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SERVICE
MANUAL
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1979
JEEP TECHNICAL
SERVICE MANUAL
Maintenance |
CHAPTERS
1A GENERAL SERVICE AND DIAGNOSIS
1B ENGINES
1C COOLING SYSTEMS
1D BATTERIES
1E CHARGING SYSTEM
1F STARTING SYSTEM
1G IGNITION SYSTEM
1H CRUISE COMMAND
1J FUEL SYSTEMS
1K EXHAUST SYSTEMS "
1L POWER PLANT INSTRUMENTATION
2E
2J
2K2L
3N
3J
3A
3B
Jeep Corporation
Service Department
Copyright 1978 Jeep Corporation
All Rights Reserved Litho in U.S.A.
3D
3C
CHAPTERS
2A CLUTCH
2B MANUAL TRANSMISSION
2C AUTOMATIC TRANSMISSION
2D TRANSFER CASE
2E PROPELLER SHAFT
2F AXLES
2G BRAKES
- 2H WHEELS AND TIRES
2J STEERING COLUMNS
2K MANUAL STEERING GEAR 2L POWER STEERING GEAR AND PUMP
2M STEERING LINKAGE
2N SUSPENSION
CHAPTERS
3A WATER LEAK/WIND NOISE
DIAGNOSIS AND REPAIR
3B METAL REPAIR AND PAINTING
3C INSTRUMENT PANELS
AND COMPONENTS
3D HEATER
3E AIR CONDITIONING
3F BODY AND FRAME COMPONENTS
3G HOODS
3H LIFTG ATESTAILGATES
3J
DOORS
3K REAR" QUARTER
3L LUGGAGE RACKS
3M SEAT ASSEMBLIES
3N WINDSHIELD-REAR WINDOW
3P HEADLINING - HARDTOP ENCLOSURE EXTERIOR DECALS AND OVERLAYS
3R LIGHTING SYSTEMS
3S HORN SYSTEMS
3T WINDSHIELD WIPERS
3U TAILGATE WINDOW DEFOGGER
3V RADIO SOUND SYSTEMS
Alphabetical
Index
pip
1979 Model Jeep Vehicles
Conversion of English and Metric Measures
Decimal Equivalents
General Dimensions
How To Use This Manual
Keys and Locks
Metric SystemSI
mm mmm
Power Train Combinations1979 CJ Models
Power Train Combinations
1979 CherokN-Wagoneer-TncK Models
Standard Torque Specifications ani Capscrew Markings
Towing
Vehicle Identification
A-3
A-10
A-14
A-13
A-1
A-7
A-11
Page
A-12
A-12
A-2
A-8
A-6
80371 A
SEQUENCE
RESULT
<$><
CAUTION
DO NOT TOU
ANY OTHER
IGNITION
SYSTEM WIRES
CHECK FOR
FUEL SYSTEM OR
MECHANICAL
ENGINEPROBlEM
80371B
A-2
GENERAL INFORMATION
CHECK
CONNECT
DISCONNECT
REPAI R OR
REPLACE
80371C
The charts are divided into three sections: step, sequence and result. Always start at the first step and go
through the complete sequence from left to right.
CONNECT JUMPER
BETWEEN
COIL NEGATIVE
TERMINAL
AND GROUND
CONNECT VOLTMETER
TO COIL POSITIVE
TERMINAL AND
TO GROUND
Torque Information
TURN IGNITION ON
VOLTAGE
BETWEEN
4.9 AND 7.9 VOLTS
VOLTAGE ABOVE
8 VOLTS
UNCOUPLE AND
COUPLE CONNECTORS
AT CONTROL UNIT
AND DISTRIBUTOR
OiQ
VOLTAGE
BETWEEN
4.9 AND 7.9"'
VOLTS
8
REPLACE
VOLTAGE CONDENSER
BELOW
4.8 VOLTS
' -0
VOLTAGE
BELOW
4.8 VOLTS
You will also find Service Diagnosis Charts throughout this manual. These charts list causes of specific
problems in descending order of probability. It i s more
likely that a problem would result from the first listed
"possible cause" than the fourth, for instance.
Visual inspection often leads directly to the correct
solution. All service procedures should begin with a
careful visual inspection of any suspected part or
assembly.
DISCONNECT RADIO
INTERFERENCE CONDENSER
o
80371D
SAE GRADE 1 or 2
(Used Infrequently)
SAE GRADE 5
(Used Frequently)
SAE GRADE 6 or 7
(Used at Times)
SAE GRADE 8
(Used Frequently)
Torque
Torque
Torque
Torque
CAPSCREW
BODY SIZE
inches Thread
Ft-Lb
SAE 1 or 2
SAE 6 or 7
SAE 5
SAE 8
Nm
Ft-Lb
Nm
Ft-Lb
Nm
Ft-Lb
Nm
12
14
16.2698
18.9815
1/4-20
-28
5
6
6.7791
8.1349
8
10
10.8465
13.5582
10
13.5582
5/16-18
-24
11
13
14.9140
17.6256
17
19
23 0 4 8 9
25.7605
19
25.7605
24
27
32.5396
36 6 0 7 1
3/8-16
-24
18
20
24.4047
27.1164
31
35
42.0304
47.4536
34
46.0978
44
49
7/16-14
-20
28
30
37.9629
40.6745
49
55
66.4351
74.5700
55
74.5700
70
78
59.6560
66.4351
94.9073
105.7538
1/2-13
-20
39
41
52.8769
55.5885
75
85
101.6863
115.2445
85
115.2445
105
120
9/16-12
-18
51
55
69.1467
74.5700
110
120
149.1380
162.6960
120
162.6960
155
170
142.3609
162.6960
210.1490
230.4860
5/8-11
-18
83
95
112.5329
128.8027
150
170
203.3700
230.4860
167
226.4186
210
240
284.7180
325.3920
3/4-10
105
115
142.3609
155.9170
270
295
366.0660
399.9610
280
379.6240
375
-16
420
508.4250
569.4360
7/8- 9
-14
160
175
216.9280
237.2650
395
435
535.5410
589.7730
440
596.5520
605
675
820.2590
915.1650
1- 8
-14
235
250
318.6130
338.9500
590
660
799.9220
894.8280
660
894.8280
910
1233.7780
1342.2420
990
70090
-: ~^mm
T a r e " " ~ :
i^rz^zr^iZL
'^aasr-
'mm^^^^^^^mm^^^
Ton-lead Fasteners
Various sizes of internal and external hex-lobular
(Torx) head fasteners are used as attaching hardware on
numerous components and assemblies in 1979 Jeep vehicles. Due to the ever-changing usage and application
of automotive fasteners, Torx-head fasteners may not be
identified as such throughout this manual. However,
these fasteners may be removed or installed using Tool
Set J - 2 5 3 5 9 - 0 2 .
Fly.A-1
CJ-i Modal
Fig. A-2
CJ-7 Modal
OJ Models
Two CJ models are available for 1979: the 83.5-inch
wheelbase CJ-5, model 83, and the 93.5-inch wheelbase
CJ-7, model 93. See figures A-l and A-2. Beyond the 10inch difference in wheelbase, CJ-5 and CJ-7 differ primarily in available options. CJ-7 models are available
with an automatic transmission, Quadra-Trac full-time
4-wheel drive, and a molded hardtop. These options are
not available on CJ-5 models.
The Renegade Package continues to be offered on CJ
models for 1979. It features new 9-inch by 15-inch tires
mounted on 8-inch wide, styled-steel wheels along with
unique exterior and interior trim.
The Golden Eagle trim package continues to be available on 1979 CJ models. The package includes unique
exterior paint and decals, 9-inch by 15-inch tires
mounted on 8-inch wide, slotted-steel wheels, rear
mounted spare tire, roll bar, and deluxe interior with a
clock and tachometer.
Refer to the Power Train Combinations Chart in this
section for engine and transmission availability.
Cherokee Models
For 1979, three Cherokee models are offered: the base
2-door model 16, the Wide Track model 17, and the 4door model 18. See figures A-3, A-4, and A-5.
A-4
GENERAL INFORMATION
Fig. A-4
Fig. A-5
Cherokee Model 17
Cherokee Model 18
Wagoiieer Model
%
A-3
Cherokee Model 16
GENERAL INFORMATION
A-5
The Golden Eagle trim package is available on 1979 J10 Truck models. The package includes unique exterior
paint and decals, 10-inch by 15-inch tires mounted on 8inch wide, slotted-steel wheels, tubular steel grille
guard, rear step bumper, off-road driving lamps and
deluxe interior.
Refer to the Power Train Combinations Chart in this
section for engine and transmission availability.
Fig A-6
Wagoneer Model 15
F5g. A-7
Fig. A-8
Wheelbase
(Inches)
J-10
25
J-10
J-20
Series
Option 1
Option 2
119
6200
45
131
6200
46
131
6800
7600
8400
60532
A-6
GENERAL INFORMATION
VEHICLE IDENTIFICATION
JEEP CORP.
TOLEDO, OH USA
SSR & 0 No
Sales Order N
Trim
Option No.
Paint
Option No.
Vehicle Identification
(VIN) Number
Jeep
Model No.
60534
Fig. A-9
All Vehicle Identification Numbers contain 13 characters in a combination of letters and numbers that provide specific information about the vehicle. VIN's for all
Jeep vehicles can be decoded using the following chart.
Special Sales Request and Order (SSR&O) Number
Transmission
Jeep
A -
GVW/Model
A 3750 83, 93
E 4150 83, 93 HD
N -6200 15 16, 17, 18, 25, 45
P - 6 8 0 0 46
S - 7 6 0 0 46
Y - 8 4 0 0 46
Auto
F 3-Speed
M 4-Speed
Plant of Manufacture
and Serial No.
000.001 - 699,999
Toledo Built
700.001 - 999,999
tampion Built
000001
Model
WB (in)
109
109
109
109
119
131
131
83
93
Engine
GENERAL INFORMATION
A-7
Color
Classic Black
Firecracker Red
Alpaca Brown Metallic
Olympic White
Russet Metallic
Wedgewood Blue
Cumberland Green Metallic
Arrowhead Silver Metallic
Sable Brown Metallic
Saxon Yellow
Morocco Buff
Bordeaux Metallic
Ensign Blue
Mandarin Orange
80379
GVWR:
-RAIN.TIRE SIZE
GAWR. FRT.
M I N . TIRE SIZE
M GAWR. RR.
M I N . TIRE SIZE
M A X . COLD T I R E PRESS. FRT.
RR.
RIM SIZE
1
I
VEHICLE NUMBER
TYPE
Fig,
80384
Safety Sticker
POSITIONS
12345
12 3 4 5
KEY C O D E S
41049
Fig. A-11
A-8
GENERAL INFORMATION
TOWING
General
A conventional towing sling is recommended for use
on all Jeep vehicles because of its stability and reduced
likelihood of damage. The following instructions apply
only to this device. When using other than sling-type
towing equipment, be sure to follow the manufacturer's
instructions.
A safety chain system that is completely independent
of the lifting and towing attachment must be used. Be
careful when installing safety chains so that they do not
damage the vehicle.
If additional ground clearance is required, a towing
dolly may be used. The end of the vehicle to be placed on
the dolly should be lifted with the same equipment as
when towing.
WARNING: Never tow a Jeep vehicle with the Emergency Drive control activated or reduction unit in low
range (automatic transmission only).
Safety Precautions
Whenever possible, tow the vehicle from the rear to
prevent damage to the transmission or rear axle.
Secure loose or protruding parts of a damaged
vehicle.
The end of the vehicle being towed should be lifted a
minimum of four inches off the ground. Check opposite end for adequate ground clearance.
Always use a safety chain system that is independent of the lifting and towing attachment.
Do not allow any of the towing equipment to bear on
the fuel tank.
Do not go under the vehicle while it is lifted by the
towing equipment.
Do not allow passengers to ride in a towed vehicle.
Always observe all state and local laws regarding
such items as warning signals, night illumination,
speed, etc.
Do not attempt a towing operation which could
jeopardize the operator, any bystanders or other
motorists.
WARNING: Never tow a Jeep vehicle with the Emergency Drive control activated or reduction unit in low
range (automatic transmission only).
CJ Models
Front (Refer to Figure A-12)
GENERAL INFORMATION
:
~~ ~-mm8m$m*r
-mmtemwrnZ:
Fig. 1-12
Fig. A - 1 4
Fig. A-13
Fig. A-15
A-10
GENERAL INFORMATION
Truck Mollis
80370
Fig. A - 1 7
i E I E i t l INFORMATION A-11
M e t r i c System-Si
The International System of Units (Systeme International d'Unites) officially abbreviated
"SI" in all languages - the modern metric system
QUANTITY
EXAMPLES OF
Length
EXAMPLES OF
METRIC UNIT
SYMBOL
QUANTITY
meter
Celsius Temperature
General use
circumference
Thermodynamic
General use
Turning circle/
Temperature
APPLICATIONS
Dimensions
METRIC UNIT
SYMBOL
degree Celsius
APPLICATIONS
Tire rolling
k
* kelvin
radius
Electric Current
Braking distance
General use
Greater than 9 9 9
meter
Dimensions
kilometer
millimeter
milliampere
mA
microampere
uA
kilovolt
kV
km
mm
Potential Difference
Depth of surface
Area
ampere
General use
(Electromotive
finish
micrometer
urn
square centimeter
cm2
Force)
volt
millivolt
mV
microvolt
uV
megohm
Mn
linings
kilohm
kn
ohm
ii
farad
Small areas
Electric Resistance
square millimeter
mm2
Electric Capacitance
General use
General use
microfarad
Volume
cubic meter
Engine Capacity
liter
capacity
cubic c e n t i m e t e r
cm
Measurement of
elapsed time
picofarad
pF
Fuel Consumption
Vehicle performance
1/100 k m
Oil Consumption
Vehicle performance
1/1000 km
l/s
Stiffness
Linear stiffness
kilonewton meter
kN/m
second
Tire Revolutions
Tire Data
rev/km
minute
min
Pressure
Tire
kilopascal
kPa
Vehicle fluid
Volume Flow
T i m e Interval
hour
day
Coolant
General use
m/s
Road speed
kilometer per h o u r
km/h
Engine compression
General use
m/s2
Lubricating oil
Velocity
Manifold
Acceleration &
Deceleration
squared
Frequency
Rotational
Electronics
General use
Speed
Mass
Vehicle mass
1L.cij<ii
anall UIdnuaHfdiifiy
rsit Inn
Density
hertz
Hz
kilohertz
kHz
megahertz
mHz
Luminous Intensity
Bulbs
candela
cd
rpm
Accumulator
Battery
ampere hour
A-h
rps
Storage Rating
megagram
General use
kilogram
kg
Small masses
gram
milligram
mg
General use
Barometric pressure
U.S.A./METRIC COMPARISON
kg/m
centimeter
g/cm
kg/I
newton
Force
Moment of Force
QUANTITY
USA
METRIC -
Length
Inch-Foot-Mile
Meter
Weight (mass)
Ounce-Pound
Kilogram
Area
Square inch/Foot
Square Meter
Volume-Dry
SYMBOL
m
Kg
2
Cubic inch/Foot
Cubic Meter
Ounce-Pint-Quart-Gallon
Liter
Velocity
m/s
Road Speed
km/h
Force
Pound-Force
Newton
Handbrake lever
Torque
Foot-Pounds
N e w t o n meter
N-m
effort etc.
Power
Horsepower
Kilowatt
kW
Pressure
Kilopascal
kPa
Temperature
Degrees Fahrenheit
Degrees Kelvin
and Celsius
Pedal effort
Torque
n e w t o n meter
N-m
(Torque)
Power, Heat
General use
watt
Flow Rate
Bulbs
kilowatt
kW
-Liquid
Alternator output
Engine performance
Starter performance
70091
A-12
GENERAL INFORMATION
GVWR
3 T-150
CJ-5
Model 8 3
83.5-Inch
Wheelbase
CJ-7
Model 9 3
93.4-Inch
Wheelbase
Soft Top
3750
6-258-2V
(3)
Hard Top
4150
(1)
304-2V
Soft T o p
3750
6-258-2V
Hard T o p
4150
(1)
Transfer
Case
Axle Ratio
20
Clutch
QT. (Inches)
3.07
NA
Engine
4 T-18
O
NA
10.5
0(2)
Front
Rear
Standard
Wheels
Dana
30
Open
End
AMC/
Jeep
11.7
Inch
Disc
Std.
11x2
Drum
15x6
5 Bolt
5.50 B.C.
Dana
30
Open
End
AMC/
Jeep
11.7
Inch
Disc
Std.
11x2
Drum
10.5
s
O
10.5
15x6
5 Bolt
5.50 B.C.
Notes:
(1)
Brakes (Inches)
Rear
NA
S
Axle Model
Front
NA
0(3)
304.2V
Trac-Lok
(2)
Abbreviations:
(2)
(3)
Transmission
Series
Engine
3 ( T 15 A) 4 ( T 18) A
Wagoneer
Model 15
109 - Inch
Wheelbase
6200 GVWR
J - 10 Truck
Model 25
119 - Inch
Wheelbase
Model 4 5
131 - Inch
Wheelbase
6200 GVWR
J - 2 0 Truck
Model 4 6
130.7 - Inch
Wheelbase
6 8 0 0 GVWR
7 6 0 0 Opt.
8 4 0 0 Opt.
6-258-2V
(1) (4)
0
O
360-2V
6-258-2V
(1) (4)
0(1)
0
360-2V
N A California
4.88 Ratio Available Trac-Lok Only
N A with Q T
Low range NA with Q T
11.0(1)
4.88
Brakes
Front
Rear
Front
Rear
Standard
Wheels
Dana
Open
End
Dana
44
12 Inch
Disc
11x2
Drum
15x6
6 Bolt
5.50 B.C.
Dana
Open
End
Dana
44
12 Inch
Disc
15x6
11x2
6 Bolt
D r u m 5.50 B.C.
Dana
Open
End
Dana
44
12 Inch
Disc
11x2
Drum
Dana
Open
End
Dana
60
12.5
Inch
Disc
12x
2.50
Drum
15x6
6 Bolt
5.50 B.C.
S
11.0(1)
S(1)
0
S(1)
0(1)
4.09
S(1)
S(1)
3.73
Axle Model
11.0
S(1)
S(1)
3.54
S
0
Notes:
(1)
(2)
(3)
(4)
360-2V
11.0(1)
S(1)
0
3.07
Trac-Lok
(3)
11.0
S(1)
0(1)
11.0
S
S(1)
360-2V
QT
S
Cherokee
Models 16, 17
& 18
108.7 - Inch
Wheelbase
6200 GVWR
20
Clutch
(Inches)
16.5
x
6.75
8 Bolt
6.50 B.C.
Abbreviations:
B.C. - Bolt Circle
GVWR - Gross Vehicle Weight Rating
N A - Not Available
O - Optional Equipment
S - Standard Equipment
60539
CJ Models
CJ-5
Wagoneer
Models
Cherokee Models
CJ-7
Model 16
2-Dr.
Model 17
2 Dr.
Model 18
4-Dr.
Model 15
Truck Models
J-10 Series
Model 25
Model 45
j
J-20 Series
Model 46
Wheelbase
83.5(212.0)
93.5(237.5)
108.7(276.1)
108.7(276.1)
108.7(276.1)
108.7(276.1)
118.7(301.5)
130.7(332.0)
130.7(332.0)
Overall Length
138.4(402.3)
147.9(375.7)
183.5(466.1)
183.5(466.1)
183.5(466.1)
183.5(466.1)
192.5(489.0)
204.5(519.4)
204.5(519.4)
23.5(59.7)
31.4(79.8)
23.5(59.7)
30.9(78.5)
29.9(75.9)
44.9(114.0)
29.9(75.9)
44.9(114.0)
29.9(75.9)
44.9(114.0)
29.9(75.9)
44.9(114.0)
29.9(75.9)
43.9(111.5)
29.9(75.9)
43.9(111.5)
29.9(75.9)
43.9(111.5)
68.6(174.2)
68.6(174.2)
Overhang
Front
Rear
Overall Width
Overall Height
Open Body
Soft Top
Hard Top
Step Height
Front
Rear
75.6(192.0)
78.9(200.4)
75.6(192.0)
75.6(192.0)
78.9(200.4)
78.9(200.4)
78.9(200.4)
66.9(169.9)
67.6(171.7)
66.9(169.9)
66.7(169.4)
69.3(176.0)
69.1 (175.5)
70.7(179.6)
20.7(52.6)
19.9(50.5)
20.8(52.8;
19.9(50.5)
20.8(52.8)
20.7(52.6)
20.7(52.6)
22.1(56.1)
67.6(171.7)
71.4(181.4)
71.3(181.1)
67.6(171.7)
71.3(181.1)
70.5(179.1)
27.0(68.6)
26.1(66.3)
19.9(50.5)
Front Tread
51.5(130.8)
51.5(130.8)
59.2(150.4)
65.4(166.1)
59.2(150.4)
59.4(150.9)
63.3(160.8)
63.3(160.8)
64.6(164.1)
Rear Tread
50.0(127.0)
50.0(127.0)
57.8(146.8)
62.3(158.2)
57.8(146.8)
57.8(146.8)
63.8(162.1)
63.8(162 1)
65.9(167.4)
6.9(17.5)
6.9(17.5;
7.7(19.6)
8.6(21.8)
7.7(19.6)
7 7(19.6)
7.7(19.6)
7.7(19.6)
8.1 (20.6)
Min.Turning Diameter-feet(m)
34.1 (10.4)
38.0(1 1.6)
37.7(11.5)
39.4(12.0)
37.7(11.5)
37.7(11.5)
40.6(12.4)
44.5(13.6)
44.5(13.6)
37.9(96.3)
30.5(77.5)
39.1(99.3)
35.0(88.9)
41.9(106.4)
37.0(94.0)
41.9(106.4)
37.0(94.0)
41.9(106.4)
37.0(94.0)
41.3(104.9)
37.0(94.0)
41.3(104.9)
41.3(104.9)
41.3(104.9)
55.4(140.7)
36.0(91.4)
53.8(136.7)
36.0(91.4)
60.5(153.7)
60.9(154.7)
60.5(153.7)
60.9(154.7)
60.5(153.7)
60.9(154.7)
60.5(153.7)
60.9(154.7)
60.5(153.7)
60.5(153.7)
60.5(153.7)
Shoulder Room
Front
Rear
55.4(140.7)
55.4(140.7)
53.8(136.7)
56.3(143.0)
58.3(148.1)
58.3(148.1)
58.3(148.1)
58.3(148.1)
58.3(148.1)
58.3(148.1)
58.3(148.1)
58.3(148.1)
58.3(148.1)
58.3(148.1)
58.3(148.1)
38.0(96.5)
38.0(96.5)
38.0(96.5)
38.0(96.5)
40.2(102.1)
40.2(102.1)
40.2(102.1)
39.8(101.1)
40.8(103.6)
40.9(103.9)
40.6(103.1)
39.9(101.3)
39.6(100.6)
37.2(94.5)
37.2(94.5)
37.2(94.5)
37.2(94.5)
25.2(64.0)
25.1(63.8)
24.9(63.2)
25.6(65.0)
24.9(63.2)
24.7(62.7)
10.2(288.8)*
40.2(102.1)
36.0(91.4)
36.0(91.4)
35.8(90.9)
46.8(118.9)
36.0(91.4)
36.0(91.4)
34.5(87.6)
Cargo Space
Overall Length
Length at Floor
Width at Wheelhouse
Width at Floor
Width of Tailgate Opening
Height of Sides and Tailgate
81.6(207.3)
44.3(112.5)
60.9(154.7)
54.9(139.4)
81.6(207.3)
44.3(112.5)
60.9(154.7)
54.9(139.4)
81.6(207.3)
44.3(112.5)
60.9(154.7)
54.9(139.4)
81.6(207.3)
44.3(112.5)
60.9(154.7)
54.9(139.4)
26.8(68.0)
86.5(219.7)
84.3(214.1)
50.0(127.0)
68.0(172.7)
57.2(145.3)
20.5(52.1)
26.4(67.0)
28.2(71.6)
77.7(2200.2)
77.7(2200.2)
98.5(250.2)
96.3(244.6)
50.0(127.0)
68.0(172.7)
57.2(145.3)
20.5(52.1)
98.5(250.2)
96.3(244.6)
50.0(127.0)
68.0(172.7)
57.2(145.3)
20.5(52.1)
80363
A-14
GENERAL I N W W X i
Decimal Equivalents
Millimeter
Decimal
.1
.0039
.15
.0059
Fraction
Drill
Milli-
Size
meter
1.75
Decimal
Fraction
Drill
Milli-
Size
meter
Decimal
Fraction
50
.0700
4.0
Millimeter
22
.1570
.0689
Drill
Size
.1575
.2
.0079
1.8
.0709
.1590
21
.25
.0098
1.85
.0728
.1610
20
.3
.0118
.35
.0156
.4
.0157
79
1/64
.0177
.65
.7
.0827
2.15
.0846
74
2.2
.0866
2.25
.0885
73
.0250
72
.0256
.0260
71
.0280
70
.0276
.0315
66
2.6
65
2.7
.1063
.0360
64
2.75
.1082
.0370
63
2.78
.1094
.0335
1.0
1.05
.0354
.0374
62
.0390
61
2.8
.0394
.0400
60
.0410
59
.0413
58
.0430
57
1.1
.0433
1.15
.0452
2.9
56
.0465
3.1
.1220
3.18
.1250
3.2
.1260
3.25
.1279
1.3
.0512
55
3.5
.1378
54
3.57
.1406
3.6
.1417
1.59
.0625
.0629
.0635
1.65
1.7
3.7
.1457
3.75
.1476
53
.1850
.1870
52
5.2
.1960
.1968
.2031
.2067
.2086
.2187
.2205
28
27
26
.2244
5.75
.2263
.1535
23
5/32
7.8
.3071
15.08
.5937
19/32
7.9
.3110
15.48
.6094
39/64
15.5
.6102
7.94
.3125
8.0
.3150
.2344
.2362
.3189
16.27
.6406
16.5
.6496
16.67
.6562
17.0
.6693
.2441
6.25
.2460
6.3
.2480
6.35
.2500
6.4
.2520
6.5
.2559
.2638
6.75
.2657
6.75
.2657
.2660
.3248
21/64
.3346
.3386
R
41/64
21/32
17.06
.6719
43/64
17.46
.6875
11/16
17.5
.6890
17.86
.7031
18.0
.7087
18.26
.7187
18.5
.7283
18.65
.7344
19.0
.7480
45/64
23/32
.3425
.3437
8.75
.3445
19.05
.7500
3/4
8.8
.3465
19.45
.7656
49/64
11/32
19.5
.7677
8.9
.3504
19.84
.7812
9.0
.3543
20.0
.7874
.3583
20.24
.7969
20.5
.8071
47/64
25/32
51/64
9.13
.3594
9.2
.3622
9.25
.3641
21.03
.8281
53/64
9.3
.3661
21.43
.8437
27/32
21.5
.8465
9.4
.3701
21.83
.8594
9.5
.3740
22.0
.8661
9.53
.3750
22.23
.8750
22.5
.8858
15/64
23/64
.3680
3/8
.3770
1/4
5/8
8.7
.3580
37/64
8.73
9.1
20.64
.8125
21.0
.8268
13/16
55/64
7/8
9.6
.3780
22.62
.8906
9.7
.3819
23.0
.9055
9.75
.3838
23.02
.9062
29/32
9.8
.3858
23.42
.9219
59/64
23.5
.9252
23.81
.9375
24.0
.9449
.3860
.2598
6.7
.3230
.3480
.6299
.3228
7/32
.6250
16.0
8.2
8.5
15.88
8.1
.2401
6.2
.3160
.3307
.2323
5.95
5/16
.3390
9.9
.3898
9.92
.3906
10.0
.2610
24
.5906
8.4
.2283
6.0
6.6
.5781
15.0
8.6
.2570
25
14.68
.3051
9/16
.3031
.3268
35/64
7.75
.3320
.2210
5.7
1/2
7.7
.3281
.2165
5.56
19/64
.2992
8.33
.2126
5.6
.3020
8.3
13/64
.2420
9/64
.2968
.2047
5.3
6.1
.2953
7.54
8.25
.2380
29
7.5
.2008
5.25
.1496
.1562
10
.2010
5.16
5.8
30
.1540
3.97
.1935
.2340
.1520
3.9
.1929
.1990
5.9
.1495
3.8
3/16
.2280
1/8
.1470
1/16
51
13
4.7
.2090
31
.1440
.0669
.0670
14
.2913
.2950
7.6
.1820
. 4.75
32
.1405
.0649
.1811
.2130
.1360
.0610
.5709
7/64
.1285
.0531
1.6
36
.1181
.1338
1.55
.5625
14.5
15
.2055
.1200
3/64
.0595
14.29
4.6
33
3.4
.0591
.5512
.1130
.0492
1.5
.5469
14.0
16
.1771
9/32
.2900
7.4
.2040
.1141
1.25
.0570
13.89
5.5
.1299
.0551
.5315
34
3.3
1.45
17/32
13.5
17
.1770
.1102
.0472
1.4
.5312
.1110
.0469
.0550
33/64
13.49
5.4
1.2
1.35
.5156
.1732
35
1.19
.0520
13.10
4.4
.1024
.1160
3.0
.0420
.5118
5.1
.1100
.0380
.5000
13.0
40
.1065
31/64
12.7
5.0
37
.4724
.2854
41
.1040
.0350
15/32
12.0
.2874
.0945
.0330
29/64
.4687
7.25
11/64
2.4
38
.4531
11.91
7.3
18
.1695
11
39
11.51
.1719
4.9
.1015
7/16
4.37
42
.0995
.4528
.4843
.1910
67
.2811
.4375
.4921
.0937
.0320
.2795
11.11
11.5
12.5
2.38
.0984
.2756
12.30
12
.0980
.2720
7.0
.2835
.1890
2.5
.4330
.2812
.1875
68
1/32
11.0
7.2
4.76
.0964
.2716
7.14
4.8
.0960
27/64
6.9
.1693
.0905
2.45
Fraction
.4219
.1673
.0925
3/32
Decimal
4.3
2.35
.0935
meter
4.25
2.3
69
.0295
43
.0890
Milli-
10.72
19
.1800
44
Drill
Size
.2677
.2770
.1660
4.5
.0860
.0240
.8
.95
45
2.1
.0310
.9
.0820
Fraction
6.8
7.1
.1730
46
75
.0236
.1654
.0807
76
.0217
.1614
4.2
47
.0810
.0210
.0312
5/64
.0787
.0200
.79
.85
2.0
.0197
.0292
.75
.0781
2.05
.0225
.6
.0767
1.98
77
.0180
.55
1.95
4.1
48
.0785
78
.0160
.5
.0748
.0760
.0145
.45
1.9
.0138
.39
49
.0730
80
.0135
Decimal
25/64
.3937
.3970
.4040
17/64
10.32
.4062
10.5
.4134
.4130
H
Y
13/32
Z
24.21
.9531
24.5
.9646
24.61
.9687
25.0
.9843
25.03
25.4
.9844
1.0000
57/64
15/16
61/64
31/32
63/64
1
80280
E E A D E E S COMMENTS
1979 Jeep Technical Service Manual
Jeep Corporation needs user feedbackyour critical evaluation of this Manual. Your
comments and suggestions will help us in our continuous effort to improve the quality
and usefulness of our service manual.
Why?
Name
Street
City
Occupation.
State
Zip or Country.
70093
Fold Here
BUSINESS REPLY M A I L
No Postage Stamp Necessary if Mailed in the United States
Postage will be paid by
JEEP C O R P O R A T I O N
14250 P L Y M O U T H R D .
D E T R O I T , MICHIGAN 48232
A T T E N T I O N : SERVICE DEPARTMENT
B-1
Page
Pip
1979 Jeep Maintenance Schedule
Description of ServicesChassis Components
Description of ServicesEngine Components
B-2
B-8
B-5
beneml
General
Unscheduled Maintenance
B-1
B-15
Two maintenance schedules are listed: one for Engine Maintenance; one for Chassis Maintenance (including body). Each schedule is followed by detailed
footnotes.
The services listed are those which experience and
testing have indicated are most likely needed at the time
or distance intervals shown.
Perform the maintenance services as indicated in the
Engine Maintenance Schedule and the Chassis Maintenance Schedule. The symbol tells you what service is
required followed by the time and/or distance interval
(mileage) at which the service should be performed,
under both normal and heavy-duty operation. For
example:
0<
P I
B-2
nzirz.
MAINTENANCE
-Zix ~zz:Tzz:z~::T:~~:rzY"
"
bra/ce drums and front axle U-joints and yokes, to prevent undue wear and unnecessary part failure.
C A U T I O N : If the vehicle is driven through water deep
enough to cover the hubs, inspect the wheel bearings and
axle differentials for water damage or contamination.
'
- -
~ T
- T ^ T ^ ^ I
J2>
For example: Engine Oil (Number 10) should be drained and replaced every 5 months or 5,000 miles (8 000 km), whichever comes
first, under normal use, and every 3 months or 3,000 miles (4 800
km), whichever comes first, under heavy-duty operation. (The lettered footnotes provide additional information about certain components or services.)
COMPONENT
INTERVAL
1. AIR CLEANER
(FILTER)
2.
AUTOMATIC
TRANSMISSION
DIPSTICK/FILLER
3. BATTERY
4. BRAKE MASTER
CYLINDER
5. C O O L A N T
(RADIATOR)
*Y
6. DRIVE BELTS
7. E X H A U S T HEAT
VALVE
8. FUEL FILTER
MAINTENANCE
i-3
Footnotes
V
9. OIL D I P S T I C K
5 m o / 5 , 0 0 0 mi (8 000 km) c.
3 m o / 3 , 0 0 0 mi (4 800 km)
1 1 . OIL FILTER
5 m o / 5 , 0 0 0 mi (8 000 km)
3 m o / 3 , 0 0 0 mi (4 800 km)
13. PCV V A L V E
14. POWER S T E E R I N G
PUMP
5 m o / 5 , 0 0 0 mi (8 000 km)
3 m o / 3 , 0 0 0 mi (4 800 km)
15. T U N E - U P
5,000 mi (8 000 km) Check and a d just c u r b and high idle speeds, as
required, e.
Legend of Symbols
Y
C H E C K OR INSPECTION
gai
<
LUBRICATION
SERVICE C O M P O N E N T REPLACEMENT
Inspect:
Fuel tank, c a p , lines and connections.
Air cleaner thermostatic control system (TAC).
C h o k e linkage for free movement.
PCV system hoses.
Replace charcoal canister air inlet filter.
Final Adjustments
Ignition t i m i n g .
Idle mixture.
