2001 JEEP GRAND CHEROKEE Service Repair Manual.pdf

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2001 JEEP GRAND CHEROKEE Service Repair Manual.pdf

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ApprovedEngineOils__Update1__012814 RESEARCH 106_ePDS PROPOSAL

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GROUP TAB LOCATOR Documents Introduction

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0 2 3

Lubrication & Maintenance Suspension Differential & Driveline

5

Brakes

7

Cooling

8A

Audio

8B

Chime/Buzzer

8E

Electronic Control Modules

8F

Engine Systems

8G

Heated Systems

8H 8I 8J 8L

Horn Ignition Control Instrument Cluster Lamps

8M

Message Systems

8N

Power Systems

8O

Restraints

8P

Speed Control

8Q

Vehicle Theft Security

8R

Wipers/Washers

8W

Wiring

9

Engine

11

Exhaust System

13

Frame & Bumpe Bumpers rs

14

Fuel System

19 21

Steering Transmission and Transfer Case

22

Tires/Wheels

23

Body

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24

Heating & Air Useful Conditioning 

25

Emissions Control

30

New Vehicle Preparation

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INTRO INT RODU DU

WJ

INTRODUCTION

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TABLE OF CONTENTS page BODY CODE PLATE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . FASTENER IDENTIFICATION DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . FASTENER USAGE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . METRIC SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . .

......1 ......1 ......4

TORQUE REFERENCES DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . VECI LABEL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . VEHICLE SAFETY CERTIFICATION LABEL DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . .

......4 ......5

BODY CODE PLATE

FASTENER IDENTIFICATIO

DESCRIPTION

DESCRIPTION

A m et et a l B o d y C od e p l a t e i s l oc oca t e d i n t h e e ng ng in in e com pa pa r t m en en t a n d a t t a c he h e d t o t h e t op op of t h e r ig ig h t frame rail. The information listed on the plate (Fig. 1) is used for manufacturing and service purposes.

The SAE bolt strength grades range from to grade 8. The higher the grade number, the the bolt strength. Identification is determine line marks on the top of each bolt head. Th bolt bo lt strength grad e correspo corresponds nds to the numb ma rks plus 2. The The most co commonly mmonly used s t re re n gt gt h cl a s se s e s a r e 9. 8 a n d 10. 9. T strength class identification number is impr t h e h e a d of t h e b ol ol t . Th Th e h i g h e r t h e c l a s s t h e g r ea ea t e r t h e b o lt lt s t r en en g t h . S o m e m e t r i i m pr pr i n t ed ed w i t h a s i n gl gl ee-d i g it it s t r e n gt gt h c l n u t f a ce ce . R e fe f e r t o t h e F a s t e n er er I d en en t i f F a s t e n er er S t r e ng ng t h C h a r t s .

Sign up to vote on this title Fig. 1 Body Code Plate

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INTRO INT RODU DUC CTIO ION N

FASTENER FAST ENER IDENTIFICA IDENTIFICATION TION (Continued)


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INTRO INT RODU DU

WJ FASTENER FAST ENER IDENTIFICA IDENTIFICATION TION (Continued)


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FASTENER USAGE

DESCRIPTION - THREADED HOLE REPA

DESCRIPTION - FASTENER USAGE

Most strippe Most stripped d t hreaded h ol oles es can be repair a Helic Helicoi oill . F ol ol l ow ow t h e m a n u f a c t u r e s r e c o tions for application and repair procedures.

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WAR ARNI NING: NG: USE OF AN IN INCO CORRE RRECT CT FAS ASTE TENE NER R MAY MA Y RES RESUL ULT T IN COMP COMPONE ONENT NT DAM DAMAGE AGE OR PER PER-SONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is i m po por t a n t t o s a l v a g e a l l f a s t e n e r s ( n u t s , b ol ol t s , e t c .) .) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS

DESCRIPTION - INTERNATIONAL SYMB

Th e g r a p h i c s y m b ol ol s i l lu lu s t r a t e d i n t h e International Control and Display Symbols C u s ed ed t o i d en en t i fy fy v a r i ou ou s i n st st r u m en en t co symbols correspond to the controls and disp a r e l oc oc a t e d o n t h e i n s t r u m e n t p a n e l .

INTERNATIONAL SYMBOLS 1 2 3 4 5 6

High Beam Fog Lamps Headlamp, Parking Lamps, Panel Lamps Turn Warning Tu Hazard Warning Windshield Washer

13 14 15 16 17 18

Rear Window Washer Fuel Sign up to vote on this title Engine Coolant Temperature B atterUseful y Charging ConNot ditiouseful n Engine Oil Seat Belt

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INTRO INT RODU DU

WJ

The following chart will assist in convertin u n it it s t o e q u iv iv a l en en t E n g li l i sh sh a n d S AE AE u n i versa.

METRIC SYSTEM Sheet Music

DESCRIPTION - METRIC SYSTEM The metric system is based on quantities of one, t e n , o n e h u n d r e d, d, on e t h ou ou s a n d a n d on e m i l l io ion .

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY

BY

TO GET

MULTIPLY

BY

T

in-lbs

x 0.11298

= Newton Meters (N·m)

N·m

x 8.851

= in-lb

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

= Inch

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

mm

x 0.03937

= Inch

Feet

x 0.3048

= Meters (M)

M

x 3.281

= Feet

Yards

x 0.9144

= Meters

M

x 1.0936

= Yard

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

mph

x 0.4470

= Meters/Sec (M/S)

M/S

x 2.237

= mph

Kilometers/ Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilome (Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters

1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter

1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter

1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers R e fe fe r t o t h e M e t r ic ic C on v er er s i on on C h a r t t o c on on v er er t torque values listed in metric Newton- meters (N·m). Al s o, o, u s e t h e c h a r t t o c on on v e rt rt b et et w e e n m i l li li m et et e r s (mm) and inches (in.)


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METRIC METR IC SYST SYSTEM EM (Cont (Continued) inued)


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INTRO INT RODU DU

WJ

TORQUE REFERENCES Sheet Music

DESCRIPTION I n di d i vi vi du d u a l Tor q ue ue C h a r t s a p pe pe a r a t t h e e n d of m a n y G r ou ou p s. s. R e fe fe r t o t h e S t a n d a r d Tor q u e S p ec ec if if i cations Chart for torque references not listed in the i n d iv iv i du du a l t o r q u e c h a r t s .


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TORQUE TORQ UE REFE REFERENCE RENCES S (Cont (Continued) inued)


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INTRO INT RODU DU

WJ

VECI LABEL

The VECI label(s) contain the following: E n g i n e f a m i l y a n d d i s pl pl a c em em e n t E v a p or or a t i v e f a m i ly ly Emission control system schematic C ertifi ertification cation applic applicat at io ion n Spark plug and gap Th e l a b el el a l s o con t a i n s a n e ng ng in in e v a c ma tic. There There a re unique labels for vehicl s a le l e i n t h e s t a t e of C a l if if or or n ia ia a n d t h e c o C a n a da d a . C a n a di d i a n l a be be l s a r e w r it it t en en i English and French languages. These labels m a n e nt n t l y a t t a ch ed e d a n d ca n n ot o t b e r e m ov ov e defacing information and destroying label. •

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DESCRIPTION Al l v e h i cl cl es es a r e e q u ip ip pe pe d w i t h a c om om b i n ed ed VE C I label(s). The label is located in the engine compartm e n t on t h e v eh eh i cl cl e h o od od (F i g . 2 ). ). Tw o l a b el el s a r e used for vehicles built for sale in the country of Canada.

• • • •

VEHICLE IDENTIFICATION NUMBER DESCRIPTION

The Vehic ehicle le Identific Identificat at io ion n Number (VIN) a t t a c h e d t o t h e t o p l ef ef t s i d e of of t h e i n s t r u m e Th e VI N con t a i n s 17 ch a r a c t er er s t h a t p r conce co ncerning rning the vehic vehicle. le. Refer Refer to t he decoding decoding determine the identification of a vehicle.

Fig. 2 VECI Label Location 1 - VECI LABEL (CANADIAN) 2 - VECI LABEL 3 - HOOD


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VEHICLE IDENTIFICATION IDENTIFICATION NUMBER (Continued) VEHICLE IDENTIFICATION NUMBER DECODING CHART



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POSITION

INTERPRETATION

CODE = DESCRIPTION

1

Country of Origin

1 = United States

2

Make

J = Jeep

3

Vehicle Type

4 = MP V

4

Gross Vehicle Weight Rating

G = 5001-6000 lbs.

5

Vehicle Line

6

Series

5 = Laredo 6 = Limited

7

Body Style

8 = 4dr Sport Utility

8

E n gi ne

S = 4.0 Liter N = 4.7Liter

9

Check Digit

10

Model Year

1= 200 1

11

Assembly Plant

C = Jefferson Assembly

12 thru 17

Vehicle Build Sequence

VEHICLE SAFETY CERTIFICATION LABEL

2= Grand Cherokee 4X2 (L W = Grand Cherokee 4X4 (LH

Country of origin. Th e l a be b e l i s l oc oca t e d shut-face. •

on

t h e d ri r i ve ve

DESCRIPTION A v eh eh ic i cl e s a fe f e t y ce r t if if ic ica t i on on l a be b e l (F ig i g . 3) i s attached to every Chrysler Corporation vehicle. The l a b e l c er er t i f ie ie s t h a t t h e v e h ic icl e c on on f or or m s t o a l l a p p li li c a b le le F e d er er a l M ot ot o r Ve h ic icl e S a f et et y S t a n d a r d s . Th e l a b e l a l s o l is is t s : M o n t h a n d y e a r of v e h i cl cl e m a n u f a c t u r e . Gross Vehicle Weight Rating (GVWR). The gross f r on on t a n d r ea ea r a x l e w ei gh gh t r a t i n gs g s (G AW AWR ’s ’s ) a r e based on a minimum rim size and maximum cold tire inflation pre pressure. ssure. Vehicle Identification Number (VIN). Type of vehicle. Type Type of rea r wh eels. Bar code. Month, Day and Hour (MDH) of final assembly. P aint an d Trim Trim codes. codes. • •

• • • • • •

Fig. 3 Vehicle Safety Certification Lab  Sign up to vote on this title

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LUB LU BRIC RICA ATI TIO ON & MAINT MAINTE ENA NANC NC

WJ

LUBRICATION & MAINTENANCE

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TABLE OF CONTENTS page INTERNATIONAL SYMBOLS DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PARTS & LUBRICANT RECOMMENDATION STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 1 FLUID TYPES DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 OPERA OPE RATI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECI SP ECIFI FICA CATI TIONS ONS . . . . . . . . . . . . . . . . . . . . . . . . . 4 FLUID CAPACITIES SPECI SP ECIFI FICA CATI TIONS ONS . . . . . . . . . . . . . . . . . . . . . . . . . 6 FLUID FILL/CHECK LOCATIONS DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

MAINTENANCE SCHEDULES DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . LIFT POINTS STANDARD PROCEDURE . . . . . . . . . . . . . HOISTING AND JACKING RECOMMENDATIONS. . . . . . . . . . . . . . . JUMP STARTING STANDARD PROCEDURE . . . . . . . . . . . . . EMERGENCY EMERGE NCY TOW HOOKS DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . . TOWING STANDARD PROCEDURE . . . . . . . . . . . . .

INTERNATIONAL SYMBOLS

PARTS & LUBRICANT RECOMMENDATION

DESCRIPTION D a i m l er er C h r y sl s l er er C or or po por a t i on on u s es es i n t er er n a t i on on a l s y m b ol ol s t o i d en en t i f y e n g in in e c om om p a r t m e n t l u br br i ca ca n t and fluid inspection and fill locations (Fig. 1).

STANDARD PROCEDURES

Lubricating grease is rated for quality an by the NLGI. All approved products have t s y m bo bol (F i g. g . 2) o n t h e l a b el el . At At t h e b o symbol is the usage and quality identificatio Wh e el el b ea ea r i n g l u br br i ca ca n t i s i d en en t i f ie ie d b y “G”. Chassis lubricant is identified by the l Th e l et et t e r f ol ol lo low i n g t h e u s a g e l et et t e r i n d i quality of the lubricant. The following symb c a t e t h e h i g h e st st q u a l i t y. y.


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Fig. 1 International Symbols Fig. 2 NLGI Symbol

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LUB LU BRIC RICA ATI TIO ON & M AINT INTE ENA NANC NCE E

FLUID TYPES Sheet Music

DESCRIPTION ETHYLENE ET HYLENE-GL -GLYCOL YCOL M IXTUR ES CAUTION CAUT ION:: Ric Riche herr an anti tifr free eeze ze mi mixt xtur ures es ca cann nnot ot be meas me asur ured ed wit with h no norm rmal al fi field eld eq equi uipm pmen entt an and d ca can n cause problems problems associ associated ated with 100 percent ethylene-glycol. The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle opera ting co condit ndit ions. The The reco recommend mmend ed mixtur e of 50/50 e t h y le le n ee-g l y co col a n d w a t e r w i l l p r ov ov i d e p r ot ot e ct ct i on on against freezing to -37 deg. C (-35 deg. F). The antifreeze concentration must always b e a m i n i m u m o f 44 percent, year-round in all climates. If percentage is lowe lower r tha than n 44 pe perce rcent, nt, engine engine pa parts rts ma may y be erode roded d by cavitat cavitation, ion, and coo cooli ling ng sy sys ste tem m com com-pone po nents nts ma may y be se seve verely rely dam damag age ed by corros corrosion. ion. M a x im im u m p ro rot e ct ct i on on a g a i n s t f r ee ee zi zi n g i s p ro rov id id ed ed w i t h a 68 p er er ce ce nt nt a n t i f re r e ez ez e con ce ce nt nt r a t i on on , w h i ch ch prevents freezing down to -67.7 deg. C (-90 deg. F). A h i g h er er p er er c en en t a g e w i l l f r e ez ez e a t a w a r m e r t e m p er er a t u r e. e. Al so so, a h i gh gh er er p er er ce ce nt nt a g e of a n t i f re r e ez ez e ca n ca u s e t h e en g in in e t o ov er er h ea ea t b ec eca u s e t h e s pe peci fi fi c heat of antifreeze is lower than that of water. Use of 10 100 0 pe perce rcent nt ethylene ethylene--glyc glycol ol w ill cause fo forrmation of additive deposits in the system, as the corrosion rosi on inhibitive a dditives in ethylene ethylene--glyc glycol ol require the presence of water to dissolve. The deposits act as i n s u la la t i on on , c a u s i n g t e m p er er a t u r e s t o r i s e t o a s h i g h a s 1 49 49 d e g. g. C (3 00 00 ) d eg eg . F ). ). Th i s t e m pe pe r a t u r e i s h ot ot e n ou ou gh gh t o m el el t p l a st s t i c a n d s of of t en en s ol ol de de r. Th e i n cr cr e a s ed ed t e m pe pe r a t u r e c a n r e su su l t i n e n g in in e d e t on on a tion. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F ).

components. compo nents. Also lso,, onc oncee ethylene ethylene--glyc glyco ol lenele ne-glyc glycol ol ba sed co coo olant s ar e mixe mixed d in conventional methods of determining freeze p n ot ot b e a cc ur ur a t e . B o t h t h e r e f r a c t i ve ve i n d e x cific ci fic gravity diffe differr between ethylene glycol glycol a lene glyco glycol. l.

