Escolar Documentos
Profissional Documentos
Cultura Documentos
Introduction
2 Suspension
5 Brakes
7 Cooling
8A Audio
8B Chime/Buzzer
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Systems
8N Power Systems
8O Restraints
8P Speed Control
8R Wipers/Washers
8W Wiring
9 Engine
11 Exhaust System
14 Fuel System
19 Steering
22 Tires/Wheels
23 Body
25 Emissions Control
INTRODUCTION
TABLE OF CONTENTS
page page
FASTENER IDENTIFICATION
WJ INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)
FASTENER STRENGTH
4 INTRODUCTION WJ
INTERNATIONAL SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
WJ INTRODUCTION 5
TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
cations Chart for torque references not listed in the
individual torque charts.
8 INTRODUCTION WJ
TORQUE REFERENCES (Continued)
TORQUE SPECIFICATIONS
WJ INTRODUCTION 9
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
DESCRIPTION
A vehicle safety certification label (Fig. 3) is
attached to every Chrysler Corporation vehicle. The
label certifies that the vehicle conforms to all appli-
cable Federal Motor Vehicle Safety Standards. The
label also lists:
Month and year of vehicle manufacture.
Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWRs) are
based on a minimum rim size and maximum cold tire
inflation pressure.
Vehicle Identification Number (VIN).
Type of vehicle.
Type of rear wheels. Fig. 3 Vehicle Safety Certification Label
Bar code.
Month, Day and Hour (MDH) of final assembly.
Paint and Trim codes.
WJ LUBRICATION & MAINTENANCE 0-1
page page
PROPYLENE-GLYCOL MIXTURES
Its overall effective temperature range is smaller
than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32 deg. C (-26 deg. F).
5 deg. C higher than ethylene-glycols freeze point.
The boiling point (protection against summer boil-
over) of propylene-glycol is 125 deg. C (257 deg. F )
at 96.5 kPa (14 psi), compared to 128 deg. C (263
deg. F) for ethylene-glycol. Use of propylene-glycol
can result in boil-over or freeze-up on a cooling sys-
tem designed for ethylene-glycol. Propylene glycol
also has poorer heat transfer characteristics than Fig. 3 Temperature/Engine Oil Viscosity
ethylene glycol. This can increase cylinder head tem-
peratures under certain conditions. ENERGY CONSERVING OIL
Propylene-glycol/ethylene-glycol Mixtures can An Energy Conserving type oil is recommended for
cause the destabilization of various corrosion inhibi- gasoline engines. The designation of ENERGY CON-
tors, causing damage to the various cooling system SERVING is located on the label of an engine oil con-
tainer.
WJ LUBRICATION & MAINTENANCE 0-3
FLUID TYPES (Continued)
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 4).
DESCRIPTION
API SERVICE GRADE CERTIFIED A multi-purpose, hypoid gear lubricant which con-
Use an engine oil that is API Service Grade Certi- forms to the following specifications should be used.
fied. MOPARt provides engine oils that conform to Mopar Hypoid Gear Lubricant conforms to all of
this service grade. these specifications.
SPECIFICATIONS
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
FUEL REQUIREMENTS
Mopart ATF Plus 4, Type 9602, automatic trans- Your engine is designed to meet all emissions reg-
mission fluid is the recommended fluid for Daimler- ulations and provide excellent fuel economy and per-
Chrysler automatic transmissions. formance when using high quality unleaded regular
Dexron II fluid IS NOT recommended. Clutch gasoline having an octane rating of 87. The routine
chatter can result from the use of improper use of premium gasoline is not recommended. Under
fluid. normal conditions the use of premium fuel will not
Mopart ATF Plus 4, Type 9602, automatic trans- provide a benefit over high quality regular gasolines
mission fluid when new is red in color. The ATF is and in some circumstances may result in poorer per-
dyed red so it can be identified from other fluids used formance.
in the vehicle such as engine oil or antifreeze. The Light spark knock at low engine speeds is not
red color is not permanent and is not an indicator of harmful to your engine. However, continued heavy
fluid condition. As the vehicle is driven, the ATF will spark knock at high speeds can cause damage and
begin to look darker in color and may eventually immediate service is required. Engine damage result-
become brown. This is normal. A dark brown/black ing from operation with a heavy spark knock may
fluid accompanied with a burnt odor and/or deterio- not be covered by the new vehicle warranty.
ration in shift quality may indicate fluid deteriora- Poor quality gasoline can cause problems such as
tion or transmission component failure. hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
FLUID ADDITIVES before considering service for the vehicle.
DaimlerChrysler strongly recommends against the Over 40 auto manufacturers world-wide have
addition of any fluids to the transmission, other than issued and endorsed consistent gasoline specifications
those automatic transmission fluids listed above. (the Worldwide Fuel Charter, WWFC) to define fuel
Exceptions to this policy are the use of special dyes properties necessary to deliver enhanced emissions,
to aid in detecting fluid leaks. performance and durability for your vehicle. We rec-
Various special additives and supplements exist ommend the use of gasolines that meet the WWFC
that claim to improve shift feel and/or quality. These specifications if they are available.
additives and others also claim to improve converter
WJ LUBRICATION & MAINTENANCE 0-5
SPECIFICATIONS (Continued)
REFORMULATED GASOLINE affect the performance of the vehicles catalytic con-
Many areas of the country require the use of verter. This may cause the Malfunction Indicator
cleaner burning gasoline referred to as reformulat- Lamp (MIL), Check Engine or Service Engine Soon
ed gasoline. Reformulated gasoline contain oxygen- light to illuminate. We recommend that you try a dif-
ates, and are specifically blended to reduce vehicle ferent brand of unleaded gasoline having lower sulfur
emissions and improve air quality. to determine if the problem is fuel related prior to
We strongly support the use of reformulated gaso- returning your vehicle to an authorized dealer for
line. Properly blended reformulated gasoline will pro- service.
vide excellent performance and durability for the
engine and fuel system components. CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
GASOLINE/OXYGENATE BLENDS ing, immediate service is required; see on-board
Some fuel suppliers blend unleaded gasoline with diagnostics system section.
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
MATERIALS ADDED TO FUEL
during the winter months to reduce carbon monoxide
All gasoline sold in the United States and Canada
emissions. Fuels blended with these oxygenates may
are required to contain effective detergent additives.
be used in your vehicle.
Use of additional detergents or other additives is not
CAUTION: DO NOT use gasoline containing METH- needed under normal conditions.