Curb and high idle speeds.
p /,
fUMItyTKMAIIPC
INTERVAL
COMPONENT
1. AXLE
DIFFERENTIALS
(FRONT AND REAR)
2. BEARINGS, FRONT
WHEEL
3. BRAKE AND
CHASSIS
INSPECTION
BODY
LUBRICATION
- JB"j
4. CLUTCH LEVER
AND LINKAGE
CJ
- jmm
CHEROKEE, '
WAGONEER,
TRUCK
(j^j
5. EXHAUST SYSTEM
INSPECTION
6. MANUAL STEERING
GEAR
^"||
(^)
Lubrication points
Chassis Illustration
Legend of Symbols
Y
E N G I N E TUNE-UP
" " 3 ^ . ^
3<
7. PROPELLER SHAFTS
(FRONT AND REAR)
CJ
-am
CHEROKEE,
WAGONEER,
TRUCK
8. STEERING LINKAGE
CJ
JM"
^
|JJ
CHECK OR INSPECTION
DRAIN AND REPLACE FLUID
mJtB
CHEROKEE,
WAGONEER,
TRUCK
jjjjjHi,
HEAVY-DUTY OPERATION
J.UBFMCATICN
SERVICE COMPONENT REPLACEMENT
9. STEERING SHAFT
U-JOINT
MAINTENANCE
ALL
y
Ij^jl
y
jjjjjjjj
Y
e. Inspect and replace torn or ruptured grease seals, replace damaged steering components, and lubricate ball joints.
f.
Component Service
Engine
AUTOMATIC
Chassis
Recommended
Interval
Footnotes
miles
(km)
5,000
(8 000)
a.
Rear wheel bearings do not require periodic or scheduled
lubrication.
2. !
3. J
4.
Service
11. TRANSMISSION
MANUAL
Component
QUADRA-TRAC
d.
Lubricate sleeve yokes (splines) and single and double cardan
U-joints.
Service
MODEL 20
Model
Y
10. TRANSFER CASE
B-5
j All
4. i--as! CJ
1. !
5. [
J All
5. |
6. j
J All
6. i
10. J
J All
11. !
J All
8.
Brakes
Front and rear brake linings for wear.
Rear brake self-adjusting mechanism for proper
operation.
Master cylinder, calipers, wheel cylinders and differentials
warning valves for leaks.
Brake lines, fittings and hoses for condition and leaks.
Parking brake for proper operation.
Overall brake condition and action.
10,000
(16 000)
15,000
(24 000)
14. !
15. 1
Y .:
j
8. ! >C
1S
- j
CJ
\"-
3.
C.W.T
All
4. r JS5 JC.W.T
V a.
Steering/Suspension
7. i- - 3 ! C,W,T
8.
25,000
(40 000)
30,000
(48 000)
to.
|'-a"jC,W,T
io. ! y j aii
2. j^pyj AH.
I. ]
All
Alld
II. j
| All
Also:
12. !
13. i
0~C
15. J
Body Lubrication
Footnotes
a.
b.
Quadra-Trac Only
c.
d.
B-6
MAINTENANCE
'
...
3. Batt@rf
WARNING: Wear safety glasses, rubber gloves and
protective clothing when servicing the battery. Battery
fluid contains sulfuric acid and must be kept away from
Fig. B-1
MAINTENANCE B-7
Air Conditioner
Six-Cylinder
Eight-Cylinder
A i r Pump
Six-Cylinder w/PS
Other Six-Cylinder
and all EightCylinder
Fan A l l Engines
Power Steering
A l l Engines
Initial
Newtons
New Belt
Reset
Newtons
Used Belt
Initial
Pounds
New Belt
Reset
Pounds
Used Belt
556-689
556-689
400-512
400-512
125-155
125-155
90-115
90-115
289-334
267-311
65-75
60-70
556-689
556-689
400-512
400-512
125-155
125-155
90-115
90-115
556-689
400-512
125-155
90-115
80414
S. Ciolant
'
TO
CARBURETOR
80296
Fig. B-2
For more detailed procedures on fuel filter replacement, refer to Chapter 1JFuel Systems.
9. OIL CHECK
6. Drive Belts
Check belts driving fan, air pump, alternator, power
steering pump and air conditioning compressor for
cracks, fraying, wear, and general condition at scheduled interval. Use Tension Gauge J-23600 to check drive
belt tension. Compare reading obtained against the tension specified for used belts in the following chart. If
installing a new belt, use the new belt setting shown in
the chart. Refer to Chapter 1CCooling for replacement
or adjustment procedures.
B-8
MAINTENANCE
Recommended
Single
Viscosity
Recommended
MultiViscosity
Above + 4 0 F
(+5C)
SAE 30 or 40
SAE 10W-30,
20W-40, or 10W-40
Above 0 F
(-18C)
SAE 20W-20
SAE 10W-30 or
10W-40
Below 0 F
<-18C)
SAE 10W*
SAE 5W-20 or
5W-30
Crankcase capacity is 5 quarts (4.7 liters) for sixcylinder engines, 4 quarts (3.7 liters) for eight-cylinder
engines. Add 1 additional quart (1 liter) when the filter
is changed.
11. Oil Filter
Change the oil filter every 5,000 miles (8 000 km) or
every 5 months, whichever comes first, under normal
conditions.
A full-flow oil filter is mounted on the lower center
right side of six-cylinder engines and on the lower right
side on eight-cylinder engines.
Remove the throwaway filter unit from the adapter
with Oil Filter Removal Tool J-22700 or equivalent. To
install, turn the replacement unit by hand until the
gasket contacts the seat and then tighten an additional
one-half turn. CAUTION: Use only a short-type, full-flow oil filter
(AMC/Jeep Part No. 8993U6 or equivalent) for replacement. Filters exceeding k% inches (108 mm) in length
Fig. B-3
15. Tune-Up
Certain items (such as the choke system and ignition
timing) must be checked and serviced between regularly
scheduled complete tune-ups on some models. Refer to
the Engine Maintenance Schedule for details.
Perform a complete precision tune-up at the scheduled interval. Perform a precision electronic diagnosis
whenever questionable engine performance occurs between scheduled tune-ups.
Refer to Chapter 1AGeneral Service and Diagnosis
for detailed procedures and specifications.
MAINTENANCE
B-9
FRONT A X L E - A L L MODELS
72206B
REAR A X L E - CJ MODELS .
Fig. 1 4 lilt
CAUTION: Do not overfill the wheel hub. Too much
grease can cause overheating and bearing damage, or it
can leak and contaminate brake linings.
Install the inner bearing and a new grease seal. Assemble the hub assembly and adjust bearings as described in Chapter 2GWheels and Tires.
Inspect bearings, and clean and repack if necessary,
when they are removed for other services.
B-10
MAINTENANCE
Fig. 1-8
Fig.B-9DoorHingesCourtesy Light
Cherokee-Wagoneer-Truck Models
Button
inspection procedures.
replaced.
ifflTEKE
1-11
80188
Fig. B-10
Fig. B-13
Check brake lining thickness through caliper inspection port (fig. B-14).
A wear sensor is attached to the brakeshoes. When
brakelining wears to the point that replacement is necessary, the sensor contacts the disc, making a screeching
or scraping noise to warn the driver that brakeshoes
need replacement.
Rear Brake LiningsAll Models
Hi
OIL HOLE
Master Cylinder
80188
Fig. B-12 Tailgate Hin ii Lubrication Hole
Cherokee aid Wag inter Models
Inspect the cap bail for proper tension and fit. The cap
should maintain a tight seal. Check the rubber diaphragm seal for cracks, cuts or distortion. Check fittings
and housing for signs of leakage. If internal leaks are
suspected or if fluid loss occurs but a leak is not evident,
check for leaks at the rear of the master cylinder. Correct as required.
B-12
f "
MAINTENANCE
HT
m>
"liEIIZZZZZ^^
^ J ^ ^ ^
Check tires for visible signs of wear which may indicate underinflation or need for front-end alignment,
tire rotation or wheel balancing. Also check for bulging,
cracks or other road hazard damage. Check and adjust
inflation pressures according to the specifications listed
in the tire pressure sticker on the glove box door.
Overall Steering/Suspension Action
Fig. B-14
Pull the dust boot back and inspect for leaks. Check
the condition of the pistons and cylinder bores.
;
Check for improper brake action, performance complaints or signs of overheating, dragging or pulling. Correct as required.
Steering Gear and Linkage
MilTEIANCE B-18
Apply grease gun pressure to sleeve y o k e grease fitting until lubricant appears a t pressure relief hole in
expansion plug a t sleeve yoke end of s p l i n e . A t this
point, cover pressure relief hole with finger a n d continue
to apply pressure until grease appears a t sleeve yoke
seal. This will ensure complete lubrication of spline.
Double Cardan Joint
90143
Fig. B-16
8. Steering Linkage
Fig. B-15
B-14
MAINTENANCE
REDUCTION
UNIT
INSPECTION PLUG
Fig. B-17
11. Transmission
Refer to Engine Components for procedure on checking fluid level for automatic transmission.
Fluid levels in the Model 20 transfer case and manual
transmission must be checked at the same time, as
scheduled. Fill plugs for all manual transmissions are
located on the right side of the assembly.
To check lubricant level, remove the transmission fill
plug. Lubricant should be level with each fill plug hole.
If not, bring up to level with make-up lubricant and
install fill plug. Refer to Recommended Fluids and Lubricants chart and Fluid Capacities chart at the end of
this chapter.
Automatic Transmission Fluid Changes
Fig. B-18
(1)
(2)
(3)
(4)
(5)
UNSCHEDULED MAINTENANCE
Services detailed in this subsection are n o t l i s t e d in
t h e Maintenance Schedule for performance a t a specified interval. They are to "be performed as r e q u i r e d to
restore vehicle to original specifications. U n s c h e d u l e d
maintenance services include such items as fuel s y s t e m
cleaning; engine carbon deposit removal; r e t i g h t e n i n g
loose parts and connections; replacement of m a n u a l
transmission clutch components, b r a k e linings, s h o c k
absorbers, light bulbs, wiper blades, belts or h o s e s ; r e placement of interior trim, bright metal t r i m , p a i n t e d
parts and other appearance items o r rubber-like p a r t s .
Need for these unscheduled services is usually i n d i c a t e d
by a change in performance, handling, or the a p p e a r a n c e
of the vehicle or a particular component. Owners, u s e r s
and service mechanics should be alert for i n d i c a t i o n s
that service or replacement is needed.
Catalftic Conwerter
Fluid Capacities
Capacities, Approximate Refill
Engine Oil (includes 1 quart for filter change)
258 CID engines
304 CID & 360 CID engines
Cooling System (Includes 1 quart for heater)
258 CID engine
304 CID engine
360 CID engine
Transfer Case
Model 20
(a) Quadra-Trac
(a) Quadra-Trac w i t h Reduction Unit
Axles
AMC Model Rear A x l e - C J Models
Model 3 0 - F r o n t A x l e - C J Models
(b) Model 4 4 - F r o n t or Rear A x l e - A l l but CJ Models
(b) Model 60-3(FF) Rear A x l e - T r u c k s over 6500 G V W
imperial Measure
Metric Measure
6.0 quarts
5.0 quarts
5.0 quarts
4.2 quarts
5.7 liters
4.7 liters
10.5 quarts
13.0 quarts
14.0 quarts
8.7 quarts
10.8 quarts
11.6 quarts
9.9 liters
12.3 liters
13.2 liters
2.6 pints
3.3 pints
4.2 pints
1.5 liters
1.9 liters
2.4 liters
3.2 pints
2.0 quarts
2.5 quarts
Transmission
Manual 3-SpeedCJ Models
Manual 3-SpeedCherokee, Wagoneer, & Truck
Manual 4-SpeedAll Models
AutomaticChange Only
AutomaticAt Overhaul
U.S. Measure
2.8
2.8
6.5
5.0
11.0
pints
pints
pints
quarts
quarts
2.3
2.3
5.5
4.2
9.2
pints
pints
pints
quarts
quarts
4.8
2.5
3.0
6.0
pints
pints
pints
pints
4.0
2.1
2.5
5.0
pints
pints
pints
pints
14.8 gallons
21.5 gallons
18.2 gallons
12.3 gallons
17.9 gallons
15.2 gallons
1.3
1.3
3.1
4.7
10.4
liters
liters
liters
liters
liters
2.3
1.2
1.4
2.8
liters
liters
liters
liters
55.9 liters
81.4 liters
68.8 liters
B-16
MAINTENANCE
ENGINE
COMPONENT
CHASSIS (Continued)
SPECIFICATION
COMPONENT
SPECIFICATION
Distributor rotor t i p *
A M C Silicone Dielectric C o m p o u n d
or equivalent.
Manual transmission
Engine coolant
Engine oil
Exhaust m a n i f o l d heat
valve
CHASSIS
COMPONENT
A u t o m a t i c transmission
Brake master c y l i n d e r *
Quadra-Trac lubricant o n l y .
AMC/Jeep All-Purpose Lubricant
or equivalent l i t h i u m base chassis
lubricant.
T r a c - L o k axle differential
SPECIFICATION
AMC/Jeep A u t o m a t i c Transmission
Fluid or equivalent labeled D e x r o n
or Dexron 11 .
Conventional axle
differentials
D r u m brake support
plate ledges*
F r o n t suspension ball
joints, steering linkage,
propeller shafts, single and
double cardan joints and
yokes
F r o n t wheel bearings
BODY
COMPONENT
SPECIFICATION
Ashtray slides
F r o n t seat tracks
Hinges: door, h o o d ,
liftgate, tailgate, glove box
Latches: door, h o o d ,
liftgate, tailgate, glove box
Weatherstrips: door,
w i n d o w , liftgate, tailgate
Navigation Tools: Click on the "Chapter" below, or use the Bookmarks to the left.
POWER PLANT
General Service and Diagnosis
Engines
Cooling Systems
m
r
in
Batteries
Charging System
ff1
Starting System
Ignition System
CHAPTER
Cruise Command 1
INDEX
Fuel Systems
fi:
la
Mil
::.:
Exhaust Systems | | | |
Power Plant Instrumentation
Section 2 - Chassis
Section 3 - Body
1A-1
K
N
n
D
SECTION
General Information
Power Plant Diagnosis
G E N E R A L
_
"
INDEX
1A-1
1A-2
"
"
Page
Emission ComponentsCalifornia Light Duty
1A-14
"
Page
1A-1
This chapter contains general information which applies to all Jeep engines: 258 CID six-cylinder, 304 CID
eight-cylinder, and 360 CID eight-cylinder. Refer to
Chapter IBEngines for specific procedures for engine
replacement, engine disassembly, internal component
repairs and replacement and mechanical specifications.
The section of this chapter titled Power Plant Diagnosis presents information and procedures useful in locating problems not normally encountered in routine
maintenance and routine tune-ups.
The section of this chapter titled Power Plant Tune-
1A-2
Vehicle
Trans.
M3
CJ-5
258
2V
M4
M3
M4
CJ-7
A
360
2V
Cherokee
Wagoneer
Truck
Air
Guard
Cat.
Conv.
EGR
9
0
0
0
O
EGR
CTO
FTVC
PCV
TAG
Type
Spark
Delay
Spark
CTO
Vac
m
o
Vac
Vac
Vac
Vac
Vac
Vac
Vac
217
21701
1
1
CTO
Temp.
Non
Linear
Carb.
Vent
Elec.
Choke
0 1
217
21701
149
149
149
149
Solenoid
Trans.
Cat. Conv.
CTO
EGR
PCV
TAC
TCS
0
90182
1A-2
CID &
Venturas
Vehicle
CJ-5
CJ-7
258
2V
Cherokee
Wagoneer
Truck
CJ-5
304
2V
CJ-7
Cherokee
360
2V
Wagoneer
Air
Guard
Cat.
Conv.
EGR
EGR
CTO
FTVC
PCV
M3
Vac
M4
M3
M4
Vac
Vac
Vac
Vac
M3
M4
M3
M3
M3
M3
M4
Vac
Vac
Vac
M3
Truck
TAC
Type
Trans.
M4
Vac
Vac
Vac
Vac
Vac
Vac
Vac
Vac
Vac
Spark
Delay
Spark
CTO
CTO
Temp.
149
149
149
149
149
1490
1490
Non
Linear
Carb.
Vent
Elec.
Choke
1490
149
149
14 o
9
2170
7 in.
2170
7 in.
2170
7 in.
Vac
220
Vac
220
149
Vac
Vac
Solenoid
149
220
7 in.
220
7 in.
149
90181
Pill
Blown Cylinder Head Gasket Diagnosis
Compression Test
Cylinder Leakage Test
Diagnosis with Scope Analyser
1A-13
1A-I1
1A-11
1A-11
General
Intake Leak Diagnosis
Service DiagnosisMechanical
Service DiagnosisPerformance
1A-2
1A-13
1A-3
1A-6
GENERAL
Other tests and diagnostic procedures may be necessary to pinpoint a particular problem. Information is
provided under Diagnosis With Scope Analyzer, Compression Test, Cylinder-Leakage Test, Blown Cylinder
Head Gasket Diagnosis and Intake Leak Diagnosis.
the
Service
Diag-
1A-3
Service DiagnosisMechanical
EXTERNAL OIL
LEAKS
(1)
(1)
Replace gasket.
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(7)
Replace seal.
(8)
(8)
(9)
(9)
EXCESSIVE OIL
CONSUMPTION
(Continued)
Correction
Possible Cause
Condition
(3)
(1)
(2)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(7)
(8)
(8)
Repair as necessary.
(9)
(9)
Repair as necessary.
1A-4
Possible Cause
Condition
NO OIL PRESSURE
MAIN BEARING
NOISE
Correction
(1)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(V)
(7)
(1)
(2)
(1)
(2)
(1)
(2)
(3)
(3)
(4)
Oil pickup tube and screen assembly has restriction or air leak.
(4)
(5).
(5)
(6)
(6)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
i
60259B
IA-5
Condition
CONNECTING ROD
BEARING NOISE
PISTON NOISE
Possible Cause
Correction
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
Repair as necessary.
(5)
(5)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(7)
(1)
(1)
(2)
(2)
Check for:
(a) Low oil level.
(b) Low oil pressure.
(c) Plugged pushrods.
(d) Wrong hydraulic tappets.
(e) Plugged oil gallery in block.
(f) Excessive tappet to bore
clearance
Replace worn or bent push rods.
(3)
(3)
(4)
(4)
Clean tappets.
(5)
(5)
(6)
(6)
(7)
(7)
(8)
(8)
(9)
Replace valve.
60259C
1A-6
Condition
Possible C a u s e
HARD STARTING
(ENGINE CRANKS
NORMALLY)
(6)
R O U G H I D L E OR
STALLING
Lubricate or replace.
(10) I m p r o p e r choke s e t t i n g .
1A-7
S e r v i c e D i a g n o s i s P e r f o r m a n c e (Continued)
F A U L T Y LOWSPEED OPERATION
FAULTY
ACCELERATION
Correction
Possible Cause
Condition
(14)
(14)
(6)
Replace gasket.
(7)
Adjust choke.
(8)
Condition
FAULTY HIGH
SPEED OPERATION
(9)
( I D Faulty coil.
(6)
^ FAULTY HIGH
SPEED OPERATION
(Continued)
Correction
(6)
(16)
(16)
(18)
Replace shaft.
70334C
1A-9
Condition
M I S F I R E A T ALL
SPEEDS
MISFIRE AT ALL
SPEEDS
(Continued)
POWER NOT UP
TO NORMAL
Correction
Possible Cause
(1) F a u l t y spark plug(s).
(5)
(5)
Set to specifications.
(6)
(6)
(7)
(7)
(8)
(8)
(9)
(9)
(10)
(10)
Replace camshaft.
(11)
Vacuum leak.
(11)
(12)
(12)
Adjust carburetor.
(13)
(14)
(14)
Replace gasket.
(15)
(15)
(16)
(16)
(1)
(1)
Adjust timing.
(2)
(2)
Replace rotor.
(3)
(3)
(4)
(4)
Adjust gap.
(5)
Faulty fuel p u m p .
(5)
(6)
(6)
(7)
Faulty coil.
(7)
(8)
Faulty ignition.
(8)
(9)
(9)
(10)
(10)
Replace gasket.
70334D
1A-10
INTAKE BACKFIRE
EXHAUST BACKFIRE
PING OR
SPARK KNOCK
SURGING (CRUISING
SPEEDS TO
TOP SPEEDS)
Correction
Possible Cause
Condition
(11)
(ii)
(12)
(12)
Replace shaft.
(1)
(1)
Adjust timing.
(2)
(2)
Repair as necessary.
(3)
(3)
Repair as necessary.
(4)
(5)
(6)
(6)
(1)
Vacuum leak.
(1)
(2)
(2)
(3)
(3)
Repair as necessary.
(4)
Exhaust leak.
(4)
(1)
(1)
Adjust timing.
(2)
(2)
(3)
(3)
(4)
(4)
Adjust carburetor.
(5)
Vacuum leak.
(5)
(6)
(6)
(7)
(7)
(8)
(8)
(9)
(9)
Grind smooth.
(1)
(1)
(2)
(2)
Replace fuel p u m p .
(3)
(3)
70334E
Condition
Correction
(4)
(4)
(5)
Vacuum leak.
(5)
(6)
(6)
(7)
(7)
(8)
(8)
(9)
(9)
(10)
(10)
COMPRESSION TEST
(1) Clean spark plug recesses with compressed air.
(2) Remove spark plugs.
(3) Remove coil wire from distributor and connect
to ground.
(4) Block throttle in wide open position.
1A-12
POINT
FIRING
LINE
SPARK
LINE
5-16 K V A T
COIL
SYSTEM
RESERVE
1000 R P M
NO MORE
T H A N 3-5 K V
POINT CLOSE
POINT
SHORT DOWNWARD
SPIKE F O L L O W E D
BY G R A D U A L L Y S M A L L E R
OSCILLATIONS
ABRUPT 90
ANGLE START OF
NEXT CYLINDER
FIRING LINE
TESTS:
DIRTY, BURNED
OR M I S A L I G N E D
POINTS A N D
WEAK POINT TENSION.
TESTS:
PITTED POINTS
I
OR ARCING FROM
POOR CONDENSER
ACTION.
VARIATION
OPEN
BETWEEN
CYLINDERS
ZERO
LINE
TESTS:
PLUG A N D
ROTOR GAP,
BROKEN WIRES
FUEL MIXTURE.
TESTS:
PLUGS. WIRES
CAP. ROTOR.
OR ENGINE
CONDITION
AFFECTING
PLUG FIRING.
TEST:
DEFECT I N COIL,
CONDENSER, OR
PRIMARY CIRCUIT.
TESTS:
PLUG A N D
ROTOR GAP,
BROKEN WIRES,
FUEL MIXTURE.
ZERO
LINE
TESTS:
PLUGS. WIRES
CAP. ROTOR.
OR ENGINE
CONDITION
AFFECTING
P L U G FIRING.
Fig 1A-1
Condition
Oiagfieois
Correction
Possible Cause
Air escapes
through
carburetor.
(i)
(1)
Air escapes
through tailpipe.
(2)
(2)
Air escapes
through radiator.
More than 25%
leakage on
adjacent cylinder.
(3)
(8)
(5)
(4)
(4)
(5)
70335
Exierior L u l
Two tests are possible, one with engine oil and one
with acetylene.
(1) Start engine.
(2) Apply oil to gasketed areas of intake manifold.
If oil is drawn into manifold, or if smoke is evident in
exhaust, manifold is leaking.
.
. (3) Open acetylene valve of oxyacetylene torch. Do
not ignite. Pass torch tip over gasketed areas. If engine
speed increases, manifold is leaking.
1A-14
Engine Assembly
Exhaust System
Fuel Systems
1A-14
1A-21
1A-18
GENERAL
General
Ignition System
Specifications
1A-14
1A-14
1A-21
A complete precision tune-up is required at the intervals outlined in the Maintenance Schedule in Chapter B.
A tune-up accomplishes several things. First, it assures
that the engine is performing as efficiently and as economically as it was designed to perform. Second, it assures that exhaust and fuel system emissions are within
the limits defined by Federal regulations.
A complete precision tune-up includes all of the items
listed in the Engine Maintenance Schedule. Some items
on the chart are highly-specialized emission control devices. These devices are discussed as systems in their
respective chapters of this book. They are mentioned
here for reference only.
ENGINE ASSEMBLY
Oil Filler Cap
On eight-cylinder engines, a polyurethane foam filter
in the oil filler cap routes air into the PCV system. To
clean the filter, apply light air pressure in the direction
opposite normal flow (through the filler tube opening).
If the filter is deteriorated, replace the filler cap.
Oriwe Belts
Inspect belts for defects such as fraying or cracking.
Check belt tension. Belt adjustment, arrangement and
tension specifications are covered in C h a p t e r
1CCooling.
70208
IGNITION SYSTEI
Spark F l i p
Remove and examine spark plugs for burned electrodes and dirty, fouled, cracked or broken porcelains. Keep
plugs arranged in the order removed from the engine.
An isolated plug displaying an abnormal condition indicates that a problem exists in the cylinder from which
it was removed. Replace plugs at mileage intervals recommended in the Engine Maintenance Schedule. Plugs
with lower mileage may be cleaned under some circumstances. Refer to Spark Plug Condition. After cleaning,
file the center electrode flat with a point file. Set the gap
0.033 to 0.037 inch (fig. 1A-2).
Always use a torque wrench when installing spark
plugs. Distortion from overtightening will change the
gap clearance of the plug. Tighten to 25 to 30 footpounds (34 to 41 Nm) torque.
Fig. 1 A-2
1A-15
AGap Bridging
Gap bridging may be traced to flying deposits in the
combustion chamber. Fluffy deposits may accumulate
on the plugs during in-town driving. When the engine is
suddenly put under heavy load, this material can melt
and bridge the gap.
BScavenger Deposits
Fuel scavenger deposits shown may be white or yellow. They may appear to be harmful but this is a normal
appearance caused by additives in certain fuel brands.
Such additives are designed to change the chemical n a ture of deposits to lessen misfire tendencies. Notice that
accumulation on the ground electrode and shell areas
may be heavy, but the material is easily removed. Such
plugs can be considered normal in condition and can be
cleaned using standard procedures.
CChipped Insulator
Chipped insulators usually result from bending the
center electrode while gapping of the plug. Under certain conditions, severe detonation can also split insulator firing ends.
DPre-ignition Damage
Pre-ignition damage is caused by excessive temperatures. First the center electrode melts and, somewhat
later, the ground electrode. Insulators appear relatively
clean of deposits. Check for correct plug heat range,
overadvanced ignition timing and similar reasons for
overheating.
Fig. 1A-3
IMS
Ignition Coil
Always check a suspected defective ignition coil on the
vehicle. Since a coil may break down after it has reached
operating temperature, it is important that the coil be at
operating temperature when tests are made. Perform
the tests following the instructions of the particular test
equipment manufacturer.
Dlstrllitor
The distributor used on all engines is the solid state
type. Other than cap and rotor inspection as outlined in
Chapter B, there is no scheduled maintenance for this
distributor. Refer to Chapter 1GIgnition System for
distributor service procedures.
Distributor Rotor
Visually inspect the rotor for cracks, evidence of burning or corrosion on the metal tip, or evidence of mechanical interference with the cap (fig. 1A-4). Some burning is
normal on the end of the metal tip. The grease applied to
the rotor tip for radio interference suppression will appear charred. This is normal. Do not remove charred
grease. Inspect the spring for insufficient tension. Replace a rotor displaying any of the conditions shown.
INSUFFICIENT
SPRING
TENSION
Wire Test
Ohms
CRACKS
Oto 15
3,000 to 10,000
15 to 25
4,000 to 15,000
25 to 35
6,000 to 20,000
Over 35
8,000 to 25,000
ROTOR
TIP
CORRODED
60748
70202
Fig. 1 1 4
Rotor Inspection
Distributor Cap
B U R N E D OR
ERODED T E R M I N A L S
C A R B O N PATH
CRACK
CARBON PATH
70203
Fig-11-5
BTDC
ATDC
A socket is cast into the timing case cover for use with
a special magnetic timing probe which senses the milled
notch on the vibration damper. The probe is inserted
through the socket until it touches the vibration damper
and is automatically spaced away from the damper by
80001
Fig. 1 A - 6
11-18
(4) If total advance at 2000 rpm is less than specified, disconnect vacuum advance hose at distributor.
(5) Check maximum centrifugal degrees advance at
engine rpm specified. Refer to Distributor Curves in
Specifications.
If the centrifugal advance degrees are as specified,
replace the vacuum unit.
Distributor AdvanceOn Tester
Fig. 1 A - 7
Distributor advance also may be tested with the distributor out of the vehicle. Follow distributor test equipment manufacturer's instructions.
Information given in the Distributor Curves is for onvehicle testing. If the distributor advance is checked on a
distributor tester, convert the information in the Distributor Curves from engine rpm to distributor rpm and
from engine degrees to distributor degrees. Divide engine rpm by 2 to obtain distributor rpm. Divide engine
degrees advance by 2 to obtain distributor degrees advance. For instance, if the Distributor Curve indicates 8
to 12 degrees advance at 2000 rpm, the corresponding
on-tester specifications would be 4 to 6 degrees advance
at 1000 rpm.
NOTE: The inches of vacuum reading is the same,
regardless if test is on-engine or off-engine.
riming Procedure
FUEL SYSTEIS
General Inspection
NOTE: If the timing light has an advance control feature, turn the control of the Off position.
(3) Start engine.
(4) Adjust idle speed to 500 rpm.
(5) Adjust initial ignition timing to setting specified
on the Tune-Up SpecificationsOn Vehicle chart by
loosening distributor holddown clamp and rotating
distributor.
(6) Tighten distributor holddown clamp and verify
ignition timing."
Air Cleaner
Distributor Advance Meehinlsm
Adjustable Advance Control Timing Light Procedure
Replace the dry-type air cleaner element at each precision tune-up. Under extreme conditions, more frequent
replacement is recommended.
Fill Filter
All Jeep vehicles have two fuel filters. The in-tank
filter is designed to be maintenance-free. The in-line
filter between the fuel pump and carburetor requires
periodic replacement. When installing the replacement
filter, be careful to position the fuel return nipple at the
top of the filter.
- y -
ir~-
1A-1I
......
The idle drop (tachometer) method is the only recommended mixture setting procedure.
General
Precautions
Because automatic transmission vehicles are adjusted in Drive, set the parking brake firmly and do
not accelerate the engine.
Bring the engine up to operating temperature before
setting idle and mixture.
Perform procedures with the air cleaner installed.
Do not idle the engine more than 3 minutes at a
time.
I f the mixture setting procedure takes more than 3
minutes, run the engine at 2000 rpm (in Neutral) for
1 minute.
B e sure the curb idle setting is correct before adjusting mixture.
Be careful of fan, belts and other moving objects
while working under the hood with the engine running. Do not stand in direct line with the fan blades.
Idle Setting Procedure
IDLE M I X T U R E
ADJUSTING SCREWS
80659
Fig. 1J-8
NOTE: When setting idle speed, put manual transmission in Neutral Put automatic transmission in Drive.
80128
Fig. 1 J - 9
1A-20
Free-up carburetor linkage by applying Jeep Carburetor and Combustion Area Cleaner, or equivalent.
Never use oil to lubricate carburetor linkage.
For correct choke system adjustments, refer to Chapter 1JFuel Systems.
MOULDED
Idle Drop
Engine
Transmission
Manual
258
2V
Automatic
49 - State
50
49 - State
(Cherokee & J-10)
25
California
50
49 - State
California
49 - State
20
100
Automatic
49 - State
40
Manual
49 - State
50
Automatic
All
20
Eight-Cylinder Engine
A polyurethane foam PCV air inlet filter is located in
the sealed oil filler cap. To clean the filter, apply light air
pressure in direction opposite normal flow (through the
filler tube opening of the cap). Do not oil the filter. If the
liter is deteriorated, replace the filler cap.
25
California (CJ)
Manual
304
2V
360
2V
Emission Package
90183
Choke Linkage
Check all choke linkage including the fast idle cam for
free movement at the mileage intervals specified in the
Mechanical Maintenance Schedule.
The fuel tank, filler cap, fuel lines and vent lines must
be maintained in good condition to prevent raw fuel
vapors (hydrocarbons) from entering the atmosphere.
Inspect the filler cap for evidence of fuel leakage
stains at the filler neck opening. Remove the cap and
check the condition of the sealing gasket. Replace the
filler cap if the gasket is damaged or deteriorated.
Inspect the fuel tank for evidence of fuel leakage
stains. Trace stain to its origin and repair or replace the
tank as required.
1A-21
EXHAUST SYSTEM
SPECIFICATIONS
Tune-Up SpecificationsOn-Vehicle
CID
and
Venturi
Model
Transmission
Curb Idle
RPM
Set
To
Manual
(49)
700
CJ
Manual
(California)
OK
Range
600
800
Automatic
(49)
258
2V
Automatic
(California)
Cherokee
Wagoneer
Truck
600
Initial Timing
at Curb Idle
Set
To
40
6
100
Automatic
(49)
Manual
(49)
700
600
800
5
304
2V
360
2V
CJ
Cherokee
Wagoneer
Truck
Manual
(California)
600
550
750
Manual
(49)
800
700
900*
Automatic
(49)
600
500
700
3231915
8128773
29.1
to
37.8
3232434
8128453
20.7
to
29.8
Tot. Degrees
Centrifugal
Advance at
Advance
2000 RPM
3231915
8128773
29.1
to
37.8
3232434
8128453
20.7
to
29.8
3234693
8128770
28.7
to
37.5
3231340
8128772
25.3
to
34.5
3233959
8130029
34.4
to
44.5
3233174
8128770
27.5
to
37.0
3
70
650
850
Automatic
(49)
Automatic
(California)
" J-20 OK Range 750 to 9 5 0
750
Vacuum
Unit
Number
40
8
2
6
500
700
Manual
(49)
OK
Range
Distributor
Model
Mumber
6
10
Spark
Plug
N13L
(Alt.
RN13L)
Gap
0.033
to
0.038
Refer
to
Distributor
Cu rves
N12Y
(Alt.
