl i p and
detent bal l
• fl ui d fi l ter
• converter cl utch sol enoi d
The remai ni ng val ve body components are servi ced
onl y as part of a compl ete val ve body assembl y.
Cl ean the val ve body components i n a parts cl ean-
i ng sol uti on onl y. Do not use gasol i ne, kerosene, or
any type of causti c sol uti on. Dry the parts wi th com-
pressed ai r. Make sure al l passages are cl ean and
free from obstructi ons.
Fig. 217 Governor Components
1 – SEAL RING (PLAIN END)
2 – SEAL RING (HOOK END)
3 – PARK GEAR
4 – GOVERNOR BODY
5 – GOVERNOR VALVE
6 – VALVE SHAFT
7 – E-CLIPS (2)
8 – FILTER
9 – SNAP RING (THIN)
10 – SNAP RING (THICK)
11 – SNAP RING
12 – RETAINER WASHER
13 – GOVERNOR WEIGHT ASSEMBLY
14 – GOVERNOR BODY BOLTS (4)
15 – WASHER
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 185
CLEANING AND INSPECTION (Continued)
NOTE: Do not use rags or shop towels to wipe off
valve body components. Lint from these materials
will adhere to the valve body components. Lint will
interfere with valve operation and may clog filters
and fluid passages.
I nspect the throttl e and manual val ve l evers and
shafts. Do not attempt to strai ghten a bent shaft or
correct a l oose l ever. Repl ace these components i f
worn, bent, l oose or damaged i n any way.
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th cro-
cus cl oth. The cl oth shoul d be i n sheet form and be
posi ti oned on a surface pl ate, sheet of pl ate gl ass, or
equal l y fl at surface. However, i f di storti on i s severe
or any surfaces are heavi l y scored, the val ve body
wi l l have to be repl aced.
Fig. 218 Park Sprag, Shaft And Spring
1 – SPRAG SHAFT
2 – PARALLEL JAW SNAP RING PLIERS
3 – SPRAG
4 – SPRING
Fig. 219 Park Sprag Reaction Plug And Spring
Location
1 – SPRING CLIP
2 – REACTION PLUG
Fig. 220 Correct Position Of Sprag And Spring
1 – SPRAG SHAFT
2 – SPRAG LOCKING LUG
3 – SPRING
21 - 186 AUTOMATIC TRANSMISSION— 30/32RH TJ
CLEANING AND INSPECTION (Continued)
CAUTION: Many of the valve body valves and plugs
are made of coated aluminum. Aluminum compo-
nents can be identified by the dark color of the spe-
cial coating applied to the surface (or by testing
with a magnet). DO NOT polish or sand aluminum
valves or plugs with any type of material, or under
any circumstances. This practice might damage the
special coating and cause the valves and plugs to
stick and bind.
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Al so i nspect the coati ng on the al u-
mi num val ves and pl ugs (Fi g. 221). I f the coati ng i s
damaged or worn through, the val ve (or val ve body)
shoul d be repl aced.
Al umi num val ves and pl ugs shoul d not be sanded
or pol i shed under any ci rcumstances. However, mi nor
burrs or scratches on steel val ves and pl ugs can be
removed wi th crocus cl oth but do not round off the
val ve or pl ug edges. Squareness of these edges i s
vi tal l y i mportant. These edges prevent forei gn matter
from l odgi ng between the val ves, pl ugs and bore.
I nspect al l the val ve and pl ug bores i n the val ve body.
Use a penl i ght to vi ew the bore i nteri ors. Repl ace the
val ve body i f any bores are di storted or scored. I nspect
al l of the val ve body spri ngs. The spri ngs must be free
of di storti on, warpage or broken coi l s.
Tri al fi t each val ve and pl ug i n i ts bore to check
freedom of operati on. When cl ean and dry, the val ves
and pl ugs shoul d drop freel y i nto the bores. Val ve
body bores do not change di mensi onal l y wi th use. I f
the val ve body functi oned correctl y when new, i t wi l l
conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
Fig. 221 Valve Body Components
1 – GOVERNOR PLUG END PLATE
2 – SHUTTLE VALVE
3 – 1–2 GOVERNOR PLUG
4 – VALVE BODY
5 – REGULATOR VALVE THROTTLE PRESSURE PLUG
6 – SLEEVE
7 – LINE PRESSURE PLUG
8 – RETAINER
9 – 1–2 SHIFT VALVE
10 – 1–2 SHIFT CONTROL VALVE
11 – KICKDOWN LIMIT VALVE
12 – END PLATE
13 – THROTTLE PRESSURE PLUG
14 – KICKDOWN LIMIT VALVE BODY
15 – E-RING
16 – 2–3 SHIFT VALVE
17 – GUIDES
18 – 2–3 GOVERNOR PLUG
19 – PRIMARY SPRING
20 – SHUTTLE VALVE THROTTLE PLUG
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 187
CLEANING AND INSPECTION (Continued)
TRANSMISSION
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will
readily adhere to case surfaces and transmission
components and will circulate throughout the trans-
mission after assembly. A sufficient quantity of lint
can block fluid passages and interfere with valve
body operation.
I nspect the case for cracks, porous spots, worn
servo bores, or damaged threads. However, the case
wi l l have to be repl aced i f i t exhi bi ts damage or wear.
Lubri cate the front band adjusti ng screw and l ock-
nut wi th petrol eum jel l y and thread i t part way i nto
the case. Be sure the screw turns freel y and does not
bi nd. I nstal l the l ocknut on the screw after checki ng
screw thread operati on.
I nspect al l the transmi ssi on bushi ngs duri ng over-
haul . Bushi ng condi ti on i s i mportant as worn, scored
bushi ngs contri bute to l ow pressures, cl utch sl i p and
accel erated wear of other components. Repl ace worn,
or scored bushi ngs, or i f doubt exi sts about bushi ng
condi ti on.
Use recommended tool s to repl ace bushi ngs. The
tool s are si zed and desi gned to remove, i nstal l and
seat bushi ngs correctl y. The bushi ng repl acement
tool s are i ncl uded i n Bushi ng Tool Sets C-3887-B, or
C-3887-J.
Pre-si zed servi ce bushi ngs are avai l abl e for
repl acement purposes. Onl y the sun gear bushi ngs
are not servi ced. Repl ace the gear as an assembl y i f
the bushi ngs are severel y scored, or worn.
Hel i -Coi l i nserts are recommended for repai ri ng
damaged, stri pped or worn threads i n al umi num
parts. Stai nl ess steel i nserts are preferred.
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on
val ves, use extreme care to avoi d roundi ng off sharp
edges. Sharp edges are vi tal as they prevent forei gn
matter from getti ng between the val ve and val ve
bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or
O-ri ngs duri ng overhaul . Repl ace these parts as a
matter of course. Al so do not reuse snap ri ngs or
E-cl i ps that are bent or di storted. Repl ace these parts
as wel l .
Lubri cate transmi ssi on parts wi th Mopar௡ ATF
Pl us 3, Type 7176 transmi ssi on fl ui d duri ng assem-
bl y. Use Mopar௡ Door Ease, or Ru-Gl yde to l ubri cate
pi ston seal s and O-ri ngs. Use petrol eum jel l y on
thrust washers and to hol d parts i n pl ace duri ng
reassembl y.
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM/OVERDRIVE PISTON RETAINER
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
l ow-reverse drum, and overdri ve pi ston retai ner i n
sol vent. Dry them wi th compressed ai r after cl ean-
i ng.
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse drum i f the cl utch race,
rol l er surface or i nsi de di ameter i s scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Exami ne the overdri ve pi ston retai ner careful l y for
wear, cracks, scori ng or other damage. Be sure the
retai ner hub i s a snug fi t i n the case and drum.
Repl ace the retai ner i f worn or damaged.
FRONT SERVO
Cl ean the servo pi ston components wi th sol vent
and dry them wi th compressed ai r. Wi pe the band
cl ean wi th l i nt free shop towel s.
Repl ace the front band i f di storted, l i ni ng i s
burned, fl aki ng off, or worn to the poi nt where the
grooves i n the l i ni ng materi al are no l onger vi si bl e.
I nspect the servo components (Fi g. 222). Repl ace
the spri ngs i f col l apsed, di storted or broken. Repl ace
the gui de, rod and pi ston i f cracked, bent, or worn.
Di scard the servo snap ri ng i f di storted or warped.
Check the servo pi ston bore for wear. I f the bore i s
severel y scored, or damaged, i t wi l l be necessary to
repl ace the case.
Repl ace any servo component i f doubt exi sts about
condi ti on. Do not reuse suspect parts.
REAR SERVO
Remove and di scard the servo pi ston seal ri ng (Fi g.
223). Then cl ean the servo components wi th sol vent
and dry wi th compressed ai r. Repl ace ei ther spri ng i f
col l apsed, di storted or broken. Repl ace the pl ug and
pi ston i f cracked, bent, or worn. Di scard the servo
snap ri ngs and use a new ones at assembl y.
OIL PUMP AND REACTION SHAFT SUPPORT
(1) Cl ean pump and support components wi th sol -
vent and dry them wi th compressed ai r.
(2) Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
21 - 188 AUTOMATIC TRANSMISSION— 30/32RH TJ
CLEANING AND INSPECTION (Continued)
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
(3) I nspect the pump and support components.
Repl ace the pump or support i f the seal ri ng grooves
or machi ned surfaces are worn, scored, pi tted, or
damaged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
(4) I nspect the pump bushi ng. Then check the
reacti on shaft support bushi ng. Repl ace ei ther bush-
i ng onl y i f heavi l y worn, scored or damaged. I t i s not
necessary to repl ace the bushi ngs unl ess they are
actual l y damaged.
(5) I nstal l the gears i n the pump body and mea-
sure pump component cl earances as fol l ows:
(a) Cl earance between outer gear and reacti on
shaft housi ng shoul d be 0.010 to 0.063 mm (0.0004
to 0.0025 i n.). Cl earance between i nner gear and
reacti on shaft housi ng shoul d be 0.010 to 0.063
mm (0.0004 to 0.0025 i n.). Both cl earances can be
measured at the same ti me by:
(I ) I nstal l i ng the pump gears i n the pump
housi ng.
(I I ) Posi ti on an appropri ate pi ece of Pl asti -
gage௢ across both gears.
(I I I ) Al i gn the pl asti gage to a fl at area on the
reacti on shaft housi ng.
(I V) I nstal l the reacti on shaft to the pump
housi ng.
(V) Separate the reacti on shaft housi ng from
the pump housi ng and measure the Pl asti gage௢
fol l owi ng the i nstructi ons suppl i ed wi th i t.
(b) Cl earance between i nner gear tooth and
outer gear shoul d be 0.08 to 0.19 mm (0.0035 to
0.0075 i n.). Measure cl earance wi th an appropri ate
feel er gauge.
(c) Cl earance between outer gear and pump
housi ng shoul d al so be 0.010 to 0.19 mm (0.0035 to
0.0075 i n.). Measure cl earance wi th an appropri ate
feel er gauge.
FRONT CLUTCH
Cl ean and i nspect the front cl utch components.
Repl ace the cl utch di scs i f warped, worn, scored,
burned or charred, or i f the faci ng i s fl aki ng off.
Repl ace the steel pl ates i f heavi l y scored, warped, or
broken. Be sure the dri vi ng l ugs on the pl ates are i n
good condi ti on. The l ugs must not be bent, cracked or
damaged i n any way.
Repl ace the cl utch spri ng and spri ng retai ner i f
ei ther i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged.
Check acti on of the check bal l i n the retai ner (Fi g.
224). The bal l must move freel y and not sti ck.
NOTE: Inspect the clutch retainer bushings care-
fully (Fig. 225). The retainer bushings are NOT ser-
viceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
Fig. 222
1 – PISTON RINGS
2 – O-RING
3 – SNAP-RING
4 – SEAL RING
5 – PISTON ROD GUIDE
6 – SNAP-RING
7 – SERVO SPRING
8 – PISTON ROD
9 – SERVO PISTON
Fig. 223 Rear Servo Components
1 – SNAP RING
2 – PISTON SEAL
3 – PISTON PLUG
4 – SPRING RETAINER
5 – SNAP RING
6 – PISTON SPRING
7 – CUSHION SPRING
8 – PISTON
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 189
CLEANING AND INSPECTION (Continued)
REAR CLUTCH
Cl ean the cl utch components wi th sol vent and dry
them wi th compressed ai r.
Check condi ti on of the i nput shaft seal ri ngs. I t i s
not necessary to remove or repl ace ri ngs unl ess they
are broken, cracked, or no l onger securel y hooked
together.
I nspect the i nput shaft spl i nes and machi ned sur-
faces. Very mi nor ni cks or scratches can be smoothed
off wi th crocus cl oth. repl ace the shaft i f the spl i nes
are damaged, or any of the machi ned surfaces are
severel y scored.
Repl ace the cl utch di scs i f warped, worn, scored,
burned/charred, the l ugs are damaged, or i f the fac-
i ng i s fl aki ng off.
Repl ace the steel pl ates and the pressure pl ate i f
heavi l y scored, warped, or broken. Be sure the dri v-
i ng l ugs on the di scs and pl ates are al so i n good con-
di ti on. The l ugs must not be bent, cracked or
damaged i n any way.
Repl ace the pi ston spri ng and wave spri ng i f ei ther
part i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged. Al so
check acti on of the retai ner check bal l . The bal l must
move freel y and not sti ck.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y damaged.
Check thrust washer condi ti on. Washer thi ckness
shoul d be 1.55 to 1.60 mm (0.061 to 0.063 i n.).
Repl ace the washer i f worn or damaged.
Check condi ti on of the two seal ri ngs on the i nput
shaft and the si ngl e seal ri ng on the pi ston retai ner
hub. Repl ace the seal ri ngs onl y i f severel y worn,
cracked, or cannot be hooked together.
PLANETARY GEARTRAIN/OUTPUT SHAFT
Cl ean the i ntermedi ate shaft and pl anetary compo-
nents i n sol vent and dry them wi th compressed ai r.
Do not spi n the pl anetary pi ni on gears wi th com-
pressed ai r.
I nspect the pl anetary gear sets and annul us gears.
The pl anetary pi ni ons, shafts, washers, and retai ni ng
pi ns are servi ceabl e. However, i f a pi ni on carri er i s
damaged, the enti re pl anetary gear set must be
repl aced as an assembl y.
Repl ace the annul us gears i f the teeth are chi pped,
broken, or worn, or the gear i s cracked. Repl ace the
pl anetary thrust pl ates and the tabbed thrust wash-
ers i f cracked, scored or worn.
I nspect the machi ned surfaces of the output shaft.
Be sure the oi l passages are open and cl ear. Repl ace
the shaft i f scored, pi tted, or damaged.
I nspect the sun gear and dri vi ng shel l . I f ei ther
component i s worn or damaged, remove the sun gear
rear retai ni ng ri ng and separate the sun gear and
thrust pl ate from the dri vi ng shel l . Then repl ace the
necessary component.
Repl ace the sun gear as an assembl y i f the gear
teeth are chi pped or worn. Al so repl ace the gear as
an assembl y i f the bushi ngs are scored or worn. The
sun gear bushi ngs are not servi ceabl e. Repl ace the
thrust pl ate i f worn, or severel y scored. Repl ace the
dri vi ng shel l i f di storted, cracked, or damaged i n any
way.
Repl ace al l snap ri ngs duri ng geartrai n assembl y.
Reusi ng snap ri ngs i s not recommended.
Fig. 224 Front Clutch Piston Retainer Check Ball
Location
1 – RETAINER CHECK BALL
Fig. 225 Retainer Bushing Location/Inspection
1 – FRONT CLUTCH RETAINER BUSHINGS (NON-
SERVICEABLE)
21 - 190 AUTOMATIC TRANSMISSION— 30/32RH TJ
CLEANING AND INSPECTION (Continued)
ADJ USTMENTS
GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n Park
and Neutral . Adjustment i s OK i f the engi ne starts
onl y i n these posi ti ons. Adjustment i s i ncorrect i f the
engi ne starts i n one but not both posi ti ons. I f the
engi ne starts i n any posi ti on other than Park or Neu-
tral , or i f the engi ne wi l l not start at al l , the park/
neutral posi ti on swi tch may be faul ty.
Gearshift Adjustment Procedure
(1) Shi ft transmi ssi on i nto Park.
(2) Rai se vehi cl e.
(3) Rel ease cabl e adjuster cl amp (at transmi ssi on
end of cabl e) to unl ock cabl e.
(4) Unsnap cabl e from cabl e mounti ng bracket on
transmi ssi on (Fi g. 226).
(5) Sl i de cabl e eyel et off transmi ssi on shi ft l ever.
(6) Veri fy transmi ssi on shi ft l ever i s i n Park
detent by movi ng l ever ful l y rearward. Last rearward
detent i s Park posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Sl i de cabl e eyel t onto transmi ssi on shi ft l ever.
(9) Snap shi ft cabl e adjuster i nto mounti ng
bracket on transmi ssi on.
(10) Lock shi ft cabl e by pressi ng cabl e adjuster
cl amp down unti l i t snaps i nto pl ace.
(11) Lower vehi cl e and check engi ne starti ng.
Engi ne shoul d start onl y i n Park and Neutral .
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE ADJUSTMENT
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove shi ft l ever bezel and consol e screws.
Rai se bezel and consol e for access to cabl e.
(3) Pul l cabl e l ock button up to rel ease cabl e (Fi g.
227).
(4) Turn i gni ti on swi tch to LOCK posi ti on.
(5) Use a spacer to create a one mi l l i meter gap
between the shi fter pawl and top of the shi ft gate.
(6) Pul l cabl e forward. Then rel ease cabl e and
press cabl e l ock button down unti l i t snaps i n pl ace.
(7) Check adjustment as fol l ows:
(a) Check movement of rel ease shi ft handl e but-
ton (fl oor shi ft) or rel ease l ever (col umn shi ft). You
shoul d not be abl e to press button i nward or move
col umn l ever.
(b) Turn i gni ti on swi tch to RUN posi ti on.
(c) Shi fti ng out of park shoul d not be possi bl e.
(d) Appl y the brake and attempt to shi ft out of
PARK. Shi fti ng shoul d be possi bl e.
(e) Whi l e the transmi ssi on i s shi fted out of
PARK, rel ease the brake and attempt to shi ft
through al l gears. Rel ease the shi ft button at l east
once duri ng thi s procedure. The i gni ti on key shoul d
not go to the LOCK posi ti on.
(f) Return transmi ssi on to the PARK posi ti on
wi thout appl yi ng the brake.
(8) Move shi ft l ever back to PARK and check i gni -
ti on swi tch operati on. You shoul d be abl e to turn
Fig. 226 Shift Cable Attachment At
Transmission–Typical
1 – THROTTLE VALVE CABLE
2 – TRANSMISSION SHIFT LEVER
3 – SHIFT CABLE
4 – SHIFT CABLE BRACKET
Fig. 227 Park Lock Cable Attachment
1 – PARK LOCK CABLE
2 – CABLE LOCK BUTTON
3 – SHIFT LEVER ASSEMBLY
4 – SHIFT CABLE
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 191
swi tch to LOCK posi ti on and shi ft l ever rel ease but-
ton/l ever shoul d not move.
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 228). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A retai ni ng cl i p at the engi ne-end of the cabl e
i s removed to provi de for cabl e adjustment. The
retai ni ng cl i p i s then i nstal l ed back onto the throttl e
val ve cabl e to l ock i n the adjustment.
A correctl y adjusted throttl e val ve cabl e wi l l cause
the throttl e l ever on the transmi ssi on to move si mul -
taneousl y wi th the throttl e body l ever from the i dl e
posi ti on. Proper adjustment wi l l al l ow si mul taneous
movement wi thout causi ng the transmi ssi on throttl e
l ever to ei ther move ahead of, or l ag behi nd the l ever
on the throttl e body.
Checking Throttle Valve Cable Adjustment
(1) Turn i gni ti on key to OFF posi ti on.
(2) Remove ai r cl eaner.
(3) Veri fy that l ever on throttl e body i s at curb i dl e
posi ti on. Then veri fy that transmi ssi on throttl e l ever
(Fi g. 229) i s al so at i dl e (ful l y forward) posi ti on.
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
• Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on.
• I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
• I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
• I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
Throttle Valve Cable Adjustment Procedure
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) I nsert a smal l screwdri ver under edge of
retai ni ng cl i p and remove retai ni ng cl i p.
(6) Center cabl e end on attachment stud to wi thi n
1 mm (0.039 i n.).
Fig. 228 Throttle Cable Attachment At Engine
1 – TRANSMISSION THROTTLE VALVE CABLE
2 – ACCELERATOR CABLE
3 – CABLE ENGINE BRACKET
4 – THROTTLE BODY
5 – CABLE GUIDE
Fig. 229 Throttle Cable Attachment At Transmission
1 – RETURN SPRING
2 – THROTTLE VALVE CABLE
3 – THROTTLE VALVE CABLE BRACKET
4 – THROTTLE VALVE LEVER
5 – GEAR SELECTOR LEVER
6 – SHIFT CABLE BRACKET
21 - 192 AUTOMATIC TRANSMISSION— 30/32RH TJ
ADJ USTMENTS (Continued)
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(7) I nstal l retai ni ng cl i p onto cabl e housi ng.
(8) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
FRONT BAND ADJUSTMENT
The front (ki ckdown) band adjusti ng screw i s
l ocated on the l eft si de of the transmi ssi on case
above the manual val ve and throttl e val ve l evers.
(1) Rai se vehi cl e.
(2) Loosen band adjusti ng screw l ocknut (Fi g. 230).
Then back l ocknut off 3-5 turns. Be sure adjusti ng
screw turns freel y i n case. Appl y l ubri cant to screw
threads i f necessary.
(3) Ti ghten band adjusti ng screw to 8 N·m (72 i n.
l bs.) torque wi th I nch Pound Torque Wrench
C-3380-A, a 3-i n. extensi on and appropri ate torx
socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw, tighten the screw to only 5 N·m
(47-50 in. lbs.) torque.
(4) Back off front band adjusti ng screw 2-1/2 turns
for the 30RH and 2-1/4 turns for the 32RH.
(5) Hol d adjuster screw i n posi ti on and ti ghten
l ocknut to 41 N·m (30 ft. l bs.) torque.
(6) Lower vehi cl e.
REAR BAND ADJUSTMENT
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(1) Rai se vehi cl e.
(2) Remove transmi ssi on oi l pan and drai n fl ui d.
(3) Loosen band adjusti ng screw l ocknut 5-6 turns.
Be sure adjusti ng screw turns freel y i n l ever.
(4) Ti ghten adjusti ng screw to 5 N·m (41 i n. l bs.)
for the 30RH and 8 N·m (72 i n. l bs.) torque for the
32RH (Fi g. 231).
(5) Back off adjusti ng screw 7 turns for the 30RH
and 4 turns for the 32RH.
(6) Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 N·m (25 ft. l bs.) torque.
(7) Posi ti on new gasket on oi l pan and i nstal l pan
on transmi ssi on. Ti ghten pan bol ts to 17 N·m (13 ft.
l bs.) torque.
(8) Lower vehi cl e and refi l l transmi ssi on wi th
Mopar௡ ATF Pl us 3, Type 7176, fl ui d.
Fig. 230 Front Band Adjustment Screw Location
1 – FRONT BAND ADJUSTING SCREW
2 – LOCK NUT
3 – MANUAL LEVER SHAFT
4 – PARK/NEUTRAL POSITION SWITCH
Fig. 231 Rear Band Adjustment Screw Location
1 – 30RH REAR BAND LEVER AND ADJUSTING SCREW
2 – 32RH REAR BAND LEVER AND ADJUSTING SCREW
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 193
ADJ USTMENTS (Continued)
VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
val ve body;
• Li ne Pressure
• Throttl e Pressure
Li ne and throttl e pressures are i nterdependent
because each affects shi ft qual i ty and ti mi ng. As a
resul t, both adjustments must be performed properl y
and i n the correct sequence. Adjust l i ne pressure fi rst
and throttl e pressure l ast.
LINE PRESSURE ADJUSTMENT
Measure di stance from the val ve body to the i nner
edge of the adjusti ng screw wi th an accurate steel
scal e (Fi g. 232).
Di stance shoul d be 33.4 mm (1-5/16 i n.).
I f adjustment i s requi red, turn the adjusti ng screw
i n, or out, to obtai n requi red di stance setti ng.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One compl ete turn of the adjusti ng screw changes
l i ne pressure approxi matel y 1-2/3 psi (9 kPa).
Turni ng the adjusti ng screw countercl ockwi se
i ncreases pressure whi l e turni ng the screw cl ockwi se
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
I nsert Gauge Tool C-3763 between the throttl e
l ever cam and the ki ckdown val ve stem (Fi g. 233).
Push the gauge tool i nward to compress the ki ck-
down val ve agai nst the spri ng and bottom the throt-
tl e val ve.
Mai ntai n pressure agai nst ki ckdown val ve spri ng.
Turn throttl e l ever stop screw unti l the screw head
touches throttl e l ever tang and the throttl e l ever cam
touches gauge tool .
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
Fig. 232 Line Pressure Adjustment
1 – WRENCH
2 – 1–5/16 INCH
Fig. 233 Throttle Pressure Adjustment
1 – HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 – SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
21 - 194 AUTOMATIC TRANSMISSION— 30/32RH TJ
ADJ USTMENTS (Continued)
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TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 195
SCHEMATICS AND DIAGRAMS (Continued)
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21 - 196 AUTOMATIC TRANSMISSION— 30/32RH TJ
SCHEMATICS AND DIAGRAMS (Continued)
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TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 197
SCHEMATICS AND DIAGRAMS (Continued)
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21 - 198 AUTOMATIC TRANSMISSION— 30/32RH TJ
SCHEMATICS AND DIAGRAMS (Continued)
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TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 199
SCHEMATICS AND DIAGRAMS (Continued)
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21 - 200 AUTOMATIC TRANSMISSION— 30/32RH TJ
SCHEMATICS AND DIAGRAMS (Continued)
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TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 201
SCHEMATICS AND DIAGRAMS (Continued)
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21 - 202 AUTOMATIC TRANSMISSION— 30/32RH TJ
SCHEMATICS AND DIAGRAMS (Continued)
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TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 203
SCHEMATICS AND DIAGRAMS (Continued)
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21 - 204 AUTOMATIC TRANSMISSION— 30/32RH TJ
SCHEMATICS AND DIAGRAMS (Continued)
SPECIFICATIONS
30/32RH AUTOMATIC TRANSMISSION
GENERAL
COMPONENT METRIC INCH
Oil pump gear tip clearance 0.089-0.190 mm 0.0035-0.0075 in.
Planetary end play 0.125-1.19 mm 0.001-0.047 in.
Input shaft end play 0.56-2.31 mm 0.022-0.091 in.
Clutch pack clearance/Front 4-disc. 1.70-3.40 mm 0.067-0.134 in.
Clutch pack clearance/Rear 4-disc. 0.559-0.940 mm 0.022-0.037 in.
Front clutch spring usage 1 spring
32RH-Front Band adjustment from 72 in. lbs. Back off 2.25 turns
32RH-Rear Band adjustment from 72 in. lbs. Back off 4 turns
30RH-Front Band adjustment from 72 in. lbs. Back off 2.5 turns
30RH-Rear Band adjustment from 41 in. lbs. Back off 7 turns
Recommended fluid Moparா, ATF Plus 3, Type 7176
THRUST WASHER/SPACER/SNAP RING
DIMENSIONS
COMPONENT METRIC INCH
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Output shaft thrust plate (output shaft pilot hub) 1.5-1.6mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.7-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.086 in.
Rear clutch pack snap ring 1.5-1.6 mm 0.06-0.062 in.
1.7-1.8 mm 0.068-0.070 in.
1.9-2.0 mm 0.076-0.078 in.
Planetary geartrain snap ring
(at front of output shaft)
1.0-1.1 mm 0.040-0.044 in.
1.6-1.7 mm 0.062-0.066 in.
2.1-2.2 mm 0.082-0.086 in.
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 205
PRESSURE TEST— ALL
ITEM RANGE PRESSURE
Line pressure (at accumulator) Closed throttle 372-414 kPa (54-60 psi).
Front servo Third gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
Governor D range closed
throttle
Pressure should respond smoothly to changes in mph and
return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi) at
stand still will prevent transmission from downshifting.
TORQUE
DESCRIPTION TORQUE
Bol t/nut, crossmember . . . . . . . . 68 N·m (50 ft. l bs.)
Bol t, dri vepl ate to crankshaft . . 75 N·m (55 ft. l bs.)
Pl ug, front band reacti on . . . . . 17 N·m (13 ft. l bs.)
Locknut, front band adj. . . . . . . 34 N·m (25 ft. l bs.)
Swi tch, park/neutral . . . . . . . . . 34 N·m (25 ft. l bs.)
Bol t, fl ui d pan . . . . . . . . . . . . . . 17 N·m (13 ft. l bs.)
Bol t, oi l pump . . . . . . . . . . . . . . 20 N·m (15 ft. l bs.)
Bol t, overrunni ng cl utch cam . . 17 N·m (13 ft. l bs.)
Pl ug, pressure test port . . . . . . . 14 N·m (10 ft. l bs.)
Bol t, reacti on shaft support . . . . 20 N·m (15 ft. l bs.)
Locknut, rear band . . . . . . . . . . 41 N·m (30 ft. l bs.)
Bol t. speedometer adapter . . . . . . 11 N·m (8 ft. l bs.)
Screw, fl ui d fi l ter . . . . . . . . . . . . 4 N·m (35 i n. l bs.)
Bol t, val ve body to case . . . . . 12 N·m (100 i n. l bs.)
SPECIAL TOOLS
30/32RH TRANSMISSIONS
Remover—6957
Installer—6951
Retainer, Detent Ball and Spring—6583
Snap-ring Plier—6823
Pilot Stud—C-3288-B
21 - 206 AUTOMATIC TRANSMISSION— 30/32RH TJ
SPECIFICATIONS (Continued)
Pressure Gauge—C-3292
Pressure Gauge—C-3293SP
Dial Indicator—C-3339
Spring Compressor—C-3422-B
Spring Compressor—C-3575-A
Spring Compressor—C-3863-A
Adapter, Band Adjuster—C-3705
Transmission Repair Stand—C-3750-B
Puller, Slide Hammer—C-3752
Gauge, Throttle Setting—C-3763
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 207
SPECIAL TOOLS (Continued)
Seal Installer—C-3860-A
Bushing Remover/Installer—C-3887-J
Cup, Remover—SP-3633
Remover, Bushing—SP-5301
Installer, Bushing—SP-5118
Installer, Bushing—SP-5302
Remover, Bushing—SP-3550
Remover, Bushing—SP-3629
Installer, Bushing—SP-5511
Snap-ring Plier—C-3915
21 - 208 AUTOMATIC TRANSMISSION— 30/32RH TJ
SPECIAL TOOLS (Continued)
Seal Remover—C-3985-B
Bushing, Remover—6957
Flusher, Oil Cooler—6906
Installer—C-3995-A
Universal Handle—C-4171
Remover/Installer—C-4470
Nut, Bushing Remover—SP-1191
TJ AUTOMATIC TRANSMISSION— 30/32RH 21 - 209
SPECIAL TOOLS (Continued)
NV231 TRANSFER CASE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 210
LUBRICANT AND FILL LEVEL . . . . . . . . . . . . . . 211
DIAGNOSIS AND TESTING
NV231 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . 211
REMOVAL AND INSTALLATION
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . 212
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 213
SPEEDOMETER. . . . . . . . . . . . . . . . . . . . . . . . . 214
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . . 214
DISASSEMBLY AND ASSEMBLY
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 215
CLEANING AND INSPECTION
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 233
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . 237
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
SPECIAL TOOLS
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
DESCRIPTION AND OPERATION
NV231 TRANSFER CASE
DESCRIPTION
The NV231 i s a part-ti me transfer case wi th a l ow
range reducti on gear system. The NV231 has three
operati ng ranges pl us a Neutral posi ti on. A l ow range
system provi des a reducti on rati o for i ncreased l ow
speed torque capabi l i ty.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
Transfer case operati ng ranges are:
• 2WD (2-wheel dri ve)
• 4x4 (4-wheel dri ve)
• 4 Lo (4-wheel dri ve l ow range
The 2WD range i s for use on any road surface at
any ti me.
The 4x4 and 4 Lo ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4 Lo range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a fl oor mounted
shi ft l ever. The shi ft l ever i s connected to the trans-
fer case range l ever by an adjustabl e l i nkage rod. A
strai ght l i ne shi ft pattern i s used. Range posi ti ons
are marked on the shi fter bezel cover pl ate.
IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
OPERATION
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range hub. The
front output shaft i s operated by a dri ve chai n that
connects the shaft to a dri ve sprocket on the mai n-
shaft. The dri ve sprocket i s engaged/di sengaged by
the mode fork, whi ch operates the mode sl eeve and
Fig. 1 Fill/Drain Plug And I. D. Tag Locations
1 – I. D. TAG
2 – FILL PLUG
3 – DRAIN PLUG
21 - 210 NV231 TRANSFER CASE TJ
hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
LUBRICANT AND FILL LEVEL
DESCRIPTION
Recommended l ubri cant for the NV231 transfer
case i s Mopar௡ Dexron I I , or ATF Pl us 3, type 7176.
Approxi mate l ubri cant fi l l capaci ty i s 1.2 l i ters (2.5
pi nts).
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 2). Correct fi l l l evel i s to the bottom edge of the
fi l l pl ug hol e. Be sure the vehi cl e i s l evel to ensure
an accurate fl ui d l evel check.
DIAGNOSIS AND TESTING
NV231 DIAGNOSIS
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.
1) Vehicle speed to great to permit
shifting.
1) Slow vehicle and shift into
desired range.
2) If vehicle was operated for an
extended period in 4H mode on dry
surface, driveline torque load may
cause difficulty.
2) Stop vehicle and shift transfer
case to Neutral position. Transfer
case can then be shifted to the
desired mode.
3) Transfer case shift linkage
binding.
3) Repair or replace linkage as
necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill transfer case with
the correct type and quantity of
lubricant.
5) Internal transfer case
components binding, worn, or
damaged.
5) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct type and quantity of
lubricant.
Fig. 2 Fill/Drain Plug Locations
1 – I. D. TAG
2 – FILL PLUG
3 – DRAIN PLUG
TJ NV231 TRANSFER CASE 21 - 211
DESCRIPTION AND OPERATION (Continued)
Condition Possible Cause Correction
Transfer case noisy while in, or
jumps out of, 4L mode.
1) Transfer case not completely
engaged in 4L position.
1) Slow vehicle, shift transfer case
to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of
adjustment.
2) Adjust linkage as necessary.
3) Transfer case shift linkage loose
or binding.
3) Repair, replace, or tighten linkage
components as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
4) Repair or replace components as
necessary.
5) Low range gear worn or
damaged.
5) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4H mode
on dry surfaces,
1) Operate vehicle in 2H mode on
dry surfaces.
REMOVAL AND INSTALLATION
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(2) Rai se vehi cl e.
(3) Support transmi ssi on wi th jack stand.
(4) Remove ski d pl ate.
(5) Drai n transfer case l ubri cant.
(6) Mark front and rear propel l er shaft yokes for
al i gnment reference.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 3)
and i ndi cator swi tch harness.
(11) Support transfer case wi th transmi ssi on jack.
(12) Secure transfer case to jack wi th chai ns.
(13) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(2) Secure transfer case to jack wi th chai ns.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 N·m (26 ft. l bs.) torque (Fi g. 3).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch. Secure wi re harness to cl i ps on transfer
case.
Fig. 3 Transfer Case Mounting
1 – VENT TUBE
2 – TRANSFER CASE
3 – TRANSMISSION
21 - 212 NV231 TRANSFER CASE TJ
DIAGNOSIS AND TESTING (Continued)
(8) Al i gn and connect propel l er shafts. Refer to
Group 3, Di fferenti al and Dri vel i ne, for proper proce-
dures and speci fi cati ons.
(9) Fi l l transfer case wi th correct fl ui d. Check
transmi ssi on fl ui d l evel . Correct as necessary.
(10) Connect shi ft rod to transfer case range l ever.
(11) Adjust transfer case shi ft l i nkage.
(12) I nstal l ski d pl ate.
(13) Remove transmi ssi on jack and support stand.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(2) Rai se vehi cl e.
(3) Loosen adjusti ng trunni on l ocknut and sl i de
shi ft rod out of trunni on (Fi g. 4). I f rod l acks enough
travel to come out of trunni on, push trunni on out of
torque shaft.
(4) Lower vehi cl e.
(5) Remove consol e. Refer to Group 23, Body, for
proper procedures.
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. Refer to Group 23, Body, for
proper procedures.
(3) Rai se vehi cl e.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
Fig. 4 Shift Linkage
1 – RIVNUT (4)
2 – SHIFT LEVER ASSEMBLY
3 – FLOORPAN
4 – TRUNNION LOCK BOLT
5 – SELECTOR ROD AND TRUNNION
6 – SHIFT LEVER ROD
7 – TORQUE SHAFT FRAME BRACKET
8 – TORQUE SHAFT
9 – TRANSFER CASE SHIFT LEVER
10 – TORQUE SHAFT TRANSFER CASE BRACKET
TORQUE
A 3-4 N•m
(27-35 in. lbs.)
B 11-14 N•m
(97-123 in.Ë lbs.)
C 8-14 N•m
(72-120 in. lbs.)
TJ NV231 TRANSFER CASE 21 - 213
REMOVAL AND INSTALLATION (Continued)
(6) Lower vehi cl e and check transfer case shi ft
operati on.
SPEEDOMETER
REMOVAL
(1) Rai se vehi cl e.
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 5).
(4) Remove speed sensor and speedometer adapter
as an assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
Repl ace pi ni on i f chi pped, cracked, or worn.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 5).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar௡ el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
severel y corroded, or damaged.
INSTALLATION AND INDEXING
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter (Fi g. 5), i f necessary.
(3) Lubri cate sensor and adapter O-ri ngs wi th
transmi ssi on fl ui d.
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 N·m
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 6).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 N·m (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel i f necessary.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove front propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
Fig. 5 Speedometer Components
1 – SENSOR O-RING
2 – SPEEDOMETER ADAPTER
3 – ADAPTER O-RING
4 – SPEEDOMETER PINION
5 – ADAPTER CLAMP
6 – VEHICLE SPEED SENSOR
ITEM TORQUE
A 2-3 N·m (15-27 in. lbs.)
B 10-12 N·m (90-110 in. lbs.)
21 - 214 NV231 TRANSFER CASE TJ
REMOVAL AND INSTALLATION (Continued)
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
7).
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143 as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 8). Once seal i s started, conti nue tappi ng
seal i nto bore unti l i nstal l er tool seats agai nst case.
DISASSEMBLY AND ASSEMBLY
NV231 TRANSFER CASE
DISASSEMBLY
Posi ti on transfer case on shal l ow drai n pan.
Remove drai n pl ug and drai n l ubri cant remai ni ng i n
case.
REAR RETAINER AND OIL PUMP REMOVAL
(1) Remove the speedometer adapter.
(2) Spread band cl amp whi ch hol ds output shaft
boot to sl i nger wi th a sui tabl e awl , or equi val ent.
(3) Remove output shaft boot from sl i nger and out-
put shaft.
(4) Usi ng Pul l er MD-998056-A, remove rear
sl i nger (Fi g. 9).
(5) Use a sui tabl e pry tool , or a sl i de hammer
mounted screw, to remove the seal from the rear
retai ner (Fi g. 10).
(6) Remove the rear output beari ng I . D. retai ni ng
ri ng (Fi g. 11).
(7) Remove the bol ts hol di ng the rear retai ner to
the rear case hal f.
(8) Tap rear retai ner wi th rawhi de or rubber mal -
l et to l oosen seal er bead.
(9) Remove rear retai ner from rear case hal f (Fi g.
12).
Fig. 6 Location Of Index Numbers On Speedometer
Adapter
1 – SPEEDOMETER ADAPTER
2 – INDEX NUMBER LOCATION
Fig. 7 Remove Front Output Shaft Seal
1 – OUTPUT SHAFT SEAL
2 – PRYBAR
Fig. 8 Front Output Seal Installation
1 – INSTALLER 8143
2 – TRANSFER CASE
TJ NV231 TRANSFER CASE 21 - 215
REMOVAL AND INSTALLATION (Continued)
(10) Remove snap-ri ng hol di ng oi l pump i n posi -
ti on on output shaft.
(11) Di sengage oi l pi ckup tube from oi l pump and
remove oi l pump assembl y. Remove oi l pump by ti l t-
i ng the edge of the oi l pump from under the edge of
the rear case hal f and sl i di ng the pump (Fi g. 13).
(12) Remove pi ck-up tube o-ri ng from oi l pump
(Fi g. 14), i f necessary. Do not di sassembl e the oi l
pump, i t i s not servi ceabl e.
Fig. 9 Rear Slinger Removal
1 – TRANSFER CASE
2 – SPECIAL TOOL MD998056–A
3 – SLINGER
Fig. 10 Rear Retainer Seal
1 – REAR RETAINER
2 – OUTPUT SHAFT SEAL
Fig. 11 Output Shaft Rear Bearing Retaining Ring
1 – SNAP RING PLIERS
2 – REAR BEARING I. D. RETAINING RING
Fig. 12 Rear Retainer Removal
1 – MAINSHAFT
2 – REAR RETAINER
Fig. 13 Oil Pump Removal
1 – OIL PUMP
21 - 216 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
YOKE AND RANGE LEVER REMOVAL
(1) Remove transfer case i ndi cator swi tch.
(2) Remove front yoke nut as fol l ows:
(a) Move range l ever to 4L posi ti on.
(b) Then remove nut wi th socket and i mpact
wrench (Fi g. 15).
(3) Remove yoke. I f yoke i s di ffi cul t to remove by
hand, remove i t wi th beari ng spl i tter, or wi th stan-
dard two jaw pul l er (Fi g. 16). Be sure pul l er tool i s
posi ti oned on yoke and not on sl i nger as sl i nger wi l l
be damaged.
(4) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(5) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft (Fi g. 17).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Support transfer case so rear case i s faci ng
upward.
(2) Remove bol ts hol di ng front case to rear case.
The case al i gnment bol ts requi re fl at washers (Fi g.
18).
(3) Loosen rear case wi th fl at bl ade screwdri ver to
break seal er bead. I nsert pry tool bl ade onl y i nto
notches provi ded at each end of case (Fi g. 19).
(4) Remove rear case from front case.
Fig. 14 Pick-up Tube O-ring Location
1 – OIL PUMP
2 – O-RING
Fig. 15 Yoke Nut Removal
1 – IMPACT WRENCH
2 – SOCKET
3 – YOKE
Fig. 16 Yoke Removal
1 – PULLER TOOL
2 – YOKE
Fig. 17 Range Lever Removal
1 – RANGE LEVER
2 – SECTOR SHAFT
TJ NV231 TRANSFER CASE 21 - 217
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Remove oi l pi ckup tube from rear case (Fi g.
20).
(6) Remove mode fork spri ng (Fi g. 21).
(7) Pul l front output shaft upward and out of front
output shaft beari ng (Fi g. 22).
(8) Remove front output shaft and chai n.
Fig. 18 Rear Case Alignment Bolt Locations
1 – DOWEL BOLT AND WASHER (2)
2 – CASE BOLT (5)
3 – SPLINE HEAD BOLT (1)
Fig. 19 Loosening Rear Case
1 – REAR CASE
2 – PRY TOOL
(IN CASE SLOT)
3 – FRONT CASE
Fig. 20 Oil Pickup Tube Removal
1 – CONNECTING HOSE
2 – PICKUP SCREEN
3 – PICKUP TUBE
Fig. 21 Mode Fork Spring Removal
1 – MODE SPRING
21 - 218 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT FORKS AND MAINSHAFT REMOVAL
(1) Remove detent pl ug, O-ri ng, detent spri ng and
detent pl unger (Fi g. 23).
(2) Remove mai nshaft from mode sl eeve and i nput
gear pi l ot beari ng.
(3) Remove mode fork and sl eeve as an assembl y
(Fi g. 24). Note posi ti on of sl eeve for assembl y refer-
ence. The short si de of the sl eeve faces upward.
(4) Remove range fork and hub as an assembl y
(Fi g. 25). Note fork posi ti on for i nstal l ati on reference.
(5) Remove shi ft sector from front case (Fi g. 26).
(6) Remove shi ft sector bushi ng and O-ri ng (Fi g.
27).
Fig. 22 Remove Front Output Shaft And Chain
1 – DRIVE CHAIN
2 – FRONT OUTPUT SHAFT
3 – SHAFT FRONT BEARING
Fig. 23 Detent Plug, Spring And Plunger Removal
1 – POPPET
2 – SPRING
3 – SCREW
4 – POPPET BORE (IN CASE)
Fig. 24 Mode Fork And Sleeve Removal
1 – MODE SLEEVE
2 – MODE FORK AND RAIL
Fig. 25 Range Fork And Hub Removal
1 – RANGE HUB
2 – RANGE FORK
TJ NV231 TRANSFER CASE 21 - 219
DISASSEMBLY AND ASSEMBLY (Continued)
MAINSHAFT DISASSEMBLY
(1) Remove mode hub retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 28).
(2) Sl i de mode hub off mai nshaft (Fi g. 29).
(3) Sl i de dri ve sprocket off mai nshaft (Fi g. 30).
Fig. 26 Shift Sector Removal
1 – SHIFT SECTOR
Fig. 27 Sector Bushing And O-Ring Removal
1 – SEAL RETAINER
2 – SECTOR SHAFT BORE
3 – O-RING SEAL
Fig. 28 Mode Hub Retaining Ring Removal
1 – MODE HUB
2 – SNAP RING PLIERS (HEAVY DUTY)
3 – MODE HUB RETAINING RING
Fig. 29 Mode Hub Removal
1 – MAINSHAFT
2 – MODE HUB
21 - 220 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
INPUT GEAR AND LOW RANGE GEAR REMOVAL
(1) Remove front beari ng retai ner attachi ng bol ts
(Fi g. 31).
(2) Remove front beari ng retai ner. Pry retai ner
l oose wi th pry tool posi ti oned i n sl ots at each end of
retai ner (Fi g. 32).
(3) Remove front beari ng retai ner seal . Tap seal
out wi th dri ft and hammer.
(4) Remove i nput gear retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 33)
Fig. 30 Drive Sprocket Removal
1 – DRIVE SPROCKET
2 – MAINSHAFT
Fig. 31 Front Bearing Retainer Bolts
1 – FRONT CASE
2 – FRONT BEARING RETAINER
3 – RETAINER BOLTS
Fig. 32 Front Bearing Retainer Removal
1 – FRONT BEARING RETAINER
2 – RETAINER SLOT
Fig. 33 Removing Input Gear Retaining Ring
1 – INPUT GEAR BEARING RETAINING RING
2 – INPUT GEAR BEARING
3 – SNAP RING PLIERS
TJ NV231 TRANSFER CASE 21 - 221
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Pl ace front case i n hori zontal posi ti on. Then
remove i nput gear and l ow range gear as an assem-
bl y (Fi g. 34). Tap gear out of beari ng wi th pl asti c
mal l et i f necessary.
INPUT AND LOW RANGE GEAR DISASSEMBLY
(1) Remove snap-ri ng that retai ns i nput gear i n
l ow range gear (Fi g. 35).
(2) Remove retai ner (Fi g. 36).
(3) Remove front tabbed thrust washer (Fi g. 37).
(4) Remove i nput gear (Fi g. 38).
(5) Remove rear tabbed thrust washer from l ow
range gear (Fi g. 39).
Fig. 34 Input Gear And Planetary Carrier Removal
1 – PLANETARY ASSEMBLY
2 – INPUT GEAR
Fig. 35 Input Gear Snap-Ring Removal
1 – CARRIER LOCK RETAINING RING
2 – INPUT GEAR
3 – PLANETARY CARRIER
4 – SCREWDRIVER
Fig. 36 Input Gear Retainer Removal
1 – INPUT GEAR
2 – LOW RANGE GEAR
3 – RETAINER
Fig. 37 Front Tabbed Thrust Washer Removal
1 – FRONT TABBED THRUST WASHER
21 - 222 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
Lubri cate transfer case components wi th Mopar௡
Dexron I I automati c transmi ssi on fl ui d or petrol eum
jel l y (where i ndi cated) duri ng assembl y.
BEARING AND SEAL INSTALLATION
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
(1) Remove the front output shaft seal from case
wi th pry tool (Fi g. 40).
(2) Remove the front output shaft beari ng retai n-
i ng ri ng wi th screwdri ver (Fi g. 41).
(3) Remove beari ng wi th Tool Handl e C-4171 and
Tool 5065 (Fi g. 42).
Fig. 38 Input Gear Removal
1 – INPUT GEAR
2 – LOW RANGE GEAR
Fig. 39 Rear Tabbed Thrust Washer Removal
1 – LOW RANGE GEAR
2 – REAR TABBED THRUST WASHER
Fig. 40 Front Output Seal Removal
1 – OUTPUT SHAFT SEAL
2 – PRYBAR
Fig. 41 Front Output Shaft Bearing Retaining Ring
Removal
1 – SCREWDRIVERS
2 – SNAP RING
3 – FRONT OUTPUT SHAFT BEARING
4 – FRONT CASE
TJ NV231 TRANSFER CASE 21 - 223
DISASSEMBLY AND ASSEMBLY (Continued)
(4) I nstal l front output shaft front beari ng i n case
wi th Tool Handl e C-4171 and I nstal l er 5064 (Fi g. 43).
(5) I nstal l output shaft front beari ng retai ni ng
ri ng (Fi g. 44). Start ri ng i nto pl ace by hand. Then
use smal l screwdri ver to work ri ng i nto case groove.
Be sure ri ng i s ful l y seated before proceedi ng.
(6) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143 as fol l ows:
(a) Pl ace new seal on tool . Garter spring on
seal goes toward interior of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 45). Once seal i s started, conti nue tap-
pi ng seal i nto bore unti l i nstal l er tool bottoms
agai nst case.
(7) Remove the output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 46).
(8) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 47). The beari ng bore i s
chamfered at the top. I nstal l the beari ng so i t i s
fl ush wi th the l ower edge of thi s chamfer (Fi g. 48).
Fig. 42 Front Output Shaft Bearing Removal
1 – FRONT CASE
2 – SPECIAL TOOL C-4171
3 – SPECIAL TOOL 5065
Fig. 43 Front Output Shaft Bearing Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL 5064
Fig. 44 Installing Output Shaft Front Bearing
Retaining Ring
1 – WORK RETAINING RING INTO BORE GROOVE WITH SMALL
SCREWDRIVER
Fig. 45 Front Output Seal Installation
1 – INSTALLER 8143
2 – TRANSFER CASE
21 - 224 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(9) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng from i nsi de the annul us
gear openi ng i n the case. (Fi g. 49).
(10) I nstal l l ocati ng ri ng on new beari ng.
(11) Posi ti on case so forward end i s faci ng upward.
(12) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng i nto case. The beari ng
l ocati ng ri ng must be ful l y seated agai nst case sur-
face (Fi g. 50).
(13) Remove i nput gear pi l ot beari ng by i nserti ng
a sui tabl y si zed dri ft i nto the spl i ned end of the i nput
gear and dri vi ng the beari ng out wi th the dri ft and a
hammer (Fi g. 51).
(14) I nstal l new pi l ot beari ng wi th I nstal l er 5065
and Handl e C-4171 (Fi g. 52).
Fig. 46 Output Shaft Rear Bearing Removal
1 – REAR CASE
2 – SPECIAL TOOL L-4454–1 AND L-4454–3
3 – SPECIAL TOOL 8148
Fig. 47 Output Shaft Rear Bearing Installation
1 – HANDLE C-4171
2 – OUTPUT SHAFT INNER BEARING
3 – INSTALLER 5066
Fig. 48 Output Shaft Rear Bearing Installation Depth
1 – BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 – CHAMFER
Fig. 49 Input Shaft Bearing Removal
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-4210
TJ NV231 TRANSFER CASE 21 - 225
DISASSEMBLY AND ASSEMBLY (Continued)
(15) Remove front beari ng retai ner seal wi th sui t-
abl e pry tool .
(16) I nstal l new front beari ng retai ner seal wi th
I nstal l er 7884 (Fi g. 53).
(17) Remove seal from oi l pump housi ng wi th a
sui tabl e pry tool
(18) I nstal l new seal i n oi l pump housi ng wi th
I nstal l er 7888 (Fi g. 54).
Fig. 50 Seating Input Shaft Bearing
1 – SNAP RING
2 – INPUT SHAFT BEARING
Fig. 51 Remove Input Gear Pilot Bearing
1 – DRIFT
2 – INPUT GEAR
Fig. 52 Install Input Gear Pilot Bearing
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL 5065
3 – INPUT GEAR
Fig. 53 Install Front Bearing Retainer Seal
1 – FRONT BEARING RETAINER
2 – SPECIAL TOOL 7884
21 - 226 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(19) Remove rear retai ner beari ng wi th I nstal l er
8128 and Handl e C-4171.
(20) I nstal l rear beari ng i n retai ner wi th Handl e
C-4171 and I nstal l er 5064 (Fi g. 55).
INPUT AND LOW RANGE GEAR ASSEMBLY
(1) Lubri cate gears and thrust washers (Fi g. 56)
wi th recommended transmi ssi on fl ui d.
(2) I nstal l fi rst thrust washer i n l ow range gear
(Fi g. 56). Be sure washer tabs are properl y al i gned i n
gear notches.
(3) I nstal l i nput gear i n l ow range gear. Be sure
i nput gear i s ful l y seated.
(4) I nstal l remai ni ng thrust washer i n l ow range
gear and on top of i nput gear. Be sure washer tabs
are properl y al i gned i n gear notches.
(5) I nstal l retai ner on i nput gear and i nstal l snap-
ri ng.
INPUT GEAR AND LOW RANGE GEAR INSTALLATION
(1) Al i gn and i nstal l l ow range/i nput gear assem-
bl y i n front case (Fi g. 57). Be sure l ow range gear
pi ni ons are engaged i n annul us gear and that i nput
gear shaft i s ful l y seated i n front beari ng.
(2) I nstal l snap-ri ng to hol d i nput/l ow range gear
i nto front beari ng (Fi g. 58).
(3) Cl ean gasket seal er resi due from retai ner and
i nspect retai ner for cracks or other damage.
(4) Appl y a 3 mm (1/8 i n.) bead of Mopar௡ gasket
maker or si l i cone adhesi ve to seal i ng surface of
retai ner.
(5) Al i gn cavi ty i n seal retai ner wi th fl ui d return
hol e i n front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying Moparா gas-
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.
(6) I nstal l bol ts to hol d retai ner to transfer case
(Fi g. 59). Ti ghten to 21 N·m (16 ft. l bs.) of torque.
Fig. 54 Oil Pump Seal Installation
1 – HOUSING SEAL
2 – SPECIAL TOOL 7888
3 – OIL PUMP FEED HOUSING
Fig. 55 Installing Rear Bearing In Retainer
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL 5064
3 – REAR RETAINER
Fig. 56 Input/Low Range Gear Components
1 – SNAP RING
2 – RETAINER PLATE
3 – INPUT GEAR
4 – LOW RANGE GEAR
5 – THRUST WASHERS
TJ NV231 TRANSFER CASE 21 - 227
DISASSEMBLY AND ASSEMBLY (Continued)
MAINSHAFT ASSEMBLY
(1) Lubri cate mai nshaft spl i nes wi th recommended
transmi ssi on fl ui d.
(2) Sl i de dri ve sprocket onto mai nshaft.
(3) Sl i de mode hub onto mai nshaft.
(4) I nstal l mode hub retai ni ng ri ng. Veri fy that the
retai ni ng ri ng i s ful l y seated i n mai nshaft groove.
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 60).
(2) I nstal l shi ft sector i n case (Fi g. 61). Lubri cate
sector shaft wi th transmi ssi on fl ui d before i nstal l a-
ti on.
(3) I nstal l range l ever, washer, and nut on sector
shaft (Fi g. 62). Ti ghten range l ever nut to 27–34 N.m
(20–25 ft. l bs.) torque.
(4) Assembl e and i nstal l range fork and hub (Fi g.
63). Be sure hub i s properl y seated i n l ow range gear
and engaged to the i nput gear.
(5) Al i gn and i nsert range fork pi n i n shi ft sector
sl ot.
(6) I nstal l assembl ed mai nshaft (Fi g. 64). Be sure
shaft i s seated i n pi l ot beari ng and i nput gear.
(7) I nstal l new pads on mode fork i f necessary.
Fig. 57 Input/Low Range Gear Installation
1 – ANNULUS GEAR
2 – INPUT/LOW RANGE GEAR
Fig. 58 Install Snap-Ring
1 – INPUT GEAR
2 – SNAP RING
Fig. 59 Install Front Bearing Retainer
1 – FRONT BEARING RETAINER
Fig. 60 Sector O-Ring And Bushing Installation
1 – SECTOR BUSHING
2 – O-RING
21 - 228 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(8) I nsert mode sl eeve i n mode fork mode fork. Be
sure l ong si de of sl eeve i s toward l ong end of shi ft
rai l (Fi g. 65).
(9) I nstal l assembl ed mode fork and sl eeve (Fi g.
66). Be sure fork rai l goes through range fork and
i nto case bore. Al so be sure sl eeve i s al i gned and
seated on mai nshaft hub.
(10) Rotate sector to Neutral posi ti on.
(11) I nstal l new O-ri ng on detent pl ug (Fi g. 67).
(12) Lubri cate detent pl unger wi th transmi ssi on
fl ui d or l i ght coat of petrol eum jel l y.
(13) I nstal l detent pl unger, spri ng and pl ug (Fi g.
67).
(14) Veri fy that pl unger i s properl y engaged i n sec-
tor.
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) Lubri cate front output shaft-sprocket assembl y,
dri ve chai n, and dri ve sprocket wi th transmi ssi on
fl ui d.
Fig. 61 Shift Sector Installation
1 – SHIFT SECTOR
Fig. 62 Range Lever Installation
1 – RANGE LEVER
2 – LEVER NUT
Fig. 63 Install Range Fork And Hub Assembly
1 – RANGE HUB
2 – RANGE FORK
Fig. 64 Mainshaft Assembly Installation
1 – DRIVE SPROCKET
2 – MODE HUB
3 – MAINSHAFT
Fig. 65 Assembling Mode Fork And Sleeve
1 – MODE SLEEVE
2 – MODE FORK AND RAIL
TJ NV231 TRANSFER CASE 21 - 229
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Assembl e dri ve chai n and front output shaft
(Fi g. 68).