ENGINE OIL

WAR ARNI NING NG:: NE NEW W OR US USED ED EN ENGI GINE NE OI IRRITATING TO THE SKIN. AVOID PROLON REPE RE PEA ATE TED D SK SKIN IN CO CONT NTAC ACT T WI WITH TH EN CONTAMINANTS IN USED ENGINE OIL, CA INTERNAL COMBUSTION, CAN BE HAZARD YOUR YOU R HEA HEAL LTH. THOR THOROUG OUGHL HLY Y WASH SKIN SK IN WI WITH TH SO SOAP AP AN AND D WATE TER. R. DO NO SKIN WITH GASOLINE, DIESEL FUEL, THIN SOLVENTS, SOL VENTS, HEAL HEALTH TH PROBLEM PROBLEMS S CAN RES NOT NO T PO POLL LLUT UTE, E, DIS DISPO POSE SE OF US USED ED EN PROPERLY. CONTACT YOUR DEALER OR G MENT MEN T AGEN AGENCY CY FOR LOC LOCA ATIO TION N OF COL CENTER IN YOUR AREA.

API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Gra fied. MOP AR  p r ov ov i d es es e n gi gi n e o i ls ls t h a t this service grade.

SAE VISCOSITY

An SAE viscosity grade is used to specify cosity of engine oil. Use only engine oils wi ple vis co cosities sities such a s 5W 5W--30 or 10 10W W-30 specified with a dual SAE viscosity grade wh c a t e s t h e c ol ol d -t -t o -h -h ot ot t e m pe pe r a t u r e v i sc sc o Select an engine oil that is best suited to y t i cu cu l a r t e m pe pe r a t u r e r a n g e a n d v a r i a t i o n ( F i

PROPYLENE-GLYCOL MIXTURES It’s overall effective temperature range is smaller th a n t ha t of ethy lenelene-glycol. glycol. The The freeze point of 50/ 50/50 propylene-glycol and water is -32 deg. C (-26 deg. F). 5 deg. C higher t ha n ethylene ethylene--glyc glycol ol’’s free freeze ze point. point. The bo boiling iling point (pro protectio tection n aga inst summer bo boililover) ove r) of propylene-glyco propylene-glycoll is 12 125 5 deg. C (25 257 7 deg. F )


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WJ FLUID TYPES (Conti (Continued) nued)

CONTAINER CONT AINER ID IDENTIFICA ENTIFICATION TION

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Sheet Music

S t a n d a r d e n gi gi n e o il il i d en en t i f ic ica t i on on n ot ot a t i on on s h a v e been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 4).

Fig. 5 Temperature/Engine Oil Viscosity - 3 Engine Fig. 4 Engine Oil Container Standard Notations

DESCRIPTION - ENGINE OIL WAR ARNI NING NG:: NE NEW W OR US USED ED EN ENGI GINE NE OI OIL L CA CAN N BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPE RE PEA ATE TED D SK SKIN IN CO CONT NTAC ACT T WI WITH TH EN ENGI GINE NE OI OIL. L. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEA HEAL LTH. THO THOROUG ROUGHL HLY Y WASH EXP EXPOSE OSED D SKIN SK IN WI WITH TH SO SOAP AP AN AND D WATE TER. R. DO NO NOT T WAS ASH H SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, SOL VENTS, HEAL HEALTH TH PROBLE PROBLEMS MS CAN RESUL RESULT T. DO NOT NO T PO POLL LLUT UTE, E, DI DISP SPOSE OSE OF US USED ED ENG ENGIN INE E OI OIL L PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY AGENCY FOR LOC LOCA ATION OF COLL COLLECT ECTION ION CENTER IN YOUR AREA.

CONTA CO NTAINER INER IDENTIFI CA CATION TION

S t a n d a r d e n gi gi n e o il il i d en en t i f ic ic a t i on on n ot ot a been adopted to aid in the proper selection o oil. The identifying notations are located on of engine oil plastic bottles and the top of e cans (Fig. 6).

Fig. 6 API Symbol

DESCRIPTION API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOP AR  p r ov ov i d es es e n gi gi n e oi ls ls t h a t c on on f or or m t o this service grade.

SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple visco viscosities sities such a s 5W 5W--30 or 10 10W W-30 30.. These oil oilss are specified with a dual SAE viscosity grade which indicat indic at es the co coldld-toto-hot hot temperature visc viscosi osity ty ra nge. Select an engine oil that is best suited to your par-

A multi-purpose, hypoid gear lubricant wh forms to the following specifications should M op op a r H y po poi d G e a r L u br br ic ica n t con fo f or m s these specifications.

FRONT AXLE Th e l u br br i ca ca n t s h ou ou l d h a v e M I L -L -L  AP I G L 5Sign q u aup l it itto y vote s p ec econ i f ic icthis a t i on otitle ns. L u br br i ca n t i s S AE AENot 7 5W 5useful W-14 0 S Y N TH TH E caUseful  lubricant. •

•

REAR AXLE

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FLUID TYPES (Conti (Continued) nued) NOTE: Trac NOTE: rac-lo -lok k and Vari ari-lo -lok k equipp equipped ed axle axles s require a friction modifier be added to the lubricant. CAUTION:: If axl CAUTION axle e is sub submer merged ged in wat water er,, lubric lubricant ant must mu st be re repl plac aced ed im imme medi diat ately ely to avoid avoid po poss ssib ible le premature axle failure.

DESCRIPTION - TRANSFER CASE - NV242 R e co com m e n d ed ed l u br br i ca ca n t f or or t h e N V2 V2 42 42 t r a n s f e r c a s e i s M o p a r  AT ATF + 4, type 96 9602 02 Automa Automa tic Tra nsmission Fluid.

DESCRIPTION - TRANSFER CASE - NV247 Mopar  Tra nsf er C a se L ubrica nt (P/N 05016 05016796 796)) is t h e on l y l ub ub r ic ica n t r ec ecom m en en d ed ed f or or t h e N V2 V247 t r a n s f e r ca s e .

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID NOTE: Ref NOTE: Refer er to the maintenan maintenance ce sch schedu edules les in thi this s group for the recommended maintenance (fluid/filter change) intervals for this transmission. NOTE: Refer to Service Procedures in this group for fluid level checking procedures. Mopar  AT ATF P lus 4, Type Type 9602, 9602, a utomat ic t ran smission fluid is the recommended fluid for DaimlerC h r y s l er er a u t o m a t i c t r a n s m i s s i on on s . Dexron De xron I I fluid I S NOT rec recom omm mende nded. d. Clutch chat ch atte ter r ca can n re res sult fro from m th the e us use e of imp improp rope er fluid. Mopar  AT ATF P lus 4, Type Type 9602, 9602, a utomat ic t ran smission missio n fluid w hen new is red in co colo lor. r. The The AT ATF is dyed red so it can be identified identified from other fluids used i n t h e v e hi hi cl cl e s u c h a s e n gi gi n e o il il or a n t i fr fr e ez ez e. e. Th e red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will b eg eg in in t o l oo ook d a r k er er i n col or or a n d m a y e ve ven t u a l ly ly become brown. This is normal. A da rk brown/black fluid a cc ccomp ompan an ied w ith a burnt odor a nd/or deteriodeterior a t i o n i n s h i ft ft q u a l i t y m a y i n d ic ic a t e f l u id id d e t er er i or or a tion or transmission component failure.

cl u t ch ch op er er a t i o n a n d i n h i bi bi t ov er er h e a t i n g , varnish, and sludge. These claims have not b p or or t ed ed t o t h e s a t i s fa fa c t io ion of D a i m l er er C h r y these additives mus mustt not be us used ed.. The use mission “sealers” should also be avoided, si m a y a d v er e r s el el y a f f ec ect t h e i n t eg eg r it it y o f t r a n seals.

OPERATION OPERA TION - AUT AUTOMAT OMATIC IC TRA TRANSM NSM ISSI FLUID

The automatic transmission fluid is select upon several qualities. The fluid must provi l ev ev e l of p r ot ot e ct ct i on on f or or t h e i n t er er n a l com p o p r ov ov i d in in g a l u br br i ca ca t i n g f i lm lm b et et w e e n a d j a c e components. The fluid must also be therma s o t h a t i t c a n m a i n t a i n a con s i s t en en t v i s co cos i t y a l a r g e t e m p er er a t u r e r a n g e. e. I f t h e v i s co co s i t y s s t a n t t h r ou ou g h t h e t e m pe pe ra ra t u r e r a n g e of transmission operation and shift feel will rem sistent. Tran Tran smissio smission n fluid must also be a ductor of heat. The fluid must absorb heat internal transmission components and tran heat to the transmission case.

SPECIFICATIONS

FUEL REQUIREMENTS

Your engine is designed to meet all emiss ulations and provide excellent fuel economy formance when using high quality unleaded gasoline having an octane rating of 87. The use of premium gasoline is not recommende n or or m a l con d i t i on on s t h e u s e o f p r e m iu iu m f u e provide a benefit over high quality regular g and in some circumstances may result in po formance. L i gh gh t s pa pa r k k n oc ock a t l ow ow e ng ng in in e s pe pe e h a r m f u l t o y ou ou r e n g in in e . H ow e v er er, c on on t i n u e spark knock at high speeds can cause dam immediate service is required. Engine damag i n g f r om om op er er a t i on on w i t h a h ea ea v y s pa r k pa Sign up to vote on this title not be covered by the new vehicle warranty. P o o r q u a lUseful i t y g a s o l i n eNot c auseful n cause problems hard starting, stalling and hesitations. If you ence these symptoms, try another brand of

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WJ SPECIFICA SPEC IFICATION TIONS S (Cont (Continued) inued)

REFORMULATED GASOLINE

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M a ny n y a r ea ea s of t h e cou nt n t r y r eq eq ui u i r e t h e u se s e of c le le a n e r b u r n in in g g a s o li li n e r e f er er r e d t o a s “ r ef ef or or m u l a t ed” ga sol soline. ine. Reformulat Reformulat ed ga sol soline ine conta conta in ox oxygenygena t e s, s, a n d a r e s p ec eci f ic ic a l ly ly b l en en d e d t o r e d uc uce v e h ic icl e emissions and improve air quality. We strongly support the use of reformulated gasoline.. P rop line roperly erly blended reformulat reformulat ed ga sol soline ine w ill proprov id id e e xc xcel le le nt nt p er er f or or m a n ce ce a n d d u r a b il il it it y f or or t h e engine and fuel system components.

GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with ox y ge ge n a t e s s u ch ch a s 10 % e t h a n ol ol , M TB TB E , a n d E TB TB E . Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle.

CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol methanol may damage critical fuel system components.

M MT IN GA GASO SOLINE LINE M M T is is a m a n g a n e se se -c -con t a i n i n g m e t a l l ic ic a d d i t i v e that is blended into some gasoline to increase octane. Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane numb er er w i t ho h ou t M MT MT. G a s ol o l in in e b le le n d ed ed w i t h M MT MT r e d uc uce s p a r k p lu lu g l if if e a n d r e d uc uc e e m i ss ss i on on s y s t e m perfo pe rforma rma nce in some vehicles. vehicles. We We rec reco ommend tha t gasolines free of MMT be used in your vehicle. The MMT co content ntent of gasoline gasoline ma y n ot be indicated on t he gasoline pump; therefore, you should ask your gasoline reta ile ilerr whether or not his/her gasoline conta conta ins MMT. It is even more important to look for gasoline withou t M M T i n C a n a d a b ec eca u s e M M T ca ca n b e u s ed ed a t l ev ev el el s h ig i g h er er t h a n a l lo low e d i n t h e U n i te t e d S t a t e s. s. M M T is is p r oh oh i b it it e d i n F e d er er a l a n d C a l i fo for n i a r e fo fo r mulated gasoline.

SULFUR IN GASOLINE I f y ou ou l iv iv e i n t h e n or or t h ea ea s t U n i t ed ed S t a t e s, s , y ou ou r v eh eh i cl cl e m a y h a v e b ee ee n d e si si g n ed ed t o m e et et C a l i fo for n i a

affect the performance of the vehicle’s catal v er er t er er. Th i s m a y ca u s e t h e M a l fu fu n ct ct i o Lamp (MIL), Check Engine or Service Eng light to illuminate. We recommend that you ferent fere nt bran d of unleaded ga so soline line having low t o d e t e r m in in e i f t h e p r ob ob l em em i s f u el el r e la la t r e t u r n in in g y ou ou r v eh eh i cl cl e t o a n a u t h o r i ze ze d d service.

CAUTION: CAUTIO N: If the Mal Malfun functi ction on Ind Indica icator tor Lam Check Engine or Service Engine Soon light ing,, imm ing immedi ediate ate ser servic vice e is req requir uired; ed; see diagnostics system section.

MATERIALS ADDED TO FUEL

All gasoline sold in the United States and are required to contain effective detergent a Use of additional detergents or other additiv needed under normal conditions.

FUEL SYSTEM CAUTIONS

CAUTION: Follow these guidelines to main vehicle’s performance:

The use of leaded gas is prohibited by law. Using leaded gasoline can impair engin m a n ce c e , d a m a g e t h e e m is is s io ion con t r ol ol s y s t could result in loss of warranty coverage. An out-of-tune engine, or certain fuel or m a l fu f u n ct ct i on on s , ca n ca u s e t h e ca t a l y t ic ic c ov e rh rh e a t . I f y ou ou n ot ot i ce ce a p u n ge ge n t b u r n i some light smoke, your engine may be out o m a l f u n ct ct i on on i n g a n d m a y r e q u ir ir e i m m ed ed i a t e Contact your dealer for service assistance. Wh Wh en en p ul ul li li n g a h ea ea v y l oa oa d or d r iv iv i loaded vehicle when the humidity is low and p er er a t u r e i s h i gh gh , u s e a p re re mi mi um um u n le le a d e h e lp lp p r ev ev en en t s p a r k k n oc ock . I f s p a r k k n o lighten the load, or engine piston damage ma Th Th e u s e o f f u e l a d d i t iv iv e s w h i ch ch a r e  sold so ld a s oc octa ta ne ncers nce rsthis is title not rec recommend ommend Sign upenha to vote on of t h es e s e p ro rod u ct ct s con t a i n h i gh gh con ce ce n Useful Not useful   m et et h a n ol o l . F u el el s y s t em em d a m a g e or v eh eh i c mance problems resulting from the use of su or a d d i t iv iv es es i s n ot ot t h e r es es po pon s ib ib il il it it y o •

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FLUID CAPACITIES Sheet Music

SPECIFICATIONS

SPECIFICATIONS - FLUID CAPACITIES DESCRIPTION

SPECIFICATION

FUEL TANK

20 U.S. Gallons (76 Liters)****

Engine Oil - with Filter 4.0L

5.7L (6.0 qts.)