RN12Y)
Gap
0.033
to
0.038
90206
1A-22
Distributor Curves-On-Vehicle
36
MECHANICAL ADVANCE
3231915
258 C I D S I X - C Y L I N D E R
- 4 9 S T A T E M A N U A L (CJ)
- 4 9 STATE AUTOMATIC
32
yj 28
cc
24
Q
tu 20
Z
0 16
Z
yy
>
800
400
1600
1200
2400
2000
3200
2800
Q
<
4000
3600
4400
4
0
-4
ENGINE RPM
VACUUM (IN.-HG)
36
MECHANICAL ADVANCE
3233174
360 C I D E I G H T - C Y L I N D E P
- 4 9 STATE M A N U A L A N D AUTOMATIC
- C A L I F O R N I A AUTOMATIC
32
28
24
20
16
12
8
4
0
800
400
1600
1200
2400
2000
3200
2800
4000
3600
4400
-4
ENGINE RPM
VACUUM (IN.-HG)
90185A
1A-23
Distributor Curves-On-Vehicle
800
400
1600
1200
2400
2000
3200
4000
2800 3600
4400
ENGINE RPM
32
23
24
20
16
8
10
12
14
VACUUM (IN.-HG)
8
10
12
14
VACUUM (IN.-HG)
8
10
12
14
VACUUM (IN.-HG)
16
18
20
-iiirfii iiiiTiiiii i
MECHANICAL ADVANCE
3232434
258 C I D S I X - C Y L I N D E R
- 4 9 STATE MANUAL
{CHEROKEE, W A G O N E E R , T R U C K )
-CALIFORNIA M A N U A L
AND AUTOMATIC
12
8
4
0
-4
800
400
1600
1200
2400
2000
3200
2800
4000
3600
4400
ENGINE RPM
20
36
32
28
24
MECHANICAL ADVANCE
3231340
304 CID E I G H T - C Y L I N D E R
- C A L I F O R N I A MANUAL
20
16
12
8
4
0
800
400
1600
1200
2400
2000
3200
2800
ENGINE RPM
4000
3600
4400
16
18
20
90185B
11-24
LEFT BANK
FRONT
CLOCKWISE R O T A T I O N
1-8-4-3-6-5-7-2
RIGHT BANK
CLOCKWISE R O T A T I O N
1-5-3-6-2-4
S I X - C Y L I N D E R ENGINES
FRONT
E I G H T C Y L I N D E R ENGINES
42189
11-1
S E C T I O N
I N D E X
Page
Slx-Cyllndir Engine
Eight-Cylinder Engine
Page
1B-1
1B-36
Tools
1B-73
SIX-CYLINDER ENGINE
Page
Camshaft and Bearings
Connecting Rods
Connecting Rod and Piste* Assembly
Crankshaft
Cylinder Block
Cylinder Bore Reconditioning
Cylinder Head and Cover
Engine Holding Fixture
Engine Installation
Engine Mounting
Engine Removal
Exhaust Manifold Replacement
General
Hydraulic Valve Tappets
Intake and Exhaust Manifolds
Page
1B-8
1B-22
1B-22
1B-28
1B-32
1B-33
IB-15
1B-17
1B-19
1B-21
I B 19
Pistons
Rocker Arm Assembly
Short Engine Assembly
1B-25
1B-5
1B-2
Specifications
Timing Case Cover
1B-34
1B-3
1B-4
Timing Chain
1B-13
1B-5
1B-4
1B-16
1B-3
1B-4
iB-15
Valves
Valve Train
Vibration Damper
1B-1
IB-10
1B-12
1B-31
1B-14
mm
GENEiAL
The 258 CID (4.2 liter) is a six-cylinder, in-line, overhead valve engine (fig. 1B-1 and 1B-2) which operates
only on no-lead gasoline. Cylinders are numbered from
front to rear. Firing order is 1-5-3-6-2-4, Crankshaft
rotation is clockwise, viewed from the front. The crankshaft is supported by seven two-piece bearings. The
camshaft is supported by four one-piece, line bored
bearings.
The six-cylinder engine features a quench-head design. The combustion chamber shape, both in the head
and in the piston crown, compresses the combustion
mixture closer to the spark plug. In most applications,
this permits the use of more ignition timing advance for
better fuel economy.
Identification
Build Date Code
1B-2
ENGINES
Fig. 11-1
Fig. 11-2
S l i - l f l l i l i r Engine
fissmlSfTpinI
ENGINES 1B-3
^ ;
A;,;,.
Jk ; ;
3EI:
2EL
.33z
JB^J
' .
Compression
CID
Carburetor
258
2V
8.0:1
1st
Character
(Year)
4th
Character
(Engine Type)
5th and 6 t h
Characters
(Day)
2 - 1978
3-1979
01-12
Code
EXAMPLE: 3
03
Ratio
01 - 31
18
60257
Definition
- 0.010-inch
(.254) oversize
-0.010-inch
(.254) undersize
-0.010-inch
(.254) undersize
-0.010-inch
(.254) oversize
EXAMPLE: The code letters PM mean that the crankshaft main bearing
journals and connecting rod journals are 0.010-inch undersize.
60258
Fig. 1B-5
Engine MountingTypical
Fig. 1B-4
UPPER T R U N N I O N
ENGINE MOUNTING
Resilient rubber cushions support the engine and
transmission at three points: at each side on the centerline of the engine and at the rear between the transmission e x t e n s i o n h o u s i n g a n d t h e r e a r s u p p o r t
crossmember (fig. 1B-5). Replacement of a cushion may
be accomplished by supporting the weight of the engine
or transmission at the area of the cushion.
H A R D W O O D BLOCK
41883
Fig. 1B-6
1B-4
ENGINES
ENGINE REMOVAL
The engine is removed without the transmission and
bellhousing. Raise the vehicle slightly to gain working
clearance.
(1) Drain cooling system.
(2) On all models except CJ, remove hood. Mark
hinge locations for alignment during installation.
(3) Remove battery on Cherokee-Wagoneer-Truck
models. On CJ models, disconnect negative battery
cable.
(4) Remove air cleaner. Disconnect and plug fuel
line to fuel pump. Disconnect fuel return line from tubing at flexible hose connection to frame.
(5) Disconnect heater hoses at front of engine on CJ
models and at heater on other models.
(6) Disconnect accelerator cable from engine.
(7) Disconnect harness wiring from engine and alternator and lay aside.
(8) Identify vacuum lines from dash panel and disconnect from engine.
(9) Disconnect shroud, if equipped, from radiator.
(10) Remove radiator, fan and shroud. Install bolt in
pulley after fan is removed to keep pulley in alignment
with bolt holes in water pump.
(11) Disconnect cable from starter motor. Remove
starter motor.
(12) Remove motor mount cushion-to-frame attaching nuts.
(13) Disconnect exhaust pipe.
(14) If equipped with manual transmission:
(a) Remove bellhousing screws.
(b) Remove clutch linkage and shield.
(15) If equipped with automatic transmission:
(a) Remove transmission cover.
(b) Mark converter and flex plate for alignment
during installation.
(c) Remove converter drive screws. Rotate
crankshaft for access to each screw.
(d) Remove c o n v e r t e r
housing-to-engine
screws. Remove oil pan screws which retain transmission cooler lines.
(16) Support transmission with jack.
(17) If equipped with power steering, disconnect
hoses at steering gear. Tie hoses to engine to prevent
draining.
(18) If equipped with air conditioning:
(a) Turn compressor service fitting valve stem
to seat.
(b) Loosen service fitting.
(c) Allow compressor refrigerant to escape.
(d) Remove fittings from compressor.
(19) Attach engine lift device. Pull engine forward to
disengage from transmission. Lift upward to remove.
ENGINE INSTALLATION
(1) Remove right mount from engine.
VALVE TRAIN
Itieral
The six-cylinder engine has overhead valves operated
by push rods and rocker arms. A chain-driven camshaft
is mounted in the cylinder block. Hydraulic valve tappets provide automatic valve lash adjustments.
ENGINES
3ff7Z.>- " w ~ - w w
.w
- w w -
w~>77WF
~ w
w- w
1B-5
:~w-^w~1
Reclir A n Asseiif'
Installation
jj ROCKER A R M
J CAPSCREW
BRIDGED
PIVOT
Valvis
NOTE: The following procedures apply only after the
cylinder head has been removed from the engine. Refer
to Cylinder Head for removal procedures.
Removal
(1) Compress each valve spring with Spring Compressor Tool J-21931-01 and remove valve locks, retainers, springs and valve stem oil deflectors.
(2) Remove valves and place in rack in same order
as removed from cylinder head.
Fig. 1B-7
Removal
Clean all parts with a cleaning solvent and use compressed air to blow out oil passages in the rocker arms
and push rods.
Inspect the pivot surface of each rocker arm and
bridged pivot. Replace any parts which are scuffed, pitted or excessively worn. Inspect valve stem tip contact
surface of each rocker arm and replace any rocker arm
which is deeply pitted. Inspect each push rod end for
excessive wear and replace as required. If any push rod
is excessively worn due to lack of oil, replace the push
rod and inspect the corresponding lifter.
It is not normal to find a wear pattern along the
length of the push rod. Check the cylinder head for
obstruction if this condition exists.
1B-6
ENGINES
1/32-INCH
( 0 . 7 8 7 mm)
VALVE MARGIN
Valve Glides
CORRECT V A L V E
FACING
NO M A R G I N
Reamer
Tool Number
>
J-6042-1
J-6042-5
J-6042-4
Size
0.003-inch
0.015-inch
0.030-inch
60260
INCORRECT V A L V E
FACING
60117
Fig. 1B-8
Valve Refacing
Valve stem-to-guide clearance may be checked by either of the following two methods.
Preferred Method:'
(1) Remove valve from head and clean valve guide
with solvent and bristle brush.
(2) Insert telescoping gauge into valve guide approximately 3/8-inch (9.525 mm) from valve spring side
of head (fig. 1B-10) with contacts crosswise to cylinder
head. Measure telescoping gauge with micrometer.
(3) Repeat measurement with contacts lengthwise
to cylinder head.
(4) Compare crosswise to lengthwise readings to determine out-of-roundness. If measurements differ by
more than 0.0025-inch (0.064 mm), ream guide to accomodate oversize valve.
(5) Compare valve guide diameter with diameter
listed in Specifications. If measurement differs more
than 0.003-inch (0.076 mm), ream guide to accomodate
oversize valve.
GAUGE
Fig. 1B-9
GH8 11-7
dm*.
tfeiL
4Uf&.
-.^Mis^Trzr
^&z~:
^ . T . - -
Alternate Method:
(1) Use dial indicator to measure lateral movement
of valve stem with valve installed in its guide and just
off valve seat (fig. 1B-11).
(2) Correct clearance is 0.001- to 0.003-inch (0.025
mm to 0.076 mm). If indicated movement exceeds this
amount, ream guide to accomodate oversize valve.
aggr-
jftj!k_
_ i
Fig. 1 B-11
Installation
Valve Springs
Valve Spring and Oil Deflector Removal
11-8 ENGINES
AJ41885
Fig. 1B-13
certain
Fig. 1 1 - 1 4
Ci
LiIQ
Lilt
Measurement
ENGINES
Camshaft Removal
Camshaft liipsilin
1B-9
Camshaft Installation
Camshaft bearing replacement requires that the engine be removed from the vehicle. Remove timing case
cover, crankshaft and camshaft rear bearing plug. When
installing bearings, use a screw-type tool that provides
steady pressure. Do not use a driver-type tool to install
bearings. Care must be taken to align oil holes in bearings with oil galleries in the block. It is not necessary to
line ream camshaft bearings after installation.
11=10
ENGINES
C H A R G I N G CYCLE
LEAK-DOWN
CYCLE
80443
Fig. 1 B-16
Removal
4281 1
Cleailig and
Inspection
ENGINES
AJ41890 ,
Fip. 1 B-1 ?
J-579
AJ41891
Fig, 11=18
After cleaning and inspection, leak-down test the tappet to ensure its zero-lash operating ability. Figure 1B18 illustrates tool J-5790 which can be used to test tappet
leak-down accurately.
(1) Swing weighted arm of tester away from ram of
tester.
(2) Place 0.312- to 0.313-inch (7.925 to 7.950 mm)
diameter ball bearing on plunger cap of tappet.
(3) Lift ram and place tappet with ball bearing inside tester cup.
(4) Lower ram, then adjust nose of ram until it
contacts ball bearing. Do not tighten hex nut on ram.
(5) Fill tester cup with Valve Tappet Test Oil J-5268
until tappet is completely covered.
(6) Swing weighted arm onto ram and pump up and
down on tappet to remove air. When air bubbles cease,
swing weighted arm away and allow plunger to rise to
normal position.
(7) Adjust nose of ram to align pointer with SET
mark on scale of tester and tighten hex nut.
(8) Slowly swing weighted arm ^ onto ram.. Rotate
cup by turning handle at base of tester clockwise one
revolution every two seconds.
1B-11
N O T E : Do not charge the tappet assemblies with engine oil. They will charge themselves within 3 to 8 minutes of engine operation.
Installation
(1) Dip tappet assembly in Jeep Engine Oil Supplement (EOS), or equivalent.
(2) Use Hydraulic Valve Tappet Remover and Installer Tool J-21884 to install each tappet in same bore
from which it was removed.
(3) Install cylinder head and replacement gasket
and tighten screws. Refer to Cylinder Head Installation
for tightening sequence.
(4) Install push rods in same order as removed.
(5) Install rocker arms and bridged pivot assemblies. Loosely install capscrews to each bridged pivot. At
each bridged pivot, tighten capscrews alternately, one
turn at a time, to avoid damaging or breaking bridge.
(6) Pour remaining EOS over entire valve train.
N O T E : The EOS must remain in the engine for at least
1,000 miles but need not be drained until the next scheduled oil change.
(7) Install cylinder head cover and gasket.
(8) Refill coolant.
AJ41894
Fig. 11-21
(4) Position timing case cover on engine. Place Timing Case Cover Alignment Tool and Seal Installer J22248 in crankshaft opening of cover (fig. 1B-21).
43174
FI|. 1B-19
Tlslsg
Cover
Alignment
Removal
(1) Remove drive belt(s), engine fan and hub assembly, damper pulley and vibration damper. Refer to Vibration Damper Removal for procedure.
(2) Remove oil pan-to-timing case cover screws and
cover-to-block screws.
(3) Remove timing case cover and gasket from
engine.
' (4) Cut off oil pan gasket end tabs flush with front
face of cylinder block and remove gasket tabs.
(5) Clean timing- case cover, oil pan and cylinder
block gasket surfaces.
(6) Remove crankshaft oil seal from timing case
cover.
Installation
(1) Apply seal compound (Perfect Seal, or equivalent) to both sides of replacement timing case cover
gasket and position gasket on cylinder block.
(2) Cut end tabs off replacement oil pan gasket corresponding to pieces cut off original gasket. Install these
pieces on oil pan and cement in place.
(3) Coat seal end tabs generously with Permatex
No. 2, or equivalent, and position seal on timing case
cover (fig. 1B-20).
(5) Install cover-to-block screws and oil pan-tocover screws. Tighten cover-to-block screws to 5 footpounds (7 Nm) torque and oil pan-to-cover screws to 11
foot-pounds (15 Nm) torque.
(6) Remove cover aligning tool and position replacement oil seal on tool with seal Hp facing outward. Apply
light film of Perfect Seal, or equivalent, on outside diameter of seal.
(7) Insert draw screw from tool J-9163 Into seal
installing tool. Tighten nut against tool until tool bottoms against cover (fig. 1B-22).
(8) Remove tools and apply light film of engine oil
on seal Hp.
(9) Install vibration damper and tighten retaining
screw to 80 foot-pounds (108 Nm) torque.
(10) Install damper pulley.
(11) Install engine fan and hub assembly.
(12) Install drive belt(s) and tighten to specified tension. Refer to Chapter 1C-Cooling.
Timing Case
I n s r ill
Seal Replncement ( C o w
lit
Removed)
NGINES 1B-13
Fig. 11-22
Timing Chain
Installation of the timing chain with the timing marks
of the crankshaft and camshaft sprockets properly
aligned assures correct valve timing. A worn timing
chain will adversely affect valve timing. Replace the
timing chain if it deflects more than 1/2 inch (13 mm).
The correct timing chain has 48 pins. A chain with
more than 48 pins will cause excessive slack.
Removal
41898
11-24
Installation
Fig. 1B-23
11-14
EllilES
timing
INTAKE MANIFOLD
GASKET
EXHAUST
MANIFOLD
Fig. 1B-26
60116
AJ41899
(4) Remove spark CTO vacuum tubes and disconnect TCS solenoid vacuum valve wiring, if equipped.
(5) Disconnect vacuum hose from EGR valve.
(6) Disconnect Air Guard hoses at air pump and air
injection manifold check valve. Disconnect diverter vacuum hose and remove diverter valve with hoses.
(7) Remove air pump/power steering mounting
bracket, if equipped.
(8) Remove air pump.
(9) Detach power steering pump and set aside, if
equipped. Do not remove hoses.
(10) Remove air conditioning drive belt idler assembly from cylinder head, if equipped.
(11) Disconnect exhaust pipe from manifold flange.
(12) Remove manifold attaching screws, nuts and
clamps. Remove intake and exhaust manifold as an assembly. Discard gasket.
(13) Clean mating surfaces of manifolds and cylinder
head.
ENGINES
10
14
1B-15
Fig. 1 B - 2 7
1B-16
ENGINES
(12) Install manifold assembly to cylinder head. Refer to Intake and Exhaust Manifold Assembly Installation for procedure.
(13) Install carburetor spring bracket.
(14) Install carburetor to intake manifold.
(15) Torque carburetor mounting nuts to 14 footpounds (19 Nm).
(16) Install carburetor control shaft. Install throttle
return spring. '
(17) Install choke heater tube and clean air tube to
carburetor.
' (18) Start engine and check for leaks.
(19) Install air cleaner.
InstallationGasket Method
may
InstallationSilicone Method
A room temperature vulcanizing (RTV) silicone rubber adhesive is required for this procedure. Use Jeep
Gasket-in-a-Tube, or equivalent.
(1) Clean gasket surface of adhesive and gasket
material.
(2) Wipe gasket surface of cylinder head with oily
rag. This prevents adhesion but permits sealing.
(3) Apply 1/8-inch bead of silicone along entire
length of cover flange.
(4) Before silicone begins to cure, install cover to
cylinder head. Be careful to not touch rocker arms with
silicone.
. . '
(5) Apply dab of silicone to each screw hole. Insert
screw through silicone. ...
(6) Tighten all screws by hand. Then tighten screws
to 50 inch-pounds (6 Nm) torque.
(7) Connect PCV valve to grommet in cylinder head
cover, connect canister hose.
,
(8) Install air cleaner and connect PCV hose.
Cylinder Head
Removal
ENGINES
(2) Remove carbon deposits from combustion chambers and top of pistons.
(3) Use straightedge and feeler gauge to check flatness of cylinder head and block mating surfaces. Refer
to Specifications.
Installation
1B-17
(12) Install power steering bracket and pump. Adjust belt tension.
(13) Install Air Guard pump bracket screws to head.
Adjust belt tension.
(14) Install each push rod to its original location.
(15) Install rocker arms and bridged pivot assemblies to original locations. Loosely install capscrews to
each bridged pivot. At each bridged pivot, tighten capscrews alternately one turn at a time to avoid damaging
bridge. Tighten screws to, 19 foot-pounds (26 Nm)
torque.
(16) Install cylinder head cover. Use replacement
gasket or silicone rubber material.
(17) Connect hoses to thermostat housing and fill
cooling system to specified level. Install temperature
sending unit.
N O T E : The head gasket is made of aluminum-coated
embossed steel and does not require that the head
screws be retorqued.
(18) Install fuel and vacuum advance lines.
(19) Operate engine with radiator cap off. Check for
leaks and continue running engine until thermostat
opens. Add coolant, if required. To bleed air from system refer to Chapter 1CCooling-Bleeding Air from
System.
(20) Install air cleaner.
LUBRICATION SYSTEM
General
A gear-type positive displacement pump is mounted
at the underside of the block opposite the No. 4 main
bearing (fig. 1B-29). The pump draws oil through the
screen and inlet tube from the sump at the rear of the oil
pan. The oil is driven between the drive and idler gears
and the pump body, then is forced through the outlet to
the block. An oil gallery in the block channels oil to the
inlet side of the full flow oil filter. After passing through
the filter element, the oil passes from the center outlet
of the filter through an oil gallery up to the main oil
gallery which extends the entire length of the block.
Fig 1B-28
Fig. 1B-29
Lubrication Systtn
60329
ENGINES
1B-19
Oil Filter
A full flow oil filter, mounted on the lower right side
of the engine, is accessible through the hood opening. A
bypass valve incorporated in the filter mounting boss on
the cylinder block provides a safety factor if the filter
becomes inoperative as a result of dirt or sludge accumulation (fig. 1B-30).
Tool J-22700 will facilitate removal of the oil filter.
Before installation, apply a thin film of oil to the replacement filter gasket. Install filter until gasket con-
Oil Pump
The positive-displacement gear-type oil pump is
driven by the distributor shaft, which is driven by a gear
on the camshaft. Crankcase oil is drawn into the pump
through an inlet tube and screen assembly which is
pressed into the pump body (fig. 1B-30). The pump incorporates a non-adjustable pressure relief valve to
regulate maximum pressure. A setting of 75 pounds
VALVE
SPRING
RETAINER
BYPASS
VALVE
FILTER
D R I V E GEAR
ASSEMBLY
SPRING
RETAINER
OIL PRESSURE
RELIEF SPRING
OIL I N L E T TUBE
A N D SCREEN
ASSEMBLY
41082
Fig 1B-30
1B-20
ENGINES
NOTE: Oil pump removal or replacement will not affect distributor timing as the distributor drive gear remains in mesh with the camshaft gear.
(1) Drain engine oil.
(2) Remove oil pan. Refer to Oil Pan Removal.
(3) Remove oil pump retaining screws, oil pump and
gasket.
CAUTION: Do not disturb position of oil inlet tube and
screen assembly in pump body. If tube is moved within
pump body, a replacement tube and screen assembly
must be installed to assure an airtight seal.
Fig. 11-81
(1) Remove cover retaining screws, cover and gasket from pump body.
(2) Measure gear end clearance.
Preferred Method:
(a) Place strip of Plastigage across full width of
each gear end (fig. 1B-31).
(b) Install pump cover and gasket. Tighten
screws to 70 inch-pounds (8 N*m).
(c) Remove pump cover and determine amount
of clearance by measuring width of compressed Plastigage with scale on Plastigage envelope. Correct clearance by this method is 0.002 to 0.008 inch (0.002 inch
preferred) [0.051 to 0.203 mm (0.051 mm preferred)].
Alternate Method:
(a) Place straightedge across ends of gears and
pump body.
(b) Select feeler gauge which fits snugly but
freely between straightedge and pump body (fig. 1B-32).
Correct clearance by this method is 0.004 to 0.008 inch
(0.007 inch preferred) [0.102 to 0.203 mm (0.178 mm
preferred)].
If gear end clearance is excessive, replace oil pump
assembly.
NOTE: The oil inlet tube must be moved to allow removal of the relief valve. Install a replacement pickup
tube assembly.
ENGINES
1B-21
before installing
the oil
0i! Pan
Removal
AJ41902
Fig.
1M
Hi
Gear-to-Body
Umrmm
Measurement
TOOL
J-21882
\
INLET
'TUBE
it:J
Cim^
AJ41903
11-22
E i l i l E S
Oil Pressure l i n p
Refer to Chapter 1LPower Plant Instrumentation
for operation, diagnosis and replacement of oil pressure
gauge.
limifil
...
Installation
(1) Clean cylinder bores thoroughly. Apply light
film of clean engine oil to bores with clean, lint-free
cloth.
' (2) Install piston rings on pistons. Refer to Piston
Rings for sequence.
(3) Lubricate piston and rings with clean engine oil.
(4) Use Piston Ring Compressor Tool J-5601 to install connecting rod and piston assemblies through top
of cylinder bores (fig. 1B-35).
NOTE: Be careful that connecting rod screws do not
scratch the connecting rod journals or cylinder walls.
Short pieces of rubber hose slipped over the screws will
provide protection during installation.
Fig. 1B-35
Piston instillation
raKraEGTTisaE
The connecting rods are malleable iron, balanced assemblies with bearing inserts at the crankshaft journal
end. The piston pin is a 2,000 pound (907.2 kg) press-fit.
A squirt hole in the crankshaft end of the connecting
rod provides lubrication for the camshaft lobes, distributor drive gear, cylinder walls and piston pins. The
squirt hole faces the camshaft when the connecting rod
is installed.
Misaligned or bent connecting rods cause abnormal
wear on pistons, piston rings, cylinder walls, connecting
rod bearing or crankshaft connecting rod journals. If
wear patterns or damage to any of these components
indicate the probability of a misaligned connecting rod,
check rod alignment. Replace misaligned or bent rods.
face
_
:
'*BmY&m*.:.- .-lL.
jjgjggj^igfe
.iffi&EEE^
EiGINES
_ " . %
Yellow
Orange
Black
Red
-2.0955
-2.0948
-2.0941
-2.0855
to
to
to
to
2.0948
2.0941
2.0934
2.0848
Yellow
Yellow
Black
Red
(Standard)
(0.0007 Undersize)
(0.0014 Undersize)
(0.010 Undersize)
Standard
Standard
.001-Inch Undersize
.010-Inch Undersize
Yellow
Black
Black
Red
Standard
.001-inch Undersize
.001 -inch Undersize
.010-inch Undersize
60261
color-coded bearing inserts as shown in the bearing fitting chart. The bearing color code appears on the edge of
the insert.
NOTE: Bearing size is not stamped on inserts used in
production.
The rod journal size is identified in production by a
color coded paint mark on the adjacent cheek or counterweight toward the flanged (rear) end of the crankshaft.
The color codes used to indicate journal size are shown
in the bearing fitting chart.
When required, upper and lower bearing inserts of
different sizes may be used as a pair. A standard size
insert is sometimes used in combination with a 0.001inch (0.025 mm) undersize insert to reduce clearance
0.0005 inch (0.013 mm).
NOTE: Never use a pair of bearing inserts with
than 0.001-inch (0.025 mm) difference in size.
more
Example:
Bearing insert Pairs
Insert
Correct
Incorrect
Upper
Standard
Standard
Lower
0.001-inch
undersize
0.002-inch
undersize
70242
0.012-inch
Removal
LOWER
Fig. 1B-36
60757
1B-24
ENGINES
UPPER
brittle,
Fig. 1 1 - 3 7
.60760
Fig. 1B-38
A B N O R M A L CONTACT A R E A
DUE TO LOCKING TABS NOT
F U L L Y SEATED OR BENT TABS
60758
Fig. 1B-39
L i c i i g Tab Inspection
ENGINES 1B-25
SCALE
Fig. 1B-41
COMPRESSED
PLASTIGAGE
41907
Fig. 1B-40
(3) Check for taper and out-of-round condition. Correct tolerance is 0.0005-inch (0.013 mm) maximum for
both taper and out-of-round. If any rod journal is not
within specifications, the crankshaft must be replaced.
(4) Compare reading obtained with journal diameters listed in Connecting Rod Bearing Fitting Chart and
select inserts required to obtain specified bearing
clearance.
Micrometer Method
Installation
Piston Fitting
PISTONS
Aluminum alloy autothermic pistons are used. Steel
reinforcements provide strength and control expansion.
The ring belt area above the piston pin provides for two
compression rings and one oil control ring.
The piston pin boss is offset from the centerline of the
piston to place it nearer the thrust side of the piston,
minimizing piston slap.
An arrow on the top surface of the piston ensures
correct installation in the bore. The arrow points toward
the front of engine when installed (fig. 1B-41).
1B-26
ENGINES
I - I I * . " - : : : ! I I V ; : : : , . ; ; . .
3.333 i n .
(84.6502mm)
T328 in.
---IIIGA^^
DIAMETER
1ST AND
2ND
(84.5312mm)
3.339 i n .
(84.8106mm)
' 3.329 i n .
(84.5566mm)
GROOVE
DIAMETER
3RD
GROOVE
.0805 in.
(2.0447mm)
.0795 in.
(2.0193mm)
.1895 in.
(4.8133mm)
- - - ^ T ^ r m m r ~ r j z z r . z ^
GROOVE
HEIGHT
.188 in.
(4.7752mm)_
MEASURE PISTON
A T THIS AREA
FOR F I T T I N G
41909
Fig. 1141
Pistil i i i s u r i i i s i l
(2) Check ring side clearance with feeler gauge fitted snugly between ring land and ring. Rotate ring in
groove. It must move freely a t all points (fig. 1B-43).
Refer to Specifications for correct ring side clearance.
Fig. 1 1 4 4
Ring l i p Clearance
Installation
Fig. 1 I 4 S
ENGINES
1B-27
BOTTOM
COMPRESSION RING
TOP O I L
CONTROL R A I L
OIL RAIL
SPACER
BOTTOM OIL
CONTROL R A I L
R I N G EXPANDER
RECOMMENDED
IMAGINARY
LINE T H R O U G H
CENTER
OF PISTON
SKIRT
I M A G I N A R Y LINE
PARALLEL
TO PISTON PIN
RING GAP POSITION M A Y
V A R Y 2 0 FROM
POSITION I L L U S T R A T E D
41913
80124
J 21872 3
J-21872 3
J-21872-2
J-21872 1
J-21872-1
60122
Fig. 1 B 4 6
Fig. 1B49
1B-28
ENGINES
(2) Use Piloted Driver J-21872-3 to press pin completely out of piston. Note position of pin through gauge
window of remover support.
Pin lispntlii
(1) Inspect pin and pin bore for nicks and burrs
Remove as necessary.
NOTE: Never reuse piston pin after it has been installed in and removed from a connecting rod.
(2) With pin removed from piston, clean and dry
piston pin bore and replacement piston pin.
(3) Position piston so that pin bore is in vertical
position. Insert pin in bore. At room temperature, the
replacement pin should slide completely through pin
bore without pushing.
(4) Replace piston if pin jams in pin bore.
listiSiiflii
Removal or Replacement
If the crankshaft is damaged to the extent that reconditioning is not feasible, it must be replaced. Removal and installation procedures are outlined under
Cylinder Block.
CRANKSHAFT
The nodular iron crankshaft is counterweighted and
balanced. The crankshaft has twelve counterweights.
Both have seven main bearing journals and six connecting rod journals. End thrust is controlled by the No.
3 main bearing.
An oil slinger is provided at the rear main journal,
inboard of the rear oil seal. The component parts and
crankshaft are individually balanced. Then the complete
assembly is balanced as a unit.
Service replacement dampers, crankshafts, flywheels,
torque converters and clutch components are balanced
individually and may be replaced as required without
balancing the complete assembly.
Fig. 1B-50
specifications, inspect
If no wear is apparent,
end play. If end play is
crankshaft.
. v;.
ENGINES 11-2S
size
is not
stamped
on inserts used in
The main bearing journal size is Identified i n production by a color-coded paint mark on the adjacent cheek
toward the flanged (rear) end of the crankshaft, except
for the rear main journal which is on the crankshaft
rear flange.
When required, upper and lower bearing Inserts of
different sizes may be used as a pair. A standard size
insert is sometimes used In combination with a 0.001Inch undersize insert to reduce clearance by 0.0005 inch
(0.013 mm).
Example:
Removal
BEND H E A D T O FOLLOW
CONTOUR OF J O U R N A L
Correct
Incorrect
Upper
Standard
Standard
Lower
0.001-inch
undersize
0.002-inch
undersize
70242
with
60763
Fig. 1B-51
Inspection
(1) Wipe lower insert clean and inspect for abnormal wear pattern and for dirt or metal imbedded in
lining. Normal main bearing wear pattern is shown in
figure 1B-53.
NOTE: The
production.
0.012-inch
-2.5001
-2.4996
-2.4991
-2.4986
-2.4901
to
to
to
to
to
2.4996
2.4991
2.4986
2.4981
2.4896
(Standard)
(0.0005 Undersize)
(0.001 Undersize)
(0.0015 Undersize)
(0.010 Undersize)
Standard
Standard
.001-inch Undersize
.001-inch Undersize
.010-inch Undersize
Standard
.001-inch
.001-inch
.002-inch
.010-inch
Undersize
Undersize
Undersize
Undersize
60262
1B-30
ENGINES
F!g. '33-52
PATTERN ON
LOWER B E A R I N G
60762
Fig. 1B-53
ENGINES 1B-31
Installation
clean and
Vibration Damper
The vibration damper is balanced independently and
then rebalanced as part of the complete crankshaft
assembly.
11-32
ENGINES
Removal
breaking
CYLINDER BLOCK
Disassembly
WRENCH
AJ41892
P""*
Fig. 1B-56
Installation
ENGINES
1B-33
bearings and
lubrication
Asseibly
(1) Install upper main bearing inserts in cylinder
block.
(2) Install crankshaft.
(3) Install main bearing caps and inserts. Apply oil
to insert before installing. Tighten screws to 80 footpounds torque in steps of 40, 60 and 80 foot-pounds
torque (54, 81, 108 N*m). Plastigage all bearings if replacement bearings or crankshaft have been installed.
(4) Clean cylinder bores thorougly. Apply light film
of clean engine oil to bores with clean, lint-free cloth.
(5) Install piston rings on piston. Refer to Piston
Rings for sequence.
(6) Lubricate piston and rings with clean engine oil.
(7) Use Piston Ring Compressor Tool J-5601 to install connecting rod and piston assemblies through top
of cylinder bores (fig. 1B-34).
NOTE: Be careful that connecting rod bolts do not
scratch the connecting rod journals or cylinder walls.
Short lengths of rubber hose slipped over the connecting
rod bolts will provide protection during installation.
(8) Apply oil to inserts. Install connecting rod bearing caps and inserts in same order as removed. Tighten
retaining nuts to 33 foot-pounds (45 N*m) torque.
80304
Fig. 1B-57
CAUTION: Do not use rigid type hones to remove cylinder glaze. A slight amount of taper always exists in
cylinder walls after engine has been in service.
(1) Use expanding hone to true cylinder bore and to
remove glaze for faster ring seating. Move hone up and
down at sufficient speed to produce uniform 60 angle
Crosshatch pattern on cylinder walls. Do not use more
1B-34
ENGINES
SPECIFICATIONS
Six-Cylinder Engine Specifications
(USA)
Inches
Unless
Otherwise
Specified
In Line, O H V , Six-Cylinder
Type . . . . . . . . . . . . . . . . .
3.75
95.25
Bore
Stroke
258
3.895
98.93
Displacement
258 .
258 cubic inches
4.2 liters
Compression Ratio
8.0:1
Compression Pressure
258
150 psi
1034.3 kPa
Maximum Variation Between
Cylinders
20 psi
137.9 kPa
Firing Order . . . . . . . . . . . . . . .
1-5-3-6-2-4
Taxable Horsepower . . . . . . . . . .
33.75 Bhp
25.2 kW
Fuel.
unleaded
Camshaft
Fuel Pump Eccentric Diameter
Tappet Clearance
End Play
Bearing Clearance
Bearing Journal Diameter
No. 1
No. 2
No. 3
. . . .
No. 4
Base Circle Runout
Cam Lobe Lift.
Intake Valve Timing
Opens. . . . . . . . . . . . .
Closes.
Exhaust Valve Timing
Opens
Closes.
Valve Overlap . . ...
.
Intake Duration
Exhaust Duration
1.615-1.625
41.02-41.28
Zero Lash (Hydraulic tappets)
Zero (engine operating)
0.001-0.003
0.025-0.076
2.029-2.030
2.019-2.020
2.009-2.010
1.999-2.000
0.001 (max)
0.248
51.54-51.56
51.28-51.31
51.03-51.05
50.78-50.80
0.03 (max)
6.30
14.58 BTDC
68.790 ABDC
55.59 BBDC
27.78 A T D C
42.36
263.37
263.37
Connecting Rods
Total Weight (less bearings)
258 .
.