(3) Start chai n on mai nshaft dri ve sprocket.
(4) Gui de front shaft i nto beari ng and dri ve
sprocket onto mai nshaft dri ve gear (Fi g. 68).
(5) I nstal l mode spri ng on upper end of mode fork
shi ft rai l (Fi g. 69).
Fig. 66 Mode Fork And Sleeve Installation
1 – MODE SLEEVE
2 – MODE FORK AND RAIL
Fig. 67 Shift Detent Components
1 – POPPET
2 – SPRING
3 – SCREW
4 – POPPET BORE (IN CASE)
Fig. 68 Installing Drive Chain And Front Output
Shaft
1 – FRONT OUTPUT SHAFT
2 – DRIVE CHAIN
3 – MAINSHAFT
4 – DRIVE SPROCKET
Fig. 69 Install Mode Fork Spring
1 – MODE SPRING
21 - 230 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION
(1) I nstal l magnet i n front case pocket (Fi g. 70).
(2) Assembl e oi l pi ckup screen, connecti ng hose,
and tube.
(3) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 71).
(4) I nsert oi l pi ckup tube i n oi l pump i nl et.
(5) Posi ti on assembl ed oi l pump and pi ckup tube
i n rear case. Be sure pi ckup screen i s securel y seated
i n case sl ot. Al so be sure oi l pump l ocati ng tabs are
outsi de rear case (Fi g. 72).
(6) Appl y 3 mm (1/8 i n.) wi de bead of Mopar௡ gas-
ket maker or si l i cone adhesi ve seal er to mounti ng
fl ange of front case. Work seal er bead around bol t
hol es.
(7) Li ft rear case and oi l pump and careful l y posi -
ti on assembl y on front case. Be sure case dowel s are
al i gned and that mode fork rai l extends through rear
case before seati ng rear case on front case.
(8) I nstal l case attachi ng bol ts. Al i gnment bol ts at
each end of case are onl y ones requi ri ng washers
(Fi g. 73).
(9) Ti ghten case bol ts to 27-34 N·m (20-25 ft. l bs.)
torque.
YOKE AND RANGE LEVER INSTALLATION
(1) I nstal l i ndi cator swi tch i n front case. Ti ghten
swi tch to 20–34 N·m (15–25 ft. l bs.) torque.
(2) I nstal l range l ever, washer and l ocknut on sec-
tor shaft (Fi g. 74). Ti ghten l ocknut to 27-34 N·m
(20-25 ft. l bs.) torque.
(3) I nstal l new seal washer on front output shaft
(Fi g. 76).
(4) Lubri cate yoke hub wi th transmi ssi on fl ui d and
i nstal l yoke on front shaft.
(5) I nstal l new seal washer on front shaft.
(6) I nstal l yoke and new yoke nut on front output
shaft (Fi g. 75).
Fig. 70 Installing Case Magnet
1 – MAGNET
Fig. 71 Pickup Tube O-Ring Position
1 – OIL PUMP
2 – O-RING
Fig. 72 Oil Pump And Pickup Tube Installation
1 – OIL PUMP
2 – PICKUP TUBE
3 – PICKUP SCREEN AND CONNECTOR
Fig. 73 Alignment Bolt Location
1 – ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
TJ NV231 TRANSFER CASE 21 - 231
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Ti ghten yoke nut to 122-176 N·m (90-130 ft.
l bs.) torque. Use Tool C-3281, or si mi l ar tool to hol d
yoke whi l e ti ghteni ng yoke nut.
REAR RETAINER INSTALLATION
(1) Appl y bead of Mopar௡ Seal er P/N 82300234, or
Locti te௢ Ul tra Gray, to mati ng surface of rear
retai ner. Seal er bead shoul d be a maxi mum of 3/16
i nch.
(2) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 20–27 N·m (15–20 ft. l bs.) torque.
(3) I nstal l rear beari ng I . D. retai ni ng ri ng and
spacer on output shaft.
(4) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(5) Sl i de seal onto Seal Protector 6992 (Fi g. 77).
Sl i de seal protector and seal onto output shaft.
(6) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th I nstal l er
C-4076-B and Handl e MD-998323 (Fi g. 78).
(7) I nstal l rear sl i nger wi th I nstal l er 8408.
(8) I nstal l boot on output shaft sl i nger and cri mp
retai ni ng cl amp wi th tool C-4975-A (Fi g. 79).
Fig. 74 Range Lever Installation
1 – RANGE LEVER
2 – WASHER
3 – LOCKNUT
Fig. 75 Output Shaft Yoke Installation
1 – OUTPUT SHAFT YOKE
2 – YOKE NUT
Fig. 76 Yoke Seal Washer Installation
1 – YOKE SEAL WASHER
Fig. 77 Output Shaft Seal and Protector
1 – OUTPUT SHAFT SEAL
2 – SPECIAL TOOL 6992
3 – TRANSFER CASE
21 - 232 NV231 TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
CLEANING AND INSPECTION
NV231 TRANSFER CASE
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and 3M
al l purpose cl eaner. Use compressed ai r to remove
sol vent resi due from oi l feed passages i n the case
hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
MAINSHAFT/SPROCKET/HUB INSPECTION
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket (Fi g. 80). Mi nor ni cks and
scratches can be smoothed wi th an oi l stone. However,
repl ace any part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320–400 gri t emery cl oth but do
not try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 81). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300–400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
Fig. 78 Rear Seal Installation
1 – SPECIAL TOOL C-4076–B
2 – SPECIAL TOOL MD998323
3 – TRANSFER CASE
Fig. 79 Slinger Boot Installation
1 – SPECIAL TOOL C-4975–A
2 – SLINGER
3 – BOOT
4 – CLAMP
TJ NV231 TRANSFER CASE 21 - 233
DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 82). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320–400 gri t emery cl oth.
I nspect the shi ft fork wear pads (Fi g. 83). The
mode fork pads are servi ceabl e and can be repl aced i f
necessary. The range fork pads are not servi ceabl e.
The fork must be repl aced as an assembl y i f the pads
are worn or damaged.
Fig. 80 Mainshaft, Mode Hub, And Drive Sprocket
1 – MODE HUB
2 – DRIVE SPROCKET
3 – MAINSHAFT
4 – MODE HUB RETAINING RING
Fig. 81 Input Gear And Carrier Components
1 – PLANETARY CARRIER
2 – REAR THRUST WASHER
3 – FRONT THRUST WASHER
4 – CARRIER LOCK RING
5 – CARRIER LOCK RETAINING RING
6 – INPUT GEAR
21 - 234 NV231 TRANSFER CASE TJ
CLEANING AND INSPECTION (Continued)
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
I nspect the retai ner components (Fi g. 84). Repl ace
the beari ng i f rough or noi sy. Check the retai ner for
cracks or wear i n the beari ng bore. Cl ean the
retai ner seal i ng surfaces wi th a scraper and 3M al l
purpose cl eaner. Thi s wi l l ensure proper adhesi on of
the seal er duri ng reassembl y.
Repl ace the sl i nger and seal outri ght; do not reuse
ei ther part.
Repl ace any part i f di storted, bent, or broken. Al so
repl ace the boot i f cut or torn. Repl ace the boot band
cl amps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces of the
yoke sl i nger (Fi g. 85). Thi s surface must be cl ean and
smooth to ensure proper seal l i fe. Repl ace the yoke
nut and seal washer as nei ther part shoul d be
reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320–400 gri t emery
to smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 86)
Fig. 82 Shift forks
1 – RANGE FORK
2 – MODE FORK AND RAIL
3 – MODE SPRING
Fig. 83 Shift Fork And Wear Pad Locations
1 – RANGE FORK
2 – MODE FORK
3 – WEAR PADS (SERVICEABLE)
4 – WEAR PADS (NON-SERVICEABLE)
TJ NV231 TRANSFER CASE 21 - 235
CLEANING AND INSPECTION (Continued)
Fig. 84 Rear Retainer Components
1 – REAR RETAINER
2 – REAR BEARING I. D. RETAINING RING
3 – REAR SEAL
4 – BOOT
5 – BAND CLAMPS
6 – REAR SLINGER
7 – REAR BEARING O. D. RETAINING RING
8 – REAR BEARING
Fig. 85 Seal Contact Surface Of Yoke Slinger
1 – FRONT SLINGER (PART OF YOKE)
2 – SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 86 Low Range Annulus Gear
1 – FRONT CASE
2 – LOW RANGE ANNULUS GEAR
21 - 236 NV231 TRANSFER CASE TJ
CLEANING AND INSPECTION (Continued)
FRONT-REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Cl ean the seal i ng surfaces wi th a scraper and
3M al l purpose cl eaner. Thi s wi l l ensure proper
seal er adhesi on at assembl y. Repl ace the i nput
retai ner seal ; do not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai nl ess
steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ADJ USTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shi ft transfer case i nto 4L posi ti on.
(2) Rai se vehi cl e.
(3) Loosen l ock bol t on adjusti ng trunni on (Fi g.
87).
(4) Be sure l i nkage rod sl i des freel y i n trunni on.
Cl ean rod and appl y spray l ube i f necessary.
(5) Veri fy that transfer case range l ever i s ful l y
engaged i n 4L posi ti on.
(6) Ti ghten adjusti ng trunni on l ock bol t.
(7) Lower vehi cl e.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Detent . . . . . . . . . . 16–24 N·m (12–18 ft. l bs.)
Pl ug, Drai n/Fi l l . . . . . . . 20–34 N·m (15–20 ft. l bs.)
Pl ug, Drai n/Fi l l . . . . . . . 40–45 N·m (30–40 ft. l bs.)
Bol t, Extensi on Housi ng . 35–46 N·m (26–34 ft. l bs.)
Bol t, Front Brg. Retai ner . . . . . 21 N·m (16 ft. l bs.)
Bol t, Case Hal f . . . . . . . . 27–34 N·m (20–25 ft. l bs.)
Nut, Front Yoke . . . . 122–176 N·m (90–130 ft. l bs.)
Nut, Range Lever . . . . . . 27–34 N·m (20–25 ft. l bs.)
Bol t, Rear Retai ner . . . . 35–46 N·m (26–34 ft. l bs.)
Nuts, Mounti ng . . . . . . . 29–40 N·m (22–30 ft. l bs.)
Swi tch, I ndi cator . . . . . . 20–34 N·m (15–25 ft. l bs.)
Fig. 87 Shift Linkage
1 – TRANSFER CASE RANGE LEVER SHAFT
2 – SEAL
3 – TRANSFER CASE SHIFT LEVER ASSEMBLY
4 – FLOORPAN
5 – TRUNNION LOCK BOLT
6 – SHIFT ROD
7 – ADJUSTING TRUNNION
8 – TORQUE SHAFT BRACKET
9 – RANGE LEVER
10 – TORQUE SHAFT ROD
11 – TORQUE SHAFT
12 – LINKAGE BRACKET
TJ NV231 TRANSFER CASE 21 - 237
CLEANING AND INSPECTION (Continued)
SPECIAL TOOLS
NV231
Installer—C-4076-B
Puller, Slinger—MD-998056–A
Installer—MD-998323
Seal Protector—6992
Installer, Boot Clamp—C-4975-A
Installer, Seal—8143
Handle, Universal—C-4171
Installer, Seal—C-4210
Installer, Bearing—5064
Installer, Bearing—5065
21 - 238 NV231 TRANSFER CASE TJ
Installer, Bushing—5066
Installer, Bearing—8128
Remover—L-4454
Cup—8148
Installer, Seal—7884
Installer, Pump Housing Seal—7888
TJ NV231 TRANSFER CASE 21 - 239
SPECIAL TOOLS (Continued)
TIRES AND WHEELS
TABLE OF CONTENTS
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . . . . . 2
SPARE TIRE–TEMPORARY . . . . . . . . . . . . . . . . . . 2
TIRE INFLATION PRESSURES . . . . . . . . . . . . . . . 2
TIRE PRESSURE FOR HIGH SPEED. . . . . . . . . . . 3
REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . . . . 3
TREAD WEAR INDICATORS . . . . . . . . . . . . . . . . . 3
TIRE WEAR PATTERNS. . . . . . . . . . . . . . . . . . . . . 3
TIRE NOISE OR VIBRATION . . . . . . . . . . . . . . . . . 4
SERVICE PROCEDURES
ROTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MATCH MOUNTING. . . . . . . . . . . . . . . . . . . . . . . . 4
REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING AND INSPECTION
CLEANING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
TIRE SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION
TIRES
DESCRIPTION
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl e’s requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
• Rapi d accel erati on
• Severe brake appl i cati ons
• Hi gh speed dri vi ng
• Excessi ve speeds on turns
• Stri ki ng curbs and other obstacl es
Radi al -pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val shown i n the secti on on Ti re Rotati on. Thi s wi l l
hel p to achi eve a greater tread l i fe.
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 1).
Performance ti res have a speed rati ng l etter after
the aspect rati o number.
The speed rati ng i s not al ways pri nted on the ti re
si dewal l .
LETTER SPEED RATING
S 180 km/h (112 mph)
T 190 km/h (118 mph)
U 200 km/h (124 mph)
H 210 km/h (130 mph)
V 240 km/h (149 mph)
W 270 km/h (168 mph)
Y 300 km/h (186 mph)
TJ TIRES AND WHEELS 22 - 1
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to the Owner’s Manual for more i nformati on.
RADIAL-PLY TIRES
DESCRIPTION
Radi al -pl y ti res i mprove handl i ng, tread l i fe and
ri de qual i ty, and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of
four. Under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
The use of ti res from di fferent manufactures on the
same vehi cl e i s NOT recommended. The proper ti re
pressure shoul d be mai ntai ned on al l four ti res.
SPARE TIRE–TEMPORARY
DESCRIPTION
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty, then rei nstal l ed.
Do not exceed speeds of 50 M. P. H. when usi ng the
temporary spare ti re. Refer to Owner’s Manual for
compl ete detai l s.
TIRE INFLATION PRESSURES
DESCRIPTION
Under i nfl ati on wi l l cause rapi d shoul der wear, ti re
fl exi ng, and possi bl e ti re fai l ure (Fi g. 2).
Over i nfl ati on wi l l cause rapi d center wear and
l oss of the ti re’s abi l i ty to cushi on shocks (Fi g. 3).
Fig. 1 Tire Identification
Fig. 2 Under Inflation Wear
1 – THIN TIRE TREAD AREAS
Fig. 3 Over Inflation Wear
1 – THIN TIRE TREAD AREA
22 - 2 TIRES AND WHEELS TJ
DESCRIPTION AND OPERATION (Continued)
I mproper i nfl ati on can cause:
• Uneven wear patterns
• Reduced tread l i fe
• Reduced fuel economy
• Unsati sfactory ri de
• Vehi cl e dri ft
For proper ti re pressure speci fi cati on refer to the
Ti re I nfl ati on Pressure Chart provi ded wi th the vehi -
cl es Owners Manual . A Certi fi cati on Label on the
dri vers si de door pi l l ar provi des the mi ni mum ti re
and ri m si ze for the vehi cl e. The l abel al so l i st the
col d i nfl ati on pressure for these ti res at ful l l oad
operati on
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once a month. Ti re
pressure decreases as the ambi ent temperature
drops. Check ti re pressure frequentl y when ambi ent
temperature vari es wi del y.
Ti re i nfl ati on pressures are col d i nfl ati on pressure.
The vehi cl e must si t for at l east 3 hours to obtai n the
correct col d i nfl ati on pressure readi ng. Or be dri ven
l ess than one mi l e after si tti ng for 3 hours. Ti re
i nfl ati on pressures may i ncrease from 2 to 6 pounds
per square i nch (psi ) duri ng operati on. Do not reduce
thi s normal pressure bui l d-up.
WARNING: OVER OR UNDER INFLATED TIRES
CAN AFFECT VEHICLE HANDLING AND TREAD
WEAR. THIS MAY CAUSE THE TIRE TO FAIL SUD-
DENLY, RESULTING IN LOSS OF VEHICLE CON-
TROL.
TIRE PRESSURE FOR HIGH SPEED
DESCRIPTION
Where speed l i mi ts al l ow the vehi cl e to be dri ven
at hi gh speeds, correct ti re i nfl ati on pressure i s very
i mportant. For speeds up to and i ncl udi ng 120 km/h
(75 mph), ti res must be i nfl ated to the pressures
shown on the ti re pl acard. For conti nuous speeds i n
excess of 120 km/h (75 mph), ti res must be i nfl ated
to the maxi mum pressure speci fi ed on the ti re si de-
wal l .
Vehi cl es l oaded to the maxi mum capaci ty shoul d
not be dri ven at conti nuous speeds above 75 mph
(120 km/h).
For emergency vehi cl es that are dri ven at speeds
over 90 mph (144 km/h), speci al hi gh speed ti res
must be used. Consul t ti re manufacturer for correct
i nfl ati on pressure recommendati ons.
REPLACEMENT TIRES
DESCRIPTION
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
• Ri de
• Noi se
• Handl i ng
• Durabi l i ty
• Tread l i fe
• Tracti on
• Rol l i ng resi stance
• Speed capabi l i ty
I t i s recommended that ti res equi val ent to the ori g-
i nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res may cause i nterference
wi th vehi cl e components. Under extremes of suspen-
si on and steeri ng travel , i nterference wi th vehi cl e
components may cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DIAGNOSIS AND TESTING
PRESSURE GAUGES
A qual i ty ai r pressure gauge i s recommended to
check ti re pressure. After checki ng the ai r pressure,
repl ace val ve cap fi nger ti ght.
TREAD WEAR INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 4).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
TIRE WEAR PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 5).
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 5).
TJ TIRES AND WHEELS 22 - 3
DESCRIPTION AND OPERATION (Continued)
TIRE NOISE OR VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on and
decel erati on. The engi ne, di fferenti al and exhaust
noi ses wi l l change as speed vari es, whi l e the ti re
noi se wi l l usual l y remai n constant.
SERVICE PROCEDURES
ROTATION
Ti res on the front and rear operate at di fferent
l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons they wear at
unequal rates and tend to devel op i rregul ar wear
patterns. These effects can be reduced by rotati ng
the ti res at regul ar i nterval s. The benefi ts of ti re
rotati on are:
• I ncrease tread l i fe
• Mai ntai n tracti on l evel s
• A smooth, qui et ri de
The suggested method of ti re rotati on i s (Fi g. 6).
Other rotati on methods can be used, but they wi l l
not provi de al l the ti re l ongevi ty benefi ts.
MATCH MOUNTING
Ti res and wheel s are currentl y match mounted at
the factory. Match mounti ng i s a techni que used to
reduce runout i n the wheel /ti re assembl y. Thi s means
that the hi gh spot of the ti re i s al i gned wi th the l ow
spot on the wheel ri m. The hi gh spot on the ti re i s
marked wi th a pai nt mark or a bri ght col ored adhe-
si ve l abel on the outboard si dewal l . The l ow spot on
the ri m i s i denti fi ed wi th a l abel on the outsi de of the
ri m and a dot on the i nsi de of the ri m. I f the outsi de
l abel has been removed the ti re wi l l have to be
removed to l ocate the dot on the i nsi de of the ri m.
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
Fig. 4 Tread Wear Indicators
1 – TREAD ACCEPTABLE
2 – TREAD UNACCEPTABLE
3 – WEAR INDICATOR
Fig. 5 Tire Wear Patterns
22 - 4 TIRES AND WHEELS TJ
DIAGNOSIS AND TESTING (Continued)
(1) Use a di al i ndi cator to l ocate the hi gh spot of
the ti re on the center tread ri b (Fi g. 7). Record the
i ndi cator readi ng and mark the hi gh spot on the ti re.
Pl ace a mark on the ti re at the val ve stem l ocati on
(Fi g. 8).
(2) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 9).
(3) Measure the total runout agai n and mark the
ti re to i ndi cate the hi gh spot.
(4) I f runout i s sti l l excessi ve use the fol l owi ng
procedures.
(a) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot and i s sti l l excessi ve, repl ace the
ti re.
(b) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot on the wheel , the wheel may be out
of speci fi cati ons. Refer to Wheel and Ti re Runout.
(c) I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 10). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount.
Fig. 6 Tire Rotation Pattern
Fig. 7 Dial Indicator
Fig. 8 First Measurement On Tire
1 – REFERENCE MARK
2 – 1ST MEASUREMENT HIGH SPOT MARK TIRE AND RIM
3 – WHEEL
4 – VALVE STEM
Fig. 9 Remount Tire 180 Degrees
1 – VALVE STEM
2 – REFERENCE MARK
TJ TIRES AND WHEELS 22 - 5
SERVICE PROCEDURES (Continued)
REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 11). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Defl ate ti re compl etel y before removi ng the ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
torque speci fi cati on.
CLEANING AND INSPECTION
CLEANING TIRES
Remove the protecti ve coati ng on the ti res before
del i very of a vehi cl e. Thi s coati ng may cause deteri -
orati on of the ti res.
To remove the protecti ve coati ng, appl y warm
water and l et i t soak for a few mi nutes. Afterwards,
scrub the coati ng away wi th a soft bri stl e brush.
Steam cl eani ng may al so be used to remove the coat-
i ng.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or a wire brush for cleaning.
SPECIFICATIONS
TIRE SIZE
Fig. 10 Remount Tire 90 Degrees In Direction of
Arrow
1 – 2ND HIGH SPOT ON TIRE
2 – 1ST HIGH SPOT ON TIRE
Fig. 11 Tire Repair Area
1 – REPAIRABLE AREA
TIRE SIZE SUPPLIER
P205/75R15 Goodyear
P215/75R15 Goodyear
P225/75R15 Goodyear
P225/70R16 Michelin
30x9.50R15 Goodyear
22 - 6 TIRES AND WHEELS TJ
SERVICE PROCEDURES (Continued)
WHEELS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING
WHEEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . 7
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 9
TIRE AND WHEEL BALANCE. . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION AND OPERATION
WHEEL
DESCRIPTION
The ri m si ze i s on the vehi cl e safety certi fi cati on
l abel l ocated on the dri vers door shut face. The si ze
of the ri m i s determi ned by the dri vetrai n package.
Ori gi nal equi pment wheel s/ri ms are desi gned for
operati on up to the speci fi ed maxi mum vehi cl e capac-
i ty.
Al l model s use stamped steel , cast al umi num or
forged al umi num wheel s. Every wheel has rai sed sec-
ti ons between the ri m fl anges and ri m drop wel l
cal l ed safety humps (Fi g. 1).
I ni ti al i nfl ati on of the ti re forces the bead over
these rai sed secti ons. I n case of rapi d l oss of ai r pres-
sure, the rai sed secti ons hel p hol d the ti re on the
wheel .
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. Al l al umi num and some steel wheel s
have wheel stud nuts wi th an enl arged nose. Thi s
enl arged nose i s necessary to ensure proper retenti on
of the wheel s. Do not use repl acement studs or nuts
wi th a di fferent desi gn or l esser qual i ty.
DIAGNOSIS AND TESTING
WHEEL INSPECTION
I nspect wheel s for:
• Excessi ve run out
• Dents or cracks
• Damaged wheel l ug nut hol es
• Ai r Leaks from any area or surface of the ri m
NOTE: Do not attempt to repair a wheel by ham-
mering, heating or welding.
I f a wheel i s damaged an ori gi nal equi pment
repl acement wheel shoul d be used. When obtai ni ng
repl acement wheel s, they shoul d be equi val ent i n
l oad carryi ng capaci ty. The di ameter, wi dth, offset,
pi l ot hol e and bol t ci rcl e of the wheel shoul d be the
same as the ori gi nal wheel .
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY AFFECT
THE SAFETY AND HANDLING OF THE VEHICLE.
USED WHEELS ARE NOT RECOMMENDED. THE
SERVICE HISTORY OF THE WHEEL MAY HAVE
INCLUDED SEVERE TREATMENT OR VERY HIGH
MILEAGE. THE RIM COULD FAIL WITHOUT WARN-
ING.
TIRE AND WHEEL RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 2).
Lateral runout i s the wobble of the ti re or wheel .
Fig. 1 Safety Rim
1 – FLANGE
2 – RIDGE
3 – WELL
TJ TIRES AND WHEELS 22 - 7
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Dri ve vehi cl e a short di stance to el i mi nate ti re
fl at spotti ng from a parked posi ti on.
(2) Check wheel beari ngs and adjust i f adjustabl e
or repl ace i f necessary.
(3) Check the wheel mounti ng surface.
(4) Rel ocate wheel on the mounti ng, two studs
over from the ori gi nal posi ti on.
(5) Ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
(6) Check radi al runout. I f sti l l excessi ve, mark
ti re si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly effec-
tive when there is runout in both tire and wheel.
(1) Remove ti re from wheel and mount wheel on
servi ce dynami c bal ance machi ne.
(2) Check wheel radi al runout (Fi g. 3) and l ateral
runout (Fi g. 4).
• STEEL WHEELS: Radi al runout 0.040 i n., Lat-
eral runout 0.045 i n. (maxi mum)
• ALUMI NUM WHEELS: Radi al runout 0.030 i n.,
Lateral runout 0.035 i n. (maxi mum)
(3) I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout, Refer to match mounti ng procedure.
Fig. 2 Checking Tire/Wheel/Hub Runout
1 – RADIAL RUNOUT
2 – LATERAL RUNOUT
Fig. 3 Radial Runout
1 – MOUNTING CONE
2 – SPINDLE SHAFT
3 – WING NUT
4 – PLASTIC CUP
5 – DIAL INDICATOR
6 – WHEEL
7 – DIAL INDICATOR
Fig. 4 Lateral Runout
1 – MOUNTING CONE
2 – SPINDLE SHAFT
3 – WING NUT
4 – PLASTIC CUP
5 – DIAL INDICATOR
6 – WHEEL
7 – DIAL INDICATOR
22 - 8 TIRES AND WHEELS TJ
DIAGNOSIS AND TESTING (Continued)
SERVICE PROCEDURES
WHEEL INSTALLATION
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on (Fi g. 5).
WARNING: NEVER USE OIL OR GREASE ON
STUDS OR NUTS. INSTALLING WHEELS WITHOUT
GOOD METAL-TO-METAL CONTACT OR USING
CHROME PLATED LUG NUTS WITH CHROME
PLATED WHEELS COULD CAUSE LOOSENING OF
WHEEL NUTS. THIS COULD AFFECT THE SAFETY
AND HANDLING OF THE VEHICLE.
WHEEL REPLACEMENT
Wheel s must be repl aced i f they have:
• Excessi ve runout
• Bent or dented
• Leak ai r through wel ds
• Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
• Load carryi ng capaci ty
• Di ameter
• Wi dth
• Offset
• Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
TIRE AND WHEEL BALANCE
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two
plane balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
Off-vehi cl e bal anci ng i s recommended.
For stati c bal anci ng, fi nd l ocati on of heavy spot
causi ng the i mbal ance. Counter bal ance wheel
di rectl y opposi te the heavy spot. Determi ne wei ght
requi red to counter bal ance the area of i mbal ance.
Pl ace hal f of thi s wei ght on the inner ri m fl ange and
the other hal f on the outer ri m fl ange (Fi g. 6).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to l ocate the amount of wei ght to be appl i ed
to both the i nner and outer ri m fl ange (Fi g. 7).
Fig. 5 Lug Nut Tightening Pattern
TJ TIRES AND WHEELS 22 - 9
Fig. 6 Static Unbalance & Balance
1 – HEAVY SPOT
2 – CENTER LINE OF SPINDLE
3 – ADD BALANCE WEIGHTS HERE
4 – CORRECTIVE WEIGHT LOCATION
5 – TIRE OR WHEEL TRAMP, OR WHEEL HOP
Fig. 7 Dynamic Unbalance & Balance
1 – CENTER LINE OF SPINDLE
2 – ADD BALANCE WEIGHTS HERE
3 – CORRECTIVE WEIGHT LOCATION
4 – HEAVY SPOT WHEEL SHIMMY AND VIBRATION
22 - 10 TIRES AND WHEELS TJ
SERVICE PROCEDURES (Continued)
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Lug Nut
1/2 X 20 wi th 60° Cone . . . . . . . . 115 to 156 N·m
(85 to 115 ft. l bs.)
TJ TIRES AND WHEELS 22 - 11
BODY
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . 1
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STATIONARY GLASS. . . . . . . . . . . . . . . . . . . . . . . . 6
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BODY COMPONENT SERVICE . . . . . . . . . . . . . . . 14
DESCRIPTION AND OPERATION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 1
SERVICE PROCEDURES
SAFETY PRECAUTIONS AND WARNINGS . . . . . . 2
DESCRIPTION AND OPERATION
BODY COMPONENTS
PAINT
DESCRIPTION
The ori gi nal equi pment fi ni sh i s a mul ti -step pro-
cess that i nvol ves cl eani ng, el ectrodeposti on (e-coat),
base coat, and cl ear coat steps. Addi ti onal l y, sel ected
areas of the vehi cl e may be coated wi th an anti -chi p
fi ni sh.
OPERATION
On most vehi cl es a two-stage pai nt appl i cati on
(base coat/cl ear coat) i s used. Col or that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
STATIONARY GLASS
DESCRIPTION
Wi ndshi el d gl ass i s a structural member of the
vehi cl e. The wi ndshi el d gl ass i s bonded to the wi nd-
shi el d frame wi th urethane adhesi ve.
OPERATION
Wi ndshi el ds are made of two pi eces of gl ass wi th a
pl asti c i nner l ayer. Wi ndshi el ds and other stati onary
gl ass protect the occupants from the effects of the
el ements. Wi ndshi el ds are al so used to retai n some
ai rbags i n posi ti on duri ng depl oyment. Urethane
bonded gl ass i s di ffi cul t to sal vage duri ng removal .
The urethane bondi ng i s di ffi cul t to cut or cl ean from
any surface. Before removi ng the gl ass, check the
avai l abi l i ty of repl acement components.
SEATS
DESCRIPTION
Seat modul es are made up of a seat frame, seat
cushi on, seat back cushi on, a coveri ng materi al , and
the el ectri cal components used for power operati on.
Some seat systems al so contai n seat bel t components
and suppl emental restrai nt systems.
OPERATION
Seat assembl i es transport the occupants i n comfort
and safety. Seat assembl i es al so hel p posi ti on occu-
pants correctl y i n the event of ai rbag depl oyment.
Seat cushi ons, coveri ngs, and el ectri cal components
are servi ceabl e. Refer to the appropri ate group i n
thi s manual .
EXTERIOR COMPONENTS
DESCRIPTION
Exteri or sheet metal components make up the
exteri or of the vehi cl e. The Wrangl er uses ei ther a
soft (fabri c) top, or a hard (composi te) top. Some exte-
ri or tri m i tems are made of composi te.
TJ BODY 23 - 1
OPERATION
The exteri or sheet metal i s repai rabl e and adjust-
abl e for fi t and fi ni sh. The composi te hard top i s
repai rabl e or repl aceabl e. Tri m components made of
composi te are stamped wi th the type of materi al
used. Dai ml erChrysl er uses vari ous fasteners to
retai n tri m i tems. At ti mes, i t i s not possi bl e to
remove tri m i tems wi thout damagi ng the fastener. I f
i t i s not possi bl e to remove an i tem wi thout damag-
i ng a component, cut or break the fasteners and use
new ones when i nstal l i ng the component.
SERVICE PROCEDURES
SAFETY PRECAUTIONS AND WARNINGS
DESCRIPTION
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL – BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
Dai ml erChrysl er Corporati on uses many di fferent
types of push-i n fasteners to secure the i nteri or and
exteri or tri m to the body. Most of these fasteners can
be reused to assembl e the tri m duri ng vari ous repai r
procedures. At ti mes, a push-i n fastener cannot be
removed wi thout damagi ng the fastener or the com-
ponent i t i s hol di ng. I f i t i s not possi bl e to remove a
fastener wi thout damagi ng a component or body, cut
or break the fastener and use a new one when
i nstal l i ng the component. Never pry or pound on a
pl asti c or pressed-board tri m component. Usi ng a
sui tabl e fork-type pryi ng devi ce, pry the fastener
from the retai ni ng hol e behi nd the component bei ng
removed. When i nstal l i ng, veri fy fastener al i gnment
wi th the retai ni ng hol e by hand. Push di rectl y on or
over the fastener unti l i t seats. Appl y a l ow-force pul l
to the panel to veri fy that i t i s secure.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges hol di ng the component i n
pl ace.
23 - 2 BODY TJ
DESCRIPTION AND OPERATION (Continued)
PAINT
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BASE COAT/CLEAR COAT FINISH. . . . . . . . . . . . . 3
FINESSE SANDING, BUFFING, AND
POLISHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . . 3
AFTERMARKET PAINT REPAIR PRODUCTS . . . . . 4
HARD TOP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
PAINT CODE
The pai nt code i s i denti fi ed on the Vehi cl e Safety
Certi fi cati on Label , whi ch i s l ocated on the dri ver’s
door shut face The col or names, provi ded i n the Pai nt
and Tri m Code Descri pti on chart, are the col or
names used on most repai r product contai ners.
BASE COAT/CLEAR COAT FINISH
On most vehi cl es a two-stage pai nt appl i cati on
(base coat/cl ear coat) i s used. Col or that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
FINESSE SANDING, BUFFING, AND
POLISHING
Mi nor aci d etchi ng, orange peel , or surface
scratches i n cl ear coat or si ngl e-stage fi ni shes can be
reduced wi th l i ght fi nesse sandi ng, buffi ng, and pol -
i shi ng. If the finish has been finesse sanded in
the past, it cannot be repeated. Finesse sanding
operation should be performed by a trained
automotive paint technician.
CAUTION: Do not remove clear coat finish more
than.5 mils, if equipped (Use a paint thickness
gauge to verify paint thickness). Base coat paint
must retain clear coat for durability.
PAINTED SURFACE TOUCH-UP
DESCRIPTION
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar௡
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. Refer to I ntroducti on group of thi s manual for
Body Code Pl ate i nformati on.
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
OPERATION
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar௡ Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the defect wi thout runni ng. Do
not stroke brush appl i cator on body surface. Al l ow
the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up
col or can be l i ghtl y fi nesse sanded (1500 gri t) and
pol i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, appl y cl ear top coat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL – BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
TJ BODY 23 - 3
AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLOR
EXTERIOR
COLOR
DAIMLER
CHRYSLER
CODE
PPG DuPONT
S-W**
M-S**
AKZO
NOBEL
SIKKENS
SPIES
HECKER
ICI**
Flame Red
Clear Coat
PR4 4679 B9326 46916 CHA93:PR4 30116 RNN6B
Chili Pepper
Red
VEA 5361 B9823 54470 CHA98:VEA 33688 HMT3B
Medium Fern
Pearl Coat
RJP 4969 B9524 50270 CHA99:RJP 61088 7CD6B
Deep
Amethyst
Pearl Coat
TCN 5246 B9736 52566 CHA97:TCN 54755 FNE4B
Forest Green
Pearl Coat
SG8 5065 B9609 51062 CHA95:SG8 61633 7MR8B
Desert Sand WTD 5474 B9884 56153 CHA99:WTD 81764 KGC7B
Intense Blue
Pearl Coat
VB3 5357 B9822 54468 CHA98:VB3 55321 HMR9B
Gun Metal
Pearl Coat
TQ7 5248 B9735 52952 CHA97:TQ7 73320 ERA9B
Black Clear
Coat
DX8 9700 99
34858
90-5950
CHA85:DX8 73328 TC60B
Stone White
Clear Coat
SW1 83542 B9622 51539 CHA96:SW1 15069 8KY5B
HARD TOP
HARD TOP
DAIMLER
CHRYSLER
CODE*
PPG DuPONT
S-W**
M-S**
AKZO
NOBEL
SIKKENS
SPIES
HECKER
ICI**
Spice LTB 27315 C9523 46487 CHA90:LTB FPP6
Carmel VK9 28589 C9846 58115 CHAVK9M NVM9
Black BX7 9418 44219 58115 CHABX7M NVN1
Stone White SW1 5072 C9622 52779
CHASWM1 NNV6
INTERIOR COLOR
INTERIOR
COLOR
DAIMLER
CHRYSLER
CODE*
PPG DuPONT
S-W**
M-S**
AKZO
NOBEL
SIKKENS
SPIES
HECKER
ICI**
Agate AZ 9856 / 2-1461 C9208 45994 CHALAZI 75016 7WC8
Camel K5 27731 / 2-1584 C9603 51541 CHARJ5I 81796 7VX6
Camel /
Dark Green
KG N/A N/A N/A
N/A N/A K5/G8
23 - 4 BODY TJ
SERVICE PROCEDURES (Continued)
NOTE: *Herberts Standox and BASF use the
Chrysler paint code as listed on the Body Code
Plate and the Vehicle Safety Certification label. **
S-W = Sherwin-Williams, M-S = Martin Senour, ICI =
ICI Autocolor.
HARD TOP REPAIR
The hard top fi bergl ass materi al can be repai red.
The requi red repai r materi al s i ncl ude:
• Fi bergl ass mat or cl oth.
• Fi bergl ass resi n and hardener.
• structural adhesi ve (3M brand or an equi val ent
product).
• Gl azi ng putty.
• Pl asti c spreader.
HARD TOP HOLE REPAIR
(1) Use a gri nder to remove the pai nt and outl i ne
the damaged area. Use a grade 36 gri t di sc for pai nt
removal .
(2) Gri nd the outl i ned surface area agai n wi th a
50 gri t di sc to prevent coarse scratches from appear-
i ng i n the fi nal fi ni sh.
(3) I f cracks extend from the hol e, i t wi l l be neces-
sary to stop-dri l l the crack(s) wi th a 3-mm (1/8-i n)
di ameter dri l l bi t.
(4) Posi ti on a fi bergl ass mat or cl oth on the repai r
surface area. Cut the mat to al l ow a 2.5-cm (1-i n)
overl ap of the repai r surface area.
(5) Cl ean the repai r surface area.
(6) Pl ace the fi bergl ass cl oth on al umi num foi l .
(7) Pour the fi bergl ass resi n i nto a cl ean contai ner.
(8) Mi x the appropri ate amount of hardener and
resi n. Fol l ow the manufacturers i nstructi ons.
(9) Appl y the hardener/resi n mi xture to both si des
of the fi bergl ass cl oth.
(10) Pl ace the fi bergl ass cl oth over the repai r sur-
face area. Next, pl ace the al umi num foi l over the
cl oth. Use a pl asti c spreader to smooth-out the cl oth
and resi n. Use fi rm pressure to remove ai r bubbl es
and to smooth-out the cl oth.
(11) Al l ow the resi n to cure.
(12) Smooth-out the surface area to the contour of
the hard top wi th a 50-gri t di sc.
(13) Appl y pl asti c fi l l er to compl ete the repai r. Fi n-
i sh smoothi ng the surface area wi th 80-gri t paper.
(14) Repeat the previ ous step on the i nsi de surface
area of the hard top.
(15) Featheredge the repai red surface area.
(16) Pri me the repai red surface area wi th PPG
Epoxy Pri mer, or an equi val ent product.
(17) Appl y surface pri mer to the surface area.
(18) Pri me the surface area for the col or coat.
(19) Appl y col or coat to the repai red surface area.
FRACTURE REPAIR
(1) Use a gri nder to remove the pai nt (from both,
the i nner and outer surface areas of the hard top)
and to outl i ne the damaged area.
(2) Stop-dri l l the crack(s) wi th a 3-mm (1/8-i n)
di ameter dri l l bi t.
(3) Bevel the edges of the crack(s) on both si des
wi th a rotary fi l e.
NOTE: The edges should be beveled on the inside
and outside of the top to ensure sufficient surface
area for good bonding.
(4) Compl ete the repai rs wi th fi bergl ass cl oth and
resi n as descri bed above i n the hard top hol e repai r
procedure.
TJ BODY 23 - 5
SERVICE PROCEDURES (Continued)
STATIONARY GLASS
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
WINDSHIELD SAFETY PRECAUTIONS . . . . . . . . . 6
REMOVAL AND INSTALLATION
WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
QUARTER GLASS . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE PROCEDURES
WINDSHIELD SAFETY PRECAUTIONS
DESCRIPTION
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER’S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
OPERATION
The wi ndshi el d i s attached to the wi ndow frame
wi th urethane adhesi ve. The urethane adhesi ve i s
appl i ed col d and seal s the surface area between the
wi ndow openi ng and the gl ass. The pri mer adheres
the urethane adhesi ve to the wi ndshi el d.
I t i s di ffi cul t to sal vage a wi ndshi el d duri ng the
removal operati on. The wi ndshi el d i s part of the
structural support for the roof. The urethane bondi ng
used to secure the wi ndshi el d to the fence i s di ffi cul t
to cut or cl ean from any surface. I f the mol di ngs are
set i n urethane, i t woul d al so be unl i kel y they coul d
be sal vaged. Before removi ng the wi ndshi el d, check
the avai l abi l i ty of the wi ndshi el d and mol di ngs from
the parts suppl i er.
REMOVAL AND INSTALLATION
WINDSHIELD
The wi ndshi el d i s posi ti oned i n the reveal mol di ng
and i s bonded to the wi ndshi el d frame wi th urethane
adhesi ve. The wi ndshi el d i nteri or tri m mol di ng i s
posi ti oned onto the i nner wi ndshi el d frame pi nch-
wel d.
REMOVAL
(1) Cover body surface areas wi th protecti ve cover-
i ng to avoi d pai nt damage and extra cl ean-up ti me.
(2) Remove the wi ndshi el d wi per arms and the
rearvi ew mi rror.
(3) Usi ng a razor kni fe, sl i de the bl ade between
the wi ndshi el d gl ass and the i nboard edge of the
reveal mol di ng.
(4) Cut around the i nteri or peri meter of the reveal
mol di ng and sever the cap of the reveal mol di ng.
23 - 6 BODY TJ
(5) Usi ng a col d kni fe, cut the urethane around the
peri meter of the wi ndshi el d (Fi g. 1).
(6) Remove the wi ndshi el d gl ass from the frame
(Fi g. 2).
INSTALLATION
(1) Tri m the urethane from the pi nchwel d fl anges.
Leave a 3 mm (0.1 i n.) l evel base of urethane on the
pi nchwel d fl anges.
(2) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng and posi ti on gl ass i n the center of the open-
i ng agai nst pi nchwel d fl ange.
(3) Veri fy the gl ass l ays evenl y agai nst the pi nch
wel d fence at the si des, top and bottom of the
repl acement wi ndshi el d. I f not, the pi nchwel d fl ange
must be formed to the shape of the new gl ass. Next,
make al i gnment marks on gl ass and body wi th a
grease penci l .
(4) Remove repl acement wi ndshi el d from wi nd-
shi el d openi ng.
(5) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 3).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Cl ean i nsi de of wi ndshi el d wi th ammoni a based
gl ass cl eaner and l i nt-free cl oth.
(7) Appl y mol di ng to peri meter of wi ndshi el d. The
butt wel d of the mol di ng shoul d be centered at the
bottom edge of the wi ndshi el d.
(8) Appl y Gl ass Prep adhesi on promoter 25 mm (1
i n.) wi de around peri meter of wi ndshi el d and wi pe
wi th cl ean/dry l i nt-free cl oth unti l no streaks are vi s-
i bl e.
(9) Appl y Gl ass Pri mer 25 mm (1 i n.) wi de around
peri meter of wi ndshi el d. Al l ow at l east three mi nutes
dryi ng ti me.
(10) Appl y Pi nchwel d pri mer 15 mm (.75 i n.) wi de
around the wi ndshi el d fence. Al l ow at l east three
mi nutes dryi ng ti me.
(11) Appl y a urethane bead (Fi g. 4) on the pi nch-
wel d fl ange surface area 6 mm (.25 i n.) from the out-
board edge.
CAUTION: Be prepared to install the windshield
glass immediately after applying the adhesive. The
adhesive begins to cure within 10-15 minutes.
(12) Al i gn the wi ndshi el d wi th the grease penci l
marks and posi ti on wi ndshi el d on pi nchwel d fl anges.
(13) Push the wi ndshi el d gl ass i nward unti l the
reveal mol di ng i s seated on the wi ndshi el d frame.
Use care to avoi d excessi ve squeeze-out of adhesi ve.
(14) Open wi ndows and l i ftgate to prevent pres-
sure bui l d-up whi l e the urethane i s curi ng.
(15) Starti ng i n each corner, appl y 150 mm (6 i n.)
l engths of 50 mm (2 i n.) maski ng tape spaced 250
mm (10 i n.) apart to hol d wi ndshi el d i n pl ace unti l
urethane cures.
(16) I nstal l the rearvi ew mi rror on the mi rror but-
ton.
(17) I nstal l the wi per arms.
(18) After urethane has cured, remove tape stri ps
and water test wi ndshi el d to veri fy repai r.
Fig. 1 Cutting Urethane Around Windshield—Typical
1 – WINDSHIELD
2 – COLD KNIFE
Fig. 2 Windshield
1 – WINDSHIELD
2 – INNER TRIM MOLDING
3 – WINDSHIELD FRAME
4 – WINDSHIELD MOLDING
TJ BODY 23 - 7
REMOVAL AND INSTALLATION (Continued)
QUARTER GLASS
REMOVAL
(1) Cover surface areas wi th protecti ve coveri ng to
avoi d pai nt damage and extra cl ean-up ti me.
(2) Usi ng a razor kni fe, sl i de the bl ade between
the quarter gl ass and the i nboard edge of the reveal
mol di ng.
(3) Cut around the i nteri or peri meter of the reveal
mol di ng and sever the cap of the reveal mol di ng.
(4) Usi ng a col d kni fe, cut the urethane around the
peri meter of the quarter gl ass.
(5) Remove the quarter gl ass from the openi ng
(Fi g. 5).
INSTALLATION
(1) Tri m the urethane from the quarter gl ass open-
i ng fence. Leave a 3 mm (0.1 i n.) l evel base of ure-
thane on the quarter gl ass openi ng fence.
(2) Pl ace repl acement quarter gl ass i nto quarter
gl ass openi ng and posi ti on gl ass i n the center of the
openi ng agai nst fence.
(3) Veri fy the gl ass l ays evenl y agai nst the fence at
the si des, top and bottom of the repl acement quarter
gl ass. Next, make al i gnment marks on gl ass and top
wi th a grease penci l .
(4) Remove repl acement quarter gl ass from open-
i ng.
(5) Posi ti on the quarter gl ass i nsi de up on a sui t-
abl e work surface.
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN QUARTER GLASS BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Cl ean i nsi de of quarter gl ass wi th ammoni a
based gl ass cl eaner and l i nt-free cl oth.
(7) Cl ean the outer edge of the wi ndow gl ass wi th
naphtha or a si mi l ar product.
(8) Appl y mol di ng to peri meter of quarter gl ass.
The butt wel d of the mol di ng shoul d be centered at
the bottom edge of the quarter gl ass.
(9) Appl y Gl ass Prep adhesi on promoter 25 mm (1
i n.) wi de around peri meter of the quarter gl ass and
wi pe wi th cl ean/dry l i nt-free cl oth unti l no streaks
are vi si bl e.
(10) Appl y Gl ass Pri mer 25 mm (1 i n.) wi de
around peri meter of quarter gl ass. Al l ow at l east
three mi nutes dryi ng ti me.
Fig. 3 Work Surface Set up and Molding Installation
1 – WINDSHIELD AND MOLDINGS
2 – BLOCKS
Fig. 4 Urethane Bead
1 – WINDSHIELD
2 – MOLDING
3 – URETHANE BEAD
Fig. 5 Hard Top Quarter Glass
1 – HARD TOP
2 – QUARTER GLASS REVEAL MOLDING
3 – QUARTER GLASS
23 - 8 BODY TJ
REMOVAL AND INSTALLATION (Continued)
(11) Appl y Pi nchwel d pri mer 15 mm (.75 i n.) wi de
around the quarter gl ass fence. Al l ow at l east three
mi nutes dryi ng ti me.
(12) Appl y a 10 mm (0.4 i n.) di ameter bead of ure-
thane to the center of the quarter gl ass fence surface
area.
CAUTION: Be prepared to install the quarter glass
immediately after applying the adhesive. The adhe-
sive begins to cure within 10-15 minutes.
(13) Al i gn the quarter gl ass wi th the grease penci l
marks and posi ti on quarter gl ass on fence.
(14) Push the quarter gl ass i nward unti l the
reveal mol di ng i s seated on the hardtop. Use care to
avoi d excessi ve squeeze-out of adhesi ve.
(15) Open wi ndows and l i ftgate to prevent pres-
sure bui l d-up whi l e the urethane i s curi ng.
(16) Appl y 150 mm (6 i n.) l engths of 50 mm (2 i n.)
maski ng tape spaced 250 mm (10 i n.) apart to hol d
quarter gl ass i n pl ace unti l urethane cures.
(17) After urethane has cured, remove tape stri ps
and water test quarter gl ass to veri fy repai r.
TJ BODY 23 - 9
REMOVAL AND INSTALLATION (Continued)
SEATS
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . . . . 10
BUCKET SEATBACK COVER. . . . . . . . . . . . . . . . 11
RECLINER RELEASE CABLE. . . . . . . . . . . . . . . . 11
BUCKET SEAT CUSHION COVER . . . . . . . . . . . . 11
REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . . . 12
REAR SEATBACK COVER. . . . . . . . . . . . . . . . . . 12
REAR SEAT CUSHION COVER . . . . . . . . . . . . . . 13
REMOVAL AND INSTALLATION
BUCKET SEATBACK
REMOVAL
(1) Remove seat.
(2) Remove the i nboard seatback pi vot bol t.
(3) Di sengage the retai ners attachi ng the cushi on
cover to the outboard seat cushi on frame (Fi g. 1).
(4) Di sengage the seat cushi on corner cover zi pper.
(5) Remove the bol ts attachi ng the recl i ner to the
seat cushi on frame (Fi g. 2).
(6) Passenger seat and dri ver dumpi ng seat:
(a) Di sengage seat track rel ease cabl e from back
i nboard U-nut (Fi g. 2).
(7) Route the recl i ner handl e through the seat
cushi on cover and separate the seatback from the
seat cushi on.
INSTALLATION
(1) Posi ti on the seatback on the seat cushi on whi l e
routi ng the recl i ner handl e through the cushi on cover
openi ng.
(2) Passenger seat and dri ver dumpi ng seat:
(a) Engage seat track rel ease cabl e to back
i nboard U-nut
(3) I nstal l the bol ts attachi ng the recl i ner to the
seat cushi on frame.
(4) Engage the seat cushi on corner cover zi pper.
Fig. 1 Cushion Cover Retainers
1 – CUSHION COVER
2 – RECLINER HANDLE
3 – RETAINER
Fig. 2 Passenger Seat
1 – RECLINER
2 – KNOB
3 – RECLINER RELEASE CABLE
4 – SEAT BACK FRAME
5 – EDGE PROTECTOR
6 – RECLINER SHIELD
7 – SEAT CUSHION FRAME
8 – U-NUT
9 – SPRING
10 – BUCKLE
23 - 10 BODY TJ
(5) Engage the retai ners attachi ng the cushi on
cover to the outboard seat cushi on frame.
(6) I nstal l the i nboard seatback pi vot bol t.
(7) I nstal l seat.
BUCKET SEATBACK COVER
REMOVAL
(1) Remove seat.
(2) Remove seatback.
(3) Di sengage zi pper at seatback base.
(4) Rol l cover upward and over ti l t rel ease l ever.
(5) Conti nue to rol l cover upward and di sengage
hook and l oop fastener (Fi g. 3).
(6) Passenger seat and dri ver dumpi ng seat:
(a) Route recl i ner rel ease cabl e/strap through
cover.
(7) Separate cover from seatback.
INSTALLATION
(1) Posi ti on cover on seatback.
(2) Passenger seat and dri ver dumpi ng seat:
(a) Route recl i ner rel ease cabl e/strap through
cover.
(3) Rol l cover downward and engage hook and l oop
fastener.
(4) Engage zi pper at seatback base.
(5) I nstal l seatback.
(6) I nstal l seat.
RECLINER RELEASE CABLE
REMOVAL
(1) Remove seat.
(2) Di sengage seat track rel ease cabl e from bottom
of cushi on and pi vot bracket.
(3) Remove seat back.
(4) Remove seat back cover.
(5) Di sengage cabl e from recl i ner rel ease.
(6) Route cabl e through seat back pad.
(7) Di sengage cabl e from mounti ng bracket.
INSTALLATION
(1) Engage cabl e to mounti ng bracket.
(2) Route cabl e through seat back pad.
(3) Engage cabl e to recl i ner rel ease.
(4) I nstal l seat back cover.
(5) I nstal l seat back.
(6) Engage seat track rel ease cabl e to bottom of
cushi on and pi vot bracket.
(7) I nstal l seat.
BUCKET SEAT CUSHION COVER
REMOVAL
(1) Remove seat.
(2) Remove seatback.
(3) Di sengage i nboard J-strap.
(4) Di sengage front J-strap.
(5) Rol l cover up to access hog ri ngs.
(6) Di sengage i nboard, outboard and front hog
ri ngs.
(7) From the undersi de of the cushi on, di sengage
the rear hog ri ngs (Fi g. 4).
(8) Separate cover from cushi on.
INSTALLATION
(1) Posi ti on cover on cushi on and al i gn seams.
(2) From the undersi de of the cushi on, engage the
rear hog ri ngs.
(3) Engage i nboard, outboard and front hog ri ngs.
(4) Rol l cover over cushi on edges.
(5) Engage i nboard J-strap.
(6) Engage front J-strap.
(7) I nstal l seatback.
(8) I nstal l seat.
Fig. 3 Seat Back Cover
1 – SEAT BACK
2 – SEAT BACK COVER
3 – SEAT BACK CUSHION
4 – HOOK AND LOOP FASTENER
TJ BODY 23 - 11
REMOVAL AND INSTALLATION (Continued)
REAR SEATBACK
REMOVAL
(1) Remove rear seat from vehi cl e.
(2) Remove torx bol ts attachi ng seatback to seat
cushi on (Fi g. 5).
(3) Separate the seat back from the seat cushi on.
INSTALLATION
(1) Posi ti on the seat back on the seat cushi on.
(2) I nstal l the torx bol ts attachi ng seatback to seat
cushi on.
(3) I nstal l rear seat.
REAR SEATBACK COVER
REMOVAL
(1) Remove rear seat.
(2) Remove the seatback.
(3) Di sengage the hook and l oop fasteners at the
seatback l ower corners (Fi g. 6).
(4) Di sengage the seatback cover zi pper.
(5) Careful l y, remove the seatback frame from the
cushi on/cover.
(6) Rol l the seatback cover upward and di sengage
the hook and l oop fasteners.
INSTALLATION
(1) Posi ti on the cover on the seatback cushi on.
(2) Rol l the seatback cover downward over the
cushi on.
(3) I nstal l the seatback frame i nto the cushi on/
cover.
(4) Engage the seatback cover zi pper.
(5) Engage the hook and l oop fasteners at the seat-
back l ower corners.
(6) I nstal l the seatback.
(7) I nstal l rear seat.
Fig. 4 Rear Hog Rings
1 – SEAT CUSHION FRAME
2 – SEAT CUSHION
3 – HOG RINGS
Fig. 5 Rear Seat Components
1 – SEAT BACK FRAME
2 – SPRING
3 – SEAT BACK RELEASE LEVER
4 – BUMPER
5 – U-NUT
6 – SEAT CUSHION FRAME
Fig. 6 Seat Back Cover
1 – SEAT BACK
2 – ZIPPER
3 – REAR SEAT RELEASE LEVER
4 – HOOK AND LOOP FASTENER
23 - 12 BODY TJ
REMOVAL AND INSTALLATION (Continued)
REAR SEAT CUSHION COVER
REMOVAL
(1) Remove rear seat.
(2) Remove the seatback.
(3) Di sengage the J-straps at the rear cushi on cor-
ners.
(4) Di sengage the seat cushi on cover zi pper.
(5) Careful l y, remove the seat cushi on frame from
the cushi on/cover.
(6) Rol l the cover from seat cushi on and di sengage
the hook and l oop fasteners (Fi g. 7).
INSTALLATION
(1) Posi ti on the cover on the cushi on and rol l cover
downward over the corners.
(2) I nstal l the seat cushi on frame i nto the cushi on/
cover.
(3) Engage the seat cushi on cover zi pper.
(4) Engage the J-straps at the rear cushi on cor-
ners.
(5) I nstal l the seatback.
(6) I nstal l rear seat.