Engine Oil - with Filter 4.7L

5.7L (6.0 qts.)

Cool Co olin ing g Sy Sys ste tem m - 4. 4.0L 0L

14.1 14 .1L L (1 (15 5 qt qts. s.)* )*** **

Cool Co olin ing g Sy Syst stem em - 4. 4.7L 7L

13.7 13 .7L L (1 (14. 4.5 5 qt qts. s.)* )*** **

Power Steering AUTOMATIC AUTOMA TIC TRANSMISSION Service Fill - 42RE

3.8L (4.0 qts)

O-ha Ohaul ul Fi Fill ll - 42 42RE RE

9.19. 1-9. 9.5L 5L (19 19-2 -20 0 pt pts) s)

O-haul Fill - 45RFE

13.33L (28.0 pts.)

Fig. 7 Fill/Drain Plug 1 - I.D. TAG 2 - FILL PLUG 3 - DRAIN PLUG

INSPECTION The fluid fill/chec check k lo locat cat ions a nd lubricat are located in each applicable group.

TRANSFER TRANSF ER CASE NV242

1.35L (2.85 pts.)

NV247

1.6L (3.4 pts.)

DESCRIPTION

FRONT AXLE Model 186 FBI

MAINTENANCE SCHEDUL

1.18L (2.5 pts.)

* When equipped with Vari-Lok, include 0.07L (0.15 pts.) of Friction Modifier. REAR AXLE Model 194 RBI

1.66L (3.5 pts.)*

Model 226 RBA

2.24L (4.75 pts.)**

* When equipped with Trac-lok, include 2.5 ounces of Friction Modifier. ** When equipped with Trac-lok or Vari-Lok, include 2.5 ounces of Friction Modifier. *** Includes 0.9L (1.0 qts.) for coolant reservoir. ****Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerance and refill procedure.

Th er e r e a r e t w o m a i n t en en a n c e s c h ed ed u le le s proper service for the Grand Cherokee. F i r st st i s S c he hed u le le “A”. I t l is is t s a l l t h e maintenance to be performed under “normal ing conditions. Second is Schedule “B” . I t i s a s ch ch e d u cles that are operated under the following co Frequent short trip driving less than 5 km ) Frequent driving in dusty conditions Extensive idling Tra Tra iler t owing  Sign uphigh to vote on this title Sustained speed operation Off  road driving Useful  Not useful Desert operation Frequent starting and stopping Cold climate operation •

• • • • • • •

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WJ MAINTENANCE SCHEDULES SCHEDULES (Continued) f u n ct ct i on on i n g of t h e e m is is s i on on c on on t r o l s y s t e m . Th e se se , and all other maintenance services included in this m a n u a l , s h o u ld ld b e d o n e t o p r ov ov i d e t h e b es es t v eh eh i cl cl e p er er f or or m a n c e a n d r e li li a b i li li t y. y. M or or e f r eq eq u e n t m a i n t e na nce may be needed needed fo forr vehic vehicles les in seve severe re operat operat ing con d it it i on on s s u ch ch a s d u st s t y a r e a s a n d v er er y s h or or t t r i p driving.

UNSCHEDULED INSPECTION AT EACH STOP FOR FUEL Check engine oil level, add as required. C h ec eck w i nd nd s h hii el el d w a s h er er s ol ol ve ve n t a n d a d d i f required. • •

22,500 Miles (36 000 km) or at 18 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Inspect brake hoses. Inspect exhaust system. • • • • • • •

30,000 Miles (48 000 km) or at 24 months Change engine oil. Replace engine oil filter. Replace engine engine air clea cleane ner r elem leme e Replace spark spark plug plugs. s. Drain and refill transfer case fluid. Lubricate upper knuckle ball stud. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect exhaust system. • • • • •

ONCE A MONTH C h e ck ck t i r e p r es es s u r e (i n cl cl u d in in g s p a r e) e) a n d l oo ook for unusual wear or damage. Inspect battery and clean and tighten terminals a s r e q u ir ir e d . C h ec ec k f l ui ui d l ev ev el el s of c oo ool a n t r e se se r vo voi r, r, p ow ow e r steering and transmission and add as needed. •

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37,500 Miles (60 000 km) or at 30 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect exhaust system. • •

AT EACH OIL CHANGE Inspect exhaust system. Inspect brake hoses. R ot ot a t e t h e t ir i r es es a t e a ch ch oi l ch a n ge ge i n t er er va va l shown on Schedule Schedule— —A (7, (7,50 500 0 mile miles) s) or eve every ry other interva l shown on Schedule—B Schedule—B (6,0 6,000 00 miles). miles). Check coolant level, hoses and clamps. Lubricate suspension ball joints. After completion of off-road (4WD) operation, the u n de de r s id id e of t h e v eh eh ic i cl e s h ou ou ld ld b e t h or or ou ou gh g h ly ly inspected. Examine threaded fasteners for looseness. • •

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45,000 Miles (72 000 km) or at 36 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Flush and replace engine coolant at 36 or 52,500 Miles (84 000 km). Lubricate upper knuckle ball stud. Inspect exhaust system. • • • • • • •

M AINTENA AINTENANCE NCE SCHE SCHEDULES DULES

•

SCHEDULE SCHE DULE— —A NOTE: Where both time and mileage are indicated, follow the interval which occurs first.

•

52,500 Miles (84 000 km) or at 42 months Change engine oil. Replace engine oil filter.  Sign up to vote onanthis titlel, h ose I nspec nspect t engine coolan cool t leve level, oses, s, cl Inspect brake hoses.  Useful  Not useful Inspect exhaust system. • •

7,500 miles (12 000 km) or at 6 months Change engine oil. Replace engine oil filter. ol level, lev el, hoses, clamps. •

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•

60,000 Miles (96 000 km) or at 48 months

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MAINTENANCE SCHEDULES SCHEDULES (Continued) I n sp s p e ct a n d r ep ep la la ce c e d ri r i ve ve b el el t i f n ec ece s sa sa r y (4.0L). Drain and replace brake fluid. Drain and refill transfer case fluid. Lubricate upper knuckle ball stud. Inspect exhaust system.

97,500 Miles (156 000 km) or at 78 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect exhaust system.

67,500 Miles (108 000 km) or at 54 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect brake linings Inspect brake hoses. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Inspect exhaust system.

100,000 Miles (160 000 km) D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s and change filter (except 45RFE & 545RFE tions). Adjust bands (except 45RFE & 545RFE tions). D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s a n d ch a n g e m a i n s u m p f i lt lt e r i n 45R F E applications. Change spin-on cooler return filter in 4 545RFE 54 5RFE appic appicat at io ions. ns.

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75,000 Miles (120 000 km) or at 60 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Flush and replace engine coolant if it has been 3 0, 0, 00 00 0 m i l es es (4 8 0 00 00 k m ) o r 24 m on on t h s s i n ce ce l a s t change. I n sp s p e ct a n d r ep ep la la ce c e d ri r i ve ve b el el t i f n ec ece s sa sa r y (4.0L). ** Inspect brake hoses. Inspect exhaust system. Lubricate upper knuckle ball stud. •

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82,500 Miles (132 000 km) or at 66 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Flush and replace engine coolant if it has been 3 0, 0, 00 00 0 m i l es es (4 8 0 00 00 k m ) o r 24 m on on t h s s i n ce ce l a s t change. Inspect brake hoses. Inspect exhaust system. •

105,000 Miles (168 000 km) or at 84 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Flush and replace engine coolant if it h 3 0, 0, 00 000 m i le le s (4 8 0 00 00 k m ) o r 2 4 m o n t h s change. I n sp sp ect a n d r ep ep l a ce c e d ri r i v e b el el t 4.7L ). ** Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system. • • • •

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90,000 Miles (144 000 km) or at 72 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Replace eng engine air clea cleane ner r elem leme ent. Replace spark spark plugs plugs.. Inspect PCV valve and replace if necessary (4.7 (4 .7L L only).* • • • • • •

112,500 Miles (180 000 km) or at 90 months Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Flush and replace engine coolant if it h 3 0, 0, 00 000 m i le le s (4 8 0 00 00 k m ) o r 2 4 m o n t h s change. Inspect brake hoses. Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i  pe r p i n s . pe Sign up to vote on this title Inspect exhaust system.  Useful  Not useful 120,000 Miles (192 000 km) or at 96 months Change engine oil. • • • •

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WJ MAINTENANCE SCHEDULES SCHEDULES (Continued) •

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•

Lubricate upper knuckle ball stud. Inspect exhaust system.

NOTE: Ins NOTE: Inspec pectio tion n and ser servic vice e sho should uld als also o be per per-formed for med any anytim time e a mal malfun functi ction on is obs observ erved ed or sussuspected. en a n ce c e i s r ec ecom m en e n d ed ed , b u t i s n ot ot *Th i s m a i n t en r eq eq u ir ir ed ed t o m a i n t a i n w a r r a n t y on t h e P C V v a l v e. e. **T h i s m a i n t e n a n c e i s n o t r e q u i r e d i f t h e b e l t w a s previously replaced.

SCHEDULE SCHE DULE— —B NOTE: Where both time and mileage are indicated, follow the interval which occurs first.

• •

Inspect brake hoses. Inspect exhaust system.

18,000 Miles (29 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect exhaust system. Lubricate upper knuckle ball stud. • • • • • •

21,000 Miles (34 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect exhaust system. • • • • •

3,000 Miles (5 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect brake hoses. Inspect exhaust system. • • • • •

24,000 Miles (38 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Drain and refill front and rear axles. Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system. • • • • •

6,000 Miles (10 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system. • • • • • •

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27,000 Miles (43 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect exhaust system. • •


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30,000 Miles (48 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Replace engine engine air clea cleane ner r elem leme e Replace spark spark plug plugs. s.  Sign up to vote on this title Inspect PCV valve and replace if ne (4.7 (4 .7L L only).*  Useful  Not useful Inspect brake hoses. D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s and change filter (except 45RFE & 545RFE • •

12,000 Miles (19 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Drain and refill front and rear axles. Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . • • • • • •

• • • •

• •

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LUB LU BRIC RICA ATIO TION N & M AINT INTE ENA NANC NCE E

MAINTENANCE SCHEDULES SCHEDULES (Continued) 33,000 Miles (53 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect brake hoses. Inspect exhaust system. • • • • •

51,000 Miles (82 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Flush and replace engine coolant. Inspect brake hoses. Inspect exhaust system. • • • • • •

36,000 Miles (58 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Drain and refill front and rear axles. Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system. • • • • • • •

54,000 Miles (86 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system. • • • • • •

• •

57,000 Miles (91 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect exhaust system. •

39,000 Miles (62 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect brake hoses. Inspect exhaust system. • • •

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60,000 Miles (96 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Replace engine engine air clea cleane ner r elem leme e Inspect PCV valve and replace if ne (4.7 (4 .7L L only).* Replace spark spark plug plugs. s. Inspect and replace drive belt (4.0L onl D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s an d change filter (ex exce cept pt 45 45RFE RFE & 54 545RFE 5RFE tions). Adjust bands (except 45RFE & 545RFE tions). D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s a n d ch a n g e m a i n s u m p f i lt lt e r i n 45R F E applications. Drain and refill transfer case fluid. Drain and refill front and rear axles. Sign up to vote on this title Inspect brake hoses. Inspect brake linings.  Useful  Not useful Drain and replace brake fluid. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . •


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• • •

45,000 Miles (72 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect and replace drive belt if necessary (4.0L only). I ns nspe pect ct eng ngine ine air clea cleane ner r elem leme ent, rep r eplace lace as necessary. Inspect brake hoses. Inspect exhaust system. • • • •

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48,000 Miles (77 000 km) Change engine oil. •

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WJ MAINTENANCE SCHEDULES SCHEDULES (Continued) 66,000 Miles (106 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system.

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Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system.

87,000 Miles (139 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses. Inspect exhaust system. •


• • • •

90,000 Miles (144 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Replace engine engine air clea cleane ner r elem leme e Replace spark spark plug plugs. s. Inspect PCV valve and replace if ne (4.7 (4 .7L L only).* Inspect and replace drive (4.0L and 4.7 D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s an d change filter (ex exce cept pt 45 45RFE RFE & 54 545RFE 5RFE tions). Adjust bands (except 45RFE & 545RFE tions). D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s a n d ch a n g e m a i n s u m p f i lt lt e r i n 45R F E applications. Change spin-on cooler return filter in 4 545RFE 54 5RFE appic appicat at io ions. ns. Inspect brake hoses. Drain and refill transfer case fluid. Lubricate upper knuckle ball stud. Inspect exhaust system. •

72,000 Miles (115 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Drain and refill front and rear axles. Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system. • • • • • • • • •

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75,000 Miles (120 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect and replace drive belt(4.0L and 4.7L). ** I ns nspe pect ct eng ngine ine air clea cleane ner r elem leme ent, rep r eplace lace as necessary. Inspect brake hoses. Inspect exhaust system. • • • • •

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93,000 Miles (149 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Inspect brake hoses.  Signexhaust up to votesystem. on this title Inspect  Useful  Not useful 96,000 Miles (154 000 km) Change engine oil. • • • • •

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MAINTENANCE SCHEDULES SCHEDULES (Continued) 99,000 Miles (158 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Inspect brake hoses. Inspect exhaust system. • • • • •

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Inspect exhaust system.

120,000 Miles (192 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t leve level, l, h ose oses, s, cl Replace engine engine air clea cleane ner r elem leme e Inspect PCV valve and replace if ne (4.7 (4 .7L L only).* Replace spark spark plug plugs. s. I nspec nspectt an d repl replace ace drive belt (4. 4.0L 0L a D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s and change filter (ex exce cept pt 45 45RFE RFE & 54 545RFE 5RFE tions). Adjust bands (except 45RFE & 545RFE tions). D r a i n a n d r ef ef il il l a u t om om a t i c t r a n s m i s a n d ch a n g e m a i n s u m p f i lt lt e r i n 45R F E applications. Drain and refill transfer case fluid. Drain and refill front and rear axles. Inspect brake hoses. Inspect brake linings. Drain and replace brake fluid. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Lubricate upper knuckle ball stud. Inspect exhaust system. • • • •


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105,000 Miles (168 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. I ns nspe pect ct eng ngine ine air clea cleane ner r elem leme ent, rep r eplace lace as necessary. I nspec nspectt an d rep replace lace drive belt (4.0L (4.0L an d 4. 4.7L) 7L).. ** Inspect brake hoses. Inspect exhaust system. • • • •

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108,000 Miles (173 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Drain and refill front and rear axles. Inspect brake linings. C l ea ea n a n d l u br br i ca ca t e b r a k e c a l i pe pe r p i n s . Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system. •

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111,000 Miles (178 000 km) Change engine oil. Replace engine oil filter. I nspec nspectt engine cool coolan an t lev level, el, hoses, clamps. Flush and replace engine coolant. Inspect brake hoses. Inspect exhaust system. • • • • • •


NOTE: Insp NOTE: Inspect ection ion and ser service vice should also formed for med anytime anytime a mal malfun functi ction on is obs observ erv pected. en a n ce c e i s r ec ecom m en en d ed ed , *Th i s m a i n t en r eq eq u ir ir ed ed t o m a i n t a i n w a r r a n t y on t h e P C V en a n c e i s n o t r e q u ir ir e d i f t h e **Th i s m a i n t en previously replaced.