Total Length (center-to-center)
258
Piston Pin Bore Diameter
Connecting Rod Bore (less bearings)
Bearing Clearance
Side Clearance. .
Maximum Twist.
Maximum Bend .
Maximum Out-of-Round
(All Journals)
Maximum Taper (All Journals)
0.0005
per inch
149.17-140.28
23.59-23.62
56.09-56.08
0.03-0.06
(0.044
preferred)
0.13-0.36
0.025 per
25.4 mm
0.0127 per
25.4 mm
0.0015-0.0065
2.4986-2.5001
0.038-0.165
63.464-63.502
1.086-1.098
1.271-1.273
1.182-1.188
0.001-0.003
(0.0025
preferred)
27.58-27.89
32.28-32.33
30.02-30.18
0.03-0.08
(0.064
preferred)
2.0934-2.0955
1.070-1.076
0.001-0.0025
(0.0015-0.002
preferred)
53.17-53.23
27.18-27.33
0.03-0.06
(0.038-0.051
preferred)
0.0005
0.0005
0.013
0.013
9.487-9.493
0.0148
(below block)
3.7501-3.7533
0.005
240.97-241.12
0.3759
(below block)
95.253-95.334
0.13
0.003
0.08
0.905-0.906
22.99-23.01
0.001/1-0.002/6 0.03/25-0.05/152
0.0008 (max)
0.20 (max)
Cylinder Head
Combustion Chamber Volume . . . .
67.84-70.84cc
Valve Arrangement
EI-IE-IE-EI-EI-IE
Valve Guide ID (Integral)
0.3735-0.3745
9.487-9.512
Valve Stem-to-Guide Clearance . . . . 0.001-0.003
0.03-0.08
Intake Valve Seat Angle
30
Exhaust Valve Seat Angle
44.5
Valve Seat Width
0.040-0.060
1.02-1.52
Valve Seat Runout
0.0025
0.064
Cylinder Head Flatness
0.001/1-0.002/6 0.03/25-0.05/152
0.008 (max)
0 20 (max)
Lubrication System
Engine Oil Capacity.
5.873-5.877
0.9288-0.9298
2.2085-2.2080
0.001-0.0025
(0.0015-0.002
preferred)
0.005-0.014
0.001 per inch
(METRIC)
Millimeters
Unless
Otherwise
Specified
Cylinder Block
Deck Height
Deck Clearance
695-703 grams
Crankshaft
End Play
Main Bearing Journal Diameter
Main Bearing Journal Width
No. 1
No. 3
No. 2-4-5-6-7
Main Bearing Clearance. . . . .
(USA)
Inches
Unless
Otherwise
Specified
(METRIC)
Millimeters
Unless
Otherwise
Specified
3.8 liters
4 quarts
(Add 0.9
(Add 1 quart
liter with filter
with filter
change)
change)
89.6 kPa at
13psi at
600 rpm;
600 r p m ;
255.1-517.1
37-75 psi
(max) at
kPa (max) at
1600+ rpm
1600+ rpm
75 psi (max) 517.1 kPa (max)
0.0005-0.0025 0.0127-0.0635
(0.0005
(0.0127
preferred)
preferred)
0.002-0.008
0.0508-0.2032
(0.0508
(0.002
preferred)
preferred)
0.1016-0.2032
0.004-0.008
(0.1778
(0.007
preferred)
preferred)
Pistons
Weight (less pin)
Piston Pin Bore Centerline-to-Piston
Top
Piston-to-Bore Clearance
498-502 grams
1.599-1.603
0.0009-0.0017
(0.0012-0.0013
preferred)
40.61-40.72
0.023-0.043
(0.030-0.033
preferred)
0.010-0.020
0.25-0.51
60263A
ENGINES
IMS
Otherwise
Otherwise
Specified
No. 2 Compression
Oil Control
(USA)
Inches
Unless
Otherwise
Specified
(METRIC)
Millimeters
Unless
Inches
Specified
0.010-0.025
0.25-0.64
0.0015-0.003
<0.0015
preferred)
0.0015-0.003
(0.0015
preferred)
0.001-0.008
(0.003
preferred)
0.038-0.076
(0.038
preferred)
0.038-0.076
(0.038
preferred)
0.03-0.20
(0.08
preferred)
0.0795-0.0805
0.188-0.1895
2.019-2.045
4.78-4.80
3.328-3.333
3.329-3.339
0.9308-0.9313
0.9304-0.9309
0.0003-0.0005
loose
(0.0005
preferred)
2000 lb.
press-fit
84.53-84.66
84.56-84.81
23.642-23.655
23.632-23.645
0.008-0.013
loose
(0.013
preferred)
907.2 kg
press-fit
313-.312
0.904-0.9045
0.001-0.002
7.95-7.93
22.96-22.97
0.03-0.05
Valves
Valve Length
(Tip-to-Gauge Dim. Line) . . . . . 4.7895-4.8045
121.653-122.034
Valve Stem Diameter
0.3715-0.3725
9.436-9.462
Stem-to-Guide Clearance
0.001-0.003
0.03-0.08
Intake Valve Head Diameter
. 1.782-1.792
45.26-45.52
Intake Valve Face Angle
29
Exhaust Valve Head Diameter
1.401-1.411
35.59-35.84
Exhaust Valve Face Angle . . . . . . .
44
Maximum Allowable Removed for
Tip Refinishing
0.010
0.25
Valve Springs, Exhaust
Valve Open .
Valve Closed
I.D
80-88 at 1.625
210-226 at 1.188
1.000-1.020
1 6:1
9.640-9.660 244.856-245.364
' (METRIC)
Millimeters
Unless
Otherwise
Specified
Inside Diameter
1.99 approx.
50.55 approx.
64-72 lbs.
at 1.786
188-202 lbs.
at 1.411
0.948-0.968
29.0-32.7 bg.
at 45.24
85.3-91.6 bg.
at 36.51
24.08-24.59
60263B
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
Metric ( N m )
USA (ft.lbs.)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
20
20
25
20
28
18
28
33
20 in-lbs.
50
14
14
33
105
50 in-lbs.
20
12
27
43
13
13
23
20
18
15-20
15-22
18-28
15-22
20-35
15-20
23-30
30-35
17-25 in-lbs.
45-55
12-20
10-18
30-35
95-115
42-58 in-lbs.
15-25
9-15
22-30
37-47
10-18
9-18
18-28
15-25
12-25
27
27
34
27
38
24
38
45
2
68
19
19
45
142
6
27
16
37
58
18
18
31
27
24
20-27
20-30
24-38
20-30
27-47
20-27
31-41
41-47
2-3
61-75
16-27
14-24
41-47
129-156
5-7
20-34
12-20
30-41
50-64
14-24
12-24
24-38
20-34
16-34
60264A
1B-36
ENGINES
22
105
35
33
37
16
50
7
33
23
80
48
70 in-lbs.
10
17
7
11
23
43
28
38
58
30
43
33
18
19
28
5
16
13
80
13
Service
In-Use
Recheck
Torque
20-25
95-120
25-40
27-38
30-45
13-19
35-60
4-9
28-38
18-28
75-85
42-55
60-80 in-lbs.
8-1 3
12-20
5-9
9-13
18-28
37-47
25-35
30-45
40-65
20-35
40-55
27-38
12-25
16-26
22-33
4-8
13-19
10-18
70-90
9-18
Metric (N-m)
Service
Set-To
Torque
30
142
47
45
50
22
68
9
45
31
108
65
8
14
23
9
15
31
58
38
52
79
41
65
45
24
26
38
7
22
18
108
18
Service
In-Use
Recheck
Torque
27-34
129-163
34-54
36-52
41-61
18-26
47^81
5-12
38-52
24-38
102-115
57-75
7-9
11-18
16-27
7-12
12-18
24-38
50-64
34-47
41-61
54-88
27^7
54-75
37-52
16-34
22-35
30-45
5-11
18-26
14 24
95-122
12-24
All Torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Markings Chart in Section A of this manual for any torque specifications not listed above.
60264B
rip
Page
1143
Intake Manifold
1B-50
Connecting Rods
1B-58
Lubrication System
1B-53
Piston Assembly
1B-57
Oil Filter
1B-53
Crankshaft
16-64
Oil Pan
1B-66
Cylinder Block
13-68
11-57
1B-68
Oil Pump
11-58
11-51
Pistons
1B-60
Connecting
Rods
Cylinder Head mi
Cover
11=38
11-40
Engine Installation
11-39
11-38
Engine Mounting
1B-38
Specifications
11-70
Engine Removal
1B-38
11-47
Exhaust Manifold
1B-51
Timing Chain
1149
General
1B-37
Valves
1140
10-45
Valve Train
1140
1B-50
Vibration Damper
1B-67
ENGINES
The 304 (5 liter) and 360 (6 liter) CID engines are 90degree V-8 designs incorporating overhead valves (fig.
1B-58 and 1B-59). The cylinders are numbered from
front to rear: 1-3-5-7 on the left bank and 2-4-6-8 on the
right bank. The cylinder firing order is 1-8-4-3-6-5-7-2.
The crankshaft, supported by five two-piece main
bearings, rotates in a counterclockwise direction as
viewed from the rear. The camshaft is supported by five
one-piece, line-bored bearings.
Bridged pivot assemblies control movement of intake
and exhaust rocker arms and are paired by cylinders.
Due to the similarity of these engines, service procedures have been consolidated and typical illustrations
are used.
1B-37
-) _ ...
, !<' >'
:
Identification
The cubic-inch displacement numbers are cast into
both sides of the cylinder block. These numbers are
located between the engine mounting bracket bosses.
Build Date Code
The engine Build Date Code is located on a tag attached to the right bank cylinder head cover (fig. 1B-60).
The code numbers identify the year, month, and day
that the engine was built. The code letter identifies the
cubic inch displacement, carburetor type and compression ratio.
The example code identifies a 304 CID (5 liter) with
2V carburetor and 8.4:1 compression ratio built on May
15,1979.
Compression
CID
Carburetor
H
N
304
360
2V
2V
8.4:1
8.25:1
1st
Character
(Year)
4th
Character
(Engine Type)
01-12
H or N
01-31
Code
2 - 1978
Ratio
3 - 1979
EXAMPLE:
05
15
60265
1B-38
ENGINES
ENGINE H U N T I N G
Resilient rubber mounting cushions support the engine and transmission at three points. A cushion is located at each side on the centerline of the engine. The
rear is supported by a cushion between the transmission
extension housing and the rear support crossmember
(fig.lB-61).
Fig. 18-60
J42579
Fig. 1B-61
Removal or replacement of any cushion may be accomplished by supporting the weight of the engine or
transmission in the area of the cushion.
Single Letter B
Single Letter M
Single Letter F
Double Letters PM
Single Letter C
60258
ENGINE RE10VAL
The engine is removed without the transmission and
bellhousing.
(1) On Cherokee, Wagoneer and Truck models,
mark hood hinge locations at hood panel for alignment
during installation. Remove hood from hinges. On CJ
models, hood will tilt far enough rearward for access to
engine.
(2) Remove air cleaner assembly.
(3) Drain cooling system and disconnect upper and
lower radiator hoses. Disconnect heater hoses.
(4) If equipped with automatic transmission, disconnect cooler lines from radiator and engine assembly.
NOTE: If vehicle is equipped with a radiator shroud,
separate the shroud from the radiator to facilitate removal and installation of the radiator and engine fan.
ENGINES
UPPER T R U N N I O N
BEARING
9/16 INCH - 12
1 - INCH D I A HOLE
1/2 INCH - 13
L I F T I N G EYE
INSTALLED
IN I N T A K E
MANIFOLD
2 INCH X 2 INCH X 6 INCH
HARDWOOD BLOCK
Fig. 1B-62
41950
1B-39
(17) On vehicles equipped with automatic transmission, remove upper screws securing transmission bellhousing to engine.
If equipped with manual transmission, remove upper
screws securing clutch housing to engine.
(18) Disconnect exhaust pipes at exhaust manifolds
and support bracket.
(19) Remove starter motor.
(20) Support transmission with floor jack.
(21) If equipped with automatic transmission, remove engine adapter plate inspection cover. Mark assembled position of converter and flex plate and remove
the converter-to-flex plate capscrews.
(22) Remove remaining screws securing transmission bellhousing to engine.
If equipped with manual transmission, remove clutch
housing lower cover and remaining screws securing
clutch housing to engine.
(23) Remove engine by lifting upward and forward.
CAUTION: If equipped with power brakes, be careful
to avoid damaging the power unit while removing the
engine.
ENGINE INSTALLATION
(1) Lower engine slowly into engine compartment
and align with transmission housing. On manual transmissions, be sure clutch shaft is aligned properly with
splines of clutch driven plate.
(2) Install transmission housing screws. Tighten
screws to specified torque (automatic transmission: 28
foot-pounds (38 Nm), manual transmission: 27 footpounds 37 Nm).
(3) Remove floor jack which was used to support
transmission.
(4) If equipped with automatic transmission, align
marks previously made on converter and flex plate, install converter-to-flex plate capscrews and tighten to
specified torque.
(5) Install inspection cover (automatic transmission) or the clutch housing lower cover (manual
transmission).
(6) Install starter motor.
(7) On CJ models, install left front support cushion
and bracket to cylinder block. Tighten screws to 28 footpounds (38 N@m) torque.
(8) Lower engine onto supports. Remove lifting
device.
(9) Install front support cushion retaining nuts.
Tighten nuts to 33 foot-pounds (45 Nm) torque.
(10) Connect exhaust pipes at exhaust manifolds and
support bracket.
(11) If equipped with automatic transmission, connect transmission filler tube bracket to right cylinder
head.
(12) Install battery, if removed.
1B-40
ENGINES
before
VALVE THIN
Genril
All eight-cylinder engines have overhead valves operated by push rods and rocker arms. A chain-driven camshaft is mounted in the cylinder block. Hydraulic valve
tappets provide automatic valve lash adjustment.
Fig. 1B-63
Clean all parts with a good cleaning solvent. Use compressed air to clean out the oil passages in the rocker
arms and push rods.
Inspect the pivot surface of each rocker and pivot
assembly. Replace parts which are scuffed, pitted or
excessively worn. Inspect the valve stem contact surface
of each rocker arm and replace if deeply pitted. Inspect
each push rod end for scuffing or excessive wear. If any
push rod is excessively worn from lack of oil, replace
the push rod as well as the corresponding hydraulic
valve tappet and rocker arm.
It is not normal to find a pattern along the length of
the push rod. Check the cylinder head for obstruction if
this condition exists.
Installation
ENGINES
1141
Removal
Clean all carbon buildup from the combustion chambers, valve ports, valve stems and heads.
Remove all dirt and gasket cement from the cylinder
head gasket mating surface.
Inspect for cracks in the combustion chambers and
valve ports and in the gasket surface at each coolant
passage.
Inspect for burned or cracked valve heads and scuffed
valve stems. Replace any valve which is bent, warped or
scuffed.
Valve Refacing
Fig. 1B-65
CORRECT V A L V E FACING
NO M A R G I N
INCORRECT V A L V E FACING
Reamer
T o o l Number
Size
J-6042-1
J-6042-5
J-6042-4
0.003-inch
0.015-inch
0.030-inch
60117
Fig. 1B-65
Valve Refacing
60268
11-42 ENGINES
GAUGE
Valve Springs
Valve springs and oil deflectors can be removed without removing the cylinder head. Refer to Valves for
removal procedure with the cylinder head removed.
Valve Spring and Oil Deflector Removal
Fig. 1B-66
Alternate Method
Use a dial indicator to measure the lateral movement
of the valve stem with the valve installed in its guide
and just off the valve seat (fig. 1B-67). Correct clearance
is 0.001 to 0.003 inch (0.025 mm to 0.076 mm).
Installation
ENGINES
1B-43
Installation
General
60475
Fig. 11-18
spe-
Fig. 11=89
1B-44
ENGINES
(8) Crank engine slowly in direction of normal rotation (clockwise viewed from front) until dial indicator
indicates 0.020 inch (0.508 mm).
(9) This should place milled timing mark on vibration damper in line with TDC marking on timing case
cover. If more than 1/2-inch (13 mm) variation exists in
either direction, remove timing case cover and inspect
timing chain installation.
Check for incorrect camshaft sprocket indexing. The
sprocket keyway should align with the centerline of the
first lobe of the camshaft.
Camshaft Removal
and
ENGINES
r
- ~~ ~ ~~~l:
. ^ T ^ - X I ^ ~
I Z ^ " ^ " I
KEY
L
T ~ ~
T ~ "
"
"~T.
~"~T~"
T ~
~I
1B-45
~
;>1
. ^ m
D R I V E GEAR
Fig. 1B-71
Camshaft D r i f t Gear
Camshaft installation
1B-46
ENGINES
in the
Fig. 1B-72
42811
HOLLOW
PUSHROD
CHARGING CYCLE
LEAK-DOWN
CYCLE
80443
Fig. 1B-73
Fig. 1B-74
ENGINES
1B-47
3
N O T E : Do not charge the tappet assemblies with engine oil as they will charge themselves within three to
eight minutes of engine operation.
T I M I N G CASE
COVER O I L SEAL
41933
Installation
Removal
1B-48
ENGINES
Fig. 1 1 - 7 6
ENGINES 1B-49
w
~w
.-W:----.-w^-
Timing Chain
The timing chain consists of 62 links joined by 62 pins.
It is a single-row design.
To ensure correct valve timing, install the timing
chain with the timing marks of the crankshaft and camshaft sprockets properly aligned. A worn timing chain
will adversely affect valve timing. If the timing chain
deflects more than 1/2 inch (13 mm), it should be
replaced.
Removal
TIMING
MARK
41936
1B-50
r-r~
ENGINES
:-.,^-vr^Tr.
^ - - p ^ . -
- ^ - ^
r ^ ^ i ^ ^ ^ ^ ^
Installation
Fig. 1B-80
Intake lanlfell
The cast iron intake manifold is designed to enclose
and seal the tappet area between the cylinder heads. A
one-piece metal gasket, used to seal the intake manifold
to the cylinder heads and block, also serves as an oil
splash baffle.
The intake manifold contains coolant passages, a
crankcase ventilator passage and an exhaust crossover
passage. Passages are also incorporated within the intake manifold for the Exhaust Gas Recirculation (EGR)
system.
Induction system passages distribute a uniform fuel
and air mixture to the combustion chamber of each
cylinder. The left side of the carburetor supplies fuel-air
mixture through passages in the intake manifold to
numbers 1, 7, 4 and 6 cylinder intake ports. The right
side supplies 3, 5, 2, and 8.
Removal
ENGINES
Installation
1B-51
1B-52
ENilfi
(3) Apply bead of Jeep Gasket-in-a-Tube, or equivalent, to cylinder head and cylinder head cover gasket
surface.
N O T E : If the original silicone gasket is not badly damaged during removal, it is not necessary to clean and
reseal cover completely. Use Jeep Gasket-in-a-Tube, or
equivalent, to repair small gaps in silicone gasket.
(4) Position cylinder head cover on engine.
(5) Install retaining screws and tighten to 50-inch
pounds (6 Nm) torque.
(6) Connect ignition wires and install plastic wire
separator to cylinder head cover bracket.
(7) Right side:
(a) Install heater hose to choke cover clamp.
(b) Install TAC hot air hose.
(8) Left side:
(a) Connect power brake vacuum hose at intake
manifold.
(b) Connect throttle stop solenoid wire.
(9) Connect air delivery hose to air injection
manifold.
(10) Install air cleaner assembly.
Cylinder Head
Removal
a a d
AJ41929
Fig. 1B-81
ENGINES
LUBRICATION SYSTEM
Oil is drawn from the sump of the oil pan through a
tube and screen assembly to a horizontal oil gallery
located at the lower right side of the engine block (fig.
1B-82). A passage in the timing case cover channels oil
into the oil pump. Pressure is developed when oil is
driven between the gears and pump body.
The oil is forced from the pump through a passage in
the oil pump cover to the oil filter (fig. 1B-83).
The oil passes through the filtering elements and on to
an outlet passage in the oil pump cover. From the oil
pump cover passage, the oil enters an adjoining passage
in the timing case cover and is channeled into a gallery
which extends up the left front of the cylinder block.
This gallery channels oil directly to the right main oil
gallery which intersects with a short passage that channels oil to the left main oil gallery.
The left and right main oil galleries extend the length
of the cylinder block. The left oil gallery channels oil to
each hydraulic tappet on the left bank. The right oil
gallery channels oil to each hydraulic tappet on the right
bank. In addition, passages extend down from the right
oil gallery to the five camshaft bearings and on to the
five upper main bearing inserts. The crankshaft is
drilled to allow oil to flow from each main journal to
adjacent connecting rod journals. A squirt hole in each
connecting rod bearing cap distributes oil to the cylinder
walls, pistons and piston pins as the crankshaft rotates.
A small passage within the front camshaft bearing
journal channels oil through the camshaft sprocket to
the timing case cover area where the case and sprockets
throw off oil to lubricate the distributor gears and fuel
113-53
Oil
A full flow oil filter mounted on the oil pump at the
lower right-hand side of the engine is accessible from
below the chassis.
A bypass valve in the filter mounting base provides a
safety factor in the event the filter becomes inoperative
as a result of dirt or sludge accumulation (fig. 1B-84). Oil
Filter Remover Tool J-22700 will facilitate removal.
Before installation, apply a thin film of oil to the filter
gasket. Do not u s e grease. Install filter until gasket
contacts the seat of the oil pump cover. Tighten by hand
only, following instructions on replacement filter. If instructions are not printed on filter, tighten filter until
gasket contacts seat and then tighten an additional 3/4
of a turn. Operate engine at fast idle and check for leaks.
Oil Pump
The positive-displacement gear-type oil pump is
driven by the distributor shaft, which is driven by a gear
on the camshaft (fig. 1B-84). The pump is incorporated
in the timing case cover. A cavity in the cover forms the
body of the pump. A pressure relief valve regulates
maximum pressure.
Oil pump removal or replacement will not affect distributor timing. The distributor drive gear remains in
mesh with the camshaft gear.
Oil Pressure Relief Valve
The oil pressure relief valve is not adjustable. A setting of 75 pounds (517 kPa) maximum pressure is built
into the tension of the spring.
In the relief position, the valve permits oil to bypass
through a passage in the pump cover to the inlet side of
the pump (fig. 1B-84).
Removal
1B-54
ENGINES
70001
Fig. 1B-82
Lubrication System
O I L PUMP
CAVITY
TIMING
CASE
COVER
IDLER SHAFT
IDLER GEAR
ANTI-LOCK
RELIEF
PORT
(RELIEVES
TO PUMP
INLET
PASSAGE)
PUMP
OUTLET
(TO OIL
FILTER)
PRESSURE
RELIEF
VALVE
INLET
O I L PRESSURE RELIEF
V A L V E ASSEMBLY
ANTI-LOCK
RELIEF PORT
(ALLOWS O I L
WHICH HAS
BEEN TRAPPED
BEHIND POPPET
V A L V E TO
BLEED OFF)
O I L FILTER BYPASS
V A L V E ASSEMBLY
O I L FILTER
PRESSURE
RELIEF
VALVE
ASSEMBLY
GASKET
60266
Fig. 1B-83
DRIVE SHAFT
A N D GEAR
OIL FILTER
ADAPTER
Fig. 1B-84
41923
70298
Fig. 1B-85
1B-56
Eli
41940
Fig. 1B-87
ft
^fjjy,
Fig. 1B-86
4 1 9 3 9 *'
Gear-to-Body Clearance
Oil Pan
Removal
Installation
Installation
(1) Install replacement oil pan front seal to timingcase cover. Apply generous amount of Jeep Gasketin-a-Tube (RTV silicone), or equivalent, to end tabs.
EasaEJ&a^
Remowal
(1) Remove cylinder head cover(s).
(2) Remove two capscrews at each bridged pivot.
Alternately loosen capscrews one turn at a time to avoid
damaging bridge. Remove bridged pivot and rocker
arms.
(3) Remove push rods.
(4) Remove intake manifold assembly.
(5) Remove exhaust manifold(s). It is not necessary
to disconnect manifold from exhaust pipe.
(6) Remove cylinder head and gasket.
(7) Position pistons, one at a time, near bottom of
stroke. Use ridge reamer to remove any ridge from top
end of cylinder walls.
(8) Drain engine oil.
(9) Remove oil pan.
(10) Remove connecting rod bearing caps and inserts. Keep in same order as removed.
Jl_.r=
ENSUES
i.
la
Installation
(1) Thoroughly clean cylinder bores. Apply light
film of clean engine oil to bores with clean, lint-free
cloth.
(2) Arrange piston ring gaps. Refer to Piston Rings
for procedure.
(3) Lubricate piston and ring surfaces with clean
engine oil.
(4) Use piston ring compressor tool to install connecting rod and piston assemblies through top of cylinder bores. Be careful that connecting rod screws do not
scratch connecting rod journals or cylinder walls. Short
lengths of rubber hose slipped over connecting rod
screws will provide protection during installation.
NOTE: Squirt holes in connecting rods must face inward (fig. 1B-88).
(5) Install connecting rod bearing caps and inserts
in same order as removed. Tighten retaining nuts to 33
foot-pounds (45 Nm) torque.
(6) Install engine oil pan using replacement gaskets
and seals.
(7) Install cylinder heads and replacement gaskets.
(8) Install push rods.
(9) Install rocker arms and bridged pivot assemblies. Loosely install capscrews to each bridged pivot. At
each bridged pivot, alternately tighten capscrews one
turn at a time to avoid damaging bridge. Tighten capscrews to 19 foot-pounds (26 N*m) torque.
(10) Install intake manifold gasket and manifold
assembly.
(11) Install exhaust manifolds.
(12) Reseal and install cylinder head cover(s).
(13) Fill crankcase with clean oil to specified level.
(14) Start engine check for leaks.
ROD A N D
CYLINDER
NUMBERS
TO OUTSIDE
1B-57
:L^mmmmmmmmmmmm
Fig. 1B-88
1B-58
ENGINES
CONNECTING RODS
The connecting rods are malleable iron and are independently balanced. The crankshaft end of the connecting rod incorporates a two-piece bearing insert. The
number stamped onto the removeable bearing cap and
onto the adjacent machined surface of the rod corresponds to the cylinder in which the rod was assembled
(fig. 1B-88). The piston end of the rod is a 2000-pound
(907 kg) press-fit to the piston pin.
Have the connecting rod alignment checked by a competent machine shop whenever engine wear patterns or
damage indicates probable rod misalignment. Always
replace bent connecting rods.
The connecting rod bearings are precision-type steelbacked aluminum alloy. The connecting rod bearings are
selectively fitted to their respective journals to obtain
the desired operating clearance. In production, the select fit is obtained by using various sized color coded
bearing inserts as shown in the bearing fitting chart.
The bearing color code appears on the edge of the insert.
NOTE: Bearing
inserts.
on
production
with
Example:
Insert
Correct
Incorrect
Upper
Standard
Standard
Lower
0.001-inch
undersize
0.002-inch
undersize
70242
0.012-inch
undersize
inserts
Yellow
Orange
Black
Red
Yellow
Yellow
Black
Red
Standard
Standard
.001-inch Undersize
.010-inch Undersize
Yellow
Black
Black
Red
Standard
.001-inch Undersize
.001-inch Undersize
.010-inch Undersize
60270
1B-59
ENGINES
Removal
LOWER
60759
Fig. 1B-91
Inspection
UPPER
LOCKING TABS
60760
Fig. 1B-92
LOWER
60757
Fig. 1B-90
Fig. 1B-93
1B-60
ENGINES
Fig. 1B-94
will Plastigage
(8) If oil clearance exceeds specification when 0.002inch undersize inserts are installed, measure connecting
rod journal with micrometer. If journal size is correct,
inside diameter of connecting rod is incorrect and rod
must be replaced.
NOTE: Journal may
(0.254 mm) undersize.
have
been ground
0.010-inch
SCALE
COMPRESSED
PLASTIGAGE
surfaces
PISTONS
Aluminum alloy autothermic pistons are steel reinforced for strength and controlled expansion.
ENGINES 1B-61
DIAMETER
1ST A N D
2ND
GROOVE
360 CID
3.680 in.
(93.477mm)
~ 6 7 0 in.
(93.218mm)
3.333 in.
(84.6582mm)
3.328 in.
(84.5312mm)
3.339 in.
(84.8106mm)
3.329 in.
(84.5566mm)
DIAMETER
3RD
GROOVE
DIAMETER
1ST A N D
2ND
GROOVE
>
304 CID
DIAMETER
3RD
GROOVE
.0805 in.
(2.0447mm)
.0795 in.
(2.0193mm)
LL
1?
MEASURE PISTON
AT THIS AREA
FOR F I T T I N G
.1895 in.
'(4.8133mm)
.1880 in.
(4.7752mm)
GROOVE
HEIGHT
80050
Ftg
I M S
41909
Piston Fitting
Micrometer Method
Fig. 1B-97
Piston Measurements
Piston Rings
Ring Fitting
16-62
ENGINES
Installation
BOTTOM
COMPRESSION RING
TOP OIL
CONTROL R A I L
OIL R A I L
SPACER
BOTTOM OIL
CONTROL R A I L
IMAGINARY
LINE T H R O U G H
CENTER
OF PISTON
SKIRT
80051
Fig. 1B-97
I M A G I N A R Y LINE
PARALLEL
TO PISTON PIN
Fig. 1B-99
^!3>!3H3i;i=IIKI3El!^*^'
T
Fig. 1B-98
Fig. 1 B-100
60122
ENGINES 1B-63
(2) Install lower compression ring using ring installer to expand ring around piston.
N O T E : Be sure upper and lower compression rings are
installed right side up. Figure 1B-101 shows typical ring
markings to indicate the top side of the ring.
(3) Install upper compression ring using ring installer to expand ring around piston (fig. 1B-102).
Fig. 1B-101
Fig. 1 B-103
RING
INSTALLER
Fig. 1B-102
AJ41914
Piston Pins
The piston pins are pressed into the rods with 2000
pounds (907 kg) pressure and require no locking device.
Removal
(1) Inspect pin and pin bore for nicks and burrs.
Replace as necessary.
N O T E : Never reuse piston pin after it has been installed in and removed from a connecting rod.
Installation
1B-64
ENGINES
CRANKSHAFT
The crankshaft Is counterweighted and balanced independently. The component parts of the crankshaft assembly are individually balanced, then the complete
assembly is balanced as a unit. Service replacement
dampers, crankshafts, flywheels and torque converters
may be replaced without rebalancing the assembly.
There are five main bearings and four connecting rod
journals. The end thrust is controlled by No. 3 main
bearing.
The rear main bearing oil seal is protected from excessive oil by a slinger which is a machined part of the
crankshaft.
NOTE: Mark the torque converter and converter flexplate prior to removal Install in the same position during assembly.
-Removal i r Replacement
Replace the crankshaft if it is damaged beyond reconditioning. Use the procedures outlined under Cylinder Block to remove or replace the crankshaft.
Crankshaft Eni Plif Measurement
Crankshaft end play is controlled at the No. 3 main
bearing which is flanged for this purpose.
(1) Attach dial indicator to crankcase adjacent to
No. 3 main bearing.
(2) Set dial indicator push rod on face of adjacent
counterweight (fig. 1B-104).
on
production
The main bearing journal size is identified in production by a color-coded paint mark on the adjacent cheek
toward the flanged (rear) end of the crankshaft except
for the rear main journal. The paint mark for the rear
main journal is on the crankshaft rear flange.
Use the Bearing Fitting Chart to select proper bearing
inserts to obtain the specified bearing clearance. The
correct clearance is 0.0015 to 0.0020 inch (0.038 mm to
0.051 mm) on No. 1 through No. 4 main bearings and
0.0023 to 0.0027 inch (0.058 mm to 0.069 mm) for the rear
main bearing.
When required, use different sized upper and lower
bearing inserts as a pair. Use a standard size upper
insert in combination with a 0.001-inch undersize lower
insert to reduce clearance by 0.0005 inch or 1/2
thousandth of an inch (0.013 mm).
Example:
Insert
Correct
Incorrect
Upper
Standard
Standard
Lower
0.001-inch
undersize
0.002-inch
undersize
70242
Fig. 1 B-104
NOTE: When servicing upper and lower inserts of different sizes, install undersize inserts either all on the top
(upper) or all on the bottom (lower). Never use bearing
inserts with greater than 0.001-inch difference in pairs.
ENGINES
1B-65
-2.7489
-2.7484
-2.7479
-2.7474
-2.7389
to
to
to
to
to
2.7484
2.7479
2.7474
2.7469
2.7384
(Standard)
(0.0005 Undersize)
(0.001 Undersize)
(0.0015 Undersize)
(0.010 Undersize)
Standard
Standard
.001-inch Undersize
.001-inch Undersize
.010-inch Undersize
Yellow
Black
Black
Green
Red
Standard
.001-inch
.001-inch
.002-inch
.010-inch
Un<
Urn
Un<
Un<
iize
;IZE *
IIZE
ize
60273
Removal
P A T T E R N ON
LOWER B E A R I N G
6Q7S2
BEND H E A D T O FOLLOW
CONTOUR OF JOURNAL
Fig. 1 B-106
Fig. 1 B-1 OS
Inspection
(1) Wipe lower insert clean and inspect for abnormal wear pattern and for dirt or metal imbedded in
1B-66
ENGINES
obtain
COMPRESSED
PLASTIGAGE
41917
Fig. 1 B-107
ENGINES
Removal
1B-67
Fig. 1B-108
1B-68
ENGINES
NOTE: On manual transmission, the flywheel is balanced as an individual component and also as part of the
crankshaft assembly. Do not attempt to duplicate original flywheel balance holes when installing a service
replacement.
CYLINDER
BLOCK
Disassembly
Fig. 1 B-109
ENGINES
1B-69
Assembly
80304
Fig. 1B-110
CAUTION: Do not use rigid type hones to remove cylinder glaze. A slight amount of taper always exists in
cylinder walls after the engine has been in service.
(1) Use expanding hone to true cylinder bore and to
remove glaze for faster ring seating. Move hone up and
down at sufficient speed to produce uniform 60 angle
Crosshatch pattern on the cylinder walls. Do not use
more than ten strokes per cylinder. A stroke is one
down-and-up motion.
CAUTION: Protect engine bearings
system from abrasives.
and
lubrication
1B-7Q
ENGINES
. SPECIFICATIONS
Eight-Cylinder Engine Specifications
(USA)
Inches
Unless
Otherwise
Specified
(METRIC)
Millimeters
Unless
Otherwise'
Specified
Bore
304
360
3.75
4.08
95.25 '
103.63
Stroke
304
3.44
87.38
3.44
87.38
360
Displacement
304 .
360
Compression Ratio
304
360
5 liter
360 cu.in.