Fig. 7 Hook And Loop Fasteners
1 – REAR SEAT CUSHION COVER
2 – HOOK AND LOOP FASTENER
3 – REAR SEAT CUSHION
TJ BODY 23 - 13
REMOVAL AND INSTALLATION (Continued)
BODY COMPONENT SERVICE
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL AND INSTALLATION
RADIATOR GRILLE PANEL . . . . . . . . . . . . . . . . . 15
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HOOD SAFETY LATCH . . . . . . . . . . . . . . . . . . . . 17
COWL WEATHERSTRIP. . . . . . . . . . . . . . . . . . . . 17
COWL GRILLE AND SCREEN . . . . . . . . . . . . . . . 17
WINDSHIELD FRAME . . . . . . . . . . . . . . . . . . . . . 18
WINDSHIELD FRAME WEATHERSTRIP. . . . . . . . 18
WINDSHIELD HINGE . . . . . . . . . . . . . . . . . . . . . . 19
BODY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . 20
FENDER FLARE . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT FENDER . . . . . . . . . . . . . . . . . . . . . . . . . 21
BODY SIDE MOLDING. . . . . . . . . . . . . . . . . . . . . 23
SIDE STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FULL DOOR TRIM PANEL . . . . . . . . . . . . . . . . . . 24
FULL DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FULL DOOR HINGE. . . . . . . . . . . . . . . . . . . . . . . 25
FULL DOOR OUTSIDE RELEASE HANDLE . . . . . 25
FULL DOOR LOCK CYLINDER. . . . . . . . . . . . . . . 26
LOCK CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . 26
FULL DOOR LATCH. . . . . . . . . . . . . . . . . . . . . . . 26
FULL DOOR LATCH STRIKER . . . . . . . . . . . . . . . 27
FULL DOOR INSIDE HANDLE ACTUATOR. . . . . . 27
FULL DOOR GLASS. . . . . . . . . . . . . . . . . . . . . . . 28
FULL DOOR INNER BELT WEATHERSTRIP. . . . . 28
FULL DOOR OUTER BELT SEAL . . . . . . . . . . . . . 29
FULL DOOR GLASS RUN CHANNEL
WEATHERSTRIP. . . . . . . . . . . . . . . . . . . . . . . . 29
FULL DOOR WEATHERSTRIP . . . . . . . . . . . . . . . 29
FULL DOOR WINDOW REGULATOR . . . . . . . . . . 30
HALF DOOR TRIM PANEL . . . . . . . . . . . . . . . . . . 30
HALF DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HALF DOOR HINGE. . . . . . . . . . . . . . . . . . . . . . . 31
HALF DOOR OUTSIDE HANDLE . . . . . . . . . . . . . 31
HALF DOOR LOCK CYLINDER . . . . . . . . . . . . . . 31
HALF DOOR LATCH. . . . . . . . . . . . . . . . . . . . . . . 32
HALF DOOR LATCH STRIKER. . . . . . . . . . . . . . . 32
HALF DOOR INSIDE HANDLE ACTUATOR. . . . . . 33
HALF DOOR WEATHERSTRIP. . . . . . . . . . . . . . . 33
HALF DOOR WINDOW. . . . . . . . . . . . . . . . . . . . . 33
HARD TOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
HARD TOP AIR EXHAUSTER. . . . . . . . . . . . . . . . 35
SOFT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SOFT TOP FABRIC . . . . . . . . . . . . . . . . . . . . . . . 36
HARD/SOFT TOP LATCH. . . . . . . . . . . . . . . . . . . 36
DOOR OPENING FRAME. . . . . . . . . . . . . . . . . . . 37
FRONT SHOULDER/LAP BELT AND BUCKLE . . . 37
REAR SHOULDER/LAP BELT AND BUCKLE . . . . 38
BUCKET SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
MINI FLOOR CONSOLE. . . . . . . . . . . . . . . . . . . . 41
FULL FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . 41
CONSOLE LOCK CYLINDER . . . . . . . . . . . . . . . . 42
SHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ADD-A-TRUNK. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FRONT CARPET . . . . . . . . . . . . . . . . . . . . . . . . . 44
CENTER CARPET . . . . . . . . . . . . . . . . . . . . . . . . 44
CARGO AREA CARPET . . . . . . . . . . . . . . . . . . . . 44
WHEELHOUSE CARPET . . . . . . . . . . . . . . . . . . . 44
SPORT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REAR VIEW MIRROR . . . . . . . . . . . . . . . . . . . . . 47
REARVIEW MIRROR SUPPORT BRACKET . . . . . 47
SUNVISOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
WHEELHOUSE SPLASH SHIELD. . . . . . . . . . . . . 48
LIFTGATE GLASS SUPPORT CYLINDER. . . . . . . 48
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . . 49
LIFTGATE GLASS HINGE . . . . . . . . . . . . . . . . . . 49
LIFTGATE GLASS WEATHERSTRIP. . . . . . . . . . . 50
SPARE TIRE CARRIER . . . . . . . . . . . . . . . . . . . . 50
LICENSE PLATE BRACKET . . . . . . . . . . . . . . . . . 50
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TAILGATE HINGE. . . . . . . . . . . . . . . . . . . . . . . . . 51
TAILGATE OUTSIDE HANDLE . . . . . . . . . . . . . . . 51
TAILGATE LOCK CYLINDER . . . . . . . . . . . . . . . . 52
TAILGATE LATCH. . . . . . . . . . . . . . . . . . . . . . . . . 52
TAILGATE LATCH STRIKER. . . . . . . . . . . . . . . . . 52
TAILGATE WEATHERSTRIP AND CHANNEL . . . . 53
ADJUSTMENTS
HOOD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . 53
DOOR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . 53
TAILGATE ADJUSTMENT. . . . . . . . . . . . . . . . . . . 53
SPECIFICATIONS
BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . 54
WELD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 55
SEALER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . 81
BODY OPENING DIMENSIONS . . . . . . . . . . . . . . 87
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . 92
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
23 - 14 BODY TJ
SERVICE PROCEDURES
BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
senger’s cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri od-
i cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng):
• Spray a smal l amount of l ock cyl i nder l ubri cant
di rectl y i nto the l ock cyl i nder.
• Appl y a smal l amount to the key and i nsert i t
i nto the l ock cyl i nder.
• Rotate i t to the l ocked posi ti on and then back to
the unl ocked posi ti on several ti mes.
• Remove the key. Wi pe the l ubri cant from i t wi th
a cl ean cl oth to avoi d soi l i ng of cl othi ng.
REMOVAL AND INSTALLATION
RADIATOR GRILLE PANEL
REMOVAL
(1) Remove the front crossmember cover.
(2) Remove the crossmember val ence cover.
(3) Remove the radi ator overfl ow bottl e.
(4) Remove the bol ts that attach the radi ator and
shroud from the gri l l e panel .
(5) I f A/C equi pped:
(a) Evacuate the system.
(b) Di sconnect the hi gh and l ow pressure l i nes
at the qui ck di sconnect coupl i ngs.
(c) Cover (cap) the l i nes to prevent contami na-
ti on.
(6) Remove the bol ts attachi ng the radi ator sup-
port rods to the gri l l e panel .
(7) Di sconnect the head l amp, turn si gnal , marker
l amp and horn wi re harness connectors.
(8) Remove the bol ts attachi ng the fenders to the
gri l l e panel .
(9) Remove the bol t attachi ng the gri l l e to the
frame mount.
(10) Separate the gri l l e from the vehi cl e.
INSTALLATION
Transfer al l rel ated components.
(1) Posi ti on the gri l l e panel on the vehi cl e. Ensure
the rubber support bumpers are al i gned (Fi g. 1).
(2) I nstal l the bol t attachi ng the gri l l e to the frame
mount.
(3) I nstal l the bol ts attachi ng the fenders to the
gri l l e panel .
(4) Connect the head l amp, turn si gnal , marker
l amp and horn wi re harness connectors.
(5) I nstal l the bol ts attachi ng the radi ator support
rods to the gri l l e panel .
(6) I f A/C equi pped:
(a) Connect the hi gh and l ow pressure l i nes at
the qui ck di sconnect coupl i ngs.
(b) Evacuate and charge the system.
(7) I nstal l the radi ator and shroud to the gri l l e
panel .
(8) I nstal l the radi ator overfl ow bottl e.
(9) I nstal l the crossmember val ence cover.
(10) I nstal l the front crossmember cover.
HOOD
REMOVAL
(1) Rai se and support the hood.
(2) Di sconnect the underhood l amp wi re harness
connector.
(3) Di sconnect the wi ndshi el d washer nozzl es.
(4) Di sconnect the ground strap.
Fig. 1 Grille Bumpers
1 – GRILLE PANEL
2 – BUMPER
TJ BODY 23 - 15
(5) Mark the posi ti on of the hi nges on the hood for
i nstal l ati on al i gnment reference.
(6) Remove the screws attachi ng the hood to the
hi nge and remove the hood (Fi g. 2).
(7) I f the hood must be repl aced, remove and
transfer the i nsul ator panel , hi nges, l atches,
bumpers, brackets, footman l oop, hood l amp, support
rod, and safety l atch to the repl acement hood (Fi g.
2).
INSTALLATION
(1) Posi ti on the hood on the vehi cl e and i nstal l the
screws attachi ng the hi nge to the hood.
(2) Al i gn the hi nges wi th the i nstal l ati on reference
marks on the hood and ti ghten the hi nge screws
securel y.
(3) Connect the underhood l amp wi re harness con-
nector.
(4) Connect the wi ndshi el d washer nozzl es.
(5) Connect the ground strap.
(6) Cl ose the hood.
HOOD HINGE
REMOVAL
(1) Remove the wi per arms.
(2) Remove the cowl panel and screen.
(3) Remove the bol ts attachi ng the hi nge to the
cowl .
(4) Usi ng a wax penci l , mark the posi ti on of the
hi nge on the hood for i nstal l ati on al i gnment refer-
ence.
(5) Remove the screws attachi ng the hi nge to the
hood (Fi g. 2).
(6) Separate the hi nge from the hood.
INSTALLATION
(1) Prepare and pai nt the repl acement hi nge to
match the body pai nt col or.
(2) Al i gn the hi nge wi th the i nstal l ati on reference
marks on the hood
(3) I nstal l the screws attachi ng the hi nge to the
hood and cowl . Ti ghten the screws to 17 N·m (155 i n.
l bs.) torque.
(4) I nstal l the bol ts attachi ng the hi nge to the
cowl .
Fig. 2 Hood Components
1 – WINDSHIELD REST BUMPER
2 – HOOD HINGE
3 – HOOD
4 – HOOD CATCH BRACKET
5 – HOOD CATCH
6 – PROP ROD CLIP
7 – PROP ROD
8 – WINDSHIELD HOOD DOWN LOOP
23 - 16 BODY TJ
REMOVAL AND INSTALLATION (Continued)
(5) I nstal l the cowl panel and screen.
(6) I nstal l the wi per arms.
HOOD SAFETY LATCH
REMOVAL
(1) Rai se and support the hood.
(2) Remove the bol t attachi ng the safety l atch to
the hood (Fi g. 3).
(3) Remove the l atch from the hood.
INSTALLATION
(1) Posi ti on the l atch on the hood.
(2) I nstal l the bol t attachi ng the safety l atch to the
hood.
(3) Remove the support rod and cl ose the hood.
COWL WEATHERSTRIP
REMOVAL
(1) Careful l y separate the weatherstri p from the
cowl fl ange (Fi g. 4).
INSTALLATION
(1) Posi ti on the weatherstri p on the cowl fl ange
and press i t i nto pl ace.
COWL GRILLE AND SCREEN
REMOVAL
(1) Open the hood and remove the screws that
attach the cowl gri l l e and screen to the cowl (Fi g. 5).
(2) Remove the gri l l e and screen from the cowl .
Fig. 3 Hood Safety Latch
1 – SAFETY LATCH
2 – HOOD
Fig. 4 Cowl Weatherstrip
1 – COWL
2 – COWL FLANGE
3 – COWL PLENUM DRAIN
4 – COWL WEATHERSTRIP
Fig. 5 Cowl Grille And Screen
1 – COWL GRILLE
2 – COWL GRILLE SCREEN
3 – COWL
4 – U NUT
5 – DASH PANEL TIE ROD
6 – U NUT
TJ BODY 23 - 17
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
NOTE: When installing the cowl grille, ensure the
foam seals on the cowl (Fig. 6) are positioned cor-
rectly and in good condition. Misaligned or dam-
aged seals may allow water to enter the HEVAC.
(1) Posi ti on the cowl screen and gri l l e on the cowl .
(2) I nstal l the screws that attach the gri l l e and
screen to the cowl .
WINDSHIELD FRAME
REMOVAL
(1) Unl atch top.
(2) Remove the bol ts attachi ng the sport bar to the
wi ndshi el d frame.
(3) Remove the wi ndshi el d wi per arms.
(4) Remove the torx screw cl osest to the hi nge
pi vot poi nt and ti l t the wi ndshi el d forward.
(5) Remove the torx screws attachi ng the wi nd-
shi el d hi nge to the wi ndshi el d frame (Fi g. 7).
(6) Separate the wi ndshi el d frame from the vehi -
cl e.
INSTALLATION
(1) Posi ti on the wi ndshi el d frame on the vehi cl e.
(2) I nstal l the torx screws attachi ng the wi nd-
shi el d hi nge to the wi ndshi el d frame.
(3) Ti l t the wi ndshi el d rearward.
(4) I nstal l the torx screw cl osest to the hi nge pi vot
poi nt and l ock the wi ndshi el d i n the upri ght posi ti on.
(5) I nstal l the wi ndshi el d wi per arms.
(6) I nstal l the bol ts attachi ng the sport bar to the
wi ndshi el d frame.
(7) Latch top.
WINDSHIELD FRAME WEATHERSTRIP
UPPER FRAME WEATHERSTRIP REMOVAL
(1) Di sconnect the top from the wi ndshi el d frame.
(2) Di sengage the push-i n fasteners attachi ng the
weatherstri p to the wi ndshi el d frame.
(3) Peel the weatherstri p from the frame.
UPPER FRAME WEATHERSTRIP INSTALLATION
(1) Cl ean the seal contact surface on the wi nd-
shi el d frame wi th i sopropyl al cohol or equi val ent.
NOTE: Ensure that the contact surface is dry and
free from any residue, poor adhesion will result.
(2) Posi ti on the weatherstri p on the wi ndshi el d
frame, al i gn the push-i n fasteners and press i t i nto
pl ace (Fi g. 8).
(3) Remove adhesi ve backi ng from the bottom of
the weatherstri p.
(4) Usi ng forceful hand pressure, seat the adhesi ve
on the contact surface.
NOTE: If tape surface becomes contaminated, it
will not adhere to the windshield frame.
(5) Connect the top to the wi ndshi el d frame.
Fig. 6 Cowl Foam Seal
1 – FOAM SEAL
Fig. 7 Windshield Frame
1 – WINDSHIELD HOLD DOWN LOOP
2 – WINDSHIELD HINGE
23 - 18 BODY TJ
REMOVAL AND INSTALLATION (Continued)
LOWER FRAME WEATHERSTRIP REMOVAL
The l ower wi ndshi el d frame weatherstri p can be
removed wi th the frame ti l ted forward to the ful l hor-
i zontal posi ti on.
(1) Mark the posi ti on of the wi per arms and
remove the arms.
(2) Di sconnect the top from the wi ndshi el d frame.
(3) Remove the cowl gri l l e.
(4) Remove the torx screws on each si de of the
wi ndshi el d frame al l owi ng the wi ndshi el d frame to
ti l t to the ful l hori zontal posi ti on.
(5) Di sengage the outboard push-i n fasteners at
the top of cowl and unscrew the fasteners that hol d
the weatherstri p on each hi nge pi l l ar (Fi g. 8).
(6) Di sengage the push-i n fastener at the center of
cowl .
(7) Remove the weatherstri p from the cowl .
LOWER FRAME WEATHERSTRIP INSTALLATION
(1) Posi ti on the weatherstri p on the cowl , al i gn the
center push-i n fastener and press i t i nto pl ace.
(2) Al i gn the outer push-i n fasteners and press i t
i nto pl ace.
(3) I nstal l the screws attachi ng the l ower weather-
stri p to the hi nge pi l l ars.
(4) Ti l t the wi ndshi el d frame rearward to the ful l
verti cal posi ti on.
(5) I nstal l the torx screws on each si de of the
wi ndshi el d securi ng the wi ndshi el d frame.
(6) Connect the top to the wi ndshi el d frame.
(7) I nstal l cowl gri l l e and wi per arms.
WINDSHIELD HINGE
REMOVAL
I f both hi nges are to be repl aced, the wi ndshi el d
must be ti l ted to the ful l forward posi ti on. Refer to
the Wi ndshi el d Frame Removal /I nstal l ati on proce-
dure i n thi s group for wi ndshi el d frame l oweri ng
i nformati on.
(1) Remove door.
(2) Remove the bol ts attachi ng the hi nge to the
cowl (Fi g. 9).
(3) Remove the bol ts attachi ng the hi nge to the
wi ndshi el d frame.
(4) Separate the hi nge from the vehi cl e.
INSTALLATION
(1) Pai nt as requi red.
(2) Cl ean the contact surface of the hi nge and cowl
wi th i sopropyl al cohol or equi val ent.
(3) Appl y a 4 mm bead of Mopar Vi nyl Acryl i c
Seal ant or equi val ent around the peri meter of the
hi nge contact surface. The bead shoul d be 10 mm
i nboard of the edge.
(4) Posi ti on the hi nge on the vehi cl e.
(5) I nstal l the bol ts attachi ng the hi nge to the
wi ndshi el d frame.
(6) I nstal l the bol ts attachi ng the hi nge to the
cowl .
(7) Ensure that the seal ant provi des compl ete cov-
erage. Wi pe away excess seal ant.
(8) I nstal l door.
Fig. 8 Windshield Frame Weatherstrip
1 – WINDSHIELD FRAME
2 – UPPER WEATHERSTRIP
3 – PUSH-IN FASTENER
4 – LOWER WEATHERSTRIP
5 – COWL
6 – VIEW OF ARROW Y
7 – PUSH-IN FASTENER
8 – LOWER WEATHERSTRIP
9 – COWL
Fig. 9 Windshield Hinge
1 – COWL
2 – WINDSHIELD
3 – WINDSHIELD HINGE
TJ BODY 23 - 19
REMOVAL AND INSTALLATION (Continued)
BODY DECALS
TJ decal s (Fi g. 10) are durabl e tape decal s wi th a
adhesi ve backi ng.
To el i mi nate bl i sters and ai r bubbl es i n a decal ,
pi erce them wi th a needl e or pi n. Force the trapped
ai r out of the hol e.
A heat gun can al so be used to remove smal l wri n-
kl es and i rregul ari ti es i n a decal .
REMOVAL
NOTE: The key to successful decal removal is to
apply heat to area and slowly peel the decal from
panel.
(1) Cl ean the surface as necessary.
(2) Pl ace a pi ece of maski ng tape above or bel ow
the decal as a reference mark.
(3) Start at one end of the decal and appl y heat
wi th a heat gun. Sl owl y peel the decal from the panel
by pul l i ng i t back. Do not pull the decal outward
from the panel.
INSTALLATION
(1) The area that wi l l be covered by the decal must
be cl eaned wi th an cl eani ng sol uti on to remove any
resi due pai nt. Freshl y pai nted surfaces must be thor-
oughl y dry.
(2) Cl ean pai nted surface wi th a commerci al wax
and si l i cone removal sol uti on. Wi pe surface wi th a
cl ean cl oth and al l ow to dry.
(3) Posi ti on decal and carri er on panel and hol d i t
i n-pl ace wi th pi eces maski ng tape.
(4) Li ft the bottom edge of the decal and carri er,
use the tape secti ons as hi nges, and reverse the posi -
ti on of the decal and carri er.
CAUTION: Always remove the carrier from the tape
stripe/decal, never remove the tape stripe/decal
from the carrier.
(5) Bend a corner of the carri er outward, separate
the corner of the carri er from the decal .
(6) Usi ng the maski ng tape on the body panel ,
al i gn the decal .
(7) Separate the carri er from one end of the decal .
(8) Hol d tape decal fi rml y agai nst the panel sur-
face whi l e separati ng the carri er from the decal .
(9) I nspect tape decal wi th refl ected l i ght to check
for defects that coul d have devel oped duri ng the
i nstal l ati on process. Remove al l ai r and/or moi sture
bubbl es.
SIDE VIEW MIRROR
REMOVAL
(1) Remove the screws attachi ng the mi rror to the
door hi nge (Fi g. 11).
(2) Remove the mi rror from the door hi nge.
INSTALLATION
(1) Cl ean the door hi nge-mi rror base contact sur-
face.
(2) Posi ti on the mi rror base at the door hi nge.
(3) I nstal l the screws attachi ng the mi rror base to
the door hi nge.
Fig. 10 TJ—Decals
Fig. 11 Side View Mirror
1 – MIRROR
23 - 20 BODY TJ
REMOVAL AND INSTALLATION (Continued)
FENDER FLARE
REMOVAL
(1) Remove the si de marker l amp.
(2) Remove the screws that attach the fl are to the
front fender or rear wheel house (Fi g. 12).
(3) Separate the fl are from the body.
INSTALLATION
(1) Cl ean the contact surface on the body.
(2) Cl ean the contact surface on the fl are and posi -
ti on i t on the front fender or wheel house.
(3) I nstal l the screws attachi ng the fl ares to the
front fender or wheel house.
(4) I f removed, i nstal l the si de marker l amp.
FRONT FENDER
RIGHT FENDER REMOVAL
(1) Di sconnect and remove the battery.
(2) Remove the ai r cl eaner housi ng.
(3) Remove the bol ts attachi ng the Power Di stri bu-
ti on Center (PDC) to the fender.
(4) Di sengage the PDC wi re harness retai ners on
the battery tray and fender.
(5) Move and secure the PDC.
(6) Di sengage the hi gh pressure ai r condi ti oni ng
l i ne retai ner on the fender.
(7) Di sengage the front end l i ghti ng wi re harness
retai ners on the fender.
(8) Remove the battery tray.
(9) Di sengage the battery temperature sensor con-
nector.
(10) Di sengage the vacuum l i ne at the reservoi r
under the battery tray rei nforcement bracket.
(11) Di sengage the headl amp wi re connector.
(12) Route the fog l amp (i f equi pped), park l amp
and si de marker wi re harness through the access
hol e i n the fender wel l .
(13) I f equi pped, remove the fender fl are extensi on
and body si de mol di ng (Fi g. 13).
(14) Remove the bol ts attachi ng the fender to the
cowl (Fi g. 14).
(15) Remove the bol ts attachi ng the fender to the
battery tray rei nforcement bracket.
(16) Remove the bol ts attachi ng the fender to the
gri l l e.
(17) Separate the fender from the vehi cl e.
RIGHT FENDER INSTALLATION
Transfer al l rel ated components. Repl ace harness
retai ners i f damaged.
(1) Posi ti on the fender on the vehi cl e.
Fig. 12 Fender Flares
1 – U-NUT
2 – FENDER FLARE
3 – NUTSERT
4 – SPLASH SHIELD
5 – RIVET
6 – NUTSERT
7 – FENDER FLARE
8 – U-NUT
TJ BODY 23 - 21
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l the bol ts attachi ng the fender to the
gri l l e.
(3) I nstal l the bol ts attachi ng the fender to the
battery tray rei nforcement bracket.
(4) I nstal l the bol ts attachi ng the fender to the
cowl .
(5) I f equi pped, i nstal l the fender fl are extensi on
and body si de mol di ng.
(6) Route the fog l amp (i f equi pped), park l amp
and si de marker wi re harness through the access
hol e i n the fender wel l . Seat the grommet
(7) Engage the headl amp wi re connector.
(8) Engage the battery temperature sensor connec-
tor.
(9) Engage the vacuum l i ne at the reservoi r under
the battery tray rei nforcement bracket.
(10) I nstal l the battery tray.
(11) Posi ti on the front end l i ghti ng wi re harness
i nto the retai ners on the fender. Engage the retai ners
to secure.
(12) Posi ti on the hi gh pressure ai r condi ti oni ng
l i ne i nto the retai ner on the fender. Engage the
retai ner to secure.
Fig. 14 Front Fender
1 – REINFORCEMENT
2 – BATTERY TRAY
3 – BODY
4 – REINFORCEMENT
5 – FENDER
6 – TRAY
7 – RADIATOR GRILLE PANEL
Fig. 13 Body Side Molding
1 – NUTSERT
2 – MOLDING SUPPORT
3 – RIVET
4 – BODY SIDE MOLDING
5 – FENDER FLARE EXTENSION
6 – NUTSERT
23 - 22 BODY TJ
REMOVAL AND INSTALLATION (Continued)
(13) Posi ti on the PDC on the fender and i nstal l the
bol ts.
(14) Posi ti on the PDC wi re harness i nto the
retai ners on the fender and battery tray. Engage the
retai ners to secure.
(15) I nstal l the ai r cl eaner housi ng.
(16) I nstal l and connect the battery.
LEFT FENDER REMOVAL
(1) Di sconnect the negati ve termi nal on the bat-
tery.
(2) Remove the wi ndshi el d washer reservoi r.
(3) Di sengage horn wi re connectors.
(4) Remove horns.
(5) Remove EVAP cani ster.
(6) Remove the bol ts attachi ng the ABS Hydraul i c
Control Uni t (HCU) to the support tray.
(7) Secure the HCU.
(8) Remove the HCU tray.
(9) Di sengage the front end l i ghti ng wi re harness
retai ners on the fender.
(10) Di sengage the headl amp wi re connector.
(11) Route the fog l amp (i f equi pped), park l amp
and si de marker wi re harness through the access
hol e i n the fender wel l .
(12) I f equi pped, remove the body si de mol di ng
(Fi g. 13).
(13) Remove the bol ts attachi ng the fender to the
cowl (Fi g. 14).
(14) Remove the bol ts attachi ng the fender to the
HCU tray rei nforcement bracket.
(15) Remove the bol ts attachi ng the fender to the
gri l l e.
(16) Separate the fender from the vehi cl e.
LEFT FENDER INSTALLATION
Transfer al l rel ated components. Repl ace harness
retai ners i f damaged.
(1) Posi ti on the fender on the vehi cl e.
(2) I nstal l the bol ts attachi ng the fender to the
gri l l e.
(3) Posi ti on the front end l i ghti ng wi re harness
i nto the retai ners on the fender. Engage the retai ners
to secure.
(4) I nstal l the bol ts attachi ng the fender to the
HCU tray rei nforcement bracket.
(5) I nstal l the bol ts attachi ng the fender to the
cowl .
(6) I f equi pped, i nstal l the body si de mol di ng.
(7) Route the fog l amp (i f equi pped), park l amp
and si de marker wi re harness through the access
hol e i n the fender wel l . Seat the grommet
(8) Engage the headl amp wi re connector.
(9) I nstal l the HCU tray.
(10) Posi ti on the HCU on the support tray and
i nstal l the bol ts.
(11) I nstal l EVAP cani ster.
(12) I nstal l horns.
(13) Engage horn wi re connectors.
(14) I nstal l the wi ndshi el d washer reservoi r.
(15) Connect the negati ve termi nal on the battery.
BODY SIDE MOLDING
REMOVAL
(1) Remove the bol ts from undersi de of the body
si de mol di ng (Fi g. 15).
(2) Li ft the mol di ng upward to rel ease i t from the
mol di ng support.
(3) Remove the mol di ng support by dri l l i ng out the
ri vets.
INSTALLATION
(1) I f removed, posi ti on the mol di ng support on the
body and i nstal l the ri vets.
(2) Pl ace the upper edge of the mol di ng over the
top of the mol di ng support and sl i de i t downward.
(3) I nstal l the bol ts i nto the undersi de of the body
si de mol di ng.
SIDE STEP
REMOVAL
(1) Remove the bol ts that attach the si de step to
the frame (Fi g. 16).
(2) Separate the si de step from the frame.
INSTALLATION
(1) Posi ti on the si de step on the frame.
Fig. 15 Body Side Molding
1 – NUTSERT
2 – MOLDING SUPPORT
3 – RIVET
4 – BODY SIDE MOLDING
5 – FENDER FLARE EXTENSION
6 – NUTSERT
TJ BODY 23 - 23
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l the bol ts that attach the si de step to the
frame.
FULL DOOR TRIM PANEL
REMOVAL
(1) Lower the wi ndow.
(2) Remove the cl i p attachi ng the wi ndow gl ass
regul ator handl e to the regul ator. Remove the han-
dl e.
(3) Remove the screws attachi ng tri m panel to
door (Fi g. 17).
(4) Remove push-i n fasteners attachi ng tri m panel
to door wi th speci al tool C-4829.
(5) Li ft the tri m panel upward and separate the
tri m panel from the door.
INSTALLATION
(1) Posi ti on the tri m panel on the door.
(2) Press the push-i n fasteners attachi ng tri m
panel to door i nto pl ace.
(3) I nstal l the screws attachi ng tri m panel to door.
(4) Posi ti on the cl i p on regul ator handl e and
i nstal l the handl e on the regul ator.
FULL DOOR
REMOVAL
(1) Open the door.
(2) Di sconnect the door restrai nt strap from the
pi n (Fi g. 18).
(3) Remove the nuts at the door hi nge pi vots and
l i ft the door from the body.
Fig. 16 Side Step
1 – FRAME
2 – SIDE STEP
3 – NUTSERT
Fig. 17 Full Door Trim Panel
1 – FULL DOOR
2 – GRAB HANDLE BRACKET
3 – TRIM PANEL
4 – NUT
Fig. 18 Restraint Strap
1 – BODY
2 – FOOTMAN LOOP
3 – STRAP
4 – RESTRAINT PIN
23 - 24 BODY TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on the door i n the hi nge and i nstal l the
nuts.
(2) Connect the door restrai nt strap at the pi n.
FULL DOOR HINGE
REMOVAL
(1) Remove the door.
(2) Mark the outl i ne of the exi sti ng hi nge on the
body and the door wi th a wax penci l for i nstal l ati on
al i gnment reference.
(3) Remove the nut from the upper hi nge pi n (Fi g.
19).
NOTE: When removing the door or hinge DO NOT
discard the plastic shims or the hinge pin.
(4) Remove the hi nge-to-body screws and the
hi nge-to-door screws. Remove the hi nge from the
door and body. Support the door as necessary.
The upper hi nge i s i ntegrated wi th the wi ndshi el d
hi nge. When removi ng i t, support the wi ndshi el d
frame wi th an appropri ate devi ce pri or to removal .
INSTALLATION
(1) Cl ean the repl acement hi nge wi th an appropri -
ate sol vent and dry i t wi th compressed ai r.
(2) Pai nt the hi nge to match the vehi cl e body.
(3) Lubri cate the hi nge wi th spray l ubri cant.
(4) Posi ti on the hi nge on the door, al i gn careful l y
wi th the wax penci l i nstal l ati on al i gnment reference
marks, and i nstal l the screws.
(5) Posi ti on the hi nge on the vehi cl e body. Al i gn
the wax penci l marks i nstal l ati on al i gnment refer-
ence marks. I nstal l the screws.
(6) I nstal l the door,
(7) I nspect the wi ndshi el d al i gnment after hi nge
i nstal l ati on.
(8) I nspect the door al i gnment. Adjust, i f neces-
sary.
FULL DOOR OUTSIDE RELEASE HANDLE
REMOVAL
(1) Remove the door tri m panel .
(2) Posi ti on the wi ndow i n the ful l upward posi -
ti on.
(3) Remove the grab handl e support bracket (Fi g.
20).
(4) Peel back the waterdam from the door i nner
panel to access the door l atch.
(5) Di sconnect from the l atch, the i nsi de l ock knob
to l atch rod and, the outsi de rel ease handl e to l atch
rod (Fi g. 21).
(6) Di sengage tai l of retai ner from handl e keeper.
(7) Usi ng a l ong fl at bl ade, tap the handl e keepers
upward and remove from the door handl e (Fi g. 22).
(8) Remove the l atch rel ease rod from the door
handl e.
(9) Separate the handl e and gasket from the door.
Fig. 19 Full Door Hinge
1 – HINGE HALF
2 – HINGE HALF
3 – TAPPING PLATE
4 – HINGE HALF
5 – HINGE HALF
Fig. 20 Grab Handle Support Bracket
1 – FULL DOOR
2 – GRAB HANDLE BRACKET
3 – TRIM PANEL
4 – NUT
TJ BODY 23 - 25
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Engage the l atch rel ease rod to the door han-
dl e.
(2) Posi ti on the gasket and handl e i n the door.
(3) Sl i de the keepers i nto the door handl e from the
top.
(4) Lower the wi ndow.
(5) Usi ng a l ong fl at bl ade, l i ghtl y tap the handl e
keepers downward to secure the handl e. The tai l of
the retai ner must be posi ti oned on the 2nd or 3rd
step from the bottom on the handl e keeper.
(6) Rai se the wi ndow.
(7) Connect to the l atch, the i nsi de l ock knob to
l atch rod and, the outsi de rel ease handl e to l atch rod.
(8) I nstal l the waterdam
(9) I nstal l the grab handl e support bracket.
(10) I nstal l the door tri m panel .
FULL DOOR LOCK CYLINDER
REMOVAL
(1) Remove tri m panel .
(2) Peel back waterdam.
(3) Di sconnect l ock cyl i nder to l atch rod.
(4) Remove l ock cyl i nder retai ni ng cl i p.
(5) Remove the l ock cyl i nder from the door.
INSTALLATION
(1) I nstal l the l ock cyl i nder i n the door.
I nstal l l ock cyl i nder retai ni ng cl i p.
(2) Connect l ock cyl i nder to l atch rod.
(3) I nstal l the l ock cyl i nder i n the door.
I nstal l l ock cyl i nder retai ni ng cl i p.
(4) Connect l ock cyl i nder to l atch rod.
(5) Secure the waterdam to the door.
(6) I nstal l tri m panel .
LOCK CYLINDERS
I gni ti on, door, deck l i d, and rear hatch l ock cyl i n-
ders are al l codabl e to the key. Lock barrel s, tum-
bl ers, and tumbl er spri ngs are avai l abl e to al l ow the
techni ci an to change repl acement l ocks cyl i nders to
match the customer’s ori gi nal key set. See the appro-
pri ate secti on i n thi s manual for l ock cyl i nder
removal . See the Mopar௡ catal ogue for part numbers
and l ock codi ng procedures.
FULL DOOR LATCH
REMOVAL
(1) Remove tri m panel .
(2) Rol l wi ndow to ful l upward posi ti on.
(3) Di sconnect the l ock cyl i nder to l atch rod (Fi g.
23).
(4) Di sconnect the l ock knob to l atch rod.
(5) Di sconnect the outsi de handl e to l atch rod.
Fig. 21 Latch Rods
1 – U-NUT
2 – INSIDE HANDLE TO LATCH ROD
3 – INSIDE LOCK TO LATCH ROD
4 – LATCH
5 – LOCK CYLINDER TO LATCH ROD
6 – INSIDE HANDLE ACTUATOR
7 – WINDOW REGULATOR HANDLE
8 – TRIM PANEL
9 – SPACER
Fig. 22 Outside Door Handle Removal
1 – TAIL
2 – OUTSIDE HANDLE
3 – RETAINER
4 – HANDLE KEEPER
5 – DOOR
23 - 26 BODY TJ
REMOVAL AND INSTALLATION (Continued)
(6) Remove the screws attachi ng the l atch to the
door (Fi g. 24).
(7) Lower the l atch i n the door and di sconnect the
i nsi de handl e to l atch rod.
(8) Remove the l atch from the door.
INSTALLATION
(1) Posi ti on the l atch i n the door.
(2) Connect the i nsi de handl e to l atch rod.
(3) I nstal l the screws attachi ng the l atch to the
door.
(4) Posi ti on the door weatherstri p i n pl ace, appl y
adhesi ve as necessary.
(5) Connect the outsi de handl e to l atch rod.
(6) Connect the l ock knob to l atch rod.
(7) Connect the l ock cyl i nder to l atch rod.
(8) I nstal l tri m panel .
FULL DOOR LATCH STRIKER
REMOVAL
(1) Remove the screws attachi ng the stri ker to the
body.
(2) Separate the stri ker and the spacer from the
body (Fi g. 25).
INSTALLATION
(1) Posi ti on the stri ker and the spacer on the body.
(2) I nstal l the screws attachi ng the stri ker and
spacer to the body.
FULL DOOR INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the torx screw attachi ng the i nsi de
handl e to the door.
(2) Careful l y pul l the handl e from the door.
(3) Di sconnect the l atch rods from the handl e (Fi g.
26).
Fig. 23 Latch Rods
1 – U-NUT
2 – INSIDE HANDLE TO LATCH ROD
3 – INSIDE LOCK TO LATCH ROD
4 – LATCH
5 – LOCK CYLINDER TO LATCH ROD
6 – INSIDE HANDLE ACTUATOR
7 – WINDOW REGULATOR HANDLE
8 – TRIM PANEL
9 – SPACER
Fig. 24 Full Door Latch
1 – LATCH
2 – FULL DOOR
Fig. 25 Latch Striker
1 – STRIKER
2 – SPACER
3 – BODY
TJ BODY 23 - 27
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
INSTALLATION
(1) Connect the l atch rods to the handl e.
(2) Posi ti on handl e and seal i n door.
(3) I nstal l the torx screw attachi ng the i nsi de han-
dl e the to door.
FULL DOOR GLASS
REMOVAL
(1) Remove the door tri m panel and the waterdam.
(2) Pul l the door gl ass run channel from the door
sai l .
(3) Rol l gl ass ful l y downward.
(4) Remove the door sai l panel (Fi g. 27) and (Fi g.
28).
(5) Rol l gl ass 1/4 upward to access regul ator arm
gui de.
(6) Remove the screws that attach the regul ator
arm gui de to the gl ass.
(7) Li ft the gl ass upward whi l e ti l ti ng i nward and
remove from the door.
INSTALLATION
(1) Posi ti on the gl ass i n the door ensuri ng the
gl ass i s al i gned i n the gl ass run channel .
(2) I nstal l the screws that attach the regul ator
arm gui de to the gl ass.
(3) I nstal l the door sai l panel .
(4) I nstal l the run channel i n the door sai l .
(5) I nstal l the waterdam and the door tri m panel .
FULL DOOR INNER BELT WEATHERSTRIP
The i nner bel t weatherstri p i s attached to the door
tri m panel and i s not servi ceabl e. I f the i nner bel t
weatherstri p needs to be repl aced, repl ace the door
tri m panel .
Fig. 26 Inside Handle Actuator
1 – LOCK KNOB TO LATCH ROD
2 – U-NUT
3 – HALF DOOR TRIM PANEL
4 – INSIDE RELEASE HANDLE TO LATCH ROD
Fig. 27 Door Sail Screws
1 – DOOR SAIL
2 – DOOR
Fig. 28 Door Sail Removal
1 – DOOR FRAME
2 – TRIM STICK
3 – DOOR SAIL
23 - 28 BODY TJ
REMOVAL AND INSTALLATION (Continued)
FULL DOOR OUTER BELT SEAL
REMOVAL
(1) Remove the door sai l panel .
(2) Di sengage the cl i ps attachi ng the outer bel t
seal to the door (Fi g. 29).
(3) Separate the seal from the door.
INSTALLATION
(1) Posi ti on the seal on the door.
(2) Engage the cl i ps attachi ng the outer bel t seal
to the door.
(3) I nstal l the door sai l panel .
FULL DOOR GLASS RUN CHANNEL
WEATHERSTRIP
REMOVAL
(1) Lower the wi ndow.
(2) Usi ng a tri m sti ck, careful l y pry the gl ass run
channel weatherstri p from the wi ndow openi ng
frame.
(3) Remove the door gl ass.
(4) Grasp the gl ass run channel weatherstri p i n
the door (Fi g. 30) and pul l from the channel .
INSTALLATION
Appl yi ng a smal l amount of l ubri cant to the weath-
erstri p may ease the i nstal l ati on.
(1) Posi ti on the weatherstri p i n the door channel s
and press i nto pl ace.
(2) I nstal l the door gl ass.
(3) Posi ti on the weatherstri p i n the wi ndow open-
i ng frame and press i nto pl ace.
NOTE: Ensure that the glass is seated properly.
Improperly seated door glass will result in high
glass roll-up/roll-down effort.
FULL DOOR WEATHERSTRIP
The upper porti on of the weatherstri p i s seated
i nto a channel around the wi ndow openi ng frame.
The channel that seats the l ower porti on of the
weatherstri p i s attached to the door wi th push-i n fas-
teners and doubl e si ded tape.
REMOVAL
(1) Peel the weatherstri p from the channel .
(2) Separate the weatherstri p from the door.
(3) I f necessary, remove the push-i n fasteners
attachi ng the weatherstri p channel to the door and
peel the channel from the door (Fi g. 31).
INSTALLATION
(1) I f the weatherstri p channel has been removed,
cl ean the contact surfaces wi th i sopropyl al cohol or
equi val ent.
(2) Remove backi ng from the weatherstri p chan-
nel , posi ti on the channel on the door and i nstal l the
push-i n fasteners. Use a rol l er or forceful hand pres-
sure to ensure good adhesi ve contact.
(3) I nstal l the weatherstri p i n the upper and l ower
weatherstri p channel s ensuri ng that the weather-
stri p i s compl etel y engaged to the weatherstri p chan-
nel s.
Fig. 29 Full Door Outer Belt Seal
1 – OUTER BELTLINE WEATHERSTRIP
2 – OUTSIDE DOOR HANDLE
3 – CLIPS
Fig. 30 Full Door Glass Run Channel Weatherstrip
1 – WINDOW GLASS
2 – REGULATOR
3 – GROMMET
4 – GLASS RUN CHANNEL WEATHERSTRIP
5 – DOOR
TJ BODY 23 - 29
REMOVAL AND INSTALLATION (Continued)
FULL DOOR WINDOW REGULATOR
REMOVAL
(1) Remove door tri m panel .
(2) Remove door gl ass.
(3) Loosen the bol ts i n the sl otted hol es (Fi g. 32).
(4) Remove the bol ts attachi ng the regul ator to the
door i nner panel .
(5) Li ft the regul ator upward to free i t from the
sl otted hol es i n the door i nner panel .
(6) Lower the regul ator and remove i t through the
access hol e i n the door i nner panel (Fi g. 33).
INSTALLATION
(1) Posi ti on the regul ator i n the door.
(2) Al i gn regul ator bol ts i nto sl otted hol es.
(3) I nstal l bol ts attachi ng regul ator to the i nner
door panel .
(4) Ti ghten the bol ts i n the sl otted hol es.
(5) I nstal l door gl ass.
(6) I nstal l door tri m panel .
HALF DOOR TRIM PANEL
REMOVAL
(1) Remove hal f door wi ndow.
(2) Rotate wi ndow retai ner sl eeves 90°. Usi ng a
tri m sti ck, pry sl eeve retai ners from door.
(3) Remove the screws attachi ng tri m panel to
door.
(4) Remove push-i n fasteners attachi ng tri m panel
to door wi th speci al tool C-4829.
(5) Separate the tri m panel from the door.
INSTALLATION
(1) Posi ti on the tri m panel on the door.
(2) Press the push-i n fasteners attachi ng tri m
panel to door i nto pl ace.
Fig. 31 Full Door Weatherstrip
1 – FULL DOOR
2 – WEATHERSTRIP
3 – WATERDAM
4 – OUTER DOOR BELT SEAL
Fig. 32 Window Regulator Bolts
1 – LOOSEN BOLTS
2 – REMOVE BOLTS
Fig. 33 Regulator Removal
1 – DOOR
2 – REGULATOR ASSEMBLY
23 - 30 BODY TJ
REMOVAL AND INSTALLATION (Continued)
(3) I nstal l the screws attachi ng tri m panel to door.
(4) Posi ti on retai ner sl eeves i nto door. Rotate
retai ner sl eeves 90° to secure i nto pl ace.
(5) I nstal l hal f door wi ndow.
HALF DOOR
REMOVAL
(1) Open the door.
(2) Di sconnect the door restrai nt strap from the
pi n (Fi g. 34).
(3) Remove the nuts at the door hi nge pi vots and
l i ft the door from the body.
INSTALLATION
(1) Posi ti on the door i n the hi nge and i nstal l the
nuts.
(2) Connect the door restrai nt strap at the pi n.
HALF DOOR HINGE
The servi ce procedures for the hal f door hi nge are
the same as the ful l door hi nge. Refer to, Ful l Door
Hi nge Removal /I nstal l ati on procedures i n thi s group.
HALF DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove tri m panel .
(2) Di sconnect the outsi de handl e to l atch rod (Fi g.
35).
(3) Remove screws attachi ng the outsi de handl e to
the door.
(4) Separate the outsi de handl e and seal from the
door.
INSTALLATION
(1) Posi ti on the outsi de handl e and seal i n the
door.
(2) I nstal l screws attachi ng the outsi de handl e to
the door.
(3) Connect the outsi de handl e to l atch rod.
(4) I nstal l tri m panel .
HALF DOOR LOCK CYLINDER
REMOVAL
(1) Remove tri m panel .
(2) Peel back the waterdam.
(3) Di sconnect l ock cyl i nder to l atch rod (Fi g. 36).
(4) Remove l ock cyl i nder retai ni ng cl i p.
(5) Remove the l ock cyl i nder from the door.
INSTALLATION
(1) I nstal l the l ock cyl i nder i n the door.
I nstal l l ock cyl i nder retai ni ng cl i p.
(2) Connect l ock cyl i nder to l atch rod.
(3) Secure the waterdam.
Fig. 34 Restraint Strap
1 – BODY
2 – FOOTMAN LOOP
3 – STRAP
4 – RESTRAINT PIN
Fig. 35 Outside Handle
1 – OUTSIDE HANDLE TO LATCH ROD
2 – SEAL
3 – INSIDE HANDLE TO LATCH ROD
4 – INSIDE LOCK TO LATCH ROD
5 – LATCH
6 – LOCK CYLINDER TO LATCH ROD
7 – OUTSIDE HANDLE TO LATCH ROD
8 – INSIDE HANDLE ACTUATOR
9 – TRIM PANEL
10 – HALF DOOR
11 – OUTSIDE HANDLE
TJ BODY 23 - 31
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l tri m panel .
HALF DOOR LATCH
REMOVAL
(1) Remove tri m panel .
(2) Di sconnect the l ock cyl i nder to l atch rod (Fi g.
36).
(3) Di sconnect the l ock knob to l atch rod.
(4) Di sconnect the outsi de handl e to l atch rod.
(5) Usi ng a tri m sti ck or equi val ent, pry back the
door weatherstri p at the l atch to access the screw
attachi ng the l atch to the door.
(6) Remove the screws attachi ng the l atch to the
door (Fi g. 37).
(7) Lower the l atch i n the door and di sconnect the
i nsi de handl e to l atch rod.
(8) Remove the l atch from the door.
INSTALLATION
(1) Posi ti on the l atch i n the door.
(2) Connect the i nsi de handl e to l atch rod.
(3) I nstal l the screws attachi ng the l atch to the
door.
(4) Posi ti on the door weatherstri p i n pl ace, appl y
adhesi ve as necessary.
(5) Connect the outsi de handl e to l atch rod.
(6) Connect the l ock knob to l atch rod.
(7) Connect the l ock cyl i nder to l atch rod (Fi g. 36).
(8) I nstal l tri m panel .
HALF DOOR LATCH STRIKER
REMOVAL
(1) Remove the screws attachi ng the stri ker to the
body.
(2) Separate the stri ker and the spacer from the
body (Fi g. 38).
INSTALLATION
(1) Posi ti on the stri ker and the spacer on the body.
(2) I nstal l the screws attachi ng the stri ker and
spacer to the body.
Fig. 36 Half Door Latch Rods
1 – LOCK CYLINDER
2 – HALF DOOR
3 – HALF DOOR
4 – LATCH
5 – LOCK CYLINDER TO LATCH ROD
6 – LOCK CYLINDER
7 – RETAINER
8 – OUTSIDE HANDLE
9 – INSIDE HANDLE TO LATCH ROD
10 – INSIDE LOCK TO LATCH ROD
Fig. 37 Door Latch
1 – LATCH
2 – HALF DOOR
Fig. 38 Latch Striker
1 – STRIKER
2 – SPACER
3 – BODY
23 - 32 BODY TJ
REMOVAL AND INSTALLATION (Continued)
HALF DOOR INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the torx screw attachi ng the i nsi de
handl e to the door.
(2) Careful l y pul l handl e from door.
(3) Di sconnect the l atch rods from the handl e (Fi g.
39).
INSTALLATION
(1) Connect the l atch rods to the handl e.
(2) Posi ti on handl e and seal i n door.
(3) I nstal l the torx screw attachi ng the i nsi de han-
dl e the to door.
HALF DOOR WEATHERSTRIP
The weatherstri p i s seated i nto a channel around
the door. The channel that seats the weatherstri p i s
attached to the door wi th push-i n fasteners and dou-
bl e si ded tape.
REMOVAL
(1) Remove tri m panel .
(2) Remove wi ndow retai ni ng sl eeve.
(3) Remove the push-i n fasteners attachi ng the
weatherstri p to the top of the door.
(4) Peel the weatherstri p from the channel .
(5) I f necessary, remove the push-i n fasteners
attachi ng the weatherstri p channel to the door and
peel the channel from the door (Fi g. 40).
INSTALLATION
(1) I f the weatherstri p channel has been removed,
cl ean the contact surfaces wi th i sopropyl al cohol or
equi val ent.
(2) Remove the backi ng from the weatherstri p
channel , posi ti on the channel on the door and i nstal l
the push-i n fasteners. Use a rol l er or forceful hand
pressure to ensure good adhesi ve contact.
(3) Posi ti on the seal on the door and press i t i nto
pl ace.
(4) I nstal l the weatherstri p i n the weatherstri p
channel ensuri ng that the weatherstri p i s ful l y
engaged i n the weatherstri p channel .
(5) I nstal l wi ndow retai ni ng sl eeve.
(6) I nstal l tri m panel .
HALF DOOR WINDOW
REMOVAL
(1) Open the door.
(2) Grasp the wi ndow at both front and rear edges
and fi rml y l i ft upward (Fi g. 41).
INSTALLATION
(1) Starti ng at the most forward al i gnment pi n,
posi ti on the wi ndow al i gnment pi ns i nto the restrai nt
sl eeves and push downward unti l seated.
Fig. 39 Inside Handle Actuator
1 – LOCK KNOB TO LATCH ROD
2 – U-NUT
3 – HALF DOOR TRIM PANEL
4 – INSIDE RELEASE HANDLE TO LATCH ROD
Fig. 40 Half Door Weatherstrip
1 – HALF DOOR
2 – WEATHERSTRIP
TJ BODY 23 - 33
REMOVAL AND INSTALLATION (Continued)
HARD TOP
REMOVAL
(1) Di sengage l atches at wi ndshi el d frame (Fi g.
42).
(2) Remove the bol ts that attach the hard top to
the body (Fi g. 43).
(3) Depress tab on wi per motor connector and pul l
downward to di sengage (Fi g. 44).
(4) Di sconnect the rear washer fl ui d hose. Cap the
hose to prevent washer fl ui d l eakage (Fi g. 45).
(5) Remove the hard top from the vehi cl e.
Fig. 41 Half Window
Fig. 42 Hard Top Latch
1 – LATCH
2 – HARD TOP
3 – WINDSHIELD FRAME
Fig. 43 Hard Top Removal
1 – HARD TOP
2 – HOLD DOWN BOLT
3 – BODY RAIL
Fig. 44 Rear Wiper Wire Harness Connector
1 – WIPER MOTOR CONNECTOR
Fig. 45 Rear Washer Fluid Tube
1 – CAP
2 – WASHER FLUID TUBE
23 - 34 BODY TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nspect the hard top seal s for damage and
repl ace, i f necessary.
(2) Careful l y posi ti on the hard top on the vehi cl e.
Ensure that the l atches are not pi nched between the
top and wi ndshi el d frame.
(3) Loosel y i nstal l the bol ts. Ensure that the top i s
centered on the vehi cl e. Ti ghten the bol ts securel y.
(4) Connect the wi re wi per motor harness connec-
tor.
(5) Connect the rear washer fl ui d hose.
(6) Engage the l atches at wi ndshi el d frame.
HARD TOP AIR EXHAUSTER
The hard top ai r exhauster fi ts very ti ghtl y i nto
the hard top and general l y cannot be removed wi th-
out bei ng damaged. I t i s recommended that avai l abi l -
i ty of a repl acement ai r exhauster i s determi ned
pri or to attempti ng to remove i t.
REMOVAL
(1) Usi ng a tri m sti ck, C-4755, between ai r
exhauster and hard top, di sengage one edge of
exhauster from hard top.
(2) Separate the ai r exhauster from the hard top.
INSTALLATION
(1) Posi ti on the ai r exhauster on the hard top.
(2) Press ai r exhauster i nto openi ng i n hard top
unti l ful l y seated.
SOFT TOP
REMOVAL
(1) Di sengage the retai ners attachi ng the rear wi n-
dow to the body.
(2) Remove rear wi ndow, unzi ppi ng from ri ght to
l eft.
(3) Di sengage J-straps at soft top rear corners
(Fi g. 46).
(4) Unzi p quarter wi ndows, di sengage J-strap and
remove quarter wi ndows.
(5) Starti ng at the rear of the upper door openi ng
frame and worki ng forward, di sengage dri prai l
retai ners attachi ng the soft top to the door openi ng
frame.
(6) Unl atch top at wi ndshi el d frame.
(7) Lower the top to the rearward posi ti on.
(8) Remove the screws attachi ng the roof bows to
the pi vot bracket (Fi g. 47).
(9) Li ft up bows at pi vot bracket to di sengage from
pi vot bracket.
(10) Remove the top (Fi g. 48).
INSTALLATION
(1) Posi ti on the top on the vehi cl e.
(2) I nstal l the screws attachi ng the roof bows to
the pi vot bracket. (The front bow i s attached to the
pi vot bracket on the upper outward l ocati on).
(3) Rai se the top.
(4) Posi ti on l atch i n wi ndshi el d frame.
(5) I nstal l the quarter wi ndows.
(6) Worki ng from front to rear, engage the J-straps
attachi ng the quarter wi ndow to the body.
(7) I nstal l rear wi ndow.
(8) Engage dri prai l retai ners above door openi ng
frame.
Fig. 46 Soft Top J-Straps
1 – SOFT TOP CORNER J-STRAP
2 – QUARTER PANEL
Fig. 47 Roof Bow Removal
1 – SPORT BAR
2 – REAR ROOF BOW
3 – SIDE ROOF BOW
TJ BODY 23 - 35
REMOVAL AND INSTALLATION (Continued)
(9) Worki ng from front to rear, engage J-straps at
soft top rear corners.
(10) Engage the retai ners attachi ng the rear wi n-
dow to the body.
(11) Cl ose l atch at wi ndshi el d frame.
SOFT TOP FABRIC
REMOVAL
(1) Di sengage the snaps attachi ng the soft top fab-
ri c to the rear roof bow.
(2) Di sengage the hook and l oop fastener attachi ng
soft top fabri c to the center roof bow.
(3) Lower the soft top.
(4) Remove the screws attachi ng the soft top fabri c
to the front roof bow and fol d back fabri c.
(5) Separate the soft top fabri c from the frame.
INSTALLATION
(1) Posi ti on the soft top fabri c on the frame.
(2) I nstal l the screws attachi ng the soft top fabri c
to the front roof bow.
(3) Engage the hook and l oop fastener attachi ng
soft top fabri c to the center roof bow.
(4) Engage the snaps attachi ng the soft top fabri c
to the rear roof bow.
(5) Rai se and secure the soft top.
HARD/SOFT TOP LATCH
REMOVAL
(1) Unl atch the top (Fi g. 49).
(2) Usi ng a wax penci l , mark the posi ti on of the
l atch on the top.
(3) Remove the screws attachi ng the l atch to the
top.
INSTALLATION
(1) Posi ti on the l atch on the top and i nstal l the
screws.
Fig. 48 Soft Top
1 – HALF DOOR WINDOW
2 – DOOR OPENING FRAME
3 – QUARTER WINDOW
4 – SOFT TOP
5 – ROOF BOW
6 – LATCH REINFORCEMENT
23 - 36 BODY TJ
REMOVAL AND INSTALLATION (Continued)
DOOR OPENING FRAME
Vehi cl es equi pped wi th a soft top requi re a door
openi ng frame to compl ete the seal for the soft top
door assembl y.
REMOVAL
(1) Lower the top to the rearward posi ti on.
(2) Turn the knobs l ocated on top of the door open-
i ng frame counter cl ockwi se and remove compl etel y
(Fi g. 50).
(3) Pul l door openi ng frame outward and up. Sep-
arate from vehi cl e.
INSTALLATION
(1) I nstal l the al i gnment pi n at the base of the
door openi ng frame i nto the hol e at the top of the
quarter panel .
(2) Posi ti on the door openi ng frame on the si de
support bar and i nstal l the knobs.
(3) Rai se and secure the top.
FRONT SHOULDER/LAP BELT AND BUCKLE
WARNING: INSPECT THE SHOULDER BELT,
RETRACTOR AND BUCKLE. REPLACE THE BELT
OR BUCKLE THAT IS EITHER CUT, FRAYED, TORN
OR DAMAGED. REPLACE THE BELT IF THE
RETRACTOR IS INOPERATIVE.
FRONT SHOULDER/LAP BELT AND RETRACTOR
REMOVAL
(1) Move front seat to the ful l forward posi ti on.
(2) Remove the bol t attachi ng the retractor to the
sport bar (Fi g. 51).
(3) Usi ng a smal l fl at bl ade, pry the cover from the
turni ng l oop.
(4) Remove the bol t attachi ng the turni ng l oop to
the hei ght adjuster (Fi g. 52).
(5) Separate the bel t assembl y from the vehi cl e.
Fig. 49 Hard/Soft Top Latch
1 – LATCH
2 – HARD TOP
3 – WINDSHIELD FRAME
Fig. 50 Door Opening Frame
1 – DOOR OPENING FRAME
2 – KNOBS
Fig. 51 Front Retractor
1 – SPORT BAR
2 – RETRACTOR
TJ BODY 23 - 37
REMOVAL AND INSTALLATION (Continued)
FRONT SHOULDER/LAP BELT AND RETRACTOR
INSTALLATION
(1) Posi ti on the turni ng l oop on the hei ght adjuster
and i nstal l the bol t. Ti ghten the bol t to 47 N·m ( 35
ft. l bs.) torque.
(2) Cl ose the cover on the turni ng l oop.
(3) I nstal l the bol t attachi ng the retractor to the
sport bar. Ti ghten the bol t to 47 N·m ( 35 ft. l bs.)
torque.
FRONT SEAT BELT BUCKLE REMOVAL
(1) Remove the bol t attachi ng the seat bel t buckl e
to the seat track/seat ri ser (Fi g. 53).
(2) Di sengage seat bel t harness connector (dri ver’s
seat onl y).
(3) Remove buckl e from vehi cl e.
FRONT SEAT BELT BUCKLE INSTALLATION
(1) Posi ti on the buckl e on the seat track/seat ri ser
and i nstal l the bol t.
(2) Engage seat bel t harness connector (dri ver’s
seat onl y).
REAR SHOULDER/LAP BELT AND BUCKLE
WARNING: INSPECT THE SHOULDER BELT,
RETRACTOR AND BUCKLE. REPLACE THE BELT
OR BUCKLE THAT IS EITHER CUT, FRAYED, TORN
OR DAMAGED. REPLACE THE BELT IF THE
RETRACTOR IS INOPERATIVE.
SEAT/LAP BELT AND RETRACTOR REMOVAL
(1) Move the rear seat to the forward tumbl e posi -
ti on.
(2) Remove the anchor bol t attachi ng the bel t to
the wheel house (Fi g. 56).
(3) Usi ng a fl at bl ade, pry the cover off the turni ng
l oop (Fi g. 54).
(4) Remove the bol t attachi ng the turni ng l oop to
the sport bar (Fi g. 55).
(5) Remove the bol t attachi ng the retractor to the
sport bar.
(6) Separate the bel t assembl y from the vehi cl e.
Fig. 52 Front Turning Loop
1 – HEIGHT ADJUSTER
2 – SPORT BAR
3 – HEIGHT ADJUSTER COVER
4 – TURNING LOOP
Fig. 53 Seat Belt Buckle
1 – SEAT CUSHION
2 – SEATBACK
3 – TRIM ATTACHMENT WIRE
4 – SEAT TRACK
5 – SEAT RISER
6 – BUCKLE
23 - 38 BODY TJ
REMOVAL AND INSTALLATION (Continued)
SEAT/LAP BELT AND RETRACTOR INSTALLATION
(1) Posi ti on the retractor on the sport bar and
i nstal l the bol t. Ti ghten the bol t to 47 N·m ( 35 ft.
l bs.) torque.