LIFT POINTS

STANDARD PROCEDURES - HOISTING A JACK JA CKING ING REC RECOM OM M ENDA ENDATIONS TIONS  Sign up to vote on this title

FLOOR JACK  Useful

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When properly positioned, a floor jack can t o l i ft ft a WJ v eh eh i ccll e ( F ig ig . 8 ). ). S u p po por t t h e

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WJ LIFT POINTS (Conti (Continued) nued) •

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• •

The engine or transmission oil pan. The fuel tank. A front suspension arm.

HOIST A vehicle can be lifted with: A single-post, frame-contact hoist. A twin-post, chassis hoist. A ramp-type, drive-on hoist. • • •

NOTE:: Wh NOTE When en a fr fram amee-co cont ntac actt ty type pe ho hois istt is us used ed,, verify ver ify tha thatt the lif liftin ting g pad pads s are pos positi itione oned d pro proper perly ly (Fig. 8). WAR ARNI NING NG:: TH THE E HO HOIS ISTI TING NG AN AND D JA JACK CK LI LIFT FTIN ING G POINTS POIN TS PRO PROVIDE VIDED D ARE FOR A COM COMPLE PLETE TE VEH VEHIICLE.. WHE CLE WHEN N A CHAS CHASSIS SIS OR DRIV DRIVETR ETRAIN AIN COMP COMPOONENT IS REMOVED FROM A VEHICLE, THE CENTER CEN TER OF GRA GRAVIT VITY Y IS AL ALTER TERED ED MAK MAKING ING SOM SOME E HOISTIN HOIS TING G CON CONDITI DITIONS ONS UNS UNST TABL ABLE. E. PRO PROPER PERL LY SUPP SU PPOR ORT T OR SE SECU CURE RE VE VEHI HICL CLE E TO HO HOIS ISTI TING NG DEVICE WHEN THESE CONDITIONS EXIST.

JUMP STARTING

STANDARD PROCEDURE - JUMP START PROCEDURE

WARN ARNING: ING: REVI REVIEW EW ALL SAF SAFETY ETY PREC AND WARN ARNINGS INGS IN GRO GROUP UP 8A, BA BATTE TTE ING/CHA ING /CHARGIN RGING G SYST SYSTEMS EMS DIAG DIAGNOS NOSTICS TICS JUMP JU MP ST STAR ART T A FR FROZ OZEN EN BA BATT TTER ERY Y, INJURY CAN RESULT. DO NOT JUMP STAR MAINTENANCE FREE BATTERY INDICATO YELLOW OR BRIGHT CO COL LOR. DO N START ST ART A VEH VEHICL ICLE E WHE WHEN N THE BA BATTE TTERY RY BELO BE LOW W TH THE E TOP OF LE LEAD AD PL PLA ATE TES. S. ALL AL LOW JUM UMPE PER R CA CABL BLE E CL CLAM AMPS PS T EACH OTHER WHEN CONNECTED TO A B SOURCE SOU RCE.. DO NOT USE OPE OPEN N FLA FLAME ME TERY TE RY.. RE REMO MOVE VE ME MET TAL ALLI LIC C JE JEWE WELR LRY Y HAND HA NDS S OR WR WRIST ISTS S TO AVO VOID ID INJ INJUR URY Y DENT DEN TAL ARC ARCING ING OF BA BATTE TTERY RY CUR CURREN REN USIN US ING G A HI HIGH GH OU OUTP TPUT UT BOO BOOST STIN ING G DE NOT ALL ALLOW OW BA BATTE TTERY RY VOL VOLT TAGE TO EX VOL VO LTS TS.. RE REFE FER R TO IN INST STRU RUCT CTIO IONS NS WITH DEVICE BEING USED.

CAUTION: When using another veh booste boo sterr, do not allo allow w veh vehicl icles es to tou touch. ch. systems can be damaged on either vehicle

TO JUMP START A DISABLED VEHICLE:

(1) R a i s e h oo ood on d i sa sa b l ed ed v eh eh i cl cl e a n d inspect engine compartment for: B at tery cable clamp condition, condition, clean clean if n Frozen battery. Yellow or bright color test indicator, if e Low battery fluid level. Generator drive belt condition and tens Fuel fumes or leakage, correct if necess • • • • • •

CAUTION:: If the cause of sta CAUTION starti rting ngpro proble ble Sign upistosevere, vote on this title to booste abled vehicle damage charging Useful can Not useful system  result.

(2) Wh en en u si s i ng ng a n ot ot h er er v eh eh ic icl e a s park the bo h i cl cl e w i t h i n c a b

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JUMP STARTING STARTING (Continued) (3) On disabled vehicle, place gear selector in park or n e u t r a l a n d s et et p a r k b r a k e . Tu Tu r n of f a l l a c ce ce s so sories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+ ). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite e nd nd of ca b l es es t o t ou ou ch ch , e le le ct ct r i ca ca l a r c w i ll l l r es es u lt lt . R e v ie ie w a l l w a r n i n g s i n t h i s p r oc oce d ur ur e . (5) On disabled vehicle, connect RED jumper cable cl a m p t o p os os it it i ve ve (+ ) t e rm rm i na na l . C on on n ec ect B L AC AC K ju m p er er c a b le le c l a m p t o e n g i n e g r ou ou n d a s c lo los e t o t h e ground cable attaching point as possible (Fig. 9). (6) Start the engine in the vehicle which has the b oo oos t er er b a t t e ry r y, l et et t h e e ng ng in in e i d le le a f ew ew m i n ut ut e s, s, t h en en s t a r t t h e en g in in e i n t h e v eh eh ic i cl e w i t h t h e d is is charged battery.

Wh en en u si s i ng ng a B o os os t er er v eh eh ic i cl e, e, BLACK cable clamp from battery negative D i s co con n e ct ct R E D c a b le le c la la m p f r om om b a t t e r y terminal. D i s c on on n e ct ct R E D ca b l e c l a m p f r om om b a t t tive terminal on disabled vehicle. •

•

EMERGENCY TOW HOOKS DESCRIPTION

WARNING: REMAIN AT A SAFE DISTANCE VEHI VE HICL CLE E TH THA AT IS BE BEIN ING G TO TOWE WED D VI VIA A HOOKS. THE TOW STRAPS/CHAINS COULD AND CAUSE SERIOUS INJURY. Some J ee eep p vehicles vehicles a re equipped equipped with gency tow hoo gency hooks ks (Fig. 10 10)). The tow hoo hooks ks used for EMERGENCY purposes p urposes only.

CAUTION: CAUTIO N: DO NOT use eme emerge rgency ncy tow tow truck hook-up or highway towing.

Fig. 9 Jumper Cable Clamp Connections 1 - ENGINE GROUND 2 - NEGATIVE JUMPER CABLE 3 - BATTERY NEGATIVE CABLE 4 - POSITIVE JUMPER CABLE 5 - BATTERY POSITIVE CABLE 6 - BATTERY 7 - TEST INDICATOR

Fig. 10 Emerg Emergency ency Tow Hooks 1 - TOW HOOK

CAUTION:: Do not crank sta CAUTION starte rterr mot motor or on dis disable abled d vehicle for more than 15 seconds, starter will overheat and could fail.


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TOWING

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STANDARD PROCEDURES

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TOWING (Continued)

WARNING: ENSURE VEHICLE IS ON A LEV FACE OR TH THE E WH WHEE EELS LS AR ARE E BL BLOC OCKE KE VENT VEHICLE FROM ROLLING.

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TWO WHEEL DRIVE TOWING-REAR END LI

CAUTIO CAUT ION: N: Do no nott us use e st stee eeri ring ng co colu lumn mn secure steering wheel during towing opera

Fig. 11 Tow Vehicles With Approved Equipment

SAFETY SAFE TY PREC PRECAUTIONS AUTIONS CAUTION: The following safety precautions must be observed when towing a vehicle: Secure loose and protruding parts. Al Al w a y s u s e a s a f et et y ch a i n s y s t e m t h a t i s i n d eep en en d e n t o f t h e l i f t in in g a n d t o w i n g e q u i pm pm e n t . D o n o t a l l ow ow t ow ow i n g e qu qu i pm pm en e n t t o c on t a c t t h e disabled vehicle’s fuel tank. D o n ot ot a l l ow ow a n y o n e u n d er er t h e d i s a b l e d v e h ic i cl e while it is lifted by the towing device. D o n o t a l lo low p a s s en en ge g e r s t o r id id e i n a v eh eh ic icl e being towed. Al Al w a y s ob s er er v e s t a t e a n d l oc oca l l a w s r eg eg a r d in in g towing regulations. D o n ot ot t ow ow a v eh eh ic i cl e i n a m a n n er er t h a t cou ld ld jeopardize the safety of the operator, pedestrians or other m oto otorists. rists. D o not a tt ach tow chains , TT-hoo hooks, ks, or J -hoo hooks ks t o a bumper, steering linkage, drive shafts or a non-reinforced frame hole. Do not tow a heavily loaded vehicle. Use a flatbed device to transport a loaded vehicle.

2WD vehicles can be towed with the fron on t h e s u r f a ce ce f o r e x t en en d e d d i s t a n c e s a t exceeding exce eding 48 km /h (30 m ph). (1) Attach wheel lift device to rear wheels (2) Place the transmission in neutral. (3) Raise vehicle to towing position. (4) At At t a c h s a f et et y ch a i n s . R ou ou t e c h a i n s interfere with tail pipe when vehicle is lifte (5) Turn the ignition sw itch to t he OFF unlock the steering wheel.

CAUTIO CAUT ION: N: Do no nott us use e st stee eeri ring ng co colu lumn mn secure steering wheel during towing opera

• •

•

•

•

•

•

•

•

TWO-WHEEL-DRIVE VEHICLE TOWING D a i m le le r C h r y s le le r C o r po por a t i o n r e co com m e n d s t h a t a vehicle be towed with the rear end lifted, whenever possible.

(6) S e cu cu r e s t e e r in in g w h e e l i n s t r a i g h t tion with a clamp device designed for towin (7) P l a c e t r a n s m i s s i on on i n p a r k .

TWO WHEEL DRIVE TOWING-FRONT END

CAUTIO CAUT ION: N: Ma Many ny ve vehic hicle les s ar are e eq equi uipp pped ed dams da ms,, sp spoil oiler ers, s, an and/ d/or or gr grou ound nd ef effe fect ct avoid component damage, a wheel-lift tow cle or a flat-bed hauling vehicle is recomm

(1) Attach wheel lift device to rear wheels (2) Place the transmission in neutral. (3) Raise the rear of the vehicle off the gro install tow dollies under rear wheels. (4) At A t t a c h w h e el el l if if t d ev ev ic ice t o f r on on t raise vehicle to towing position. (5) At t a c h t h e s a f e t y c h a i n s .

 SignDo up to vote onethis title CAUTIO CAUT ION: N: not no t us use stee st eeri ring ng co colu lumn mn secure steering during usefultowing opera  Usefulwheel  Not (6) Turn the ignition sw itch to t he OFF unlock the steering wheel.

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TOWING (Continued) WARN ARNING: ING: WHE WHEN N TOW TOWING ING A DIS DISABL ABLED ED VEH VEHICL ICLE E AND AN D THE DR DRIV IVE E WH WHEE EELS LS AR ARE E SE SECU CURE RED D IN A WHEE WH EEL L LI LIFT FT OR TOW DO DOLL LLIE IES, S, EN ENSU SURE RE TH THE E TRANSMISSION IS IN THE PARK POSITION. CAUTION CAUT ION:: Ma Many ny ve vehic hicles les ar are e eq equi uipp pped ed wi with th ai airr dams da ms,, sp spoi oiler lers, s, an and/ d/or or gr grou ound nd ef effe fect ct pa pane nels ls.. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended.

FOUR W HEE HEEL L DRI VE TOWI TOWI NG— REA REAR R END LI FTE FTED D WARNING: ENSURE VEHICLE IS ON A LEVEL SURFAC ACE E OR TH THE E WH WHEEL EELS S AR ARE E BL BLOC OCKE KED D TO PRE PRE-VENT VEHICLE FROM ROLLING. (1) Attach wheel lift device to front wheels. (2) Place the transmission in neutral. (3 ) R a i s e t h e f r on on t of t h e v eh eh i cl cl e o f f t h e g r ou ou n d a n d i n s t a l l t ow d ol ol l ie ie s u n d e r f r o n t w h e e ls ls . (4) At At t a c h w h e el el l if if t d ev ev ic ice t o r ea ea r w h e el el s a n d raise vehicle to towing position. (5) At At t a c h s a f et et y c h a i n s . R o u t e c h a i n s s o n o t t o interfere with tail pipe when vehicle is lifted. (6) Turn the ignitio ignition n sw itch to t he OFF po positio sition n to unlock the steering wheel.

(7) S e cu cu r e s t e e r in in g w h e e l i n s t r a i g h t tion with a clamp device designed for towin (8) P l a c e t r a n s m i s s i on on i n p a r k .

FOUR WHEE FOUR WHEEL L DRIVE TOWING— FRO FRONT NT LIFTED

WARNING: ENSURE VEHICLE IS ON A LEV FACE OR TH THE E WH WHEE EELS LS AR ARE E BL BLOC OCKE KE VENT VEHICLE FROM ROLLING.

(1) Attach wheel lift device to rear wheels (2) Place the transmission in neutral. (3) Raise the rear of the vehicle off the gro install tow dollies under rear wheels. (4) At A t t a c h w h e el el l if if t d ev ev ic ice t o f r on on t raise vehicle to towing position. (5) At t a c h t h e s a f e t y c h a i n s .

CAUTIO CAUT ION: N: Do no nott us use e st stee eeri ring ng co colu lumn mn secure steering wheel during towing opera (6) Turn the ignition sw itch to t he OFF unlock the steering wheel. (7) S e cu cu r e s t e e r in in g w h e e l i n s t r a i g h t tion with a clamp device designed for towin (8) P l a c e t r a n s m i s s i on on i n p a r k .

CAUTIO CAUT ION: N: Do no nott us use e st stee eeri ring ng co colu lumn mn lo lock ck to secure steering wheel during towing operation.