ANOL. Gasoline containing methanol may damage
critical fuel system components. FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
MMT IN GASOLINE vehicles performance:
MMT is a manganese-containing metallic additive
The use of leaded gas is prohibited by Federal
that is blended into some gasoline to increase octane.
law. Using leaded gasoline can impair engine perfor-
Gasoline blended with MMT provide no performance
mance, damage the emission control system, and
advantage beyond gasoline of the same octane num-
could result in loss of warranty coverage.
ber without MMT. Gasoline blended with MMT
An out-of-tune engine, or certain fuel or ignition
reduce spark plug life and reduce emission system
malfunctions, can cause the catalytic converter to
performance in some vehicles. We recommend that
overheat. If you notice a pungent burning odor or
gasolines free of MMT be used in your vehicle. The
some light smoke, your engine may be out of tune or
MMT content of gasoline may not be indicated on the
malfunctioning and may require immediate service.
gasoline pump; therefore, you should ask your gaso-
Contact your dealer for service assistance.
line retailer whether or not his/her gasoline contains
When pulling a heavy load or driving a fully
MMT.
loaded vehicle when the humidity is low and the tem-
It is even more important to look for gasoline with-
perature is high, use a premium unleaded fuel to
out MMT in Canada because MMT can be used at
help prevent spark knock. If spark knock persists,
levels higher than allowed in the United States.
lighten the load, or engine piston damage may result.
MMT is prohibited in Federal and California refor-
The use of fuel additives which are now being
mulated gasoline.
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
SULFUR IN GASOLINE
methanol. Fuel system damage or vehicle perfor-
If you live in the northeast United States, your
mance problems resulting from the use of such fuels
vehicle may have been designed to meet California
or additives is not the responsibility of Daimler-
low emission standards with Cleaner-Burning Cali-
Chrysler Corporation and may not be covered under
fornia reformulated gasoline with low sulfur. If such
the new vehicle warranty.
fuels are not available in states adopting California
emission standards, your vehicles will operate satis- NOTE: Intentional tampering with emissions control
factorily on fuels meeting federal specifications, but systems can result in civil penalties being assessed
emission control system performance may be against you.
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
0-6 LUBRICATION & MAINTENANCE WJ
FLUID CAPACITIES
SPECIFICATIONS
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 20 U.S. Gallons (76
Liters)****
Engine Oil - with Filter - 5.7L (6.0 qts.)
4.0L
Engine Oil - with Filter - 5.7L (6.0 qts.)
4.7L
Cooling System - 4.0L 14.1L (15 qts.)*** Fig. 7 Fill/Drain Plug
Cooling System - 4.7L 13.7L (14.5 qts.)*** 1 - I.D. TAG
Power Steering 2 - FILL PLUG
3 - DRAIN PLUG
AUTOMATIC TRANSMISSION
Service Fill - 42RE 3.8L (4.0 qts)
O-haul Fill - 42RE 9.1-9.5L (19-20 pts) INSPECTION
The fluid fill/check locations and lubrication points
O-haul Fill - 45RFE 13.33L (28.0 pts.) are located in each applicable group.
TRANSFER CASE
NV242 1.35L (2.85 pts.)
MAINTENANCE SCHEDULES
NV247 1.6L (3.4 pts.)
FRONT AXLE DESCRIPTION
Model 186 FBI 1.18L (2.5 pts.) There are two maintenance schedules that show
* When equipped with Vari-Lok, include 0.07L (0.15 proper service for the Grand Cherokee.
pts.) of Friction Modifier. First is Schedule A. It lists all the scheduled
maintenance to be performed under normal operat-
REAR AXLE ing conditions.
Model 194 RBI 1.66L (3.5 pts.)* Second is ScheduleB . It is a schedule for vehi-
Model 226 RBA 2.24L (4.75 pts.)** cles that are operated under the following conditions:
Frequent short trip driving less than 5 miles (8
* When equipped with Trac-lok, include 2.5 ounces of
km)
Friction Modifier.
Frequent driving in dusty conditions
** When equipped with Trac-lok or Vari-Lok, include Extensive idling
2.5 ounces of Friction Modifier. Trailer towing
*** Includes 0.9L (1.0 qts.) for coolant reservoir. Sustained high speed operation
****Nominal refill capacities are shown. A variation Off road driving
may be observed from vehicle to vehicle due to Desert operation
manufacturing tolerance and refill procedure. Frequent starting and stopping
Cold climate operation
Commercial service
FLUID FILL/CHECK Use the schedule that best describes the driving
conditions.
LOCATIONS Where time and mileage are listed, follow the
interval that occurs first.
DESCRIPTION - TRANSFER CASE
The fill and drain plugs are both in the rear case EMISSION CONTROL SYSTEM MAINTENANCE
(Fig. 7). Correct fill level is to the bottom edge of the The scheduled emission maintenance listed in bold
fill plug hole. Be sure the vehicle is level to ensure typeon the Maintenance Schedules, must be done at
an accurate fluid level check. the mileage specified to assure the continued proper
WJ LUBRICATION & MAINTENANCE 0-7
MAINTENANCE SCHEDULES (Continued)
functioning of the emission control system. These, 22,500 Miles (36 000 km) or at 18 months
and all other maintenance services included in this Change engine oil.
manual, should be done to provide the best vehicle Replace engine oil filter.
performance and reliability. More frequent mainte- Inspect engine coolant level, hoses, clamps.
nance may be needed for vehicles in severe operating Inspect brake linings.
conditions such as dusty areas and very short trip Clean and lubricate brake caliper pins.
driving. Inspect brake hoses.
Inspect exhaust system.
UNSCHEDULED INSPECTION
30,000 Miles (48 000 km) or at 24 months
AT EACH STOP FOR FUEL Change engine oil.
Check engine oil level, add as required. Replace engine oil filter.
Check windshield washer solvent and add if Replace engine air cleaner element.
required. Replace spark plugs.
Drain and refill transfer case fluid.
ONCE A MONTH Lubricate upper knuckle ball stud.
Check tire pressure (including spare) and look Inspect engine coolant level, hoses, clamps.
for unusual wear or damage. Inspect brake hoses.
Inspect battery and clean and tighten terminals Inspect exhaust system.
as required.
Check fluid levels of coolant reservoir, power 37,500 Miles (60 000 km) or at 30 months
steering and transmission and add as needed. Change engine oil.
Replace engine oil filter.
AT EACH OIL CHANGE Inspect engine coolant level, hoses, clamps.
Inspect exhaust system. Inspect brake hoses.