(2) Posi ti on the turni ng l oop on the sport bar and
i nstal l the bol t. Ti ghten the bol t to 47 N·m ( 35 ft.
l bs.) torque.
(3) Cl ose cover on turni ng l oop.
(4) Posi ti on the bel t anchor on the wheel house and
i nstal l the bol t. Ti ghten the bol t to 47 N·m ( 35 ft.
l bs.) torque.
(5) Move the rear seat back to the l atch posi ti on.
REAR BUCKLE REMOVAL
(1) Move the rear seat to the forward tumbl e posi -
ti on.
(2) Grasp the carpet between the buckl es and l i ft
to access the anchor bol t.
(3) Remove the anchor bol t and separate the
buckl e from the vehi cl e (Fi g. 57).
Fig. 54 Turning Loop Cover
1 – SPORT BAR
2 – REAR SHOULDER BELT
3 – TURNING LOOP
4 – TURNING LOOP COVER
Fig. 55 Turning Loop
1 – SPORT BAR
2 – TURNING LOOP COVER
3 – TURNING LOOP
4 – REAR SHOULDER BELT
5 – ANCHOR BOLT
Fig. 56 Rear Belt Assembly
1 – TURNING LOOP
2 – SPACER
3 – RETRACTOR
4 – SPORT BAR
5 – WASHER
6 – SPACER
TJ BODY 23 - 39
REMOVAL AND INSTALLATION (Continued)
REAR BUCKLE INSTALLATION
(1) Route the buckl e through the carpet and al i gn
the hol es.
(2) I nstal l the anchor bol t. Ti ghten the bol t to 43
N·m ( 32 ft. l bs.) torque.
(3) Move the rear seat back to the l atch posi ti on.
BUCKET SEAT
REMOVAL
(1) Di sengage seat bel t el ectri cal connector (Fi g.
58).
(2) Remove the bol ts attachi ng the seat frame to
the fl oor panel (Fi g. 59).
(3) Remove the seat from the vehi cl e.
INSTALLATION
(1) Posi ti on the seat i n the vehi cl e.
(2) I nstal l the bol ts attachi ng the rear of seat
frame to the fl oor panel . Ti ghten outboard bol t to 33
N·m (25 ft. l bs.) torque. Ti ghten i nboard bol t to 74
N·m (55 ft. l bs.) torque.
(3) I nstal l the bol ts attachi ng the front of seat
frame to the fl oor panel . Ti ghten bol ts to 33 N·m (25
ft. l bs.) torque.
(4) Engage seat bel t el ectri cal connector.
Fig. 57 Rear Buckle
1 – REAR BUCKLE
Fig. 58 Bucket Seat
1 – CONNECTOR
2 – SEAT
3 – BODY
Fig. 59 Bucket Seat Removal
1 – BUCKLE
2 – SEAT
3 – TURNING LOOP
4 – COVER
5 – ADJUSTER
6 – RETRACTOR
7 – MOUNTING BRACKET
23 - 40 BODY TJ
REMOVAL AND INSTALLATION (Continued)
MINI FLOOR CONSOLE
REMOVAL
(1) Move the seats to the ful l rearward posi ti on.
(2) Grasp shi ft handl e (auto trans onl y) and fi rml y
pul l upward to remove.
(3) Usi ng a smal l fl at bl ade, pry up shi ft i ndi cator
bezel , di sengage bezel l amp connector and remove
bezel (auto trans onl y).
(4) Usi ng a tri m sti ck, pry up shi ft boot and
remove (manual trans onl y).
(5) Remove the tri m di sc from the bottom of the
cup hol der.
(6) Remove the bol ts attachi ng the consol e to the
fl oor pan (Fi g. 60).
(7) Shi ft transfer case to four l ow posi ti on.
(8) Li ft the consol e upward and shi ft transmi ssi on
to L (2nd gear for man. trans.).
(9) Remove consol e through the passenger door.
INSTALLATION
(1) Posi ti on and al i gn the consol e i n the vehi cl e.
(2) I nstal l the bol ts attachi ng the consol e to the
fl oor pan.
(3) I nstal l the tri m di sc
(4) I nstal l shi ft boot/i ndi cator bezel .
(5) Return seats to normal posi ti on.
(6) I nstal l the shi ft handl e.
FULL FLOOR CONSOLE
REMOVAL
(1) Move the seats to the ful l rearward posi ti on.
(2) Move the passenger seat i n the ful l recl i ne
posi ti on.
(3) Grasp shi ft handl e (auto trans onl y) and fi rml y
pul l upward to remove.
(4) Usi ng a smal l fl at bl ade, pry up shi ft i ndi cator
bezel , di sengage bezel l amp connector and remove
bezel (auto trans onl y).
(5) Usi ng a tri m sti ck, pry up shi ft boot and
remove (manual trans onl y).
(6) Remove the bol ts attachi ng the consol e to the
fl oor pan (Fi g. 61).
(7) Shi ft transfer case to four l ow posi ti on.
(8) Engage parki ng brake.
(9) Li ft the consol e upward and rotate to remove
through the passenger door.
INSTALLATION
(1) Posi ti on and al i gn the consol e i n the vehi cl e.
Fig. 60 Mini Floor Console
1 – MAT
2 – SHIFT BEZEL
3 – HANDLE
4 – CUP HOLDER MAT
5 – CONSOLE MOUNTING BRACKET
6 – FLOOR PAN
7 – CONSOLE
Fig. 61 Full Floor Console
1 – MAT
2 – SHIFT BEZEL
3 – HANDLE
4 – CUP HOLDER MAT
5 – CONSOLE
6 – CONSOLE MOUNTING BRACKET
7 – FLOOR PAN
TJ BODY 23 - 41
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l the bol ts attachi ng the consol e to the
fl oor pan.
(3) I nstal l shi ft boot/i ndi cator bezel .
(4) Return seats to normal posi ti on.
(5) I nstal l the shi ft handl e.
CONSOLE LOCK CYLINDER
REMOVAL
(1) Open the consol e cover.
(2) Remove the screw that attaches the retai ner to
the l ock and then remove the retai ner from the l ock
(Fi g. 62).
(3) Remove the l ock cyl i nder from the consol e
cover.
INSTALLATION
(1) I nsert the assembl ed l ock i n the consol e cover
hol e and posi ti on the retai ner on the l ock and i nstal l
the screw.
SHIFT BOOT
REMOVAL
(1) Usi ng a tri m sti ck, pry the shi ft boot from the
bezel .
(2) Usi ng a smal l fl at bl ade, pry the shi ft pattern
i nsert from the shi ft knob.
(3) Remove the nut attachi ng the shi ft knob to the
shi ft l ever (Fi g. 63).
(4) Remove the knob and sl i de the shi ft boot from
the shi ft l ever.
INSTALLATION
(1) Sl i de the shi ft boot over the shi ft l ever.
(2) Posi ti on the shi ft knob on the l ever and i nstal l
the nut.
(3) Posi ti on the shi ft pattern i nsert on the knob
and press i nto pl ace.
REAR SEAT
REMOVAL
(1) Move the front seats to the ful l forward posi -
ti on.
(2) Pul l on the rear seat l atch to di sengage the
rear seat from the stri ker.
(3) Li ft the rear seat to the forward tumbl e posi -
ti on.
(4) Remove the hi tch pi ns from the seat frame
pi vot pi ns.
(5) Sl i de the seat to the l eft to di sengage the pi vot
pi n from the pi vot bracket.
(6) Sl i de the seat to the ri ght to di sengage the
opposi te pi vot pi n from the pi vot bracket (Fi g. 64).
(7) Remove the seat through the passenger door
openi ng.
INSTALLATION
(1) Posi ti on the seat on the rear fl oor panel and
engage the seat frame pi vot pi ns wi th the pi vot
brackets.
(2) I nstal l the hi tch pi ns on the seat frame pi vot
pi ns.
(3) Move the seat back to the l atch posi ti on and
engage the stri kers wi th the l atch brackets.
Fig. 62 Console Lock Cylinder
1 – ATTACHING SCREW
2 – LOCK
3 – LOCK CYLINDER
4 – RETAINER
Fig. 63 Shift Boot
1 – COVER
2 – BEZEL
3 – SHIFT BOOT
4 – SHIFT PATTERN INSERT
5 – NUT
6 – KNOB
7 – SHIFT LEVER
8 – SHIFT TUBE
23 - 42 BODY TJ
REMOVAL AND INSTALLATION (Continued)
ADD-A-TRUNK
REMOVAL
(1) Rel ease l atches under trunk panel and l i ft
panel up.
(2) Remove bol ts attachi ng trunk to i nner body
panel (Fi g. 65).
(3) Separate trunk from vehi cl e.
INSTALLATION
(1) Posi ti on the trunk i n the cargo space.
(2) I nstal l the bol ts.
Fig. 64 Rear Seat
1 – PIVOT BRACKET
2 – SEAT LATCH STRIKER
3 – REAR BUCKLE
4 – REAR SEAT
5 – STRAP
6 – WASHER
Fig. 65 Add-A-Trunk
1 – RIVET
2 – ADD-A-TRUNK CARPET
3 – ADD-A-TRUNK PANEL
TJ BODY 23 - 43
REMOVAL AND INSTALLATION (Continued)
FRONT CARPET
REMOVAL
(1) Remove the screws attachi ng the consol e to the
fl oor pan.
(2) Remove the retai ners attachi ng the carpet to
the dash panel (Fi g. 66).
(3) Di sengage the snaps under front seats.
(4) Remove carpet from the vehi cl e
INSTALLATION
(1) Posi ti on the carpet i n the vehi cl e
(2) Engage the snaps around under front seats.
(3) I f equi pped, I nstal l the retai ners attachi ng the
carpet to the dash panel .
(4) I nstal l the screws attachi ng the consol e to the
fl oor pan.
CENTER CARPET
REMOVAL
(1) Di sengage the snaps under front seats.
(2) Remove the carpet.
INSTALLATION
(1) Posi ti on the carpet i n the vehi cl e.
(2) Engage the snaps under front seats.
CARGO AREA CARPET
REMOVAL
(1) Posi ti on the rear seat i n the ful l forward posi -
ti on.
(2) Pul l the carpet from under the rear seat.
(3) I f equi pped, remove the Add-A-Trunk.
(4) Route the rear seat bel t buckl es through the
cargo area carpet.
(5) Separate the carpet from the vehi cl e (Fi g. 67).
INSTALLATION
(1) Posi ti on the carpet i n the vehi cl e.
(2) Route the rear seat bel t buckl es through the
cargo area carpet.
(3) I f equi pped, i nstal l the Add-A-Trunk.
(4) Return the rear seat to the ful l rearward posi -
ti on.
WHEELHOUSE CARPET
REMOVAL
(1) Posi ti on the rear seat i n the ful l forward posi -
ti on.
(2) I f equi pped, remove the Add-A-trunk.
(3) Grasp wheel house carpet and remove from
vehi cl e (Fi g. 67).
INSTALLATION
(1) Posi ti on wheel house carpet i n vehi cl e and
adjust as necessary.
(2) I f equi pped, i nstal l the Add-A-trunk.
(3) Return the rear seat to the ful l rearward posi -
ti on.
Fig. 66 Front Carpet
1 – DASH PANEL
2 – CARPET
3 – PUSH ON RETAINER
23 - 44 BODY TJ
REMOVAL AND INSTALLATION (Continued)
SPORT BAR
REMOVAL
(1) Remove hard top and/or soft top.
(2) Remove the door openi ng frames.
(3) Remove the sunvi sors.
(4) Remove the A-pi l l ar weatherstri ps stri ps (Fi g.
68).
(5) Di sengage center support bar cover zi pper.
(6) Remove the bol ts attachi ng the si de support
bars to the center support bar (Fi g. 69).
(7) Remove the bol ts attachi ng the si de support
bars to the wi ndshi el d frame.
(8) Separate the si de support bars from the vehi -
cl e.
(9) Pul l back the center secti on of the carpet and
remove the bol ts attachi ng the sport bar to the cargo
fl oor panel .
(10) Lower the rear seat and l i ft rear seat to the
ful l forward posi ti on.
(11) Pul l back wheel house carpet and remove bol ts
attachi ng the di recti onal cross bars to the wheel -
house.
(12) Remove the bol ts attachi ng the seatbel t
anchors to the wheel house.
(13) Di sconnect sound bar. Refer to Group 8F,
Audi o Systems for removal and i nstal l ati on proce-
dures.
(14) Careful l y l i ft the sport bar upward and
remove i t from the vehi cl e.
(15) I f necessary, remove the pads and covers from
the sport bar.
INSTALLATION
(1) I f necessary, transfer al l attached components.
(2) Cl ean the base pl ate contact surface areas on
the fl oor and wheel house panel s.
(3) Appl y epoxy chromate pri mer to the attachi ng
hol e edges for protecti on agai nst corrosi on.
(4) Posi ti on the sport bar base pl ates on the fl oor
and wheel house panel s wi th the hol es al i gned.
NOTE: To prevent water seepage, apply 3M Drip-
Chek Sealant (or an equivalent product) to the
underside of the sport bar base flanges and all the
bolt heads before installation.
Fig. 67 Vehicle Carpet
1 – WHEEL HOUSE CARPET
2 – CARGO AREA CARPET
3 – CENTER FLOOR CARPET
4 – FRONT FLOOR CARPET
5 – SNAP
TJ BODY 23 - 45
REMOVAL AND INSTALLATION (Continued)
(5) Connect sound bar. Refer to Group 8F, Audi o
Systems for removal and i nstal l ati on procedures.
(6) I nstal l the bol ts attachi ng the seatbel t anchors
to the wheel house.
(7) I nstal l the bol ts attachi ng the di recti onal cross
bars to the wheel house and i nstal l the wheel house
carpet. Ti ghten the bol ts to 40 N·m (30 ft. l bs.)
torque.
(8) Return seat back to upri ght posi ti on.
(9) I nstal l the bol ts attachi ng the sport bar to the
cargo fl oor panel and i nstal l the center carpet.
Ti ghten the bol ts to 40 N·m (30 ft. l bs.) torque.
(10) Posi ti on si de supports at the wi ndshi el d and
i nstal l the bol ts attachi ng the si de support bars to
the wi ndshi el d frame. Ti ghten the bol ts to 32 N·m
(24 ft. l bs.) torque.
(11) I nstal l the bol ts attachi ng the si de support
bars to the center support bar. Ti ghten the bol ts to
71 N·m (53 ft. l bs.) torque.
(12) Engage center support bar cover zi pper.
(13) I nstal l the A-pi l l ar wi ndshi el d stri ps.
(14) I nstal l the door openi ng frames.
(15) I nstal l hard top and/or soft top.
Fig. 69 Sport Bar
1 – SIDE SUPPORT BAR
2 – CENTER SUPPORT BAR
3 – COVER
4 – COVER
5 – DIRECTIONAL CROSS BAR
6 – COVER
7 – BRACKET
8 – STRAP
9 – COVER
Fig. 68 A-Pillar Weatherstrip
1 – A-PILLAR WEATHERSTRIP
2 – WINDSHIELD FRAME
23 - 46 BODY TJ
REMOVAL AND INSTALLATION (Continued)
REAR VIEW MIRROR
REMOVAL
(1) Loosen the mi rror set screw.
(2) Sl i de the mi rror up and off the support button
(bracket) (Fi g. 70).
INSTALLATION
(1) Sl i de the mi rror onto the support button
(bracket).
CAUTION: Do not over-tighten the setscrew
because glass chipping and/or breakage could
result.
(2) Ti ghten the mi rror setscrew to 1 N·m (9 i n.
l bs.) torque.
REARVIEW MIRROR SUPPORT BRACKET
INSTALLATION
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
• Crush the vi al to saturate the fel t appl i cator.
• Remove the paper sl eeve.
• Appl y accel erator to the contact surface on the
bracket.
• Al l ow the accel erator to dry for fi ve mi nutes.
• Do not touch the bracket contact surface after
the accel erator has been appl i ed.
(5) Appl y adhesi ve accel erator to the bracket con-
tact surface on the wi ndshi el d gl ass. Al l ow the accel -
erator to dry for one mi nute. Do not touch the gl ass
contact surface after the accel erator has been
appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
• Appl y one drop of adhesi ve at the center of the
bracket contact-surface on the wi ndshi el d gl ass.
• Appl y an even coat of adhesi ve to the contact
surface on the bracket.
• Al i gn the bracket wi th the marked posi ti on on
the wi ndshi el d gl ass.
• Press and hol d the bracket i n pl ace for at l east
one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
SUNVISOR
REMOVAL
(1) Remove the screws that attach the sunvi sor
arm support brackets to the wi ndshi el d frame (Fi g.
71).
(2) Remove the sunvi sor from the wi ndshi el d
frame
Fig. 70 Rear View Mirror
1 – REAR VIEW MIRROR
2 – SUPPORT BUTTON
Fig. 71 Sunvisor
1 – WINDSHIELD FRAME
2 – SUNVISOR
3 – SUNVISOR SUPPORT
TJ BODY 23 - 47
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on the sunvi sor on the wi ndshi el d frame
and al i gn the arm support bracket hol es wi th the
frame.
(2) I nstal l the screws that attach the sunvi sor arm
support brackets to the frame. Ti ghten the screws
securel y.
WHEELHOUSE SPLASH SHIELD
REMOVAL
(1) Remove the pl asti c push pi ns that attach the
spl ash shi el d to the wheel house (Fi g. 72).
(2) Remove the push-i n fasteners attachi ng the
spl ash shi el d to the wheel house. (The push-i n fasten-
ers are mol ded i nto the spl ash shi el d.)
(3) Remove the spl ash shi el d from the wheel house.
INSTALLATION
(1) Posi ti on the spl ash shi el d i n the wheel house.
(2) Press the spl ash shi el d push-i n fasteners i nto
pl ace.
(3) Attach the spl ash shi el d to the wheel house
wi th push pi ns.
LIFTGATE GLASS SUPPORT CYLINDER
REMOVAL
WARNING: DO NOT REMOVE THE LIFTGATE SUP-
PORT RODS WITH THE LIFTGATE CLOSED. THE
SUPPORT ROD PISTONS ARE OPERATED BY HIGH
PRESSURE GAS AND COULD CAUSE PERSONAL
INJURY AND/OR VEHICLE DAMAGE IF THEY ARE
REMOVED WITH THE PISTONS COMPRESSED
(LIFTGATE CLOSED). ONCE REMOVED, DO NOT
ATTEMPT TO DISASSEMBLE OR REPAIR THE SUP-
PORT RODS.
(1) Open and support the l i ftgate gl ass.
(2) Remove the support rod cyl i nder retai ni ng cl i ps
at both ends of each support rod cyl i nder (Fi g. 73).
(3) Pul l the support rods off the bal l studs (Fi g.
74).
INSTALLATION
(1) Posi ti on the support rod cyl i nders on the bal l
studs.
(2) I nstal l the support rod cyl i nder retai ner cl i ps.
Fig. 72 Wheelhouse Splash Shield
1 – BODY
2 – WHEELHOUSE SPLASH SHIELD
3 – PUSH-IN FASTENERS
4 – RIVET
Fig. 73 Support Rod Cylinder
1 – CLIP
2 – LIFTGATE GLASS
3 – SUPPORT CYLINDER
Fig. 74 Support Rod Cylinder Removal
1 – REAR WINDOW LIFT GLASS
2 – SUPPORT CYLINDER
23 - 48 BODY TJ
REMOVAL AND INSTALLATION (Continued)
LIFTGATE GLASS
REMOVAL
(1) I f equi pped, di sconnect the rear defroster har-
ness connectors (Fi g. 75).
(2) I f equi pped, di sconnect the wi per motor har-
ness connectors.
WARNING: DO NOT REMOVE THE LIFTGATE SUP-
PORT RODS WITH THE LIFTGATE CLOSED. THE
SUPPORT ROD PISTONS ARE OPERATED BY HIGH
PRESSURE GAS AND COULD CAUSE PERSONAL
INJURY AND/OR VEHICLE DAMAGE IF THEY ARE
REMOVED WITH THE PISTONS COMPRESSED
(LIFTGATE CLOSED). ONCE REMOVED, DO NOT
ATTEMPT TO DISASSEMBLE OR REPAIR THE SUP-
PORT RODS.
(3) Open the tai l gate and l i ftgate.
(4) Remove support rod cyl i nders.
(5) Remove the bol ts attachi ng the l i ftgate hi nge to
the hardtop (Fi g. 76).
(6) Separate the l i ftgate gl ass from the hard top.
INSTALLATION
Transfer al l rel ated components
(1) I f removed, i nstal l support rod bal l studs.
Ti ghten the nut to 12 N·m ( 112 i n. l bs.) torque.
(2) Posi ti on the l i ftgate gl ass at the hard top.
(3) I nstal l the bol ts attachi ng the l i ftgate hi nge to
the hardtop. Ti ghten the bol ts to 10 N·m (95 i n. l bs.)
torque.
(4) Posi ti on the support rod cyl i nders on the bal l
studs and i nstal l the cl i ps.
LIFTGATE GLASS HINGE
REMOVAL
(1) Open tai l gate.
(2) Open and support l i ftgate gl ass.
(3) Remove wi per motor cover (ri ght hi nge onl y).
(4) Remove the nut attachi ng the l i ftgate hi nge to
the l i ftgate gl ass.
(5) Mark the posi ti on of the hi nge i n the top and
remove the bol ts attachi ng the hi nge to the top (Fi g.
77).
INSTALLATION
(1) Al i gn and posi ti on the hi nge on the top and
i nstal l the bol ts.
Fig. 75 Rear Defroster Connectors
1 – CONNECTOR
2 – HARD TOP
Fig. 76 Liftgate Glass
1 – LIFTGATE REAR WINDOW
2 – HARD TOP
Fig. 77 Liftgate Hinge
1 – LIFTGATE HINGE
2 – LIFTGATE GLASS
TJ BODY 23 - 49
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l the nut attachi ng the l i ftgate hi nge to
the l i ftgate gl ass. Ti ghten the nut to 6 N·m ( 53 i n.
l bs.) torque.
(3) I f removed, i nstal l wi per motor cover.
LIFTGATE GLASS WEATHERSTRIP
The l i ftgate gl ass weatherstri p i s attached to the
l i ftgate gl ass and i s not servi ceabl e. I f the l i ftgate
gl ass weatherstri p needs to be repl aced, repl ace the
l i ftgate gl ass.
SPARE TIRE CARRIER
REMOVAL
(1) Remove the spare ti re from the wheel bracket
(Fi g. 78).
(2) Remove the bol ts that attach the ti re bracket
to the tai l gate (Fi g. 79).
(3) Di sconnect CHMSL.
(4) Remove the bracket and the gaskets from the
tai l gate.
INSTALLATION
(1) Posi ti on the gaskets and the ti re bracket on the
tai l gate and i nstal l the bol ts. Ti ghten the bol ts to 24
N·m (17 ft. l bs.) torque.
(2) Connect CHMSL connector.
(3) I nstal l the spare ti re on the ti re bracket.
LICENSE PLATE BRACKET
REMOVAL
(1) I f i nstal l ed, remove the l i cense pl ate.
(2) Remove the screws attachi ng the l i cense pl ate
bracket to the body (Fi g. 80).
(3) Separate the bracket from the body.
INSTALLATION
(1) Posi ti on the bracket on the body.
(2) I nstal l the screws attachi ng the l i cense pl ate
bracket to the body.
(3) I f removed, i nstal l the l i cense pl ate.
Fig. 78 Spare Tire
1 – WHEEL NUT
2 – CHMSL
3 – LOCK NUT
Fig. 79 Spare Tire Bracket
1 – BUMPER
2 – GASKET
3 – TAILGATE
4 – SPARE TIRE BRACKET
Fig. 80 License Plate Bracket
1 – LICENSE PLATE BRACKET
23 - 50 BODY TJ
REMOVAL AND INSTALLATION (Continued)
TAILGATE
REMOVAL
(1) Remove the spare ti re.
(2) Open the tai l gate and remove the CHMSL con-
tact cover (Fi g. 81).
(3) Di sengage the CHMSL el ectri cal connectors.
(4) Remove the screws that attach the tai l gate
hi nge to the tai l gate.
(5) Separate the tai l gate from the vehi cl e.
INSTALLATION
I f necessary, transfer tai l gate rel ated components.
(1) I nstal l the screws that attach the tai l gate
hi nge to the tai l gate.
(2) Engage the CHMSL el ectri cal connectors.
(3) I nstal l the CHMSL contact cover.
(4) Cl ose the tai l gate and i nstal l the spare ti re.
TAILGATE HINGE
Hi nges may be servi ced i ndi vi dual l y. I f both are to
be servi ced, remove/i nstal l hi nges one at a ti me.
REMOVAL
(1) Usi ng a wax penci l , mark the posi ti on of the
hi nge on the body.
(2) Remove the screws attachi ng the hi nge to the
body and tai l gate (Fi g. 82).
(3) Separate the hi nge from the tai l gate.
INSTALLATION
(1) Prepare and pai nt the repl acement hi nge to
match the body pai nt col or.
(2) Lubri cate the hi nge wi th spray l ubri cant.
(3) Al i gn and posi ti on the hi nge on the body and
tai l gate.
(4) I nstal l the screws. Ti ghten the screws to 23
N·m (200 i n. l bs.) torque
TAILGATE OUTSIDE HANDLE
REMOVAL
(1) Remove the l atch from the tai l gate.
(2) Remove the screws attachi ng the outsi de han-
dl e to the tai l gate (Fi g. 83).
(3) Separate the outsi de handl e and seal from the
tai l gate.
Fig. 81 CHMSL Contact Cover
1 – TAILGATE
2 – COVER
3 – CHMSL CONTACT COVER BRACKET
Fig. 82 Tailgate Hinge
1 – TAILGATE
2 – NUT PLATE
3 – HINGE
Fig. 83 Tailgate Outside Handle
1 – OUTSIDE HANDLE
2 – SEAL
3 – TAILGATE
TJ BODY 23 - 51
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on the seal and outsi de rel ease handl e on
the tai l gate. and i nstal l screws.
(2) I nstal l the screws attachi ng the outsi de handl e
to the tai l gate.
(3) I nstal l the l atch.
TAILGATE LOCK CYLINDER
REMOVAL
(1) Open the tai l gate.
(2) Remove the l atch cover.
(3) Remove the l ock cyl i nder retai ner cl i p.
Remove the l ock cyl i nder from the tai l gate open-
i ng.
INSTALLATION
(1) Posi ti on the l ock cyl i nder i n the tai l gate open-
i ng.
(2) Connect the l ock cyl i nder to l atch rod.
(3) I nstal l the l ock cyl i nder retai ner cl i p.
(4) I nstal l the l atch cover.
TAILGATE LATCH
REMOVAL
(1) Open the tai l gate and remove the l atch tri m
cover (Fi g. 84).
(2) Di sconnect the outsi de handl e to l atch rod.
(3) Di sconnect the l ock cyl i nder to l atch rod.
(4) Remove the screw attachi ng l atch to tai l gate.
(5) Separate the l atch from the tai l gate.
INSTALLATION
(1) Posi ti on the l atch i n the tai l gate.
(2) I nstal l the screw attachi ng l atch to tai l gate. Do
not ti ghten screw.
(3) Connect the l ock cyl i nder to l atch rod.
(4) Connect the outsi de handl e to l atch rod.
(5) I nstal l the l atch tri m cover. Ti ghten al l screws.
TAILGATE LATCH STRIKER
REMOVAL
(1) Remove the stri ker from the bracket wi th a
Torx bi t.
(2) Remove the shi m washers from the bracket.
(3) Remove the screws attachi ng the stri ker
bracket to the body.
INSTALLATION
(1) Posi ti on the stri ker bracket on the body and
i nstal l the screws.
(2) Posi ti on the stri ker and shi m washers on the
stri ker bracket.
(3) I nstal l the stri ker i n the bracket wi th a Torx
bi t. Ti ghten the stri ker to 71 N·m (52 ft. l bs.) torque.
Fig. 84 Tailgate Latch Cover
1 – SLEEVE
2 – OUTSIDE HANDLE TO LATCH ROD
3 – CLIP
4 – OUTSIDE HANDLE
5 – LATCH
6 – STRIKER MOUNTING BRACKET
7 – LATCH TO LOCK CYLINDER ROD
8 – LATCH COVER
9 – TAILGATE
23 - 52 BODY TJ
REMOVAL AND INSTALLATION (Continued)
TAILGATE WEATHERSTRIP AND CHANNEL
REMOVAL
(1) Open the tai l gate.
(2) Remove the push-i n fasteners attachi ng the
weatherstri p to the top corners of the tai l gate (Fi g.
85).
(3) Peel the weatherstri p from the upper tai l gate
corners.
(4) Sl i de the weatherstri p out of the tai l gate.
(5) I f the weatherstri p channel requi res repl ace-
ment, peel the weatherstri p channel from the tai l -
gate.
INSTALLATION
(1) I f the weatherstri p channel i s bei ng repl aced;
(a) Cl ean the channel contact surface on the tai l -
gate wi th i sopropyl al cohol , or equi val ent.
(b) Peel the paper backi ng from the weatherstri p
channel .
(c) Posi ti on weatherstri p channel to the tai l gate
and press i nto pl ace.
(d) Use hand pressure or a rol l er to wet out the
tape adhesi ve hol di ng the weatherstri p channel to
the tai l gate.
(2) Sl i de the weatherstri p i nto the weatherstri p
channel .
(3) Cl ean the weatherstri p contact surface on the
tai l gate wi th i sopropyl al cohol , or equi val ent.
(4) Remove paper backi ng from upper ends of
weatherstri p.
(5) Posi ti on the weatherstri p to the tai l gate and
press i t i nto pl ace.
(6) I nstal l the push-i n fasteners attachi ng the
weatherstri p to the tai l gate.
(7) Use hand pressure or a rol l er to wet out the
tape adhesi ve hol di ng the weatherstri p to the tai l -
gate.
ADJ USTMENTS
HOOD ADJUSTMENT
The hood hi nge screw hol es are oversi zed to faci l i -
tate hood adjustment movement.
(1) Loosen the screws.
(2) Move the hood i n the di recti on(s) requi red for
correct al i gnment.
(3) Ti ghten the screws.
DOOR ADJUSTMENT
The doors are adjusted at the hi nge attachi ng l oca-
ti ons on ei ther the body or the door. Enl arged hol es
are l ocated i n the body (l ower hi nge onl y) for fore, aft
and ti l t adjustments. Enl arged hol es are al so l ocated
i n the door (upper and l ower hi nges) for up, down,
fore, aft and ti l t adjustments.
Pri or to door adjustment or al i gnment, the door
l atch must be removed to al l ow the door to cl ose
freel y and be properl y al i gned.
The door l atch stri ker shoul d be adjusted i n or out
to al l ow the door l atch to be ful l y engaged. The door
shoul d be fl ush wi th the adjacent body panel s.
TAILGATE ADJUSTMENT
(1) Loosen the tai l gate hi nge-to-body screws.
(2) Al i gn the tai l gate i n the body openi ng and
ti ghten the hi nge screws.
Fig. 85 Tailgate Weatherstrip
1 – TAILGATE
2 – WEATHERSTRIP
TJ BODY 23 - 53
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
BODY LUBRICANTS
COMPONENT SERVICE INTERVAL LUBRICANT
Door Latches As Required Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Hood Latch, Release Mechanism &
Safety Latch
As Required
(When Performing Other
Underhood Service)
Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Hood Hinges As Required Engine Oil
Seat Track & Release Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Tailgate Hinge As Required Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Liftgate Support Arms As Required Engine Oil
Tailgate Latches As Required White Spray Lubricant (3)
Tailgate Release Handle As Required Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Window System Components As Required White Spray Lubricant (3)
Lock Cylinders Twice A Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2
EP (1)
1 = Mopar Wheel Bering Grease (High
Temp)
2 = Mopar Multi-Mileage Lubricant
3 = Mopar Spray White Lube
4 = Mopar Lock Cylinder Lubricant
23 - 54 BODY TJ
WELD LOCATIONS
DASH, COWL AND PLENUM
TJ BODY 23 - 55
SPECIFICATIONS (Continued)
DASH, COWL AND PLENUM
23 - 56 BODY TJ
SPECIFICATIONS (Continued)
DASH, COWL AND PLENUM
TJ BODY 23 - 57
SPECIFICATIONS (Continued)
DASH, COWL AND PLENUM
23 - 58 BODY TJ
SPECIFICATIONS (Continued)
DASH, COWL AND PLENUM
TJ BODY 23 - 59
SPECIFICATIONS (Continued)
DASH, COWL AND PLENUM SUPPORTS AND
REINFORCEMENTS
23 - 60 BODY TJ
SPECIFICATIONS (Continued)
DASH, COWL AND PLENUM SUPPORTS AND
REINFORCEMENTS
TJ BODY 23 - 61
SPECIFICATIONS (Continued)
DASH, COWL AND PLENUM SUPPORTS AND
REINFORCEMENTS
23 - 62 BODY TJ
SPECIFICATIONS (Continued)
DASH, COWL AND PLENUM SUPPORTS AND
REINFORCEMENTS
TJ BODY 23 - 63
SPECIFICATIONS (Continued)
FRONT FLOOR, STRAINER, REINFORCEMENT AND
COWL SIDE LOWER
23 - 64 BODY TJ
SPECIFICATIONS (Continued)
FRONT FLOOR, STRAINER, REINFORCEMENT AND
COWL SIDE LOWER
TJ BODY 23 - 65
SPECIFICATIONS (Continued)
FRONT FLOOR, STRAINER, REINFORCEMENT AND
COWL SIDE LOWER
23 - 66 BODY TJ
SPECIFICATIONS (Continued)
FRONT FLOOR, STRAINER, REINFORCEMENT AND
COWL SIDE LOWER
TJ BODY 23 - 67
SPECIFICATIONS (Continued)
SIDE APERTURE
23 - 68 BODY TJ
SPECIFICATIONS (Continued)
SIDE APERTURE
TJ BODY 23 - 69
SPECIFICATIONS (Continued)
SIDE APERTURE
23 - 70 BODY TJ
SPECIFICATIONS (Continued)
SIDE APERTURE
TJ BODY 23 - 71
SPECIFICATIONS (Continued)
SIDE APERTURE
23 - 72 BODY TJ
SPECIFICATIONS (Continued)
WHEELHOUSE
TJ BODY 23 - 73
SPECIFICATIONS (Continued)
WHEELHOUSE
23 - 74 BODY TJ
SPECIFICATIONS (Continued)
WHEELHOUSE
TJ BODY 23 - 75
SPECIFICATIONS (Continued)
REAR FLOOR PAN AND REINFORCEMENTS
23 - 76 BODY TJ
SPECIFICATIONS (Continued)
REAR FLOOR PAN AND REINFORCEMENTS
TJ BODY 23 - 77
SPECIFICATIONS (Continued)
REAR FLOOR PAN AND REINFORCEMENTS
23 - 78 BODY TJ
SPECIFICATIONS (Continued)
DOOR OUTER PANELS
TJ BODY 23 - 79
SPECIFICATIONS (Continued)
DOOR OUTER PANELS
23 - 80 BODY TJ
SPECIFICATIONS (Continued)
SEALER LOCATIONS
APPLICATION METHODS
TJ BODY 23 - 81
SPECIFICATIONS (Continued)
COWL AND PLENUM
23 - 82 BODY TJ
SPECIFICATIONS (Continued)
COWL TOP END AND PLENUM
TJ BODY 23 - 83
SPECIFICATIONS (Continued)
COWL AND WINDSHIELD OUTER PANEL
INNER WHEELHOUSE
23 - 84 BODY TJ
SPECIFICATIONS (Continued)
REAR FLOOR RISER AND OUTER BODY SEAMS
REAR CORNER PANEL
TJ BODY 23 - 85
SPECIFICATIONS (Continued)
HALF DOOR
FULL DOOR
23 - 86 BODY TJ
SPECIFICATIONS (Continued)
BODY OPENING DIMENSIONS
WINDSHIELD OPENING
• A & B. Center of radi us at bottom to center of
radi us top.
TJ BODY 23 - 87
SPECIFICATIONS (Continued)
DOOR OPENING
• A. Center of radi us at bottom front to center of
radi us at top rear.
• B. Center of door l ower rear corner to center of
top of wi ndshi el d frame.
• C. Center of door l ower rear corner to top of
cowl .
• D. Center of door hi nge mount to center of door
stri ker mount.
23 - 88 BODY TJ
SPECIFICATIONS (Continued)
QUARTER WINDOW OPENING
TJ BODY 23 - 89
SPECIFICATIONS (Continued)
ENGINE COMPARTMENT
23 - 90 BODY TJ
SPECIFICATIONS (Continued)
TAILGATE AND LIFTGATE OPENING
• A. Center of l i ftgate openi ng to fl oor.
• B. Center of radi us upper corner to center of
body and fl oor corner.
• C. Li ftgate openi ng di stance.
• D. Tai l gate openi ng di stance.
TJ BODY 23 - 91
SPECIFICATIONS (Continued)
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Hood hi nge screws . . . . . . . . . 17 N·m (155 i n. l bs.)
Bucket seat front anchor bol t . . 47 N·m (35 ft. l bs.)
Bucket seat rear i nboard anchor bol t . . . . . 74 N·m
(55 ft. l bs.)
Bucket seat rear outboard anchor bol t . 33 N·m (25
ft. l bs.)
Li ftgate gl ass bal l stud nut . . 12 N·m ( 112 i n. l bs.)
Li ftgate gl ass hi nge nut . . . . . . 6 N·m ( 53 i n. l bs.)
Li ftgate hi nge to hardtop bol t . 10 N·m ( 95 i n. l bs.)
Front turni ng l oop bol t . . . . . . . 47 N·m ( 35 ft. l bs.)
Front retractor bol t . . . . . . . . . 47 N·m ( 35 ft. l bs.)
Rear retractor bol t . . . . . . . . . . 47 N·m ( 35 ft. l bs.)
Rear turni ng l oop bol t . . . . . . . 47 N·m ( 35 ft. l bs.)
Rear bel t anchor bol t . . . . . . . . 47 N·m ( 35 ft. l bs.)
Rearvi ew mi rror setscrew . . . . . . . 1 N·m (9 i n. l bs.)
Rear buckl e anchor bol t . . . . . . 43 N·m ( 32 ft. l bs.)
Si de support bar to sport bar bol ts . . . . . . . 71 N·m
(53 ft. l bs.)
Sport bar to wheel house bol ts . . 40 N·m (30 ft. l bs.)
Sport bar to cargo fl oor bol ts . . . 40 N·m (30 ft. l bs.)
Sport bar to wi ndshi el d frame bol ts . . . . . . 32 N·m
(24 ft. l bs.)
Tai l gate hi nge screws . . . . . . . 23 N·m (200 i n. l bs.)
Tai l gate stri ker . . . . . . . . . . . . . 71 N·m (52 ft. l bs.)
SPECIAL TOOLS
BODY
Trim Stick C-4755
Remover, Moldings C-4829
23 - 92 BODY TJ
SPECIFICATIONS (Continued)
HEATING AND AIR CONDITIONING
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BLOWER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . 2
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . . 2
BLOWER MOTOR RESISTOR. . . . . . . . . . . . . . . . 3
BLOWER MOTOR SWITCH. . . . . . . . . . . . . . . . . . 3
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPRESSOR CLUTCH. . . . . . . . . . . . . . . . . . . . 3
COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . . 4
CONDENSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . 4
FIXED ORIFICE TUBE . . . . . . . . . . . . . . . . . . . . . . 4
HEATER AND AIR CONDITIONER CONTROL . . . . 5
HEATER AND AIR CONDITIONER. . . . . . . . . . . . . 5
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . . . . 6
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . . . . 6
LOW PRESSURE CYCLING CLUTCH SWITCH. . . 7
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERANT LINES. . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERANT LINE COUPLERS . . . . . . . . . . . . . 8
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . . . . . . 8
REFRIGERANT SYSTEM SERVICE PORT. . . . . . . 8
VACUUM CHECK VALVE. . . . . . . . . . . . . . . . . . . . 9
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING
A/C PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . 9
BLOWER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . 12
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . 13
BLOWER MOTOR RESISTOR. . . . . . . . . . . . . . . 14
BLOWER MOTOR SWITCH. . . . . . . . . . . . . . . . . 14
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMPRESSOR CLUTCH COIL . . . . . . . . . . . . . . 15
COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . 15
HEATER PERFORMANCE . . . . . . . . . . . . . . . . . . 16
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . . . 17
LOW PRESSURE CYCLING CLUTCH SWITCH. . 17
REFRIGERANT SYSTEM LEAKS. . . . . . . . . . . . . 17
VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE PROCEDURES
REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . . . . 22
REFRIGERANT RECOVERY. . . . . . . . . . . . . . . . . 22
REFRIGERANT SYSTEM CHARGE . . . . . . . . . . . 22
REFRIGERANT SYSTEM EVACUATE. . . . . . . . . . 22
REFRIGERANT SYSTEM SERVICE
EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND PRECAUTIONS . . . . 24
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . 25
BLEND-AIR DOOR MOTOR . . . . . . . . . . . . . . . . 26
BLOWER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . 27
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . 27
BLOWER MOTOR RESISTOR. . . . . . . . . . . . . . . 28
BLOWER MOTOR SWITCH. . . . . . . . . . . . . . . . . 28
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 29
COMPRESSOR CLUTCH. . . . . . . . . . . . . . . . . . . 30
COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . 32
CONDENSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DUCTS AND OUTLETS . . . . . . . . . . . . . . . . . . . . 34
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . 36
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . 36
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . . . . 36
HEATER-A/C HOUSING. . . . . . . . . . . . . . . . . . . . 38
HEATER-A/C HOUSING DOOR . . . . . . . . . . . . . . 40
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . . . 42
KICK COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
LIQUID LINE/FIXED ORIFICE TUBE . . . . . . . . . . 43
LOW PRESSURE CYCLING CLUTCH SWITCH. . 44
MODE DOOR VACUUM ACTUATOR . . . . . . . . . . 44
REFRIGERANT LINE COUPLER . . . . . . . . . . . . . 46
SUCTION AND DISCHARGE LINE . . . . . . . . . . . 47
VACUUM CHECK VALVE. . . . . . . . . . . . . . . . . . . 48
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 48
SPECIFICATIONS
A/C APPLICATION TABLE. . . . . . . . . . . . . . . . . . 49
TJ HEATING AND AIR CONDITIONING 24 - 1
DESCRIPTION AND OPERATION
ACCUMULATOR
DESCRIPTION
The accumul ator i s mounted i n the engi ne com-
partment between the evaporator coi l outl et tube and
the compressor i nl et.
OPERATION
Refri gerant enters the accumul ator cani ster as a
l ow pressure vapor through the i nl et tube. Any l i q-
ui d, oi l -l aden refri gerant fal l s to the bottom of the
cani ster, whi ch acts as a separator. A desi ccant bag i s
mounted i nsi de the accumul ator cani ster to absorb
any moi sture whi ch may have entered and become
trapped wi thi n the refri gerant system (Fi g. 1).
BLOWER MOTOR
DESCRIPTION
The bl ower motor and bl ower wheel are l ocated i n
the passenger si de end of the heater-A/C housi ng,
bel ow the gl ove box. The bl ower motor control s the
vel oci ty of ai r fl owi ng through the heater-A/C hous-
i ng by spi nni ng a squi rrel cage-type bl ower wheel
wi thi n the housi ng at the sel ected speed. The bl ower
motor and wheel can be removed through an openi ng
i n the engi ne compartment si de of the dash panel
wi thout heater-A/C housi ng removal .
OPERATION
The bl ower motor wi l l onl y operate when the i gni -
ti on swi tch i s i n the On posi ti on, and the heater-A/C
mode control swi tch knob i s i n any posi ti on, except
Off. The bl ower motor recei ves a ground feed at al l
ti mes. The bl ower motor battery feed ci rcui t i s pro-
tected by a fuse i n the fusebl ock modul e for al l
bl ower speeds except hi gh. The hi gh speed battery
feed ci rcui t i s protected by a fuse i n the Power Di s-
tri buti on Center (PDC). Bl ower motor speed i s con-
trol l ed by regul ati ng the battery feed through the
bl ower motor swi tch, bl ower motor resi stor, and a
bl ower motor rel ay.
The bl ower motor and bl ower motor wheel cannot
be repai red and, i f faul ty or damaged, they must be
repl aced. The bl ower motor and bl ower wheel are ser-
vi ced onl y as a uni t.
BLOWER MOTOR RELAY
DESCRIPTION
The bl ower motor rel ay i s a I nternati onal Stan-
dards Organi zati on (I SO)-type rel ay. The rel ay i s a
el ectromechani cal devi ce that swi tches battery cur-
rent to the bl ower motor.
OPERATION
When the bl ower motor swi tch i s i n any posi ti on
except off, and the i gni ti on i s turned on, the bl ower
motor rel ay i s energi zed and provi des battery feed to
the bl ower motor from a fuse i n the fusebl ock modul e
through the bl ower motor resi stor.
The bl ower motor rel ay coi l i s control l ed by a vol t-
age si gnal from the bl ower motor swi tch. See Bl ower
Motor Rel ay i n the Di agnosi s and Testi ng secti on of
thi s group for more i nformati on.
The bl ower motor rel ay i s i nstal l ed i n a wi re har-
ness connector l ocated near the passenger si de out-
board end of the heater-A/C housi ng i n the passenger
compartment, next to the heater-A/C wi re harness
connector.
The bl ower motor rel ay cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
Fig. 1 Accumulator - Typical
1 – LOW PRESSURE CYCLING CLUTCH SWITCH
2 – PRESSURE SWITCH FITTING
3 – OUTLET TO COMPRESSOR
4 – ANTI-SIPHON HOLE
5 – DESICCANT BAG
6 – OIL RETURN ORIFICE FILTER
7 – VAPOR RETURN TUBE
8 – ACCUMULATOR DOME
9 – O-RING SEAL
10 – INLET FROM EVAPORATOR
24 - 2 HEATING AND AIR CONDITIONING TJ
BLOWER MOTOR RESISTOR
DESCRIPTION
The bl ower motor resi stor i s mounted to the bot-
tom of the heater-A/C housi ng on the passenger si de
of the vehi cl e under the i nstrument panel . I t can be
accessed for servi ce by removi ng the heater-A/C
housi ng ki ck cover.
OPERATION
The resi stor has mul ti pl e resi stor wi res, each of
whi ch reduce the current fl ow to the bl ower motor, to
change the bl ower motor speed. The bl ower motor
swi tch di rects battery current to the correct resi stor
wi re to obtai n the sel ected speed. When the hi ghest
bl ower motor speed i s sel ected, the bl ower motor
rel ay connects the bl ower motor di rectl y to battery
current, bypassi ng the bl ower motor resi stor.
The bl ower motor resi stor cannot be repai red and,
i f faul ty or damaged, i t must be repl aced.
BLOWER MOTOR SWITCH
DESCRIPTION
The heater-onl y or heater-A/C bl ower motor i s con-
trol l ed by a four posi ti on rotary-type bl ower motor
swi tch, mounted i n the heater-A/C control panel . The
swi tch al l ows the sel ecti on of one of four bl ower
motor speeds, but can onl y be turned off by sel ecti ng
the Off posi ti on wi th the heater-A/C mode control
swi tch.
OPERATION
The bl ower motor swi tch recei ves i gni ti on-swi tched
battery current through the mode control swi tch from
a fuse i n the fusebl ock modul e. The bl ower motor
swi tch di rects the battery current to the bl ower
motor resi stor, or to the bl ower motor rel ay, as
requi red to achi eve the sel ected bl ower motor speed.
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, i t must be repl aced. The bl ower
motor swi tch knob i s avai l abl e for servi ce repl ace-
ment.
COMPRESSOR
DESCRIPTION
The ai r condi ti oni ng system uses a Denso 10PA17
seven cyl i nder, reci procati ng wobbl e pl ate-type com-
pressor on al l model s. Thi s compressor has a fi xed
di spl acement of 150 cubi c centi meters (9.375 cubi c
i nches), and has both the sucti on and di scharge ports
l ocated on the cyl i nder head. A l abel i denti fyi ng the
use of R-134a refri gerant i s l ocated on the compres-
sor.
OPERATION
The compressor i s dri ven by the engi ne through an
el ectri c cl utch, dri ve pul l ey and bel t arrangement.
The compressor i s l ubri cated by refri gerant oi l that i s
ci rcul ated throughout the refri gerant system wi th the
refri gerant.
The compressor draws i n l ow-pressure refri gerant
vapor from the evaporator through i ts sucti on port. I t
then compresses the refri gerant i nto a hi gh-pressure,
hi gh-temperature refri gerant vapor, whi ch i s then
pumped to the condenser through the compressor di s-
charge port.
The compressor cannot be repai red. I f faul ty or
damaged, the enti re compressor assembl y must be
repl aced. The compressor cl utch, pul l ey and cl utch
coi l are avai l abl e for servi ce.
COMPRESSOR CLUTCH
DESCRIPTION
The compressor cl utch assembl y consi sts of a sta-
ti onary el ectromagneti c coi l , a hub beari ng and pul -
l ey assembl y, and a cl utch pl ate (Fi g. 2). The
el ectromagneti c coi l uni t and the hub beari ng and
pul l ey assembl y are each retai ned on the nose of the
compressor front housi ng wi th snap ri ngs. The cl utch
pl ate i s keyed to the compressor shaft and secured
wi th a nut. These components provi de the means to
engage and di sengage the compressor from the
engi ne serpenti ne accessory dri ve bel t.
Fig. 2 Compressor Clutch
1 – CLUTCH PLATE
2 – SHAFT KEY
3 – PULLEY
4 – COIL
5 – CLUTCH SHIMS
6 – SNAP RING
7 – SNAP RING
TJ HEATING AND AIR CONDITIONING 24 - 3
DESCRIPTION AND OPERATION (Continued)
OPERATION
When the cl utch coi l i s energi zed, i t magneti cal l y
draws the cl utch i nto contact wi th the pul l ey and
dri ves the compressor shaft. When the coi l i s not
energi zed, the pul l ey freewheel s on the cl utch hub
beari ng, whi ch i s part of the pul l ey. The compressor
cl utch and coi l are the onl y servi ced parts on the
compressor.
The compressor cl utch engagement i s control l ed by
several components: the heater-A/C mode control
swi tch, the l ow pressure cycl i ng cl utch swi tch, the
hi gh pressure cut-off swi tch, the compressor cl utch
rel ay, and the Powertrai n Control Modul e (PCM).
The PCM may del ay compressor cl utch engagement
for up to thi rty seconds. Refer to Group 14 - Fuel
System for more i nformati on on the PCM control s.
COMPRESSOR CLUTCH RELAY
DESCRIPTION
The compressor cl utch rel ay i s a I nternati onal
Standards Organi zati on (I SO) mi cro-rel ay. The termi -
nal desi gnati ons and functi ons are the same as a con-
venti onal I SO rel ay. However, the mi cro-rel ay
termi nal ori entati on (footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the rel ay case di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment. Refer to the PDC l abel for rel ay i denti fi cati on
and l ocati on.
OPERATION
The compressor cl utch rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the compres-
sor cl utch coi l when the Powertrai n Control Modul e
(PCM) grounds the coi l si de of the rel ay. The PCM
responds to i nputs from the heater-A/C mode control
swi tch, the l ow pressure cycl i ng cl utch swi tch, and
the hi gh pressure cut-off swi tch. See Compressor
Cl utch Rel ay i n the Di agnosi s and Testi ng secti on of
thi s group for more i nformati on.
The compressor cl utch rel ay cannot be repai red
and, i f faul ty or damaged, i t must be repl aced.
CONDENSER
DESCRIPTION
The condenser i s l ocated i n the ai r fl ow i n front of
the engi ne cool i ng radi ator. The condenser i s a heat
exchanger that al l ows the hi gh-pressure refri gerant
gas bei ng di scharged by the compressor to gi ve up i ts
heat to the ai r passi ng over the condenser fi ns.
OPERATION
When the refri gerant gas gi ves up i ts heat, i t con-
denses. When the refri gerant l eaves the condenser, i t
has become a hi gh-pressure l i qui d refri gerant. The
vol ume of ai r fl owi ng over the condenser fi ns i s cri t-
i cal to the proper cool i ng performance of the ai r con-
di ti oni ng system. Therefore, i t i s i mportant that
there are no objects pl aced i n front of the radi ator
gri l l e openi ngs i n the front of the vehi cl e or forei gn
materi al on the condenser fi ns that mi ght obstruct
proper ai r fl ow. Al so, any factory-i nstal l ed ai r seal s or
shrouds must be properl y rei nstal l ed fol l owi ng radi a-
tor or condenser servi ce.
The condenser cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
EVAPORATOR COIL
DESCRIPTION
The evaporator coi l i s l ocated i n the heater-A/C
housi ng, under the i nstrument panel . The evaporator
coi l i s posi ti oned i n the heater-A/C housi ng so that
al l ai r that enters the housi ng must pass over the
fi ns of the evaporator before i t i s di stri buted through
the system ducts and outl ets. However, ai r passi ng
over the evaporator coi l fi ns wi l l onl y be condi ti oned
when the compressor i s engaged and ci rcul ati ng
refri gerant through the evaporator coi l tubes.
OPERATION
Refri gerant enters the evaporator from the fi xed
ori fi ce tube as a l ow-temperature, l ow-pressure l i q-
ui d. As ai r fl ows over the fi ns of the evaporator, the
humi di ty i n the ai r condenses on the fi ns, and the
heat from the ai r i s absorbed by the refri gerant. Heat
absorpti on causes the refri gerant to boi l and vapor-
i ze. The refri gerant becomes a l ow-pressure gas when
i t l eaves the evaporator.
The evaporator coi l cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
FIXED ORIFICE TUBE
DESCRIPTION
The fi xed ori fi ce tube i s factory i nstal l ed as part of
the l i qui d l i ne, and connects the outl et of the con-
denser to the i nl et of the evaporator. The ori fi ce tube
i s l ocated i n the end of the l i qui d l i ne that i s cl osest
to the condenser outl et tube.
The i nl et end of the fi xed ori fi ce tube has a nyl on
mesh fi l ter screen, whi ch fi l ters the refri gerant and
hel ps to reduce the potenti al for bl ockage of the
meteri ng ori fi ce by refri gerant system contami nants
(Fi g. 3). The outl et end of the tube has a nyl on mesh
di ffuser screen. The O-ri ngs on the pl asti c body of
the fi xed ori fi ce tube seal the tube to the i nsi de of
24 - 4 HEATING AND AIR CONDITIONING TJ
DESCRIPTION AND OPERATION (Continued)
the l i qui d l i ne and prevent the refri gerant from
bypassi ng the fi xed meteri ng ori fi ce.
OPERATION
The fi xed ori fi ce tube i s used to meter the fl ow of
l i qui d refri gerant i nto the evaporator coi l . The hi gh-
pressure l i qui d refri gerant from the condenser
expands i nto a l ow-pressure l i qui d as i t passes
through the meteri ng ori fi ce and di ffuser screen of
the fi xed ori fi ce tube.
The fi xed ori fi ce tube i s not servi ceabl e. I t cannot
be repai red, and i f faul ty or pl ugged, i t must be
repl aced as part of the refri gerant l i ne.
HEATER AND AIR CONDITIONER CONTROL
DESCRIPTION
Both the heater-onl y and heater-A/C systems use a
combi nati on of mechani cal , el ectri cal , and vacuum
control s. These control s provi de the vehi cl e operator
wi th a number of setti ng opti ons to hel p control the
cl i mate and comfort wi thi n the vehi cl e. Refer to the
owner’s manual i n the vehi cl e gl ove box for more
i nformati on on the suggested operati on and use of
these control s.
OPERATION
The heater-onl y or heater-A/C control panel i s
l ocated i n the i nstrument panel center bezel bel ow
the radi o and above the accessory swi tch bezel and
ash recei ver. The control panel contai ns a rotary-type
temperature control , a rotary-type mode control
swi tch, and a rotary-type bl ower motor speed swi tch.
The heater-onl y or heater-A/C control panel cannot
be repai red. I f faul ty or damaged, the enti re uni t
must be repl aced. The i l l umi nati on l amps, the bl ower
motor swi tch, and the control knobs are avai l abl e for
servi ce repl acement.
HEATER AND AIR CONDITIONER
DESCRIPTION
Al l vehi cl es are equi pped wi th a common heater-
A/C housi ng assembl y (Fi g. 4). The system combi nes
ai r condi ti oni ng, heati ng, and venti l ati ng capabi l i ti es
i n a si ngl e uni t housi ng mounted under the i nstru-
ment panel . On heater-onl y systems, the evaporator
coi l and reci rcul ati ng ai r door are omi tted from the
housi ng.
Outsi de fresh ai r enters the vehi cl e through the
cowl top openi ng at the base of the wi ndshi el d, and
passes through a pl enum chamber to the heater-A/C
system bl ower housi ng. Ai r fl ow vel oci ty can then be
adjusted wi th the bl ower motor speed sel ector swi tch
on the heater-A/C control panel . The ai r i ntake open-
i ngs must be kept free of snow, i ce, l eaves, and other
obstructi ons for the heater-A/C system to recei ve a
suffi ci ent vol ume of outsi de ai r.
I t i s al so i mportant to keep the ai r i ntake openi ngs
cl ear of debri s because l eaf parti cl es and other debri s
that i s smal l enough to pass through the cowl pl e-
num screen can accumul ate wi thi n the heater-A/C
housi ng. The cl osed, warm, damp and dark envi ron-
ment created wi thi n the heater-A/C housi ng i s i deal
for the growth of certai n mol ds, mi l dews and other
fungi . Any accumul ati on of decayi ng pl ant matter
provi des an addi ti onal food source for fungal spores,
whi ch enter the housi ng wi th the fresh ai r. Excess
debri s, as wel l as objecti onabl e odors created by
decayi ng pl ant matter and growi ng fungi can be di s-
charged i nto the passenger compartment duri ng
heater-A/C system operati on.