6 liter
Taxable Horsepower
304
360
Fuel
Camshaft
Fuel Pump Eccentric Diameter
Tappet Clearance
End Play
Bearing Clearance
20 psi
45.00
53.27
33.56 kW
39.72 kW
unleaded
2.182-2.192 - 55.423-55.677
Zero lash (hydraulic tappets)
Zero (engine operating)
0.001-0.003
0.0254-0.0762
(0.0017-0.0020 (0.0432-0.0508
preferred)
preferred)
2.1195-2.1205
2.0895-2.0905
2.0595-2.0605
2.0295-2.0305
1.9995-2.0005
0.001
53.835-53.861
53.073-53.099
52.311-52.337
51.549-51.575
50.787-50.813
0.0254
0.266
6.7564
14.75 BTDC
6 8 . 7 5 BTDC
5 6 . 7 5 BBDC
26.75 A T D C
Valve Overlap
304/360
.
Exhaust Duration
304/360 . . . . . . . . . . . . . . .
Connecting Rods
Total Weight (Less Bearings)
304/360
Total Length (Center-to-Center)
304/360
Bearing Clearance
(METRIC)
Millimeters
Unless
Otherwise
Specified
681-689 grams
Side Clearance . . . . . . . . . . . . . .
Maximum Twist
Maximum Bend
8.40:1
8.25:1
Compression Pressure
304
360
Maximum Variation Between
Cylinders
Intake Duration
304/360
304 cu.in.
(USA)
Inches
Unless
Otherwise
Specified
5.873-5.877
0.001-0.003
(0.0020-0.0025
preferred)
0.006-0.018
0.0005
per inch
0.001
per inch
149.17-149.28
0.03-0.08
(0.051 -0.064
preferred)
0.15-0.46
0.013
per 25.4 m m
0.03
per 25.4 m m
Crankshaft
End Play
Main Bearing Journal Diameter
No. 1 , 2 , 3 , 4 . . . . . .
Rear Main
0.003-0.008
0.08-0.20
2.7474-2.7489
2.7464-2.7479
69.784-69.822
69.759-69.797
1.2635-1.2695
1.246-1.248
1.273-1.275
1.246-1.248
1.215-1.217
32.093-32.25
31.65-31.70
32.33-32.39
31.65-31.70
30.86-30.91
0.001-0.003
(0.0017-0.0020
preferred)
0.03-0.08
(0.04-0.05
preferred)
0.002-0.004
(0.0025-0.003
preferred)
0.05-0.10
(0.06-0.08
preferred)
2.0934-2.0955
53.172-53.266
1.998-2.004
50.75-50.90
0.001-0.003
(0.0020-0.0025
preferred)
0.0005
0.03-0.08
(0.051-0.064
preferred)
0.013
0.0005
0.013
9.205-9.211
233.81-233.96
0.0145
(below block)
0.368
(below block)
Rear Main
No. 5 .
41.50
263.50
Cylinder Block
Deck Height
263.50
Deck Clearance
304/360
. . . .
.
60271 A
ENGINES
(USA)
Indies
Unless
Otherwise
Specified
(METRIC)
Millimeters
Unless
Otherwise
Specified
0.005
0.003
0.9055-0.9065
0.001/10.002/6
0.008 (max)
0.13
0.08
22.999-23.025
0.03/250.05/152
0.20 (max)
Cylinder Head
Combustion Chamber Volume
304
.
57.42-60.42 cc
360 . .
58.62-61.62 cc
Valve Arrangement
.
EI-IE-EI-IE
Valve Guide ID (Integral)
' . . 0.3735-0.3745
9.487-9.512
Valve Stem-to-Guide Clearance . . . .
0.001-0.003
0.03-0.08
Intake Valve Seat Angle . . . . . . . .
30
Exhaust Valve Seat Angle . . . . . . .
44.5
Valve Seat Width
0.040-0.060
1.02-1.52
Valve Seat Runout
0.0025 (max)
0.064 (max)
Cylinder Head Flatness
..
0.001/10.03/250.002/6
0.05/152
0.008 (max)
0.20 (max)
Lubrication System
Engine Oil Capacity .
Pistons
Weight (Less Pin)
304
360 . . .
Piston-to-Bore Clearance
304 . . . ,
3.8 liters
(add 0.9 liters
w i t h filter
change)
13 psi at
600 rpm
37-75 psi
at 1600+ rpm
75 psi (max)
0.0005-0.0025
(0.0005
preferred)
0.0005-0.006
(0.002
preferred)
9 0 kPa at
600 rpm
255-517 kPa
at 1600+ rpm
517 kPa (max)
0.013-0.064
(0.013
preferred)
0.051-0.152
(0.051
preferred)
506-510 grams
601-605 grams
360
4 quarts
(add 1 quart
with filter
change)
1.599-1.603
40.62-40.72
0.0010-0.0018
(0.0014
preferred)
0.0012-0.0020
(0.0016
preferred)
0.025-0.46
(0.035
preferred)
0.030-0.051
(0.041
preferred)
0.010-0.020
(0.010-0.012
preferred)
0.25-0.51
(0.25-0.305
preferred)
0.010-0.025
0.015-0.045
(0.010-0.020
preferred)
0.25-0.64
0.38-1.14
(0.25-0.51
preferred)
No. 2
Oil Control
360
No. 1
No. 2
Oil Control
Piston Ring Groove Height
No. 1 and No. 2
Oil Control
Piston Ring Groove Diameter
304
No. 1 and No. 2
Oil Control
360
No. 1 and No. 2
Oil Control
Piston Pin Diameter
304/360
Piston Pin Bore Diameter
304/360 . . . . . . . . . . . . . . .
Piston-to-Pin Clearance . . .
0.038-0.089
(0.038
preferred)
(USA)
(METRIC)
Inches
Unless
Otherwise
Specified
Millimeters
Unless
Otherwise
Specified
0.0015-0.003
(0.0015
preferred)
0.0011 -0.008
0.038-0.076
(0.038
preferred)
0.028 -0.203
0.0015-0.003
(0.0015
preferred)
0.0015-0.0035
(0.0015
preferred)
0.000-0.007
0.038-0.076
(0.038
preferred)
0.038-0.089
(0.038
preferred)
0.000-0.18
0.0795-0.0805
0.1880-0.1895
2.019-2.045
4.775-4.813
3.328-3.333
3.329-3.339
84.53-84.66
84.56-84.81
3.624-3.629
3.624-3.635
92.05-92.18
92.05-92.33
0.9308-0.9313
23.649-23.655
0.9288-0.9298
0.0003-0.0005
(0.005
preferred)
loose
23.592-23.617
0.008-0.013
(0.013
preferred)
loose
4.7895-4.8045
0.3715-0.3725
0.001-0.003
121.653-122.034
9.436-9.462
0.03-0.08
1.782-1.792
2.020-2.030
45.26-45.52
51.31-51.56
1.401-1.411
1.675-1.685
Valve Springs
Free Length
Spring Tension
Valve Closed
Valve Open
0.0015-0.0035
(0.0015
preferred)
1B-71
29
35.59-35.84
42.55-42.80
44
1.99
50.55
64-72 lbs.
at 1.786
202-220 lbs.
at 1.356
0.948-0.968
29.0-32.7 kg.
at 45.36
91.6-99.8 kg.
at 34.44
24.08-24.59
60271B
1B-72
ENGINES
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft.lbs.)
. .
. . . . . . . .
.
.
.
. . . . . . . .
. ,
.
. . . . . . . .
Metric ( N m )
Service
Service
In-Use
Recheck
Set-To
Torque
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
38
20
25
20
28
18
28
33
20 in.lbs.
30
14
14
33
23
110
50 in.lbs.
13
22
13
30-45
15-22
18-2S
15-22
20-35
15-20
23-30
30-35
17-25 in.lbs.
25-35
12-15
12-15
30-35
18-28
100-120
42-58 in.lbs.
10-18
20-25
9-18
52
27
34
27
38
24
38
45
2
41
19
19
45
31
149
6
18
30
18
41-61
20-30
24-38
20-30
27-47
20-27
31-41
41-47
2-3
34-47
16-20
16-20
41-47
24-38
136-163
5-7
14-24
27-34
12-24
25
15
.20
18
105
35
37
16
33
7
43
100
55 in.lbs.
20-30
12-18
15-25
12-25
95-115
25-40
30^5
13-19
28-38
4-9
37-47
90-105
45-65 in.lbs.
34
20
27
24
142
47
50
22
45
9
58
136
6
27-41
16-24
20-34
16-34
129-156
34-54
41-61
18-26
38-52
5-12
50-64
122-142
5-7
7
11
28
23
43
28
30
33
48
18
19
28
18
13
40in.lbs.
25
90
48 in.lbs.
5-9
9-13
22-35
18-28
37-47
25-35
20-35
27-38
40-55
12-25
16-26
22-33
13-25
10-18
30-50 in.lbs.
18-33
80-100
40-55 in.lbs.
9
15
38
31
58
38
41
45
65
24
26
38
24
18
5
34
122
5
7-12
12-18
30-47
24-38
50-64
34-47
27^7
37-52
54-75
16-34
22-35
30-45
18-34
14-24
3-6
24-45
108-136
5-6
All Torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Markings Chart in Chapter A of this manual for any torque specifications not listed above.
60272
ENGINES
1B-73
Tools
J-22534-1
V A L V E SPRING
REMOVER A N D
INSTALLER
t?JF
J-21791
V I B R A T I O N DAMPER
REMOVER
^ -
PISTON PIN R E M O V E R A N D I N S T A L L E R
J-26562
T I M I N G CASE COVER
,
=
iMSTALLER
J-5790
H Y D R A U L I C V A L V E LIFTER TESTER
J-6042-1,4, 5
V A L V E GUIDE REAMERS
J-5959-4
DIAL INBICATOR
CLAMP A N D ROD
J-26562
O I L SEAL I N S T A L L E R
J-8520
D I A L I N D I C A T O R SET
(0-1 I N C H -.001 I N C H G R A D U A T I O N )
J-22700
OIL F I L T E R WRENCH
SCREW, T I M I N G CASE
COVER C R A N K S H A F T
SEAL I N S T A L L E R
PART OF T O O L J-9163
J-22248
T I M I N G CASE COVER
ALIGNMENT TOOL AND
SEAL I N S T A L L E R
-J-8056
VALVE A N D CLUTCH
SPRING TESTER
J-21882
O I L PUMP JNLET
TUBE INSTALLER
-
-'"
'" j_9 56 T I M I N G CASE COVER
O I L SEAL REMOVER
%
J-5601
PISTON RING
COMPRESSOR 3-3/4"
3
J-6042-1,4,5
V A L V E G U I D E REAMERS
J-21884 H Y D R A U L I C V A L V E TAPPET
REMOVER A N D I N S T A L L E R
J-21791 V I B R A T I O N
DAMPER R E M O V E R
TOOL J-22534-1
V A L V E SPRING REMOVER
AND INSTALLATION TOOL
TOOL
J-22534-4
TOOL
J-22534-5
NOTES
1C-1
S
Page
Adjustments
Components
Coolant
Coolant Recovery Bottle
Coolant Temperature Override Switch
Cooling System Diagnosis
Cooling System Operation
Engine Block Heater
Fan
General
S E C T I O N
I N D E X
Page
1C-14
Heater Core
Radiator
Specifications
Temperature Gauge
Testing
Thermostat Replacement
Tools
Troubleshooting
Water Pump
Water Pump Pulley
1C-2
1C-16
1C-3
1C-4
1C4
1C-17
1C-18
~
GENERAL
The cooling system regulates engine operating temperature by allowing the engine to reach normal operating temperature as quickly as possible, maintaining
normal operating temperature, and preventing overUPPER
RADIATOR
aBBBBts:
'
r^aMmrz^rrzrrr-T~:
1C-4
1C-18
1C-21
ie-3
1C-12'
1C-19
1C-25
1C-11
1C-20
1C-18
-jmrns^m,
HEATER
HOSE (TO
UPPER R A D I A T O R HOSE
LOWER R A D I A T O R HOSE
70169
Fig. 1C-1
Fig. 1G-2
1C-2
COOLING SYSTEMS
COMPONENTS
Coolant
The coolant Is a mixture of low mineral content water
and ethylene glycol-based antifreeze. The addition of
antifreeze to water alters several physical characteristics of water that are important to cooling system
performance. The freezing point is lowered, the boiling
point is raised and tendencies for corrosion and foaming
are reduced. The lowered freezing point protects the
engine and cooling system components from damage
caused by the expansion of water as it freezes. The
raised boiling point contributes to more efficient heat
transfer. Reduced corrosion and reduced foaming permit unobstructed coolant flow for more efficient cooling.
During heat-soak conditions after engine shutdown, the
higher boiling point helps prevent coolant loss due to
boilover. The higher boiling point also helps minimize
damage caused by cavitation.
NOTE: Cavitation is the formation of a partial vacuum
by moving a solid body (pump impeller) swiftly through
a liquid (coolant). The vacuum reduces the boiling point
of the liquid and allows the formation of vapor bubbles,
which burst when contacting a hard surface. If enough
bubbles do this in a localized area, metal can be eroded,
causing leakage.
Water Pump
A centrifugal water pump circulates the coolant
through the water jackets, passages, radiator core and
hoses of the system. The pump is driven by the engine
vibration damper pulley, through a v-type belt. The steel
water pump impeller is pressed onto the rear of the
shaft which rides in bearings pressed into the cast iron
housing. The housing has a small hole to allow seepage
to escape. The water pump seals are lubricated by the
antifreeze in the coolant. No additional lubrication is
necessary.
Hoses
Rubber hoses route coolant to the heater core and
radiator. On some vehicles with eight-cylinder engines,
the heater return hose is routed through a bracket attached to the carburetor choke housing.
The lower radiator hose on all models is spring-reinforced to prevent collapsing caused by water pump
suction.
Thermostat
A pellet-type thermostat controls operating temperature of the coolant by controlling coolant flow to the
radiator. The temperature-sensitive pellet keeps the water control valve closed below 195F (91 C), causing
coolant to be recirculated within the engine. Above
Raiator
The radiator, a tube and spacer type, is composed of
two tanks soldered to the cooling tubes. The filler neck
has an overflow tube that routes overboil to the road or
to the coolant recovery bottle.
The radiator used on all models is of the downflow
type. A top tank and a bottom tank are soldered to
vertical cooling tubes. The radiator cap and filler neck
are located on the top, or inlet, tank. The bottom, or
outlet, tank contains the drain cock. It also contains the
oil cooler on vehicles with automatic transmission.
Some radiators have a plastic shroud or metal ring
attached to funnel air more directly through the radiator for improved cooling at idle and low road speeds.
Fai
WARNING: Do not stand in line with fan when engine
is running, particularly at speeds above idle.
A water pump-driven fan is used to pull cooling air
through the radiator. This is particularly important at
low road speeds. At higher speeds, the motion of the
vehicle forces air through the radiator.
Two types of fans are used. The rigid fan, having 4 or
7 blades, is attached to the water pump by a spacer. The
spacer positions the fan close to the radiator for efficiency. The seven blade Tempatrol fan has a fluid coupling attaching the fan blade to the water pump (fig. 1C3). The fluid coupling is torque and temperature sensitive and automatically increases or decreases fan speed
for proper cooling. Regulation is accomplished by a thermostatic coil in the fluid coupling which reacts to changing temperature of airflow through the radiator. The
COOLING SYSTEMS
1C-3
MOUNTING
FLANGE
mi
mm
SILICONE
FLUID
CHAMBER
^^^m
"V.'..':
FAN BLADE
ATTACHING
SCREWS (4)
42415
Fig. 1C-3
Tinpatral F n
Fig. 1C-4
1C4
COOLING SYSTEMS
, ,
TOP
90187
RADIATOR
NECK
VACUUM
VALVE
PRESSURE
VALVE
OVERFLOW
TUBE
VACUUM
VALVE
OPERATION
PRESSURE
VALVE
OPERATION
COOLING SYSTEMS
1G-5
CTO Operation
Standard Cooling CTO Switch
1C-6
COOLING SYSTEMS
Service Diagnosis
Possible Cause
Condition
HIGH TEMPERATURE
INDICATIONOVERHEATING
Correction
(1)
(1)
(2)
(2)
(3)
(3)
Replace hose(s).
(4)
(4)
(5)
(5)
Replace cap.
(6)
Vehicle overloaded.
(6)
(7)
(7)
(8)
(8)
(9)
(9)
Purge air.
(10)
(10)
(ID
(11)
(12)
Faulty thermostat.
(12)
Replace thermostat.
(13)
(13)
Replace water p u m p .
(14)
(14)
Flush radiator.
(15)
(15)
Flush system.
(16)
(16)
(17)
Brakes dragging.
(17)
Repair brakes.
(18)
(18)
Repair engine.
(19)
(19)
(20)
(20)
NOTE: Immediately after shutdown, the engine enters a condition known as heat soak. This is caused by the
, cooling system being inoperative while engine temperature is still high. If coolant temperature rises above boiling
\ point, expansion and pressure may push some coolant out of the radiator overflow tube. If this does not occur
frequently, it is considered normal.
701 70A
IVSTlil
1C-7
COOLANT LOSSBOILOVER
COOLANT ENTRY
INTO CRANKCASE
OR CYLINDER
COOLANT RECOVERY
SYSTEM
INOPERATIVE
Correction
Possible Cause
Condition
(21)
Faulty gauge.
(21)
(22)
(22)
(1)
(1)
(2)
(2)
(3)
(3)
Purge system.
(4)
(4)
(5)
(5)
Replace coolant.
(6)
(6)
(7)
(7)
(8)
(8)
Replace as necessary.
(1)
(1)
(2)
(2)
Replace as necessary.
(1)
(1)
(2)
Leak in system.
(2)
(3)
(3)
Repair as necessary.
70170B
1C-8
COOLING SYSTEMS
Service Diagnosis (Continued)
Possible Cause
Condition
NOISE
Correction
(4)
(4)
Replace cap.
(5)
(5)
Repair as necessary.
(6)
(6)
Repair as necessary.
(7)
(7)
Remove restriction.
(1)
(1)
(2)
(2)
Replace p u m p .
(3)
(3)
(4)
(4)
(5)
(5)
Replace pulley.
(6)
(6)
(7)
Belt alignment.
(7)
(1)
Replace thermostat.
(2)
(1)
Remove obstruction.
(2)
(3)
LOW TEMPERATURE
INDICATIONUNDERCOOLING
NO COOLANT FLOW
THROUGH HEATER
CORE
(2)
(2)
Faulty gauge.
(4)
(5)
(5)
Remove obstruction.
(6)
(6)
"(4)
70170C
COOLING SYSTEMS
1C-9
OK
NOT OK
Torque Housing Bol ts to
C Specifications
No Coolant Loss
Coolant Loss
NOT OK
OK
I
NOT OK
OK
OK
NOT OK
N E X T PAGE
701722/
1C-10
COOLING SYSTEMS
Engine Overheating Diagnosis Guide (Continued)
Check Coolant Level in Radiator
and Coolant Overflow Bottle
Not Low
OK
Check Coolant for Foaming
NOT OK
NOT OK
OK
NOT OK
<
Repair Leaks
OK (Hot)
I
Check Exhaust
Heat Valve
OK
NOT OK
Replace or Rebuild Radiator
Check for Collapsed
Lower Radiator Hose
!
OK
I
NOT OK
Reposition Hose Stiffener
or Replace Hose
Replace Thermostat
COOLING SYSTEMS
TROUBLESHOOTING
Cooling System Leakage
N O T E i Engine must be warm.
(1) Carefully remove radiator pressure cap from
filler neck and check coolant level.
NOTE: The cap must
from the stop tabs.
be pushed
down to
disengage
1C 1 1
80052
Fig. 1G-7
NOTE: Do not operate engine with spark plug disconnected for more than a minute or catalytic converter
may be damaged.
1C-12
COOLING SYSTEMS
internal engine leaks to the cooling system exist, bubbles will appear in the coolant. If bubbles do not appear,
there are no internal leaks.
CAUTION: Do not run engine too long, to avoid overheating. Open drain cock immediately after test to eliminate boilover.
A J 4 2 8 3 6 '
Fig. 1C-8
TESTING
Coolant Freezing Point Test
Coolant freezing point, or freeze protection, should be
checked with an antifreeze hydrometer to determine
protection level. Refer to Coolant.
Thermostat Test
(1) Remove thermostat. Refer to Thermostat
Replacement.
(2) Insert 0.003-inch (0.0762 mm) feeler gauge, with
wire or string attached, between valve and seat (fig. 1C9).
41959
Fig. 1G-9
Testing Thermostat
(3) Submerge thermostat in container of pure antifreeze, suspended so it does not touch sides or bottom of
container.
. (4). Suspend thermometer in solution so it does not
touch container.
WARNING: Do not breathe fumes.
(5) Heat solution.
(6) Apply slight tension on feeler gauge while solution is heated. When valve opens 0.003-inch (0.0762 mm),
feeler gauge will slip free from valve. Note temperature
flash o r
othei?
N O T E : Remove pump from engine before revn&iing n striction to prevent contamination (pf coohmt with
debris. Refer to Water Pump Removal.
Loose Impeller
50470
Fig. 1 G - 1 0
Fig. 1C-11
l l s i i i i i e l l i i T i i i p i t i S Spring
1C-14
COOLING SYSTEMS
ADJUSTMENTS
Drive Belts
Inspect drive belts frequently for defects such as fraying or cracking.
CAUTION: Do not use any commercial belt dressing or
oil-based lubricant on any drive belt Do not dress the
sides of any drive belt with a file or other abrasive. Each
belt has 5 or 6 tensile members wrapped around it If
these members are cut, the belt could fail.
Hi. 1C-11
Drive belts are adjusted by moving the driven component in its mount to achieve desired tension. In some
cases, a belt may drive several components. It is necessary to loosen and move only one component.
(1)
(2)
(3)
(4)
Loosen
Loosen
Loosen
Adjust
Fig. 1C-13
COOLING SYSTEMS
1C-15
Fig. 1 C-14
ADJUSTING
SOCKET
REAR
PIVOT
SCREW
FRONT
PIVOT
SCREW
ADJUSTING
SLOT
WELD
NUT
CLAMPING
SCREW
70441
Fig. 1C-16
CLAMPING
NUTS
REAR M O U N T I N G
BRACKET
Air conditioning drive belts pass around the crankshaft damper pulley, the compressor pulley and either
the alternator or an idler pulley. Adjustment of the
alternator is covered under Fan and Alternator Belt
Adjustment. The idler pulley is manufactured with a
square socket which accepts a 1/2 inch drive wrench. To
adjust, loosen clamp screw and pivot screw, apply pressure to socket with suitable wrench and tighten screws.
FRONT MOUNTING
BRACKET
70442
Six-Cylinder
Fig 1C-17
1C-16
COOLING SYSTEMS
_ _
Hoses
Check hoses at regular intervals. If a hose is cracked
or feels brittle when squeezed, it should be replaced. If a
hose swells excessively when under pressure, it should
be replaced.
In places where specific routing clamps are not provided, make sure hoses are positioned to clear exhaust
pipes, fan blades and drive belts. Improperly positioned
hoses may be damaged, resulting in coolant loss and
overheating.
The lower radiator hose on all vehicles is fitted with
an internal spring to prevent hose collapse. When performing a hose inspection, check for proper position of
the spring.
few moments with hood up, then shut engine Off and let
it cool 15 minutes before removing cap. Pressure can be
reduced during cooling by spraying the radiator with
cool water.
Shroud Position
Draining Coolant
COOLANT
Maintain coolant level with a mixture of ethylene
glycol-based antifreeze and low mineral content water.
The coolant can be drained from the radiator by loosening the drain cock on the bottom tank.
Coolant can be drained from the engine block by removing the drain plugs.
Six-CylinderTwo located on left side of block,
which may be replaced by one or two CTO switches.
Eight-CylinderCentrally located on each side of
block.
Filling
Coolant LiVilWltliit Coolant (tBCOWBff
: ^
Before filling, install all drain plugs and tighten radiator drain cock. Add the proper mixture of coolant to
meet local requirements for freeze protection.
CAUTION: The antifreeze concentration must always
be at least 50 percent, year-round and in all climates. If
concentration is lower, engine parts can be eroded by
cavitation.
Fill the radiator to the proper coolant level. On vehicles with coolant recovery system, fill the radiator to
the top and install the radiator cap. Add sufficient coolant to the recovery bottle.
After refilling the system or when air pockets are
suspected, bleed the cooling system of excess air.
COOLBNO SYSTEMS
Diameter
(inches)
2
2
Engine Flushing
7/8
1
1 1/2
11/2
60248
1C-17
1C-18
COOLING SYSTEMS
CAUTION: Be careful when tightening heater mounting screw. Improper tightening may damage seal or
allow heater to loosen, resulting in coolant loss and
engine damage.
FAN
Fan blade assemblies are balanced within 0.25 in.-oz.
and should not be altered in any way. A damaged or
bent fan must be replaced. Do not attempt repair. Refer
to the Cooling System Components chart for fan
applications.
CAUTION: Fans are designed to fit certain applications only. DO NOT attempt to increase cooling capacity by installing a fan not intended for a given engine.
Fan or water pump damage and noise may result.
RAOIATOR
Radiators are identified by Jeep part number and the
vendor build code number embossed on the upper tank.
In some Cherokees, Wagoneers and Trucks, the code is
on the radiator right side support.
Blackstone
or
BLK
Vendor
Blackstone
Month
A-Jan
B-Feb
ReplacementAll Mollis
(1) Disconnect fan s h r o u d from r a d i a t o r , if
equipped.
(2) Remove fan attaching screws.
(3) Remove fan, spacer and shroud.
(4) Install fan, spacer and shroud.
(5) Install fan attaching screws and tighten.
(6) Install shroud attaching screws and tighten, if
removed.
B4
Vendor
Modine
78
Year
8-1978
9-1979
05
Vendor
Assembly
Plate
Month
01-Jan
02-Feb
Year
8-1978
9-1979
60336
Radiator Identification
COOLING SYSTEMS
^ ^ ^ ^ ^ ^
"TT
ReplacementAll Models
T ~ T
-y
~~
THERMOSTAT REPLACEMENT
Replacement
solution
Solvent Cleaning
In some cases, use of a radiator cleaner (Jeep Radiator
Kleen, or equivalent) prior to flushing will soften scale
and deposits and reinforce the flushing operation.
to follow
directions
1C-19
-
CAUTION: Be sure
container.
on
the
Reverse Flushing
Fig. 1C-19
TharmosSsS RecessSlx-Gylindr
Fig. 1C-20
TtermostiS RecessElflfot-Cyllndor
1C-20
COOLING SYSTEMS
WATER PUMP
The water pump Impeller Is pressed onto the rear of
the pump shaft and bearing assembly. The water pump
is serviced only as a complete assembly.
RemovalSix-Cylinder
The following procedure applies to all vehicles with or
without power steering, Air Guard and air conditioning.
(1) Drain cooling system.
(2) Disconnect radiator and heater hoses from water pump.
(3) Remove drive belts.
(4) Remove fan shroud attaching screws from radiator, if equipped.
(5) Remove fan and hub assembly and remove fan
ring or shroud.
NOTE: On some models, fan removal may be easier if
the fan shroud is rotated 1/2 turn.
(6) Remove water pump and gasket.
InstallationSix-Cylinder
Before installing a replacement pump, clean gasket
sealing surfaces and remove deposits and other foreign
material from impeller cavity. Inspect block surface for
erosion or other faults.
(1) Install replacement gasket and water pump.
Tighten screws to 13 foot-pounds (18 Nm) torque. Rotate shaft by hand to be sure it turns freely.
(2) Position shroud against front of engine, if removed, and install fan and hub assembly. Tighten
screws to 18 foot-pounds (24 Nm) torque.
(3) Install shroud to radiator.
(4) Install drive belts and tighten to specified tension, using Belt Tension Gauge J-23600. Refer to
Specifications.
(5) Connect hoses to water pump.
(6) Fill radiator with coolant.
(7) Operate engine with heater control valve open
and radiator cap off until thermostat opens to remove
air from cooling system.
(8) Check coolant level and add as required.
RemovalEight-Cylinder
(1) Disconnect battery negative cable.
(2) Drain radiator and disconnect upper radiator
hose at radiator.
(3) Loosen all drive belts.
(4) If vehicle is equipped with radiator shroud, separate shroud from radiator.
(5) Install one radiator/shroud screw to retain
radiator.
(6) Remove fan and hub from water pump. Remove
fan and shroud, if equipped, from engine compartment.
(7) If vehicle is equipped with air conditioning, install double nut on air conditioning compressor bracket
to water pump stud and remove stud (fig. 1C-21).
NOTE: Removal of this stud eliminates removing compressor mounting bracket.
(8) Remove alternator and mount bracket assembly
and place aside. Do not disconnect wires.
(9) If equipped with power steering, remove two
nuts that attach power steering pump to rear half of
pump mounting bracket.
(10) Remove two screws that attach front half of
bracket to rear half.
(11) Remove remaining upper screw from inner air
pump support brace, loosen lower bolt and drop brace
away from power steering front bracket (fig. 1C-21).
(12) Remove front half of power steering bracket
from water pump mounting stud.
(13) Disconnect heater hose, bypass hose and lower
radiator hose at water pump.
(14) Remove water pump and gasket from timing
case cover.
(15) Clean all gasket material from gasket surface of
timing case cover.
Fig. 1C-21
InstallationEight-Cylinder
NOTE: Check timing case cover for erosion
caused by cavitation.
damage
COOLING SYSTEMS
(5) Install air pump drive belt, if removed, and
tighten to specified tension.
(6) Install alternator and mount bracket assembly.
(7) Connect heater hose, bypass hose and lower
radiator hose to water pump.
CAUTION: Check to be sure the wire coil is installed in
the lower radiator hose. Failure to install this coil will
result in the hose collapsing at high engine rpm.
(8) Position shroud against front of engine and install engine fan and hub assembly. Tighten retaining
screws to specified torque.
1C-21
SPECIFICATIONS
Cooling System Components
Cooling
Package
Engine
Model
STD
m
m
C5-5
83
CJ-7
93
HD
AC
258
360
2V
m
m
m
m
Auto
Man.
15
Cherokee
16,17,18
Truck
25,45,46
401
Wagoneer
360
4V
m
m
304
232
Transmission
m
m
Radiator
Fins
Per
Inch
Fan
No.
Shroud
Rows
Spacer TempaDiam.
of
of
trol
(inches)
(inches)
Blades
Tubes
16.25
16.25
.52
13
15.62
.88
15
15.62
.88
13
15.62
.88
15
15.62
.88
10.5
19
1.5
12
19
1.5
16
19.5
16
19.5
11.5
19.5
11.5
19.5
12.5
19.5
12.5
19.5
12.5
19.5
16
19.5
16
19.5
16
19.5
16
19.5
- 7
16
19.5
16
19.5
16
19.5
.52
16
19.5
16
19.5
16
19.5
16.25
10
16.25
.52
13
* m15
15.62
.88
15.62
.88
13
15.62
.88
15
15.62
.88
m
m
m
m
m
.52
1C-22
COOLING SYSTEMS
Metric (N-m)
Metric (N-m)
15 psi
103 kPa
15 psi
103 kPa
195<>F
192-198F
91C
89-92C
195F
192-198F
91<>C
89-92C
218F
103OC
2180F
103<>C
Centrifufal
Type
Drive
Radiator
Type
Cooling System Capacities (Includes 1 quart for heater)
258 CID Engines
304 CID Engines
360 CID Engines
Fan
Number of Blades
Diameter.
Drive Belt
Angle of V
Width - top of groove
Eight-Cylinder
V-Belt
Tube & Fin
38
9.931-11.506
38
0.391-0.453
plain
plain
plain
38
9.931-11.506
plain
60570
T o r q u e Specifications
Service Set-To Torques should be used when assembling components. Service (n-Use Recheck Torques should be used f o r checking a pre-torqued item.
Metric (N-m)
Service
Set-To
Torque
Accessory Drive Pulley Screws (Six-Cylinder)
Air Conditioning Idler Pulley Bracket to Timing Case Cover N u t . . .
Air Pump-to-Bracket Screws
Air Pump Bracket-to-Engine Screws
Air Pump Adjusting Strap t o Pump
Alternator Adjusting Bolt
Alternator Mounting Bracket-to-Engine Bolt
. . .
Alternator Pivot Bolt or Nut
Alternator Pivot Mounting Bolt to Head
Crankshaft Pulley t o Damper Screw
.
Engine Block Heater Nut (V-8) Compression Type
Engine Block Heater Nut Six-Cylinder T-Bolt Type
Fan Blades and Pulley t o Hub Screw
Idler Pulley Bearing Shaft t o Bracket N u t
Idler Pulley Bracket to Front Cover N u t .
Oil Cooler Line Flared Fitting Nuts
.
Oil Cooler Line Radiator Fitting
Power Steering Pump Adapter Screw
.
Power Steering Pump Bracket Screw
Power Steering Pump Mounting Screw
Power Steering Pump Pressure Line N u t .
Power Steering Pump Pulley N u t
Thermostat Housing
.
Timing Case Cover t o Block (Eight-Cylinder) (through Water Pump).
Water Pump-to-Block Screws (Six-Cylinder).
.
Water Pump t o Engine Block (Eight-Cylinder)
18
7
20
25
20
18
28
28
33
23
10
20 in-lbs.
18
33
7
25
15
23
43
28
30
58
13
25
13
25
48 in-lbs.
Service
In-Use
' Recheck
Torque
12-25
4-9
15-22
18-28
15-22
15-20
23-30
20-35
30-35
18-28
8-13
17-25 in-lbs.
12-25
28-38
4-9
15-30
10-30
18-28
37-47
25-35
30-45
40-69
10-18
18-33
9-18
18-33
40-55 in-lbs.
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
24
10
27
34
27
24
38
38
45
31
14
2
24
45
10
34
20
31
58
38
41
79
18
34
18
34
5
16-34
5-12
20-30
24-38
20-30
20-27
31-41
27-48
41-48
24-38
11-18
2-3
16-34
38-52
5-12
20-41
14-41
24-38
50-64
34-48
41-61
54-94
14-24
24-45
12-24
24-45
5-6
All Torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Markings Chart in Section A of this manual for any torque specifications not listed above.