Inspect brake hoses. Inspect exhaust system.
Rotate the tires at each oil change interval
shown on ScheduleA (7,500 miles) or every other 45,000 Miles (72 000 km) or at 36 months
interval shown on ScheduleB (6,000 miles). Change engine oil.
Check coolant level, hoses and clamps. Replace engine oil filter.
Lubricate suspension ball joints. Inspect engine coolant level, hoses, clamps.
After completion of off-road (4WD) operation, the Inspect brake hoses.
underside of the vehicle should be thoroughly Inspect brake linings.
inspected. Examine threaded fasteners for looseness. Clean and lubricate brake caliper pins.
Flush and replace engine coolant at 36 months
MAINTENANCE SCHEDULES or 52,500 Miles (84 000 km).
Lubricate upper knuckle ball stud.
SCHEDULEA Inspect exhaust system.
NOTE: Where both time and mileage are indicated, 52,500 Miles (84 000 km) or at 42 months
follow the interval which occurs first. Change engine oil.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps.
7,500 miles (12 000 km) or at 6 months Inspect brake hoses.
Change engine oil. Inspect exhaust system.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. 60,000 Miles (96 000 km) or at 48 months
Inspect brake hoses. Change engine oil.
Inspect exhaust system. Replace engine oil filter.
Inspect engine coolant level, hoses, clamps.
15,000 Miles (24 000 km) or at 12 months Replace engine air cleaner element.
Change engine oil. Replace spark plugs.
Replace engine oil filter. Inspect PCV valve and replace if necessary
Inspect engine coolant level, hoses, clamps. (4.7L only).*
Inspect brake hoses. Inspect brake hoses.
Inspect exhaust system.
Lubricate upper knuckle ball stud.
0-8 LUBRICATION & MAINTENANCE WJ
MAINTENANCE SCHEDULES (Continued)
Inspect and replace drive belt if necessary 97,500 Miles (156 000 km) or at 78 months
(4.0L). Change engine oil.
Drain and replace brake fluid. Replace engine oil filter.
Drain and refill transfer case fluid. Inspect engine coolant level, hoses, clamps.
Lubricate upper knuckle ball stud. Inspect brake hoses.
Inspect exhaust system. Inspect exhaust system.
67,500 Miles (108 000 km) or at 54 months 100,000 Miles (160 000 km)
Change engine oil. Drain and refill automatic transmission fluid
Replace engine oil filter. and change filter (except 45RFE & 545RFE applica-
Inspect engine coolant level, hoses, clamps. tions).
Inspect brake linings Adjust bands (except 45RFE & 545RFE applica-
Inspect brake hoses. tions).
Clean and lubricate brake caliper pins. Drain and refill automatic transmission fluid
Inspect exhaust system. and change main sump filter in 45RFE & 545RFE
applications.
75,000 Miles (120 000 km) or at 60 months Change spin-on cooler return filter in 45RFE &
Change engine oil. 545RFE appications.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. 105,000 Miles (168 000 km) or at 84 months
Flush and replace engine coolant if it has been Change engine oil.
30,000 miles (48 000 km) or 24 months since last Replace engine oil filter.
change. Inspect engine coolant level, hoses, clamps.
Inspect and replace drive belt if necessary Flush and replace engine coolant if it has been
(4.0L).** 30,000 miles (48 000 km) or 24 months since last
Inspect brake hoses. change.
Inspect exhaust system. Inspect and replace drive belt (4.0L and
Lubricate upper knuckle ball stud. 4.7L ).**
Inspect brake hoses.
82,500 Miles (132 000 km) or at 66 months Lubricate upper knuckle ball stud.
Change engine oil. Inspect exhaust system.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. 112,500 Miles (180 000 km) or at 90 months
Flush and replace engine coolant if it has been Change engine oil.
30,000 miles (48 000 km) or 24 months since last Replace engine oil filter.
change. Inspect engine coolant level, hoses, clamps.
Inspect brake hoses. Flush and replace engine coolant if it has been
Inspect exhaust system. 30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months Inspect brake hoses.
Change engine oil. Inspect brake linings.
Replace engine oil filter. Clean and lubricate brake caliper pins.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Replace engine air cleaner element.
Replace spark plugs. 120,000 Miles (192 000 km) or at 96 months
Inspect PCV valve and replace if necessary Change engine oil.
(4.7L only).* Replace engine oil filter.
Inspect and replace drive (4.0L and 4.7L).** Inspect engine coolant level, hoses, clamps.
Drain and refill transfer case fluid. Replace engine air cleaner element.
Inspect brake hoses. Replace spark plugs.
Inspect brake linings. Inspect PCV valve and replace if necessary
Clean and lubricate brake caliper pins. (4.7L only).*
Lubricate upper knuckle ball stud. Inspect and replace drive belt (4.0L and 4.7L).**
Inspect exhaust system. Inspect brake hoses.
Drain and replace brake fluid.
Drain and refill transfer case fluid.
WJ LUBRICATION & MAINTENANCE 0-9
MAINTENANCE SCHEDULES (Continued)
Lubricate upper knuckle ball stud. Inspect brake hoses.
Inspect exhaust system. Inspect exhaust system.
NOTE: Inspection and service should also be per- 18,000 Miles (29 000 km)
formed anytime a malfunction is observed or sus- Change engine oil.
pected. Replace engine oil filter.
Inspect engine coolant level, hoses, clamps.
*This maintenance is recommended, but is not Inspect brake hoses.
required to maintain warranty on the PCV valve. Inspect exhaust system.
**This maintenance is not required if the belt was Lubricate upper knuckle ball stud.
previously replaced.
21,000 Miles (34 000 km)
SCHEDULEB Change engine oil.
Replace engine oil filter.
NOTE: Where both time and mileage are indicated,
Inspect engine coolant level, hoses, clamps.
follow the interval which occurs first.
Inspect brake hoses.
Inspect exhaust system.
3,000 Miles (5 000 km)
24,000 Miles (38 000 km)
Change engine oil.
Replace engine oil filter. Change engine oil.
Inspect engine coolant level, hoses, clamps. Replace engine oil filter.
Inspect brake hoses. Inspect engine coolant level, hoses, clamps.
Inspect exhaust system. Drain and refill front and rear axles.
Inspect brake linings.
6,000 Miles (10 000 km) Clean and lubricate brake caliper pins.
Change engine oil. Inspect brake hoses.
Replace engine oil filter. Lubricate upper knuckle ball stud.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Inspect brake hoses.