Fig. 3 Fixed Orifice Tube - Typical
1 – DIFFUSER SCREEN
2 – “O” RINGS
3 – INLET FILTER SCREEN
4 – ORIFICE
Fig. 4 Common Blend-Air Heater-Air Conditioner
System - Typical
1 – HEATER CORE
2 – BLEND-AIR DOOR
3 – EVAPORATOR A/C ONLY
4 – RECIRCULATING AIR DOOR A/C ONLY
5 – FLOOR/PANEL DOOR
6 – FLOOR/DEFROST DOOR
TJ HEATING AND AIR CONDITIONING 24 - 5
DESCRIPTION AND OPERATION (Continued)
OPERATION
The heater and opti onal ai r condi ti oner are bl end-
ai r type systems. I n a bl end-ai r system, a bl end-ai r
door control s the amount of uncondi ti oned ai r (or
cool ed ai r from the evaporator on model s wi th ai r
condi ti oni ng) that i s al l owed to fl ow through, or
around, the heater core. A temperature control knob
on the heater-A/C control panel determi nes the di s-
charge ai r temperature by actuati ng an el ectri c
motor, whi ch operates the bl end-ai r door. Thi s al l ows
an al most i mmedi ate control of the output ai r tem-
perature of the system.
The mode control knob on the heater-onl y or heat-
er-A/C control panel i s used to di rect the condi ti oned
ai r to the sel ected system outl ets. Both mode control
swi tches use engi ne vacuum to control the mode
doors, whi ch are operated by vacuum actuator
motors.
On ai r condi ti oned vehi cl es, the outsi de ai r i ntake
can be shut off by sel ecti ng the Reci rcul ati on Mode
wi th the mode control knob. Thi s wi l l operate a vac-
uum actuated reci rcul ati ng ai r door that cl oses off
the outsi de fresh ai r i ntake and reci rcul ates the ai r
that i s al ready i nsi de the vehi cl e.
The opti onal ai r condi ti oner for al l model s i s
desi gned for the use of non-CFC, R-134a refri gerant.
The ai r condi ti oni ng system has an evaporator to cool
and dehumi di fy the i ncomi ng ai r pri or to bl endi ng i t
wi th the heated ai r. Thi s ai r condi ti oni ng system
uses a fi xed ori fi ce tube i n the l i qui d l i ne near the
condenser outl et tube to meter refri gerant fl ow to the
evaporator coi l . To mai ntai n mi ni mum evaporator
temperature and prevent evaporator freezi ng, a fi xed
pressure setti ng swi tch on the accumul ator cycl es the
compressor cl utch.
HEATER CORE
DESCRIPTION
The heater core i s l ocated i n the heater-A/C hous-
i ng, under the i nstrument panel . I t i s a heat
exchanger made of rows of tubes and fi ns.
OPERATION
Engi ne cool ant i s ci rcul ated through heater hoses
to the heater core at al l ti mes. As the cool ant fl ows
through the heater core, heat removed from the
engi ne i s transferred to the heater core fi ns and
tubes. Ai r di rected through the heater core pi cks up
the heat from the heater core fi ns. The bl end ai r door
al l ows control of the heater output ai r temperature
by control l i ng how much of the ai r fl owi ng through
the heater-A/C housi ng i s di rected through the
heater core. The bl ower motor speed control s the vol -
ume of ai r fl owi ng through the heater-A/C housi ng.
The heater core cannot be repai red and, i f faul ty or
damaged, i t must be repl aced. Refer to Group 7 -
Cool i ng System for more i nformati on on the engi ne
cool i ng system, the engi ne cool ant and the heater
hoses.
HIGH PRESSURE CUT-OFF SWITCH
DESCRIPTION
The hi gh pressure cut-off swi tch i s l ocated on the
di scharge l i ne near the compressor. The swi tch i s
screwed onto a di scharge l i ne fi tti ng that contai ns a
Schrader-type val ve, whi ch al l ows the swi tch to be
servi ced wi thout di schargi ng the refri gerant system.
The di scharge l i ne fi tti ng i s equi pped wi th an O-ri ng
to seal the swi tch connecti on.
OPERATION
The hi gh pressure cut-off swi tch i s connected i n
seri es el ectri cal l y wi th the l ow pressure cycl i ng
cl utch swi tch between ground and the Powertrai n
Control Modul e (PCM). The swi tch contacts open and
cl ose causi ng the PCM to turn the compressor cl utch
on and off. Thi s prevents compressor operati on when
the di scharge l i ne pressure approaches hi gh l evel s.
The hi gh pressure cut-off swi tch contacts are open
when the di scharge l i ne pressure ri ses above 3100 to
3375 kPa (450 to 490 psi ). The swi tch contacts wi l l
cl ose when the di scharge l i ne pressure drops to 1860
to 2275 kPa (270 to 330 psi ).
The hi gh pressure cut-off swi tch i s a factory-cal i -
brated uni t. The swi tch cannot be adjusted or
repai red and, i f faul ty or damaged, i t must be
repl aced.
HIGH PRESSURE RELIEF VALVE
DESCRIPTION
A hi gh pressure rel i ef val ve i s l ocated on the com-
pressor mani fol d, whi ch i s on the si de of the com-
pressor. Thi s mechani cal val ve i s desi gned to vent
refri gerant from the system to protect agai nst dam-
age to the compressor and other system components,
caused by condenser ai r fl ow restri cti on or an over-
charge of refri gerant.
OPERATION
The hi gh pressure rel i ef val ve vents the system
when a di scharge pressure of 3445 to 4135 kPa (500
to 600 psi ) or above i s reached. The val ve cl oses
when a mi ni mum di scharge pressure of 2756 kPa
(400 psi ) i s reached.
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce the system pressure, and then
re-seats i tsel f. The majori ty of the refri gerant i s con-
24 - 6 HEATING AND AIR CONDITIONING TJ
DESCRIPTION AND OPERATION (Continued)
served i n the system. I f the val ve vents refri gerant, i t
does not mean that the val ve i s faul ty.
The hi gh pressure rel i ef val ve i s a factory-cal i -
brated uni t. The val ve cannot be adjusted or
repai red, and must not be removed or otherwi se di s-
turbed. The val ve i s onl y servi ced as a part of the
compressor assembl y.
LOW PRESSURE CYCLING CLUTCH SWITCH
DESCRIPTION
The l ow pressure cycl i ng cl utch swi tch i s l ocated
on the top of the accumul ator. The swi tch i s screwed
onto an accumul ator fi tti ng that contai ns a Schrader-
type val ve, whi ch al l ows the swi tch to be servi ced
wi thout di schargi ng the refri gerant system. The
accumul ator fi tti ng i s equi pped wi th an O-ri ng to
seal the swi tch connecti on.
OPERATION
The l ow pressure cycl i ng cl utch swi tch i s connected
i n seri es el ectri cal l y wi th the hi gh pressure cut-off
swi tch, between ground and the Powertrai n Control
Modul e (PCM). The swi tch contacts open and cl ose
causi ng the PCM to turn the compressor cl utch on
and off. Thi s regul ates the refri gerant system pres-
sure and control s evaporator temperature. Control -
l i ng the evaporator temperature prevents condensate
water on the evaporator fi ns from freezi ng and
obstructi ng ai r condi ti oni ng system ai r fl ow.
The l ow pressure cycl i ng cl utch swi tch contacts are
open when the sucti on pressure i s approxi matel y 141
kPa (20.5 psi ) or l ower. The swi tch contacts wi l l cl ose
when the sucti on pressure ri ses to approxi matel y 234
to 262 kPa (34 to 38 psi ) or above. Lower ambi ent
temperatures, bel ow approxi matel y -1° C (30° F), wi l l
al so cause the swi tch contacts to open. Thi s i s due to
the pressure/temperature rel ati onshi p of the refri ger-
ant i n the system.
The l ow pressure cycl i ng cl utch swi tch i s a factory-
cal i brated uni t. I t cannot be adjusted or repai red
and, i f faul ty or damaged, i t must be repl aced.
REFRIGERANT
DESCRIPTION
The refri gerant used i n thi s ai r condi ti oni ng sys-
tem i s a HydroFl uoroCarbon (HFC), type R-134a.
Unl i ke R-12, whi ch i s a Chl oroFl uoroCarbon (CFC),
R-134a refri gerant does not contai n ozone-depl eti ng
chl ori ne. R-134a refri gerant i s a non-toxi c, non-fl am-
mabl e, cl ear, and col orl ess l i quefi ed gas.
Even though R-134a does not contai n chl ori ne, i t
must be recl ai med and recycl ed just l i ke CFC-type
refri gerants. Thi s i s because R-134a i s a greenhouse
gas and can contri bute to gl obal warmi ng.
OPERATION
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 added to an R-134a refri gerant
system wi l l cause compressor fai l ure, refri gerant oi l
sl udge or poor ai r condi ti oni ng system performance.
I n addi ti on, the Pol yAl kyl ene Gl ycol (PAG) syntheti c
refri gerant oi l s used i n an R-134a refri gerant system
are not compati bl e wi th the mi neral -based refri ger-
ant oi l s used i n an R-12 refri gerant system.
R-134a refri gerant system servi ce ports, servi ce
tool coupl ers and refri gerant di spensi ng bottl es have
al l been desi gned wi th uni que fi tti ngs to ensure that
an R-134a system i s not acci dental l y contami nated
wi th the wrong refri gerant (R-12). There are al so
l abel s posted i n the engi ne compartment of the vehi -
cl e and on the compressor i denti fyi ng to servi ce tech-
ni ci ans that the ai r condi ti oni ng system i s equi pped
wi th R-134a.
REFRIGERANT LINES
DESCRIPTION
The refri gerant l i nes and hoses are used to carry
the refri gerant between the vari ous ai r condi ti oni ng
system components. A barri er hose desi gn wi th a
nyl on tube i nner hose l i ner i s used for the R-134a ai r
condi ti oni ng system on thi s vehi cl e. Thi s nyl on l i ner
hel ps to further contai n the R-134a refri gerant,
whi ch has a smal l er mol ecul ar structure than R-12
refri gerant. The ends of the refri gerant hoses are
made from l i ghtwei ght al umi num or steel , and use
braze-l ess fi tti ngs.
Any ki nks or sharp bends i n the refri gerant pl umb-
i ng wi l l reduce the capaci ty of the enti re ai r condi -
ti oni ng system. Ki nks and sharp bends reduce the
fl ow of refri gerant i n the system. A good rul e for the
fl exi bl e hose refri gerant l i nes i s to keep the radi us of
al l bends at l east ten ti mes the di ameter of the hose.
I n addi ti on, the fl exi bl e hose refri gerant l i nes shoul d
be routed so they are at l east 80 mi l l i meters (3
i nches) from the exhaust mani fol d.
OPERATION
Hi gh pressures are produced i n the refri gerant sys-
tem when the ai r condi ti oni ng compressor i s operat-
i ng. Extreme care must be exerci sed to make sure
that each of the refri gerant system connecti ons i s
pressure-ti ght and l eak free. I t i s a good practi ce to
i nspect al l fl exi bl e hose refri gerant l i nes at l east once
a year to make sure they are i n good condi ti on and
properl y routed.
The refri gerant l i nes and hoses are coupl ed wi th
other components of the HVAC system wi th peanut-
bl ock styl e fi tti ngs. A stat-O seal type fl at steel gas-
ket wi th a captured compressi bl e O-ri ng, i s used to
TJ HEATING AND AIR CONDITIONING 24 - 7
DESCRIPTION AND OPERATION (Continued)
mate pl umbi ng l i nes wi th A/C components to ensure
the i ntegri ty of the refri gerant system.
The refri gerant l i nes and hoses cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
REFRIGERANT LINE COUPLERS
DESCRIPTION
Spri ng-l ock type refri gerant l i ne coupl ers are used
to connect many of the refri gerant l i nes and other
components to the refri gerant system. These coupl ers
requi re a speci al tool for di sengagi ng the two coupl er
hal ves.
OPERATION
The spri ng-l ock coupl er i s hel d together by a garter
spri ng i nsi de a ci rcul ar cage on the mal e hal f of the
fi tti ng (Fi g. 5). When the two coupl er hal ves are con-
nected, the fl ared end of the femal e fi tti ng sl i ps
behi nd the garter spri ng i nsi de the cage on the mal e
fi tti ng. The garter spri ng and cage prevent the fl ared
end of the femal e fi tti ng from pul l i ng out of the cage.
Two O-ri ngs on the mal e hal f of the fi tti ng are
used to seal the connecti on. These O-ri ngs are com-
pati bl e wi th R-134a refri gerant and must be repl aced
wi th O-ri ngs made of the same materi al .
Secondary cl i ps are i nstal l ed over the two con-
nected coupl er hal ves at the factory for added bl owoff
protecti on. I n addi ti on, some model s have a pl asti c
ri ng that i s used at the factory as a vi sual i ndi cator
to confi rm that these coupl ers are connected. After
the coupl er i s connected, the pl asti c i ndi cator ri ng i s
no l onger needed; however, i t wi l l remai n on the
refri gerant l i ne near the coupl er cage.
REFRIGERANT OIL
DESCRIPTION
The refri gerant oi l used i n R-134a refri gerant sys-
tems i s a syntheti c-based, Pol yAl kyl ene Gl ycol (PAG),
wax-free l ubri cant. Mi neral -based R-12 refri gerant
oi l s are not compati bl e wi th PAG oi l s, and shoul d
never be i ntroduced to an R-134a refri gerant system.
There are di fferent PAG oi l s avai l abl e, and each
contai ns a di fferent addi ti ve package. The 10PA17
compressor used i n thi s vehi cl e i s desi gned to use an
ND-8 PAG refri gerant oi l . Use onl y refri gerant oi l of
thi s same type to servi ce the refri gerant system.
OPERATION
After performi ng any refri gerant recovery or recy-
cl i ng operati on, al ways repl eni sh the refri gerant sys-
tem wi th the same amount of the recommended
refri gerant oi l as was removed. Too l i ttl e refri gerant
oi l can cause compressor damage, and too much can
reduce ai r condi ti oni ng system performance.
PAG refri gerant oi l i s much more hygroscopi c than
mi neral oi l , and wi l l absorb any moi sture i t comes
i nto contact wi th, even moi sture i n the ai r. The PAG
oi l contai ner shoul d al ways be kept ti ghtl y capped
unti l i t i s ready to be used. After use, recap the oi l
contai ner i mmedi atel y to prevent moi sture contami -
nati on.
REFRIGERANT SYSTEM SERVICE PORT
DESCRIPTION
The two refri gerant system servi ce ports are used
to charge, recover/recycl e, evacuate, and test the ai r
condi ti oni ng refri gerant system. Uni que servi ce port
coupl er si zes are used on the R-134a system, to
ensure that the refri gerant system i s not acci dental l y
contami nated by the use of the wrong refri gerant
(R-12), or refri gerant system servi ce equi pment.
Fig. 5 Spring-Lock Coupler - Typical
1 – MALE HALF SPRING-LOCK COUPLER
2 – FEMALE HALF SPRING-LOCK COUPLER
3 – SECONDARY CLIP
4 – CONNECTION INDICATOR RING
5 – COUPLER CAGE
6 – GARTER SPRING
7 – COUPLER CAGE
8 – “O” RINGS
24 - 8 HEATING AND AIR CONDITIONING TJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
The hi gh pressure servi ce port i s l ocated on the
refri gerant l i ne, near the di scharge port of the com-
pressor. The l ow pressure servi ce port i s l ocated on
the l i qui d l i ne at the rear of the engi ne compartment,
near the evaporator i nl et tube.
Each of the servi ce ports has a threaded pl asti c
protecti ve cap i nstal l ed over i t from the factory. After
servi ci ng the refri gerant system, al ways rei nstal l
both of the servi ce port caps.
VACUUM CHECK VALVE
DESCRIPTION
A vacuum check val ve i s i nstal l ed i n the accessory
vacuum suppl y l i ne i n the engi ne compartment, near
the vacuum tap on the engi ne i ntake mani fol d, and
at the HVAC uni t takeout. The vacuum check val ve
i s desi gned to al l ow vacuum to fl ow i n onl y one di rec-
ti on through the accessory vacuum suppl y ci rcui ts.
OPERATION
The use of a vacuum check val ve hel ps to mai ntai n
the system vacuum needed to retai n the sel ected
heater-A/C mode setti ngs. The check val ve wi l l pre-
vent the engi ne from bl eedi ng down system vacuum
through the i ntake mani fol d duri ng extended heavy
engi ne l oad (l ow engi ne vacuum) operati on.
The vacuum check val ve cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s mounted to the rear of the
ri ght front i nner fender wheel house i n the engi ne
compartment, under the battery tray. The battery
and battery tray must be removed from the vehi cl e to
access the vacuum reservoi r for servi ce.
OPERATION
Engi ne vacuum i s stored i n the vacuum reservoi r.
The stored vacuum i s used to operate the vacuum-
control l ed vehi cl e accessori es duri ng peri ods of l ow
engi ne vacuum such as when the vehi cl e i s cl i mbi ng
a steep grade, or under other hi gh engi ne l oad oper-
ati ng condi ti ons.
The vacuum reservoi r cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
DIAGNOSIS AND TESTING
A/C PERFORMANCE
The ai r condi ti oni ng system i s desi gned to provi de
the passenger compartment wi th l ow temperature
and l ow humi di ty ai r. The evaporator, l ocated i n the
heater-A/C housi ng on the dash panel bel ow the
i nstrument panel , i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes through the
cool ed evaporator, the ai r transfers i ts heat to the
refri gerant i n the evaporator and the moi sture i n the
ai r condenses on the evaporator fi ns. Duri ng peri ods
of hi gh heat and humi di ty, an ai r condi ti oni ng sys-
tem wi l l be more effecti ve i n the Reci rcul ati on Mode.
Wi th the system i n the Reci rcul ati on Mode, onl y ai r
from the passenger compartment passes through the
evaporator. As the passenger compartment ai r dehu-
mi di fi es, the ai r condi ti oni ng system performance
l evel s i mprove.
Humi di ty has an i mportant beari ng on the temper-
ature of the ai r del i vered to the i nteri or of the vehi -
cl e. I t i s i mportant to understand the effect that
humi di ty has on the performance of the ai r condi ti on-
i ng system. When humi di ty i s hi gh, the evaporator
has to perform a doubl e duty. I t must l ower the ai r
temperature, and i t must l ower the temperature of
the moi sture i n the ai r that condenses on the evapo-
rator fi ns. Condensi ng the moi sture i n the ai r trans-
fers heat energy i nto the evaporator fi ns and tubi ng.
Thi s reduces the amount of heat the evaporator can
absorb from the ai r. Hi gh humi di ty greatl y reduces
the abi l i ty of the evaporator to l ower the temperature
of the ai r.
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Wri ng-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from thei r
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
Revi ew the Servi ce Warni ngs and Precauti ons i n
the front of thi s group before performi ng thi s proce-
dure. The ai r temperature i n the test room and i n
the vehi cl e must be a mi ni mum of 21° C (70° F) for
thi s test.
(1) Connect a tachometer and a mani fol d gauge
set.
(2) Set the heater-A/C mode control swi tch knob i n
the Reci rcul ati on Mode posi ti on, the temperature
control knob i n the ful l cool posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
TJ HEATING AND AIR CONDITIONING 24 - 9
DESCRIPTION AND OPERATION (Continued)
(3) Start the engi ne and hol d the i dl e at 1,000 rpm
wi th the compressor cl utch engaged.
(4) The engi ne shoul d be at operati ng temperature.
The doors and wi ndows must be open.
(5) I nsert a thermometer i n the dri ver si de center
A/C (panel ) outl et. Operate the engi ne for fi ve mi n-
utes.
(6) The compressor cl utch may cycl e, dependi ng
upon the ambi ent temperature and humi di ty. I f the
cl utch cycl es, unpl ug the l ow pressure cycl i ng cl utch
swi tch wi re harness connector from the swi tch
l ocated on the accumul ator (Fi g. 6). Pl ace a jumper
wi re across the termi nal s of the l ow pressure cycl i ng
cl utch swi tch wi re harness connector.
(7) Wi th the compressor cl utch engaged, record the
di scharge ai r temperature and the compressor di s-
charge pressure.
(8) Compare the di scharge ai r temperature to the
Performance Temperature and Pressure chart. I f the
di scharge ai r temperature i s hi gh, see Refri gerant
System Leaks and Refri gerant System Charge i n thi s
group.
Performance Temperature and Pressure
Ambient Air
Temperature
21°C
(70°F)
27°C
(80°F)
32°C
(90°F)
38°C
(100°F)
43°C
(110°F)
Air Temperature at
Center Panel Outlet
-3 to 3°C
(27 to 38°F)
1 to 7°C
(33 to 44°F)
3 to 9°C
(37 to 48°F)
6 to 13°C
(43 to 55°F)
10 to 18°C
(50 to 64°F)
Evaporator Inlet
Pressure at Charge
Port
179 to 241 kPa
(26 to 35 psi)
221 to 283
kPa
(32 to 41 psi)
262 to 324
kPa
(38 to 47 psi)
303 to 365
kPa
(44 to 53 psi)
345 to 414 kPa
(50 to 60 psi)
Compressor Discharge
Pressure
1240 to 1655
kPa
(180 to 240
psi)
1380 to 1790
kPa
(200 to 260
psi)
1720 to 2070
kPa
(250 to 300
psi)
1860 to 2345
kPa
(270 to 340
psi)
2070 to 2690
kPa
(300 to 390 psi)
(9) Compare the compressor di scharge pressure to
the Performance Temperature and Pressure chart. I f
the compressor di scharge pressure i s hi gh, see the
Pressure Di agnosi s chart.
Fig. 6 Low Pressure Cycling Clutch Switch - Typical
1 – LOW PRESSURE CYCLING CLUTCH SWITCH
2 – ACCUMULATOR
24 - 10 HEATING AND AIR CONDITIONING TJ
DIAGNOSIS AND TESTING (Continued)
Pressure Diagnosis
Condition Possible Causes Correction
Rapid compressor clutch
cycling (ten or more cycles
per minute).
1. Low refrigerant system
charge.
1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the
refrigerant system.
2. Faulty fuse.
3. Faulty compressor clutch
coil.
4. Faulty compressor clutch
relay.
5. Improperly installed or
faulty low pressure cycling
clutch switch.
6. Faulty high pressure
cut-off switch.
7. Faulty Powertrain Control
Module (PCM).
1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
2. Check the fuses in the Power Distribution
Center and the fuseblock module. Repair the
shorted circuit or component and replace the
fuses, if required.
3. See Compressor Clutch Coil in this group. Test
the compressor clutch coil and replace, if
required.
4. See Compressor Clutch Relay in this group.
Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. See Low Pressure Cycling Clutch Switch in
this group. Test the low pressure cycling clutch
switch and tighten or replace, if required.
6. See High Pressure Cut-Off Switch in this
group. Test the high pressure cut-off switch and
replace, if required.
7. Refer to the proper Diagnostic Procedures
manual for testing of the PCM. Test the PCM and
replace, if required.
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.
1. Excessive refrigerant oil in
system.
2. Temperature control cable
improperly installed or faulty.
3. Blend-air door inoperative
or sealing improperly.
1. See Refrigerant Oil Level in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level, if
required.
2. See Temperature Control Cable in this group.
Inspect the temperature control cable for proper
routing and operation and correct, if required.
3. See Blend-Air Door under Heater-A/C Housing
Door in this group. Inspect the blend-air door for
proper operation and sealing and correct, if
required.
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.
1. Low refrigerant system
charge.
2. Refrigerant flow through
the accumulator is restricted.
3. Refrigerant flow through
the evaporator coil is
restricted.
4. Faulty compressor.
1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. See Evaporator Coil in this group. Replace the
restricted evaporator coil, if required.
4. See Compressor in this group. Replace the
compressor, if required.
TJ HEATING AND AIR CONDITIONING 24 - 11
DIAGNOSIS AND TESTING (Continued)
Pressure Diagnosis
Condition Possible Causes Correction
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.
1. Condenser air flow
restricted.
2. Inoperative cooling fan.
3. Refrigerant system
overcharged.
4. Air in the refrigerant
system.
5. Engine overheating.
1. Check the condenser for damaged fins, foreign
objects obstructing air flow through the condenser
fins, and missing or improperly installed air seals.
Refer to Group 7 - Cooling System for more
information on air seals. Clean, repair, or replace
components as required.
2. Refer to Group 7 - Cooling System for more
information. Test the cooling fan and replace, if
required.
3. See Refrigerant System Charge in this group.
Recover the refrigerant from the refrigerant
system. Charge the refrigerant system to the
proper level, if required.
4. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
5. Refer to Group 7 - Cooling System for more
information. Test the cooling system and repair, if
required.
The low side pressure is too
high, and the high side
pressure is too low.
1. Accessory drive belt
slipping.
2. Fixed orifice tube not
installed.
3. Faulty compressor.
1. Refer to Group 7 - Cooling System for more
information. Inspect the accessory drive belt
condition and tension. Tighten or replace the
accessory drive belt, if required.
2. See Fixed Orifice Tube in this group. Install the
missing fixed orifice tube, if required.
3. See Compressor in this group. Replace the
compressor, if required.
The low side pressure is too
low, and the high side
pressure is too high.
1. Restricted refrigerant flow
through the refrigerant lines.
2. Restricted refrigerant flow
through the fixed orifice tube.
3. Restricted refrigerant flow
through the condenser.
1. See Liquid Line and Suction and Discharge
Line in this group. Inspect the refrigerant lines for
kinks, tight bends or improper routing. Correct the
routing or replace the refrigerant line, if required.
2. See Fixed Orifice Tube in this group. Replace
the restricted fixed orifice tube, if required.
3. See Condenser in this group. Replace the
restricted condenser, if required.
BLOWER MOTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams. Possi bl e causes of an i noperati ve
bl ower motor i ncl ude:
• Faul ty fuse
• Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connecti ons
• Faul ty bl ower motor resi stor
• Faul ty bl ower motor rel ay
• Faul ty bl ower motor swi tch
• Faul ty heater-A/C mode control swi tch
• Faul ty bl ower motor.
Possi bl e causes of the bl ower motor not operati ng
i n al l speeds i ncl ude:
• Faul ty fuse
• Faul ty bl ower motor swi tch
• Faul ty bl ower motor resi stor
24 - 12 HEATING AND AIR CONDITIONING TJ
DIAGNOSIS AND TESTING (Continued)
• Faul ty bl ower motor rel ay
• Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors.
VIBRATION
Possi bl e causes of bl ower motor vi brati on i ncl ude:
• I mproper bl ower motor mounti ng
• I mproper bl ower wheel mounti ng
• Bl ower wheel out of bal ance or bent
• Bl ower motor faul ty.
NOISE
To veri fy that the bl ower i s the source of the noi se,
unpl ug the bl ower motor wi re harness connector and
operate the heater-A/C system. I f the noi se goes
away, possi bl e causes i ncl ude:
• Forei gn materi al i n the heater-A/C housi ng
• I mproper bl ower motor mounti ng
• I mproper bl ower wheel mounti ng
• Bl ower motor faul ty.
BLOWER MOTOR RELAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
RELAY TEST
The bl ower motor rel ay (Fi g. 7) i s l ocated i n a wi re
harness connector that i s secured to the heater-A/C
housi ng behi nd the gl ove box on the passenger si de
of the vehi cl e, next to the heater-A/C wi re harness
connector i n the passenger compartment. Remove the
rel ay from i ts connector to perform the fol l owi ng
tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 Ϯ 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Rel ay Ci rcui t Test procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to the bl ower motor. Thi s termi nal suppl i es
fused battery feed di rectl y from a fuse i n the Power
Di stri buti on Center (PDC) when the rel ay i s ener-
gi zed, and i gni ti on swi tched battery feed from a fuse
i n the fusebl ock modul e through the bl ower motor
resi stor when the rel ay i s de-energi zed. There shoul d
be conti nui ty between thi s cavi ty and the bl ower
motor feed ci rcui t cavi ty of the bl ower motor wi re
harness connector at al l ti mes. I f OK, go to Step 2. I f
not OK, repai r the open ci rcui t as requi red.
(2) The rel ay normal l y cl osed termi nal cavi ty (87A)
i s connected to the bl ower motor resi stor output.
When the rel ay i s de-energi zed, termi nal 87A i s con-
nected to termi nal 30 and provi des the bl ower motor
resi stor output to the bl ower motor feed ci rcui t.
There shoul d be conti nui ty between thi s cavi ty and
the bl ower resi stor outputs ci rcui t cavi ty of the
bl ower motor resi stor wi re harness connector at al l
ti mes. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t as requi red.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to a fused battery feed from the PDC.
When the rel ay i s energi zed, termi nal 87 i s con-
nected to termi nal 30 and provi des ful l battery cur-
rent to the bl ower motor feed ci rcui t. There shoul d be
battery vol tage at thi s cavi ty at al l ti mes. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t to the
PDC as requi red.
(4) The coi l battery termi nal cavi ty (86) i s con-
nected to the hi gh speed output contacts of the
bl ower motor swi tch. When the bl ower motor swi tch
i s pl aced i n the hi gh speed posi ti on, fused i gni ti on
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 7 Blower Motor Relay
TJ HEATING AND AIR CONDITIONING 24 - 13
DIAGNOSIS AND TESTING (Continued)
swi tch output i s di rected to the rel ay el ectromagneti c
coi l to energi ze the rel ay. There shoul d be conti nui ty
between the cavi ty for rel ay termi nal 86 and the hi gh
bl ower motor rel ay control ci rcui t cavi ty of the bl ower
motor swi tch wi re harness connector at al l ti mes. I f
OK, go to Step 5. I f not OK, repai r the open ci rcui t
as requi red.
(5) The coi l ground termi nal cavi ty (85) i s con-
nected to ground. Thi s termi nal suppl i es the ground
for the rel ay el ectromagnet coi l . There shoul d be con-
ti nui ty between the cavi ty for rel ay termi nal 85 and
a good ground at al l ti mes. I f not OK, repai r the open
ci rcui t as requi red.
BLOWER MOTOR RESISTOR
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the ki ck cover from the heater-A/C
housi ng and unpl ug the wi re harness connector from
the bl ower motor resi stor.
(3) Check for conti nui ty between each of the
bl ower motor swi tch i nput termi nal s of the resi stor
and the resi stor output termi nal . I n each case there
shoul d be conti nui ty. I f OK, repai r the wi re harness
ci rcui ts between the bl ower motor swi tch and the
bl ower motor resi stor or bl ower motor rel ay as
requi red. I f not OK, repl ace the faul ty bl ower motor
resi stor.
BLOWER MOTOR SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Turn the i gni ti on swi tch to the On posi ti on and
check for battery vol tage at the fuse i n the fusebl ock
modul e. I f OK, go to Step 2. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the heater-A/C control from the i nstrument
panel , but do not unpl ug the wi re harness connec-
tors. Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (run) ci r-
cui t cavi ty of the heater-A/C mode control swi tch
wi re harness connector. I f OK, go to Step 3. I f not
OK, repai r the open ci rcui t to the fusebl ock modul e
as requi red.
(3) Sel ect any one of the heater-A/C mode control
posi ti ons except Off to turn the system on. Check for
battery vol tage at the l ow bl ower motor dri ver ci rcui t
cavi ty of the heater-A/C mode control swi tch wi re
harness connector. I f OK, go to Step 4. I f not OK,
repl ace the faul ty heater-A/C mode control swi tch.
(4) Check for battery vol tage at the l ow bl ower
motor dri ver ci rcui t cavi ty of the bl ower motor swi tch
wi re harness connector. I f OK, go to Step 5. I f not
OK, repai r the open ci rcui t to the heater-A/C mode
control swi tch wi re harness connector as requi red.
(5) Check for battery vol tage at each of the
remai ni ng bl ower motor swi tch wi re harness connec-
tor cavi ti es as you move the swi tch to each bl ower
motor speed posi ti on. Vol tage shoul d be present i n
each cavi ty at onl y one swi tch posi ti on. I f OK, see
the di agnosi s for the bl ower motor resi stor and/or the
bl ower motor rel ay i n thi s group. I f not OK, repl ace
the faul ty bl ower motor swi tch.
COMPRESSOR
When i nvesti gati ng an ai r condi ti oni ng rel ated
noi se, you must fi rst know the condi ti ons under
whi ch the noi se occurs. These condi ti ons i ncl ude:
weather, vehi cl e speed, transmi ssi on i n gear or neu-
tral , engi ne speed, engi ne temperature, and any
other speci al condi ti ons. Noi ses that devel op duri ng
ai r condi ti oni ng operati on can often be mi sl eadi ng.
For exampl e: What sounds l i ke a fai l ed front beari ng
or connecti ng rod, may be caused by l oose bol ts, nuts,
mounti ng brackets, or a l oose compressor cl utch
assembl y.
Dri ve bel ts are speed sensi ti ve. At di fferent engi ne
speeds and dependi ng upon bel t tensi on, bel ts can
devel op noi ses that are mi staken for a compressor
noi se. I mproper bel t tensi on can cause a mi sl eadi ng
noi se when the compressor cl utch i s engaged, whi ch
may not occur when the compressor cl utch i s di sen-
gaged. Check the serpenti ne dri ve bel t condi ti on and
24 - 14 HEATING AND AIR CONDITIONING TJ
DIAGNOSIS AND TESTING (Continued)
tensi on as descri bed i n Group 7 - Cool i ng System
before begi nni ng thi s procedure.
(1) Sel ect a qui et area for testi ng. Dupl i cate the
compl ai nt condi ti ons as much as possi bl e. Swi tch the
compressor on and off several ti mes to cl earl y i den-
ti fy the compressor noi se. Li sten to the compressor
whi l e the cl utch i s engaged and di sengaged. Probe
the compressor wi th an engi ne stethoscope or a l ong
screwdri ver wi th the handl e hel d to your ear to bet-
ter l ocal i ze the source of the noi se.
(2) Loosen al l of the compressor mounti ng hard-
ware and reti ghten. Ti ghten the compressor cl utch
mounti ng nut. Be certai n that the cl utch coi l i s
mounted securel y to the compressor, and that the
cl utch pl ate and pul l ey are properl y al i gned and have
the correct ai r gap. See Compressor and Compressor
Cl utch i n the Removal and I nstal l ati on secti on of thi s
group for the procedures.
(3) To dupl i cate a hi gh-ambi ent temperature condi -
ti on (hi gh head pressure), restri ct the ai r fl ow
through the condenser. I nstal l a mani fol d gauge set
to be certai n that the di scharge pressure does not
exceed 2760 kPa (400 psi ).
(4) Check the refri gerant system pl umbi ng for
i ncorrect routi ng, rubbi ng or i nterference, whi ch can
cause unusual noi ses. Al so check the refri gerant l i nes
for ki nks or sharp bends that wi l l restri ct refri gerant
fl ow, whi ch can cause noi ses. See Sucti on and Di s-
charge Li ne i n the Removal and I nstal l ati on secti on
of thi s group for more i nformati on.
(5) I f the noi se i s from openi ng and cl osi ng of the
hi gh pressure rel i ef val ve, evacuate and recharge the
refri gerant system. See Refri gerant System Evacuate
and Refri gerant System Charge i n the Servi ce Proce-
dures secti on of thi s group. I f the hi gh pressure rel i ef
val ve sti l l does not seat properl y, repl ace the com-
pressor.
(6) I f the noi se i s from l i qui d sl uggi ng on the suc-
ti on l i ne, repl ace the accumul ator. See Accumul ator
i n the Removal and I nstal l ati on secti on of thi s group
for the procedures. Check the refri gerant oi l l evel
and the refri gerant system charge. See Refri gerant
Oi l Level and Refri gerant System Charge i n the Ser-
vi ce Procedures secti on of thi s group. I f the l i qui d
sl uggi ng condi ti on conti nues fol l owi ng accumul ator
repl acement, repl ace the compressor.
(7) I f the noi se conti nues, repl ace the compressor
and repeat Step 1.
COMPRESSOR CLUTCH COIL
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams. The battery must be ful l y-charged
before performi ng the fol l owi ng tests. Refer to Group
8A - Battery for more i nformati on.
(1) Connect an ammeter (0 to 10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0 to 20 vol t scal e) wi th cl i p-type l eads for measuri ng
the vol tage across the battery and the compressor
cl utch coi l .
(2) Wi th the heater-A/C mode control swi tch i n any
A/C mode, and the bl ower motor swi tch i n the l owest
speed posi ti on, start the engi ne and run i t at normal
i dl e.
(3) The compressor cl utch coi l vol tage shoul d read
wi thi n two vol ts of the battery vol tage. I f there i s
vol tage at the cl utch coi l , but the readi ng i s not
wi thi n two vol ts of the battery vol tage, test the
cl utch coi l feed ci rcui t for excessi ve vol tage drop and
repai r as requi red. I f there i s no vol tage readi ng at
the cl utch coi l , use a DRB scan tool and the proper
Di agnosti c Procedures manual for testi ng of the com-
pressor cl utch ci rcui t. The fol l owi ng components
must be checked and repai red as requi red before you
can compl ete testi ng of the cl utch coi l :
• Fuses i n the fusebl ock modul e and the Power
Di stri buti on Center (PDC)
• Heater-A/C mode control swi tch
• Compressor cl utch rel ay
• Hi gh pressure cut-off swi tch
• Low pressure cycl i ng cl utch swi tch
• Powertrai n Control Modul e (PCM).
(4) The compressor cl utch coi l i s acceptabl e i f the
current draw measured at the cl utch coi l i s 2.0 to 3.9
amperes wi th the el ectri cal system vol tage at 11.5 to
12.5 vol ts. Thi s shoul d onl y be checked wi th the work
area temperature at 21° C (70° F). I f system vol tage
i s more than 12.5 vol ts, add el ectri cal l oads by turn-
i ng on el ectri cal accessori es unti l the system vol tage
drops bel ow 12.5 vol ts.
(a) I f the cl utch coi l current readi ng i s four
amperes or more, the coi l i s shorted and shoul d be
repl aced.
(b) I f the cl utch coi l current readi ng i s zero, the
coi l i s open and shoul d be repl aced.
COMPRESSOR CLUTCH RELAY
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
RELAY TEST
The compressor cl utch rel ay (Fi g. 8) i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
PDC l abel for rel ay i denti fi cati on and l ocati on.
Remove the rel ay from the PDC to perform the fol -
l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
TJ HEATING AND AIR CONDITIONING 24 - 15
DIAGNOSIS AND TESTING (Continued)
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 Ϯ 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Rel ay Ci rcui t Test procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to fused battery feed. There shoul d be bat-
tery vol tage at the cavi ty for rel ay termi nal 30 at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the fuse i n the PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s not
used i n thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the compressor cl utch coi l . There shoul d
be conti nui ty between thi s cavi ty and the A/C com-
pressor cl utch rel ay output ci rcui t cavi ty of the com-
pressor cl utch coi l wi re harness connector. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t as
requi red.
(4) The rel ay coi l battery termi nal (86) i s con-
nected to the fused i gni ti on swi tch output (run/start)
ci rcui t. There shoul d be battery vol tage at the cavi ty
for rel ay termi nal 86 wi th the i gni ti on swi tch i n the
On posi ti on. I f OK, go to Step 5. I f not OK, repai r the
open ci rcui t to the fuse i n the fusebl ock modul e as
requi red.
(5) The coi l ground termi nal cavi ty (85) i s swi tched
to ground through the Powertrai n Control Modul e
(PCM). There shoul d be conti nui ty between thi s cav-
i ty and the A/C compressor cl utch rel ay control ci r-
cui t cavi ty of the PCM wi re harness connector C
(gray) at al l ti mes. I f not OK, repai r the open ci rcui t
as requi red.
HEATER PERFORMANCE
Before performi ng the fol l owi ng tests, refer to
Group 7 - Cool i ng System for the procedures to check
the radi ator cool ant l evel , serpenti ne dri ve bel t ten-
si on, radi ator ai r fl ow and the radi ator fan operati on.
Al so be certai n that the accessory vacuum suppl y
l i ne i s connected at the engi ne i ntake mani fol d.
MAXIMUM HEATER OUTPUT
Engi ne cool ant i s del i vered to the heater core
through two heater hoses. Wi th the engi ne i dl i ng at
normal operati ng temperature, set the temperature
control knob i n the ful l hot posi ti on, the mode control
swi tch knob i n the fl oor heat posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
Usi ng a test thermometer, check the temperature of
the ai r bei ng di scharged at the heater-A/C housi ng
fl oor outl ets. Compare the test thermometer readi ng
to the Temperature Reference chart.
Temperature Reference
Ambient Air Temperature
15.5°C
(60°F)
21.1°C
(70°F)
26.6°C
(80°F)
32.2°C
(90°F)
Minimum Air Temperature at
Floor Outlet
62.2°C
(144°F)
63.8°C
(147°F)
65.5°C
(150°F)
67.2°C
(153°F)
I f the fl oor outl et ai r temperature i s too l ow, refer
to Group 7 - Cool i ng System to check the engi ne cool -
ant temperature speci fi cati ons. Both of the heater
hoses shoul d be hot to the touch. The cool ant return
heater hose shoul d be sl i ghtl y cool er than the cool ant
suppl y heater hose. I f the return hose i s much cool er
than the suppl y hose, l ocate and repai r the engi ne
cool ant fl ow obstructi on i n the cool i ng system. Refer
to Group 7 - Cool i ng System for the procedures.
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 8 Compressor Clutch Relay
24 - 16 HEATING AND AIR CONDITIONING TJ
DIAGNOSIS AND TESTING (Continued)
OBSTRUCTED COOLANT FLOW Possi bl e l oca-
ti ons or causes of obstructed cool ant fl ow:
• Pi nched or ki nked heater hoses.
• I mproper heater hose routi ng.
• Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons.
• A pl ugged heater core.
I f proper cool ant fl ow through the cool i ng system i s
veri fi ed, and heater outl et ai r temperature i s sti l l
l ow, a mechani cal probl em may exi st.
MECHANI CAL PROBLEMS Possi bl e l ocati ons or
causes of i nsuffi ci ent heat:
• An obstructed cowl ai r i ntake.
• Obstructed heater system outl ets.
• A bl end-ai r door not functi oni ng properl y.
TEMPERATURE CONTROL
I f the heater outl et ai r temperature cannot be
adjusted wi th the temperature control knob on the
heater-A/C control panel , the fol l owi ng coul d requi re
servi ce:
• The heater-A/C control .
• The temperature control assembl y i n the control
head.
• The el ectri c bl end-ai r door motor.
• Any associ ated wi ri ng harness or connectors.
• The bl end-ai r door.
• I mproper engi ne cool ant temperature.
HIGH PRESSURE CUT-OFF SWITCH
Before performi ng di agnosi s of the hi gh pressure
cut-off swi tch, veri fy that the refri gerant system has
the correct refri gerant charge. See Refri gerant Sys-
tem Charge i n the Servi ce Procedures secti on of thi s
group for more i nformati on.
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the wi re harness connector from the
hi gh pressure cut-off swi tch on the refri gerant sys-
tem fi tti ng.
(3) Check for conti nui ty between the two termi nal s
of the hi gh pressure cut-off swi tch. There shoul d be
conti nui ty. I f OK, test and repai r the A/C swi tch
sense ci rcui t as requi red. I f not OK, repl ace the
faul ty swi tch.
LOW PRESSURE CYCLING CLUTCH SWITCH
Before performi ng di agnosi s of the l ow pressure
cycl i ng cl utch swi tch, be certai n that the swi tch i s
properl y i nstal l ed on the accumul ator fi tti ng. I f the
swi tch i s too l oose i t may not open the Schrader-type
val ve i n the accumul ator fi tti ng, whi ch wi l l prevent
the swi tch from correctl y moni tori ng the refri gerant
system pressure.
Al so veri fy that the refri gerant system has the cor-
rect refri gerant charge. See Refri gerant System
Charge i n thi s group for the procedures.
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the l ow pressure cycl i ng cl utch swi tch
wi re harness connector from the swi tch on the accu-
mul ator fi tti ng.
(3) I nstal l a jumper wi re between the two cavi ti es
of the l ow pressure cycl i ng cl utch swi tch wi re har-
ness connector.
(4) Connect a mani fol d gauge set to the refri gerant
system servi ce ports. See Refri gerant System Servi ce
Equi pment i n thi s group for the procedures.
(5) Connect the battery negati ve cabl e.
(6) Pl ace the heater-A/C mode control swi tch knob
i n any A/C posi ti on and start the engi ne.
(7) Check for conti nui ty between the two termi nal s
of the l ow pressure cycl i ng cl utch swi tch. There
shoul d be conti nui ty wi th a sucti on pressure readi ng
of 262 kPa (38 psi ) or above, and no conti nui ty wi th a
sucti on pressure readi ng of 141 kPa (20.5 psi ) or
bel ow. I f OK, test and repai r the A/C swi tch sense
ci rcui t as requi red. I f not OK, repl ace the faul ty
swi tch.
REFRIGERANT SYSTEM LEAKS
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
LEAK TESTING THE SYSTEM.
I f the ai r condi ti oni ng system i s not cool i ng prop-
erl y, determi ne i f the refri gerant system i s ful l y-
charged. See A/C Performance i n thi s group for the
procedures. I f the refri gerant system i s l ow or empty;
a l eak at a refri gerant l i ne, connector fi tti ng, compo-
nent, or component seal i s l i kel y.
An el ectroni c l eak detector desi gned for R-134a
refri gerant, or a fl uorescent R-134a l eak detecti on
dye and a bl ack l i ght are recommended for l ocati ng
and confi rmi ng refri gerant system l eaks. Refer to the
operati ng i nstructi ons suppl i ed by the equi pment
manufacturer for proper care and use of thi s equi p-
ment.
An oi l y resi due on or near refri gerant system l i nes,
connector fi tti ngs, components, or component seal s
can i ndi cate the general l ocati on of a possi bl e refri g-
erant l eak. However, the exact l eak l ocati on shoul d
be confi rmed wi th an el ectroni c l eak detector pri or to
component repai r or repl acement.
TJ HEATING AND AIR CONDITIONING 24 - 17
DIAGNOSIS AND TESTING (Continued)
To detect a l eak i n the refri gerant system wi th an
el ectroni c l eak detector, perform one of the fol l owi ng
procedures:
SYSTEM EMPTY
(1) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group for the proce-
dures.
(2) Connect and di spense 0.283 ki l ograms (0.625
pounds or 10 ounces) of R-134a refri gerant i nto the
evacuated refri gerant system. See Refri gerant Sys-
tem Charge i n thi s group for the procedures.
(3) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(4) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Because
R-134a refri gerant i s heavi er than ai r, the l eak detec-
tor probe shoul d be moved sl owl y al ong the bottom
si de of al l refri gerant l i nes, connector fi tti ngs and
components.
(5) To i nspect the evaporator coi l for l eaks, i nsert
the el ectroni c l eak detector probe i nto the center
i nstrument panel outl et. Set the bl ower motor swi tch
to the l owest speed posi ti on, and the mode control
swi tch i n the reci rcul ati on mode.
SYSTEM LOW
(1) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(2) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run wi th the ai r condi ti oni ng system
turned on for fi ve mi nutes.
(3) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Because
R-134a refri gerant i s heavi er than ai r, the l eak detec-
tor probe shoul d be moved sl owl y al ong the bottom
si de of al l refri gerant l i nes, connector fi tti ngs and
components.
(4) To i nspect the evaporator coi l for l eaks, i nsert
the el ectroni c l eak detector probe i nto the center
i nstrument panel outl et. Set the bl ower motor swi tch
to the l owest speed posi ti on, and the mode control
swi tch i n the reci rcul ati on mode.
VACUUM SYSTEM
Vacuum control i s used to operate the mode doors
i n the heater-A/C housi ng. Testi ng of the heater-A/C
mode control swi tch operati on wi l l determi ne i f the
vacuum, and mechani cal control s are functi oni ng.
However, i t i s possi bl e that a vacuum control system
that operates perfectl y at engi ne i dl e (hi gh engi ne
vacuum) may not functi on properl y at hi gh engi ne
speeds or l oads (l ow engi ne vacuum). Thi s can be
caused by l eaks i n the vacuum system, or a faul ty
vacuum check val ve.
A vacuum system test wi l l hel p to i denti fy the
source of poor vacuum system performance or vac-
uum system l eaks. Before starti ng thi s test, stop the
engi ne and make certai n that the probl em i sn’t a di s-
connected vacuum suppl y tube at the engi ne i ntake
mani fol d vacuum tap or the vacuum reservoi r.
Use an adjustabl e vacuum test set (Speci al Tool
C-3707-B) and a sui tabl e vacuum pump to test the
heater-A/C vacuum control system. Wi th a fi nger
pl aced over the end of the vacuum test hose probe
(Fi g. 9), adjust the bl eed val ve on the test set gauge
to obtai n a vacuum of exactl y 27 kPa (8 i n. Hg.).
Rel ease and bl ock the end of the probe several ti mes
to veri fy that the vacuum readi ng returns to the
exact 27 kPa (8 i n. Hg.) setti ng. Otherwi se, a fal se
readi ng wi l l be obtai ned duri ng testi ng.
VACUUM CHECK VALVE
(1) Remove the vacuum check val ve. The val ve i s
l ocated i n the (bl ack) vacuum suppl y tube at the
i ntake mani fol d vacuum tap.
(2) Connect the test set vacuum suppl y hose to the
heater-A/C system (natural col or) si de of the val ve.
When connected to thi s si de of the check val ve, no
vacuum shoul d pass and the test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng. I f OK, go to
Step 3. I f not OK, repl ace the faul ty val ve.
(3) Connect the test set vacuum suppl y hose to the
engi ne vacuum (bl ack col or) si de of the val ve. When
connected to thi s si de of the check val ve, vacuum
shoul d fl ow through the val ve wi thout restri cti on. I f
not OK, repl ace the faul ty val ve.
Fig. 9 Adjust Vacuum Test Bleed Valve
1 – VACUUM PUMP TOOL C-4289
2 – VACUUM TEST SET C-3707
3 – BLEED VALVE
4 – PROBE
24 - 18 HEATING AND AIR CONDITIONING TJ
DIAGNOSIS AND TESTING (Continued)
HEATER-A/C CONTROLS
(1) Connect the test set vacuum probe to the heat-
er-A/C vacuum suppl y (bl ack) tube i n the engi ne
compartment. Posi ti on the test set gauge so that i t
can be vi ewed from the passenger compartment.
(2) Pl ace the heater-A/C mode control swi tch knob
i n each mode posi ti on, one posi ti on at a ti me, and
pause after each sel ecti on. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each sel ecti on i s made. I f not OK, a component or
vacuum l i ne i n the vacuum ci rcui t of the sel ected
mode has a l eak. See the procedure i n Locati ng Vac-
uum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
LOCATING VACUUM LEAKS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect the vacuum harness connector near
the back of the heater-A/C mode control swi tch on
the control panel .
(2) Connect the test set vacuum hose probe to each
port i n the vacuum harness connector, one port at a
ti me, and pause after each connecti on (Fi g. 10). The
test set gauge shoul d return to the 27 kPa (8 i n. Hg.)
setti ng shortl y after each connecti on i s made. I f OK,
repl ace the faul ty mode control swi tch. I f not OK, go
to Step 3.
(3) Determi ne the vacuum l i ne col or of the vacuum
ci rcui t that i s l eaki ng. To determi ne the vacuum l i ne
col ors, refer to the Vacuum Ci rcui ts chart (Fi g. 11) or
(Fi g. 12).
(4) Di sconnect and pl ug the vacuum l i ne from the
component (fi tti ng, actuator, val ve, swi tch, or reser-
voi r) on the other end of the l eaki ng ci rcui t. I nstru-
ment panel di sassembl y or removal may be necessary
to gai n access to some components. See the servi ce
procedures i n thi s group.
(5) Connect the test set hose or probe to the open
end of the l eaki ng ci rcui t. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each connecti on i s made. I f OK, repl ace the faul ty
di sconnected component. I f not OK, go to Step 6.
(6) To l ocate a l eak i n a vacuum l i ne, l eave one
end of the l i ne pl ugged and connect the test set hose
or probe to the other end. Run your fi ngers sl owl y
al ong the l i ne whi l e watchi ng the test set gauge. The
vacuum readi ng wi l l fl uctuate when your fi ngers con-
tact the source of the l eak. To repai r the vacuum
l i ne, cut out the l eaki ng secti on of the l i ne. Then,
i nsert the l oose ends of the l i ne i nto a sui tabl e l ength
of 3 mi l l i meter (1/8-i nch) i nsi de di ameter rubber
hose.
Fig. 10 Vacuum Circuit Test
TJ HEATING AND AIR CONDITIONING 24 - 19
DIAGNOSIS AND TESTING (Continued)
Fig. 11 Vacuum Circuits - Heater Only
VACUUM CIRCUIT LEGEND
I. D. Function Color
A Not Used N/A
B Defrost Actuator (Full Position) Yellow
C Floor Actuator Brown
D Defrost Actuator (Mid-Position) Blue
E Vacuum Supply (Reservoir) Black
F Panel Actuator Red
G Recirculation Actuator Green
24 - 20 HEATING AND AIR CONDITIONING TJ
DIAGNOSIS AND TESTING (Continued)
VACUUM CIRCUIT LEGEND
I. D. Function Color
A Not Used N/A
B Defrost Actuator (Full Position) Yellow
C Floor Actuator Brown
D Defrost Actuator (Mid-Position) Blue
E Vacuum Supply (Reservoir) Black
F Panel Actuator Red
G Recirculation Actuator Green
Fig. 12 Vacuum Circuits - Heater-A/C
TJ HEATING AND AIR CONDITIONING 24 - 21
DIAGNOSIS AND TESTING (Continued)
SERVICE PROCEDURES
REFRIGERANT OIL LEVEL
When an ai r condi ti oni ng system i s assembl ed at
the factory, al l components except the compressor are
refri gerant oi l free. After the refri gerant system has
been charged and operated, the refri gerant oi l i n the
compressor i s di spersed throughout the refri gerant
system. The accumul ator, evaporator, condenser, and
compressor wi l l each retai n a si gni fi cant amount of
the needed refri gerant oi l .
I t i s i mportant to have the correct amount of oi l i n
the refri gerant system. Thi s ensures proper l ubri ca-
ti on of the compressor. Too l i ttl e oi l wi l l resul t i n
damage to the compressor. Too much oi l wi l l reduce
the cool i ng capaci ty of the ai r condi ti oni ng system.
I t wi l l not be necessary to check the oi l l evel i n the
compressor or to add oi l , unl ess there has been an oi l
l oss. An oi l l oss may occur due to a rupture or l eak
from a refri gerant l i ne, a connector fi tti ng, a compo-
nent, or a component seal . I f a l eak occurs, add 30
mi l l i l i ters (1 fl ui d ounce) of refri gerant oi l to the
refri gerant system after the repai r has been made.
Refri gerant oi l l oss wi l l be evi dent at the l eak poi nt
by the presence of a wet, shi ny surface around the
l eak.
Refri gerant oi l must be added when a accumul ator,
evaporator coi l , or condenser are repl aced. See the
Refri gerant Oi l Capaci ti es chart. When a compressor
i s repl aced, the refri gerant oi l must be drai ned from
the ol d compressor and measured. Drai n al l of the
refri gerant oi l from the new compressor, then fi l l the
new compressor wi th the same amount of refri gerant
oi l that was drai ned out of the ol d compressor.
REFRIGERANT RECOVERY
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE
RECOVERING REFRIGERANT.
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
used to recover the refri gerant from an R-134a refri g-
erant system. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for the proper
care and use of thi s equi pment.
REFRIGERANT SYSTEM CHARGE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
CHARGING THE REFRIGERANT SYSTEM.
After the refri gerant system has been tested for
l eaks and evacuated, a refri gerant charge can be
i njected i nto the system. See Refri gerant Charge
Capaci ty for the proper amount of the refri gerant
charge.
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
used to charge the refri gerant system wi th R-134a
refri gerant. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for proper care
and use of thi s equi pment.
REFRIGERANT CHARGE CAPACITY
The R-134a refri gerant system charge capaci ty for
thi s vehi cl e i s 0.567 ki l ograms (1.25 pounds).
REFRIGERANT SYSTEM EVACUATE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE EVAC-
UATING THE SYSTEM.
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be charged. I f moi sture and ai r enters the system
and becomes mi xed wi th the refri gerant, the com-
pressor head pressure wi l l ri se above acceptabl e
operati ng l evel s. Thi s wi l l reduce the performance of
the ai r condi ti oner and damage the compressor.
Evacuati ng the refri gerant system wi l l remove the
ai r and boi l the moi sture out of the system at near
room temperature. To evacuate the refri gerant sys-
tem, use the fol l owi ng procedure:
(1) Connect a R-134a refri gerant recovery/recy-
cl i ng/chargi ng stati on that meets SAE Standard
J2210 and a mani fol d gauge set to the refri gerant
system of the vehi cl e.
(2) Open the l ow and hi gh si de val ves and start
the chargi ng stati on vacuum pump. When the suc-
ti on gauge reads 88 kPa (26 i n. Hg.) vacuum or
greater, cl ose al l of the val ves and turn off the vac-
uum pump.
(a) I f the refri gerant system fai l s to reach the
speci fi ed vacuum, the system has a l eak that must
be corrected. See Refri gerant System Leaks i n the
Refrigerant Oil Capacities
Component ml fl oz
A/C System 180 6.1
Accumulator 90 3
Condenser 22 .75
Evaporator 45 1.5
Compressor
drain and measure
the oil from the old
compressor as noted
24 - 22 HEATING AND AIR CONDITIONING TJ
Di agnosi s and Testi ng secti on of thi s group for the
procedures.
(b) I f the refri gerant system mai ntai ns the spec-
i fi ed vacuum for fi ve mi nutes, restart the vacuum
pump, open the sucti on and di scharge val ves and
evacuate the system for an addi ti onal ten mi nutes.
(3) Cl ose al l of the val ves, and turn off the charg-
i ng stati on vacuum pump.
(4) The refri gerant system i s now ready to be
charged wi th R-134a refri gerant. See Refri gerant
System Charge i n the Servi ce Procedures secti on of
thi s group.
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE CONNECTING TO, OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
When servi ci ng the ai r condi ti oni ng system, a
R-134a refri gerant recovery/recycl i ng/chargi ng sta-
ti on that meets SAE Standard J2210 must be used.
Contact an automoti ve servi ce equi pment suppl i er for
refri gerant recovery/recycl i ng/chargi ng equi pment.
Refer to the operati ng i nstructi ons suppl i ed by the
equi pment manufacturer for proper care and use of
thi s equi pment.
A mani fol d gauge set may be needed wi th some
recovery/recycl i ng/chargi ng equi pment (Fi g. 13). The
servi ce hoses on the gauge set bei ng used shoul d
have manual (turn wheel ), or automati c back-fl ow
val ves at the servi ce port connector ends. Thi s wi l l
prevent refri gerant from bei ng rel eased i nto the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE The l ow pressure
hose (Bl ue wi th Bl ack stri pe) attaches to the sucti on
servi ce port. Thi s port i s l ocated on the l i qui d l i ne
near the evaporator i nl et tube at the rear of the
engi ne compartment.