60250
COOLING SYSTEMS
1C-23
Initial
Reset
Initial
Reset
Pounds
New Belt
Pounds
Used Belt
Newtons
New Belt
Newtons
Used Belt
125-155
125-155
90-115
90-115
556-689
556-689
400-512
400-512
125-155
65-75
125-155
125-155
90-115
60-70
90-115
90-115
556-689
289-334
556-689
556-689
400-512
267-311
400-512
400-512
6.0253
ALTERNATOR
FAN A N D
W A T E R PUMP
FAN A N D
W A T E R PUMP
A I R PUMP
DRIVE PULLEY
BASIC BELT A R R A N G E M E N T
SIX-CYLINDER
AIR G U A R D
SIX-CYLINDER
AIR PUMP
ALTERNATOR
ALTERNATOR
FAN A N D
WATER PUMP
POWER
STEERING
POWER
STEERING
LEGEND
F R O N T BELT MIDDLE BELTREAR B E L T D R I V E PULLEY &
V I B R A T I O N DAMPER
POWER STEERING
SIX-CYLINDER
A I R G U A R D A N D POWER STEERING
SIX-CYLINDER
70181C
1C-24
COOLING SYSTEMS
AIR C O N D I T I O N I N G
A I R PUMP
AIR CONDITIONING
FAN AND
WATER PUMP
IDLER
IDLER
POWER
STEERING
ALTERNATOR
ALTERNATOR
/
'
IDLER
POWER
STEERING
IDLER
D R I V E PULLEY
D R I V E PULLEY
V I B R A T I O N DAMPER
A I R C O N D I T I O N I N G A N D POWER S T E E R I N G
SIX-CYLINDER
V I B R A T I O N DAMPER
POWER S T E E R I N G , A I R G U A R D A N D A I R C O N D I T I O N I N G
SIX-CYLINDER
FAN AND
WATER PUMP
FAN A N D
WATER PUMP
ALTERNATOR
POWER
STEERING
ALTERNATOR
AIR PUMP
A I R PUMP
D R I V E PULLEY
BASIC BELT A R R A N G E M E N T W I T H
AIR GUARD
EIGHT-CYLINDER
D R I V E PULLEY
AIR G U A R D A N D POWER S T E E R I N G EIGHT-CYLINDER
LEGEND
F R O N T BELT MIDDLE BELTREAR BELT
70181A
LEGEND
F R O N T BELT
MIDDLE BELT-
REAR BELT
70181B
Tools
AJ42005
NOTES
1D-1
S E C T I O N
S
I N D E X
Page
Charging
Sinani
Maintenance
Page
Replacement
Specifications
Testing
114
1D-1
1D-2
GENERAL
For 1979, all Jeep batteries use plates containing lowantimony lead compound. The benefits are less-frequent
electrolyte check, lower self-discharge rate and longer
shelf life. It is necessary to check electrolyte only at the
beginning of the winter season and every 15,000 miles. A
difficult-to-remove cell cap design which discourages
casual removal is used on optional batteries. Some 1979
models are equipped with a smaller, lightweight battery
with conventional cell caps and a reserve capacity of 75
minutes.
The battery rating designation refers to the reserve
capacity. Refer to Reserve Capacity Ratings Chart below. Jeep batteries are available in three ratings: 75, 95
and 110 minutes. A dealer-installed optional battery is
rated at 135 minutes. Each rating has the capacity to
provide the starting power needed for specific engine
applications and accessories. All batteries are 12-volt,
lead-acid units, which use a common battery tray, but
two different holddowns. When installing an optional
battery, use the correct battery holddown. Refer to
Specifications for a particular battery model.
ie-2
1D-8
1D-5
Cold Crank
(Amps)
Color
Code
75
380
Green
95
385
Green
110
410
Red
135*
440
Blue
* Dealer-installed o p t i o n only
I
80379
iittirf Coding
Each battery is date coded at the time of shipment
from the manufacturer. This code is stamped into the
edge of the plastic case cover (fig. 1D-1). A second number stamped on the side of the battery case contains
manufacturing codes which may be ignored.
The date code is decoded as follows:
M o n t h : AJan., BFeb. (the letter I is not used)
. Year: 81978, 91979
REPLACEMENT
-RiSirwiCapailtf Rating
Reserve capacity is defined as the number of minutes
a fully charged battery at 80F (26.7C) can be discharged at a steady 25 amperes and maintain a voltage
of 1.75 volts per cell (10.50 volts total battery voltage) or
higher. Reserve capacity ratings of Jeep batteries are
identified by color codes.
Rotnoval
(1) Loosen cable clamps.
(2) Use puller to remove negative (ground) cable
from battery terminal. Then remove positive cable.
(3) Note location of positive and negative terminals
so b a t t e r y can be p r o p e r l y positioned d u r i n g
installation.
10-2
BATTERIES
CAUTION: It is imperative that the cables be connected to the battery: positive-to-positive and negativeto-negative. Reverse polarity will damage alternator
diodes and radios.
(6) Apply thin coating of grease to cable terminals.
(7) Inspect body ground cable for condition and
good connection.
MAINTENANCE
CAUTION: Always observe the correct polarity. Reversed battery connections will damage the alternator
diodes and radios.
70055
Fig. 1D-1
Installation
Fig. 1D-2
BATTERIES
..
.jmm-K-
,tmm^
Jtm&,
Frozon Electrolyte
A 3/4-charged battery is in no danger of damage from
freezing. Keep batteries at 3/4 charge or more, especially during winter weather.
Replace the battery if the electrolyte is either slushy
or frozen. A battery with this condition, depending on
the severity of the freeze, may accept and retain a
charge and even perform satisfactorily under a load test.
However, after 120 to 150 days in service, a reduction in
capacity and service life will become apparent as the
individual plates lose their active material.
CAUTION: Do not attempt to charge or use a booster
on a battery with frozen electrolyte as it may cause the
frozen battery to explode.
Freezing Temperature Chart
Specific Gravity
(Corrected to 8 0 F)
Freezing Temperature
1.270
1.250
1.200
1.150
1.100
- 84F
- 62F
-16F
+ 05 F
+ 19F
1D-3
i
, _ j f l t _
CAUTION: Keep filler caps tight so that the neutralizing solution does not enter the cells.
To ensure good contact, the battery cables must be
tight on the battery posts. Check to be sure the terminal
clamp has not stretched. This could cause the clamp
ends to become butted together without actually being
tight on the post. If the battery posts or cable terminals
are corroded, disconnect the cables by loosening the
terminal clamp bolt and remove the clamp with the aid
of a puller. Do not twist, hammer or pry on the cable to
free it from the battery post. Clean the terminals and
clamps with a soda solution and a wire brush. Connect
the cables to the battery posts, and apply a thin coat of
grease. Inspect the battery negative cable and body
ground cable for good connection and condition.
. _mbbr
,mm&:
Self-Discharge Rate
Temperature
100F (37.8C)
8 0 F (26.7C)
5 0 F (10C)
Approximate Allowable
Self-Discharge Per Day
For First Ten Days
0.0024 Specific Gravity
0.0009 Specific Gravity
0.0003 Specific Gravity
60338
CHARGING
lisclarge Cleiioal Action
A cell is discharged by completing an external circuit
such as cranking a starter motor. Sulfuric acid, acting
on both positive and negative plates, forms a new chemical compound called lead sulfate. The sulfate is supplied
by the acid solution (electrolyte). The acid becomes
weaker in concentration as the discharge continues. The
amount of acid consumed is in direct proportion to the
amount of electricity removed from the battery. When
the acid in the electrolyte is partially used up by combining with the plates and can no longer deliver electricity at a useful voltage, the battery is said to be
discharged.
The gradual weakening of the electrolyte in proportion to the electricity delivered allows the use of a hydrometer to measure how much unused acid remains with
the water in the electrolyte. This information then can
be used to determine approximately how much electrical
energy is left in each cell.
60339
Battery Storage
All wet batteries will discharge slowly when stored.
Batteries discharge faster when warm than when cold.
For example, at 100F (37.8C), a normal self-discharge
of 0.0024 specific gravity per day could be expected. At
The lead sulfate in the battery is decomposed by passing a current through the battery in a direction opposite
to that of the discharge. The sulfate is expelled from the
plates and returns to the electrolyte, gradually restoring
it to its original strength. Hydrogen and oxygen gases
are given off at the negative and positive plates as the
plates approach the fully charged condition. This is
caused by an excess of charging current not totally accepted by the plates. A perforated filter and a relief
valve in each cap relieve excess gases.
114
BATTERIES
battery
CAUTION: Always disconnect the vehicle battery cables before using a fast charger.
NOTE: Since the apparent state of charge of the battery as indicated by a hydrometer is depressed for the
first few cycles, load testing is the only valid test at the
time of activation. Hydrometer testing may be used
after the battery has been cycled in service.
The specific gravity of a newly installed Jeep battery
will be approximately 1.225 (0.010). The specific gravity will normally rise to 1.250 to 1.265 after a few days in
service.
NOTE: Electrolyte is made up of sulfuric acid and pure
water. Approximately 35 percent by weight or 2k percent by volume is acid.
CAUTION: Never add pure acid to a battery.
Slow Charge
Slow charging is the preferred method of recharging a
battery. The slow charge method may be safely used,
regardless of charge condition of the battery, provided
the electrolyte is at the proper level in all cells and is not
frozen.
CAUTION: Do not attempt to charge or use a booster
on a battery with frozen electrolyte as it may cause the
frozen battery to explode.
The normal charging rate for a battery is one amp per
positive plate per cell. The 75 minute battery has 54
Booster Charging
The correct method for starting a vehicle with a discharged battery requires either a portable starting unit
or a booster battery. When using either method, it is
essential that connections be made correctly.
When using a portable starting unit, the voltage must
not exceed 16 volts or damage to the battery, alternator,
or starter may result. Because of the accompanying high
voltage, a fast charger must not be used for booster
starting.
WARNING: Battery action generates hydrogen gas
which is flammable and explosive. Hydrogen gas is present within a battery at all times even when a battery is
in a discharged condition. Keep open flames and sparks
(including cigarettes, cigars, pipes) away from the battery. Always wear eye protection when working with a
battery.
WARNING: If fluid is not visible or ice is evident during cold weather, do not attempt to jump-start as the
battery could rupture or explode. The battery must be
brought up to 4.0F (44 C) and water added if necessary
before it can be safely jump-started or charged.
BATTERIES
(1) Remove vent caps from booster battery and
cover cap openings with dampened cloth.
CAUTION: If the vehicle is being jump-started by a
battery in another vehicle, the vehicles must not contact
each other.
(2) Connect jumper cable between positive posts ofbatteries. Positive post has " + " stamped on it. POS is
also embossed on battery cover in 1/8-inch letters adjacent to battery terminal.
(3) Connect one end of second jumper cable to negative terminal of booster battery. NEG is embossed on
battery cover in 1/8-inch letters adjacent to battery
terminal. Make certain clamps are making good contact.
DO NOT CONNECT OTHER END OF JUMPER
C A B L E TO N E G A T I V E T E R M I N A L OF D I S CHARGED BATTERY. Connect to screw, bracket or
nut on engine. Do not connect jumper to carburetor, air
cleaner or fuel line. Keep cable clear of belts and pulleys.
(4) When engine starts, remove jumper cables. Disconnect clamp on engine first.
(5) Discard cloth used to cover cap openings because
it has been exposed to sulfuric acid.
(6) Install battery caps.
TESTlIt
General
NOTE: A complete battery test includes cleaning the
top of the battery case, cleaning terminals and cable
clamps and performing hydrometer and heavy load
tests.
The condition of a battery may be determined from
the results of two testsstate of charge (hydrometer
test) and ability to deliver current (heavy load test).
Refer to Battery Diagnosis and Repair Simplification
(DARS) Chart.
Perform the hydrometer test first. If specific gravity
indicates less than 1.225, the battery must be charged
before further testing can be done. A battery which does
not accept a charge is defective and no further testing is
required.
1D-5
In rare cases where a battery goes dead and no apparent cause can be found, the battery should be fully
charged and allowed to stand on a shelf for three to
seven days to determine if self-discharge is excessive.
The Self-Discharge Rate chart shows allowable self-discharge for the first ten days of standing after a battery
has been fully charged. A battery is fully charged when
all cells are gassing freely and three corrected specific
gravity readings, taken at hourly intervals, indicate no
increase in specific gravity.
Hydrometer Test
NOTE: Periodically disassemble the hydrometer and
wash components with soap and water. Inspect-the float
for possible leaks. If the paper inside has turned brown,
the float is defective.
Prior to testing, visually inspect the battery for any
damage (broken container, cover, loose post, etc.) that
would make the battery unserviceable. To read the hydrometer correctly, position the top surface of the electrolyte in the hydrometer at eye level (fig. 1D-3).
Disregard the curvature of the liquid where the surface
rises against the float due to surface cohesion. Draw in
only enough electrolyte to keep the float off the bottom
of the hydrometer barrel with the bulb released. Keep
the hydrometer in a vertical position while drawing in
liquid and taking the reading. Be careful when inserting
the tip of the hydrometer into the cell to avoid damage
to separators. Broken separators could result in premature battery failure.
!
BULB-
BARREL-
DISREGARD
SLIGHT
CURVATURE
FLOAT
THERMOMETER.
42143
Fig. 1D-3
1D-6
BATTERIES
Specific Gravity
State of Charge
Fully Charged
75% Charged
50% Charged
25% Charged
Discharged
Specific Gravity
(Cold and Temperate Climates)
SELECTOR
KNOB
. 1.265
.
1.225
1.190
1.155
1.120
60340
4214*
Fig. 114
l i l t y Load Tssf
BATTERIES
1D-7
Chart 1
SEQUENCE
RESULT
#LOOSE
ALTERNATOR
D R I V E BELT
| # DEFECTIVE
CABLE
REPAIR OR REPLACE
IF NECESSARY
& DAMAGED
CASE
OR
COVER
CHECK
E L E C T R O L Y T E LEVEL A N D SPECIFIC
G R A V I T Y IN EACH CELL A N D RECORD
READINGS.
(OK
O
A V E R A G E SPECIFIC G R A V I T Y BELOW 1.225
(OK
V O L T A G E IS 15.5 OR LESS
(dsc
V O L T A G E ABOVE 15.5
SLOW CHARGE
BATTERY AT
3 TO 4 AMPS
FOR 48 T O
72 HOURS
o
70060A
1D-8
BATTERIES
SEQUENCE
STEP
RESULT
CHARGE B A T T E R Y AS I N D I C A T E D I N C H A R T , AFTER
CHARGE IS COMPLETED, RECHECK SPECIFIC G R A V I T Y .
AVERAGE
SPECIFIC G R A V I T Y
CHARGE RATE
(AMPS)
TIME
LESS T H A N 1.125
12 HOURS
1.125 TO
1.149
20
90 M I N .
1.150 T O
1.174
20
70 M I N .
1.175 TO
1.199
20
50 M I N .
1.200 TO
1.224
20
30 M I N .
OK
A V E R A G E SPECIFIC G R A V I T Y 1.225 OR MORE
CELL READINGS EQUAL W I T H I N .050
REPLACE
BATTERY
A V E R A G E SPECIFIC G R A V I T Y 1.225 OR MORE
BUT CELL R E A D I N G S V A R Y .050 OR MORE
C L E A N B A T T E R Y POST
A N D CABLE ENDS
CONNECT H E A V Y L O A D TESTER
DETERMINE HEAVY LOAD
FROM CHART
m ADJUST TESTER T O L O A D
H O L D L O A D FOR 15 SECONDS
READ VOLTMETER
COLOR
CODE
RESERVE
CAPACITY
COLD C R A N K
(AMPS)
HEAVY
LOAD
Green
75
380
135
Green
95
385
180
Red
110
410
190
Blue
135
440
230
VOLTAGEREADING9.6 OR MORE
o
EPLACE
VOLTAGE READING
LESS T H A N 9.6
BATTERY
4 1
OK
ENGINE
CRANKS
O
ENGINE DOES
NOT CRANK
PERFORM
STARTER
DIAGNOSIS
IN
STARTER
CHAPTER
70060B
SPECIFICATIONS
Battery Specifications
Rating
258 and 304
Reserve
Plates
360
Reserve
Plates
Optional Battery, Factory Installed
Reserve
Plates .
Optional Battery, Dealer Installed
Reserve
Plates
75 m i n .
54
95 min.
66
110 m i n .
66
135 m i n .
66
80380
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
Metric (N*m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
75
60-70
50-90
8
7-8
6-10
All torque values given in inch-pounds and newton-meters with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Markings Chart in Section A of this manual for any torque specifications not listed above.
70405
NOTES
IE 1
A
S
R
Y
G
S
SECTION I N D E X
Page
Alternator Overhaul
Alternator Replacement
Components
Drive Belt Adjustment
General
GENERAL
The Delco charging system is used on all engines. It is
a negative-ground system consisting of three main components: an alternator, a regulator and a battery. The
non-adjustable regulator is a solid-state device and is
mounted inside the alternator housing.
Available alternators are rated at 37 and 63 amperes.
COMPONENTS
Alternator
The alternator (fig. 1E-1) is belt-driven by the engine.
FRONT
HOUSING
REAR
HOUSING
3^
Operation
Specifications
stingOff-Vehicle
Tools
ling
1E-10
1E-9
1E-1
1E-13
1E-1
Page
1E-2
1E-14
1E-7
11-14
1E-3
Its major components are front and rear housings, stationary windings (stator), rotating field windings (rotor)
and rectifying diodes.
The rotor assembly is supported in the drive end housing by a ball bearing and in the slip ring end housing by
a roller bearing. These rotor bearings are manufactured
with adequate lubricant and do not require periodic
lubrication. Two brushes carry current through the two
slip rings to the field coil mounted on the rotor and
provide long periods of attention-free service. Other
t^an a regularly-scheduled belt tension check, the alternator assembly requires no periodic adjustments or
maintenance.
'T-
NO.2 T E R M I N A L
^ '
NO.1 TERMINAL
"BAT" TERMINAL
BEARING
SEAL
EST HOLE
S7ATOR
ASSEMBLY
ROTOP,
ji.'i,
VIEWS
VIEW A
}% 1E-1
4309G
1E-2
CHARGING SYSTEM
RESISTOR
SWITCH
I
DIODE
TRIO
L_
TR1_
REGULATOR
Voltage legulator
The voltage regulator utilizes an integrated circuit to
regulate current supplied to the alternator field. All
regulator components are enclosed in a solid mold, and
this unit along with the brush holder assembly is attached to the rear housing. The voltage regulator is not
adjustable.
OPERATION
F I E L D (ROTOR)
I T I f t
STATOR
General
Charging of the battery is accomplished by supplying
current directly from the alternator output terminal
(heavy red wire) to the battery, using the starter solenoid as a junction point. The positive battery cable joins
the heavy red wire at the solenoid. The alternator is
grounded to the engine to complete the return circuit to
the negative side of the battery. The amount of charge
the battery receives depends upon the state of charge
and internal condition of the battery, proper operation
of the voltage regulator and the amount of current being
consumed by electrical loads such as heater blower motor, lamps and rear window defogger.
Voltage Oitpit
When the rotor starts turning, AC voltage is generated in the stator windings. The diode trio converts some
of this to DC field current which flows through the field,
RECTIFIER
BRIDGE
Fig. 1E-2
Regulation
The No. 2 terminal on the alternator is always connected to the battery, but the discharge current is limited to a negligible value by the high resistances of R2
and R3. As the alternator speed and voltage increase,
the voltage between R2 and R3 increases and causes
zener diode D2 to conduct. Transistor TR2 then turns On
and TR1 turns Off. With TR1 Off, the field current and
system voltage decrease, and D2 then blocks current
flow, causing TR1 to turn back On. The field current and
system voltage increase. This cycle repeats many times
per second to limit the alternator voltage to a preset
value.
CHARGING SYSTEM
TROUBLESHOOTING
Close adherence to the following procedures in the
order presented will lead to the location and correction
of charging system defects in the shortest possible time.
Figure 1E-3 is a basic wiring diagram showing lead
connections.
1E-3
Visual Inspection
Check for clean and tight cable connections at the
battery posts, engine block, and starter solenoid. Check
for corrosion and loose wire connections at the alternator, starter motor solenoid, and the charging system
indicator. Inspect all wiring for cracked or broken insulation. Be sure alternator mounting screws are tight
and unit is properly grounded. Inspect the fluid level in
the battery and add water if necessary. Check for loose
alternator drive belt.
Alternator
70136
Fig. 1E-3
Noise
Battery
Alternator Leakage
If the alternator is suspected of discharging the battery because of excessive leakage, perform the following
procedure, using a bulb socket with jumper wires attached and a No. 158 bulb.
(1) Disconnect battery lead to alternator.
1E4
CHARGING SYSTEM
CHARGING SYSTEM DIAGNOSIS AND REPAIR SIMPLIFICATION (DARS) CHART
RGED
STEP
SEQUENCE
RESULT
CONNECT TEST
LIGHT BETWEEN
CABLE A N D
B A T T E R Y POST
TRACE A N D CORRECT
CONTINUOUS
D R A I N ON B A T T E R Y
TEST LIGHT O F F
(+)
( D - r O
TEST L I G H T ON
CONNECT
VOLTMETER
{+) T E R M I N A L
AND GROUND
RECONNECT
NEGATIVE
CABLE
CONNECT
JUMPER
(-) T E R M I N A L
AND GROUND
CRANK ENGINE
LONG ENOUGH
FOR S T A B I L I Z E D
READING
IF R E A D I N G IS
W I T H I N .5 V O L T OF
VOLTAGE AT ALTERNATOR
NEEDLE BELOW
9.0V
TEST B A T T E R Y
USING B A T T E R Y
LOAD TEST
PROCEDURE
BATTERY OK.
CHARGE AS
SPECIFIED BY
TEST
CHECK
VOLTAGE
ACROSS
POST
WHILE
CRANKING
IF R E A D I N G IS NOT
W I T H I N .5 V O L T OF
READING AT
ALTERNATOR,
CHECK FOR B A T T E R Y TO-ALTERNATOR
C I R C U I T RESISTANCE
70137D
CHARGING SYSTEM
STEP
1E-3
SEQUENCE
o
o
CONNECT
VOLTMETER
ACROSS
BATTERY
PLACE CARBURETOR
ON H I G H STEP
FAST I D L E C A M
RECORD
READING
START E N G I N E .
DO NOT T O U C H
ACCELERATOR
PEDAL
DISCONNECT
COIL JUMPER
(l^f)
HEADLIGHTS-M3
A/C - HI
TURN ON
ACCESSORIES
RADIO
BLOWER-TYPE
DEFOGGER
,
\\c^^
CHECK
VOLTAGE
READING
CHECK
VOLTAGE
READING
IF V O L T A G E IS
LOWER T H A N
PREVIOUS
READING (STEP 6)
Si-
IF V O L T A G E IS
HIGHER T H A N
PREVIOUS
READING (STEP 6)
ft
IF METER
READS
UNDER 12.5V
IF METER
READS
OVER 15.5V
T U R N OFF
ACCESSORIES
W A I T U N T I L UPPER
RADIATOR INLET
IS HOT
AND
VOLTMETER
NEEDLE STOPS
IF METER
READS 12V TO
15.5V SEE NOTE
IF V O L T A G E IS
HIGHER T H A N
PREVIOUS
READING (STEP 6)
^ 4 GROUND
ALTERNATOR
TOUCH SCREWD R I V E R TO TAB
AND ALTERNATOR
BODY
CHECK
VOLTAGE
READING
IF V O L T A G E IS
LOWER T H A N
PREVIOUS
READING (STEP 6)
HSTOP
REPLACE
VOLTAGE REGULATOR
OVERHAUL
ALTERNATOR
NOTE: IF N O T H I N G HAS BEEN F O U N D , EXPLAIN TO OWNER T H A T EXCESSIVE I D L I N G , A N D SLOW OR SHORT DISTANCE D R I V I N G
W I T H A L L ACCESSORIES O N , M A Y CAUSE H E A V Y D R A I N ON BATTERY - RESULTING IN U N D E R C H A R G E D C O N D I T I O N .
70137E
1E-6
CHARGING SYSTEM
SEQUENCE
STEP
RESULT
PLACE CARBURETOR
ON H I G H STEP
FAST IDLE CAM
START ENGINE.
DO NOT TOUCH
ACCELERATOR
PEDAL
CONNECT
VOLTMETER
ACROSS
BATTERY
CHECK
VOLTAGE
READING
T U R N OFF A L L
ACCESSORIES
W A I T U N T I L UPPER
RADIATOR INLET
IS H O T
,
AND
I
VOLTMETER
STOPS
E
CHECK FOR
GROUNDED
BRUSH L E A D
CLIP
IF NOT
GROUNDED
REPLACE
VOLTAGE REGULATOR
READING
IS
12.5V to 15.5V
READING
IS NOT
12.5V to 15.5V
CHARGING SYSTEM
1E-7
TESTINGOFF VEHICLE
Rotor Short-to-Ground Test
To perform this test, remove rotor and front housing
assembly from stator and rear housing assembly. Refer
to Disassembly for procedure. Perform the test with an
ohmmeter set to the 1000 scale or with a 110-volt test
lamp.
Touch one test lead to rotor shaft and touch other lead
to one slip ring (fig. 1E-4). Repeat with other slip ring. In
each case, the ohmmeter should indicate infinity (no
needle movement) or the test lamp should not light.
Test Results
Fig. 1E-5
AMMETER
12 V O L T B A T T E R Y
Fig. 1E-4
Fig. 1E-6
1E-8
CHARGING SYSTEM
Test Results
Fig. 1E-8
Fig. 1E-7
(1) Before removing diode trio, connect an ohmmeter, using lowest range scale, from brush lead clip to
rear housing (fig. 1E-9).
(2) Reverse lead connections. If both readings are
zero, check for grounded brush lead clip caused by omission of insulating washer, omission of insulating sleeve
over screw, or damaged insulation (fig. 1E-14),
(3) Remove screw to inspect sleeve. If screw assembly is correct and both ohmmeter readings are same,
replace voltage regulator.
OHMMETER
BRUSH CONNECTOR
OHMMETER
INSULATING
WASHERS
ATTACHING
NUTS
70160
DIODE
TRIO
RECTIFIER
BRIDGE
(3) Repeat steps (1) and (2) for remaining two terminal tabs.
(4) In same manner, test between insulated heat
sink and each of three terminal tabs.
Test Results
ALTERNATOR REPLACEMENT
Removal
WARNING: Failure to disconnect battery
negative
cable may result in injury from battery lead at the
alternator.
(1) Disconnect battery negative cable.
(2) Disconnect two-terminal plug and battery cable
at back of alternator.
(3) Remove mounting and adjusting screws and
washers.
(4) Remove alternator drive belt from alternator
pulley and remove alternator from mounting bracket.
(5) Remove pulley from alternator.
installation
(1) Install
alternator.
original
pulley
on
replacement
1E-10
CHARGING SYSTEM
BRUSH
HOLDER
REGULATOR
H E A T SINK
OHMMETER
Fig. 1E-11
70162
ALTERNATOR OVERHAUL
Oisassembly
CAUTION: As rotor and drive end housing assembly is
separated from slip ring housing assembly, the brushes
will spring out onto the rotor shaft and come in contact
with lubricant Immediately clean brushes which contact shaft to avoid contamination by lubricant, or they
will have to be replaced.
condition, it
CHARGING SYSTEM
1.
2.
3.
4.
5.
6.
7.
8.
ROTOR
FRONT BEARING RETAINER
COLLAR (INNER)
BEARING
WASHER
F R O N T HOUSING
C O L L A R (OUTER)
FAN
9.
10.
11.
12.
13.
14.
15.
16.
PULLEY
LOCKWASHER
PULLEY N U T
T E R M I N A L ASSEMBLY
RECTIFER BRIDGE
REGULATOR
BRUSH ASSEMBLY
SCREW
Fig. 1E-12
Alternator Components
solvent.
17.
18.
19.
20.
21.
22.
23.
1E-11
STATOR
I N S U L A T I N G WASHER
CAPACITOR
DIODE T R I O
REAR HOUSING
THROUGH-BOLT
BEARING A N D
SEAL ASSEMBLY
43105
1E-12
CHARGING SYSTEM
Fig. 1E-13
ARMATURE SHAFT
431 1 1
Fig. 1E-15
or
Assembly
(1) Fill cavity between retainer plate and bearing
one-quarter full with Delco-Remy lubricant No.
1948791, or equivalent.
N O T E : Overfilling may cause the bearing to overheat
(2) Assemble bearing and slinger into front housing
(fig. 1E-15).
60130
\*K.T!
PRY A G A I N S T
FRONT
HOUSING
70188-
1E-14
CHARGING SYSTEM
SPECIFICATIONS
Charging System Specifications
Tools
Alternator
Make
Rating
StandardAll Models
O p t i o n a l - A l l HD and AC
Field Current
Rotation (Viewing Drive End)
Pulley Size
Belt Tension
Delco-Remy
37 amp
63 amp
4.0 to 5.0 amps at 8 0 F
Clockwise
2.62 inches
(6.65 cm)
125-155 pounds, set-to
90-115 pounds, recheck
(57-70 kg, set-to
41-70 kg, recheck)
J-21008
CONTINUITY
LIGHT
Voltage Regulator
Make
Model
Type
Adjustment
Delco-Remy
1116387
Solid State
None
70271
70138
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
18
28
28
15-20
23-30
20-35
24
38
38
20-27
31-41
27-47
All Torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
70139
1F-1
A
S
R
Y
T
S
SECTION I N D E X
Page
Components
Cineral
1F-1
1M
IF-i
1F*2
Page
Specifications
Starter Motor Replacement
Starter Motor Overhaul
Tools
Troubleshooting
1F-14
1F-14
1F-10
1F-11
1F-14
m
if-z
GENERAL
Drive Assembly
COMPONENTS
MOVEABLE
POLE SHOE
Starter Motor
Identification
At the time of manufacture, the starter motor identification code is stamped on the frame adjacent to the
Jeep part number. The date is decoded as follows:
Year (81978,91979)
Month (AJan., BFeb.)
Week (Afirst week in month, Bsecond week)
Field Coils
Fig 1F-1
1F-2
STARTING SYSTEM
TROUBLESHOOTING.
'Starter Solenoid
The ground circuit for the solenoid pull-in coil is completed through the solenoid mounting bracket.
The starter solenoid is energized when battery voltage
is applied to the S-terminal of the solenoid and the pullin coil is grounded. When the solenoid coil is energized,
the contact disc is pulled into the closed position. The
disc strikes two contacts in the solenoid, completing the
circuit between the battery and the starter motor.
ON-VEHICLE TESTING
Fusible Lifts
Current is carried from the battery by cable to the
starter solenoid battery terminal. From this terminal,
current is distributed to all parts of the vehicle. A 14gauge fusible link joins the battery terminal to the main
body harness. This fusible link protects the complete
wiring system of the vehicle.
Fusible links are covered with a special non-flammable insulation. Each link is manufactured with a specific load rating and is intended for a specific circuit.
Replacement links are listed in the Parts Catalog.
OPERATION
'
\
LT BLUE
N E U T R A L SAFETY SWITCH
( A U T O M A T I C TRANSMISSION)
SOLENOID
PULL IN
COIL
IGNITION
SWITCH
(ONLY S T A R T E R
C I R C U I T SHOWN)
TO '
OTHER
VEHICLE
CIRCUITS
AMMETERCHEROKEE
WAGONEER
AND
TRUCK
ONLY
FUSIBLE
LINK (14 GAUGE)
RED-CJ
YELLOW-CKE, WAG, TRK
BATTERY
Fig. 1F-2
STARTER
MOTOR
"
SOLENOID
70107
1F-4
STARTING SYSTEM
Service Diagnosis
Correction
Possible Cause
Condition
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
Replace frame.
(1)
(1)
(2)
Faulty solenoid.
(2)
(3)
(3)
(4)
(4)
Bench-test starter.
(5)
(5)
(6)
Engine seized.
(6)
Repair engine.
(1)
(1)
(2)
(2)
(3)
(3)
(1)
(1)
(2)
(2)
Replace bushing.
(3)
(3)
(4)
(4)
Replace spring.
(5)
(5)
(6)
(6)
Reposition switch.
(7)
(7)
STARTER MOTOR
DRIVE DISENGAGES
PREMATURELY
(1)
(1)
(2)
(2)
LOW CURRENT
DRAW
(1)
Worn brushes.
(1)
Replace brushes.
(2)
(2)
Replace springs.
STARTER CRANKS
ENGINE SLOWLY
70109
STARTING SYSTEM
1F-5
OPEN
CIRCUIT
CIRCUIT
70444
Fig. 1F-4
that
very
first
after
1F-6
STARTING SYSTEM
STARTER VOLTAGE DROP TEST DIAGNOSIS AND REPAIR SIMPLIFICATION (DARS) CHARTS
Note: Refer to Chapter A General Information for details on how to use this DARS chart.
Chart 1
SEQUENCE
STEP
STARTER
I CLEAN AND
CONNECT
BATTERY
CABLES
) REMOVE COIL
WIRE FROM
DISTRIBUTOR
A N D CONNECT
TO G R O U N D
DRAW
TEST
CRANK
ENGINE
FOR
THREE
SECONDS
OK
RESULT
6 CYL.
8 CYL.
150-180 AMPS
160-210 AMPS '
- A B O V E 180 AMPS
- A B O V E 210 AMPS
B A T T E R Y CABLES A N D SOLENOID NOT TESTED
OR
V O L T A G E
G R O U N D COIL WIRE
CONNECT V O L T M E T E R
C R A N K ENGINE
READ V O L T M E T E R
NOTE A M M E T E R R E A D I N G
FROM STEP 1
REPAIR
B A T T E R Y CABLE A N D
SOLENOID REPAIRS
COMPLETED
DROP
STARTER
TEST
M A X I M U M V O L T A G E DROP
BY STARTER DRAW AMPERAGE
AMPS
VOLTS
150-210
2.15-295
300-420
425-600
0.5 V
0.7 V
1,0 V
1.5 V
OK
V O L T A G E A T OR
BELOW M A X I M U M
V O L T A G E ABOVE M A X I M U M
STARTING SYSTEM
STEP
SEQUENCE
1F-7
RESULT
V O L T A G E DROP TEST
G R O U N D COIL WIRE
CONNECT V O L T M E T E R
C R A N K ENGINE
READ V O L T M E T E R
NOTE A M M E T E R R E A D I N G
F R O M STEP 1
M A X I M U M V O L T A G E DROP
BY STARTER DRAW AMPERAGE
AMPS
150-210
215-295
300-420
425-500
VOLTS
0.3 V
0.5 V
0.6 V
0.9 V
V O L T A G E A T OR
BELOW M A X I M U M
EPAIR
ENOID-TOSTARTER CABLE
V O L T A G E ABOVE M A X I M U M
V O L T A G E DROP TEST
#
G R O U N D COIL WIRE
CONNECT V O L T M E T E R
C R A N K ENGINE
READ V O L T M E T E R
NOTE AMMETER R E A D I N G
FROM
STEP 1
M A X I M U M V O L T A G E DROP
BY STARTER DRAW AMPERAGE
AMPS
VOLTS
150-210
215-295
300-420
425-600
0.2V
0.3V
0.4V
0.5 V
OK
REPAIR
SOLENOID
V O L T A G E A T OR
BELOW M A X I M U M
REPAIR
BATTERY-TOSOLENOID
CABLE
VOLTAGE
ABOVE
MAXIMUM
V O L T A G E DROP TEST
#
%
#
%
#
G R O U N D COIL W I R E
CONNECT V O L T M E T E R
C R A N K ENGINE
READ V O L T M E T E R
NOTE AMMETER R E A D I N G
FROM
STEP 1
M A X I M U M V O L T A G E DROP
BY S T A R T E R DRAW AMPERAGE
AMPS
150-210
215-295
300-420
425-600
VOLTS
0.2V
0.3V
0.4V
0.5 V
(OK
V O L T A G E A T OR
BELOW M A X I M U M
REPAIRS TO SOLENOID
OR CABLES P E R F O R M E D
IN A PREVIOUS STEP
REPAIRS TO SOLENOID
CABLES NOT R E Q U I R E D
IN A PREVIOUS STEP
REPAIR
STARTER
REPAIR
ENGINE-TOBATTERY
CABLE
70066B
TF-8
STARTING SYSTEM
OFF-VEHICLE TESTING
No-Load Test The starter motor no-load test will indicate such
faults as open or shorted windings, worn bushings (rubbing armature) or bent armature shaft.