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SUS USP PENS NSIO IO

WJ

SUSPENSION TABLE OF CONTENTS page SUSPENSION DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2 SUSPENSION AND STEERING SYSTEM . . . . . . 2 WHEEL ALIGNMENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERA OPE RATI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 4 CAMB CA MBER ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CAST CA STER ER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TOE TO E POSIT POSITIO ION N ................. ........4 SPECI SP ECIFI FICA CATI TIONS ONS . . . . . . . . . . . . . . . . . . . . . . . . . 5 FRONT SUSPEN SUSPENSION SION DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 6 SERVICE SERVI CE WARNINGS WARNINGS AND PRECAUTIONS PRECAUTIONS . . . . 6 SPECI SP ECIFI FICA CATI TIONS ONS . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BUSHINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HUB / BEARING DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERA OPE RATI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 JOUNCE BUMPER DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERA OPE RATI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 KNUCKLE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERA OPE RATI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOWER BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOWER CONTROL ARM DESCR DE SCRIP IPTI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . STABILIZER BAR DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . . . . . . . . . . TRACK BAR DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . . . . . . . . . . UPPER BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . UPPER CONTROL ARM DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . . . . . . . . . . REAR SUSPENS SUSPENSION ION DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . . WARNING . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING . . . . . . . . . . . . REAR REA R SUSPE SUSPENSI NSION ON . . . . . . . . . . . . . . . SPEC SP ECIF IFIC ICA ATI TION ONS S ... ......... ...... SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . JOUNCE BUMPER DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . LOWER CONTROL ARM DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . . . . . . . . . . SHOCK  DESC DE SCRI RIPT PTIO ION . . .on . .this . . .title ............ Sign upNto. .vote OPERATION. . . .Not . . .useful ...............  Useful. . .  REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . . . . . . . . . . SPRING

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SUS USP PENS NSIO ION N

UPPER BALL JOINT DESCR DE SCRIP IPTI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 20 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

UPPER CONTROL ARM DESC DE SCRI RIPT PTIO ION N. . . . . . . . . . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . . . . . . . . . .

SUSPENSION DIAGNOSIS AND TESTING - SUSPENSION AND STEERIN STEE RING G SYSTEM CONDITION FRON FR ONT T EN END D NO NOIS ISE E

EXCESSIVE PLAY IN STEERING

FRON FR ONT T WH WHEEL EELS S SHI SHIMM MMY Y

VEHI VE HICL CLE E IN INST STAB ABIL ILIT ITY Y

EXCESSIVE STEERING EFFORT

POSSIBLE CAUSES

CORRECTION

1. Lo Loos ose e or wo worn rn wh whee eell be bear arin ings gs..

1. Ad Adju just st or re repl plac ace e wh whee eell be bear arin in

2. Loose or worn steering or suspension components.

2. Tighten or replace components a necessary.

1. Loo Loose se or wor worn n whe wheel el bea bearin rings. gs.

1. Adj Adjust ust or rep replac lace e whe wheel el bea bearin rin



3. Lo Loos ose e or wo worn rn st stee eeri ring ng ge gear ar..

3. Ad Adju just st or re repl plac ace e st stee eeri ring ng ge gear ar

1. Lo Loos ose e or wo worn rn wh whee eell bea beari ring ngs. s.

1. Ad Adju just st or re repl plac ace e wh whee eell bea beari ring ng



3. Tir ires es wo worn rn or ou outt of ba bala lanc nce. e.

3. Re Repl plac ace e or ba bala lanc nce e ti tire res. s.

4. Alignment.

4. Align vehicle to specifications.

5. Le Leak akin ing g st stee eeri ring ng da damp mpen ener er..

5. Re Repl plac ace e st stee eeri ring ng da damp mpen ener er..

1. Lo Loos ose e or wo worn rn wh whee eell be bear arin ings gs..

1. Ad Adju just st or re repl plac ace e wh whee eell be bear arin in



3. Tire pressure.

3. Adjust tire pressure.

4. Alignment.

4. Align vehicle to specifications.

1. Lo Loos ose e or wo worn rn st stee eeri ring ng ge gear ar..

1. Ad Adju just st or re repl plac ace e st stee eeri ring ng ge gear ar

2. Po Powe werr st stee eeri ring ng flu luid id lo low w. 3. Column coupler binding. 4. Tire pressure. 5. Alignment.

2. Ad Add d fl flui uid d an and d rep epai airr le leak ak..  Sign up to vote on this title 3. Replace couple lerr. useful  4Useful . Adjust  tire Not pres sure. 5. Align vehicle to specifications.

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WJ SUSPENSION (Continued) CONDITION VEHICLE LEADS OR DRIFTS FROM STRAIGHT AHEAD DIRECTION ON UNCROWNED UNCROW NED ROAD

KNOCKING, RATTLING OR SQUEAKI SQUEAKING NG

IMPR IM PROPE OPER R TR TRAC ACKI KING NG

POSSIBLE CAUSES

CORRECTION

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.


5. Wheel Alignment.

5. Align vehicle.


6. Repair as necessary.

7. Cross caster out of spec.

7. Align vehic icle le..

1. Worn shock bushings.

1. Replace shock.

2. Loose, worn or bent steering/ suspension components.

2. Inspect, tighten or replace compo as necessary.

3. Shock valve.

3. Replace shock.

1. Lo Loos ose, e, wo worn rn or be bent nt tr trac ack k ba barr.

1. In Insp spec ect, t, ti tigh ghte ten n or re repl plac ace e co comp mp necessary.

2. Loose, worn or bent steering/ suspension components.


WHEEL ALIGNMENT

OPERATION

CASTER i s t h e f o r w a r d o r r e a r w a r d t steering knuckle knuckle from vertical. Tilting t he t knuckle knuck le rear wa rd pro provide videss po positive sitive cast er er.. t o p o f t h e k n u ck ck le le f or or w a r d p r ov ov i d es es n e ga ga t C a s t e r i s a d i re re ct ct i on on a l s t a b i li li t y a n g l e. e. e n a b le le s t h e f ro r on t w h ee e e l s t o r et et u rn rn t o ahead position after turns. CAMBER i s t h e i n w a r d o r o u t w a r d t i wheel relat ive to t he center of th e vehicle. vehicle. T t o p o f t h e w h e e l i n w a r d p r ov ov i d es es n e ga ga t i v e Tilting t he t op of of t he w heel outw outw ar d pro provide vide ca m b er e r. I n co cor r ec ect ca m b er er w i l l c a u s e w e a r inside or outside edge of the tire. The ang adjusta ble ble,, d am aged co compo mponent( nent(s) s) must to correct the camber angle. i s the WHEEL TO TOE E PO POS SITIO ITION N is Sign up to vote on this title between the leading inside edges and trailin useful wheel toe  Not edges of theUseful front tires. Incorrect is the most common cause of unstable stee uneven tire wear. The wheel toe position is •

DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning i s a c co com p li li sh sh ed ed t h r ou ou g h s u sp sp en en s io ion a n d s t ee ee ri ri n g l in in k a g e a d ju ju s t m en en t s . An a l i gn gn m en en t i s con s id id er er ed ed essential for efficient steering, good directional stabili t y a n d t o m i ni ni m iz iz e t i r e w e a r. r. Th e m os os t i m po por t a n t m ea ea s u r em em en en t s of a n a l i gn gn m en en t a r e ca s t e r, r, ca m b er er and toe position (Fig. 1).

CAUTION:: Nev CAUTION Never er att attemp emptt to mod modify ify sus suspen pension sion 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.

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WHEEL WHEE L ALIGN ALIGNMENT MENT (Cont (Continued) inued)

Fig. 1 Wheel Alignment Alignment Measu Measuremen rements ts 1 - WHEEL CENTERLINE 2 - NEGATIVE CAMBER ANGLE 3 - PIVOT CENTERLINE 4 - SCRUB RADIUS 5 - TRUE VERTICAL

of t h e r e a r a x l e THRUST ANGLE i s t h e a n g l e of r e la la t i v e t o t h e ce n t er er l in in e of t h e v eh eh i cl cl e. e. I n c or or r e ct ct thrust angle can cause off-center steering and excess i v e t i r e w e a r . Th Th i s a n g l e i s n o t a d j u s t a b l e, e, d a m a g e d component(s) must be replaced to correct the thrust angle. •

STANDARD PROCEDURE - CAMBER Before each alignment reading the vehicle should

6 - KING PIN 7 - VERTICAL 8 - POSITIVE CASTER

STANDARD PROCEDURE - CASTER

B e f or or e e a ch ch a l i g n m en en t r e a d i n g t h e v e h i b e jou n ce ce d (r ea ea r f ir ir s t , t h en en f ro ron t ). ). G r a b u m p e r a t t h e c e n t e r a n d j o u n c e t h e vehicl d o w n t h r eSign e t iup m eto s . vote A l won a y this s r etitle lease the bump down position.  Useful  Not useful To o bt bt a i n a n a c cu cu r a t e a l i g n m en en t , a 4 w h e ment machine must be used and the equipm

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WJ WHEEL WHEE L ALIGN ALIGNMENT MENT (Cont (Continued) inued) To o bt bt a i n a n a c cu cu r a t e a l i g n m en en t , a 4 w h e el el a l i gn gn ment machine must be used and the equipment calibrat io ion n verif verified. ied.

SPECIFICATIONS

NOTE: For an acc NOTE: accura urate te whe wheel el toe pos positi ition on adj adjust ust-ment the engine must be engine running.

NOTE: Specifications are in degrees.

(1) Apply parking brakes. (2) S t a r t t h e en g in in e a n d t u rn r n w h ee e el s b ot ot h w a y s before straightening the steering wheel. Center and secure the steering wheel. (3) L oo oos en en t h e t i e r od od a d ju ju s t m en en t s le le ev ev e cl a m p bolts bo lts (Fig. 2) . (4) Turn th e sleeve to obta obta in t he preferred positive TO E -I -I N s p ec ec if if ic ic a t i on on . P os i t i on on t h e c la la m p b ol ol t s a s shown (Fig. 2) for for pro prope perr cl cleara eara nce nce.. (5) Tighten the clamp bolts to 68 N·m (50 ft. lbs.).

FRONT WHEELS - STANDARD SUSPENSIO

NOTE: Mak NOTE: Make e sur sure e the toe set settin ting g doe does s not change change during clamp tightening. (6 ) Ve Ve r if if y a l i g n m en en t s p ec ec if if i ca ca t i on on s , t h e n t u r n t h e engine off.

ALIGNMENT

SPECIFICATIONS

DESCRIPTION

SPECIFICATIO

PREF PR EFER ERRE RED D

CASTER CAST ER + 6.75°

CAMBER − 0.37°

RANGE

+ 6.0° to to + 7.5°

− 0.75°to + 0.5°

MAX RT/LT DIFFERENCE

0.5°

0.5°

FRONT WHEELS - UP-COUNTRY SUSPENS SPECIFICATIONS

DESCRIPTION

SPECIFICATIO

PREF PR EFER ERRE RED D

CASTER CAST ER + 6.5°

CAMBER − 0.37°

RANGE

+ 5.7° to to + 7.2°

− 0.75°to + 0°

MAX RT/LT DIFFERENCE

0.5°

0.5°

REAR AXLE SPECIFICATIONS

Fig. 2 Steering Linkage 1 - DRAG LINK ADJUSTMENT SLEEVE 2 - TIE ROD ADJUSTMENT SLEEVE

STEERING WHEEL CENTERING NOTE: The steering wheel can be centered without affecting the toe position.

DESCRIPTION PREFERRED

SPECIFICATIO CASTER

THRUST ANGLE

RANGE 0° to  0.25°  –0.5° Sign up to vote on this title

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FRONT SUSPENSION

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FRONT SUSP SUSPENSI ENSION ON (Cont (Continued) inued)

slot in the nut does not line up with the c hole, tighten nut until it is aligned. Never lo nut to align the cotter pin hole.

Sheet Music

CAUTIO CAUT ION: N: Su Susp spen ensi sion on co comp mpon onen ents ts wi bushings must be tightened with the vehic mal ride height. It is important to have the supporting the weight of the vehicle when teners are torqued. If springs are not at the ride rid e pos positio ition, n, veh vehicle icle rid ride e com comfor fortt will and cause premature bushing wear.

STANDARD PROCEDURES - SERVICE WARNINGS AND CAUTIONS Fig. 3 Front

CAUTIO CAUT ION: N: Su Susp spen ensi sion on co comp mpon onen ents ts wi bushings must be tightened with the vehic mal ride height. It is important to have the supporting the weight of the vehicle when teners are torqued. If springs are not at the ride rid e pos positio ition, n, veh vehicle icle rid ride e com comfor fortt will and cause premature bushing wear.

1 - SHOCK 2 - COIL SPRING 3 - UPPER SUSPENSION ARM 4 - STABILIZER BAR 5 - LOWER SUSPENSION ARM 6 - TRACK BAR

CAUTION: Components attached with a nut and cotter pin must be torqued to specification. Then if the

SPECIFICATIONS

TORQUE CHA CHART RT TORQUE SPECIFICATIONS

DESCRIPTION

N· m

Ft. Lbs.

Shock Absorber Upper Nut

35

26

Shock Absorber Lower Nut

28

Suspension Arm Upper Axle Bracket Nut

61

45

Suspension Suspen sion Arm Upper Frame Bracket Bolt

61

45

Suspension Arm Lower Axle Bracket Nut

1 63

Suspension Suspen sion Arm Lower Frame Bracket Bolt

1 56

In. L 25

Sign up to vote on this title 120  Useful  Not useful 115

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WJ

SPECIAL TOOLS



Sheet Music

FRONT SUSPENSION

Remover C-4150A Remover/Installer Suspension Bushing 7932

Remover/Installer 6289

Spacer 8279

Reciever 6761

Nut, Long 7603

Sign up to vote on this title Installer 6752  Useful  Not useful Bolt, Special 7604

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BUSHINGS Sheet Music

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) P lace R ec eceiv eiver er 79 7932 32--1 over flanged end of the bushing. (Fig. 4). (4 ) P l a c e s m a l l e n d of R e m ov ov er er /I n s t a l l 7 93 93 22-2 a g a i n s t ot h e r s i d e o f t h e b u s h in in g . (5) Install bolt 7604 through remover, bushing and receiver. (6 ) I n s t a l l L on on g N u t 7 60 60 3 a n d t i g h t e n n u t t o o pu pu l l b u s h in in g ou t of t h e a x l e b r a c k et et .

Fig. 5 Bushing Installation 1 - REMOVER/INSTALLER 2 - AXLE BRACKET 3 - BOLT 4 - RECEIVER 5 - LONG NUT

(5) Remove tools and install the upper su arm.

HUB / BEARING DESCRIPTION Fig. 4 Bushing Removal 1 - RECEIVER 2 - AXLE BRACKET 3 - BOLT 4 - REMOVER/INSTALLER 5 - LONG NUT

(7) Remove nut, bolt, receiver, remover and bushing.

NOTE: On 4x2 vehicle and right side of 4x4 vehicle, leave lea ve Spa Spacer cer 827 8279 9 in pos positio ition n for bus bushin hing g ins instal tallalation.

INSTALLATION

The bearing used on the fro front nt hub of th t h e com b in in ed ed h u b a n d b ea ea r i n g u n it it t y p This unit assembly combines the front whee ing hub (flange) and the front wheel bearin on e p ie iece u n it it . Th e w h e el el m ou ou n t in in g s t u d s on l y r ep ep la la c ea ea b l e com po pon en en t of t h e h u assembly.