HI GH PRESSURE GAUGE HOSE The hi gh pres-
sure hose (Red wi th Bl ack stri pe) attaches to the di s-
charge servi ce port. Thi s port i s l ocated on the
mani fol d di rectl y over the di scharge port of the com-
pressor.
RECOVERY/RECYCLI NG/EVACUATI ON/CHARG-
I NG HOSE The center mani fol d hose (Yel l ow, or
Whi te, wi th Bl ack stri pe) i s used to recover, evacu-
ate, and charge the refri gerant system. When the l ow
or hi gh pressure val ves on the mani fol d gauge set
are opened, the refri gerant i n the system wi l l escape
through thi s hose.
Fig. 13 Manifold Gauge Set - Typical
1 – HIGH PRESSURE GAUGE
2 – VALVE
3 – VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK
STRIPE)
4 – HIGH PRESSURE HOSE (RED W/BLACK STRIPE)
5 – LOW PRESSURE HOSE (BLUE W/BLACK STRIPE)
6 – VALVE
7 – LOW PRESSURE GAUGE
TJ HEATING AND AIR CONDITIONING 24 - 23
SERVICE PROCEDURES (Continued)
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND PRECAUTIONS
WARNING:
• THE AIR CONDITIONING SYSTEM CONTAINS
REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER
SERVICE PROCEDURES. REPAIRS SHOULD ONLY
BE PERFORMED BY QUALIFIED SERVICE PERSON-
NEL.
• AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
• DO NOT EXPOSE THE REFRIGERANT TO
OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELEC-
TRONIC LEAK DETECTOR IS RECOMMENDED.
• IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF
REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.
• THE EVAPORATION RATE OF R-134a REFRIG-
ERANT AT AVERAGE TEMPERATURE AND ALTI-
TUDE IS EXTREMELY HIGH. AS A RESULT,
ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
THE SKIN OR DELICATE OBJECTS FROM DIRECT
CONTACT WITH THE REFRIGERANT.
• THE R-134a SERVICE EQUIPMENT OR THE
VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
CAUTION:
• Liquid refrigerant is corrosive to metal sur-
faces. Follow the operating instructions supplied
with the service equipment being used.
• Never add R-12 to a refrigerant system
designed to use R-134a. Damage to the system will
result.
• R-12 refrigerant oil must not be mixed with
R-134a refrigerant oil. They are not compatible.
• Do not use R-12 equipment or parts on the
R-134a system. Damage to the system will result.
• Do not overcharge the refrigerant system. This
will cause excessive compressor head pressure
and can cause noise and system failure.
• Recover the refrigerant before opening any fit-
ting or connection. Open the fittings with caution,
even after the system has been discharged. Never
open or loosen a connection before recovering the
refrigerant.
• Do not remove the secondary retention clip
from any spring-lock coupler connection while the
refrigerant system is under pressure. Recover the
refrigerant before removing the secondary retention
clip. Open the fittings with caution, even after the
system has been discharged. Never open or loosen
a connection before recovering the refrigerant.
• The refrigerant system must always be evacu-
ated before charging.
• Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system.
• Before disconnecting a component, clean the
outside of the fittings thoroughly to prevent con-
tamination from entering the refrigerant system.
• Immediately after disconnecting a component
from the refrigerant system, seal the open fittings
with a cap or plug.
• Before connecting an open refrigerant fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connect-
ing.
• Do not remove the sealing caps from a replace-
ment component until it is to be installed.
• When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system compo-
nents or any sharp edges, which may damage the
line.
• Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refriger-
ant system will not tolerate overtightening.
• When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will pre-
vent twisting of the refrigerant lines or tubes.
• Refrigerant oil will absorb moisture from the
atmosphere if left uncapped. Do not open a con-
tainer of refrigerant oil until you are ready to use it.
Replace the cap on the oil container immediately
after using. Store refrigerant oil only in a clean, air-
tight, and moisture-free container.
• Keep service tools and the work area clean.
Contamination of the refrigerant system through
careless work habits must be avoided.
24 - 24 HEATING AND AIR CONDITIONING TJ
COOLING SYSTEM REQUIREMENTS
To mai ntai n the performance l evel of the heati ng-
ai r condi ti oni ng system, the engi ne cool i ng system
must be properl y mai ntai ned. The use of a bug
screen i s not recommended. Any obstructi ons i n front
of the radi ator or condenser wi l l reduce the perfor-
mance of the ai r condi ti oni ng and engi ne cool i ng sys-
tems.
The engi ne cool i ng system i ncl udes the heater core
and the heater hoses. Refer to Group 7 - Cool i ng Sys-
tem for more i nformati on before the openi ng of, or
attempti ng any servi ce to the engi ne cool i ng system.
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS
Ki nks or sharp bends i n the refri gerant pl umbi ng
wi l l reduce the capaci ty of the enti re system. Hi gh
pressures are produced i n the system when i t i s oper-
ati ng. Extreme care must be exerci sed to make sure
that al l refri gerant system connecti ons are pressure
ti ght.
A good rul e for the fl exi bl e hose refri gerant l i nes i s
to keep the radi us of al l bends at l east ten ti mes the
di ameter of the hose. Sharp bends wi l l reduce the
fl ow of refri gerant. The fl exi bl e hose l i nes shoul d be
routed so they are at l east 80 mi l l i meters (3 i nches)
from the exhaust mani fol d. I t i s a good practi ce to
i nspect al l fl exi bl e refri gerant system hose l i nes at
l east once a year to make sure they are i n good con-
di ti on and properl y routed.
There are two types of refri gerant fi tti ngs:
• Al l fi tti ngs wi th O-ri ngs need to be coated wi th
refri gerant oi l before i nstal l ati on. Use onl y O-ri ngs
that are the correct si ze and approved for use wi th
R-134a refri gerant. Fai l ure to do so may resul t i n a
l eak.
• Uni fi ed pl umbi ng connecti ons wi th gaskets can-
not be servi ced wi th O-ri ngs. The gaskets are not
reusabl e and new gaskets do not requi re l ubri cati on
before i nstal l i ng.
Usi ng the proper tool s when maki ng a refri gerant
pl umbi ng connecti on i s very i mportant. I mproper
tool s or i mproper use of the tool s can damage the
refri gerant fi tti ngs. Al ways use two wrenches when
l ooseni ng or ti ghteni ng tube fi tti ngs. Use one wrench
to hol d one si de of the connecti on stati onary, whi l e
l ooseni ng or ti ghteni ng the other si de of the connec-
ti on wi th a second wrench.
The refri gerant must be recovered compl etel y from
the system before openi ng any fi tti ng or connecti on.
Open the fi tti ngs wi th cauti on, even after the refri g-
erant has been recovered. I f any pressure i s noti ced
as a fi tti ng i s l oosened, ti ghten the fi tti ng and
recover the refri gerant from the system agai n.
Do not di scharge refri gerant i nto the atmosphere.
Use an R-134a refri gerant recovery/recycl i ng devi ce
that meets SAE Standard J2210.
The refri gerant system wi l l remai n chemi cal l y sta-
bl e as l ong as pure, moi sture-free R-134a refri gerant
and refri gerant oi l i s used. Di rt, moi sture, or ai r can
upset thi s chemi cal stabi l i ty. Operati onal troubl es or
seri ous damage can occur i f forei gn materi al i s
present i n the refri gerant system.
When i t i s necessary to open the refri gerant sys-
tem, have everythi ng needed to servi ce the system
ready. The refri gerant system shoul d not be l eft open
to the atmosphere any l onger than necessary. Cap or
pl ug al l l i nes and fi tti ngs as soon as they are opened
to prevent the entrance of di rt and moi sture. Al l l i nes
and components i n parts stock shoul d be capped or
seal ed unti l they are to be i nstal l ed.
Al l tool s, i ncl udi ng the refri gerant recycl i ng equi p-
ment, the mani fol d gauge set, and test hoses shoul d
be kept cl ean and dry. Al l tool s and equi pment must
be desi gned for R-134a refri gerant.
ACCUMULATOR
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system. See Refri gerant Recovery i n thi s group for
the procedures.
(3) Unpl ug the wi re harness connector from the
l ow pressure cycl i ng cl utch swi tch.
(4) Remove the pl asti c cl i p that secures the l i qui d
l i ne to the accumul ator outl et tube near the dash
panel .
(5) Loosen the screw that secures the accumul ator
retai ni ng band to the support bracket on the dash
panel (Fi g. 14).
(6) Di sconnect the sucti on l i ne from the accumul a-
tor outl et tube refri gerant l i ne fi tti ng. See Refri ger-
ant Li ne Coupl er i n thi s group for the procedures.
I nstal l pl ugs i n, or tape over al l of the opened refri g-
erant l i ne fi tti ngs.
(7) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne fi tti ng from the evaporator outl et tube. See
Refri gerant Li ne Coupl er i n thi s group for the proce-
dures. I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(8) Pul l the accumul ator and retai ni ng band uni t
forward unti l the screw i n the band i s cl ear of the
sl otted hol e i n the support bracket on the dash panel .
(9) Remove the accumul ator from the vehi cl e.
TJ HEATING AND AIR CONDITIONING 24 - 25
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l the accumul ator and retai ni ng band as
a uni t by sl i di ng the screw i n the band i nto the sl ot-
ted hol e i n the support bracket on the dash panel .
(2) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the accumul ator i nl et tube and the
evaporator outl et tube. Connect the accumul ator i nl et
tube refri gerant l i ne coupl er to the evaporator outl et
tube. See Refri gerant Li ne Coupl er i n thi s group for
the procedures.
(3) Ti ghten the accumul ator retai ni ng band screw
to 4.5 N·m (40 i n. l bs.).
(4) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the sucti on l i ne and the accumul ator
outl et tube. Connect the sucti on l i ne to the accumu-
l ator outl et tube refri gerant l i ne coupl er. See Refri g-
erant Li ne Coupl er i n thi s group for the procedures.
(5) I nstal l the pl asti c cl i p that secures the l i qui d
l i ne to the accumul ator outl et tube near the dash
panel .
(6) Pl ug the wi re harness connector i nto the l ow
pressure cycl i ng cl utch swi tch.
(7) Connect the battery negati ve cabl e.
(8) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group for the proce-
dures.
(9) Charge the refri gerant system. See Refri gerant
System Charge i n thi s group for the procedures.
NOTE: If the accumulator is replaced, add 120 mil-
liliters (4 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
BLEND-AIR DOOR MOTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the wi re connector from the bl end-
ai r door motor.
(3) Remove the screws that secure the bl end-ai r
door motor to the housi ng (Fi g. 15).
(4) Remove the bl end-ai r door motor.
INSTALLATION
(1) Reverse the removal procedures for i nstal l a-
ti on.
Fig. 14 Accumulator Remove/Install
1 – ACCUMULATOR
2 – CLIP
3 – NUT
4 – BRACKET
5 – EVAPORATOR
6 – BAND
7 – LOW PRESSURE CYCLING CLUTCH SWITCH
8 – SCREW
9 – CLIP
Fig. 15 Blend-Air Door Motor
1 – ELECTRICAL CONNECTOR
2 – BLEND-AIR DOOR MOTOR
3 – SCREW MOUNTING POINTS
24 - 26 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l and ti ghten the screws that secures the
bl end-ai r door motor to the housi ng. Ti ghten the
mounti ng screws to 1 N·m (10 i n. l bs.).
(3) Connect the battery negati ve cabl e.
BLOWER MOTOR
REMOVAL
(1) Remove the battery from the battery tray.
Refer to Group 8A - Battery for the procedures.
(2) Remove the three screws that secure the Pow-
ertrai n Control Modul e (PCM) to the mounti ng
bracket on the engi ne compartment si de of the dash
panel . Move the PCM away from the bl ower motor
openi ng i n the dash panel (Fi g. 16).
(3) Unpl ug the bl ower motor wi re harness connec-
tor (Fi g. 17).
(4) Remove the three screws that secure the
bl ower motor and wheel assembl y to the heater-A/C
housi ng.
(5) Rotate and ti l t the bl ower motor uni t as needed
for cl earance to remove the bl ower motor and wheel
from the heater-A/C housi ng.
INSTALLATION
(1) Al i gn and i nstal l the bl ower motor and wheel
assembl y i nto the heater-A/C housi ng.
(2) I nstal l and ti ghten the three screws that secure
the bl ower motor and wheel assembl y to the heater-
A/C housi ng. Ti ghten the mounti ng screws to 2.2
N·m (20 i n. l bs.).
(3) Pl ug i n the bl ower motor wi re harness connec-
tor.
(4) Posi ti on the PCM to the mounti ng bracket on
the dash panel . I nstal l and ti ghten the three screws
that secure the PCM to the dash panel mounti ng
bracket.
(5) I nstal l the battery i n the battery tray. Refer to
Group 8A - Battery for the procedures.
BLOWER MOTOR RELAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . Refer to Gl ove Box i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Locate the bl ower motor rel ay through the
i nstrument panel gl ove box openi ng. The rel ay i s
mounted upri ght and to the ri ght of the i nstrument
panel harness. (Fi g. 18).
(4) Unpl ug the bl ower motor rel ay from i ts wi re
harness connector.
Fig. 16 Powertrain Control Module (PCM) Remove/
Install
1 – POWERTRAIN CONTROL MODULE
2 – BLOWER MOTOR
3 – POWER DISTRIBUTION CENTER
4 – BATTERY TRAY
Fig. 17 Blower Motor Remove/Install
1 – BLOWER MOTOR
2 – WIRE HARNESS CONNECTOR
3 – MOUNTING SCREWS
TJ HEATING AND AIR CONDITIONING 24 - 27
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l the bl ower motor rel ay by al i gni ng the
rel ay termi nal s wi th the cavi ti es i n the wi re harness
connector and pushi ng the rel ay fi rml y i nto pl ace.
(2) Rei nstal l the gl ove box i n the i nstrument
panel . Refer to Gl ove Box i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Connect the battery negati ve cabl e.
(4) Test the rel ay operati on.
BLOWER MOTOR RESISTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the ki ck cover from the heater-A/C
housi ng. See Ki ck Cover i n thi s group for the proce-
dures.
(3) Pul l out the l ock on the bl ower motor resi stor
wi re harness connector to unl ock the connector l atch
(Fi g. 19).
(4) Depress the l atch on the bl ower motor resi stor
wi re harness connector and unpl ug the connector
from the resi stor.
(5) Remove the two screws that secure the resi stor
to the heater-A/C housi ng.
(6) Remove the resi stor from the heater-A/C hous-
i ng.
(7) Reverse the removal procedures to i nstal l .
Ti ghten the mounti ng screws to 2.2 N·m (20 i n l bs.).
BLOWER MOTOR SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the bl ower motor swi tch
knob off of the swi tch stem from the front of the
heater-A/C control .
(3) Remove the heater-A/C control from the i nstru-
ment panel . See Heater-A/C Control i n thi s group for
the procedures.
(4) Remove the screw that secures the bl ower
motor swi tch to the rear of the heater-A/C control
(Fi g. 20).
Fig. 18 Blower Motor Relay Remove/Install
1 – HEATER-A/C HOUSING
2 – BLOWER MOTOR RELAY
3 – VACUUM ACTUATOR
4 – HEATER-A/C WIRE HARNESS
5 – INSTRUMENT PANEL WIRE HARNESS
Fig. 19 Blower Motor Resistor Remove/Install
1 – SCREWS
2 – WIRE HARNESS CONNECTOR
3 – CONNECTOR LOCK
4 – HEATER-A/C HOUSING
5 – BLOWER MOTOR RESISTOR
24 - 28 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
(5) Remove the bl ower motor swi tch from the rear
of the heater-A/C control .
INSTALLATION
(1) Reverse the removal procedures to i nstal l .
Ti ghten the heater-A/C control and swi tch mounti ng
screws to 2.2 N·m (20 i n. l bs.).
COMPRESSOR
The compressor may be removed and reposi ti oned
wi thout di sconnecti ng the refri gerant l i nes or di s-
chargi ng the refri gerant system. Di schargi ng i s not
necessary i f servi ci ng the compressor cl utch or cl utch
coi l , the engi ne, the cyl i nder head, or the generator.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Recover the refri gerant from the refri gerant
system. See Refri gerant Recovery i n thi s group for
the procedures.
(2) Di sconnect and i sol ate the battery negati ve
cabl e.
(3) Remove the serpenti ne dri ve bel t. Refer to
Group 7 - Cool i ng System for the procedures.
(4) Unpl ug the compressor cl utch coi l wi re harness
connector.
(5) Remove the screws that secure the sucti on l i ne
and di scharge l i ne bl ock fi tti ngs to the mani fol d on
the compressor (Fi g. 21) and (Fi g. 22). I nstal l pl ugs
i n, or tape over al l of the opened refri gerant fi tti ngs.
Fig. 20 Blower Motor Switch Remove/Install
1 – HEATER-A/C CONTROL
2 – SINGLE MOUNTING SCREW
3 – BLOWER MOTOR SWITCH
4 – VACUUM HARNESS
5 – VACUUM/ELECTRIC MODE SWITCH
Fig. 21 Compressor Lines - 4 Cylinder Engine
1 – SERVICE PORT
2 – SUCTION LINE
3 – COMPRESSOR
4 – HIGH PRESSURE CUT-OFF SWITCH
5 – TO CONDENSER
6 – DISCHARGE LINE
7 – ACCUMULATOR
Fig. 22 Compressor Lines - 6 Cylinder Engine
1 – SUCTION LINE
2 – SERVICE PORT
3 – HIGH PRESSURE CUT-OFF SWITCH
4 – ENGINE MOUNTING BRACKET
5 – COMPRESSOR
6 – DISCHARGE LINE
TJ HEATING AND AIR CONDITIONING 24 - 29
REMOVAL AND INSTALLATION (Continued)
(6) Remove the screws that secure the compressor
(Fi g. 23) and (Fi g. 24).
(7) Remove the compressor.
INSTALLATION
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. See Refrigerant Oil Level in this group for the
procedures. Use only refrigerant oil of the type rec-
ommended for the compressor in the vehicle.
(1) I nstal l the compressor.
Ti ghten the 4.0L mounti ng bol ts fasteni ng the com-
pressor to the bl ock to 45-65 N·m (35-50 ft. l bs.).
Ti ghten the mounti ng bol ts hol di ng the rear brace to
the compressor and bl ock to 40-55 N·m (30-40 ft.
l bs.).
Ti ghten the 2.5L mounti ng bol ts to 28 N·m (21 ft.
l bs.).
(2) Remove the tape or pl ugs from al l of the
opened refri gerant l i ne fi tti ngs. I nstal l the sucti on
l i ne and di scharge l i ne bl ock fi tti ngs to the mani fol d
on the compressor. Ti ghten the mounti ng screws to
25.4 N·m (20 ft. l bs.).
(3) I nstal l the serpenti ne dri ve bel t. Refer to
Group 7 - Cool i ng System for the procedures.
(4) Pl ug i n the compressor cl utch coi l wi re harness
connector.
(5) Connect the battery negati ve cabl e.
(6) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group for the proce-
dures.
(7) Charge the refri gerant system. See Refri gerant
System Charge i n thi s group for the procedures.
COMPRESSOR CLUTCH
The refri gerant system can remai n ful l y-charged
duri ng compressor cl utch, pul l ey, or coi l repl acement.
The compressor cl utch can be servi ced i n the vehi cl e.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the serpenti ne dri ve bel t. Refer to
Group 7 - Cool i ng System for the procedures.
(3) Remove the bol t that secures the compressor
cl utch to the compressor shaft (Fi g. 25). A band-type
oi l fi l ter wrench may be used to secure the cl utch
duri ng bol t removal .
(4) Tap the cl utch pl ate wi th a pl asti c mal l et to
rel ease i t from the spl i nes on the compressor shaft.
Remove the cl utch pl ate and shi m(s) from the com-
pressor shaft (Fi g. 26).
CAUTION: Do not pry between the clutch plate
assembly and the pulley to remove it from the com-
pressor shaft. Prying may damage the clutch plate
assembly.
(5) Remove the external snap ri ng that secures the
compressor cl utch pul l ey to the nose of the compres-
sor front housi ng wi th snap ri ng pl i ers (Speci al Tool
C-4574) and sl i de the pul l ey assembl y off of the com-
pressor (Fi g. 27).
Fig. 23 Compressor - 4 Cylinder Engine
1 – A/C COMPRESSOR
2 – MOUNTING BOLTS
3 – A/C COMPRESSOR MOUNTING BRACKET
Fig. 24 Compressor - 6 Cylinder Engine
1 – POWER STEERING PUMP MOUNTING BRACKET
2 – BRACE
3 – A/C COMPRESSOR
24 - 30 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
(6) Remove the screw and retai ner from the cl utch
coi l l ead wi re harness on the compressor front hous-
i ng.
(7) Remove the external snap ri ng that secures the
compressor cl utch coi l to the nose of the compressor
front housi ng wi th snap ri ng pl i ers and sl i de the coi l
assembl y off of the compressor (Fi g. 28).
INSPECTION
Exami ne the fri cti on surfaces of the cl utch pul l ey
and the cl utch pl ate for wear. The pul l ey and pl ate
shoul d be repl aced i f there i s excessi ve wear or scor-
i ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for refri gerant oi l .
Remove the fel t wi ck from around the shaft i nsi de
the nose of the compressor front housi ng. I f the fel t
i s saturated wi th refri gerant oi l , the compressor
Fig. 25 Compressor Shaft Bolt
1 – COMPRESSOR CLUTCH PLATE
2 – COMPRESSOR SHAFT BOLT
Fig. 26 Clutch Plate and Shim
1 – COMPRESSOR SHAFT
2 – CLUTCH PLATE
3 – CLUTCH PLATE SHIM
Fig. 27 Pulley Snap Ring
1 – SNAP RING
Fig. 28 Clutch Coil Snap Ring
1 – SNAP RING PLIERS
2 – CLUTCH COIL
3 – SNAP RING
4 – COMPRESSOR
TJ HEATING AND AIR CONDITIONING 24 - 31
REMOVAL AND INSTALLATION (Continued)
shaft seal i s l eaki ng and the compressor must be
repl aced.
Check the cl utch pul l ey beari ng for roughness or
excessi ve l eakage of grease. Repl ace the beari ng, i f
requi red.
INSTALLATION
(1) Al i gn the dowel pi n on the back of the cl utch
fi el d coi l wi th the hol e i n the compressor front hous-
i ng and press the fi el d coi l i nto pl ace over the nose of
the compressor.
(2) I nstal l the cl utch coi l l ead wi re harness retai n-
i ng cl i p on the compressor front housi ng and ti ghten
the retai ni ng screw.
(3) I nstal l the cl utch fi el d coi l and snap ri ng wi th
snap ri ng pl i ers (Speci al Tool C-4574). The bevel si de
of the snap ri ng must be faci ng outward. Al so, both
eyel ets of the snap ri ng must be to the ri ght or l eft of
the pi n on the compressor. Press i n on the snap ri ng
to be certai n that i t i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(4) I nstal l the pul l ey assembl y onto the compres-
sor. I f necessary, pl ace a bl ock of wood on the fri cti on
surface and tap gentl y wi th a hammer (Fi g. 29).
CAUTION: Do not mar the pulley friction surface.
(5) I nstal l the pul l ey assembl y retai ni ng snap ri ng
(bevel si de outward) wi th snap ri ng pl i ers (Speci al
Tool C-4574). Press i n on the snap ri ng to be certai n
that i t i s properl y seated i n the groove.
(6) I f the ori gi nal cl utch pl ate assembl y and pul l ey
assembl y are to be reused, the ol d shi m(s) can be
used. I f not, pl ace a stack of shi m(s) equal to the ol d
shi m(s) on the shaft agai nst the shoul der.
(7) I nstal l the cl utch pl ate assembl y onto the
shaft.
(8) Wi th the cl utch pl ate assembl y ti ght agai nst
the shi m(s), measure the ai r gap between the cl utch
pl ate and the pul l ey face wi th feel er gauges. The ai r
gap shoul d be between 0.35 to 0.65 mi l l i meter (0.014
to 0.026 i nch). I f the proper ai r gap i s not obtai ned,
add or subtract shi ms as needed unti l the desi red ai r
gap i s obtai ned.
(9) I nstal l the compressor shaft bol t. Ti ghten the
bol t to 13 N·m (115 i n. l bs.).
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is still correct. Spin the
pulley before performing a final check of the air
gap.
(10) Reverse the remai ni ng removal procedures to
compl ete the i nstal l ati on.
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the heater-A/C control i n the
Reci rcul ati on Mode, the A/C button i n the on posi -
ti on, the bl ower motor swi tch i n the hi ghest speed
posi ti on, and the engi ne speed at 1500 to 2000 rpm.
Thi s procedure (burni shi ng) wi l l seat the opposi ng
fri cti on surfaces and provi de a hi gher compressor
cl utch torque capabi l i ty.
COMPRESSOR CLUTCH RELAY
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 30).
(3) Refer to the l abel on the PDC for compressor
cl utch rel ay i denti fi cati on and l ocati on.
(4) Unpl ug the compressor cl utch rel ay from the
PDC.
(5) I nstal l the compressor cl utch rel ay by al i gni ng
the rel ay termi nal s wi th the cavi ti es i n the PDC and
pushi ng the rel ay fi rml y i nto pl ace.
(6) I nstal l the PDC cover.
(7) Connect the battery negati ve cabl e.
(8) Test the rel ay operati on.
Fig. 29 Pulley Assembly Install
1 – PULLEY ASSEMBLY
2 – WOOD BLOCK
24 - 32 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
CONDENSER
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system. See Refri gerant Recovery i n thi s group for
the procedures.
(3) Remove the three retai ners that secure the
upper condenser ai r seal to the gri l l e panel and
remove the upper ai r seal (Fi g. 31).
(4) Remove the two screws that secure the upper
condenser mounti ng brackets to the top of the gri l l e
panel .
(5) Reach through the ri ght si de of the gri l l e panel
openi ng from the front of the vehi cl e to remove the
screws that secure the condenser i nl et jumper tube
and outl et jumper tube bl ock fi tti ngs to the con-
denser. I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(6) Remove the three retai ners that secure the
l ower condenser ai r seal to the passenger si de frame
rai l and the bottom of the gri l l e panel and remove
the l ower ai r seal .
(7) Remove the two screws that secure the l ower
condenser mounti ng bracket to the bottom of the
gri l l e panel .
(8) Remove the three screws on each si de of the
radi ator that secure the radi ator mounti ng brackets
to the si des of the gri l l e panel .
(9) Ti l t the radi ator and shroud uni t back towards
the engi ne. Use care to prevent the cool i ng fan bl ades
from damagi ng the radi ator fi ns.
(10) Careful l y l i ft the condenser out of the vehi cl e.
INSTALLATION
(1) Careful l y posi ti on the condenser i n the vehi cl e.
(2) I nstal l and ti ghten the two screws that secure
the upper condenser mounti ng brackets to the top of
the gri l l e panel . Ti ghten the screws to 2.2 N·m (20 i n.
l bs.).
(3) Al i gn the radi ator mounti ng brackets to the
si des of the gri l l e panel . I nstal l the si x screws that
secure the radi ator and shroud uni t to the gri l l e
panel . Ti ghten the screws to 8 N·m (72 i n. l bs.).
(4) I nstal l the upper condenser ai r seal to the top
of the gri l l e panel wi th three retai ners.
(5) Remove the tape or pl ugs from the condenser
and the i nl et and outl et jumper tube refri gerant l i ne
bl ock fi tti ngs. Reach through the gri l l e openi ng from
the front of the vehi cl e to i nstal l the i nl et and outl et
jumper tube bl ock fi tti ngs to the condenser wi th two
screws. Ti ghten the mounti ng screws to 12 N·m (105
i n. l bs.).
(6) I nstal l the two screws that secure the l ower
condenser bracket to the bottom of the gri l l e panel .
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(7) I nstal l the l ower condenser ai r seal to the bot-
tom of the gri l l e panel and the passenger si de frame
rai l wi th three retai ners.
(8) Connect the battery negati ve cabl e.
(9) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group for the proce-
dures.
(10) Charge the refri gerant system. See Refri ger-
ant System Charge i n thi s group for the procedures.
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
Fig. 30 Power Distribution Center
1 – POSITIVE CABLE
2 – NEGATIVE CABLE
3 – DASH PANEL
4 – FENDER
5 – POWER DISTRIBUTION CENTER
6 – NUT
TJ HEATING AND AIR CONDITIONING 24 - 33
REMOVAL AND INSTALLATION (Continued)
DUCTS AND OUTLETS
Onl y the demi ster hoses and the panel outl et bar-
rel s can be removed wi thout i nstrument panel
assembl y removal . Removal of the fresh ai r duct and
col l ar requi res that the heater-A/C housi ng al so be
parti al l y removed. The panel outl et housi ngs and
demi ster outl ets are servi ced onl y as a part of the
i nstrument panel or i nstrument panel center bezel .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
DEFROST/DEMIST DUCT
(1) Remove the i nstrument panel assembl y from
the vehi cl e. Refer to Group 8E - I nstrument Panel
Systems for the procedures.
(2) Remove the two push-nuts that secure the
defrost/demi st duct to the studs on the dash panel .
(3) Remove the defrost/demi st duct from the studs
on the dash panel .
(4) Reverse the removal procedures to i nstal l .
Fig. 31 Condenser Remove/Install
1 – RETAINER
2 – AIR SEAL
3 – GRILLE PANEL
4 – AIR SEAL
5 – FRAME RAIL
6 – RETAINER
7 – AIR SEAL
8 – TUBES AND FLANGES
9 – CONDENSER
10 – FIXED ORIFICE TUBE
11 – LIQUID LINE
12 – SERVICE PORT
13 – SCREWS
14 – AIR SEAL
24 - 34 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
DEMISTER HOSES
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel to servi ce the passenger si de demi ster hose.
Refer to Gl ove Box i n Group 8E - I nstrument Panel
Systems for the procedures. Remove the knee bl ocker
from the i nstrument panel to servi ce the dri ver si de
demi ster hose. Refer to Knee Bl ocker i n Group 8E -
I nstrument Panel Systems for the procedures.
(3) Reach through the gl ove box openi ng or the
steeri ng col umn openi ng of the i nstrument panel to
di sconnect the ends of the demi ster hose from the
demi ster outl et and the defrost/demi st duct.
(4) Reverse the removal procedures to i nstal l .
FLOOR DUCT
(1) Remove the i nstrument panel from the vehi cl e.
Refer to I nstrument Panel Assembl y i n Group 8E -
I nstrument Panel Systems for the procedures.
(2) Remove the two screws that secure the fl oor
duct to the bottom of the heater-A/C housi ng.
(3) Rel ease the snap cl i p that secures the fl oor
duct to the dash panel si de of the heater-A/C housi ng
by pushi ng the snap cl i p towards the dash panel .
(4) Sl i de the fl oor duct out from under the heater-
A/C housi ng.
(5) Reverse the removal procedures to i nstal l .
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
FRESH AIR DUCT AND COLLAR
(1) Remove the i nstrument panel from the vehi cl e.
Refer to I nstrument Panel Assembl y i n Group 8E -
I nstrument Panel Systems for the procedures.
(2) Remove the fi ve nuts from the heater-A/C
housi ng mounti ng studs on the engi ne compartment
si de of the dash panel . I f necessary, l oosen the bat-
tery hol d-downs and reposi ti on the battery for addi -
ti onal access. Refer to Group 8A - Battery for the
procedures.
(3) Remove the fl oor duct from the bottom of the
heater-A/C housi ng. See Fl oor Duct i n thi s group for
the procedures.
(4) Remove the one screw that secures the heater-
A/C housi ng to the pl enum bracket on the passenger
compartment si de of the dash panel .
(5) Push gentl y down on the top of the heater-A/C
housi ng unti l suffi ci ent cl earance i s obtai ned to
unsnap the fresh ai r duct from the top of the heater-
A/C housi ng.
(6) Remove the fresh ai r duct col l ar from the cowl
pl enum panel by reachi ng up above the heater-A/C
housi ng fresh ai r duct openi ng and pul l i ng the col l ar
downward. The col l ar i s retai ned i n the cowl pl enum
panel by a l i ght snap fi t.
(7) Reverse the removal procedures to i nstal l .
Ti ghten the pl enum bracket screw to 3.4 N·m (30 i n.
l bs.). Ti ghten the dash panel mounti ng nuts to 6.2
N·m (55 i n. l bs.).
PANEL DUCTS
(1) Remove the i nstrument panel from the vehi cl e.
Refer to I nstrument Panel Assembl y i n Group 8E -
I nstrument Panel Systems for the procedures.
(2) Remove the demi ster hoses from the demi ster
outl ets.
Instrument Panel Ducts and Outlets Remove/Install
1 – CENTER PANEL DUCT
2 – DEMISTER HOSE
3 – DEMISTER HOSE
4 – END PANEL DUCT
5 – MAIN PANEL DUCT
6 – END PANEL DUCT
Heater-A/C Housing Ducts Remove/Install
1 – DEFROST/DEMIST DUCT
2 – COLLAR
3 – FRESH AIR DUCT
4 – HEATER-A/C HOUSING
5 – SCREWS
6 – FLOOR DUCT
7 – NUT
8 – NUT
TJ HEATING AND AIR CONDITIONING 24 - 35
REMOVAL AND INSTALLATION (Continued)
(3) Remove the two screws from the center of the
rearward faci ng si de of the i nstrument panel that
secure the mai n panel duct to the i nstrument panel
base.
(4) Remove the one screw that secures each end
panel duct and/or the center panel duct to the i nstru-
ment panel base.
(5) Remove the panel ducts from the i nstrument
panel .
(6) Reverse the removal procedures to i nstal l .
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
PANEL OUTLET BARRELS
(1) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the panel outl et barrel out
of the panel outl et housi ng. The barrel i s retai ned by
a l i ght snap fi t.
(2) To i nstal l , posi ti on the barrel i n the panel out-
l et housi ng and press i n fi rml y and equal l y at both
ends of the barrel unti l i t snaps i nto pl ace.
EVAPORATOR COIL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove and di sassembl e the heater-A/C hous-
i ng. See Heater-A/C Housi ng i n thi s group for the
procedures.
(2) Li ft the evaporator coi l uni t out of the l ower
hal f of the heater-A/C housi ng (Fi g. 32).
(3) Reverse the removal procedures to i nstal l . Be
certai n that the evaporator foam i nsul ator wrap and
rubber tube seal are rei nstal l ed.
NOTE: If the evaporator is replaced, add 60 millili-
ters (2 fluid ounces) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
HEATER CORE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove and di sassembl e the heater-A/C hous-
i ng. See Heater-A/C Housi ng i n thi s group for the
procedures.
(2) Li ft the heater core out of the l ower hal f of the
heater-A/C housi ng (Fi g. 33).
(3) Reverse the removal procedures to i nstal l . Be
certai n that the heater core foam i nsul ator i s rei n-
stal l ed.
HEATER-A/C CONTROL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
Fig. 32 Evaporator Coil Remove/Install
1 – EVAPORATOR COIL
2 – TUBE SEAL
3 – CONDENSATE DRAIN TUBE
4 – FOAM INSULATOR WRAP
24 - 36 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
(2) Remove the gl ove box from the i nstrument
panel . Refer to Gl ove Box i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Remove the center bezel from the i nstrument
panel . Refer to I nstrument Panel Center Bezel i n
Group 8E - I nstrument Panel Systems for the proce-
dures.
(4) Reach through the i nstrument panel gl ove box
openi ng to access and unpl ug the two hal ves of the
heater-A/C vacuum harness connector.
(5) Remove the four screws that secure the heater-
A/C control to the i nstrument panel (Fi g. 34).
(6) Pul l the heater-A/C control assembl y away
from the i nstrument panel far enough to access the
connecti ons on the back of the control .
(7) Unpl ug the three wi re harness connectors from
the back of the heater-A/C control (Fi g. 35).
(8) Remove the heater-A/C control from the i nstru-
ment panel .
INSTALLATION
(1) Pl ug the three wi re harness connectors i nto the
back of the heater-A/C control .
(2) Posi ti on the heater-A/C control i n the i nstru-
ment panel and secure i t wi th four screws. Ti ghten
the screws to 2.2 N·m (20 i n. l bs.).
(3) Reach through the i nstrument panel gl ove box
openi ng to reconnect the two hal ves of the heater-A/C
vacuum harness connector.
(4) Rei nstal l the gl ove box i n the i nstrument
panel . Refer to Gl ove Box i n Group 8E - I nstrument
Panel Systems for the procedures.
(5) Rei nstal l the center bezel onto the i nstrument
panel . Refer to I nstrument Panel Center Bezel i n
Group 8E - I nstrument Panel Systems for the proce-
dures.
(6) Connect the battery negati ve cabl e.
Fig. 33 Heater Core Remove/Install
1 – HEATER CORE
2 – LOWER HEATER-A/C HOUSING
Fig. 34 Heater-A/C Control Remove/Install
1 – BLOWER MOTOR SWITCH
2 – TEMPERATURE CONTROL
3 – MODE SWITCH
4 – VACUUM HARNESS
5 – MOUNTING POINTS
Fig. 35 Heater-A/C Control Connections
1 – HEATER-A/C CONTROL
2 – BLOWER MOTOR SWITCH
3 – BLOWER MOTOR SWITCH CONNECTOR
4 – TEMPERATURE CONTROL AND ILLUMINATION
CONNECTOR
5 – MODE SWITCH CONNECTOR
6 – VACUUM HARNESS
7 – VACUUM/ELECTRIC MODE SWITCH
TJ HEATING AND AIR CONDITIONING 24 - 37
REMOVAL AND INSTALLATION (Continued)
HEATER-A/C HOUSING
The heater-A/C housi ng assembl y must be removed
from the vehi cl e and the two hal ves of the housi ng
separated for servi ce access of the heater core, evap-
orator coi l , bl end-ai r door, and each of the vari ous
mode control doors.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument panel from the vehi cl e.
Refer to I nstrument Panel Assembl y i n Group 8E -
I nstrument Panel Systems for the procedures.
(3) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 6. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, recover the refri gerant from the
refri gerant system. See Refri gerant Recovery i n thi s
group for the procedures.
(4) Di sconnect the l i qui d l i ne refri gerant l i ne fi t-
ti ng from the evaporator i nl et tube. See Refri gerant
Li ne Coupl er i n thi s group for the procedures. I nstal l
pl ugs i n, or tape over al l of the opened refri gerant
l i ne fi tti ngs.
(5) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne fi tti ng from the evaporator outl et tube. See
Refri gerant Li ne Coupl er i n thi s group for the proce-
dures. I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(6) Drai n the engi ne cool i ng system. Refer to
Group 7 - Cool i ng System for the procedures.
(7) Di sconnect the heater hoses from the heater
core tubes. Refer to Group 7 - Cool i ng System for the
procedures. I nstal l pl ugs i n, or tape over the opened
heater core tubes.
(8) Unpl ug the heater-A/C system vacuum suppl y
l i ne connector from the tee fi tti ng near the heater
core tubes.
(9) Remove the fi ve nuts from the heater-A/C
housi ng mounti ng studs on the engi ne compartment
si de of the dash panel (Fi g. 36). I f necessary, l oosen
the battery hol ddowns and reposi ti on the battery for
addi ti onal access. Refer to Group 8A - Battery for the
procedures.
(10) Remove the cowl pl enum drai n tube from the
heater-A/C housi ng mounti ng stud on the dash panel
di rectl y behi nd the engi ne cyl i nder head.
(11) Remove the fl oor duct from the bottom of the
heater-A/C housi ng. See Fl oor Duct i n thi s group for
the procedures.
(12) Remove the one screw that secures the heat-
er-A/C housi ng to the pl enum bracket on the passen-
ger compartment si de of the dash panel .
(13) Pul l the heater-A/C housi ng down far enough
to cl ear the defrost/demi st and fresh ai r ducts, and
rearward far enough for the mounti ng studs and the
evaporator condensate drai n tube to cl ear the dash
panel hol es.
(14) Remove the heater-A/C housi ng from the vehi -
cl e.
DISASSEMBLY
(1) Remove the heater-A/C housi ng from the vehi -
cl e and pl ace i t on a work bench.
(2) Unpl ug the vacuum harness connectors from
the fl oor door actuator and, i f the uni t i s so equi pped,
the reci rcul ati on ai r door actuator.
(3) Di sengage the vacuum harness from any rout-
i ng cl i ps l ocated on the l ower hal f of the heater-A/C
housi ng.
(4) Di sengage the heater-A/C wi re harness connec-
tor and the bl ower motor rel ay wi re harness connec-
tor push-i n retai ners from thei r mounti ng hol es on
the heater-A/C housi ng.
Fig. 36 Heater-A/C Housing Remove/Install
1 – DEFROST/DEMIST DUCT
2 – COLLAR
3 – FRESH AIR DUCT
4 – HEATER-A/C HOUSING
5 – SCREWS
6 – FLOOR DUCT
7 – NUT
8 – NUT
24 - 38 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
(5) Remove the bl ower motor and bl ower wheel
uni t from the heater-A/C housi ng. See Bl ower Motor
i n thi s group for the procedures.
(6) Careful l y remove the foam seal from the fl ange
around the bl ower motor openi ng i n the heater-A/C
housi ng. I f the seal i s deformed or damaged, i t must
be repl aced.
(7) Pul l the vacuum suppl y l i ne and connector
through the foam seal on the heater core and evapo-
rator coi l tube mounti ng fl ange of the heater-A/C
housi ng (Fi g. 37).
(8) I f the uni t i s equi pped wi th ai r condi ti oni ng,
remove the screw that secures the cl amp to the evap-
orator coi l tubes and remove the cl amp.
(9) Careful l y remove the foam seal from the heater
core and evaporator coi l tube mounti ng fl ange of the
heater-A/C housi ng. I f the seal i s deformed or dam-
aged, i t must be repl aced.
(10) Use a screwdri ver to pry off the two snap cl i ps
that hel p secure the upper and l ower heater-A/C
housi ng hal ves to each other.
(11) Remove the 14 screws that secure the upper
and l ower heater-A/C housi ng hal ves to each other.
(12) Careful l y separate the upper heater-A/C hous-
i ng hal f from the l ower hal f.
ASSEMBLY
(1) Assembl e the upper heater-A/C housi ng hal f to
the l ower hal f. Duri ng assembl y, be certai n of the fol -
l owi ng:
(a) That each of the mode door pi vot shaft ends
i s properl y engaged i n i ts pi vot hol e (Fi g. 38).
(b) That the bl ower motor venturi ri ng i s prop-
erl y i ndexed and i nstal l ed.
(c) I f the uni t i s equi pped wi th ai r condi ti oni ng,
that the evaporator coi l tube rubber seal i s prop-
erl y posi ti oned i n the grooves i n both the upper
and l ower heater-A/C housi ng hal ves.
(2) I nstal l the 14 screws and two snap cl i ps that
secure the upper and l ower heater-A/C housi ng
hal ves to each other. Ti ghten the screws to 2.2 N·m
(20 i n. l bs.).
(3) I nstal l the bl ower motor and wheel uni t i n the
heater-A/C housi ng. See Bl ower Motor i n thi s group
for the procedures.
(4) I nstal l the foam seal s on the fl anges around
the bl ower motor openi ng and the heater core and
evaporator coi l tube mounti ng fl ange of the heater-
A/C housi ng.
(5) I nsert the vacuum suppl y l i ne and connector
through the foam seal on the heater core and evapo-
rator coi l tube mounti ng fl ange of the heater-A/C
housi ng.
(6) I f the uni t i s equi pped wi th ai r condi ti oni ng,
rei nstal l the evaporator coi l tube cl amp. Ti ghten the
mounti ng screw to 2.2 N·m (20 i n. l bs.).
(7) Engage the heater-A/C wi re harness connector
and bl ower motor rel ay wi re harness connector
push-i n retai ners wi th thei r mounti ng hol es i n the
heater-A/C housi ng.
(8) Engage the vacuum harness to the routi ng
cl i ps and pl ug i n the vacuum harness connector at
the fl oor door actuator and, i f the uni t i s so equi pped,
at the reci rcul ati on ai r door actuator.
(9) I nstal l the heater-A/C housi ng i n the vehi cl e.
Fig. 37 Heater-A/C Housing Disassembly
1 – SEALS
2 – EVAPORATOR TUBE CLAMP
3 – CLIPS
4 – HEATER CORE TUBES
5 – VACUUM SUPPLY LINE
6 – BLOWER MOTOR
Fig. 38 Heater-A/C Housing Assembly
1 – BLOWER MOTOR VENTURI RING
2 – BLEND-AIR DOOR PIVOT
3 – EVAPORATOR COIL TUBE RUBBER SEAL
4 – RECIRCULATION AIR DOOR PIVOTS
TJ HEATING AND AIR CONDITIONING 24 - 39
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on the heater-A/C housi ng to the dash
panel . Be certai n that the evaporator condensate
drai n tube and the housi ng mounti ng studs are
i nserted i nto thei r correct mounti ng hol es, and that
the openi ngs on the top of the housi ng are properl y
al i gned wi th the fresh ai r duct and defrost/demi st
duct.
(2) I nstal l and ti ghten the one screw that secures
the heater-A/C housi ng to the pl enum bracket on the
passenger compartment si de of the dash panel .
Ti ghten the screw to 3.4 N·m (30 i n. l bs.).
(3) I nstal l the fl oor duct to the bottom of the heat-
er-A/C housi ng. See Fl oor Duct i n thi s group for the
procedures.
(4) I nstal l the cowl drai n tube onto the heater-A/C
housi ng mounti ng stud on the dash panel di rectl y
behi nd the engi ne cyl i nder head.
(5) I nstal l and ti ghten the fi ve nuts onto the heat-
er-A/C housi ng mounti ng studs on the engi ne com-
partment si de of the dash panel . Ti ghten the nuts to
6.2 N·m (55 i n. l bs.).
(6) I f the battery was reposi ti oned duri ng the
removal procedure, posi ti on the battery and ti ghten
the hol ddowns. Refer to Group 8A - Battery for the
procedures.
(7) Connect the heater-A/C system vacuum suppl y
l i ne connector to the tee fi tti ng near the heater core
tubes.
(8) Unpl ug or remove the tape from the heater
core tubes. Connect the heater hoses to the heater
core tubes and fi l l the engi ne cool i ng system. Refer to
Group 7 - Cool i ng System for the procedures.
(9) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 13. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, unpl ug or remove the tape from the
accumul ator i nl et tube and the evaporator outl et
tube fi tti ngs. Connect the accumul ator i nl et tube cou-
pl er to the evaporator outl et tube. See Refri gerant
Li ne Coupl er i n thi s group for the procedures.
(10) Unpl ug or remove the tape from the l i qui d
l i ne and the evaporator i nl et tube fi tti ngs. Connect
the l i qui d l i ne coupl er to the evaporator i nl et tube.
See Refri gerant Li ne Coupl er i n thi s group for the
procedures.
(11) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group for the proce-
dures.
(12) Charge the refri gerant system. See Refri ger-
ant System Charge i n thi s group for the procedures.
(13) I nstal l the i nstrument panel i n the vehi cl e.
Refer to I nstrument Panel Assembl y i n Group 8E -
I nstrument Panel Systems for the procedures.
(14) Connect the battery negati ve cabl e.
(15) Start the engi ne and check for proper opera-
ti on of the heati ng and ai r condi ti oni ng systems.
HEATER-A/C HOUSING DOOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
BLEND-AIR DOOR
(1) Remove and di sassembl e the heater-A/C hous-
i ng. See Heater-A/C Housi ng i n thi s group for the
procedures.
(2) Li ft the bl end-ai r door pi vot shaft out of the
pi vot hol e i n the bottom of the l ower hal f of the heat-
er-A/C housi ng (Fi g. 39).
(3) Reverse the removal procedures to i nstal l .
PANEL/DEMIST DOOR AND LEVER
(1) Remove and di sassembl e the heater-A/C hous-
i ng. See Heater-A/C Housi ng i n thi s group for the
procedures.
(2) Remove the defrost and panel /demi st door vac-
uum actuators from the heater-A/C housi ng. See
Mode Door Vacuum Actuator i n thi s group for the
procedures.
(3) I nsert a screwdri ver i nto the l atch hol e (Fi g.
40) of the panel /demi st door pi vot shaft to rel ease the
l atch of the panel /demi st door l ever, and pul l the
Fig. 39 Blend-Air Door
1 – BLEND-AIR DOOR
2 – EVAPORATOR COIL
3 – PIVOT HOLE
4 – HEATER CORE
24 - 40 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
l ever out of the pi vot shaft from the outsi de of the
upper hal f of the heater-A/C housi ng.
(4) Reach i nsi de the upper hal f of the heater-A/C
housi ng and careful l y fl ex the panel /defrost door (Fi g.
41) enough so that the door pi vot cl ears the pi vot
hol e i n the housi ng.
(5) Remove the panel /demi st door from the heater-
A/C housi ng.
(6) Reverse the removal procedures to i nstal l .
DEFROST DOOR AND LEVER
(1) Remove and di sassembl e the heater-A/C hous-
i ng. See Heater-A/C Housi ng i n thi s group for the
procedures.
(2) Remove the panel /demi st door and l ever from
the upper heater-A/C housi ng. See Panel /Demi st
Door and Lever i n thi s group for the procedures.
(3) I nsert a screwdri ver i nto the l atch hol e (Fi g.
40) of the defrost door pi vot shaft to rel ease the l atch
of the defrost door l ever, and pul l the l ever out of the
pi vot shaft from the outsi de of the upper hal f of the
heater-A/C housi ng.
(4) Reach i nsi de the upper hal f of the heater-A/C
housi ng and careful l y fl ex the defrost door (Fi g. 41)
enough so that the door pi vot cl ears the pi vot hol e i n
the housi ng.
(5) Remove the defrost door from the heater-A/C
housi ng.
(6) Reverse the removal procedures to i nstal l .
FLOOR DOOR AND LEVER
(1) Remove and di sassembl e the heater-A/C hous-
i ng. See Heater-A/C Housi ng i n thi s group for the
procedures.
(2) Remove the fl oor door vacuum actuator from
the l ower heater-A/C housi ng. See Mode Door Vac-
uum Actuator i n thi s group for the procedures.
(3) I nsert a screwdri ver i nto the l atch hol e (Fi g.
40) of the fl oor door pi vot shaft to rel ease the l atch of
the fl oor door l ever, and pul l the l ever out of the
pi vot shaft from the outsi de of the l ower hal f of the
heater-A/C housi ng.
(4) Reach i nsi de the l ower hal f of the heater-A/C
housi ng and careful l y fl ex the fl oor door (Fi g. 42)
enough so that the door pi vot cl ears the pi vot hol e i n
the housi ng.
(5) Unscrew the 3 attachi ng screws and remove
the fl oor door from the heater-A/C housi ng.
(6) Reverse the removal procedures to i nstal l .
RECIRCULATION AIR DOOR
A reci rcul ati on ai r door and vacuum actuator are
used onl y on model s wi th the opti onal ai r condi ti on-
i ng system.
(1) Remove and di sassembl e the heater-A/C hous-
i ng. See Heater-A/C Housi ng i n thi s group for the
procedures.
(2) Remove the reci rcul ati on ai r door vacuum
actuator from the l ower heater-A/C housi ng. See
Mode Door Vacuum Actuator i n thi s group for the
procedures.
(3) Reach i nsi de the l ower hal f of the heater-A/C
housi ng and l i ft the bottom edge of the reci rcul ati on
ai r door upwards (Fi g. 43).
Fig. 40 Mode Door Lever Remove/Install - Typical
1 – DOOR PIVOT SHAFT
2 – LATCH HOLE
3 – CRANK ARM LATCH
4 – FLAT BLADE PRY TOOL
Fig. 41 Panel/Demist and Defrost Doors
1 – PANEL/DEMIST DOOR
2 – UPPER HEATER-A/C HOUSING
3 – DEFROST DOOR
TJ HEATING AND AIR CONDITIONING 24 - 41
REMOVAL AND INSTALLATION (Continued)
(4) Gui de the reci rcul ati on ai r door l ever through
the ai r i ntake gri l l e of the heater-A/C housi ng whi l e
removi ng the door from the housi ng.
(5) Reverse the removal procedures to i nstal l .
HIGH PRESSURE CUT-OFF SWITCH
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the wi re harness connector from the
hi gh pressure cut-off swi tch, whi ch i s mounted to a
fi tti ng on the non-fl exi bl e secti on of the di scharge
l i ne nearest the compressor (Fi g. 21) and (Fi g. 22).
(3) Unscrew the hi gh pressure cut-off swi tch from
the di scharge l i ne fi tti ng.
(4) Remove the hi gh pressure cut-off swi tch from
the vehi cl e.
(5) Remove the O-ri ng seal from the di scharge l i ne
fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the di scharge l i ne fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(2) I nstal l and ti ghten the hi gh pressure cut-off
swi tch on the di scharge l i ne fi tti ng.
(3) Pl ug the wi re harness connector i nto the hi gh
pressure cut-off swi tch.
(4) Connect the battery negati ve cabl e.
KICK COVER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Loosen the two screws that secure the upper
hal f of the ki ck cover to the heater-A/C housi ng
under the passenger si de end of the i nstrument panel
(Fi g. 44).
(3) Remove the two screws that secure the l ower
hal f of the ki ck cover to the heater-A/C housi ng.
(4) Pul l the ki ck cover down towards the fl oor
panel to di sengage the sl otted upper mounti ng tabs
from under the two l oosened heater-A/C housi ng
screws.
(5) Remove the ki ck cover from the heater-A/C
housi ng.
INSTALLATION
(1) Posi ti on the sl otted upper ki ck cover mounti ng
tabs under the heads of the two l oosened heater-A/C
Fig. 42 Floor Door
1 – LOWER HEATER-A/C HOUSING
2 – PIVOT SHAFT
3 – CRANK ARM
4 – FLOOR DOOR
Fig. 43 Recirculation Air Door
1 – RECIRCULATION AIR DOOR
2 – LOWER HEATER-A/C HOUSING
3 – LEVER
4 – PIVOT SHAFT
24 - 42 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
housi ng screws. Ti ghten the screws to 2.2 N·m (20 i n.
l bs.).
(2) I nstal l the two screws that secure the l ower
ki ck cover to the heater-A/C housi ng. Ti ghten the
screws to 2.2 N·m (20 i n. l bs.).
(3) Connect the battery negati ve cabl e.
LIQUID LINE/FIXED ORIFICE TUBE
NOTE: The fixed orifice tube is part of the liquid
line assembly and cannot be serviced separately.
Follow the liquid line removal and installation pro-
cedures for orifice tube replacement.
Any ki nks or sharp bends i n the refri gerant pl umb-
i ng wi l l reduce the capaci ty of the enti re ai r condi -
ti oni ng system. Ki nks and sharp bends reduce the
fl ow of refri gerant i n the system. A good rul e for the
fl exi bl e hose refri gerant l i nes i s to keep the radi us of
al l bends at l east ten ti mes the di ameter of the hose.
I n addi ti on, the fl exi bl e hose refri gerant l i nes shoul d
be routed so they are at l east 80 mi l l i meters (3
i nches) from the exhaust mani fol d.
Hi gh pressures are produced i n the refri gerant sys-
tem when the ai r condi ti oni ng compressor i s operat-
i ng. Extreme care must be exerci sed to make sure
that each of the refri gerant system connecti ons i s
pressure-ti ght and l eak free. I t i s a good practi ce to
i nspect al l fl exi bl e hose refri gerant l i nes at l east once
a year to make sure they are i n good condi ti on and
properl y routed.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system. See Refri gerant Recovery i n thi s group for
the procedures.
(3) Remove the secondary cl i p from the spri ng-l ock
coupl er whi ch secures the l i qui d l i ne to the accumu-
l ator outl et tube near the dash panel (Fi g. 45).
(4) Di sconnect the l i qui d l i ne refri gerant l i ne fi t-
ti ng from the evaporator i nl et tube. See Refri gerant
Li ne Coupl er Removal and I nstal l ati on for the proce-
dures. I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(5) Remove the fastener, and di sconnect the l i qui d
l i ne from the condenser outl et tube refri gerant l i ne
fi tti ng. I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(6) Remove the l i qui d l i ne from the pl asti c cl i ps
that secures i t to the ri ght i nner fender shi el d.
(7) Remove the l i qui d l i ne from the vehi cl e.
INSTALLATION
(1) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the condenser outl et tube and the
condenser end of the l i qui d l i ne. Fasten the l i qui d
l i ne to the condenser outl et tube refri gerant l i ne cou-
pl er. Ti ghten the fastener to 9 N·m (80 i n. l bs.).
(2) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the evaporator end of the l i qui d l i ne
and the evaporator i nl et tube. Connect the l i qui d l i ne
refri gerant l i ne coupl er to the evaporator i nl et tube.
See Refri gerant Li ne Coupl er i n thi s group for the
procedures.
Fig. 44 Kick Cover Remove/Install
1 – HEATER-A/C HOUSING
2 – MOUNTING SCREWS
3 – KICK COVER
Fig. 45 Liquid Line Mounting
1 – LIQUID LINE
2 – SERVICE PORT
3 – CONDENSER
4 – LINE MOUNTING CLIPS
TJ HEATING AND AIR CONDITIONING 24 - 43
REMOVAL AND INSTALLATION (Continued)
(3) I nstal l the secondary cl i p that secures the l i q-
ui d l i ne to the accumul ator outl et tube near the dash
panel .
(4) I nstal l the l i qui d l i ne i nto the cl i ps that secure
i t to the ri ght i nner fender shi el d.
(5) Connect the battery negati ve cabl e.
(6) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group for the proce-
dures.
(7) Charge the refri gerant system. See Refri gerant
System Charge i n thi s group for the procedures.
LOW PRESSURE CYCLING CLUTCH SWITCH
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the wi re harness connector from the
l ow pressure cycl i ng cl utch swi tch on the top of the
accumul ator (Fi g. 46).
(3) Unscrew the l ow pressure cycl i ng cl utch swi tch
from the fi tti ng on the top of the accumul ator.
(4) Remove the O-ri ng seal from the accumul ator
fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the accumul ator fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(2) I nstal l and ti ghten the l ow pressure cycl i ng
cl utch swi tch on the accumul ator fi tti ng. The swi tch
shoul d be hand-ti ghtened onto the accumul ator fi t-
ti ng.
(3) Pl ug the wi re harness connector i nto the l ow
pressure cycl i ng cl utch swi tch.
(4) Connect the battery negati ve cabl e.