Fig. 1F-6
STARTING SYSTEM
HKMB*
^fSSP*
Fig. 1F-7
1F-9
S'iftWflip-
Fig. 1F-9
Fig. 1F-8
Fig. 1F-10
1F-10
STARTING SYSTEM
Armature Tests.
Test the armature for grounds, shorts and balance
whenever the starter motor is overhauled. Follow the
test equipment manufacturer's procedure or the
following.
Armature Ground Test
Fig. 1F-11
Installation
(1) Position starter motor to bellhousing.
N O T E : Make sure mounting surfaces are free of burrs
and debris.
(2) Install mounting screws and tighten to 18 footpounds (24 Nm) torque.
STARTING SYSTEM
1F-11
(1)
(2)
plate.
(3)
holder.
assembly.
DRIVE
YOKE
COVER""
SOLENOID
POINT
ACTUATOR
H O L D - I N COIL
TERMINAL
STARTER D R I V E
YOKE
DRIVE YOKE
R E T U R N SPRING
D R I V E END
HOUSING
THROUGH
BOLT
BRUSH
END
PLATE
BRUSH HOLDER
A N D INSULATOR
POLE
SHOE
GROUND
BRUSH
70859
Fig. 1F-14
Parts Identification
1F-12
STARTING SYSTEM
CONVERTER
D R I V E PLATE
STARTER MOTOR
MOUNTING
SURFACE
AUTO
TRANSMISSION
6CYLINDER
1.2465
TO
1.2060
1 - 1/4
TO
1 - 13/64
0.8305
TO
0.7700
53/64
TO
49/64
8-CYLINDER
1.2465
TO
1.2035
1 - 1/4
TO
1 - 13/64
0.8305
TO
0.7675
53/64
TO
49/64
60138
S T A R T E R MOTOR P I N I O N
1
DISENGAGED
ENGAGED,
S T A R T E R MOTOR
DRIVE END HOUSING
STARTER M O T O R
MOUNTING
SURFACE
MANUAL
TRANSMISSION
F L Y W H E E L (INCHES)
ENGINE
6-CYLINDER
1.2465
TO
1.2060
1 - 1/4
TO
1 - 13/64
0.8365
TO
0.7660
27/32
TO
49/64
8-CYLINDER
1.2465
TO
1.2035
1 - 1/4
TO
1 - 13/64
0.8365
TO
0.7635
27/32
TO
49/64
60137
Fig. 1F-15
STARTING SYSTEM
1F-13
Rising Replacement
Drive End Bushing
Fig. IF-16
N O T E : Be sure holes for second rivet are aligned before upsetting copper rivet.
(6) Install plastic insulator, upper contact and fiber
washer to remaining hole in frame. Install aluminum
rivet and upset.
N O T E : Be sure upper contact is positioned on shoulder
of plastic insulator before upsetting rivet.
(7) Install field coil assembly, pole shoes, and
screws. Apply a drop of Loctite or equivalent to each
screw.
(8) Solder hold-in coil wire to terminal strip.
(9) Solder field coil strap to upper contact. Use 600
watt soldering iron and rosin-core solder.
70872
Fig. IF-17
1F-14
STARTING SYSTEM
3
Usage.
Brush Length
Wear L i m i t . .
No Load Test (Free Speed)
Volts
Amps
M i n . RPM
Max. RPM
. .
Contact Point Clearance
ALL
0.5 in.
0.25 in.
.12
77
8900
9600
.0.100-0.020 in.
0.060 preferred
70878
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
. . .
Metric ( N m )
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
18
55 in-lbs.
13-25
40-70 in-lbs.
24
6
18-34
4.5-8
All Torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
70111
Tools
J-22516
STARTER POLE
SCREW WRENCH
70112
1G-1
mwmm
Page
SECTION
INDEX
T i l l s 1G-21
18-1
11-18
DISTRIBUTOR, C I I ^ MMW
ELECTRONIC CONTROL WMm
Operation 1G-3
Components 16-1
Distributor Component Replacement
Distributor Replacement
Specifications
Testing
Troubleshooting
18-16
1G-15
General 11-1
GENERAL
The Solid State Ignition (SSI) system used on all Jeep
engines has no breaker points, cam or condenser. Current flow through the coil is controlled by a trigger
wheel, a sensor and an electronic control unit. Conventional rotor, advance mechanism and distributor cap are
employed.
1G-18
1G-14
1G-3
ELECTRONIC
CONTROL U W H
COMPONENTS
The SSI system consists of several major components:
ignition switch, electronic ignition control unit, ignition
coil, primary resistance wire and bypass, distributor,
ignition wires and spark plugs.
COMNgCTOR
CDitfDi Olit
The electronic control unit is a solid-state, moistureresistant module (fig. 1G-1). The component parts are
permanently sealed in a potting material to resist vibration and environmental conditions. All connections are
weatherproof. The control unit has built-in reverse polarity protection and transient voltage protection.
N O T E : This unit is not repairable and must be serviced
as a unit.
70861
1G-2
IGNITION SYSTEM
Ignition Coil
The ignition coil is oil-filled and hermetically sealed
(standard construction). The coil has two windings on a
soft iron core. The primary winding .consists of comparatively few turns of heavy wire. The secondary winding consists of many turns of fine wire.
The function of the ignition coil in the SSI system is to
transform battery voltage in the primary winding to
high voltage for the secondary system.
The ignition coil does not require special service other
than keeping terminals and connectors clean and tight.
When an ignition coil is suspected of being defective,
check it on the vehicle. A coil may break down after it
has reached operating temperature. It is important that
the coil be at operating temperature when tests are
made. Perform the tests following the instructions of
the test equipment manufacturer.
Fig. 11-3
Tachometer Giinectioi
Coil Connector
Resistance Wire
The coil terminals and coil connector are of unique
design. Remove the connector from the coil by grasping
both sides and pulling connector away from coil (fig. 1G2).
Distributor
The distributor consists of three groups of components: sensor and trigger wheel, spark advance, and
cap and rotor.
Fig. IK"?
When current flows through the ignition coil, a magnetic field is created by the primary windings. When the
circuit is open and current flow stops, the magnetic field
collapses and induces high voltage in the secondary
windings. The circuit ground is switched open and closed
electronically by the control unit. The distributor sensor
and trigger wheel provide the signal that operates the
control unit.
IGNITION SYSTEM
The trigger wheel is mounted to the distributor shaft.
There is one tooth on the trigger wheel for each cylinder.
The wheel is mounted so that the teeth rotate past the
sensor one at a time.
The sensor is a coil of fine wire mounted to a permanent magnet. The sensor develops an electromagnetic
field that is sensitive to the presence of metal. The
sensor detects the trigger wheel teeth as they pass the
sensor. When a trigger wheel tooth disturbs the magnetic field around the sensor, a zero signal level occurs.
16-3
Spark Advance
Efficient engine operation requires each spark to occur at the correct instant. Varying engine speed or engine load requires the spark to occur earlier or later than
required at constant speed or engine load.
Centrifugal advance is controlled by engine speed.
Flyweights connected to the distributor shaft are
thrown outward by centrifugal force. Higher rpm
throws the weights further out. Calibrated-rate springs
are used to control this movement. The outward motion
of the centrifugal weights causes the rotor and trigger
wheel to be rotated on the distributor shaft several
degrees in the direction of normal rotation. This is referred to as centrifugal spark advance.
When the engine is running under light load, the carburetor throttle plates restrict airflow. This causes a
relatively lean mixture to enter the combustion chambers. Ignition must occur earlier, because the lean mixture takes longer to burn. This is accomplished by the
vacuum spark advance unit (fig. 1G-4). When carburetor
ported vacuum is high, the vacuum unit rotates the
sensor several degrees opposite to the direction the distributor is turning. This causes the sensor to detect
trigger wheel teeth earlier. This is known as vacuum
spark advance. Under low vacuum conditions, such as
full throttle acceleration, a spring in the vacuum unit
pushes the sensor back to a position of no advance.
Fig. 1 1 4
OPERATION
The control unit is activated when the ignition switch
is in the Start or Run position (fig. 1G-5). The primary
circuit is closed and the coil primary is energized. When
the engine begins turning the distributor, the trigger
wheel teeth rotate past the sensor. As each tooth aligns
with the sensor, a high voltage surge leaves the coil and
flows to the distributor cap. The rotor directs the high
voltage to the proper spark plug. The timing of the
sparks is constantly monitored and changed by the vacuum and centrifugal advance mechanisms.
TR00DLESN00TING
For troubleshooting purposes, ignition problems are
placed in three categories: full failure, intermittent failure and spark knock.
Full failure is always a no-spark situation. The engine will not start. If a full failure occurs when the
engine is running, it will refuse t o re-start.
1G-4
IGNITION SYSTEM
Distributor rotor.
Spark plugs.
A
TO CARBURETOR
SOLENOID IF
REQUIRED
13A - CJ
13F - CHEROKEE-WAGONEER-TRUCK
NEUTRAL
SAFETY
SWITCH OR
JUMPER BAR
IGNITION
SWITCH
70865
Fig. 1G-5
IGNITION SYSTEM
Secondary Circuit Check
1G-5
SERVICE DIAGNOSIS
Possible Cause
Condition
ENGINE FAILS TO
START (NO SPARK
AT PLUGS)
ENGINE BACKFIRES
BUT FAILS TO START
Correction
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
Replace cap
(7)
Defective rotor
(7)
Replace rotor
(1)
(1)
(2)
Moisture in distributor
(2)
(3)
(3)
(4)
(4)
16-6
IGNITION SYSTEM
Correction
Possible Cause
Condition
ENGINE RUNS ONLY
WITH KEY IN START
POSITION
(1)
(i)
ENGINE CONTINUES
TO RUN WITH KEY
OFF
(1)
(i)
Replace solenoid
(2)
(2)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
Replace solenoid
(5)
(5)
Install pin
(6)
(6)
(1)
(1)
(2)
(2)
ERRATIC TIMING
ADVANCE
(1)
(1)
TIMING NOT
AFFECTED BY
VACUUM
(1)
(1)
(2)
(2)
Clean pivot
INTERMITTENT
OPERATION
(1)
(2)
Defective sensor
(2)
(3)
(4)
(5)
(5)
EXCESSIVE FUEL
CONSUMPTION
IGNITION SYSTEM
1G-7
Chart 1
STEP
SEQUENCE
RESULT
80699A
10-8
IGNITION SYSTEM
Chart 1
SEQUENCE
STEP
RESULT
REPAIR
AS
REQUIRED
CHECK S O L E N O I D
AS O U T L I N E D
I N CHAPTER 1F
DISCONNECT WIRE
FROM STARTER
SOLENOID l-TERMINAL
IGNITION
REMAINS
ON
OBSERVE
VOLTAGE
A T COIL
POSITIVE
TERMINAL
REPLACE
STARTER
SOLENOID
VOLTAGE
REMAINS
AT
BATTERY
VOLTAGE
CONNECT
JUMPER
BETWEEN
COIL N E G A T I V E
TERMINAL
AND GROUND
VOLTAGE
DROPS TO
6V + .5V
VOLTAGE
DOES NOT DROP
REPAIR D E F E C T I V E
RESISTANCE WIRE
CHECK:
CONTINUITY
BETWEEN C O I L
NEGATIVE TERMINAL
A N D D4
OK
CONTINUITY
REPLACE C O N T R O L U N I T
Dl T O G R O U N D
CONTINUITY
NOT OK
LOCATE A N D
REPAIR OPEN
80699B
IGNITION SYSTEM
1B-B
Chart 1
SEQUENCE
STEP
RESULT
TURN IGNITION
OFF
RESISTANCE
TOO H I G H
(1.40 OHMS
OR MORE)
CONNECT
OHMMETER
BETWEEN
C O I L POSITIVE
TERMINAL AND
DASH CONNECTOR A V
REPAIR
RESISTANCE
WIRE
RESISTANCE
ACCEPTABLE
(1.35 1.05 OHMS)
CONNECT
OHMMETER
BETWEEN
DASH CONNECTOR
AV AND IGNITION
SWITCH
T E R M I N A L 11
I IGNITION
REMAINS
OFF
o
RESISTANCE
ACCEPTABLE
(LESS T H A N
0.1 OHM)
RESISTANCE
TOO HIGH
(MORE T H A N
0.1 O H M )
REPLACE
IGNITION
SWITCH OR
REPAIR
SWITCH FEED
POOR
TERMINAL
CONNECTIONS
A T DASH
CONNECTOR
OR I G N I T I O N
SWITCH
DEFECTIVE WIRING
80699C
Chart 2
STEP
SEQUENCE
RESULT
LIMITS
80699D
STEP
SEQUENCE
RESULT
F R O M CENTER TOWER OF
DISTRIBUTOR AND HOLD
1/2 - INCH F R O M ENGINE
W I T H I N S U L A T E D PLIERS
80699E
16-12
IGNITION SYSTEM
raggs:
;g%re7
jmi.
: a B K r
Chart 3
SEQUENCE
STEP
CONNECT O H M M E T E R
TO B2 A N D B3
RESULT
OK
OHMMETER
INDICATES
400 - 800 OHMS
O H M M E T E R DOES
NOT INDICATE
400 - 8 0 0 OHMS
OK
OHMMETER
INDICATES
ZERO (NOT
A B O V E 0.002
OHM)
OHMMETER .
INDICATES
ABOVE
0.002 O H M .
CONNECT
OHMMETER
BETWEEN
D1 A N D
BATTERY
NEGATIVE
TERMINAL
CONNECT DC
VOLTMETER
TO D2 A N D D3
LOCATE A N D
REPAIR
SOURCE OF
BAD G R O U N D
GROUND
CABLE
RESISTANCE
DISTRIBUTORTO-BLOCK
RESISTANCE
G R O U N D SCREW
IN D I S T R B U T O R
TO D1
OK
VOLTMETER
FLUCTUATES,
INDICATING
PROPER
SENSOR
A N D T R I G G E R WHEEL
OPERATION
LOCATE A N D
REPAIR F A U L T
CRANK
ENGINE
VOLTMETER
DOES N O T
FLUCTUATE
DEFECTIVE
T R I G G E R WHEEL
DISTRIBUTOR
NOT T U R N I N G
80699F
IGNITION SYSTEM
IGNITION FEED TO
ELECTRONIC CONTROL UNIT
Chart 4
N O T E : DO N O T P E R F O R M C H A R T 4
WITHOUT PERFORMING CHART 3
RESULT
SEQUENCE
STEP
OK
VOLTMETER INDICATES
BATTERY VOLTAGE
W I T H I N 0.2V.
#
16-13
REPLACE
CONTROL UNIT
TURN
IGNITION ON
o
UNPLUG 2 WIRE CONNECTOR
AT MODULE A N D CONNECT
V O L T M E T E R BETWEEN F 2
AND GROUND
mi
V O L T M E T E R DOES N O T
INDICATE BATTERY
V O L T A G E W I T H I N 0.2V
OK
LOCATE A N D REPAIR CAUSE
OF V O L T A G E R E D U C T I O N
C O R R O D E D DASH C O N N E C T O R
I G N I T I O N SWITCH
STOP
SPARK A V A I L A B L E
A T C O I L WIRE
STOP
SPARK N O T A V A I L A B L E
A T COIL WIRE
D I S C O N N E C T 4-WIRE
CONNECTOR
AT CONTROL UNIT
REPLACE
CONTROL UNIT
CONNECT AMMETER
BETWEEN
C1 A N D G R O U N D
STOP
A M M E T E R READS 1 AMP + 0.1
STOP
AMMETER READS
H I G H E R OR LOWER
REPLACE M O D U L E
80699G
10-14
IGNITION SYSTEM
Humidity
Low humidity increases the tendency to spark
knock. High humidity decreases spark knock.
Fuel Octane Rating
Fuels of equivalent research octane rating may
vary in their knocking characteristics in a given
engine. It may be necessary to reduce initial timing (not more than 2 degrees from specifications)
or select an alternate source of fuel.
Ignition Timing
Ignition timing should be checked to be sure it is
set within specifications.
NOTE: The white paint mark on the timing degree
scale represents the specified spark setting at idle speed,
not TDC (Top Dead Center).
NOTE: Engine
temperature.
must
be warmed
up to
operating
TESTING .
Electrical Tests
IGNITION SYSTEM
(3) Repeat for negative wire.
(4) Connect ammeter between positive terminal and
disconnected positive wire.
(5) Connect jumper wire from coil negative terminal to known good ground.
(6) Turn ignition to On position.
(7) Amperage should read approximately 7 amps,
and should not exceed 7.6 amps.
(8) If current flow is more than 7.6 amps, replace
coil.
(9) Leave ammeter connected to coil positive terminal. Remove jumper wire from negative terminal. Connect coil green wire to negative terminal. Current flow
should be approximately 4 amps.
If current flow is less than 3.5 amps, check for poor
connections in 4-wire and 3-wire connectors or poor
ground at ground screw inside distributor. If currect
flow is greater than 5 amps, the control unit is defective.
(10) Start engine. Normal current flow with engine
running is 2.0 to 2.4 amps.
If current flow is outside specifications, the control unit
is defective.
1G-15
OiSTliBUTOl IEPLICE1ENT
Removal
(1) Unfasten distributor cap retaining screws. Remove distributor cap with high tension cables and position aside.
(2) Disconnect vacuum hose from distributor vacuum advance unit.
(3) Disconnect
connector.
distributor
primary
wiring
1G-16
IGNITION SYSTEM
Fig. 1G-6
IGNITION SYSTEM
(9) If vacuum unit Is to be replaced, remove screws
and lift vacuum unit out of distributor housing. Do not
remove vacuum unit unless replacement is required.
1G-17
(b) Turn adjusting screw of replacement vacuum unit clockwise to bottom. Turn counterclockwise
same number of turns counted in step (a).
Installation
(2) Position
housing.
sensor
assembly
into
refer
distributor
Vacun Unit
liter
Inspect the rotor during precision tune-ups as outlined in Chapter 1AGeneral Service and Diagnosis. A
new feature of the SSI system is the silicone grease
applied to the rotor blade during manufacture. Radio
interference is greatly reduced by the presence of a
small quantity of silicone grease on the rotor blade.
After a few thousand miles, this grease becomes charred
by the high voltage carried by the rotor (fig. 1G-7). This
is normal. Do not scrape the residue from the rotor
blade.
When installing a replacement rotor, apply a thin coat
(0.03 to 0.12 inch) of Jeep Silicone Dielectric Compound,
or equivalent, to tip of the rotor blade.
Removal
Installation
70871
Fig. 1G-7
1G-18
IGNITION SYSTEM
SPECIFICATIONS
Distributor and Coil Specifications
Distributor Sensor Resistance
Coi!
Primary Resistance
Secondary Resistance
M i n i m u m O u t p u t at 1000 r p m
Spark Plugs
Required Voltage at 1000 r p m
M a x i m u m Variation Between Cylinders
. . . 5 to 16 KV
3 to 5 KV
70868
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft.lbs.)
Metric ( N m )
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
13
10-18
18
13-24
All Torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
70870
L E F T BANK
0 0
FRONT
CLOCKWISE R O T A T I O N
1-8-4 3-6-5-7-2
0
R I G H T BANK
CLOCKWISE R O T A T I O N
1-5-3-6 2-4
SIX C Y L I N D E R ENGINES
FRONT]
E I G H T C Y L I N D E R ENGINES
42189
zssr.
GENERAL
Manifold vacuum and carburetor ported vacuum are
both used to provide signals for the ignition spark advance mechanism. On some engines, a Coolant Temperature Override (CTO) switch chooses the proper vacuum
IGNITION SYSTEM
1G-19
3L
SPARK COOLANT
SYSTEMS
TEMPERATURE
OVERRIDE
(CTO)
PORT NO. 1
PORT D
Gneral
On all Jeep vehicles with spark CTO, the vacuum
spark advance operates on carburetor ported vacuum
after warming up. Warm-up driveability is improved by
operating the distributor vacuum spark advance by
manifold vacuum while the engine is cold. This is accomplished by the CTO system (fig. 1G-8). The CTO switch is
threaded into the left rear of the block on six-cylinder
engines, and into the thermostat housing on eight-cylinder engines. A thermal sensor on the CTO switch is in
contact with engine coolant (fig. 1G-9). Depending on
coolant temperature, the CTO switch permits either
manifold vacuum or carburetor ported vacuum to pass
through to the distributor vacuum unit.
SPARK CTO
OUTER PORT (1) - OPEN BELOW
160 F
CARBURETOR
SPARK PORT
{PORTED V A C U U M
SOURCE)
CENTER P O R T ( D )
ALWAYS
OPEN
RETURN
SPRINGS
(3)
PORT NO. 2
THERMAL
SENSOR
42024
Fig 1 1 - 1
Fig. 1G-8
This is a dual function valve which replaces the function of the standard CTO switch until an upper temperature limit is reached, at which time the valve switches
ported vacuum back to manifold vacuum. It is adapted
to the engine in the same place as the single range CTO.
When the coolant temperature is below the lower
switching temperature (149F), manifold vacuum is
routed through Port 3 into Port 2 allowing manifold
vacuum to be applied through a hose connection to the
distributor advance unit (Fig. 1G-10). This results in full
vacuum advance which improves driveability during the
warmup period by providing full distributor vacuum
advance until the coolant temperature has reached the
switching temperature (149F). At this time, Port 3
closes and Ports 1 and 2 are opened. Manifold vacuum is
blocked and carburetor ported vacuum is applied to the
distributor advance unit. This continues until the coolant temperature reaches 220F at which time the switch
closes Port 1 and reconnects Ports 2 and 3 which
reapplies manifold vacuum to the distributor advance
1G-20
IGNITION SYSTEM
Fig. 1G-10
Test
(1)
(2)
(3)
(4)
(5)
Operation
The NLRV valve has two input ports (manifold vacuum and carburetor ported vacuum) and one outlet port
(distributor vacuum unit). Under no-load or low-load
conditions, the NLRV valve provides regulated vacuum
(fig. 1G-11). Under these conditions, manifold vacuum is
high and ported vacuum is either non-existent or very
low. The NLRV valve provides a signal somewhere between the two vacuum levels, as determined by the
calibration of the valve. As engine load increases and the
signal increases above the regulated value, the regulator
valve switches to ported vacuum.
IGNITION SYSTEM
REGULATED
VACUUM
Fig. 1 6 - 1 1
1G-21
Port 1
Ported Vacuum
Port 2
To Distributor
Port 3
Manifold Vacuum
DISTRIBUTOR
VACUUM
UNIT
Tools
J-28509
T R I G G E R WHEEL
PULLER
NOTES
1H-1
# 1
SECTION INDEX
Page
Adjustments
Bellows Chain Replacement
Bellows Replacement
Components
Control Switch Replacement
General
1H-11
1H-13
1H-13
1H-1
1H-13
1H-1
GENERAL
Cruise Command automatic speed control senses vehicle speed through the speedometer cable and uses engine intake manifold vacuum to regulate the accelerator
to automatically maintain any preset cruising speed between 30 mph and the legal maximum speed limit.
A slight increase or decrease of speed (as much as 3.5
mph) is normal when vehicles are driven up or down
grades not exceeding 7% (most interstate highways). A
change of speed greater than 3.5 mph may be experienced when driving in unusually hilly terrain or at
high altitudes.
The Cruise Command control is an integral part of the
directional switch lever and consists of two separate
switches, the OFF-ON-RES (resume) slide switch and
the pushbutton switch.
To engage the speed control, move the slide switch to
the ON position and accelerate to the desired speed.
Press the pushbutton on the end of the directional
switch lever and release. The speed control system will
now maintain the selected speed. The system will automatically disengage when the brake pedal is lightly
depressed.
After accelerating to 30 mph, the speed control can be
re-engaged to the previously selected speed by moving
the slide switch to the RES position and releasing the
switch. When the RES function is used, the rate of
acceleration is regulated by engine intake manifold vacuum. The rate of acceleration cannot be adjusted. On
large displacement eight-cylinder engines, the acceleration rate will be firm.
WARNING: Cruise Command should not be used when
driving on slippery roads.
Operation
Regulator Replacement
Relay Replacement
1H-2
1H-13
1H-13
1H-5
1H-5
COMPONENTS.
The Cruise Command system consists of five basic
components: the regulator, the relay, the bellows, the
control switch and the release circuit.
Regulator
The regulator senses speed through the speedometer
cable connecting the regulator to the transmission. The
flyweight-type governor reacts to the cable speed and
engages the low speed switch at approximately 30 mph.
When the low speed switch is closed, the driver may
engage the Cruise Command system.
The regulator is serviced as an assembly.
Relay
1H-Z
CRUISE COMMAND
Bellows
The bellows, a vacuum servo, receives the modulated
vacuum and controls the vehicle speed by actuating the
throttle through a beaded chain.
Control Switch
The control switch is an integral part of the turn
signal lever. When actuated, it energizes either the solenoid valve, the coupling coil or both.
Release Circuit
When the brake pedal is depressed slightly, the stoplamp current de-energizes the solenoid valve, disengaging the speed control.
OPERATION
General,
The regulator consists of three functional groups: the
governor assembly, the solenoid and valve assembly,
and the coupling coil and centering spring assembly.
70067
Fig. 1H-1
Governor Assembly
Governor Assembly
70068
Fig. 1H-2
CRUISE COMMAND
1H-3
V A C U U M PORT
UNCOVERED
Fig. 1H-4
V A C U U M PORT
BLEED
(CENTEREQ)
V A C U U M PORT
BLOCKED
DRIVE
PIN
ADJUSTMENT
ECCENTRIC
70069
Fig. 1H-3
1H-4
CRUISE COMMAND
1
COUPLING
COIL
SOLENOID
VALVE
REGULATOR
ROTATING
VACUUM
REGULATOR
PLATE
Fig. ttf-1
Brake Release
In the speed setting phase and the speed maintaining
phase, the vacuum solenoid coil circuit is grounded
through the stoplamp bulbs. When the brakes are applied, counter voltage travels from the stoplamp switch
through the circuit until it reaches the solenoid coil (fig.
1H-8). There it counteracts hold-in voltage and the coil
immediately de-energizes. This allows the valve to seat
against the manifold vacuum seat and relieves vacuum
to the bellows. The throttle closes, and the engine is no
longer under the control of the Cruise Command system.
The coupling coil is not affected, because it does not
ground through the stoplamp bulbs. The coupling coil
and vacuum regulator plate remain held together.
CRUISE COMMAND
COUPLING
COIL
SOLENOID
VALVE
1H-5
REGULATOR
LOW SPEED
SWITCH
REED
SWITCH
ROTATING
VACUUM
REGULATOR
PLATE
W W
1
INSULATED
CONNECTOR
BLUE-
VACUUM
VENT
(VARIABLE)
[CAPACITOR
TO SERVO
PUSH
BUTTON
TURN
SIGNAL
SWITCH
VACUUM
SOURCE
WHITE
FT}--
SLIDE
SWITCH
3 <
: C
I f
fl
FUSE
PANEL
RELAY
<
Q
Q
SET
IGNITION
SWITCH
80065
Fig. 1H-6
TROUBLESHOOTING
TESTING
The following tests should be performed as part of the
diagnosis to determine the cause of the malfunction and
the correction required.
When the resume switch is returned to the ON position, the hold-in circuit keeps the vacuum solenoid valve
open.
1H-6
CRUISE COMMAND
SOLENOID
VALVE
COUPLING
COIL
REGULATOR
VEHICLE
CIRCUIT
ROTATING
VACUUM
REGULATOR
PLATE
/.
INSULATED
CONNECTOR
VACUUM
VENT
(VARIABLE)
TO SERVO
VACUUM
SOURCE
SLIDE
SWITCH
PUSH
BUTTON
ON
RES
*
<%#OFF
SET
80066
Fig. 1H-7
Circuitry Tests
Pushbutton
Depressed
Resume Slide Switch On
Slide Switch
Switch
Wire
Continuity
Off
On
Red/Brown
Open
Closed
Closed
Closed
Red/Green
Open
Closed
Closed
Open
Red/Yellow
Open
Open
Closed
Closed
NOTE:
slide switch in
70072
and
CRUISE COMMAND
1H-7
V O L T A G E A P P L I E D TO
BOTH SIDES OF C O I L .
S O L E N O I D V A L V E CLOSES
80067
Fig. 1H-8
(4) Using test lamp, ground one test lamp lead and
touch other lead to brown wire and then dark green wire
at connectors. Test lamp should light. If test lamp does
not light on either wire, check fuse, relay, control switch
and connection at power source.
(5) Push SET SPEED button in and hold. Ground
one test lamp lead and touch other lead to each wire,
connector. Test lamp should light on brown and yellow
wires and should not light on dark green or blue wire.
(6) Release SET SPEED button.
(7) Move slide switch to RES position and hold.
Ground one test lamp lead and touch other lead to each
ltf-8
CRUISE COMMAND
SOLENOID
VALVE
REGULATOR
ROTATING
VACUUM
REGULATOR
PLATE
VACUUM
VENT
(VARIABLE)
TO SERVO
PUSH
BUTTON
VACUUM
SOURCE
SLIDE
SWITCH
80068
Fig. 1H-9
CRUISE COMMAND
1H-9
Service Diagnosis
Correction
Possible Cause
Condition
BLOWING STOPLAMP
FUSES
(1)
(1)
Replace capacitor.
BLOWING FUSES
(1)
(1)
CRUISE COMMAND
DOES NOT ENGAGE
(1)
(1)
(2)
(2)
(3)
(3)
(4)
Vacuum leak.
(4)
Repair leak.
(5)
(5)
(6)
(6)
(7)
Faulty connections.
(7)
(8)
(8)
(9)
(9)
Replace bulb(s).
CRUISE COMMAND
DISENGAGES WHEN
TURN SIGNAL
SWITCH IS OPERATED
(10)
(10)
(11)
Faulty regulator.
(ID
Replace regulator.
(12)
(12)
Replace regulator.
(13)
Relay inoperative.
(13)
(1)
(1)
(2)
(2)
Replace bulb.
70078A
1H-10
CRUISE COMMAND
Possible Cause
Condition
Correction
(1)
(1)
(2)
(2)
Replace hose.
(3)
(3)
Replace capacitor.
(1)
(1)
(2)
(2)
(3)
(3)
Replace regulator.
CARBURETOR DOES
NOT RETURN TO
NORMAL IDLE OR
PULSATING
ACCELERATOR
PEDAL
(1)
(1)
(2)
(2)
SPEEDOMETER
INOPERATIVE AND
CRUISE COMMAND
OPERATES
(1)
(1)
(2)
Faulty regulator.
(2)
NEITHER
SPEEDOMETER NOR
CRUISE COMMAND
OPERATES
(1)
(1)
CRUISE COMMAND
ENGAGES ABOVE OR
BELOW DESIRED
SPEED
(1)
(1)
SYSTEM DISENGAGES
ON LEVEL ROAD
WITHOUT
APPLYING BRAKE
(1)
(1)
(2)
Loose hoses.
(2)
CRUISE COMMAND
DOES NOT
DISENGAGE WHEN
BRAKE IS APPLIED
RE-ENGAGES WHEN
BRAKE IS RELEASED
70078B
CRUISE COMMAND
Condition
Possible Cause
1H-11
Correction
SYSTEM DISENGAGES
ON LEVEL ROAD
WITHOUT
APPLYING BRAKE
(3)
(3)
(4)
(4)
ERRATIC OPERATION
O F CRUISE COMMAND
(1)
(1)
(2)
Check regulator.
(2)
CRUISE COMMAND
CONTINUES TO
ACCELERATE A F T E R
ENGAGEMENT
(1)
(1)
CAR LOSES
EXCESSIVE SPEED
ON HILLS
(1)
(1)
Refer t o Adjustments.
(2)
(2)
ADJUSTMENTS
1H-12
CRUISE COMMAND
CONTROL
BLACK
GROUND
SCREW
LUG
Fig. 1H-10
Removal
(1) Remove the following:
Horn button insert
Steering wheel
Anti-theft cover
Locking plate and horn contact
(2) Remove turn signal lever (allow handle to hang
loose outside steering column).
(3) Remove four-way flasher knob.
(4) Remove holddown screws and turn signal
switch.
(5) Remove trim piece from under steering column.
(6) Disconnect four-wire connector.
(7) Tilt ColumnRemove harness from plastic connector. Tape two of four wires back along harness (to
allow a smaller diameter) and tape string to harness.
(8) Standard ColumnTie or tape string to plastic
connector.
(9) Remove lever and harness assembly from
column.
jl^^
.,?f:%
42259
REGULATOR REPLACEIENT
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
RELAY REPLACEMENT
(1)
(2)
(3)
(4)
1ELL01S REPLACEMENT
(1) Disconnect vacuum hose from bellows.
(2) Count number of beads outside bellows tabs.
Disconnect chain from bellows.
(3) Remove bellows.
(4) Install replacement bellows.
(5) Connect chain, allowing number of beads outside tabs as counted in step 2. Crimp tabs.
(6) Connect vacuum hose.
Installation
(1) Check replacement Cruise Command control
switch by connecting to wire harness before installing in
steering column. Refer to Control Switch Continuity
Test.
N O T E : When installing the harness, be sure to feed the
harness through the turn signal lever opening as the
handle will not fit through the opening.
(2) Tape two of four leads back along harness. Tape
harness to string that was attached to original harness
before removal.
(3) Pull replacement harness down through steering column. On tilt column, harness must pass through
hole on left side of steering shaft.
N O T E : It may be necessary to loosen steering
mounting screws for easier routing of harness.
column
NOTES
1J-1
Z3BZ
Page
Carburetor Bowl Cooling
Carburetor Model BBD2
Carburetor Model 2 1 0 0 2
Carburetor Model 2 1 1 0 2
Exhaust Gas Recirculation (EGR)
System
Venturl
Venturl
Venturi
System
mmwm mm
1J-45
1J-9
1J-Z0
1J-33
1J-37
ftp
General Information
Positive Crankcase Ventilation (PCV) System
Thermostatically Controlled Air Cleaner (TAC) System
1J-1
1J-41
1J-43
Tools
1J-47
1J-38
EmmMMmwm
hi eeml
Page
Air Cleaner
Fuel Filter
Fuel Gauge
Fuel Pump
Pip
1J-1
1J-2
1J-7
1J-7
1J-5
1J-2
U-9
AIR CLEANER
Service
The replaceable element (paper-type) is used as standard equipment (fig. 1J-1). A polyurethane wrap is available for the paper element for heavy-duty use (fig. 1J-2).