OPERATION

The h ub/bearing assembly is mounted t ing knuckle and is retained by three mount accessible acce ssible from from the back of the steering  knu Sign up to vote on this title h u b/ b /b ea ea r i n g u n it it i s n ot ot s er er v ic ice a b le le a n d r e p l a c e d a s Useful an assem y i fuseful the bearing or th b lNot determined t o be defe defective ctive..

REMOVAL

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WJ HUB / BEARI BEARING NG (Conti (Continued) nued) (5) Remove the hub bearing mounting bolts from the back of the steering knuckle. Remove hub beari n g (F i g. g . 6) f r om om t h e s t ee ee ri ri n g k n uc uck le le a n d of f t h e axle shaft.

KNUCKLE DESCRIPTION

The knuckle is a single casting with legs m for the upper and lower ball joints. The knu h a s m a c h i n ed ed m ou ou n t i n g l o ca ca t i o n s f o r t h e c a l ip ip er er s a n d h u b b ea ea r i n g .

OPERATION

The steering knuckle pivot between the u l ow ow e r b a l l joi n t . S t e er er i ng ng l in in k a g e a t t a c h e knuckle allows the vehicle to be steered.

REMOVAL - STEERING KNUCKLE

Fig. 6 Hub Bearing & Knuckle 1 - HUB BEARING 2 - KNUCKLE

INSTALLATION (1) Install the hub bearing to the knuckle. (2) I n s t a l l t h e h u b b ea ea r i n g t o k n uc u ck le le b ol ol t s a n d tighten to 102 N·m (75 ft. lbs.). (3) I n s t a l l t h e h u b w a s h er e r a n d n u t . Ti Ti gh gh t en en t h e h u b n u t t o 237 N ·m ·m (175 f t . l bs bs .) .). I n s t a l l t h e n u t retainer and a new cotter pin. (4) Insta ll t he brake roto rotor, r, caliper caliper an cho chor, r, caliper caliper and ABS wheel speed sensor,(Refer to 5 - BRAKES/ E L E C TR TR I C AL AL /F R O NT NT WH WH E E L S P E E D S E N S O R INSTALLATION). (5) Install the wheel and tire assembly. (6) Remove the support and lower the vehicle.

B all stud servic servicee procedures procedures below below require of t h e h ub u b b ea ea r in in g a n d a xl x l e s h a ft ft . R e installation of upper and lower ball studs re use of Too Tooll Kit 628 6289. 9. (1) Remove hub bearing and axle shaft. (2) D i s co con n e ct ct t h e t i e -r -r od od or d r a g l in in k steering knuckle arm. Refer to Group 2, Sus for proper procedures. (3) R em e m ov ov e t h e cot t e r p in in s f r om om t h e l ow ow e r b a l l s t u d s . (4) R e m ov ov e t h e u p pe pe r a n d l ow ow e r b a l l s t u d (5) Strike the steering knuckle with a br mer to loosen knuckle from the ball studs. knuckle from ball studs (Fig. 7).

JOUNCE BUMPER DESCRIPTION Th e y a r e m o u n t ed ed u n d er er t h e u n i b od od y r a i l s t o m i n i m iz iz e t r a n s m is i s s io ion of n oi oi se se t o t h e p a s s en en g er er com partment.


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KNUCKLE KNUC KLE (Conti (Continued) nued)

INSTALLATION





(1) Position the steering knuckle on the ball studs. (2) Install and tighten the bottom retaining nut to 109 N·m (80 ft. lbs.) torque. Install new cotter pin. (3 ) I n s t a l l a n d t i g h t e n t h e t o p r e t a i n i n g n u t t o 10 10 1 N·m (75 ft. lbs.) torque. Install new cotter pin. (4) Install the hub bearing and axle shaft. (5) C on on n ec ect t h e t i ee-r od od or d r a g l in in k e nd nd t o t h e steering knuckle arm. Refer to Group 2, Suspension, for proper procedures.

LOWER BALL JOINT REMOVAL B all stud servic servicee procedure proceduress bel below ow r equire removal removal of t h e h ub u b b ea ea r in in g a n d a xl x l e s ha h a f t. t . R em em ov ov a l a n d installation of upper and lower ball studs require the use of Too Tooll Kit 628 6289. 9. (1) Position tools as shown to remove and install ball stud (Fig. 8).

LOWER CONTROL ARM DESCRIPTION

The lower suspension arms are hydroform and use voided oval bushings at one end of

OPERATION

The bushings provide isolation from the a arms mount to the unibody frame rail bra t h e a x le le b r a ck ck et et s . Th e a r m a n d b u sh sh i n l oc oc a t i on on a n d r e a ct ct t o l oa oa d s f r om om t h e a x le le .

REMOVAL

(1) Raise the vehicle and support the fron (2) Remove the lower suspension arm nut from the axle bracket (Fig. 9). (3) R e m ov ov e t h e n u t a n d b ol ol t f r om om t h e f r bracket and remove the lower suspension a 9).


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WJ LOWER LOWE R CONT CONTROL ROL ARM (Cont (Continued) inued)

REMOVAL



(1) R e m ov ov e t h e n u t , r et et a i n er er a n d g r o the shock stud in the engine compartment (F

Sheet Music

Fig. 9 Lower Suspension Arm 1 - LOWER SUSPENSION ARM 2 - FRAME RAIL BRACKET 3 - AXLE BRACKET

INSTALLATION (1) Position the lower suspension arm in the axle bracket and frame rail bracket.

NOTE:: Th NOTE The e end end of th the e ar arm m wi with th th the e ov oval al bu bush shing ing attaches to the axle bracket.

Fig. 10 Upper Shock Mounting 1 - RETAINER 2 - STUD 3 - NUT 4 - GROMMET

(2) R a i s e a n d s u pp pp or or t t h e f r o n t a x le le . (3) Remove the lower mounting nuts from bracket (Fig. 11). Remove the shock absorbe

(2) I n st st a l l t h e a x le le b r a ck ck et et b ol ol t a n d n u t f in in g er er tight. (3) Install the frame rail bracket bolt and nut finger tight. (4) Remove support and lower the vehicle. (5) Wi Wi t h t h e v eh eh i cl cl e on t h e g r ou ou n d t i gh gh t e n t h e frame bracket bolt to 156 N·m (115 ft. lbs.). Tighten the axle bracket nut to 163 N·m (120 ft. lbs.). (6) C he h e ck t he h e a li l i g n me m e n t i f n ew ew p a r ts t s w er er e installed.

SHOCK DESCRIPTION The top of the shock absorbers are bolted to the body. The bottom of the shocks are bolted to the axle b r a ck ck et et s . Th e s t a n d a r d s h oc ock s h a v e con v en en t i on on a l


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Fig. 11 Lower Shock Mounting

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SHOCK SHOC K (Cont (Continued) inued) (3) I n s t a ll l l t h e m ou ou n ti t i ng ng n u t s a n d t i gh gh t en en t o 2 8 N·m (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 N·m (26 ft. lbs.).

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

OPERATION Th e coi l s p r i n g s c on on t r o l r i d e q u a l it it y a n d m a i n t a i n properr ride height. The iso prope isolators lators pro provide vide road noi noise se isolation.

Fig. 12 Front Coil Spring 1 - UPPER ISOLATOR 2 - COIL SPRING 3 - LOWER ISOLATOR 4 - STABILIZER LINK

REMOVAL (1) R a i se s e a n d s up u p p or or t t h e v eh eh ic i cl e. e. P o si si t io ion a h y d r a u l i c ja ja c k u n d e r t h e a x l e t o s u pp pp or or t i t . (2) Remove the wheel and tire assemblies. (3) Remove stabilizer bar links mounting nuts and bolts from the axle brackets. (4) Remove Remove sh oc ock k absorbers lower mounting nuts from the axle brackets. (5) Remove the track bar mounting bolt from the axle bracket. (6) Lower the axle until the spring is free from the upper mount and isolator (Fig. 12). (7) Remove the spring from the vehicle. (8) R em em ov ov e a n d i ns ns pe pe ct t h e u pp pp e r a n d l ow ow e r spring iso isolat lat ors.

INSTALLATION (1) Install the upper isolator. (2) Install the lower isolator with the isolator locator nub in the axle pad hole (Fig. 13). (3) Position the coil spring on the axle spring pad.

CAUTION CAU TION:: Ens Ensure ure the spr spring ing is pos positio itioned ned on the


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Useful useful Fig.  13 Not Lower Isolator

1 - LOCATING NUB 2 - LOWER ISOLATOR

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WJ SPRING SPRI NG (Cont (Continued) inued)

Fig. 15 Stabilizer Bar Fig. 14 Isolator Spring Locator 1 - COIL SPRING 2 - SPRING LOCATOR 3 - LOWER ISOLATOR

(8) Tighten Tighten all suspe suspensio nsion n co compo mponents nents to pro prope perr torque. (9) Install the wheel and tire assemblies. (10) Remove support and lower vehicle.

STABILIZER BAR DESCRIPTION The bar extends across the front underside of the chassis and is mounted to the frame rails. Links are connected from the bar to the axle brackets. The stabilizer bar and links are isolated by rubber bushings.

OPERATION Th e s t a b i l iz iz er er b a r i s u s ed ed t o con t r o l v e h i cl cl e b o d y r ol ol l d u r i n g t u r n s . Th e s p r in in g s t e el el b a r h e lp lp s t o c on on t r o l t h e v eh eh i cl cl e b o dy dy i n r e la la t i o n s h ip ip t o t h e s u s pe pe n sion.

REMOVAL (1) Raise and support the vehicle. (2) R em em ov ov e l in in k n u t s a n d b ol ol ts t s (F ig i g . 1 5) a n d remove the links. (3 ) R e m o the stabili bar b ol ol t s (

1 - LINK 2 - STABILIZER BAR 3 - BUSHING 4 - RETAINER

(2) I n s t a ll l l t h e l in in k s on t o t h e s t a b i li li z a x le le b r a ck ck et et s a n d i n st st a l l t h e b ol ol t s a n d tight. (3) Remove the supports and lower the ve (4) With the vehicle on the ground tighten bilizer bar link nuts to 106 N·m (78 ft. lbs.)

TRACK BAR DESCRIPTION

Th e b a r i s a t t a ch c h ed ed t o a f ra ra m e r a il il b r axle bracket. The bar is forged and has non able isolator bushings at both ends.

OPERATION

The track bar is used to control front axl movement and provides cross car location of assembly.



REMOVAL Sign up to vote on this title (1) Raise and support vehicle. useful  Useful  Notthe

(2) R e m ov ov e t h e n u t a n d b ol ol t f r om om t h e f r bracket (Fig. 16). (3) R e t h e b ol ol t f r the axl

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TRACK BAR (Cont (Continued) inued)

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

NOTE: It may be necessary to pry the axle assembly over to in inst stal alll th the e tr trac ack k ba barr to th the e fr fram ame e ra rail il bracket. (3) Remove the supports and lower the vehicle. (4) With the vehicle on the ground tighten the nut at the frame rail bracket and to the bolt at the axle bracket to 100 N·m (74 ft. lbs.). (5 ) C h e ck ck a l i g n m en en t s p ec eci f ic ic a t i on on s i f a n e w t r a c k b a r w a s i n st st a l l ed ed .

Fig. 17 Track Bar Axle Bracket 1 - AXLE BRACKET 2 - TRACK BAR

UPPER BALL JOINT REMOVAL

B all stud servic servicee procedures procedures below below require of t h e h ub u b b ea ea r in in g a n d a xl x l e s h a ft ft . R e installation of upper and lower ball studs re use of Too Tooll Kit 628 6289. 9. (1) Position tools as shown to remove an ball stud (Fig. 18).


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WJ UPPER UPPE R BALL JOINT (Cont (Continued) inued)

Fig. 18 Upper

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

OPERATION Th e a r m s m ou ou n t t o t h e u n i bo bod y f r a m e r a i l b r a c k et et and the axle brackets. The arm and bushings provide location and react to loads from the axle. The bushings provide isolation from the axle.

REMOVAL (1) Raise vehicle and support the axle. (2 ) R e the


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Fig. 19 Upper Suspension Arm

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REAR SUSPENSION Sheet Music

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

CAUTION: Suspension components with rubber/urethane tha ne bus bushin hings gs sho should uld be tig tighte htened ned wit with h the veh vehiicle 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 premature bushing wear.

WARNING WARN ARNING: ING: Sus Suspen pension sion com compon ponent ents s wit with h rub rubber ber bushings must 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 rid e pos positi ition, on, veh vehicle icle rid ride e com comfor fortt will be aff affect ected ed and cause premature bushing wear.

Fig. 20 Rear Suspension 1 - SHOCK 2 - UPPER SUSPENSION ARM 3 - COIL SPRING 4 - STABILIZER BAR 5 - LOWER SUSPENSION ARM

DIAGNOSIS AND TESTING - REAR SUSPENSION CONDITION VEHI VE HICL CLE E IN INST STAB ABIL ILIT ITY Y

VEHICLE PULLS TO ONE SIDE

POSSIBLE CAUSES 1. Lo Loos ose e or wo worn rn wh whee eell be bear arin ings gs..

1. Re Repl plac ace e wh whee eell be bear arin ings gs..

2. Loose, worn or bent suspension components.


3. Tire pressure.


1. Weak or broken spring.

1. Replace spring.

2. Alignment. 3.Tires. 4. Brakes.

KNOCKING, RATTLING

CORRECTION

1 Worn shock bushings

2. Align vehicle to specific ations. Sign up to vote on this title 3. Replace tires. Useful Not useful

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

4. Repair as necassary. 1 Replace shock

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WJ REAR SUSP SUSPENSI ENSION ON (Conti (Continued) nued) CONDITION IMPR IM PROPE OPER R TR TRAC ACKI KING NG

POSSIBLE CAUSES

CORRECTION

1. Lo Loos ose, e, wo worn rn or be bent nt su susp spen ensi sion on components.


2. Bent axle.

2.Replace axle.

SPECIFICATIONS

TORQUE CHA CHART RT TORQUE SPECIFICATIONS

DESCRIPTION

N· m

Ft. Lbs.

Shock Absorber Upper Nut

108

80

—

Shock Absorber Lower Nut

115

85

—

Suspension Arm Upper Ball Joint Nut

142

105

—

Suspension Arm Upper Frame Bolts

100

74

—

Ball Joint Plate Bolts

136

1 00

—

Suspension Arms Lower Axle Bracket Nut

163

120

—

Suspension Arms Lower Frame Bracket Nut

156

115

—

Stabilizer Bar Retainer Bolts

54

40

—

Stabilizer Bar Bar Link Nut

54

40

—

Stabilizer Bar Bracket Link Nut

92

68

—

SPECIAL TOOLS

JOUNCE BUMPER

REAR SUSPENSION

DESCRIPTION

In. Lb

Th e jou n ce ce b u m pe pe r s a r e m ou ou n t e d insi s p r i n g , bSign e t w eup e ntot hvote e a xon l e this a n dtitle the frame rail i m i ze ze t r a n sUseful m i s s i on on  of Not n oi oiuseful se to the passe partment.