27,000 Miles (43 000 km)
Lubricate upper knuckle ball stud.
Change engine oil.
Inspect exhaust system.
Replace engine oil filter.
9,000 Miles (14 000 km) Inspect engine coolant level, hoses, clamps.
Change engine oil. Inspect brake hoses.
Replace engine oil filter. Inspect exhaust system.
Inspect engine coolant level, hoses, clamps.
30,000 Miles (48 000 km)
Inspect brake hoses.
Change engine oil.
Inspect exhaust system.
Replace engine oil filter.
12,000 Miles (19 000 km) Inspect engine coolant level, hoses, clamps.
Change engine oil. Replace engine air cleaner element.
Replace engine oil filter. Replace spark plugs.
Inspect engine coolant level, hoses, clamps. Inspect PCV valve and replace if necessary
Drain and refill front and rear axles. (4.7L only).*
Inspect brake linings. Inspect brake hoses.
Clean and lubricate brake caliper pins. Drain and refill automatic transmission fluid
Inspect brake hoses. and change filter (except 45RFE & 545RFE applica-
Lubricate upper knuckle ball stud. tions).
Inspect exhaust system. Adjust bands (except 45RFE & 545RFE applica-
tions).
15,000 miles (24 000 km) Drain and refill automatic transmission fluid
Change engine oil. and change main sump filter in 45RFE & 545RFE
Replace engine oil filter. applications.
Inspect engine coolant level, hoses, clamps. Drain and refill transfer case fluid.
Inspect engine air cleaner element, replace Lubricate upper knuckle ball stud.
as necessary. Inspect exhaust system.
0 - 10 LUBRICATION & MAINTENANCE WJ
MAINTENANCE SCHEDULES (Continued)
33,000 Miles (53 000 km) 51,000 Miles (82 000 km)
Change engine oil. Change engine oil.
Replace engine oil filter. Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. Inspect engine coolant level, hoses, clamps.
Inspect brake hoses. Flush and replace engine coolant.
Inspect exhaust system. Inspect brake hoses.
Inspect exhaust system.
36,000 Miles (58 000 km)
Change engine oil. 54,000 Miles (86 000 km)
Replace engine oil filter. Change engine oil.
Inspect engine coolant level, hoses, clamps. Replace engine oil filter.
Drain and refill front and rear axles. Inspect engine coolant level, hoses, clamps.
Inspect brake linings. Inspect brake hoses.
Clean and lubricate brake caliper pins. Lubricate upper knuckle ball stud.
Inspect brake hoses. Inspect exhaust system.
Lubricate upper knuckle ball stud.
Inspect exhaust system. 57,000 Miles (91 000 km)
Change engine oil.
39,000 Miles (62 000 km) Replace engine oil filter.
Change engine oil. Inspect engine coolant level, hoses, clamps.
Replace engine oil filter. Inspect brake hoses.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Inspect brake hoses.
Inspect exhaust system. 60,000 Miles (96 000 km)
Change engine oil.
42,000 Miles (67 000 km) Replace engine oil filter.
Change engine oil. Inspect engine coolant level, hoses, clamps.
Replace engine oil filter. Replace engine air cleaner element.
Inspect engine coolant level, hoses, clamps. Inspect PCV valve and replace if necessary
Inspect brake hoses. (4.7L only).*
Lubricate upper knuckle ball stud. Replace spark plugs.
Inspect exhaust system. Inspect and replace drive belt (4.0L only).**
Drain and refill automatic transmission fluid
45,000 Miles (72 000 km) and change filter (except 45RFE & 545RFE applica-
Change engine oil. tions).
Replace engine oil filter. Adjust bands (except 45RFE & 545RFE applica-
Inspect engine coolant level, hoses, clamps. tions).
Inspect and replace drive belt if necessary (4.0L Drain and refill automatic transmission fluid
only). and change main sump filter in 45RFE & 545RFE
Inspect engine air cleaner element, replace applications.
as necessary. Drain and refill transfer case fluid.
Inspect brake hoses. Drain and refill front and rear axles.
Inspect exhaust system. Inspect brake hoses.
Inspect brake linings.
48,000 Miles (77 000 km) Drain and replace brake fluid.
Change engine oil. Clean and lubricate brake caliper pins.
Replace engine oil filter. Lubricate upper knuckle ball stud.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Drain and refill front and rear axles.
Inspect brake linings. 63,000 Miles (101 000 km)
Clean and lubricate brake caliper pins. Change engine oil.
Inspect brake hoses. Replace engine oil filter.
Lubricate upper knuckle ball stud. Inspect engine coolant level, hoses, clamps.
Inspect exhaust system. Inspect brake hoses.
Inspect exhaust system.
WJ LUBRICATION & MAINTENANCE 0 - 11
MAINTENANCE SCHEDULES (Continued)
66,000 Miles (106 000 km) Inspect brake linings.
Change engine oil. Clean and lubricate brake caliper pins.
Replace engine oil filter. Inspect brake hoses.
Inspect engine coolant level, hoses, clamps. Lubricate upper knuckle ball stud.
Inspect brake hoses. Inspect exhaust system.
Lubricate upper knuckle ball stud.
Inspect exhaust system. 87,000 Miles (139 000 km)
Change engine oil.
69,000 Miles (110 000 km) Replace engine oil filter.
Change engine oil. Inspect engine coolant level, hoses, clamps.
Replace engine oil filter. Inspect brake hoses.
Inspect engine coolant level, hoses, clamps. Inspect exhaust system.
Inspect brake hoses.
Inspect exhaust system. 90,000 Miles (144 000 km)
Change engine oil.
72,000 Miles (115 000 km) Replace engine oil filter.
Change engine oil. Inspect engine coolant level, hoses, clamps.
Replace engine oil filter. Replace engine air cleaner element.
Inspect engine coolant level, hoses, clamps. Replace spark plugs.
Drain and refill front and rear axles. Inspect PCV valve and replace if necessary
Inspect brake linings. (4.7L only).*
Clean and lubricate brake caliper pins. Inspect and replace drive (4.0L and 4.7L).**
Inspect brake hoses. Drain and refill automatic transmission fluid
Lubricate upper knuckle ball stud. and change filter (except 45RFE & 545RFE applica-
Inspect exhaust system. tions).
Adjust bands (except 45RFE & 545RFE applica-
75,000 Miles (120 000 km) tions).
Change engine oil. Drain and refill automatic transmission fluid
Replace engine oil filter. and change main sump filter in 45RFE & 545RFE
Inspect engine coolant level, hoses, clamps. applications.