MODE DOOR VACUUM ACTUATOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
DEFROST DOOR ACTUATOR
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel . Refer to Knee Bl ocker i n Group 8E - I nstru-
ment Panel Systems for the procedures.
(3) Unpl ug the two vacuum harness connectors
from the defrost door actuator (Fi g. 47).
(4) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the heater-A/C
housi ng actuator mount (Fi g. 48). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(5) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
defrost door l ever.
(6) Remove the defrost door vacuum actuator from
the vehi cl e.
(7) Reverse the removal procedures to i nstal l .
FLOOR DOOR ACTUATOR
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel . Refer to Knee Bl ocker i n Group 8E - I nstru-
ment Panel Systems for the procedures.
(3) Unpl ug the vacuum harness connector from the
fl oor door actuator (Fi g. 47).
(4) Remove the push nut fasteni ng the fl oor door
vacuum actuator l i nkage to the fl oor door l ever.
Fig. 46 Low Pressure Cycling Clutch Switch
Remove/Install - Typical
1 – WIRE HARNESS CONNECTOR
2 – ACCUMULATOR
3 – LOW PRESSURE CYCLING CLUTCH SWITCH
24 - 44 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
(5) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the heater-A/C
housi ng actuator mount (Fi g. 48). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(6) Remove the fl oor door vacuum actuator from
the vehi cl e.
(7) Reverse the removal procedures to i nstal l .
PANEL/DEMIST DOOR ACTUATOR
(1) Remove the defrost door actuator from the
heater-A/C housi ng. See Defrost Door Actuator i n
thi s group for the procedures.
(2) Unpl ug the vacuum harness connector from the
panel /demi st door actuator (Fi g. 47).
(3) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the heater-A/C
housi ng actuator mount (Fi g. 48). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(4) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
panel /demi st door l ever.
(5) Remove the panel /demi st door vacuum actuator
from the vehi cl e.
(6) Reverse the removal procedures to i nstal l .
RECIRCULATION AIR DOOR ACTUATOR
A reci rcul ati on ai r door and vacuum actuator are
used onl y on model s wi th the opti onal ai r condi ti on-
i ng system.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the ki ck cover from the heater-A/C
housi ng. See Ki ck Cover i n thi s group for the proce-
dures.
(3) Unpl ug the vacuum harness connector from the
reci rcul ati on ai r door actuator (Fi g. 49).
(4) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the heater-A/C
housi ng actuator mount (Fi g. 48). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(5) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
reci rcul ati on ai r door l ever.
(6) Remove the reci rcul ati on ai r door vacuum
actuator from the vehi cl e.
(7) Reverse the removal procedures to i nstal l .
Fig. 47 Defrost, Floor, and Panel/Demist Door
Vacuum Actuators
1 – PANEL/DEMIST DOOR ACTUATOR
2 – DEFROST DOOR ACTUATOR
3 – FLOOR DOOR ACTUATOR
Fig. 48 Vacuum Actuator Remove/Install - Typical
1 – ACTUATOR MOUNT LATCH HOLE
2 – TRIM STICK
3 – ACTUATOR LATCH
TJ HEATING AND AIR CONDITIONING 24 - 45
REMOVAL AND INSTALLATION (Continued)
REFRIGERANT LINE COUPLER
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE PER-
FORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Recover the refri gerant from the refri gerant
system. See Refri gerant Recovery i n the Servi ce Pro-
cedures secti on of thi s group.
(2) Remove the secondary cl i p from the spri ng-l ock
coupl er.
(3) Fi t the proper si ze A/C l i ne di sconnect tool
(Speci al Tool Ki t 7193) over the spri ng-l ock coupl er
cage (Fi g. 50).
(4) Cl ose the two hal ves of the A/C l i ne di sconnect
tool around the spri ng-l ock coupl er.
(5) Push the A/C l i ne di sconnect tool i nto the open
si de of the coupl er cage to expand the garter spri ng.
Once the garter spri ng i s expanded and whi l e sti l l
pushi ng the di sconnect tool i nto the open si de of the
coupl er cage, pul l on the refri gerant l i ne attached to
the femal e hal f of the coupl er fi tti ng unti l the fl ange
on the femal e fi tti ng i s separated from the garter
spri ng and cage on the mal e fi tti ng wi thi n the di s-
connect tool .
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
(6) Open and remove the A/C l i ne di sconnect tool
from the di sconnected spri ng-l ock coupl er.
(7) Compl ete the separati on of the two hal ves of
the coupl er fi tti ng.
INSTALLATION
(1) Check to ensure that the garter spri ng i s
l ocated wi thi n the cage of the mal e coupl er fi tti ng,
and that the garter spri ng i s not damaged.
(a) I f the garter spri ng i s mi ssi ng, i nstal l a new
spri ng by pushi ng i t i nto the coupl er cage openi ng.
(b) I f the garter spri ng i s damaged, remove i t
from the coupl er cage wi th a smal l wi re hook (DO
NOT use a screwdri ver) and i nstal l a new garter
spri ng.
(2) Cl ean any di rt or forei gn materi al from both
hal ves of the coupl er fi tti ng.
(3) I nstal l new O-ri ngs on the mal e hal f of the cou-
pl er fi tti ng.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
Fig. 49 Recirculation Air Door Vacuum Actuator
Remove/Install
1 – HOOK
2 – LEVER
3 – RECIRCULATION AIR DOOR ACTUATOR
4 – BLOWER MOTOR RESISTOR
Fig. 50 Refrigerant Line Spring-Lock Coupler
Disconnect
24 - 46 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
(4) Lubri cate the mal e fi tti ng and O-ri ngs, and the
i nsi de of the femal e fi tti ng wi th cl ean R-134a refri g-
erant oi l . Use onl y refri gerant oi l of the type recom-
mended for the compressor i n the vehi cl e.
(5) Fi t the femal e hal f of the coupl er fi tti ng over
the mal e hal f of the fi tti ng.
(6) Push together fi rml y on the two hal ves of the
coupl er fi tti ng unti l the garter spri ng i n the cage on
the mal e hal f of the fi tti ng snaps over the fl anged
end on the femal e hal f of the fi tti ng.
(7) Ensure that the spri ng-l ock coupl er i s ful l y
engaged by tryi ng to separate the two coupl er hal ves.
Thi s i s done by pul l i ng the refri gerant l i nes on ei ther
si de of the coupl er away from each other.
(8) Rei nstal l the secondary cl i p over the spri ng-
l ock coupl er cage.
SUCTION AND DISCHARGE LINE
Any ki nks or sharp bends i n the refri gerant pl umb-
i ng wi l l reduce the capaci ty of the enti re ai r condi -
ti oni ng system. Ki nks and sharp bends reduce the
fl ow of refri gerant i n the system. A good rul e for the
fl exi bl e hose refri gerant l i nes i s to keep the radi us of
al l bends at l east ten ti mes the di ameter of the hose.
I n addi ti on, the fl exi bl e hose refri gerant l i nes shoul d
be routed so they are at l east 80 mi l l i meters (3
i nches) from the exhaust mani fol d.
Hi gh pressures are produced i n the refri gerant sys-
tem when the ai r condi ti oni ng compressor i s operat-
i ng. Extreme care must be exerci sed to make sure
that each of the refri gerant system connecti ons i s
pressure-ti ght and l eak free. I t i s a good practi ce to
i nspect al l fl exi bl e hose refri gerant l i nes at l east once
a year to make sure they are i n good condi ti on and
properl y routed.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system. See Refri gerant Recovery i n thi s group for
the procedures.
(3) Unpl ug the wi re harness connector from the
hi gh pressure cut-off swi tch (Fi g. 51).
(4) Remove the bol t that secures the refri gerant
l i ne support bracket to the engi ne (4.0 L) (Fi g. 52).
(5) Remove the fastener and di sengage the di s-
charge l i ne fi tti ng from the condenser i nl et tube.
I nstal l pl ugs i n, or tape over al l of the opened refri g-
erant l i ne fi tti ngs.
(6) Remove the fastener and di sengage the sucti on
l i ne from the accumul ator outl et tube refri gerant l i ne
fi tti ng. I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(7) Remove the fasteners that secure the sucti on
and di scharge l i nes to the compressor. I nstal l pl ugs
i n, or tape over al l of the opened refri gerant l i ne fi t-
ti ngs.
Fig. 51 Suction and Discharge Line 2.5 L
1 – SERVICE PORT
2 – SUCTION LINE
3 – COMPRESSOR
4 – HIGH PRESSURE CUT-OFF SWITCH
5 – TO CONDENSER
6 – DISCHARGE LINE
7 – ACCUMULATOR
Fig. 52 Suction and Discharge Line 4.0 L
1 – SUCTION LINE
2 – SERVICE PORT
3 – HIGH PRESSURE CUT-OFF SWITCH
4 – COMPRESSOR
5 – ENGINE MOUNTING BRACKET
6 – DISCHARGE LINE
TJ HEATING AND AIR CONDITIONING 24 - 47
REMOVAL AND INSTALLATION (Continued)
(8) Remove the sucti on and di scharge l i nes from
the vehi cl e.
INSTALLATION
(1) Remove the tape or pl ugs from the sucti on and
di scharge l i ne mani fol d and the compressor. I nstal l
the sucti on and di scharge l i ne mani fol d to the com-
pressor. Ti ghten the mounti ng screw to 22 N·m (200
i n. l bs.).
(2) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the sucti on l i ne and the accumul ator
outl et tube. Connect the sucti on l i ne to the accumu-
l ator outl et tube refri gerant l i ne coupl er. See Refri g-
erant Li ne Coupl er i n thi s group for the procedures.
(3) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the di scharge l i ne and the condenser
i nl et tube. Connect the di scharge l i ne refri gerant l i ne
coupl er to the condenser i nl et tube. See Refri gerant
Li ne Coupl er i n thi s group for the procedures.
(4) I nstal l the bol t that secures the di scharge l i ne
support bracket to the compressor. Ti ghten the bol t
to 28 N·m (21 ft. l bs.).
(5) Pl ug i n the wi re harness connector to the hi gh
pressure cut-off swi tch.
(6) Connect the battery negati ve cabl e.
(7) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group for the proce-
dures.
(8) Charge the refri gerant system. See Refri gerant
System Charge i n thi s group for the procedures.
VACUUM CHECK VALVE
(1) Unpl ug the heater-A/C vacuum suppl y l i ne con-
nector at the vacuum check val ve near the engi ne
i ntake mani fol d vacuum adapter fi tti ng.
(2) Note the ori entati on of the check val ve i n the
vacuum suppl y l i ne for correct rei nstal l ati on.
(3) Unpl ug the vacuum check val ve from the vac-
uum suppl y l i ne fi tti ngs.
(4) Reverse the removal procedures to i nstal l .
VACUUM RESERVOIR
(1) Remove the battery and battery tray from the
engi ne compartment. Refer to Group 8A - Battery for
the procedures.
(2) Unpl ug the vacuum suppl y l i ne connector from
the vacuum reservoi r (Fi g. 53).
(3) Remove the one screw that secures the reser-
voi r to the i nner fender panel under the battery tray
and behi nd the ri ght front wheel house.
(4) Remove the vacuum reservoi r from the engi ne
compartment.
(5) Reverse the removal procedures to i nstal l .
Ti ghten the reservoi r mounti ng screw to 1 N·m (10
i n. l bs.).
Fig. 53 Vacuum Reservoir Remove/Install
1 – TEE
2 – VACUUM CHECK VALVE
3 – INTAKE MANIFOLD
4 – INNER FENDER
5 – RESERVOIR
6 – SCREW
7 – VACUUM SUPPLY LINE
24 - 48 HEATING AND AIR CONDITIONING TJ
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
Vehicle TJ Wrangler
System R134a w/orifice
tube
Compressor Denso 10PA17 ND-8 PAG oil
Freeze–up
Control
Low Pressure
cycling cutout
switch
accumulator
mounted
Low psi Control opens < 20.5
psi - resets >
38 psi
High psi Control switch opens >
450 - 490 psi -
resets < 270 -
330 psi
discharge line
mounted switch
Control Head manual type
Mode Door vacuum
Blend Air Door electric actuator
Fresh/Recirc
door
vacuum
Blower Motor control head
switched
resistor block
Cooling Fan viscous fan
Clutch
Control relay PCM
Draw 2 - 3.9 amps @
12V
Ϯ 0.5V @ 70°F
Gap 0.016” - 0.031Љ
DRB IIIா
Reads TPS, RPM, A/C
switch test
Actuators clutch relay
TJ HEATING AND AIR CONDITIONING 24 - 49
EMISSION CONTROL SYSTEMS
TABLE OF CONTENTS
page page
ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . 1 EVAPORATIVE EMISSION CONTROLS . . . . . . . . . 24
ON-BOARD DIAGNOSTICS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
EMISSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 1
MALFUNCTION INDICATOR LAMP (MIL) . . . . . . . . 2
STATE DISPLAY TEST MODE . . . . . . . . . . . . . . . . 2
CIRCUIT ACTUATION TEST MODE . . . . . . . . . . . . 2
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . 2
DIAGNOSTIC TROUBLE CODE
DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3
TASK MANAGER . . . . . . . . . . . . . . . . . . . . . . . . . 16
MONITORED SYSTEMS. . . . . . . . . . . . . . . . . . . . 19
TRIP DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . 21
COMPONENT MONITORS . . . . . . . . . . . . . . . . . . 22
NON-MONITORED CIRCUITS . . . . . . . . . . . . . . . 22
HIGH AND LOW LIMITS. . . . . . . . . . . . . . . . . . . . 23
LOAD VALUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION AND OPERATION
EMISSION SYSTEM
OPERATION
The Powertrai n Control Modul e (PCM) moni tors
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a
probl em wi th a moni tored ci rcui t often enough to
i ndi cate an actual probl em, i t stores a Di agnosti c
Troubl e Code (DTC) i n the PCM’s memory. I f the
code appl i es to a non-emi ssi ons rel ated component or
system, and the probl em i s repai red or ceases to
exi st, the PCM cancel s the code after 40 warm-up
cycl es. Di agnosti c troubl e codes that affect vehi cl e
emi ssi ons i l l umi nate the Mal functi on I ndi cator Lamp
(MI L). The MI L i s di spl ayed as an engi ne i con on the
i nstrument panel . Refer to Mal functi on I ndi cator
Lamp (MI L) i n thi s secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored
ci rcui t even though a mal functi on has occurred. Thi s
may happen because one of the DTC cri teri a for the
ci rcui t has not been met. For example, assume the
di agnosti c troubl e code cri teri a requi res the PCM to
moni tor the ci rcui t onl y when the engi ne operates
between 750 and 2000 RPM. Suppose the sensor’s
output ci rcui t shorts to ground when engi ne operates
above 2400 RPM (resul ti ng i n 0 vol t i nput to the
PCM). Because the condi ti on happens at an engi ne
speed above the maxi mum threshol d (2000 rpm), the
PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTC’s. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
Techni ci ans must retri eve stored DTC’s by connect-
i ng the DRB scan tool (or an equi val ent scan tool ) to
the 16–way data l i nk connector (Fi g. 1).
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, connect the DRB scan
tool to the 16–way data link connector to erase all
DTC’s and extinguish the MIL.
TJ EMISSION CONTROL SYSTEMS 25 - 1
MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION
The Mal functi on I ndi cator Lamp (MI L) i s l ocated
on the i nstrument panel . I t i s di spl ayed as an engi ne
i con (graphi c).
OPERATION
As a functi onal test, the MI L i l l umi nates at key-on
before engi ne cranki ng. Whenever the Powertrai n
Control Modul e (PCM) sets a Di agnosti c Troubl e
Code (DTC) that affects vehi cl e emi ssi ons, i t i l l umi -
nates the MI L. I f a probl em i s detected, the PCM
sends a message to the i nstrument cl uster to i l l umi -
nate the l amp. The PCM i l l umi nates the MI L onl y
for DTC’s that affect vehi cl e emi ssi ons. There are
some moni tors that may take two consecuti ve tri ps,
wi th a detected faul t, before the MI L i s i l l umi nated.
The MI L stays on conti nuousl y when the PCM has
entered a Li mp-I n mode or i denti fi ed a fai l ed emi s-
si on component. Refer to the Di agnosti c Troubl e Code
charts i n thi s group for emi ssi on rel ated codes.
Al so, the MI L ei ther fl ashes or i l l umi nates conti n-
uousl y when the PCM detects acti ve engi ne mi sfi re.
Refer to Mi sfi re Moni tori ng i n thi s secti on.
Addi ti onal l y, the PCM may reset (turn off) the MI L
when one of the fol l owi ng occur:
• PCM does not detect the mal functi on for 3 con-
secuti ve tri ps (except mi sfi re and Fuel system Moni -
tors).
• PCM does not detect a mal functi on whi l e per-
formi ng three successi ve engi ne mi sfi re or fuel sys-
tem tests. The PCM performs these tests whi l e the
engi ne i s operati ng wi thi n Ϯ 375 RPM of and wi thi n
10 % of the l oad of the operati ng condi ti on at whi ch
the mal functi on was fi rst detected.
STATE DISPLAY TEST MODE
OPERATION
The swi tch i nputs to the Powertrai n Control Mod-
ul e (PCM) have two recogni zed states; HI GH and
LOW. For thi s reason, the PCM cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus
an open ci rcui t, a short ci rcui t, or a defecti ve swi tch.
I f the State Di spl ay screen shows the change from
HI GH to LOW or LOW to HI GH, assume the enti re
swi tch ci rcui t to the PCM functi ons properl y. Connect
the DRB scan tool to the data l i nk connector and
access the state di spl ay screen. Then access ei ther
State Di spl ay I nputs and Outputs or State Di spl ay
Sensors.
CIRCUIT ACTUATION TEST MODE
OPERATION
The Ci rcui t Actuati on Test Mode checks for proper
operati on of output ci rcui ts or devi ces the Powertrai n
Control Modul e (PCM) may not i nternal l y recogni ze.
The PCM attempts to acti vate these outputs and
al l ow an observer to veri fy proper operati on. Most of
the tests provi de an audi bl e or vi sual i ndi cati on of
devi ce operati on (cl i ck of rel ay contacts, fuel spray,
etc.). Except for i ntermi ttent condi ti ons, i f a devi ce
functi ons properl y duri ng testi ng, assume the devi ce,
i ts associ ated wi ri ng, and dri ver ci rcui t work cor-
rectl y. Connect the DRB scan tool to the data l i nk
connector and access the Actuators screen.
DIAGNOSTIC TROUBLE CODES
OPERATION
A Di agnosti c Troubl e Code (DTC) i ndi cates that the
Powertrai n Control Modul e (PCM) has recogni zed an
abnormal condi ti on i n the system.
DTC’s are the results of a system or circuit
failure, but do not directly identify the failed
component or components.
Techni ci ans must retri eve stored DTC’s by connect-
i ng the DRB I I I scan tool (or an equi val ent scan tool )
to the 16–way data l i nk connector. Thi s connector i s
l ocated on the l ower edge of the i nstrument panel
near the steeri ng col umn.
OBTAINING DTC’s
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
ON AN OPERATING ENGINE.
Fig. 1 Data Link (Diagnostic) Connector Location
1 – 16–WAY DATA LINK CONNECTOR
25 - 2 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(1) Connect the DRB scan tool to data l i nk (di ag-
nosti c) connector.
(2) Turn the i gni ti on swi tch on, access Read Faul t
Screen. Record al l the DTC’s shown on the DRB scan
tool .
(3) To erase DTC’s, use the Erase Troubl e Code
data screen on the DRB scan tool .
NOTE: For a list of DTC’s, refer to the following
charts.
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0030 (M) 1/1 O2 Sensor Heater Relay Circuit Problem detected in oxygen sensor heater relay circuit.
P0036 (M) 1/2 O2 Sensor Heater Relay Circuit Problem detected in oxygen sensor heater relay circuit.
P0106 Barometric Pressure Out of Range MAP sensor input voltage out of an acceptable range
detected during reading of barometric pressure at key-on.
P0107 (M) Map Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage.
P0108 (M) Map Sensor Voltage Too High MAP sensor input above maximum acceptable voltage.
P0112 (M) Intake Air Temp Sensor Voltage Low Intake air (charge) temperature sensor input below the
minimum acceptable voltage.
P0113 (M) Intake Air Temp Sensor Voltage High Intake air (charge) temperature sensor input above the
maximum acceptable voltage.
P0116 A rationatilty error has been detected in the coolant temp
sensor.
P0117 (M) ECT Sensor Voltage Too Low Engine coolant temperature sensor input below the
minimum acceptable voltage.
P0118 (M) ECT Sensor Voltage Too High Engine coolant temperature sensor input above the
maximum acceptable voltage.
P0121 (M) TPS Voltage Does Not Agree With
MAP
TPS signal does not correlate to MAP sensor signal.
P0121 (M) Accelerator Position Sensor (APPS)
Signal Voltage Too Low
APPS voltage input below the minimum acceptable
voltage.
P0122 (M) Throttle Position Sensor Voltage Low Throttle position sensor input below the acceptable
voltage range.
P0122 (M) Accelerator Position Sensor (APPS)
Signal Voltage Too Low
APPS voltage input below the minimum acceptable
voltage.
P0123 (M) Throttle Position Sensor Voltage
High
Throttle position sensor input above the maximum
acceptable voltage.
P0123 (M) Accelerator Position Sensor (APPS)
Signal Voltage Too High
APPS voltage input above the maximum acceptable
voltage.
P0125 (M) Closed Loop Temp Not Reached Time to enter Closed Loop Operation (Fuel Control) is
excessive.
P0125 (M) Engine is Cold Too Long Engine does not reach operating temperature.
P0130 (M) 1/1 O2 Sensor Heater Circuit
Malfunction
Oxygen sensor heater element malfunction.
P0131 (M) 1/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
TJ EMISSION CONTROL SYSTEMS 25 - 3
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0132 (M) 1/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0133 (M) 1/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0134 (M) 1/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor input.
P0135 (M) 1/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
P0136 (M) 1/2 O2 Sensor Heater Circuit
Malfunction
Oxygen sensor heater element malfunction.
P0137 (M) 1/2 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0138 (M) 1/2 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0139 (M) 1/2 O2 Sensor Slow Response Oxygen sensor response not as expected.
P0140 (M) 1/2 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor.
P0141 (M) 1/2 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
P0143 (M) 1/3 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0144 (M) 1/3 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0145 (M) 1/3 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0146 (M) 1/3 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor.
P0147 (M) 1/3 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
P0151 (M) 2/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0152 (M) 2/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage sustained above normal
operating range.
P0153 (M) 2/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0154 (M) 2/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor.
P0155 (M) 2/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
P0157 (M) 2/2 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0158 (M) 2/2 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0159 2/2 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0160 (M) 2/2 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor.
25 - 4 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0161 (M) 2/2 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
P0168 Decreased Engine Performance Due
To High Injection Pump Fuel Temp
Fuel temperature is above the engine protection limit.
Engine power will be derated.
P0171 (M) 1/1 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
P0172 (M) 1/1 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
P0174 (M) 2/1 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
P0175 (M) 2/1 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
P0176 Loss of Flex Fuel Calibration Signal No calibration voltage present from flex fuel sensor.
P0177 Water In Fuel Excess water found in fuel by water-in-fuel sensor.
P0178 Flex Fuel Sensor Volts Too Low Flex fuel sensor input below minimum acceptable voltage.
P0178 Water In Fuel Sensor Voltage Too
Low
Loss of water-in-fuel circuit or sensor.
P0179 Flex Fuel Sensor Volts Too High Flex fuel sensor input above maximum acceptable
voltage.
P0181 Fuel Injection Pump Failure Low power, engine derated, or engine stops.
P0182 (M) CNG Temp Sensor Voltage Too Low Compressed natural gas temperature sensor voltage
below acceptable voltage.
P0183 (M) CNG Temp Sensor Voltage Too High Compressed natural gas temperature sensor voltage
above acceptable voltage.
P0201 (M) Injector #1 Control Circuit An open or shorted condition detected in control circuit for
injector #1 or the INJ 1 injector bank.
P0202 (M) Injector #2 Control Circuit An open or shorted condition detected in control circuit for
injector #2 or the INJ 2 injector bank.
P0203 (M) Injector #3 Control Circuit An open or shorted condition detected in control circuit for
injector #3 or the INJ 3 injector bank.
P0204 (M) Injector #4 Control Circuit Injector #4 or INJ 4 injector bank output driver stage does
not respond properly to the control signal.
P0205 (M) Injector #5 Control Circuit Injector #5 output driver stage does not respond properly
to the control signal.
P0206 (M) Injector #6 Control Circuit Injector #6 output driver stage does not respond properly
to the control signal.
P0207 (M) Injector #7 Control Circuit Injector #7 output driver stage does not respond properly
to the control signal.
P0208 (M) Injector #8 Control Circuit Injector #8 output driver stage does not respond properly
to the control signal.
P0209 (M) Injector #9 Control Circuit Injector #9 output driver stage does not respond properly
to the control signal.
P0210 (M) Injector #10 Control Circuit Injector #10 output driver stage does not respond properly
to the control signal.
TJ EMISSION CONTROL SYSTEMS 25 - 5
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0215 Fuel Injection Pump Control Circuit Failure in fuel pump relay control circuit.
P0216 (M) Fuel Injection Pump Timing Failure High fuel supply restriction, low fuel pressure or possible
wrong or incorrectly installed pump keyway.
P0217 Decreased Engine Performance Due
To Engine Overheat Condition
Engine overheating. ECM will derate engine performance.
P0219 Crankshaft Position Sensor
Overspeed Signal
Engine has exceeded rpm limits.
P0222 (M) Idle Validation Signals Both Low Problem detected with idle validation circuits within APPS.
P0223 (M) Idle Validation Signals Both High
(Above 5 Volts)
Problem detected with idle validation circuits within APPS.
P0230 Transfer Pump (Lift Pump) Circuit
Out of Range
Problem detected in fuel transfer pump circuits.
P0232 Fuel Shutoff Signal Voltage Too High Fuel shut-off signal voltage too high from ECM to fuel
injection pump.
P0234 (M) Turbo Boost Limit Exceeded Problem detected in turbocharger wastegate.
P0236 (M) Map Sensor Too High Too Long Problem detected in turbocharger wastegate.
P0237 (M) Map Sensor Voltage Too Low MAP sensor voltage input below the minimum acceptable
voltage.
P0238 (M) Map Sensor Voltage Too High MAP sensor voltage input above the maximum
acceptable voltage.
P0251 (M) Fuel Inj. Pump Mech. Failure Fuel
Valve Feedback Circuit
Problem sensed with fuel circuit internal to fuel injection
pump.
P0253 (M) Fuel Injection Pump Fuel Valve
Open Circuit
Problem sensed with fuel circuit internal to fuel injection
pump.
P0254 Fuel Injection Pump Fuel Valve
Current Too High
Problem caused by internal fuel injection pump failure.
P0300 (M) Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
P0301 (M) CYLINDER #1 MISFIRE Misfire detected in cylinder #1.
P0302 (M) CYLINDER #2 MISFIRE Misfire detected in cylinder #2.
P0303 (M) CYLINDER #3 MISFIRE Misfire detected in cylinder #3.
P0304 (M) CYLINDER #4 MISFIRE Misfire detected in cylinder #4.
P0305 (M) CYLINDER #5 MISFIRE Misfire detected in cylinder #5.
P0306 (M) CYLINDER #6 MISFIRE Misfire detected in cylinder #6.
P0307 (M) CYLINDER #7 MISFIRE Misfire detected in cylinder #7
P0308 (M) CYLINDER #8 MISFIRE Misfire detected in cylinder #8.
P0309 (M) CYLINDER #9 MISFIRE Misfire detected in cylinder #9.
P0310 (M) CYLINDER #10 MISFIRE Misfire detected in cylinder #10.
P0320 (M) No Crank Referance Signal at PCM No reference signal (crankshaft position sensor) detected
during engine cranking.
P0320 (M) No RPM Signal to PCM (Crankshaft
Position Sensor Signal to JTEC)
A CKP signal has not been detected at the PCM.
25 - 6 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0325 Knock Sensor #1 Circuit Knock sensor (#1) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0330 Knock Sensor #2 Circuit Knock sensor (#2) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0336 (M) Crankshaft Position (CKP) Sensor
Signal
Problem with voltage signal from CKP.
P0340 (M) No Cam Signal At PCM No fuel sync
P0341 (M) Camshaft Position (CMP) Sensor
Signal
Problem with voltage signal from CMP.
P0350 Ignition Coil Draws Too Much
Current
A coil (1-5) is drawing too much current.
P0351 (M) Ignition Coil # 1 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time.
P0352 (M) Ignition Coil # 2 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time.
P0353 (M) Ignition Coil # 3 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time.
P0354 (M) Ignition Coil # 4 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time (High Impedance).
P0355 (M) Ignition Coil # 5 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time (High Impedance).
P0356 (M) Ignition Coil # 6 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time (high impedance).
P0357 (M) Ignition Coil # 7 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time (high impedance).
P0358 (M) Ignition Coil # 8 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time (high impedance).
P0370 Fuel Injection Pump Speed/Position
Sensor Sig Lost
Problem caused by internal fuel injection pump failure.
P0380 (M) Intake Air Heater Relay #1 Control
Circuit
Problem detected in #1 air heater solenoid/relay circuit
(not heater element)
P0381 (M) Wait To Start Lamp Inoperative Problem detected in wait-to-start bulb circuit.
P0382 (M) Intake Air Heater Relay #2 Control
Circuit
Problem detected in #2 air heater solenoid/relay circuit
(not heater element)
P0387 Crankshaft Position Sensor Supply
Voltage Too Low
CKP sensor voltage input below the minimum acceptable
voltage.
P0388 Crankshaft Position Sensor Supply
Voltage Too High
CKP sensor voltage input above the maximum acceptable
voltage.
P0401 EGR System Failure Required change in air/fuel ration not detected during
diagnostic test.
P0403 EGR Solenoid Circuit An open or shorted condition detected in the EGR
solenoid control circuit.
TJ EMISSION CONTROL SYSTEMS 25 - 7
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0404 EGR Position Sensor Rationality EGR position sensor signal does not correlate to EGR
duty cycle.
P0405 EGR Position Sensor Volts Too Low EGR position sensor input below the acceptable voltage
range.
P0406 EGR Position Sensor Volts Too High EGR position sensor input above the acceptable voltage
range.
P0412 Secondary Air Solenoid Circuit An open or shorted condition detected in the secondary
air (air switching/aspirator) solenoid control circuit.
P0420 (M) 1/1 Catalytic Converter Efficiency Catalyst 1/1 efficiency below required level.
P0432 (M) 1/2 Catalytic Converter Efficiency Catalyst 2/1 efficiency below required level.
P0441 (M) Evap Purge Flow Monitor Insufficient or excessive vapor flow detected during
evaporative emission system operation.
P0442 (M) Evap Leak Monitor Medium Leak
Detected
A small leak has been detected in the evaporative
system.
P0443 (M) Evap Purge Solenoid Circuit An open or shorted condition detected in the EVAP purge
solenoid control circuit.
P0455 (M) Evap Leak Monitor Large Leak
Detected
A large leak has been detected in the evaporative system.
P0456 (M) Evap Leak Monitor Small Leak
Detected
Leak has been detected in the evaporative system.
P0460 Fuel Level Unit No Change Over
Miles
During low fuel
P0460 Fuel Level Unit No Change Over
Miles
Fuel level sending unit voltage does not change for more
than 40 miles.
P0462 Fuel Level Sending Unit Volts Too
Low
Fuel level sensor input below acceptable voltage.
P0462 (M) Fuel Level Sending Unit Volts Too
Low
Open circuit between PCM and fuel gauge sending unit.
P0463 Fuel Level Sending Unit Volts Too
High
Fuel level sensor input above acceptable voltage.
P0463 (M) Fuel Level Sending Unit Volts Too
High
Circuit shorted to voltage between PCM and fuel gauge
sending unit.
P0500 (M) No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load
conditions.
P0500 (M) No Vehicle Speed Sensor Signal A vehicle speed signal was not detected.
P0505 (M) Idle Air Control Motor Circuits SBEC II
P0522 Oil Pressure Voltage Too Low Oil pressure sending unit (sensor) voltage input below the
minimum acceptable voltage.
P0523 Oil Pressure Voltage Too High Oil pressure sending unit (sensor) voltage input above the
maximum acceptable voltage.
P0524 Oil Pressure Too Low Engine oil pressure is low. Engine power derated.
P0545 A/C Clutch Relay Circuit Problem detected in air conditioning clutch relay control
circuit.
25 - 8 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0551 Power Steering Switch Failure Incorrect input state detected for the power steering
switch circuit. PL: High pressure seen at high speed.
P0562 Charging System Voltage Too Low Supply voltage sensed at ECM too low.
P0563 Charging System Voltage Too High Supply voltage sensed at ECM too high.
P0600 PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum)
detected.
P0602 (M) ECM Fueling Calibration Error ECM Internal fault condition detected.
P0604 RAM Check Failure Transmission control module RAM self test fault detected.
-Aisin transmission
P0605 ROM Check Falure Transmission control module ROM self test fault detected
-Aisin transmission
P0606 (M) ECM Failure ECM Internal fault condition detected.
P0615 Starter Relay Control Circuit An open or shorted condition detected in the starter relay
control circuit.
P0622 (G) Generator Field Not Switching
Properly
An open or shorted condition detected in the generator
field control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch
relay control circuit.
P0700 EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or
Aisin controller has an active fault and has illuminated the
MIL via a CCD (EATX) or SCI (Aisin) message. The
specific fault must be acquired from the EATX via CCD or
from the Aisin via ISO-9141.
P0703 Brake Switch Stuck Pressed or
Released
Incorrect input state detected in the brake switch circuit.
(Changed from P1595)
P0711 (M) Trans Temp Sensor, No Temp Rise
After Start
Relationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a
failure of the Transmission Temperature Sensor. OBD II
Rationality. Was MIL code 37.
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage. Was MIL code 37.
P0712 (M) Trans Temp Sensor Voltage Too Low Voltage less than 1.55 volts (4-speed auto. trans. only).
P0713 Trans Temp Sensor Voltage Too
High
Transmission fluid temperature sensor input above
acceptable voltage. Was MIL code 37.
P0713 (M) Trans Temp Sensor Voltage Too
High
Voltage greater than 3.76 volts (4-speed auto. trans.
only).
P0720 (M) Low Output SPD Sensor RPM,
Above 15 MPH
The relationship between the Output Shaft Speed Sensor
and vehicle speed is not within acceptable limits.
P0720 (M) Low Output Spd Sensor RPM Above
15 mph
Output shaft speed is less than 60 rpm with vehicle speed
above 15 mph (4-speed auto. trans. only).
TJ EMISSION CONTROL SYSTEMS 25 - 9
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0740 (M) Torq Con Clu, No RPM Drop at
Lockup
Relationship between engine and vehicle speeds
indicated failure of torque convertor clutch lock-up system
(TCC/PTU solenoid)
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay Circuits
An open or shorted condition detected in the torque
converter clutch (part throttle unlock) solenoid control
circuit. Shift solenoid C electrical fault - Aisin transmission
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay Circuits
An open or shorted condition detected in the torque
converter part throttle unlock solenoid control circuit (3 or
4-speed auto. trans. only).
P0748 (M) Governor Pressur Sol Control/Trans
Relay Circuits
An open or shorted condition detected in the Governor
Pressure Solenoid circuit or Trans Relay Circuit in JTEC
RE transmissions.
P0748 (M) Governor Pressure Sol Control/Trans
Relay Circuits
An open or shorted condition detected in the governor
pressure solenoid or relay circuits (4-speed auto. trans.
only).
P0751 (M) O/D Switch Pressed (Lo) More Than
5 Minutes
Overdrive override switch input is in a prolonged
depressed state.
P0751 (M) O/D Switch Pressed (LO) More Than
5 Min
Overdrive Off switch input too low for more than 5
minutes (4-speed auto. trans. only).
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
Circuits
An open or shorted condition detected in the overdrive
solenoid control circuit or Trans Relay Circuit in JTEC RE
transmissions. Was MIL code 45.
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
Circuits
An open or shorted condition detected in the transmission
2-4 shift solenoid circuit (4-speed auto. trans. only).
P0756 AW4 Shift Sol B (2-3) Functional
Failure
Shift solenoid B (2-3) functional fault - Aisin transmission
P0783 (M) 3-4 Shift Sol, No RPM Drop at
Lockup
The overdrive solenoid is unable to engage the gear
change from 3rd gear to the overdrive gear.
P0801 Reverse Gear Lockout Circuit Open
or Short
An open or shorted condition detected in the transmission
reverse gear lock-out solenoid control circuit.
P0830 Clutch Depressed Switch Circuit Problem detected in clutch switch circuit.
P0833 Clutch Released Switch Circuit Problem detected in clutch switch circuit.
P1110 Decrease Engine Performance Due
To High Intake Air Temperature
Intake manifold air temperature is above the engine
protection limit. Engine power will be derated.
P1180 Decreased Engine Performance Due
To High Injection Pump Fuel Temp
Fuel temperature is above the engine protection limit.
Engine power will be derated.
P1195 (M) 1/1 O2 Sensor Slow During Catalyst
Monitor
A slow switching oxygen sensor has been detected in
bank 1/1 during catalyst monitor test. (Also see SCI DTC
$66) (was P0133)
P1196 (M) 2/1 O2 Sensor Slow During Catalyst
Monitor
A slow switching oxygen sensor has been detected in
bank 2/1 during catalyst monitor test. (Also see SCI DTC
$7A) (was P0153)
25 - 10 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P1197 1/2 O2 Sensor Slow During Catalyst
Monitor
A slow switching oxygen sensor has been detected in
bank 1/2 during catalyst monitor test. (Also see SCI DTC
$68) (was P0139)
P1198 Radiator Temperature Sensor Volts
Too High
Radiator coolant temperature sensor input above the
maximum acceptable voltage.
P1199 Radiator Temperature Sensor Volts
Too Low
Radiator coolant temperature sensor input below the
minimum acceptable voltage.
P1281 Engine is Cold Too Long Engine coolant temperature remains below normal
operating temperatures during vehicle travel (Thermostat).
P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump
relay control circuit.
P1283 Idle Select Signal Invalid ECM or fuel injection pump module internal fault condition
detected.
P1284 (M) Fuel Injection Pump Battery Voltage
Out-Of-Range
Fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1285 (M) Fuel Injection Pump Controller
Always On
Fuel injection pump module relay circuit failure detected.
Engine power will be derated.
P1286 Accelerator Position Sensor (APPS)
Supply Voltage Too High
High voltage detected at APPS.
P1287 Fuel Injection Pump Controller
Supply Voltage Low
ECM or fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1288 Intake Manifold Short Runner
Solenoid Circuit
An open or shorted condition detected in the short runner
tuning valve circuit.
P1289 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold
tuning valve solenoid control circuit.
P1290 CNG Fuel System Pressure Too
High
Compressed natural gas system pressure above normal
operating range.
P1291 No Temp Rise Seen From Intake
Heaters
Energizing Heated Air Intake does not change intake air
temperature sensor an acceptable amount.
P1291 (M) No Temperature Rise Seen From
Intake Air Heaters
Problem detected in intake manifold air heating system.
P1292 CNG Pressure Sensor Voltage Too
High
Compressed natural gas pressure sensor reading above
acceptable voltage.
P1293 CNG Pressure Sensor Voltage Too
Low
Compressed natural gas pressure sensor reading below
acceptable voltage.
P1294 (M) Target Idle Not Reached Target RPM not achieved during drive idle condition.
Possible vacuum leak or IAC (AIS) lost steps.
P1295 (M) No 5 Volts to TP Sensor Loss of a 5 volt feed to the Throttle Position Sensor has
been detected.
P1295 (M) Accelerator Position Sensor (APPS)
Supply Voltage Too Low
APPS supply voltage input below the minimum
acceptable voltage.
P1296 No 5 Volts to MAP Sensor Loss of a 5 volt feed to the MAP Sensor has been
detected.
TJ EMISSION CONTROL SYSTEMS 25 - 11
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P1297 (M) No Change in MAP From Start To
Run
No difference is recognized between the MAP reading at
engine idle and the stored barometric pressure reading.
P1298 Lean Operation at Wide Open
Throttle
A prolonged lean condition is detected during Wide Open
Throttle
P1299 Vacuum Leak Found (IAC Fully
Seated)
MAP Sensor signal does not correlate to Throttle Position
Sensor signal. Possible vacuum leak.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the ASD or CNG
shutoff relay control ckt.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the auto
shutdown relay circuit.
P1389 No ASD Relay Output Voltage At
PCM
No Z1 or Z2 voltage sensed when the auto shutdown
relay is energized.
P1389 (M) No ASD Relay Output Voltage at
PCM
An open condition detected In the ASD relay output
circuit.
P1390 Timing Belt Skipped 1 Tooth or More Relationship between Cam and Crank signals not correct
P1391 (M) Intermittent Loss of CMP or CKP Loss of the Cam Position Sensor or Crank Position
sensor has occurred. For PL 2.0L
P1398 (M) Mis-Fire Adaptive Numerator at Limit PCM is unable to learn the Crank Sensor’s signal in
preparation for Misfire Diagnostics. Probable defective
Crank Sensor
P1399 Wait To Start Lamp Cicuit An open or shorted condition detected in the Wait to Start
Lamp circuit.
P1403 No 5V to EGR Sens Loss of 5v feed to the EGR position sensor.
P01475 Aux 5 Volt Supply Voltage High Sensor supply voltage for ECM sensors is too high.
P1476 Too Little Secondary Air Insufficient flow of secondary air injection detected during
aspirator test (was P0411)
P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during
aspirator test (was P0411).
P1478 Battery Temp Sensor Volts Out of
Limit
Internal temperature sensor input voltage out of an
acceptable range.
P1479 Transmission Fan Relay Circuit An open or shorted condition detected in the transmission
fan relay circuit.
P1480 PCV Solenoid Circuit An open or shorted condition detected in the PCV
solenoid circuit.
P1481 EATX RPM Pulse Perf EATX RPM pulse generator signal for misfire detection
does not correlate with expected value.
P1482 Catalyst Temperature Sensor Circuit
Shorted Low
Catalyst temperature sensor circuit shorted low.
P1483 Catalyst Temperature Sensor Circuit
Shorted High.
Catalyst temperature sensor circuit shorted high.
P1484 Catalytic Converter Overheat
Detected
A catalyst overheat condition has been detected by the
catalyst temperature sensor.
25 - 12 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P1485 Air Injection Solenoid Circuit An open or shorted condition detected in the air assist
solenoid circuit.
P1486 Evap Leak Monitor Pinched Hose
Found
LDP has detected a pinched hose in the evaporative hose
system.
P1487 Hi Speed Rad Fan CTRL Relay
Circuit
An open or shorted condition detected in the control
circuit of the #2 high speed radiator fan control relay.
P1488 Auxiliary 5 Volt Supply Output Too
Low
Auxiliary 5 volt sensor feed is sensed to be below an
acceptable limit.
P1488 5 Volt Supply Voltage Low Sensor supply voltage for ECM sensors is too low.
P1489 High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control
circuit of the high speed radiator fan control relay.
P1490 Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of
the low speed radiator fan control relay.
P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan
control relay control circuit. This includes PWM solid state
relays.
P1492 Ambient/Batt Temp Sen Volts Too
High
External temperature sensor input above acceptable
voltage.
P1492 (M) Ambient/Batt Temp Sensor Volts Too
High
Battery temperature sensor input voltage above an
acceptable range.
P1493 (M) Ambient/Batt Temp Sen Volts Too
Low
External temperature sensor input below acceptable
voltage.
P1493 (M) Ambient/Batt Temp Sen Volts Too
Low
Battery temperature sensor input voltage below an
acceptable range.
P1494 (M) Leak Detection Pump Sw or
Mechanical Fault
Incorrect input state detected for the Leak Detection
Pump (LDP) pressure switch.
P1495 Leak Detection Pump Solenoid
Circuit
An open or shorted condition detected in the Leak
Detection Pump (LDP) solenoid circuit.
P1496 5 Volt Supply, Output Too Low 5 volt sensor feed is sensed to be below an acceptable
limit. ( less than 4v for 4 sec )
P1498 High Speed Rad Fan Ground CTRL
Rly Circuit
An open or shorted condition detected in the control
circuit of the #3 high speed radiator fan control relay.
P1594 (G) Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1594 Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the
speed control vacuum or vent solenoid control circuits.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in the speed
control vacuum or vent solenoid circuits.
P1596 Speed Control Switch Always High Speed control switch input above maximum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below minimum acceptable
voltage.
TJ EMISSION CONTROL SYSTEMS 25 - 13
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P1597 Speed Control Switch Always Low Speed control switch input below the minimum acceptable
voltage.
P1598 A/C Pressure Sensor Volts Too High A/C pressure sensor input above maximum acceptable
voltage.
P1598 A/C Sensor Input Hi Problem detected in air conditioning electrical circuit.
P1599 A/C Pressure Sensor Volts Too Low A/C pressure sensor input below minimum acceptable
voltage.
P1599 A/C Sensor Input Lo Problem detected in air conditioning electrical circuit.
P1680 Clutch Released Switch Circuit Problem detected in clutch switch electrical circuit.
P1681 No I/P Cluster CCD/J1850
Messages Received
No CCD/J1850 messages received from the cluster
control module.
P1682 (G) Charging System Voltage Too Low Battery voltage sense input below target charging voltage
during engine operation and no significant change in
voltage detected during active test of generator output
circuit.
P1682 Charging System Voltage Too Low Charging system output voltage low.
P1683 SPD CTRL PWR Relay; or S/C 12v
Driver CKT
An open or shorted condition detected in the speed
control servo power control circuit.
P1683 Spd ctrl pwr rly, or s/c 12v driver
circuit
An open or shorted condition detected in the speed
control servo power control circuit.
P1684 Batt Loss in 50 Star The battery has been disconnected within the last 50
starts
P1685 SKIM Invalid Key The engine controler has received an invalid key from the
SKIM.
P1686 No SKIM BUS Messages Received No CCD/J1850 messages received from the Smart Key
Immobilizer Module (SKIM).
P1687 No MIC BUS Message No CCD/J1850 messages received from the Mechanical
Instrument Cluster (MIC) module.
P1688 (M) Internal Fuel Injection Pump
Controller Failure
Internal problem within the fuel injection pump. Low
power, engine derated, or engine stops.
P1689 (M) No Communication Between ECM
and Injection Pump Module
Data link circuit failure between ECM and fuel injection
pump. Low power, engine derated, or engine stops.
P1690 (M) Fuel Injection Pump CKP Sensor
Does Not Agree With ECM CKP
Sensor
Problem in fuel sync signal. Possible injection pump
timing problem. Low power, engine derated, or engine
stops.
P1691 Fuel Injection Pump Controller
Calibration Error
Internal fuel injection pump failure. Low power, engine
derated, or engine stops.
P1692 DTC Set In ECM A “Companion DTC” was set in both the ECM and PCM.
P1693 (M) DTC Detected in Companion Module A fault has been generated in the companion engine
control module.
P1693 (M) DTC Detected in PCM/ECM or DTC
Detected in ECM
A “Companion DTC” was set in both the ECM and PCM.
25 - 14 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P1694 Fault In Companion Module No CCD/J1850 messages received from the powertrain
control module-Aisin transmission
P1694 (M) No CCD Messages received from
ECM
Bus communication failure to PCM.
P1695 No CCD/J1850 Message From Body
Control Module
No CCD/J1850 messages received from the body control
module.
P1696 PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by
the control module.
P1697 PCM Failure SRI Mile Not Stored Unsuccessful attempt to update Service Reminder
Indicator (SRI or EMR) mileage in the control module
EEPROM.
P1698 No CCD/J1850 Message From TCM No CCD/J1850 messages received from the electronic
transmission control module (EATX) or the Aisin
transmission controller.
P1698 No CCD Messages received from
PCM
Bus communication failure to PCM. A “Companion DTC”
was set in both the ECM and PCM.
P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission
2-3 gear lock-out solenoid control circuit.
P1740 TCC or OD Sol Perf A rationality error has been detected in either the TCC
solenoid or overdrive solenoid systems.
P1740 (M) TCC OR O/D Solenoid Performance Problem detected in transmission convertor clutch and/or
overdrive circuits (diesel engine with 4-speed auto. trans.
only).
P1756 (M) GOV Press Not Equal to Target @
15-20 PSI
The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear. (Mid Pressure
Malfunction)
P1756 (M) Governor Pressure Not Equal to
Target @ 15-20 PSI
Governor sensor input not between 10 and 25 psi when
requested (4-speed auto. trans. only).
P1757 GOV Press Not Equal to Target @
15-20 PSI
The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear (Zero Pressure
Malfunction)
P1757 (M) Governor Pressure Above 3 PSI In
Gear With 0 MPH
Governor pressure greater than 3 psi when requested to
be 0 psi (4-speed auto. trans. only).
P1762 (M) Gov Press Sen Offset Volts Too Lo
or High
The Governor Pressure Sensor input is greater than a
calibration limit or is less than a calibration limit for 3
consecutive park/neutral calibrations.
P1762 (M) Governor Press Sen Offset Volts Too
Low or High
Sensor input greater or less than calibration for 3
consecutive Neutral/Park occurrences (4-speed auto.
trans. only).
P1763 Governor Pressure Sensor Volts Too
Hi
The Governor Pressure Sensor input is above an
acceptable voltage level.
TJ EMISSION CONTROL SYSTEMS 25 - 15
DESCRIPTION AND OPERATION (Continued)
(M) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if
required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G) Generator lamp illuminated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P1763 (M) Governor Pressure Sensor Volts Too
HI
Voltage greater than 4.89 volts (4-speed auto. trans.
only).
P1764 (M) Governor Pressure Sensor Volts Too
Low
The Governor Pressure Sensor input is below an
acceptable voltage level.
P1764 (M) Governor Pressure Sensor Volts Too
Low
Voltage less than.10 volts (4-speed auto. trans. only).
P1765 (M) Trans 12 Volt Supply Relay CTRL
Circuit
An open or shorted condition is detected in the
Transmission Relay control circuit. This relay supplies
power to the TCC
P1765 (M) Trans 12 Volt Supply Relay Ctrl
Circuit
Current state of solenoid output port is different than
expected (4-speed auto. trans. only).
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch.
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch
(3 or 4-speed auto. trans. only).
TASK MANAGER
DESCRIPTION
The PCM i s responsi bl e for effi ci entl y coordi nati ng
the operati on of al l the emi ssi ons-rel ated compo-
nents. The PCM i s al so responsi bl e for determi ni ng i f
the di agnosti c systems are operati ng properl y. The
software desi gned to carry out these responsi bi l i ti es
i s cal l the ’Task Manager’.
OPERATION
The Task Manager determi nes whi ch tests happen
when and whi ch functi ons occur when. Many of the
di agnosti c steps requi red by OBD I I must be per-
formed under speci fi c operati ng condi ti ons. The Task
Manager software organi zes and pri ori ti zes the di ag-
nosti c procedures. The job of the Task Manager i s to
determi ne i f condi ti ons are appropri ate for tests to be
run, moni tor the parameters for a tri p for each test,
and record the resul ts of the test. Fol l owi ng are the
responsi bi l i ti es of the Task Manager software:
• Test Sequence
• MI L I l l umi nati on
• Di agnosti c Troubl e Codes (DTCs)
• Tri p I ndi cator
• Freeze Frame Data Storage
• Si mi l ar Condi ti ons Wi ndow
Test Sequence
I n many i nstances, emi ssi ons systems must fai l
di agnosti c tests more than once before the PCM i l l u-
mi nates the MI L. These tests are know as ’two tri p
moni tors.’ Other tests that turn the MI L l amp on
after a si ngl e fai l ure are known as ’one tri p moni -
tors.’ A tri p i s defi ned as ’start the vehi cl e and oper-
ate i t to meet the cri teri a necessary to run the gi ven
moni tor.’
Many of the di agnosti c tests must be performed
under certai n operati ng condi ti ons. However, there
are ti mes when tests cannot be run because another
test i s i n progress (confl i ct), another test has fai l ed
(pendi ng) or the Task Manager has set a faul t that
may cause a fai l ure of the test (suspend).
• Pendi ng
Under some si tuati ons the Task Manager wi l l not
run a moni tor i f the MI L i s i l l umi nated and a faul t i s
stored from another moni tor. I n these si tuati ons, the
Task Manager postpones moni tors pending resol u-
ti on of the ori gi nal faul t. The Task Manager does not
run the test unti l the probl em i s remedi ed.
For exampl e, when the MI L i s i l l umi nated for an
Oxygen Sensor faul t, the Task Manager does not run
the Catal yst Moni tor unti l the Oxygen Sensor faul t i s
remedi ed. Si nce the Catal yst Moni tor i s based on si g-
nal s from the Oxygen Sensor, runni ng the test woul d
produce i naccurate resul ts.
• Confl i ct
There are si tuati ons when the Task Manager does
not run a test i f another moni tor i s i n progress. I n
these si tuati ons, the effects of another moni tor run-
ni ng coul d resul t i n an erroneous fai l ure. I f thi s con-
flict i s present, the moni tor i s not run unti l the
confl i cti ng condi ti on passes. Most l i kel y the moni tor
wi l l run l ater after the confl i cti ng moni tor has
passed.
For exampl e, i f the Fuel System Moni tor i s i n
25 - 16 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
progress, the Task Manager does not run the EGR
Moni tor. Si nce both tests moni tor changes i n ai r/fuel
rati o and adapti ve fuel compensati on, the moni tors
wi l l confl i ct wi th each other.
• Suspend
Occasi onal l y the Task Manager may not al l ow a two
tri p faul t to mature. The Task Manager wi l l sus-
pend the maturi ng of a faul t i f a condi ti on exi sts
that may i nduce an erroneous fai l ure. Thi s prevents
i l l umi nati ng the MI L for the wrong faul t and al l ows
more preci s di agnosi s.
For exampl e, i f the PCM i s stori ng a one tri p faul t
for the Oxygen Sensor and the EGR moni tor, the
Task Manager may sti l l run the EGR Moni tor but
wi l l suspend the resul ts unti l the Oxygen Sensor
Moni tor ei ther passes or fai l s. At that poi nt the Task
Manager can determi ne i f the EGR system i s actu-
al l y fai l i ng or i f an Oxygen Sensor i s fai l i ng.
MIL Illumination
The PCM Task Manager carri es out the i l l umi na-
ti on of the MI L. The Task Manager tri ggers MI L i l l u-
mi nati on upon test fai l ure, dependi ng on moni tor
fai l ure cri teri a.
The Task Manager Screen shows both a Requested
MI L state and an Actual MI L state. When the MI L i s
i l l umi nated upon compl eti on of a test for a thi rd tri p,
the Requested MI L state changes to OFF. However,
the MI L remai ns i l l umi nated unti l the next key
cycl e. (On some vehi cl es, the MI L wi l l actual l y turn
OFF duri ng the thi rd key cycl e) Duri ng the key cycl e
for the thi rd good tri p, the Requested MI L state i s
OFF, whi l e the Actual MI LL state i s ON. After the
next key cycl e, the MI L i s not i l l umi nated and both
MI L states read OFF.
Diagnostic Trouble Codes (DTCs)
Wi th OBD I I , di fferent DTC faul ts have di fferent
pri ori ti es accordi ng to regul ati ons. As a resul t, the
pri ori ti es determi ne MI L i l l umi nati on and DTC era-
sure. DTCs are entered accordi ng to i ndi vi dual pri or-
i ty. DTCs wi th a hi gher pri ori ty overwri te l ower
pri ori ty DTCs.
Priorities
• Pri ori ty 0 —Non-emi ssi ons rel ated troubl e codes
• Pri ori ty 1 — One tri p fai l ure of a two tri p faul t
for non-fuel system and non-mi sfi re.
• Pri ori ty 2 — One tri p fai l ure of a two tri p faul t
for fuel system (ri ch/l ean) or mi sfi re.
• Pri ori ty 3 — Two tri p fai l ure for a non-fuel sys-
tem and non-mi sfi re or matured one tri p comprehen-
si ve component faul t.
• Pri ori ty 4 — Two tri p fai l ure or matured faul t
for fuel system (ri ch/l ean) and mi sfi re or one tri p cat-
al yst damagi ng mi sfi re.
Non-emi ssi ons rel ated fai l ures have no pri ori ty.
One tri p fai l ures of two tri p faul ts have l ow pri ori ty.
Two tri p fai l ures or matured faul ts have hi gher pri -
ori ty. One and two tri p fai l ures of fuel system and
mi sfi re moni tor take precedence over non-fuel system
and non-mi sfi re fai l ures.
DTC Self Erasure
Wi th one tri p components or systems, the MI L i s
i l l umi nated upon test fai l ure and DTCs are stored.
Two tri p moni tors are components requi ri ng fai l ure
i n two consecuti ve tri ps for MI L i l l umi nati on. Upon
fai l ure of the fi rst test, the Task Manager enters a
maturi ng code. I f the component fai l s the test for a
second ti me the code matures and a DTC i s set.
After three good tri ps the MI L i s exti ngui shed and
the Task Manager automati cal l y swi tches the tri p
counter to a warm-up cycl e counter. DTCs are auto-
mati cal l y erased fol l owi ng 40 warm-up cycl es i f the
component does not fai l agai n.
For mi sfi re and fuel system moni tors, the compo-
nent must pass the test under a Si mi l ar Condi ti ons
Wi ndow i n order to record a good tri p. A Si mi l ar Con-
di ti ons Wi ndow i s when engi ne RPM i s wi thi n Ϯ375
RPM and l oad i s wi thi n Ϯ10% of when the faul t
occurred.
NOTE: It is important to understand that a compo-
nent does not have to fail under a similar window of
operation to mature. It must pass the test under a
Similar Conditions Window when it failed to record
a Good Trip for DTC erasure for misfire and fuel
system monitors.
DTCs can be erased anyti me wi th a DRB I I I . Eras-
i ng the DTC wi th the DRB I I I erases al l OBD I I
i nformati on. The DRB I I I automati cal l y di spl ays a
warni ng that erasi ng the DTC wi l l al so erase al l
OBD I I moni tor data. Thi s i ncl udes al l counter i nfor-
mati on for warm-up cycl es, tri ps and Freeze Frame.
Trip Indicator
The Trip i s essenti al for runni ng moni tors and
exti ngui shi ng the MI L. I n OBD I I terms, a tri p i s a
set of vehi cl e operati ng condi ti ons that must be met
for a speci fi c moni tor to run. Al l tri ps begi n wi th a
key cycl e.