OPERATION

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LOWER LOWE R CONT CONTROL ROL ARM (Cont (Continued) inued)

OPERATION





The bushings provide isolation from the axle. The a r m s m ou ou n t t o t h e u n ib ib od od y f r a m e r a i l b r a c ke ket a n d t h e a x l e b r a c ke ke t s. s . Th e a r m a n d b u sh sh i ng n g s p ro rov id id e l oc oc a t i on on a n d r e a ct ct t o l o a d s .

b r a ck ck et et s . Th e s t a n d a r d s h oc ock s h a v e c t w i n t u be be con s tr t r u ct ct io i on a n d a r e l ow ow p r e ch a r g ed ed . G a s ch a r g in i n g p re re ve ve nt nt s ca v i t a t i o r ou ou g h r oa oa d op er er a t i o n . U p -C -C o u n t r y s h oc oc k tube design and are high pressure gas charg

REMOVAL

OPERATION

(1 ) R a i s e t h e v e h i cl cl e a n d s u pp pp or or t t h e r e a r a x l e. e. (2) Remove the lower suspension arm nut and bolt from the axle bracket (Fig. 21). (3) R em e m ov ov e t h e n u t a n d b ol ol t (F i g. g . 21) f r om om t h e frame rail and remove the lower suspension arm.

The shoc shock k absorbers da mpen jounce jounce a m o t io ion of t h e v e hi hi cl cl e ov er er v a r i ou ou s r oa oa d and limit suspension rebound travel.

REMOVAL (1) R a i se se a n d s up u p p or t t h e v eh eh ic i cl e. e. h y d r a u l i c ja ja c k u n d e r t h e a x l e t o s u p p or or t

CAUTION CAUTI ON:: Do no nott al allo low w th the e ax axle le to ha hang ng upper suspension arm ball joint.

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

Fig. 21 Lower Suspension Arm 1 - LOWER SUSPENSION ARM 2 - AXLE BRACKET 3 - FRAME BRACKET

INSTALLATION (1) Position the lower suspension arm in the axle bracket and frame rail bracket.

NOTE:: Th NOTE The e end end of th the e ar arm m wi with th th the e ov oval al bu bush shing ing attaches to the axle bracket. (2) I n st st a l l t h e a x le le b r a ck ck et et b ol ol t a n d n u t f in in g er er tight. (3) Install the frame rail bracket bolt and nut finger tight. (4) Remove the supports and lower the vehicle.

Fig. 22 Shock Absorber 1 - SHOCK

INSTALLATION Sign up to vote on this title



(1) InstallUseful absorber useful in the frame  the shock  Not a n d i n st st a l l t h e b ol ol t a n d n u t . (2) Install the shock absorber in the axle a n d i n st st a l l t h e b ol ol t a n d n u t .

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WJ

SPRING Sheet Music

DESCRIPTION The coil springs mount up in the wheelhouse which is part of the unitized body bracket. A rubber doughnut isolator is located between the top of the spring and the body. The bottom of the spring seats on a a x l e i s ol ol a t o r m a d e o f r u b b er er w i t h a s t e el el i n s e r t . Th Th e isolat iso lat ors provide road noi noise se iso isolat lat io ion n

OPERATION Th e coi l s p r i n g s c on on t r o l r i d e q u a l it it y a n d m a i n t a i n prope pro perr ride h eight.

REMOVAL (1) R a i se s e a n d s up u p p or or t t h e v eh eh ic i cl e. e. P o si si t io ion a h y d r a u l i c ja ja c k u n d e r t h e a x l e t o s u pp pp or or t t h e a x l e. e. (2) Remove the wheel and tire assemblies. (3) Remove the stabilizer bar link from the stabilizer bar (Fig. 23). (4) Remove the shock absorber lower bolt from the axle bracket. (5) Lower the hydraulic jack and tilt the axle and remove the coil spring (Fig. 23).

Fig. 23 Coil Spring 1 - COIL SPRING 2 - ISOLATOR 3 - STABILIZER LINK 4 - ISOLATOR

Fig. 24 Isolator Locator Nub 1 - LOWER ISOLATOR 2 - LOCATOR NUB 3 - AXLE SPRING PAD

CAUTION: CAUTIO N: Ens Ensure ure the spr spring ing is pos positi itione one lowe lo werr is isol olat ator or wi witth the en end d of th the e against the isolator spring locator (Fig. 25)

Fig. 25 Isolator Spring Locator  - Typic Sign up to vote on this title

1 - LOWER ISOLATOR Useful LOCATOR 2 - SPRING 3 - COIL SPRING

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STABILIZER BAR

UPPER BALL JOINT

DESCRIPTION

DESCRIPTION - UPPER SUSPENSION A BUSHINGS, AND BALL JOINT

Sheet Music

The stabilizer bar extends across the back side of the rear axle. Links are connected between the bar and frame rail brackets. The stabilizer bar and links are isolated by rubber bushings.

OPERATION Th e s t a b i l iz iz er er b a r i s u s ed ed t o con t r o l v e h i cl cl e b o d y roll, during turns. The bar helps control the vehicle body in relationship to the suspension.

REMOVAL (1) Raise and support the (2) Remove the stabilizer b a r a n d f r a m e m ou ou n t . (F i g . (3) Remove the stabilizer (4) Remove the stabilizer

vehicle. bar links from stabilizer 2 6) 6). bar retainer bolts. bar.

The suspension suspension arm uses vertical spool spool bu i s ol ol a t e r oa oa d n oi oi se se . Th e s u sp sp en en s io ion a r m t h r o ug ug h b u s h i n gs gs t o c a g e n u t s i n t h e b od od y a joint plate to the top of the differential hous

OPERATION - UPPER SUSPENSION ARM BUSHINGS, AND BALL JOINT

The upp upper er suspe suspensio nsion n ar m pro provides vides fo lateral location of the rear axle. The suspen travel is limited through the use of jounce in compression and shock absorbers in rebo

REMOVAL

(1) Raise and support the vehicle. (2) Support the rear axle with a hydraulic (3) Remove the ball joint nut from the to upper suspension arm (Fig. 27).

Fig. 26 Rear Stabilizer Bar 1 - LINK 2 - RETAINER 3 - BUSHING 4 - STABILIZER BAR

INSTALLATION (1) P os os it it i on on t h e s t a bi b i li li ze ze r b a r on t h e a x le le a n d i n s t a l l t h e r e t a i n e r s a n d b ol ol t s . E n s u r e t h e b a r i s ce n t e r ed ed w i t h e q u a l s p a c i n g o n b ot ot h s i d es es . Ti Ti g h t en en t h e

Fig. 27 Ball Joint Nut 1 - BALL JOINT NUT 2 - UPPER SUSPENSION ARM




Notfrom usefulthe arm with (4) Separate ball  joint  Useful 8278 (Fig. 28).

NOTE: It may be necessary to strike the up

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WJ UPPER UPPE R BALL JOINT (Cont (Continued) inued)

(2) I n st st a ll l l t h e b a ll ll joi n t m ou ou nt n t in in g tighten to 136 N·m (100 ft. lbs.). (3) R a i s e t h e r ea ea r a x le le w i t h a h y dr dr a u l align the upper arm with the ball joint. (4) Pull the arm down on the ball joint i n s t a l l a ne new w nut. Tighten the nut to 142 N ft. lbs.). (5) Remove the supports and lower the ve

Sheet Music

UPPER CONTROL ARM DESCRIPTION

The suspension suspension arm uses vertical spool spool bu i s ol ol a t e r oa oa d n oi oi se se . Th e s u sp sp en en s io ion a r m t h r o ug ug h b u s h i n gs gs t o c a g e n u t s i n t h e b od od y a joint plate to the top of the differential hous

OPERATION

Fig. 28 Separate Ball Joint 1 - REMOVER - 8278 2 - UPPER SUSPENSION ARM 3 - BALL JOINT STUD

The upp upper er suspe suspensio nsion n ar m pro provides vides fo lateral location of the rear axle. The suspen travel is limited through the use of jounce in compression and shock absorbers in rebo

REMOVAL

(1) Raise and support the vehicle. (2) Support the rear axle with a hydraulic (3) Remove the park brake cables and br from the arm (Fig. 30).




Useful



 Not useful

Fig. 30 Park Brake Cables And Brake H

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UPPER UPPE R CONT CONTROL ROL ARM (Cont (Continued) inued)

Fig. 31 Ball Joint Nut 1 - BALL JOINT NUT 2 - UPPER SUSPENSION ARM

NOTE: It may be necessary to strike the upper control tr ol ar arm m wit with h a ha hamm mmer er to se sepa para rate te th the e ba ball ll joi joint nt from the arm. (6 ) R em em ov ov e t h e u p pe pe r s u s pe pe n s io ion a r m m ou ou n t i n g bolts and remove the arm (Fig. 33).

Fig. 32 Separate Ball Joint 1 - REMOVER - 8278 2 - UPPER SUSPENSION ARM 3 - BALL JOINT STUD

INSTALLATION (1) P o si si t io ion t h e u pp pp e r s us u s pe pe n s io ion a r m i n t h e frame rail brackets. (2) Install the mounting bolts and tighten to 100 N·m (74 ft. lbs.). (3) Pull the arm down on the ball joint stud and i n s t a l l a ne Tighten t he nut to 142 N·m (105 (105 new w nut. Tighten ft. lbs.). (4 ) I n s t a l l t h e p a r k b r a k e ca ca b l es es a n d b r a k e h o s e t o the arm. (5) Remove the supports and lower the vehicle.

 Sign up to vote on this title Fig. 33 Upper Suspension Arm Mounting Useful ARM Not useful SUSPENSION 1 - UPPER 2 - MOUNTING BOLT

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DIFFE DIF FERE RENT NTIA IAL L & DRIV DRIVE ELIN

WJ

DIFFERENTIAL & DRIVELINE

Sheet Music

TABLE OF CONTENTS page PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1 FRONT TUBE AXLE . . . . . . . . . . . . . . . . . . . . . . 15 15 FRONT AXLE - 186FBI . . . . . . . . . . . . . . . . . . . . 16

REAR AXLE - 198RBI . . . . . . . . . . . . . . . . REAR AXLE - 226RBA . . . . . . . . . . . . . . . .

PROPELLER SHAFT TABLE OF CONTENTS page PROPELLER SHAFT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 OPERA OPE RATI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2 PROP PR OPEL ELLE LER R SHAFT SHAFT . . . . . . . . . . . . . . . . . . . . . 2 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 4 PROP PR OPEL ELLE LER R SHAFT SHAFT . . . . . . . . . . . . . . . . . . . . . 4 SPECI SP ECIFI FICA CATI TIONS ONS . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PROPELLER SHAFT - FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PROPELLER SHAFT - FRONT 4.7L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . . . . . . . . . . PROPELLER SHAFT - REAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . . . . . . . . . . SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . DOUBLE CARDAN UNIVERSAL JOINTS DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . ASSE AS SEMB MBL LY . . . . . . . . . . . . . . . . . . . . . .

PROPELLER SHAFT

essary to accommodate the variations in len essary due t o suspension suspension tr avel. The The C /V jo transfer case end of the propeller shaft is fix tw o C/V joints joints are co connecte nnected d by a hol hollo low w Th e s h a ft ft l en en g th t h i s n ot ot a d ju ju st s t a b le le a n d according acco rding to applic applicat at io ion. n.

DESCRIPTION A p ro rop el el le le r s h a f t (F i g . 1 ) i s t h e s h a f t w h i c h con n e ct ct s t h e t r a n s m i s s i on on /t r a n s f e r c a s e t o t h e a x l e d i f ferential. This is the link through which the engine power is transmitted to the axle. The propeller shaft is designed and built with the yoke lugs in line with each other which is called zero phasing. This design pro produce ducess the smoo smoothest thest running c on on d i t i on on , a n ou t -o -of -p -p h a s e s h a f t c a n c a u s e a v i br br a -

OPERATION Sign up to vote on this title



Th e p ro ropUseful el le el le r s h a f t Not s t op er er a t e t h r o   m uuseful stantly changing relative angles between th m is i s si s i on on a n d a x le le w h en e n g oi oi ng ng ov er er v a r i surfaces. It must also be capable of changin

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PRO PR OPE PELL LLE ER SHA SHAFT FT

PROPELLER PROP ELLER SHAF SHAFT T (Cont (Continued) inued)

Fig. 1 Propeller Shafts - Except 4.7L 1 2 3 4 5

-

REAR AXLE STRAP BOLT SLIP YOKE REAR PROPELLER SHAFT

6 - PINION FLANGE 7 - FRONT AXLE 8 - BOLT 9 - FRONT PROPELLER SHAFT 10 - TRANSFER CASE

CAUTION CAUT ION:: Us Use e or origi igina nall eq equip uipme ment nt re repl plac acem emen entt parts par ts for att attach aching ing the pro propel peller ler sha shafts fts.. The spe specicified torque must always be applied when tightening the fasteners.

DIAGNOSIS AND TESTING - PROPELLER SHAFT VIBRATION Ti r es es t h a t a r e ou t -o -of -r -r ou ou n d , or w h e el el s t h a t a r e u n ba b a l a n ce c e d, d, w i l l ca u s e a l ow ow f r eeqq u en en cy cy v ib ib r a t i on on . (Refe Referr to 22 - TIRE TIRE S/WHE EL S - DIAGNOSI S AND TESTING)

B r a k e r ot ot or or s t h a t a r e u n ba ba l a n ce ce d w i l har sh, low frequenc frequencyy vibration. (Refe (Referr to 5 - DIAGNOSIS AND TESTING) D r i v el el i n e v i b r a t i on on c a n a l s o r e s u l t f r o d a m a g ed ed e n gi gi n e m o u n t s . P r op op el el l er er s h a f t v i br br a t i on on i n cr cr e a s es es a s speed is increased. A vibration that occurs s p ec eci f ic ic s p ee ee d r a n g e i s n ot ot u s u a l l y c a u s e d b p el el l er er s h a f t b ei ei n g u n b a l a n c ed ed . D e f ec ect i v e joints, or an incorrect propeller shaft angle, ally the cause of such a vibration.


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PRO PR OPE PELL LLE ER SH SHA A

WJ PROPELLER PROP ELLER SHAF SHAFT T (Cont (Continued) inued) DRIVELINE VIBRATION



Sheet Music

Drive Condition Propell Pro peller er Sha Shaft ft Noi Noise se

Univ Un iver ersa sall Jo Join intt No Nois ise e

Possible Cause

Correction

1) Und Underc ercoat oating ing or oth other er for foreig eign n mate materia riall on shaft.

1) Clean exterior of shaft and wash solvent.

2) Lo Loo ose UU-jo join intt cla lam mp sc scrrew ews. s.

2) In Inst stal alll ne new w cl clam amp ps an and d sc scre rews ws tighten to proper torque.

3) Loose or bent U-joint yoke or excessive runout.

3) Install new yoke.

4) In Inco corr rrec ectt dr driv ivel elin ine e an angu gula lari rity ty..

4) Me Meas asur ure e an and d co corr rrec ectt dr driv ivel elin ine e

5) Re Rear ar sp spri ring ng ce cent nter er bo bolt lt no nott in in sea seat. t.