Inspect and replace drive belt(4.0L and 4.7L).** Change spin-on cooler return filter in 45RFE &
Inspect engine air cleaner element, replace 545RFE appications.
as necessary. Inspect brake hoses.
Inspect brake hoses. Drain and refill transfer case fluid.
Inspect exhaust system. Lubricate upper knuckle ball stud.
Inspect exhaust system.
78,000 Miles (125 000 km)
Change engine oil. 93,000 Miles (149 000 km)
Replace engine oil filter. Change engine oil.
Inspect engine coolant level, hoses, clamps. Replace engine oil filter.
Inspect brake hoses. Inspect engine coolant level, hoses, clamps.
Lubricate upper knuckle ball stud. Inspect brake hoses.
Inspect exhaust system. Inspect exhaust system.
81,000 Miles (130 000 km) 96,000 Miles (154 000 km)
Change engine oil. Change engine oil.
Replace engine oil filter. Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. Inspect engine coolant level, hoses, clamps.
Flush and replace engine coolant. Drain and refill front and rear axles.
Inspect brake hoses. Inspect brake linings.
Inspect exhaust system. Clean and lubricate brake caliper pins.
Inspect brake hoses.
84,000 miles (134 000 km) Lubricate upper knuckle ball stud.
Change engine oil. Inspect exhaust system.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps.
Drain and refill front and rear axles.
0 - 12 LUBRICATION & MAINTENANCE WJ
MAINTENANCE SCHEDULES (Continued)
99,000 Miles (158 000 km) Inspect exhaust system.
Change engine oil.
Replace engine oil filter. 120,000 Miles (192 000 km)
Inspect engine coolant level, hoses, clamps. Change engine oil.
Inspect brake hoses. Replace engine oil filter.
Inspect exhaust system. Inspect engine coolant level, hoses, clamps.
Replace engine air cleaner element.
102,000 Miles (163 000 km) Inspect PCV valve and replace if necessary
Change engine oil. (4.7L only).*
Replace engine oil filter. Replace spark plugs.
Inspect engine coolant level, hoses, clamps. Inspect and replace drive belt (4.0L and 4.7L).**
Inspect brake hoses. Drain and refill automatic transmission fluid
Lubricate upper knuckle ball stud. and change filter (except 45RFE & 545RFE applica-
Inspect exhaust system. tions).
Adjust bands (except 45RFE & 545RFE applica-
105,000 Miles (168 000 km) tions).
Change engine oil. Drain and refill automatic transmission fluid
Replace engine oil filter. and change main sump filter in 45RFE & 545RFE
Inspect engine coolant level, hoses, clamps. applications.
Inspect engine air cleaner element, replace Drain and refill transfer case fluid.
as necessary. Drain and refill front and rear axles.
Inspect and replace drive belt (4.0L and 4.7L).** Inspect brake hoses.
Inspect brake hoses. Inspect brake linings.
Inspect exhaust system. Drain and replace brake fluid.
Clean and lubricate brake caliper pins.
108,000 Miles (173 000 km) Lubricate upper knuckle ball stud.
Change engine oil. Inspect exhaust system.
Replace engine oil filter.
Inspect engine coolant level, hoses, clamps. NOTE: Inspection and service should also be per-
Drain and refill front and rear axles. formed anytime a malfunction is observed or sus-
Inspect brake linings. pected.
Clean and lubricate brake caliper pins.
Inspect brake hoses. *This maintenance is recommended, but is not
Lubricate upper knuckle ball stud. required to maintain warranty on the PCV valve.
Inspect exhaust system. **This maintenance is not required if the belt was
previously replaced.
111,000 Miles (178 000 km)
Change engine oil.
Replace engine oil filter.
LIFT POINTS
Inspect engine coolant level, hoses, clamps.
Flush and replace engine coolant. STANDARD PROCEDURES - HOISTING AND
Inspect brake hoses. JACKING RECOMMENDATIONS
Inspect exhaust system.
FLOOR JACK
114,000 Miles (182 000 km) When properly positioned, a floor jack can be used
Change engine oil. to lift a WJ vehicle (Fig. 8). Support the vehicle in
Replace engine oil filter. the raised position with jack stands at the front and
Inspect engine coolant level, hoses, clamps. rear ends of the frame rails.
Inspect brake hoses.
Lubricate upper knuckle ball stud. CAUTION: Do not attempt to lift a vehicle with a
Inspect exhaust system. floor jack positioned under:
SUSPENSION
TABLE OF CONTENTS
page page
SUSPENSION INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2 STABILIZER BAR
SUSPENSION AND STEERING SYSTEM . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WHEEL ALIGNMENT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 4 TRACK BAR
CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TOE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FRONT SUSPENSION UPPER BALL JOINT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 6 UPPER CONTROL ARM
SERVICE WARNINGS AND PRECAUTIONS . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BUSHINGS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REAR SUSPENSION
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HUB / BEARING WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 17
JOUNCE BUMPER JOUNCE BUMPER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
KNUCKLE LOWER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LOWER BALL JOINT SHOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LOWER CONTROL ARM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPRING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SHOCK OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STABILIZER BAR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPRING OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-2 SUSPENSION WJ
SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION AND
STEERING SYSTEM
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
EXCESSIVE PLAY IN 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
STEERING
2. Loose or worn steering or 2. Tighten or replace components as
suspension components. necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
THRUST ANGLE is the angle of the rear axle STANDARD PROCEDURE - CASTER
relative to the centerline of the vehicle. Incorrect
Before each alignment reading the vehicle should
thrust angle can cause off-center steering and exces-
be jounced (rear first, then front). Grasp each
sive tire wear. This angle is not adjustable, damaged
bumper at the center and jounce the vehicle up and
component(s) must be replaced to correct the thrust
down three times. Always release the bumper in the
angle.
down position.
To obtain an accurate alignment, a 4 wheel align-
STANDARD PROCEDURE - CAMBER ment machine must be used and the equipment cali-
Before each alignment reading the vehicle should bration verified.
be jounced (rear first, then front). Grasp each The wheel caster angle is preset. This angle is not
bumper at the center and jounce the vehicle up and adjustable and cannot be altered.
down three times. Always release the bumper in the
down position. STANDARD PROCEDURE - TOE POSITION
To obtain an accurate alignment, a 4 wheel align-
Before each alignment reading the vehicle should
ment machine must be used and the equipment cali-
be jounced (rear first, then front). Grasp each
bration verified.
bumper at the center and jounce the vehicle up and
The wheel camber angle is preset. This angle is not
down three times. Always release the bumper in the
adjustable and cannot be altered.
down position.