Good Trip
The Good Tri p counters are as fol l ows:
• Speci fi c Good Tri p
• Fuel System Good Tri p
• Mi sfi re Good Tri p
• Al ternate Good Tri p (appears as a Gl obal Good
Tri p on DRB I I I )
• Comprehensi ve Components
• Major Moni tor
• Warm-Up Cycl es
TJ EMISSION CONTROL SYSTEMS 25 - 17
DESCRIPTION AND OPERATION (Continued)
Specific Good Trip
The term Good Tri p has di fferent meani ngs
dependi ng on the ci rcumstances:
• I f the MI L i s OFF, a tri p i s defi ned as when the
Oxygen Sensor Moni tor and the Catal yst Moni tor
have been compl eted i n the same dri ve cycl e.
• I f the MI L i s ON and a DTC was set by the Fuel
Moni tor or Mi sfi re Moni tor (both conti nuous moni -
tors), the vehi cl e must be operated i n the Si mi l ar
Condi ti on Wi ndow for a speci fi ed amount of ti me.
• I f the MI L i s ON and a DTC was set by a Task
Manager commanded once-per-tri p moni tor (such as
the Oxygen Sensor Moni tor, Catal yst Moni tor, Purge
Fl ow Moni tor, Leak Detecti on Pump Moni tor, EGR
Moni tor or Oxygen Sensor Heater Moni tor), a good
tri p i s when the moni tor i s passed on the next start-
up.
• I f the MI L i s ON and any other emi ssi ons DTC
was set (not an OBD I I moni tor), a good tri p occurs
when the Oxygen Sensor Moni tor and Catal yst Mon-
i tor have been compl eted, or two mi nutes of engi ne
run ti me i f the Oxygen Sensor Moni tor and Catal yst
Moni tor have been stopped from runni ng.
Fuel System Good Trip
To count a good tri p (three requi red) and turn off
the MI L, the fol l owi ng condi ti ons must occur:
• Engi ne i n cl osed l oop
• Operati ng i n Si mi l ar Condi ti ons Wi ndow
• Short Term mul ti pl i ed by Long Term l ess than
threshol d
• Less than threshol d for a predetermi ned ti me
I f al l of the previ ous cri teri a are met, the PCM wi l l
count a good tri p (three requi red) and turn off the
MI L.
Misfire Good Trip
I f the fol l owi ng condi ti ons are met the PCM wi l l
count one good tri p (three requi red) i n order to turn
off the MI L:
• Operati ng i n Si mi l ar Condi ti on Wi ndow
• 1000 engi ne revol uti ons wi th no mi sfi re
Warm-Up Cycles
Once the MI L has been exti ngui shed by the Good
Tri p Counter, the PCM automati cal l y swi tches to a
Warm-Up Cycl e Counter that can be vi ewed on the
DRB I I I . Warm-Up Cycl es are used to erase DTCs
and Freeze Frames. Forty Warm-Up cycl es must
occur i n order for the PCM to sel f-erase a DTC and
Freeze Frame. A Warm-Up Cycl e i s defi ned as fol -
l ows:
• Engi ne cool ant temperature must start bel ow
and ri se above 160° F
• Engi ne cool ant temperature must ri se by 40° F
• No further faul ts occur
Freeze Frame Data Storage
Once a fai l ure occurs, the Task Manager records
several engi ne operati ng condi ti ons and stores i t i n a
Freeze Frame. The Freeze Frame i s consi dered one
frame of i nformati on taken by an on-board data
recorder. When a faul t occurs, the PCM stores the
i nput data from vari ous sensors so that techni ci ans
can determi ne under what vehi cl e operati ng condi -
ti ons the fai l ure occurred.
The data stored i n Freeze Frame i s usual l y
recorded when a system fai l s the fi rst ti me for two
tri p faul ts. Freeze Frame data wi l l onl y be overwri t-
ten by a di fferent faul t wi th a hi gher pri ori ty.
CAUTION: Erasing DTCs, either with the DRB III or
by disconnecting the battery, also clears all Freeze
Frame data.
Similar Conditions Window
The Si mi l ar Condi ti ons Wi ndow di spl ays i nforma-
ti on about engi ne operati on duri ng a moni tor. Abso-
l ute MAP (engi ne l oad) and Engi ne RPM are stored
i n thi s wi ndow when a fai l ure occurs. There are two
di fferent Si mi l ar condi ti ons Wi ndows: Fuel System
and Mi sfi re.
FUEL SYSTEM
• Fuel System Similar Conditions Window —
An i ndi cator that ’Absol ute MAP When Fuel Sys Fai l ’
and ’RPM When Fuel Sys Fai l ed’ are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from ’NO’ to ’YES’.
• Absolute MAP When Fuel Sys Fail — The
stored MAP readi ng at the ti me of fai l ure. I nforms
the user at what engi ne l oad the fai l ure occurred.
• Absolute MAP — A l i ve readi ng of engi ne l oad
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
• RPM When Fuel Sys Fail — The stored RPM
readi ng at the ti me of fai l ure. I nforms the user at
what engi ne RPM the fai l ure occurred.
• Engine RPM — A l i ve readi ng of engi ne RPM
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
• Adaptive Memory Factor — The PCM uti -
l i zes both Short Term Compensati on and Long Term
Adapti ve to cal cul ate the Adapti ve Memory Factor
for total fuel correcti on.
• Upstream O2S Volts — A l i ve readi ng of the
Oxygen Sensor to i ndi cate i ts performance. For
exampl e, stuck l ean, stuck ri ch, etc.
• SCW Time in Window (Similar Conditions
Window Time in Window) — A ti mer used by the
PCM that i ndi cates that, after al l Si mi l ar Condi ti ons
have been met, i f there has been enough good engi ne
runni ng ti me i n the SCW wi thout fai l ure detected.
Thi s ti mer i s used to i ncrement a Good Tri p.
25 - 18 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
• Fuel System Good Trip Counter — A Tri p
Counter used to turn OFF the MI L for Fuel System
DTCs. To i ncrement a Fuel System Good Tri p, the
engi ne must be i n the Si mi l ar Condi ti ons Wi ndow,
Adapti ve Memory Factor must be l ess than cal i -
brated threshol d and the Adapti ve Memory Factor
must stay bel ow that threshol d for a cal i brated
amount of ti me.
• Test Done This Trip — I ndi cates that the
moni tor has al ready been run and compl eted duri ng
the current tri p.
MISFIRE
• Same Misfire Warm-Up State — I ndi cates i f
the mi sfi re occurred when the engi ne was warmed up
(above 160° F).
• In Similar Misfire Window — An i ndi cator
that ’Absol ute MAP When Mi sfi re Occurred’ and
’RPM When Mi sfi re Occurred’ are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from ’NO’ to ’YES’.
• Absolute MAP When Misfire Occurred —
The stored MAP readi ng at the ti me of fai l ure.
I nforms the user at what engi ne l oad the fai l ure
occurred.
• Absolute MAP — A l i ve readi ng of engi ne l oad
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
• RPM When Misfire Occurred — The stored
RPM readi ng at the ti me of fai l ure. I nforms the user
at what engi ne RPM the fai l ure occurred.
• Engine RPM — A l i ve readi ng of engi ne RPM
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
• Adaptive Memory Factor — The PCM uti -
l i zes both Short Term Compensati on and Long Term
Adapti ve to cal cul ate the Adapti ve Memory Factor
for total fuel correcti on.
• 200 Rev Counter — Counts 0–100 720 degree
cycl es.
• SCWCat 200 Rev Counter — Counts when i n
si mi l ar condi ti ons.
• SCW FTP 1000 Rev Counter — Counts 0–4
when i n si mi l ar condi ti ons.
• Misfire Good Trip Counter — Counts up to
three to turn OFF the MI L.
• Misfire Data — Data col l ected duri ng test.
• Test Done This Trip — I ndi cates YES when
the test i s done.
MONITORED SYSTEMS
OPERATION
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated. These moni tors generate
Di agnosti c Troubl e Codes that can be di spl ayed wi th
the MI L or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
• Mi sfi re Moni tor
• Fuel System Moni tor
• Oxygen Sensor Moni tor
• Oxygen Sensor Heater Moni tor
• Catal yst Moni tor
• Leak Detecti on Pump Moni tor (i f equi pped)
Al l these system moni tors requi re two consecuti ve
tri ps wi th the mal functi on present to set a faul t.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
The fol l owi ng i s an operati on and descri pti on of
each system moni tor :
OXYGEN SENSOR (O2S) MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300° to 350°C (572° to 662°F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
Catal yst and Fuel Moni tors.
The O2S can fai l i n any or al l of the fol l owi ng
manners:
• sl ow response rate
• reduced output vol tage
• dynami c shi ft
• shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
TJ EMISSION CONTROL SYSTEMS 25 - 19
DESCRIPTION AND OPERATION (Continued)
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
OXYGEN SENSOR HEATER MONITOR
I f there i s an oxygen sensor (O2S) shorted to vol t-
age DTC, as wel l as a O2S heater DTC, the O2S
faul t MUST be repai red fi rst. Before checki ng the
O2S faul t, veri fy that the heater ci rcui t i s operati ng
correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300° to 350°C (572 ° to 662°F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S sensor
are very temperature sensi ti ve. The readi ngs are not
accurate bel ow 300°C. Heati ng of the O2S sensor i s
done to al l ow the engi ne control l er to shi ft to cl osed
l oop control as soon as possi bl e. The heati ng el ement
used to heat the O2S sensor must be tested to ensure
that i t i s heati ng the sensor properl y.
The O2S sensor ci rcui t i s moni tored for a drop i n
vol tage. The sensor output i s used to test the heater
by i sol ati ng the effect of the heater el ement on the
O2S sensor output vol tage from the other effects.
LEAK DETECTION PUMP MONITOR (IF EQUIPPED)
The l eak detecti on assembl y i ncorporates two pri -
mary functi ons: i t must detect a l eak i n the evapora-
ti ve system and seal the evaporati ve system so the
l eak detecti on test can be run.
The pri mary components wi thi n the assembl y are:
A three port sol enoi d that acti vates both of the func-
ti ons l i sted above; a pump whi ch contai ns a swi tch,
two check val ves and a spri ng/di aphragm, a cani ster
vent val ve (CVV) seal whi ch contai ns a spri ng l oaded
vent seal val ve.
I mmedi atel y after a col d start, between predeter-
mi ned temperature threshol ds l i mi ts, the three port
sol enoi d i s bri efl y energi zed. Thi s i ni ti al i zes the
pump by drawi ng ai r i nto the pump cavi ty and al so
cl oses the vent seal . Duri ng non test condi ti ons the
vent seal i s hel d open by the pump di aphragm
assembl y whi ch pushes i t open at the ful l travel posi -
ti on. The vent seal wi l l remai n cl osed whi l e the
pump i s cycl i ng due to the reed swi tch tri ggeri ng of
the three port sol enoi d that prevents the di aphragm
assembl y from reachi ng ful l travel . After the bri ef
i ni ti al i zati on peri od, the sol enoi d i s de-energi zed
al l owi ng atmospheri c pressure to enter the pump
cavi ty, thus permi tti ng the spri ng to dri ve the di a-
phragm whi ch forces ai r out of the pump cavi ty and
i nto the vent system. When the sol enoi d i s energi zed
and de energi zed, the cycl e i s repeated creati ng fl ow
i n typi cal di aphragm pump fashi on. The pump i s con-
trol l ed i n 2 modes:
Pump Mode: The pump i s cycl ed at a fi xed rate to
achi eve a rapi d pressure bui l d i n order to shorten the
overal l test l ength.
Test Mode: The sol enoi d i s energi zed wi th a fi xed
durati on pul se. Subsequent fi xed pul ses occur when
the di aphragm reaches the Swi tch cl osure poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5” H20.
The cycl e rate of pump strokes i s qui te rapi d as the
system begi ns to pump up to thi s pressure. As the
pressure i ncreases, the cycl e rate starts to drop off. I f
there i s no l eak i n the system, the pump woul d even-
tual l y stop pumpi ng at the equal i zed pressure. I f
there i s a l eak, i t wi l l conti nue to pump at a rate rep-
resentati ve of the fl ow characteri sti c of the si ze of the
l eak. From thi s i nformati on we can determi ne i f the
l eak i s l arger than the requi red detecti on l i mi t (cur-
rentl y set at.040” ori fi ce by CARB). I f a l eak i s
reveal ed duri ng the l eak test porti on of the test, the
test i s termi nated at the end of the test mode and no
further system checks wi l l be performed.
After passi ng the l eak detecti on phase of the test,
system pressure i s mai ntai ned by turni ng on the
LDP’s sol enoi d unti l the purge system i s acti vated.
Purge acti vati on i n effect creates a l eak. The cycl e
rate i s agai n i nterrogated and when i t i ncreases due
to the fl ow through the purge system, the l eak check
porti on of the di agnosti c i s compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
Evaporati ve system functi onal i ty wi l l be veri fi ed by
usi ng the stri cter evap purge fl ow moni tor. At an
appropri ate warm i dl e the LDP wi l l be energi zed to
seal the cani ster vent. The purge fl ow wi l l be cl ocked
up from some smal l val ue i n an attempt to see a
shi ft i n the 02 control system. I f fuel vapor, i ndi cated
by a shi ft i n the 02 control , i s present the test i s
passed. I f not, i t i s assumed that the purge system i s
not functi oni ng i n some respect. The LDP i s agai n
turned off and the test i s ended.
25 - 20 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
MISFIRE MONITOR
Excessi ve engi ne mi sfi re resul ts i n i ncreased cata-
l yst temperature and causes an i ncrease i n HC emi s-
si ons. Severe mi sfi res coul d cause catal yst damage.
To prevent catal yti c convertor damage, the PCM
moni tors engi ne mi sfi re.
The Powertrai n Control Modul e (PCM) moni tors
for mi sfi re duri ng most engi ne operati ng condi ti ons
(posi ti ve torque) by l ooki ng at changes i n the crank-
shaft speed. I f a mi sfi re occurs the speed of the
crankshaft wi l l vary more than normal .
FUEL SYSTEM MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the Ai r Fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S sensor output. The programmed
memory acts as a sel f cal i brati on tool that the engi ne
control l er uses to compensate for vari ati ons i n engi ne
speci fi cati ons, sensor tol erances and engi ne fati gue
over the l i fe span of the engi ne. By moni tori ng the
actual fuel -ai r rati o wi th the O2S sensor (short term)
and mul ti pl yi ng that wi th the program l ong-term
(adapti ve) memory and compari ng that to the l i mi t,
i t can be determi ned whether i t wi l l pass an emi s-
si ons test. I f a mal functi on occurs such that the PCM
cannot mai ntai n the opti mum A/F rati o, then the
MI L wi l l be i l l umi nated.
CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. A mel tdown of the cerami c core can
cause a reducti on of the exhaust passage. Thi s can
i ncrease vehi cl e emi ssi ons and deteri orate engi ne
performance, dri veabi l i ty and fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2S’s) to moni tor the effi ci ency of the converter. The
dual O2S’s sensor strategy i s based on the fact that
as a catal yst deteri orates, i ts oxygen storage capaci ty
and i ts effi ci ency are both reduced. By moni tori ng
the oxygen storage capaci ty of a catal yst, i ts effi -
ci ency can be i ndi rectl y cal cul ated. The upstream
O2S i s used to detect the amount of oxygen i n the
exhaust gas before the gas enters the catal yti c con-
verter. The PCM cal cul ates the A/F mi xture from the
output of the O2S. A l ow vol tage i ndi cates hi gh oxy-
gen content (l ean mi xture). A hi gh vol tage i ndi cates a
l ow content of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstream O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2S’s.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2S’s i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L wi l l be i l l u-
mi nated.
TRIP DEFINITION
OPERATION
The term “Tri p” has di fferent meani ngs dependi ng
on what the ci rcumstances are. I f the MI L (Mal func-
ti on I ndi cator Lamp) i s OFF, a Tri p i s defi ned as
when the Oxygen Sensor Moni tor and the Catal yst
Moni tor have been compl eted i n the same dri ve cycl e.
When any Emi ssi on DTC i s set, the MI L on the
dash i s turned ON. When the MI L i s ON, i t takes 3
good tri ps to turn the MI L OFF. I n thi s case, i t
depends on what type of DTC i s set to know what a
“Tri p” i s.
For the Fuel Moni tor or Mi s-Fi re Moni tor (conti n-
uous moni tor), the vehi cl e must be operated i n the
“Si mi l ar Condi ti on Wi ndow” for a speci fi ed amount of
ti me to be consi dered a Good Tri p.
I f a Non-Conti uous OBDI I Moni tor, such as:
• Oxygen Sensor
• Catal yst Moni tor
• Purge Fl ow Moni tor
• Leak Detecti on Pump Moni tor (i f equi pped)
• EGR Moni tor (i f equi pped)
TJ EMISSION CONTROL SYSTEMS 25 - 21
DESCRIPTION AND OPERATION (Continued)
• Oxygen Sensor Heater Moni tor
fai l s twi ce i n a row and turns ON the MI L, re-run-
ni ng that moni tor whi ch previ ousl y fai l ed, on the
next start-up and passi ng the moni tor i s consi dered
to be a Good Tri p.
I f any other Emi ssi on DTC i s set (not an OBDI I
Moni tor), a Good Tri p i s consi dered to be when the
Oxygen Sensor Moni tor and Catal yst Moni tor have
been compl eted; or 2 Mi nutes of engi ne run ti me i f
the Oxygen Sensor Moni tor or Catal yst Moni tor have
been stopped from runni ng.
I t can take up to 2 Fai l ures i n a row to turn on the
MI L. After the MI L i s ON, i t takes 3 Good Tri ps to
turn the MI L OFF. After the MI L i s OFF, the PCM
wi l l sel f-erase the DTC after 40 Warm-up cycl es. A
Warm-up cycl e i s counted when the ECT (Engi ne
Cool ant Temperature Sensor) has crossed 160°F and
has ri sen by at l east 40°F si nce the engi ne has been
started.
COMPONENT MONITORS
OPERATION
There are several components that wi l l affect vehi -
cl e emi ssi ons i f they mal functi on. I f one of these com-
ponents mal functi ons the Mal functi on I ndi cator
Lamp (MI L) wi l l i l l umi nate.
Some of the component moni tors are checki ng for
proper operati on of the part. El ectri cal l y operated
components now have i nput (rati onal i ty) and output
(functi onal i ty) checks. Previ ousl y, a component l i ke
the Throttl e Posi ti on sensor (TPS) was checked by
the PCM for an open or shorted ci rcui t. I f one of
these condi ti ons occurred, a DTC was set. Now there
i s a check to ensure that the component i s worki ng.
Thi s i s done by watchi ng for a TPS i ndi cati on of a
greater or l esser throttl e openi ng than MAP and
engi ne rpm i ndi cate. I n the case of the TPS, i f engi ne
vacuum i s hi gh and engi ne rpm i s 1600 or greater
and the TPS i ndi cates a l arge throttl e openi ng, a
DTC wi l l be set. The same appl i es to l ow vacuum i f
the TPS i ndi cates a smal l throttl e openi ng.
Al l open/short ci rcui t checks or any component that
has an associ ated l i mp i n wi l l set a faul t after 1 tri p
wi th the mal functi on present. Components wi thout
an associ ated l i mp i n wi l l take two tri ps to i l l umi -
nate the MI L.
Refer to the Di agnosti c Troubl e Codes Descri pti on
Charts i n thi s secti on and the appropri ate Power-
trai n Di agnosti c Procedure Manual for di agnosti c
procedures.
NON-MONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems and condi ti ons that coul d have mal functi ons
causi ng dri veabi l i ty probl ems. The PCM mi ght not
store di agnosti c troubl e codes for these condi ti ons.
However, probl ems wi th these systems may cause the
PCM to store di agnosti c troubl e codes for other sys-
tems or components. For exampl e, a fuel pressure
probl em wi l l not regi ster a faul t di rectl y, but coul d
cause a ri ch/l ean condi ti on or mi sfi re. Thi s coul d
cause the PCM to store an oxygen sensor or mi sfi re
di agnosti c troubl e code
OPERATION
FUEL PRESSURE
The fuel pressure regul ator control s fuel system
pressure. The PCM cannot detect a cl ogged fuel
pump i nl et fi l ter, cl ogged i n-l i ne fuel fi l ter, or a
pi nched fuel suppl y or return l i ne. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng the
PCM to store an oxygen sensor or fuel system di ag-
nosti c troubl e code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an i noperati ve i gni ti on coi l ,
foul ed or worn spark pl ugs, i gni ti on cross fi ri ng, or
open spark pl ug cabl es.
CYLINDER COMPRESSION
The PCM cannot detect uneven, l ow, or hi gh engi ne
cyl i nder compressi on.
EXHAUST SYSTEM
The PCM cannot detect a pl ugged, restri cted or
l eaki ng exhaust system, al though i t may set a fuel
system faul t.
FUEL INJECTOR MECHANICAL MALFUNCTIONS
The PCM cannot determi ne i f a fuel i njector i s
cl ogged, the needl e i s sti cki ng or i f the wrong i njector
i s i nstal l ed. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng the PCM to store a di agnosti c
troubl e code for ei ther mi sfi re, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Al though the PCM moni tors engi ne exhaust oxygen
content when the system i s i n cl osed l oop, i t cannot
determi ne excessi ve oi l consumpti on.
THROTTLE BODY AIR FLOW
The PCM cannot detect a cl ogged or restri cted ai r
cl eaner i nl et or fi l ter el ement.
VACUUM ASSIST
The PCM cannot detect l eaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces. However, these coul d cause the PCM
to store a MAP sensor di agnosti c troubl e code and
cause a hi gh i dl e condi ti on.
25 - 22 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
PCM SYSTEM GROUND
The PCM cannot determi ne a poor system ground.
However, one or more di agnosti c troubl e codes may
be generated as a resul t of thi s condi ti on. The mod-
ul e shoul d be mounted to the body at al l ti mes, al so
duri ng di agnosti c.
PCM CONNECTOR ENGAGEMENT
The PCM may not be abl e to determi ne spread or
damaged connector pi ns. However, i t mi ght store
di agnosti c troubl e codes as a resul t of spread connec-
tor pi ns.
HIGH AND LOW LIMITS
OPERATION
The PCM compares i nput si gnal vol tages from each
i nput devi ce wi th establ i shed hi gh and l ow l i mi ts for
the devi ce. I f the i nput vol tage i s not wi thi n l i mi ts
and other cri teri a are met, the PCM stores a di agnos-
ti c troubl e code i n memory. Other di agnosti c troubl e
code cri teri a mi ght i ncl ude engi ne RPM l i mi ts or
i nput vol tages from other sensors or swi tches that
must be present before veri fyi ng a di agnosti c troubl e
code condi ti on.
LOAD VALUE
OPERATION
ENGINE IDLE/NEUTRAL 2500 RPM/
NEUTRAL
All Engines 2% to 8% of
Maximum Load
9% to 17% of
Maximum Load
TJ EMISSION CONTROL SYSTEMS 25 - 23
DESCRIPTION AND OPERATION (Continued)
EVAPORATIVE EMISSION CONTROLS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM . . . . . . . . . . 24
ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . . . . 24
EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . 25
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LEAK DETECTION PUMP (LDP). . . . . . . . . . . . . . 25
CRANKCASE VENTILATION SYSTEM . . . . . . . . . 26
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING
VACUUM SCHEMATICS. . . . . . . . . . . . . . . . . . . . 28
LEAK DETECTION PUMP (LDP). . . . . . . . . . . . . . 28
CRANKCASE VENTILATION SYSTEM . . . . . . . . . 28
REMOVAL AND INSTALLATION
EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . 28
EVAP CANISTER PURGE SOLENOID . . . . . . . . . 29
ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . . . . 29
LEAK DETECTION PUMP (LDP). . . . . . . . . . . . . . 29
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM
OPERATION
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When
fuel evaporates i n the fuel tank, the vapors pass
through vent hoses or tubes to a charcoal fi l l ed evap-
orati ve cani ster. The cani ster temporari l y hol ds the
vapors. The Powertrai n Control Modul e (PCM) al l ows
i ntake mani fol d vacuum to draw vapors i nto the com-
busti on chambers duri ng certai n operati ng condi -
ti ons.
Al l engi nes use a duty cycl e purge system. The
PCM control s vapor fl ow by operati ng the duty cycl e
EVAP purge sol enoi d. Refer to Duty Cycl e EVAP
Cani ster Purge Sol enoi d.
When equi pped wi th certai n emi ssi ons packages, a
Leak Detecti on Pump (LDP) wi l l be used as part of
the evaporati ve system for OBD I I requi rements.
Al so refer to Leak Detecti on Pump.
NOTE: The evaporative system uses specially man-
ufactured lines/hoses. If replacement becomes nec-
essary, only use fuel resistant hose.
ROLLOVER VALVE
DESCRIPTION
The fuel tank i s equi pped wi th 2 rol l over val ves.
The val ves are l ocated on the top of the fuel tank
(Fi g. 1).
OPERATION
The rol l over val ves wi l l prevent fuel fl ow through
the fuel tank vent (EVAP) hoses i n the event of an
acci dental vehi cl e rol l over. The EVAP cani ster draws
fuel vapors from the fuel tank through these val ves.
The val ves are not servi ceabl e. I f repl acement i s
necessary, the fuel tank must be repl aced.
Fig. 1 Rollover Valve Location
1 – FUEL PUMP MODULE
2 – FUEL SUPPLY TUBE
3 – RETAINER CLAMP
4 – FUEL FILTER/FUEL PRESSURE REGULATOR
5 – LOCKNUT
6 – ROLLOVER VALVE
7 – TOP OF FUEL TANK
8 – ELECTRICAL CONNECTOR
9 – ROLLOVER VALVE
25 - 24 EMISSION CONTROL SYSTEMS TJ
EVAP CANISTER
DESCRIPTION
The evaporati ve (EVAP) cani ster i s l ocated i n the
engi ne compartment on the l eft i nner fender (Fi g. 2).
OPERATION
A mai ntenance free, EVAP cani ster i s used on al l
vehi cl es. The EVAP cani ster i s fi l l ed wi th granul es of
an acti vated carbon mi xture. Fuel vapors enteri ng
the EVAP cani ster are absorbed by the charcoal gran-
ul es.
Fuel tank pressure vents i nto the EVAP cani ster.
Fuel vapors are temporari l y hel d i n the cani ster unti l
they can be drawn i nto the i ntake mani fol d. The duty
cycl e EVAP cani ster purge sol enoi d al l ows the EVAP
cani ster to be purged at predetermi ned ti mes and at
certai n engi ne operati ng condi ti ons.
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID
OPERATION
The duty cycl e EVAP cani ster purge sol enoi d (DCP)
regul ates the rate of vapor fl ow from the EVAP can-
i ster to the i ntake mani fol d. The Powertrai n Control
Modul e (PCM) operates the sol enoi d.
Duri ng the col d start warm-up peri od and the hot
start ti me del ay, the PCM does not energi ze the sol e-
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The engi ne enters cl osed l oop operati on after i t
reaches a speci fi ed temperature and the ti me del ay
ends. Duri ng cl osed l oop operati on, the PCM cycl es
(energi zes and de-energi zes) the sol enoi d 5 or 10
ti mes per second, dependi ng upon operati ng condi -
ti ons. The PCM vari es the vapor fl ow rate by chang-
i ng sol enoi d pul se wi dth. Pul se wi dth i s the amount
of ti me that the sol enoi d i s energi zed. The PCM
adjusts sol enoi d pul se wi dth based on engi ne operat-
i ng condi ti on.
LEAK DETECTION PUMP (LDP)
OPERATION
The Leak Detecti on Pump (LDP) i s used onl y wi th
certai n emi ssi on packages.
The LDP i s a devi ce used to detect a l eak i n the
evaporati ve system.
The pump contai ns a 3 port sol enoi d, a pump that
contai ns a swi tch, a spri ng l oaded cani ster vent val ve
seal , 2 check val ves and a spri ng/di aphragm.
I mmedi atel y after a col d start, engi ne temperature
between 40°F and 86°F, the 3 port sol enoi d i s bri efl y
energi zed. Thi s i ni ti al i zes the pump by drawi ng ai r
i nto the pump cavi ty and al so cl oses the vent seal .
Duri ng non-test test condi ti ons, the vent seal i s hel d
open by the pump di aphragm assembl y whi ch pushes
i t open at the ful l travel posi ti on. The vent seal wi l l
remai n cl osed whi l e the pump i s cycl i ng. Thi s i s due
to the operati on of the 3 port sol enoi d whi ch prevents
the di aphragm assembl y from reachi ng ful l travel .
After the bri ef i ni ti al i zati on peri od, the sol enoi d i s
de-energi zed, al l owi ng atmospheri c pressure to enter
the pump cavi ty. Thi s permi ts the spri ng to dri ve the
di aphragm whi ch forces ai r out of the pump cavi ty
and i nto the vent system. When the sol enoi d i s ener-
gi zed and de-energi zed, the cycl e i s repeated creati ng
fl ow i n typi cal di aphragm pump fashi on. The pump
i s control l ed i n 2 modes:
PUMP MODE: The pump i s cycl ed at a fi xed rate
to achi eve a rapi d pressure bui l d i n order to shorten
the overal l test ti me.
TEST MODE: The sol enoi d i s energi zed wi th a
fi xed durati on pul se. Subsequent fi xed pul ses occur
when the di aphragm reaches the swi tch cl osure
poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5 i nches
of water.
When the pump starts, the cycl e rate i s qui te hi gh.
As the system becomes pressuri zed pump rate drops.
Fig. 2 EVAP Canister, EVAP Canister Purge Solenoid
and LDP Location
1 – EVAP CANISTER
2 – LEAK DETECTION PUMP (LDP) FILTER
3 – EVAP SYSTEM TEST PORT
4 – LDP
5 – LDP ELECTRICAL CONNECTOR
6 – EVAP SOLENOID ELEC. CONNECTOR
7 – EVAP CANISTER PURGE SOLENOID
TJ EMISSION CONTROL SYSTEMS 25 - 25
DESCRIPTION AND OPERATION (Continued)
I f there i s no l eak the pump wi l l qui t. I f there i s a
l eak, the test i s termi nated at the end of the test
mode.
I f there i s no l eak, the purge moni tor i s run. I f the
cycl e rate i ncreases due to the fl ow through the
purge system, the test i s passed and the di agnosti c i s
compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
A typi cal system schemati c i s shown i n (Fi g. 3).
CRANKCASE VENTILATION SYSTEM
DESCRIPTION
Al l 2.5L 4–cyl i nder and 4.0L 6–cyl i nder engi nes
are equi pped wi th a Cl osed Crankcase Venti l ati on
(CCV) system (Fi g. 4) or (Fi g. 5).
OPERATION
The Cl osed Crankcase Venti l ati on (CCV) system
performs the same functi on as a conventi onal PCV
system, but does not use a vacuum control l ed val ve.
On 4.0L 6–cyl i nder engi nes, a mol ded vacuum tube
connects mani fol d vacuum to top of cyl i nder head
(val ve) cover at dash panel end. The vacuum fi tti ng
contai ns a fi xed ori fi ce of a cal i brated si ze. I t meters
the amount of crankcase vapors drawn out of the
engi ne.
On 2.5L 4–cyl i nder engi nes, a fi tti ng on dri vers
si de of cyl i nder head (val ve) cover contai ns the
metered ori fi ce. I t i s connected to mani fol d vacuum.
A fresh ai r suppl y CCV tube (hose) from the ai r
cl eaner i s connected to front of cyl i nder head cover
on 4.0L engi nes. I t i s connected to rear of cover on
2.5L engi nes.
Fig. 3 Evaporative System Monitor Schematic—Typical
1 – DUTY CYCLE PURGE SOLENOID (DCPS) DRIVER
2 – POWERTRAIN CONTROL MODULE (PCM)
3 – 3-PORT SOLENOID DRIVER
4 – REMOTE FILTER
5 – COMBINED CANISTER VENT VALVE & LEAK DETECTION
PUMP
6 – CANISTER
7 – TANK ROLLOVER VALVE & VAPOR FLOW CONTROL
ORIFICE
8 – INTAKE MANIFOLD
9 – THROTTLE BODY
10 – DCPS
11 – SWITCH SIGNAL INPUT TO THE PCM
12 – ENGINE VACUUM LINE
25 - 26 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
When the engi ne i s operati ng, fresh ai r enters the
engi ne and mi xes wi th crankcase vapors. Mani fol d
vacuum draws the vapor/ai r mi xture through the
fi xed ori fi ce and i nto the i ntake mani fol d. The vapors
are then consumed duri ng combusti on.
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
DESCRIPTION
Al l vehi cl es are equi pped wi th a combi ned VECI
l abel . Thi s l abel i s l ocated i n the engi ne compart-
ment (Fi g. 6).
OPERATION
The VECI l abel contai ns the fol l owi ng:
• Engi ne fami l y and di spl acement
• Evaporati ve fami l y
• Emi ssi on control system schemati c
• Certi fi cati on appl i cati on
• Engi ne ti mi ng speci fi cati ons (i f adjustabl e)
• I dl e speeds (i f adjustabl e)
• Spark pl ug and gap
The l abel al so contai ns an engi ne vacuum sche-
mati c. There are uni que l abel s for vehi cl es bui l t for
sal e i n the state of Cal i forni a and the country of
Canada. Canadi an l abel s are wri tten i n both the
Engl i sh and French l anguages. These l abel s are per-
manentl y attached and cannot be removed wi thout
defaci ng i nformati on and destroyi ng l abel .
Fig. 4 CCV System—2.5L Engine
1 – AIR TUBE
2 – CCV TUBE
3 – AIR INLET FITTING
4 – CCV TUBE
5 – FIXED ORIFICE FITTING
Fig. 5 CCV System—4.0L Engine
1 – AIR TUBE
2 – FIXED ORIFICE FITTING
3 – CCV TUBE
4 – AIR INLET FITTING
5 – CCV TUBE
Fig. 6 VECI Label Location
1 – VECI LABEL
TJ EMISSION CONTROL SYSTEMS 25 - 27
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
VACUUM SCHEMATICS
A vacuum schemati c for emi ssi on rel ated i tems can
be found on the Vehi cl e Emi ssi on Control I nforma-
ti on (VECI ) l abel . For l abel l ocati on, refer to Vehi cl e
Emi ssi on Control I nformati on (VECI ) Label .
LEAK DETECTION PUMP (LDP)
Refer to the appropri ate Powertrai n Di agnosti c
Procedures servi ce manual for LDP testi ng proce-
dures.
CRANKCASE VENTILATION SYSTEM
TESTING/CLEANING
The Crankcase Venti l ati on (CCV) system performs
the same functi on as a conventi onal PCV system, but
does not use a vacuum control l ed val ve. A vacuum
fi tti ng contai ni ng a fi xed ori fi ce of a cal i brated si ze i s
used. I t meters the amount of crankcase vapors
drawn out of the engi ne.
(1) Check each CCV system tube (l i ne) for l eaks,
cracks, ki nks or bends. Repl ace as necessary
(2) Di sconnect each CCV tube..
(3) Bl ow compressed ai r through each tube and
check for bl ockage or restri cti ons. I f cl eani ng i s nec-
essary, spray a soapy-type al l -purpose cl eaner i nto
each component and bl ow out. After restri cti on i s
cl eared, ri nse out component wi th cl ear water. Bl ow
water from component and i nstal l to vehi cl e. To pre-
vent damage to plastic components, never
spray carburetor-type cleaner into any of the
plastic tubes or the fixed orifice fitting. Never
attempt to clean the fixed orifice fitting with a
metal object as calibration could be affected. If
fixed fitting cannot be cleared, replace it.
REMOVAL AND INSTALLATION
EVAP CANISTER
The EVAP cani ster i s mounted to a bracket, l ocated
i n the engi ne compartment, on the l eft front i nner
fender (Fi g. 7).
REMOVAL
(1) Di sconnect vacuum l i nes/hoses at EVAP cani s-
ter. Note l ocati on of l i nes/hoses before removal .
(2) Remove cani ster mounti ng bol t (Fi g. 8).
(3) Di sengage cani ster from vehi cl e by sl i ppi ng 2
cani ster dowel pi ns from rubber mounti ng bracket
bushi ngs.
Fig. 7 EVAP Canister, Purge Solenoid and LDP
Location
1 – EVAP CANISTER
2 – LEAK DETECTION PUMP (LDP) FILTER
3 – EVAP SYSTEM TEST PORT
4 – LDP
5 – LDP ELECTRICAL CONNECTOR
6 – EVAP SOLENOID ELEC. CONNECTOR
7 – EVAP CANISTER PURGE SOLENOID
Fig. 8 EVAP Canister Removal/Installation
1 – EVAP CANISTER
2 – MOUNTING BRACKET
3 – L. F. FENDER
4 – MOUNTING BOLT
25 - 28 EMISSION CONTROL SYSTEMS TJ
INSTALLATION
(1) Posi ti on cani ster dowel pi ns i nto rubber bush-
i ngs.
(2) I nstal l cani ster mounti ng bol t.
(3) Ti ghten bol t to 9 N·m (80 i n. l bs.) torque.
(4) Connect vacuum l i nes/hoses at EVAP cani ster.
EVAP CANISTER PURGE SOLENOID
REMOVAL
The duty cycl e EVAP cani ster purge sol enoi d i s
l ocated i n the engi ne compartment on the EVAP can-
i ster mounti ng bracket (Fi g. 7).
(1) Di sconnect el ectri cal wi ri ng connector at sol e-
noi d.
(2) Di sconnect vacuum l i nes/hoses at sol enoi d.
(3) Li ft sol enoi d and rubber sol enoi d support from
mounti ng bracket.
INSTALLATION
(1) I nstal l purge sol enoi d and rubber support to i ts
mounti ng bracket.
(2) Connect vacuum harness and wi ri ng connector.
ROLLOVER VALVE
The fuel tank i s equi pped wi th 2 rol l over val ves.
The val ves are l ocated on the top of the fuel tank
(Fi g. 9).
The val ves are not servi ceabl e. I f repl acement i s
necessary, the fuel tank must be repl aced. Refer to
the Fuel Tank secti on of Group 14, Fuel Systems for
removal and i nstal l ati on procedures.
LEAK DETECTION PUMP (LDP)
The LDP i s l ocated i n the engi ne compartment
near the EVAP cani ster (Fi g. 7). The LDP fi l ter i s
al so l ocated near the EVAP cani ster (Fi g. 7). The
LDP and LDP fi l ter are repl aced (servi ced) as one
uni t.
REMOVAL
(1) Careful l y remove vapor/vacuum l i nes at LDP.
(2) Di sconnect el ectri cal connector at LDP.
(3) Remove LDP fi l ter mounti ng bol t.
(4) Remove 3 LDP mounti ng screws (Fi g. 10) and
remove from vehi cl e.
(5) Careful l y separate hose at bottom of LDP fi l ter.
INSTALLATION
(1) I nstal l LDP connecti ng hose to LDP and fi l ter.
(2) Posi ti on LDP and LDP fi l ter (as an assembl y)
to vehi cl e.
(3) I nstal l LDP fi l ter to mounti ng bracket. Ti ghten
bol t to 7 N·m (65 i n. l bs.) torque.
Fig. 9 Rollover Valve Location
1 – FUEL PUMP MODULE
2 – FUEL SUPPLY TUBE
3 – RETAINER CLAMP
4 – FUEL FILTER/FUEL PRESSURE REGULATOR
5 – LOCKNUT
6 – ROLLOVER VALVE
7 – TOP OF FUEL TANK
8 – ELECTRICAL CONNECTOR
9 – ROLLOVER VALVE
Fig. 10 Leak Detection Pump (LDP) Mounting
Screws
1 – LEAK DETECTION PUMP (LDP)
2 – MOUNTING SCREWS
TJ EMISSION CONTROL SYSTEMS 25 - 29
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l LDP to mounti ng bracket. Ti ghten
screws to 1 N·m (11 i n. l bs.) torque.
(5) Careful l y i nstal l vapor/vacuum l i nes to LDP.
The vapor/vacuum lines and hoses must be
firmly connected. Check the vapor/vacuum
lines at the LDP, LDP filter and EVAP canister
purge solenoid for damage or leaks. If a leak is
present, a Diagnostic Trouble Code (DTC) may
be set.
(6) Connect el ectri cal connector to LDP.
SPECIFICATIONS
TORQUE CHART
Description Torque
EVAP Cani ster Mounti ng Bol t . . 9 N·m (80 i n. l bs.)
Leak Detecti on Pump (LDP) Fi l ter
Mounti ng Bol ts . . . . . . . . . . . . 7 N·m (65 i n. l bs.)
Leak Detecti on Pump (LDP) Mounti ng
Screws . . . . . . . . . . . . . . . . . . 1 N·m (11 i n. l bs.)
25 - 30 EMISSION CONTROL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
EMISSION CONTROL SYSTEMS
TABLE OF CONTENTS
page page
ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . 1 EVAPORATIVE EMISSION CONTROLS . . . . . . . . . . 8
ON-BOARD DIAGNOSTICS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . 1
MALFUNCTION INDICATOR LAMP (MIL) . . . . . . . . 1
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . 2
MONITORED SYSTEMS . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION
EMISSION CONTROL SYSTEM
DESCRIPTION
The Powertrai n Control Modul e (PCM) moni tors
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a
probl em wi th a moni tored ci rcui t often enough to
i ndi cate an actual probl em, i t stores a Di agnosti c
Troubl e Code (DTC) i n the PCM’s memory. I f the
code appl i es to a non-emi ssi ons rel ated component or
system, and the probl em i s repai red or ceases to
exi st, the PCM cancel s the code after 40 warm-up
cycl es. Di agnosti c troubl e codes that affect vehi cl e
emi ssi ons i l l umi nate the Mal functi on I ndi cator
(check engi ne) Lamp. Refer to Mal functi on I ndi cator
Lamp i n thi s secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored
ci rcui t even though a mal functi on has occurred. Thi s
may happen because one of the DTC cri teri a for the
ci rcui t has not been met. For example, assume the
di agnosti c troubl e code cri teri a requi res the PCM to
moni tor the ci rcui t onl y when the engi ne operates
between 750 and 2000 RPM. Suppose the sensor’s
output ci rcui t shorts to ground when engi ne operates
above 2400 RPM (resul ti ng i n 0 vol t i nput to the
PCM). Because the condi ti on happens at an engi ne
speed above the maxi mum threshol d (2000 rpm), the
PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTC’s. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
Techni ci ans must retri eve stored DTC’s by connect-
i ng the DRB scan tool (or an equi val ent scan tool ) to
the 16–way data l i nk connector (Fi g. 1). Refer to
Di agnosti c Troubl e Codes i n thi s secti on.
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, connect the DRB scan
tool to the 16–way data link connector to erase all
DTC’s and extinguish the MIL (check engine lamp).
MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION
As a functi onal test, the MI L (check engi ne) i l l umi -
nates at key-on before engi ne cranki ng. Whenever
the Powertrai n Control Modul e (PCM) sets a Di ag-
nosti c Troubl e Code (DTC) that affects vehi cl e emi s-
si ons, i t i l l umi nates the MI L. I f a probl em i s
detected, the PCM sends a message to the i nstru-
ment cl uster to i l l umi nate the l amp. The PCM i l l u-
mi nates the MI L onl y for DTC’s that affect vehi cl e
emi ssi ons. There are some moni tors that may take
two consecuti ve tri ps, wi th a detected faul t, before
TJ EMISSION CONTROL SYSTEMS 25 - 1
2000 JEEP WRANGLER
the MI L i s i l l umi nated. The MI L stays on conti nu-
ousl y when the PCM has entered a Li mp-I n mode or
i denti fi ed a fai l ed emi ssi on component. Refer to the
Di agnosti c Troubl e Code charts i n thi s group for
emi ssi on rel ated codes.
Addi ti onal l y, the PCM may reset (turn off) the MI L
when one of the fol l owi ng occur:
• PCM does not detect the mal functi on for 3 con-
secuti ve tri ps (except mi sfi re and Fuel system Moni -
tors).
• PCM does not detect a mal functi on whi l e per-
formi ng three successi ve engi ne mi sfi re or fuel sys-
tem tests. The PCM performs these tests whi l e the
engi ne i s operati ng wi thi n Ϯ 375 RPM of and wi thi n
10 % of the l oad of the operati ng condi ti on at whi ch
the mal functi on was fi rst detected.
DIAGNOSTIC TROUBLE CODES
DESCRIPTION
A Di agnosti c Troubl e Code (DTC) i ndi cates the
PCM has recogni zed an abnormal condi ti on i n the
system.
Diagnostic trouble codes are the results of a
system or circuit failure, but do not directly
identify the failed component or components.
Techni ci ans must retri eve stored DTC’s by connect-
i ng the DRB scan tool (or an equi val ent scan tool ) to
the 16–way data l i nk connector.
NOTE: For a list of DTC’s, refer to the charts in this
section.
OBTAINING DIAGNOSTIC TROUBLE CODES
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
ON AN OPERATING ENGINE.
(1) Connect the DRB scan tool to data l i nk (di ag-
nosti c) connector.
(2) Turn the i gni ti on swi tch on, access Read Faul t
Screen. Record al l the DTC’s shown on the DRB scan
tool .
(3) To erase DTC’s, use the Erase Troubl e Code
data screen on the DRB scan tool .
Fig. 1 Data Link (Diagnostic) Connector Location
1 – 16–WAY DATA LINK CONNECTOR
25 - 2 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
*Check Engi ne Lamp (MI L)wi l l i l l umi nate duri ng engi ne operati on i f thi s Di agnosti c Troubl e Code was recorded.
Hex Code
Generic
Scan Tool
Code
DRB Scan Tool Display Description of Diagnostic Trouble Code
*01
P0340 No Cam Signal at PCM
No camshaft signal detected during engine
cranking.
*02
P0601
Internal Controller
Failure
PCM Internal fault condition detected.
05
Charging System
Voltage Too Low
Battery voltage sense input below target charging
during engine operation. Also, no significant
change detected in battery voltage during active
test of generator output circuit.
06 Charging System
Voltage Too High
Battery voltage sense input above target charging
voltage during engine operation.
0A Auto Shutdown Relay
Control Circuit
An open or shorted condition detected in the auto
shutdown relay circuit.
0B Generator Field Not
Switching Properly
An open or shorted condition detected in the
generator field control circuit.
*0C
P0743
Torque Converter Clutch
Soleniod/Trans Relay
Circuit
An open or shorted condition detected in the
torque converter part throttle unlock solenoid
control circuit (3 speed auto RH trans. only).
0F Speed Control Solenoid
Circuits
An open or shorted condition detected in the
Speed Control vacuum or vent solenoid circuits.
10
A/C Clutch Relay Circuit
An open or shorted condition detected in the A/C
clutch relay circuit.
*12
P0443
EVAP Purge Solenoid
Circuit
An open or shorted condition detected in the duty
cycle purge solenoid circuit.
*13
P0203
Injector #3 Control
Circuit
Injector #3 output driver does not respond
properly to the control signal.
or
*14
P0202
Injector #2 Control
Circuit
Injector #2 output driver does not respond
properly to the control signal.
or
*15
P0201
Injector #1 Control
Circuit
Injector #1 output driver does not respond
properly to the control signal.
*19
P0505
Idle Air Control Motor
Circuits
A shorted or open condition detected in one or
more of the idle air control motor circuits.
*1A
P0122
Throttle Position Sensor
Voltage Low
Throttle position sensor input below the minimum
acceptable voltage
or
*1B
P0123
Throttle Position Sensor
Voltage High
Throttle position sensor input above the maximum
acceptable voltage.
*1E
P0117
ECT Sensor Voltage Too
Low
Engine coolant temperature sensor input below
minimum acceptable voltage.
or
TJ EMISSION CONTROL SYSTEMS 25 - 3
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
Hex Code
Generic
Scan Tool
Code
DRB Scan Tool Display Description of Diagnostic Trouble Code
*1F
P0118
ECT Sensor Voltage Too
High
Engine coolant temperature sensor input above
maximum acceptable voltage.
*23
P0500
No Vehicle Speed
Sensor Signal
No vehicle speed sensor signal detected during
road load conditions.
*24
P0107
MAP Sensor Voltage Too
Low
MAP sensor input below minimum acceptable
voltage.
or
*25
P0108
MAP Sensor Voltage Too
High
MAP sensor input above maximum acceptable
voltage.
*27
P1297
No Change in MAP
From Start to Run
No difference recognized between the engine
MAP reading and the barometric (atmospheric)
pressure reading from start-up.
28
P0320
No Crank Reference
Signal at PCM
No crank reference signal detected during engine
cranking.
2B
P0351
Ignition Coil #1 Primary
Circuit
Peak primary circuit current not achieved with
maximum dwell time.
2C
P1389
No ASD Relay Output
Voltage at PCM
An Open condition Detected In The ASD Relay
Output Circuit.
31
P1696
PCM Failure EEPROM
Write Denied
Unsuccessful attempt to write to an EEPROM
location by the PCM.
*39
P0112
Intake Air Temp Sensor
Voltage Low
Intake air temperature sensor input below the
maximum acceptable voltage.
*3A
P0113
Intake Air Temp Sensor
Voltage High
Intake air temperature sensor input above the
minimum acceptable voltage.
*3D
P0204
Injector #4 Control
Circuit
Injector #4 output driver does not respond
properly to the control signal.
*3E
P0132
1/1 O2 Sensor Shorted
to Voltage
Left oxygen sensor input voltage maintained
above the normal operating range.
44
P0600
PCM Failure SPI
Communications
PCM Internal fault condition detected.
*45
P0205
Injector #5 Control
Circuit
Injector #5 output driver does not respond
properly to the control signal.
or
*46
P0206
Injector #6 Control
Circuit
Injector #6 output driver does not respond
properly to the control signal.
52 Speed Control Power
Relay or Speed Control
12V Driver Circuit
Malfunction detected with power feed to speed
control servo solenoids.
57 Speed Control Switch
Always Low
Speed control switch input below the minimum
acceptable voltage.
60 P1698 No CCD/PCI message from TCM
65 Fuel Pump Relay
Control Circuit
An open or shorted condition detected in the fuel
pump relay control circuit.
*72
P1899
Park/Neutral Switch
Stuck In Park or In Gear
Incorrect input state detected for the Park/Neutral
switch, auto. trans. only.
25 - 4 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
Hex Code
Generic
Scan Tool
Code
DRB Scan Tool Display Description of Diagnostic Trouble Code
*73
P0551
Power Steering Switch
Failure
Power steering high pressure seen at high speed.
*76
P0172
Fuel System Rich 1/1
Rich
A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
*77
P0171
Fuel System Lean 1/1
Lean
A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
*7E
P0138
1/2 O2 Sensor Shorted
to Voltage
Downstream oxygen sensor input voltage
maintained above the normal operating range.
*80
P0125
Closed Loop Temp Not
Reached
Engine does not reach 20°F within 5 minutes with
a vehicle speed signal.
*84
P0121
TPS Voltage Does Not
Agree With MAP
TPS signal does not correlate to MAP sensor
89 P0700 Aisin AW4 transmission DTC present
94
P0740
Torq Conv Clu, No RPM
Drop At Lockup
Relationship between engine speed and vehicle
speed indicates no torque converter clutch
engagement (auto. trans. only).
95 Fuel Level Sending Unit
Volts Too Low
Open circuit between PCM and fuel gauge
sending unit.
or
96 Fuel Level Sending Unit
Volts Too High
Circuit shorted to voltage between PCM and fuel
gauge sending unit.
*99
P1493
Battery Temp Sensor
Voltage Too Low
Battery temperature sensor input voltage below
an acceptable range.
or
*9A
P1492
Battery Temp Sensor
Voltage Too High
Battery temperature sensor input voltage above
an acceptable range.
*9B
P0131
Upstream O2s Voltage
Shorted to Ground
O2 sensor voltage too low, tested after cold start.
or
*9C
P0137
Downstream O2s
Voltage Shorted to
Ground
O2 sensor voltage too low, tested after cold start.
*9D
P1391
Intermittent Loss of CMP
or CKP
Intermittent loss of either camshaft or crankshaft
position sensor
TJ EMISSION CONTROL SYSTEMS 25 - 5
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
MONITORED SYSTEMS
DESCRIPTION
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator (Check
Engi ne) Lamp wi l l be i l l umi nated. These moni tors
generate Di agnosti c Troubl e Codes that can be di s-
pl ayed wi th the check engi ne l amp or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
• Fuel System Moni tor
• Oxygen Sensor Moni tor
• Oxygen Sensor Heater Moni tor
• Catal yst Moni tor
Al l these system moni tors requi re two consecuti ve
tri ps wi th the mal functi on present to set a faul t.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
The fol l owi ng i s an operati on and descri pti on of
each system moni tor :
OXYGEN SENSOR (O2S) MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300° to 350°C (572° to 662°F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
Catal yst and Fuel Moni tors.
The O2S can fai l i n any or al l of the fol l owi ng
manners:
• sl ow response rate
• reduced output vol tage
• dynami c shi ft
• shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
OXYGEN SENSOR HEATER MONITOR
I f there i s an oxygen sensor (O2S) shorted to vol t-
age DTC, as wel l as a O2S heater DTC, the O2S
faul t MUST be repai red fi rst. Before checki ng the
O2S faul t, veri fy that the heater ci rcui t i s operati ng
correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300° to 350°C (572 ° to 662°F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S sensor
are very temperature sensi ti ve. The readi ngs are not
accurate bel ow 300°C. Heati ng of the O2S sensor i s
done to al l ow the engi ne control l er to shi ft to cl osed
l oop control as soon as possi bl e. The heati ng el ement
used to heat the O2S sensor must be tested to ensure
that i t i s heati ng the sensor properl y.
The O2S sensor ci rcui t i s moni tored for a drop i n
vol tage. The sensor output i s used to test the heater
by i sol ati ng the effect of the heater el ement on the
O2S sensor output vol tage from the other effects.
FUEL SYSTEM MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the Ai r Fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S sensor output. The programmed
memory acts as a sel f cal i brati on tool that the engi ne
25 - 6 EMISSION CONTROL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
control l er uses to compensate for vari ati ons i n engi ne
speci fi cati ons, sensor tol erances and engi ne fati gue
over the l i fe span of the engi ne. By moni tori ng the
actual fuel -ai r rati o wi th the O2S sensor (short term)
and mul ti pl yi ng that wi th the program l ong-term
(adapti ve) memory and compari ng that to the l i mi t,
i t can be determi ned whether i t wi l l pass an emi s-
si ons test. I f a mal functi on occurs such that the PCM
cannot mai ntai n the opti mum A/F rati o, then the
MI L wi l l be i l l umi nated.
CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. A mel tdown of the cerami c core can
cause a reducti on of the exhaust passage. Thi s can
i ncrease vehi cl e emi ssi ons and deteri orate engi ne
performance, dri veabi l i ty and fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2S’s) to moni tor the effi ci ency of the converter. The
dual O2S’s sensor strategy i s based on the fact that
as a catal yst deteri orates, i ts oxygen storage capaci ty
and i ts effi ci ency are both reduced. By moni tori ng
the oxygen storage capaci ty of a catal yst, i ts effi -
ci ency can be i ndi rectl y cal cul ated. The upstream
O2S i s used to detect the amount of oxygen i n the
exhaust gas before the gas enters the catal yti c con-
verter. The PCM cal cul ates the A/F mi xture from the
output of the O2S. A l ow vol tage i ndi cates hi gh oxy-
gen content (l ean mi xture). A hi gh vol tage i ndi cates a
l ow content of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstream O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2S’s.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2S’s i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L (check
engi ne l amp) wi l l be i l l umi nated.
TJ EMISSION CONTROL SYSTEMS 25 - 7
DESCRIPTION AND OPERATION (Continued)
2000 JEEP WRANGLER
EVAPORATIVE EMISSION CONTROLS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM . . . . . . . . . . . 8
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL . . . . . . . . . . . . . . . 8
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM
DESCRIPTION
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When
fuel evaporates i n the fuel tank, the vapors pass
through vent hoses or tubes to a charcoal fi l l ed evap-
orati ve cani ster. The cani ster temporari l y hol ds the
vapors. The Powertrai n Control Modul e (PCM) al l ows
i ntake mani fol d vacuum to draw vapors i nto the com-
busti on chambers duri ng certai n operati ng condi -
ti ons.
Al l engi nes use a duty cycl e purge system. The
PCM control s vapor fl ow by operati ng the duty cycl e
EVAP purge sol enoi d. Refer to Duty Cycl e EVAP
Cani ster Purge Sol enoi d i n thi s secti on.
When equi pped wi th certai n emi ssi ons packages, a
Leak Detecti on Pump (LDP) wi l l be used as part of
the evaporati ve system. Thi s pump i s used as part of
OBD I I requi rements. Refer to Leak Detecti on Pump
i n thi s group for addi ti onal i nformati on.
NOTE: The evaporative system uses specially man-
ufactured hoses. If replacement becomes neces-
sary, only use fuel resistant hose.
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
DESCRIPTION
Al l vehi cl es are equi pped wi th a combi ned VECI
l abel . Thi s l abel i s l ocated i n the engi ne compart-
ment (Fi g. 1) and contai ns the fol l owi ng:
• Engi ne fami l y and di spl acement
• Evaporati ve fami l y
• Emi ssi on control system schemati c
• Certi fi cati on appl i cati on
• Engi ne ti mi ng speci fi cati ons (i f adjustabl e)
• I dl e speeds (i f adjustabl e)
• Spark pl ug and gap
The l abel al so contai ns an engi ne vacuum sche-
mati c. There are uni que l abel s for vehi cl es bui l t for
sal e i n the state of Cal i forni a and the country of
Canada. Canadi an l abel s are wri tten i n both the
Engl i sh and French l anguages. These l abel s are per-
manentl y attached and cannot be removed wi thout
defaci ng i nformati on and destroyi ng l abel .
Fig. 1 VECI Label Location
1 – VECI LABEL
25 - 8 EMISSION CONTROL SYSTEMS TJ
2000 JEEP WRANGLER
SERVICE MANUAL COMMENTS
What features do you find most useful? ______________________________________________
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What errors have you found? Please include page number. ___________________________
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What topics are hard to locate, confusing, or not covered completely? ________________
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What comments or suggestions do you have? ________________________________________
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______________________________________________________________________________________
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______________________________________________________________________________________
Your Name: _________________________ Dealership/Distributor: _________________________
Address: _____________________________________________________________________________
_____________________________________________________________________________
Vehicle Identification Number _________________________________________________________
Manual Name, Year, Language and Number: __________________________________________
All comments become property of DaimlerChrysler International and may be used without compensation.
DaimlerChrysler International Operations
Attn. Publications Dept.
CIMS 486-02-70
800 Chrysler Drive
Auburn Hills, MI 48326-2757
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