5) Lo Loos osen en sp spri ring ng uu-bo bolt lts s and and se 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, an evaluate.

10) Excessive drive pinion gear shaft runout.

10) Re-index propeller shaft and ev

11) Ex Exce cess ssiv ive e ax axle le yo yoke ke de defl flec ecti tion on..

11) In Insp spec ectt an and d re repl plac ace e yo yoke ke if

12)) Ex 12 Exce cess ssiv ive e tr tran ansf sfer er ca case se ru runo nout ut..

12)) In 12 Insp spec ectt an and d re repa pair ir as ne nece cess ss

1) Lo Loos ose e UU-jo join intt cla lam mp sc scrrew ews. s.

1) Ins nsttal alll ne new w cl cla amp mps s an and d sc scre rews ws tighten to proper torque.

2) Lack of lubrication.

2) Replace U-joints as necessar

BALANCE

(9) Install a screw clamp at position 1 (Fi

NOTE:: Re NOTE Remo movi ving ng an and d re re-i -ind ndex exing ing th the e pr prop opel eller ler shaft 180° relative to the yoke may eliminate some vibrations. If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure: (1) Raise the vehicle. (2) Clean all the foreign material from the propeller shaft and the universal joints. (3) Inspect the propeller shaft for missing balance w e i g h t s , b r o k e n w e l d s , a n d b e n t a r e a s . If the propell pe lle er sh shaft aft is i s bent, bent, it i t mus mustt be replaced. replaced. (4) Inspect the universal joints to ensure that they


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PROPELLER PROP ELLER SHAF SHAFT T (Cont (Continued) inued) clamp to one of the other three positions. Repeat the vibration test. (11) I f t h er e r e i s n o d i ff ff er er en en ce ce i n v ib ib r a t i on on a t t h e other positions, the source of the vibration may not be propeller shaft. (12) I f t h e v ib ib r a t i on on d ec ecr ea ea s e d, d , i n st st a l l a s ec econ d clamp (Fig. 3) and repeat the test.

Fig. 3 Two Clamp Screws At The Same Position (13) I f t h e a d d i t io ion a l cl a m p ca u s es es a n a d d i t io io n a l v i br br a t i o n , s e pa pa r a t e t h e cl a m p s (1 /4 i n ch ch a b o ve ve a n d below the mark). Repeat the vibration test (Fig. 4).

RUNOUT

(1) R em e m ov ov e d i rt rt , r u st st , p a in in t , a n d u n d f r om om t h e p r op op el el le le r s h a f t s u r f a ce ce w h e r e t h e cator will contact the shaft. (2) The dial indicator must be installed pe ular to the shaft surface. (3) Measure runout at the center and en shaft sufficiently far away from weld areas t that the effects of the weld process will not e t h e m e a s u r em em e n t s . (4) Refer to Runout Specifications chart. (5) If the propeller shaft runout is out of s tion, remove remove the pro prope pelle llerr shaft , index th e sh a n d r ee-i n st st a l l t h e p ro rop el el le le r s h a f t . M ea ea s u runout again. (6) I f t h e p ro rop el el le ler s h a f t r u n ou ou t i s n o s p ec eci f ic ic a t i on on s , m a r k t h e s h a f t a n d y ok ok es es orientation. (7) If the propeller shaft runout is not with i f ic ic a t i on on s , v e r i fy fy t h a t t h e r u n ou ou t of t h e t r a t r a n s fe fe r ca s e a n d a x le le a r e w i t hi hi n s p Correct as necessary and re-measure propel runout. (8) R e p la la c e t h e p r op op el el le le r s h a f t i f t h e exceeds the limits. RUNOUT SPECIFICATIONS

Front of Shaft

0.020 in. (0.50

Center of Shaft

0.025 in. (0.63

Rear of Shaft

0.020 in. (0.50

note: Measure front/rear runout approximately 3 (76 mm) from the weld seam at each end o shaft tube for tube lengths over 30 inches. tube lengths under 30 inches, the maximum allowed runout is 0.020 in. (0.50 mm) for th length of the tube.

STANDARD PROCEDURES - PROPELLER SHAFT ANGLE 

Fig. 4 Clamp Screws Separated 1 - 1 ⁄ 2 INCH

Sign up toapplie vote ons this The pro proce cedure dure applies to title both bo th the fro front nt s h a f t s a n d Useful t h e r ea ea  r pNot rop useful ro el le el le r s h a f t . To front fro nt (output) angle on t he C/V front pro prope pe t h e i n cl cl in in om om e t er er i s p la la c e d o n t h e m a c h i n e

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WJ PROPELLER PROP ELLER SHAF SHAFT T (Cont (Continued) inued) (3) R ot ot a t e t h e s h a f t u n t il i l t r a n s m i ss ss io ion /t r a n s f er er case output yoke bearing cap is facing downward, if necessary. Always Alwa ys make meas asure urem ment nts s fro from m fro front nt to rear. (4) Place Inclinometer on yoke bearing cap, or the p in in i on on f l a n g e r i n g , (A) p a r a l le le l t o t h e s h a f t (F i g . 5). C e n t er er b u bb bb le le i n s ig ig h t g la la s s a n d r ec ecor d m e a s ur ur eement. This me meas asurem ureme ent will give yo you u the trans transmis mis-sion or Outp Output ut Yoke Yoke Ang Angle le (A) (A)..

Fig. 6 Propeller Shaft Angle Measureme 1 - SHAFT YOKE BEARING CAP 2 - INCLINOMETER

Fig. 5 Front (Output) Angle Measurement (A) 1 - SLIP YOKE BEARING CAP 2 - INCLINOMETER

(5) R ot ot a t e p ro rop el el le le r s h a f t 90 d eg eg r ee ees a n d p la la c e Inclinometer on yoke bearing cap, or propeller shaft tube on C/V prope propelle llerr sha ft, para lle llell t o the shaft (Fig. 6). Center bubble in sight glass and record measurem en en t . Th i s m e a s u re r e m en en t ca n a l s o b e t a k e n a t t h e rear end of the shaft. This me meas asurem ureme ent will wi ll give yo you u the prop prope eller shaft angle (C). (6 ) S u b t r a c t s m a l l er er f i gu gu r e f r om om l a r g e r ( C m i n u s A) to obtain transmission output operating angle.


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Useful  Not useful Fig. 7 Rear (Input) Angle Measurement 1 - PINION YOKE BEARING CAP

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SPECIFICA SPEC IFICATION TIONS S (Cont (Continued) inued)

Fig. 8 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

SPECIFICATIONS

PROPELLER SHAFT TORQUE SPECIFICATIONS

DESCRIPTION

N· m

Front Shaft - Companion Flange Bolts

32

Rear Shaft - Yoke Nuts

19

Ft. Lbs. Sign up to vote on this title 24  Useful  Not useful 14

In. Lb  — —

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WJ

SPECIAL TOOLS

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SPECIAL TOOLS

Inclinometer 7663

PROPELLER SHAFT - FRONT REMOVAL NOTE: Different length propeller shafts are used for differ dif ferent ent dri drivet vetrai rain n app applica licatio tions. ns. Ens Ensure ure tha thatt the correct propeller shaft is used. (1) Place vehicle on floor or drive-on hoist with full weight of vehicle vehicle on suspe suspensio nsion. n. (2) Shift the transmission and transfer case, if necessary, into the Neutral position. (3) Measure the dista nce from from the face of the C/V joint jo int cup to th e end of th e C /V joint joint boo boott (Fig. 9) 9)..

(5) M a r k a l in in e a cr os os s t h e c om om p a n i on on f l t r a n s f e r c a s e a n d C /V j oi oi n t a t t h e r e a r o prope pro pelle llerr sha ft fo forr insta llation refe referenc rence. e. (6) Ma rk a line across the C /V joints joints an ion companion flanges for installation refere (7) R e m ov ov e b ol ol t s f r om om t h e f r on on t C /V j pinion companion flange. (8) R e m ov ov e b ol ol t s f r om om t h e r e a r C /V j transfer case companion flange. (9) Push the propeller shaft forward to cle f er er c a s e c om om p a n i on on f l a n g e a n d r e m ov ov e t h e

INSTALLATION

NOTE: Different length propeller shafts are differ dif ferent ent dri drivet vetrai rain n app applic licati ations ons.. Ens Ensure ure correct propeller shaft is used.

(1) Install the shaft between companion f (2) Th Th e s h a f t s h ou ou ld ld r ot ot a t e f r ee ee ly ly i n flange. (3) Align marks on the companion flanges ma rks on t he C /V joints. joints. (4) Inst all bo bolts lts to t he front C/V joint joint bolts to 32 N·m (24 ft. lbs.). (5) I n st st a l l t h e b ol ol t s t o t h e r ea ea r C /V tighten bolts to 32 N·m (24 ft. lbs.). (6) Verify propeller shaft length. (7) Lower vehicle.

PROPELLER SHAFT - FRO 4.7L REMOVAL

Fig. 9 Measurement 1 - C/V JOINT CUP

(1) Raise and support vehicle. (2) Remove crossmember/ crossmember/skid pla te a s nec gain access to the propeller shaft. (3) Shift transmission and transfer case, sary into Neutral. (4) M a r k a l in in e a c ro ros s t h e y ok ok e a t t h e  at th case, link yoke and propeller shaft yoke Sign up to vote on this title t h e f r on on t p r op op el el l er er s h a f t f or or i n s t a l l a t i on on Useful Not useful  (Fig. 10). (5) Mark a line across the propeller shaft pinion shaft yoke for installation reference.

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PROPELLER PROP ELLER SHAFT - FRON FRONT T 4.7L (Cont (Continued) inued)

(3) Align mark on the rear link yoke and u joint to the mark on the transfer case yoke. (4) L oo oos e ly ly i n s t a l l b ol ol t s t o h ol ol d u n i ve ve r s a transfer case yoke. (5) Align ma rk on front universal joint joint t on the axle pinion yoke. (6) Ti Ti g h t en en t h e U -j -joi n t s t r a p /c la la m p b o axle yoke to 19 N·m (14 ft. lbs.). (7) Ti Ti gh gh t en e n t h e u n iv iv er er s a l j o i n t t o t r a n s bolts to 27 N·m (20 ft. lbs.). (8) Lower the vehicle.

Sheet Music

PROPELLER SHAFT - REA REMOVAL Fig. 10 Reference Marks on Yokes 1 - REFERENCE MARKS

(9) P u s h r ea ea r of p ro rop el el le ler s h a f t u pw pw a r d t o cl ea ea r transfer case yoke. (10) Separate front universal joint from front axle. (11) Separate propeller shaft from vehicle.

(1) R a i s e a n d s u pp pp or or t v eh eh i cl cl e o n s a f et et y (2) S h i f t t h e t r a n s m i s s io ion a n d t r a n s f e r c a essary, to their neutral positions. (3) Mark a line across the axle pinion yok prope pro pelle llerr sha ft yok yokee for insta llation refe referenc renc (4) R e m ov ov e t h e b ol ol t s h ol ol d in in g t h e u n i v e clamps to the pinion yoke. (5) Slide the slip yoke off of the transmi transfer case, output shaft and remove the p shaft (Fig. 12).

Fig. 11 Front Propeller Shaft - 4.7L 1 - FRONT AXLE 2 - BOOT 3 - PROPELLER SHAFT 4 - DOUBLE CARDAN U-JOINT 5 - TRANSFER CASE 6 - BOOT


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WJ PROPELLER PROP ELLER SHAFT - REAR (Conti (Continued) nued)

INSTALLATION



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(1) S li l i de de t h e s li li p y ok ok e on t h e t r a n s m i ss ss io i on , 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) I n st st a l l t h e u n iv iv er er s a l joi n t cl a m p a n d cl a m p bolts to the pinion yoke. Tighten bolts to 19 N·m (14 ft. lbs.). (5) Lower the vehicle.

SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY I n d i v id id u a l c om om p on on e n t s of ca r d a n u n i ve ve r s a l joi n t s a r e n ot ot s e rv rv i ce ce a b le le . I f w o r n o r l ea ea k i n g , t h e y m u s t b e replaced as an assembly. (1) Remove the propeller shaft. (2) Using a soft drift, tap the outside of the beari n g c a p a s s e m b ly ly t o l o os os en en s n a p r i n g . (3) R em em ov ov e s n a p r in in g s f r om om b ot ot h s id id es es of y ok ok e (Fig. 13).

Fig. 14 Press Out Bearing 1 - PRESS 2 - SOCKET

(7) I f t h e b e a r i n g c a p w i l l n ot ot p u ll ll o u t o f b y h a n d a f t er er p r es es si s i ng ng , t a p t h e y ok ok e e a r b ea ea r i n g ca p t o d i s l od od g e t h e c a p . (8) To r e m ov ov e t h e op po pos i t e b ea ea r i n g ca p , yoke over and straighten the cross in the op Then, carefully press the end of the cross remaining bearing cap can be removed (Fig.

CAUTIO CAUT ION: N: If the cro ross ss or be bear arin ing g ca stra st raigh ightt du duri ring ng ins insta talla llati tion on,, th the e be bear arin in score the walls of the yoke bore and dam occur.

ASSEMBLY Fig. 13 Remove Snap Ring 1 - SNAP RING

(1) Ap pl pl y e xt xt r e m e p r e s su su r e (E P )  N.L.G.I. Sign up to vote on this title or 2 g r e a s e t o i n s id id e o f y o ke ke b o r es es t o a i d i n Useful Not useful   tion. (2) P os i t i on on t h e cr os os s i n t h e y o ke ke w i t h ting, if equip equippe ped, d, po pointing inting up (Fig. 16 16)).

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SINGLE SING LE CARDA CARDAN N UNIVE UNIVERSAL RSAL JOIN JOINTS TS (Cont (Continued) inued)

Fig. 17 Install Bearing On Trunnion Fig. 15 Press Out Remaining Bearing 1 - CROSS 2 - BEARING CAP

1 - BEARING CAP 2 - TRUNNION

(6) Repeat Step 3 and Step 4to install the b ea ea r i n g c a p . I f t h e j oi oi n t i s s t i f f o r b i n di di n g , s y ok ok e w i t h a s of of t h a m m e r t o s e a t t h e n e ed ed l e (7) Add grease to lube fitting, if equipped (8) Install the propeller shaft.

DOUBLE CARDAN UNIVER JOINTS DISASSEMBLY

I n d i v id id u a l com p on on e n t s of c a r d a n u n i v a r e n ot ot s e r vi vi ce ce a b l e. e. I f w or n or l ea ea k i n g , t h e y r e pl pl a c ed ed a s a n a s s e m b ly ly. (1) Remo Remove ve t he pro prope pelle llerr sha ft. ( 2 ) U s i n g a s o f t d r i f t , t a p t h e o u tside of t Sign up to vote on this title i n g c a p a s s e m b ly ly t o l o os os e n s n a p r i n g . (3) R e m ov ovUseful e all th e b ea ea useful r i n g ca p s n a p  Not 18). (4) Set the joint in an arbor press or vis ke who i n si si d d i is large en

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2001 JEEP GRAND CHEROKEE Service Repair Manual.pdf

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