WJ SUSPENSION 2-5
WHEEL ALIGNMENT (Continued)
To obtain an accurate alignment, a 4 wheel align- SPECIFICATIONS
ment machine must be used and the equipment cali-
bration verified. ALIGNMENT
NOTE: For an accurate wheel toe position adjust- NOTE: Specifications are in degrees.
ment the engine must be engine running.
(6) Verify alignment specifications, then turn the FRONT WHEELS - UP-COUNTRY SUSPENSION
engine off. SPECIFICATIONS
DESCRIPTION SPECIFICATION
PREFERRED CASTER CAMBER TOTAL
+ 6.5 0.37 TOE-IN
+ 0.20
RANGE + 5.7 to 0.75 to N/A
+ 7.2 + 0
MAX RT/LT 0.5 0.5 0.05
DIFFERENCE
REAR AXLE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Fig. 2 Steering Linkage
PREFERRED CASTER THRUST TOTAL
1 - DRAG LINK ADJUSTMENT SLEEVE
ANGLE TOE-IN
2 - TIE ROD ADJUSTMENT SLEEVE
RANGE 0 to 6 0.25 0 to
0.5 +0.5
STEERING WHEEL CENTERING
NOTE: The steering wheel can be centered without FRONT SUSPENSION
affecting the toe position.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
SPECIAL TOOLS
FRONT SUSPENSION
Remover C-4150A
Remover/Installer 6289
Spacer 8279
Reciever 6761
Installer 6752
Bolt, Special 7604
2-8 SUSPENSION WJ
BUSHINGS
REMOVAL
(1) Remove the upper suspension arm from axle.
(2) Position Spacer 8279 over the axle bushing on
a 4x2 vehicle and right side on a 4x4 vehicle.
(3) Place Receiver 7932-1 over flanged end of the
bushing. (Fig. 4).
(4) Place small end of Remover/Install 7932-2
against other side of the bushing.
(5) Install bolt 7604 through remover, bushing and
receiver.
(6) Install Long Nut 7603 and tighten nut too pull
bushing out of the axle bracket.
HUB / BEARING
DESCRIPTION
The bearing used on the front hub of this vehicle is
Fig. 4 Bushing Removal
the combined hub and bearing unit type assembly.
1 - RECEIVER This unit assembly combines the front wheel mount-
2 - AXLE BRACKET
ing hub (flange) and the front wheel bearing into a
3 - BOLT
one piece unit. The wheel mounting studs are the
4 - REMOVER/INSTALLER
5 - LONG NUT
only replaceable component of the hub/bearing
assembly.
OPERATION
The steering knuckle pivot between the upper and
lower ball joint. Steering linkage attached to the
knuckle allows the vehicle to be steered.
JOUNCE BUMPER
DESCRIPTION
They are mounted under the unibody rails to min-
imize transmission of noise to the passenger com-
partment.
OPERATION
The jounce bumpers are used to limit suspension
travel in compression.
Fig. 7 Steering Knuckle Removal/Installation
1 - AXLE YOKE
2 - UPPER BALL STUD
3 - LOWER BALL STUD
4 - STEERING KNUCKLE
2 - 10 SUSPENSION WJ
KNUCKLE (Continued)
Fig. 8 Lower
1 - SPECIAL TOOL 628912 5 - SPECIAL TOOL 62891
2 - SPECIAL TOOL 62894 6 - SPECIAL TOOL 62893
3 - SPECIAL TOOL 4212F
4 - SPECIAL TOOL 4212F
WJ SUSPENSION 2 - 11
LOWER CONTROL ARM (Continued)
REMOVAL
(1) Remove the nut, retainer and grommet from
the shock stud in the engine compartment (Fig. 10).
NOTE: The end of the arm with the oval bushing (2) Raise and support the front axle.
attaches to the axle bracket. (3) Remove the lower mounting nuts from the axle
bracket (Fig. 11). Remove the shock absorber.
(2) Install the axle bracket bolt and nut finger
tight.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
(4) Remove support and lower the vehicle.
(5) With the vehicle on the ground tighten the
frame bracket bolt to 156 Nm (115 ft. lbs.). Tighten
the axle bracket nut to 163 Nm (120 ft. lbs.).
(6) Check the alignment if new parts were
installed.
SHOCK
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle Fig. 11 Lower Shock Mounting
brackets. The standard shocks have conventional 1 - SHOCK ABSORBER
twin tube construction and are low pressure gas 2 - MOUNTING NUTS
charged. Gas charging prevents cavitation during
rough road operation. Up-Country shocks are mono
tube design and are high pressure gas charged. INSTALLATION
(1) Position the lower retainer and grommet on the
OPERATION shock stud. Insert the shock absorber through the
The shock absorbers dampen jounce and rebound shock tower hole.
motion of the vehicle over various road conditions (2) Install the lower shock studs into the axle
and limit suspension rebound travel. bracket.
2 - 12 SUSPENSION WJ
SHOCK (Continued)
(3) Install the mounting nuts and tighten to 28
Nm (250 in. lbs.).
(4) Remove support and lower the vehicle.
(5) Install the upper grommet, retainer and nut on
the stud in the engine compartment. Hold the shock
stud with a 8 mm wrench and tighten the nut to 35
Nm (26 ft. lbs.).
SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert.
INSTALLATION
(1) Install the upper isolator.
(2) Install the lower isolator with the isolator loca-
tor nub in the axle pad hole (Fig. 13).
(3) Position the coil spring on the axle spring pad. Fig. 13 Lower Isolator
1 - LOCATING NUB
CAUTION: Ensure the spring is positioned on the 2 - LOWER ISOLATOR
lower isolator with the end of the spring coil 3 - AXLE SPRING PAD
against the isolator spring locator (Fig. 14). 4 - LOCATING HOLE
(4) Raise the axle and guide the springs onto the
(7) Install the track bar to the axle bracket and
spring upper mounts and lower shock studs into the
install the mounting bolt.
axle brackets.
(5) Install the shock absorbers lower mounting NOTE: It may be necessary to pry the axle assem-
nuts. bly over to install the track bar bolt.
(6) Install the stabilizer bar link to the axle
bracket and install the mounting bolts and nuts.
WJ SUSPENSION 2 - 13
SPRING (Continued)
(8) Tighten all suspension components to proper (2) Install the links onto the stabilizer bar and
torque. axle brackets and install the bolts and nuts finger
(9) Install the wheel and tire assemblies. tight.
(10) Remove support and lower vehicle. (3) Remove the supports and lower the vehicle.
(4) With the vehicle on the ground tighten the sta-
bilizer bar link nuts to 106 Nm (78 ft. lbs.).
STABILIZER BAR
DESCRIPTION TRACK BAR
The bar extends across the front underside of the
chassis and is mounted to the frame rails. Links are DESCRIPTION
connected from the bar to the axle brackets. The sta- The bar is attached to a frame rail bracket and
bilizer bar and links are isolated by rubber bushings. axle bracket. The bar is forged and has non replace-
able isolator bushings at both ends.
OPERATION
The stabilizer bar is used to control vehicle body OPERATION
roll during turns. The spring steel bar helps to con- The track bar is used to control front axle lateral
trol the vehicle body in relationship to the suspen- movement and provides cross car location of the axle
sion. assembly.
REMOVAL REMOVAL
(1) Raise and support the vehicle. (1) Raise and support the vehicle.
(2) Remove link nuts and bolts (Fig. 15) and (2) Remove the nut and bolt from the frame rail
remove the links. bracket (Fig. 16).
(3) Remove the stabilizer bar retainer bolts (Fig. (3) Remove the bolt from the axle shaft tube
15)from the frame rails and remove the stabilizer bracket (Fig. 17). Remove the track bar.
bar.
INSTALLATION
INSTALLATION (1) Install the track bar to the axle tube bracket.
(1) Position the stabilizer bar on the frame rail Install the retaining bolt finger tight.
and install the retainers and bolts. Ensure the bar is (2) Install track bar to the frame rail bracket.
centered with equal spacing on both sides. Tighten Install the bolt and nut finger tight.
the bolts to 92 Nm (68 ft. lbs.).
2 - 14 SUSPENSION WJ
TRACK BAR (Continued)
NOTE: It may be necessary to pry the axle assem- UPPER BALL JOINT
bly over to install the track bar to the frame rail
bracket. REMOVAL
Ball stud service procedures below require removal
(3) Remove the supports and lower the vehicle. of the hub bearing and axle shaft. Removal and
(4) With the vehicle on the ground tighten the nut installation of upper and lower ball studs require the
at the frame rail bracket and to the bolt at the axle use of Tool Kit 6289.
bracket to 100 Nm (74 ft. lbs.). (1) Position tools as shown to remove and install
(5) Check alignment specifications if a new track ball stud (Fig. 18).
bar was installed.
WJ SUSPENSION 2 - 15
UPPER BALL JOINT (Continued)
Fig. 18 Upper
OPERATION
The arms mount to the unibody frame rail bracket
and the axle brackets. The arm and bushings provide
location and react to loads from the axle. The bush-
ings provide isolation from the axle.
REMOVAL
(1) Raise vehicle and support the axle.
(2) Remove the upper suspension arm mounting Fig. 19 Upper Suspension Arm
nut and bolt (Fig. 19) from the axle bracket. 1 - UPPER SUSPENSION ARM
(3) Remove the nut and bolt (Fig. 19) at the frame 2 - FRAME BOLT
rail and remove the upper suspension arm. 3 - AXLE BOLT
INSTALLATION (4) With the vehicle on the ground tighten the axle
(1) Position the upper suspension arm at the axle bracket nut and the frame bracket bolt to 61 Nm (45
and frame rail. ft. lbs.).
(2) Install the bolts and finger tighten the nuts. (5) Check the alignment if new parts were
(3) Remove the supports and lower the vehicle. installed.
2 - 16 SUSPENSION WJ
REAR SUSPENSION
DESCRIPTION
The rear suspension (Fig. 20) is comprised of :
Drive axle
Shock absorbers
Coil springs
Lower suspension arms
Upper suspension arm
Stabilizer bar
IMPROPER TRACKING 1. Loose, worn or bent suspension 1. Inspect, tighten or replace components
components. as necessary.
2. Bent axle. 2.Replace axle.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
OPERATION
The jounce bumpers are used to limit suspension
travel in compression.
REMOVAL OPERATION
(1) Raise the vehicle and support the rear axle. The shock absorbers dampen jounce and rebound
(2) Remove the lower suspension arm nut and bolt motion of the vehicle over various road conditions
from the axle bracket (Fig. 21). and limit suspension rebound travel.
(3) Remove the nut and bolt (Fig. 21) from the
frame rail and remove the lower suspension arm. REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
(2) Remove the upper nut and bolt from the frame
bracket (Fig. 22).
(3) Remove the lower nut and bolt from the axle
bracket. Remove the shock absorber.
INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.
Fig. 22 Shock Absorber
NOTE: The end of the arm with the oval bushing
1 - SHOCK
attaches to the axle bracket.
SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert. The
isolators provide road noise isolation
OPERATION
The coil springs control ride quality and maintain
proper ride height.
REMOVAL
(1) Raise and support the vehicle. Position a
Fig. 24 Isolator Locator Nub
hydraulic jack under the axle to support the axle.
1 - LOWER ISOLATOR
(2) Remove the wheel and tire assemblies.
2 - LOCATOR NUB
(3) Remove the stabilizer bar link from the stabi-
3 - AXLE SPRING PAD
lizer bar (Fig. 23).
(4) Remove the shock absorber lower bolt from the
axle bracket. CAUTION: Ensure the spring is positioned on the
(5) Lower the hydraulic jack and tilt the axle and lower isolator with the end of the spring coil
remove the coil spring (Fig. 23). against the isolator spring locator (Fig. 25).
INSTALLATION
(1) Position the stabilizer bar on the axle and (4) Separate ball joint from the arm with Remover
install the retainers and bolts. Ensure the bar is cen- 8278 (Fig. 28).
tered with equal spacing on both sides. Tighten the
bolts to 54 Nm (40 ft. lbs.). NOTE: It may be necessary to strike the upper con-
(2) Install the links to the stabilizer bar and frame trol arm with a hammer to separate the ball joint
brackets. from the arm.
(3) Tighten the nuts at the stabilizer bar to 54
(5) Remove the ball joint mounting bolts (Fig.
Nm (40 ft. lbs.).
29)from the differential housing.
(4) Tighten the nuts at the frame brackets to 92
(6) Remove the ball joint from the differential
Nm (68 ft. lbs.).
housing.
(5) Remove support and lower the vehicle.
WJ SUSPENSION 2 - 21
UPPER BALL JOINT (Continued)
(2) Install the ball joint mounting bolts and
tighten to 136 Nm (100 ft. lbs.).
(3) Raise the rear axle with a hydraulic jack to
align the upper arm with the ball joint.
(4) Pull the arm down on the ball joint stud and
install a new nut. Tighten the nut to 142 Nm (105
ft. lbs.).
(5) Remove the supports and lower the vehicle.
OPERATION
The upper suspension arm provides fore/aft and
lateral location of the rear axle. The suspension arm
travel is limited through the use of jounce bumpers
Fig. 28 Separate Ball Joint
in compression and shock absorbers in rebound.
1 - REMOVER - 8278
2 - UPPER SUSPENSION ARM
3 - BALL JOINT STUD
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the park brake cables and brake hose
from the arm (Fig. 30).
(4) Remove the ball joint nut from the top of the
INSTALLATION upper suspension arm (Fig. 31).
(1) Install the ball joint on the differential hous- (5) Separate ball joint from the arm with Remover
ing. 8278 (Fig. 32).
2 - 22 SUSPENSION WJ
UPPER CONTROL ARM (Continued)
INSTALLATION
(1) Position the upper suspension arm in the
frame rail brackets.
(2) Install the mounting bolts and tighten to 100
Nm (74 ft. lbs.).
(3) Pull the arm down on the ball joint stud and
install a new nut. Tighten the nut to 142 Nm (105
ft. lbs.).
(4) Install the park brake cables and brake hose to
the arm.
(5) Remove the supports and lower the vehicle.
page page
PROPELLER SHAFT
TABLE OF CONTENTS
page page
CAUTION: Use original equipment replacement Brake rotors that are unbalanced will cause a
parts for attaching the propeller shafts. The speci- harsh, low frequency vibration. (Refer to 5 - BRAKES
fied torque must always be applied when tightening - DIAGNOSIS AND TESTING)
the fasteners. Driveline vibration can also result from loose or
damaged engine mounts.
Propeller shaft vibration increases as the vehicle
DIAGNOSIS AND TESTING - PROPELLER speed is increased. A vibration that occurs within a
SHAFT specific speed range is not usually caused by a pro-
peller shaft being unbalanced. Defective universal
VIBRATION joints, or an incorrect propeller shaft angle, are usu-
Tires that are out-of-round, or wheels that are ally the cause of such a vibration.
unbalanced, will cause a low frequency vibration.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
WJ PROPELLER SHAFT 3-3
PROPELLER SHAFT (Continued)
DRIVELINE VIBRATION
Propeller Shaft Noise 1) Undercoating or other foreign material 1) Clean exterior of shaft and wash with
on shaft. solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws and
tighten to proper torque.
3) Loose or bent U-joint yoke or excessive 3) Install new yoke.
runout.
4) Incorrect driveline angularity. 4) Measure and correct driveline angles.
5) Rear spring center bolt not in seat. 5) Loosen spring u-bolts and seat center
bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out of 7) Installl new propeller shaft.
balance.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced 9) Re-index propeller shaft, test, and
condition. evaluate.
10) Excessive drive pinion gear shaft 10) Re-index propeller shaft and evaluate.
runout.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws and
tighten to proper torque.
2) Lack of lubrication. 2) Replace U-joints as necessary.
SPECIFICATIONS
PROPELLER SHAFT
TORQUE SPECIFICATIONS
SPECIAL TOOLS (5) Mark a line across the companion flange at the
transfer case and C/V joint at the rear of the front
SPECIAL TOOLS propeller shaft for installation reference.
(6) Mark a line across the C/V joints and the pin-
ion companion flanges for installation reference.
(7) Remove bolts from the front C/V joint to the
pinion companion flange.
(8) Remove bolts from the rear C/V joint to the
transfer case companion flange.
(9) Push the propeller shaft forward to clear trans-
fer case companion flange and remove the shaft.
NOTE: Different length propeller shafts are used for (1) Install the shaft between companion flanges.
different drivetrain applications. Ensure that the (2) The shaft should rotate freely in the pinion
correct propeller shaft is used. flange.
(3) Align marks on the companion flanges with the
(1) Place vehicle on floor or drive-on hoist with full marks on the C/V joints.
weight of vehicle on suspension. (4) Install bolts to the front C/V joint and tighten
(2) Shift the transmission and transfer case, if nec- bolts to 32 Nm (24 ft. lbs.).
essary, into the Neutral position. (5) Install the bolts to the rear C/V joint and
(3) Measure the distance from the face of the C/V tighten bolts to 32 Nm (24 ft. lbs.).
joint cup to the end of the C/V joint boot (Fig. 9). (6) Verify propeller shaft length.
(7) Lower vehicle.
INSTALLATION
(1) Slide the slip yoke on the transmission, or
transfer case, output shaft.
(2) Align the installation reference marks made on
the propeller shaft and pinion yoke.
(3) Position universal joint into pinion yoke.
(4) Install the universal joint clamp and clamp
bolts to the pinion yoke. Tighten bolts to 19 Nm (14
ft. lbs.).
(5) Lower the vehicle.
(7) If the bearing cap will not pull out of the yoke
by hand after pressing, tap the yoke ear near the
bearing cap to dislodge the cap.
(8) To remove the opposite bearing cap, turn the
yoke over and straighten the cross in the open hole.
Then, carefully press the end of the cross until the
remaining bearing cap can be removed (Fig. 15).
ASSEMBLY
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to inside of yoke bores to aid in installa-
Fig. 13 Remove Snap Ring tion.
1 - SNAP RING (2) Position the cross in the yoke with its lube fit-
ting, if equipped, pointing up (Fig. 16).
(3) Place a bearing cap over the trunnion and
(4) Set the yoke in an arbor press or vise with a align the cap with the yoke bore (Fig. 17). Keep the
socket whose inside diameter is large enough to needle bearings upright in the bearing assembly. A
receive the bearing cap positioned beneath the yoke. needle bearing lying at the bottom of the cap will
(5) Position the yoke with the grease fitting, if prevent proper assembly.
equipped, pointing up. (4) Press the bearing cap into the yoke bore
(6) Place a socket with an outside diameter enough to install a snap ring.
smaller than the upper bearing cap on the upper (5) Install a snap ring.
bearing cap and press the cap through the yoke to
release the lower bearing cap (Fig. 14).
3 - 10 PROPELLER SHAFT WJ
SINGLE CARDAN UNIVERSAL JOINTS (Continued)