Replace the air cleaner paper cartridge more frequently than specified in the Maintenance Schedule if
there is any apparent damage or evidence of plugging.
At the same time, inspect the polyurethane element and
replace it if torn or otherwise damaged.
To clean the optional polyurethane element, carefully
remove it from the paper cartridge and wash it in water
and detergent. Wrap the element in a clean, dry cloth
and squeeze to remove all possible water. Do not wring
the element as it may tear.
After cleaning, oil the polyurethane element liberally
with engine oil (SAE 10W-30) and squeeze to evenly
distribute the oil through the element and to remove
excess oil. The element should be slightly dampened
with oil. Install the polyurethane element on the paper
cartridge with the edges of the polyurethane element
over the plastic end plates of the paper cartridge.
1J-2
FUEL SYSTEMS
AIR CLEANER
CAP
FUEL TANK
The fuel tank on CJ models is attached to a skid plate
which is bolted to the chassis. On Cherokee and Wagoneer models, the tank is secured to the chassis by a single
strap at the center, a bracket at the rear, and a bracket
at the front. The Truck models have two straps which
run front to rear. A fuel tank skid plate is optional on
Cherokee, Wagoneer and Truck models. The various fuel
tank and venting arrangements are illustrated in figures
1J-3,1J-4 and 1J-5.
The fuel tank is an external expansion type and is
vented by vapor lines. On CJ models, vapors are routed
to a charcoal canister. Refer to Fuel Vapor Control System. On Cherokee, Wagoneer and Truck models, vapors
are routed through a rollover check valve and vent to
atmosphere. Refer to Fuel Vapor Control System.
PAPER
CARTRIDGE
RemovalCJ Models
FUEL FILTERS
All carburetors are protected against the entry of dirt
and other foreign matter through the fuel inlet by a
replaceable 15-micron, pleated paper filter located in the
carburetor fuel inlet line and secured by two short rubber hoses and clamps. Replace the filter at the intervals
outlined in the Maintenance Schedule.
FUEL SYSTEMS
Fig. 1 J - 3
1J-3
(3)
wire.
(4)
(5)
(6)
Fuel T i l l S u i n g Unit
This assembly utilizes a float pivoted to a variable
resistance element.
On CJ and Truck models, fuel pickup and fuel return
system nipples and the sending wire connection are
mounted on the sending unit mounting cover which is
secured to the fuel tank with a locking ring. On Cherokee
and Wagoneer models, the fuel pickup and return nipples are mounted on a separate cover.
To replace the fuel sending unit, remove the fuel tank.
1J-4
FUEL SYSTEMS
Fig. 1J-4
Fig. 1J-5
FUEL SYSTEMS
SPARK PORT
VACUUM
SIGNAL
1J-5
CARBURETOR
BOWL
VENT
LIQUID CHECK
VALVE
PURGE
LINE
VACUUM
SIGNAL
VAPOR
N STORAGE
CANISTER
FILTER
Fig. 1J-6
FUEL
FUEL
TANK
PORTED
VACUUM
SIGNAL
FROM
CARBURETOR
Ciipiiiits
Charcoal Canister
TO
MANIFOLD
VACUUM
SOURCE
VAPOR F R O M
FUEL TANK
Fig. 1J-7
VAPOR FROM
CARBURETOR
BOWL
1J-6
I
FUEL SYSTEMS
. .
, , _ ^ . . ^ . - _ ^ ^ - . -
VITON
NEEDLE
- ^ _ ^
VAPOR OUTLET
T O CANISTER
SEAT
WAFER IN
VENTED
POSITION
VAPOR INLETS
FROM FUEL T A N K
Fig. 1J-8
This component is used on all Jeep vehicles. The rollover check valve prevents fuel flow from the fuel tank
through the fuel line in the event of vehicle rollover. The
check valve consists of a plunger and a stainless steel
ball (fig. 1J-9). When inverted, the stainless steel ball
pushes the plunger against its seat. A properly functioning rollover valve will hold 3 psi (21 kPa) of air pressure
on the inlet side when inverted.
80266
Fig 1 J-10
60277
Fig. 1J-9
FUEL SYSTEMS
1J-7
FUEL T A N K
FUEL FILTER
FROM
F U E L PUMP
J43185
Fig. 1 J - 1 1
FUEL GAUGE
Refer to Chapter 1LPower Plant Instrumentation
for Operation, Diagnosis and Replacement. Service of
the sending unit is covered under Fuel Tank in this
chapter.
-NO
o o o o o o o o o
o oo o o o o o o
FUEL PUMP
A single-action, stamped fuel pump is used for all
engine applications.
The fuel pump consists of an actuating lever, a diaphragm and spring, an inlet valve and an outlet valve
(fig. 1J-13). An eccentric on the engine camshaft oper-
FUEL R E T U R N
LINE TO FUEL
TANK
60278
Fig. 1 J - 1 2
1J-8
FUEL SYSTEMS
. ..
I N L E T LINE
( F R O M FUEL PUMP)
Fig. IJ-14
DIAPHRAGM
SPRING
LEVER
RETURN
SPRING
ACTUATING
t
LEVER
\
FUEL PUMP
ECCENTRIC
ON C A M S H A F T
80073
Fig. 1J-13
Fuel Pump
Pressure Test
(1) Remove air cleaner assembly.
(2) Disconnect fuel inlet line or fuel filter at
carburetor.
(3) Disconnect fuel return line at fuel filter and
plug nipple on filter.
N O T E : Use care to prevent
spillage.
combustion
due to fuel
AJ41617
Vacuum Tests
Two vacuum tests may be performed on the fuel
pump. In the direct connection test, the vacuum test
gauge is connected directly to the fuel pump inlet. This
tests the pump's ability to create a vacuum. In the in-
FUEL SYSTEMS
1J-9
Installation
properly
SPECIFICATIONS
Volume
(30 seconds)
Pressure
(PSI)
SixCylinder
1 pint
(.47 liters)
EightCylinder
1 pint
(.47 liters)
Vacuum (Hg)
Direct
Indirect
4 to 5
(28 to 34 KPa)
10
(34 KPa)
3
(7 KPa)
5 to 6.5
(34 to 45 KPa)
10
(34 KPa)
3
(7 KPa)
80262B
Gallons
CJ
Cherokee
Wagoneer
Truck
CARBURETOR MODEL B B D - 2
VENTURI
Page
Carburetor Circuits
Carburetor Overhaul
Carburetor Replacement
1J-10
1J-12
IJ-12
GENERAL
The Carter Model BBD two-venturi carburetor incorporates three lightweight aluminum assemblies, the
air horn, main body and throttle body (fig. 1J-15).
Page
Choke Mechanism Service
Service Adjustment Procedures
Specifications
1J-19
1J-17
1J-19
The air horn contains the choke valve assembly, mechanical linkage for accelerator pump and metering
rods, and bowl vent.
The main body contains fuel bowl, acccelerator pump,
vacuum piston and metering rod assembly, venturi assembly and solenoid, if equipped.
1J-10
FUEL SYSTEMS
Fig. 1J-15
Identification
The carburetor is identified by a code number and
build date which is stamped on the identification tag.
Each carburetor build month is coded alphabetically
beginning with the letter A in January and ending with
the letter M in December (the letter I is not used). The
tag is attached to the carburetor and must remain with
the carburetor to assure proper identification (fig. 1J16).
60431
Fig. 1J-17
Float Circuit
When the fuel in the bowl fills to the proper level, the
float lever pushes the needle toward its seat and restricts incoming fuel, admitting only enough to replace
that being used.
BUILD DATE
Fig. 1J-16
60430
Identification Tag
Fuel for idle and early part-throttle operation is metered through the idle circuit.
Fuel flows through main metering jets into the main
wells and continues through the idle fuel pickup tube
where fuel mixes with air entering through idle air
bleeds located in the venturi cluster screws (fig. 1J-18).
At curb idle, this fuel-air mixture flows down the idle
channel and is further mixed with air entering the idle
channel through the transfer slot which is above the
position of the throttle valve at curb idle. The mixture
then passes the idle mixture adjustment screw which
controls the volume of mixture discharged below the
throttle valve.
During low speed operation, the throttle valve moves
to expose the transfer slot as well as the idle port. This
increased airflow creates a low pressure in the venturi
and the main metering system begins to discharge fuel.
CARBURETOR CIRCUITS
FUEL SYSTEIS
Fig. 1J-18
Fig. 1J-19
idle Circuit
Pump Circuit
When the throttle is opened suddenly, airflow response through the carburetor is almost immediate.
1J-11
1J-12
FUEL SYSTEMS
PUMP
ARM
ACCELERATOR
PUMP S H A F T
PUMP
DRIVE
SPRING
DISCHARGE
JET
CARBURETOR REPLACEMENT
Renewal
DISCHARGE
CHECK B A L L
INTAKE
CHECK BALL
Fig. 1 J - 2 0
CHOKE
VACUUM
DIAPHRAGM
Pump Circuit
Installation
(1) Clean gasket mounting surface of spacer. Install
replacement gasket on spacer. Position carburetor on
spacer and gasket and install nuts. To prevent leakage,
distortion or damage to carburetor body flange, alternately tighten nuts in crisscross pattern.
(2) Connect fuel line, throttle cable, choke heat
tube, PCV hose, return spring, choke clean air tube, all
vacuum hoses and solenoid wire, if equipped.
(3) Adjust engine idle speed, idle fuel mixture and
solenoid. Refer to Chapter 1AGeneral Service and
Diagnosis.
(4) Install air cleaner.
CHOKE V A L V E
CHOKE
CONTROL,
ROD
CARBURETOR OVERHAUL
C H O K E COVER
80444
Fig. 1 J - 2 1
Choke Components
FUEL SYSTEMS
Fig. 1J-22
1J 13
1J-14
FUEL SYSTEMS
R^RR-T-.w-:w~-y
-~Tr~-IF~-^--w^-^w^
-y-
y---y
y - - y
Disassembly
(1) Place carburetor on repair stand to protect
throttle valves from damage and to provide stable work
base.
(2) Remove retaining clip from accelerator pump
arm link and remove link (fig. 1J-23).
80446
Fig. 1J-24
A N D LOCKS
Fig. 1J-23
Fig. 1J-25
FUEL SYSTEMS
1J-15
(17) Invert carburetor main body and drop out accelerator pump discharge (fig. 1J-28).
60441
Fig. 1 J - 2 8
60440
Dirt, gum, water, or carbon contamination in the caburetor or on exterior moving parts is often responsible
for unsatisfactory performance. Efficient carburetion
depends upon careful cleaning and inspection.
The cleaning and inspection procedures here do not
cover those parts included in the carburetor overhaul
repair kit. Install all gaskets and parts included in the
repair kit when the carburetor is assembled. Discard
original gaskets and parts.
Wash all parts, except vacuum diaphragm, in clean
commercial carburetor cleaning solvent. If a commercial
solvent is not available, use mineral spirits, lacquer
thinner or denatured alcohol.
If commercial solvent is used, rinse the cleaned parts
in hot water to remove all traces of solvent, then blow
dry with compressed air. Wipe the parts that cannot be
1J-16
FUEL SYSTEMS
DISCHARGE
CHECK B A L L
60442
Fig. I M S
ADJUSTING
SCREW
VACUUM
PISTON
GASKET
FLOAT
60497
Fig. 1 J 3 1
M E T E R I N G RODS
60443
1J-18
FUEL SYSTEMS
STEP-UP PISTON
F U L L Y DEPRESSED
ROD L I F T E R
LOCK SCREW
60444
PUMP A R M
80447
MAKE
;y
ADJUSTMENT BY
BENDING HERE
60446
driving.conditions. If stumble or stalls occur on acceleration during engine warm-up, the choke may be set richer
or leaner to meet individual engine requirements.
NOTE: The automatic choke acts like a timer. The
richer the setting the longer spring tension acts against
the linkage and holds the choke valve in a closed position. Warmed incoming air warms the spring. Spring
tension is reduced and fast idle cam weight moves the
choke linkage against spring tension.
Idle Speed and Mixture Adjustment
Refer to procedures outlined in Chapter 1AGeneral
Service and Diagnosis.
Fast Idle Speed Adjustment.
Set the fast idle speed with the engine at operating
temperature and with EGR and TCS solenoid disconnected. Position fast idle adjusting screw in contact
with the second step and against the shoulder of the fast
idle cam. Refer to Specifications for the correct setting.
Adjust by turning the fast idle adjustment screw.
The choke mechanism may be serviced without removing the carburetor from the engine. If the choke
binds, sticks or does not operate smoothly, perform the
following:
(1) Remove choke housing cover.
(2) Remove choke lever screw and remove choke
lever.
(3) Disconnect choke control rod and remove thermostatic choke shaft from housing.
(4) Polish shaft and shaft bore in housing.
(5) Install shaft to housing. Install choke control
rod.
(6) Install choke lever to shaft.
(7) Install housing cover and set to specification.
SPECIFICATIONS
Model BBD Carburetor Calibrations (inches)
8185
8186
8187
8188
8195
8229
1.44
1.44
1.44
1.44
1.44
1.44
1.19
1.19
1.19
1.19
1.19
1.19
0.101
0.101
0.101
0.101
0.101
0.101
0.0295
0.0295
0.0295
0.0295
0.0295
0.0295
0.059
0.059
0.059
0.059
0.059
0.055
Idle A i r Bleed
0.059
0.063
0.063
0.059
0.063
0.063
0.089
0.089
0.089
0.089
0.089
0.089
0.033
0.033
0.033
0.033
0.033
0.033
120-389
120-389
120-389
120-389
1 20-389
120-389
0.042
0.042
0.042
0.042
0.042
0.042
0.078
0.078
0.078
0.078
0.078
0.078
0.059
0.059
0.059
0.059
0.059
0.059
80608
1J-20
FUEL SYSTEMS
List
Number
Application
Initial
Choke Valve
Clearance
Fast Idle
Cam Setting
Automatic
Choke Cover
Setting
(Notches Rich)
Accelerator
Pump
Dimensions
Set
To
OK
Range
Set
To
OK
Range
Set
To
OK
Range
Set
To
OK
Range
Set
To
OK
Range
Set
To
OK
Range
Choke
Unloader
Fast Idle
Speed
Set
To
OK
Range
Choke
Bimetal
ID
8185
258
Automatic
4 9 State
0.25
0.218
to
0.282
0.035
0.020
to
0.050
0.140
0.125
to
0.155
0.110
0.095
to
0.125
1NR
1/2
to
1-1/2
0.470
0.450
to
0.490
0.280
1600
1500
to
1700
8186
258
Manual
49 State
0.25
0.218
to
0.282
0.035
0.020
to
0.050
0.150
0.135
to
0.165
0.110
0.095
to
0.125
1NR
1/2
to
1-1/2
0.520
0.500
to
0.540
0.280
1500
1400
to
1600
8187
258
Automatic
California
0.25
0 218
to
0.282
0.035
0 020
to
0.050
0.140
0.125
to
0.155
0.110
0.095
to
0.125
1NR
1/2
to
1-1/2
0.470
0.450
to
0.490
0.280
1600
1500
to
1700
8188
258
Manual
California
0.25
0.218
to
0.282
0.035
0.020
to
0.050
0.150
0.135
to
0.165
0.110
0.095
to
0.125
1NR
1/2
to
1-1/2
0.520
0.500
to
0.540
0.280
1500 '
1400
to
1600
8195
258
Manual
Automatic
4 9 State
0.25
0.218
to
0.282
0.035
0.020
to
0.050
0.140
0.125
to
0.155
0.110
0.095
to
0.125
1NR
1/2
to
1-1/2
0.470
0.450
to
0.490
0.280
1400/
1600
1500/
1700
258
Manual
Hilly Terrain
0.25
0.218
to
0.282
0.035
0.020
to
0.050
0.128
0.113
to
0.143
0.095
0.080
to
0.110
1NR
1/2
to
1-1/2
0.520
0.500
to
0.540
0.280
1400
to
1600
8229
Vacuum
Piston Gap
Float
Level
1500M
1600A
1500
Page
Carburetor Circuits
Carburetor Overhaul
Carburetor Replacement
Choke Mechanism Service
1J-2G
1J-24
1J-24
1J-32
General
Service Adjustment Procedures
Specifications
GENERAL
1J-20
1J-29
1J-32
MECHANICAL
The Motorcraft Model 2100 carburetor is a two-venturi carburetor which incorporates two lightweight
aluminum assemblies, the air horn and the main body.
The air horn assembly serves as the main body cover
and also contains the choke assembly and fuel bowl
vents.
The throttle shaft assembly and all units of the fuel
metering systems are contained in the main body assembly. The automatic choke assembly and the solenoid
are attached to the main body (fig. 1J-37).
Idontlfication
The carburetor is identified by a code number and
build date which is stamped on the identification tag.
Each carburetor build month is coded alphabetically
beginning with the letter A in January and ending with
the letter M in December (the letter I is not used). The
tag is attached to the carburetor and must remain with
the carburetor to assure proper identification (fig. 1J38).
Fig. 1 J - 8 7
CARBURETOR CIRCUITS
The Model 2100 carburetor utilizes five conventional
metering circuits: Float (Fuel Inlet) Circuit, Idle (Low
CODE
ENGINE
VENTURI
TRANS.
REVISION
LETTER
VENDOR
CHECK
LETTER
YEAR
MONTH
DAY
BUILD DATE
4 1 6 4 1
VENT TO
CANISTER
BELLCRANK
FLOAT
T H R O T T L E LEVER
IN C L O S E D POSITION
80269
FUEL
BOWL
80004
Fig. 1J 39
Float Circuit
Fuel for idle and low speed operation flows from the
fuel bowl through the main jets into the main wells.
1J-22
FUEL SYSTEMS
ANTI-SIPHON
A I R BLEED
ANTI-SIPHON
AIR BLEED
IDLE
SCREW
PORT
IDLE
L I M I T E R CAP
Fig. 1J-41
80005
idle d r o i t
80006
Fig. 1J-42
FUEL SYSTEMS
LL^j.-_JEi.
BL
JBE-
1J-23
^JE^"--;^^.te^
Manifold vacuum is applied to the power valve diaphragm from an opening in the base of the main body,
through a passage in the main body and power valve
chamber to the power valve diaphragm. During idle and
normal driving conditions, manifold vacuum is high
enough to overcome the power valve spring tension and
holds the valve closed. When higher engine output is
required, the increased load on the engine results in
decreased manifold vacuum. The power valve spring
opens the first stage of the power valve when manifold
vacuum drops below a predetermined value and a pmall
amount of fuel flows through the valve.
When manifold vacuum drops to a lower value, the
power valve spring opens the second stage of the power
valve and allows a greater amount of fuel to flow
through the valve.
The fuel which flows through the power valve is added
to the fuel in the main metering circuit to enrich the
mixture. As engine load requirements decrease, manifold vacuum increases and overcomes the tension of the
power valve spring, closing the power valve.
Fig. 1J-44
Pump Circuit
Choke Circuit
80008
Fig. 1J-43
Pump Circuit
When the throttle valves are opened quickly, the airflow through the carburetor responds almost immediately. Since fuel is heavier than air, there is a brief lag in
time before the fuel flow can gain sufficient speed to
maintain the proper fuel-air ratio. During this lag, the
pump circuit supplies the required fuel until the proper
fuel-air ratio can be maintained by the other metering
circuits (fig. 1J-44).
The pump is charged when the throttle valves are
closed. - The diaphragm return spring exerts force
against the diaphragm and pushes it against the cover.
FUEL SYSTEMS
At the same time, the modulator arm contacts a tangon the choke shaft. The downward movement of the
diaphragm assembly compresses the piston spring and
exerts a pulling force on the modulator arm, causing the
choke valve to open slightly. This opening is known as
initial choke valve clearance.
Removal
PASSAGE
Fig. 1J-45
AJ41647
Choke Circuit
Installation
(1) Clean gasket mounting surfaces of spacer and
carburetor. Position gasket on intake manifold. Position
carburetor on spacer and gasket and install nuts. To
prevent leakage, distortion or damage to carburetor
body flange, alternately tighten nuts in crisscross
pattern.
(2) Connect in-line fuel filter, throttle cable, choke
heat tube, PCV hose, pullback spring, solenoid wire if
equipped, choke clean air tube and vacuum hoses.
(3) Adjust engine idle speed and idle fuel mixture.
Refer to Chapter 1AGeneral Service and Diagnosis for
procedures.
CARBURETOR OWERHAUL
The following procedure applies to complete overhaul
with the carburetor removed from the engine.
A complete disassembly is not necessary when performing adjustments. In most cases, service adjustments of individual systems may be completed without
removing the carburetor from the engine. Refer to Service Adjustment Procedures.
A complete carburetor overhaul includes disassembly,
thorough cleaning, inspection, and replacement of all
gaskets and worn or damaged parts. Refer to figure 1J46 for parts identification.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21v
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
52.
53.
54.
55.
56.
57.
58.
59.
MODULATOR COVER
MODULATOR R E T A I N I N G SCREW ( 3 )
PIVOT PIN
MODULATOR A R M
CHOKE V A L V E RETAINING SCREW (2)
CHOKE V A L V E
CHOKE SHAFT
AIR HORN
AIR HORN R E T A I N I N G SCREW (4)
AIR HORN GASKET
FLOAT AND LEVER ASSEMBLY
FLOAT SHAFT RETAINER
FLOAT SHAFT
NEEDLE R E T A I N I N G CLIP
CURB IDLE ADJUSTING SCREW
CURB IDLE ADJUSTING SCREW SPRING
THROTTLE SHAFT AND LEVER ASSEMBLY
DASHPOT
DASHPOT LOCKNUT
DASHPOT BRACKET
DASHPOT BRACKET R E T A I N I N G SCREW
ADJUSTING SCREW
CARRIAGE
ELECTRIC SOLENOID '
MOUNTING BRACKET
THROTTLE V A L V E RETAINING SCREW (4)
THROTTLE V A L V E (2)
NEEDLE AND SEAT ASSEMBLY
NEEDLE SEAT GASKET
M A I N JET (2)
M A I N BODY
ELASTOMER V A L V E
PUMP RETURN SPRING
PUMP DIAPHRAGM
PUMP LEVER PIN
PUMP COVER
PUMP ROD
PUMP ROD RETAINER
PUMP LEVER
BOWL V E N T B E L L C R A N K
FUEL INLET F I T T I N G
POWER V A L V E GASKET
POWER V A L V E
POWER V A L V E COVER GASKET
POWER V A L V E COVER
POWER V A L V E COVER
RETAINING SCREW (4)
IDLE L I M I T E R CAP (2)
IDLE M I X T U R E SCREW (2)
IDLE MIXTURE
SCREW SPRING (2)
RETAINER
FAST IDLE LEVER
RETAINING NUT
FAST IDLE
LEVER PIN
RETAINER
LEVER A N D S H A F T
FAST IDLE C A M ROD
CHOKE SHIELD
CHOKE SHIELD
RETAINING
SCREW (2)
PISTON PASSAGE
PLUG
Fig. 1J-46
74.
75.
76.
77.
78.
79.
80.
81
82.
83.
84.
85.
86.
87.
1J-26
FUEL SYSTEMS
e^^^^^M^^^^^^m
. . - ^ r - " i r - ^ ? H ^ r ^ v T ^
1:
(6)
(7)
(8)
taining
- c
--
Disassembly
(1) Remove air cleaner anchor screw.
(2) Remove automatic choke rod retainer from thermostatic choke shaft lever.
(3) Remove air horn attaching screws, lockwashers
and carburetor identification tag. Remove air horn and
air horn gasket.
(4) Remove choke rod by loosening screw that secures choke shaft lever to choke shaft. Remove rod and
plastic dust seal from air horn.
(5) Remove choke modulator assembly (fig. 1J-47).
F!g. 1J-48
(9) Remove fast idle cam rod from fast idle cam
lever.
(10) Remove choke housing assembly retaining
screws, housing assembly and gasket.
(11) Remove fast idle cam.
(12) Remove thermostat lever retaining screw and
washer. Remove thermostatic choke shaft and fast idle
cam lever from the choke housing.
(13) Pry float shaft retainer from fuel inlet seat (fig.
1J-49). Remove float, float shaft retainer and fuel inlet
needle assembly. Remove retainer and float shaft from
float lever.
Fig. 1J-47
FUEL SYSTEMS
1J-27
(14) Remove fuel inlet needle seat and gasket. Remove main jets with Main Metering Jet Wrench J-1017401 (fig. 1J-50).
(15) Remove accelerator pump discharge screw, air
distribution plate, booster venturi and gasket (fig. 1J51). Do not attempt to remove tubes from venturi assembly. Invert main body and catch accelerator pump
discharge weight and ball.
FI|. 1J-52
Fig. 1J-50
Fig. 1J-51
toiltor
Pump Assembly
Fig. 1J-53
Power Valve
1J-28
m
FUEL SYSTEMS
m
-r-
w.
- ~
Assembly
NOTE: Be sure all holes in the replacement
gaskets
have been properly punched and that no foreign material has adhered to the gaskets. Inspect vacuum diaphragms for tears or cuts.
(1) Install fast idle speed adjusting screw and
spring on fast idle lever.
(2) Install solenoid, if removed.
(3) Place fast idle lever assembly on throttle shaft
and install retaining washer and nut.
FUEL SYSTEMS
1J-29
Fig. 1J-55
1J-30
FUEL SYSTEMS
Fig. 1J-56
Fig. 1J-57
FUEL SYSTEMS
FAST I D L E
Fig. 1J-59
Fig. 1J-58
1J-31
Unloader Adjustment
Fig. 1J-6C
1J-32
FUEL SYSTEMS
AJ41662
The choke mechanism may be serviced without removing the carburetor from the engine. If the choke
binds, sticks, or does not operate smoothly, perform the
following.
(1) Remove choke cover.
(2) Remove choke lever and screw.
(3) Remove choke housing. Slide off thermostatic
choke shaft. Remove thin plastic bearing material.
(4) Polish shaft with crocus cloth. Wipe bearing material clean and insert into housing.
(5) Wipe fast idle cam clean.
(6) Install choke housing to thermostatic choke
shaft and install housing screws.
(7) Install choke lever and screw.
(8) Install housing cover and set to specification.
SPECIFICATIONS
Model 2100 Carburetor Calibrations (Inches)
9DM2
8DM2C
9DA2J
9DM2H
1.562
1.562
1.562
1.562
1.080
1.080
1.080
1.080
0.101
0.101
0.101
0.101
0.031
0.028
0.032
0.033
Economizer
0.052
0.046
0.046
0.046
0.106
0.106
0.101
0.101
44
49
44
43
0.052
0.052
0.052
0.052
9.0
5.0
10.0
5.5
9.0
5.0
7.5
2.0
0.032
0.028
0.024
0.032
0.050
0.085
0.050
0.085
0.050
0.085
0.050
0.085
0.025
0.025
0.042
0.042
DeiitVent
0.114
0.114
0.114
0.114
0.076
0.076
0.076
0.076
0.082
0.082
0.089
0.089
80600
FUEL SYSTEMS
1J-33
List
Number
Float Level
(Wet)
Application
Set
To
OK
Range
9DM2
304
Manual
49 State
0.93
0.868
to
0.992
9DM2C
304
Manual
California
0.93
0.868
to
0.992
9DA2J
304
Automatic
49 State
0.93
0.868
to
0.992
304
Manual
0.93
Hilly Terrain
0.868
to
0.992
9DM2H
Float
Level
(Dry)
Automatic
Choke Cover
Setting
(Notches Rich)
Initial
Choke Valve
Clearance
Fast Idle
Cam Setting
Set
To
OK
Range
Set
To
OK
Range
Set
To
OK
Range
0.102
to
0.148
0.120
0.105
to
0.135
1-1/2
to
2-1/2
0.300 m i n . 1500
1400
to
1600
0.120
EKL
0.109
to
0.155
0.120
0.105
to
0.135
1/2
to
1-1/2
0.250 m i n . 1500
1400
to
1600
0.120
EKL
0.105
to
0.151
0.113
0.098
to
0.128
1/2
to
1-1/2
0.300 m i n . 1600
1500
to
1700
0.120
EKL
0.163
to
0.117
0.125
0.110
to
0.140
Index
1/2R
to
1/2L
0.360 m i n . 1500
1400
to
1600
0.120
EKL
Measure
from
machined 0.125
surface
t o a point
on float
0.132
1/8-inch
from tip.
Needle
Seated.
0.128
Set to
0.555
OK Range
0.493
0.140
to
0.617
Choke
Unloader
Fast Idle
Speed
Set
To
Bowl
Choke
Vent
Bimetal
Clearance
ID
OK
Range
80601
Page
Carburetor Circuits
1J-34
Carburetor Overhaul
1J-34
Page
Service Adjust mint Procedures
Specifications
1J-35
1 J-35
Goners! IJ-33
ALTITUDE
COMPENSATION
C I R C U I T CHOKE
CHOKE D I A P H R A G M
Fig. 1 j-l
1J-34
FUEL SYSTEMS
CARBURETOR CIRCUITS
Fig. 1J-64
ALTITUDE
COMPENSAT80N
CHOKE
VALVE
ConpRSStloEi E t a ! ! Ctote Mm
CARBURETOR i f ERIAUL
METERED
AIRFLOW
Fig. 1J-63
The aneroid is factory calibrated and is not adjustable. Do not tamper with the hex-head plug on the
aneroid.
Choke Circuit
The compensation circuit is provided with a separate
choke valve linked directly to the main choke valve (fig.
1J-64). It is not adjustable.
Oisasseihlf
(1) Remove attaching screws and remove compensation assembly and gasket from carburetor body.
(2) Remove aneroid-to-chamber screws. Remove
gasket and aneroid from chamber.
VALVE
STEM
SPRING
RETAINER
DIAPHRAGM
70432
Asseiif
(1) Install aneroid to chamber using replacement
gasket. Install screws.
(2) Install assembly to carburetor body using replacement gasket. Install screws. '
VACUUM
SOURCE
ADJUSTING
SCREW
LINK
70417
SPECIFICATIONS
Model 2150 Carburetor Calibrations (Inches)
9RHM2
9RHA2
1.562
1.562
1.21
1 21
0.101
0.101
0.033
0.03b
Economizer
0.052
0.061
Idle A i r Bleed
0.086
0.086
55
55
0.055
0.055
9.0
5.0
9.0
5.0
0.024
0.024
0.050
0.085
0.050
0.085
0 114
0.114
0.076
0.076
0.089
0.089
80604
1J-36
FUEL SYSTEMS
E Z Z Z Z ~ ^ 4 L
..ZZIZZZ^Z
~7M7ZZ
~ 3 E I I I I I Z Z 3 E Z I Z I I ^
~m
~m
List
Number
Float
Level
Float .
Drop
Application
Set
To
9RHM2
360
Manual
49 State
9RHA2
360
Automatic
50 State
Initial
Choke Valve
Clearance
OK
Range
Fast Idle
Cam Setting
Automatic
Choke Cover
Setting
(Notches Rich)
Set
To
OK
Range
Set
To
OK
Range
Set
To
OK
Range
Fast Idle
Speed
Choke
Unloader
Set
To
OK
Range
Bowl
Choke
Vent
Bimetal
Clearance
ID
0.93
0.868
to
0.992
Measure
from
machined
surface t o
a point
on float
1/8-inch
from tip
Needle
Seated
0.104
0.091
to
0.127
0.086
0.071
to
0.101
1-1/2
to
2-1/2
0.348 min.
1500
1400
to
1600
0.120
EKL
0.93
0.868
to
0.992
Set to
0.555
OK Range
0.113
0.403
to
0.617
0.090
to
0.136
0.093
0.078
to
0.108
1-1/2
to
2-1/2
0.350 m i n .
1600
1500
to
1700
0.120
EKL
80605
V A C U U M THETO^FJTIJI
MODULATING (VTM)
SYSTEM
: " l y
CONNECT HOSE T O
THROTTLE MODULATING
DIAPHRAGM
Fig, 1J-67
MANIFOLD
VACUUM
SOURCE
1 / 1 6 - I N C H (0.062) CLEARANCE
(ENGINE NOT R U N N I N G )
J42627
m j i K O N
(mm)
Pip
General 1J-37
GENERAL
The EGR system used on all Jeep vehicles reduces the
formation of oxides of nitrogen (NOx) by introducing a
metered amount of exhaust gas into the combustion
chambers. Exhaust gas is inert (will not burn), so combustion temperature is reduced. Less NOx is produced a t
lower combustion temperature.
EGR does not take place until engine operating temperature has reached a preset level and engine load is
sufficient to permit proper EGR operation.
Jeep vehicles use three different types of EGR systems (fig. 1J-68, 1J-69 and 1J-70). The EGR system
without back pressure sensor; EGR system with integral back pressure sensor; EGR system with external, non-integral back pressure sensor.
C A R B U R E T O R
E G R PORT
41263A
Fig. 1 J - 6 9
EGR SystemEight-CylinderTypical
C A R B U R E T O R E G R P O R T
AJ41263B
The EGR CTO switch prevents EGR action until engine temperature reaches a preset level, and the backpressure sensor, if equipped, permits EGR action only a t
increased engine loads, improving driveability.
Depending on model applications the following components may be used either seperately or together. The
Thermal Vacuum Switch is located in the air cleaner and
is controlled by air cleaner air temperature. The TVS
controls the vacuum passage between the EGR-CTO
switch and the EGR valve. At temperatures below the
1J-38
FJEL SYSTEMS
^ B W C Z ~ -
^rawr^^^^
-nzisaaeL:
FROM CARBURETOR
PORTED V A C U U M
SOURCE
\
EGR VALVE
The EGR valve mounts on the side of the intake manifold on six-cylinder engines and on a machined surface
at the rear of the intake manifold on eight-cylinder
engines. When the separate back-pressure sensor is
used, the EGR valve mounts on the spacer which is an
integral part of the back-pressure sensor. Exhaust gas is
drawn from an area near the heat riser in six-cylinder
engines and from the exhaust crossover passage in
eight-cylinder engines.
Fig. U - 7 1
A42013
Fig. 1J-72
FUEL SYSTEMS
1J-39
Installation
CONTROL
FLOW A R E A
70421
Fig. 1J-73
Valve Opening
Test
1J-40
FUEL SYSTEMS
InstallationEight-Cylinder Engine
EGR CTO f i s t
N O T E : Engine coolant temperature
100F.
must
be below
(1) Check vacuum lines for leaks and correct routings (fig. 1J-68, 1J-69 and 1J-70).
(2) Disconnect vacuum line at back-pressure sensor
if equipped, or at the EGR valve. Connect line to vacuum
gauge.
(3) Operate engine at 1500 rpm. No vacuum should
be indicated on gauge. If vacuum is indicated, replace
EGR CTO switch.
(4) Idle engine until coolant temperature exceeds
115F (46C) (black color code) or 160F (71 C) (yellow
color code).
N O T E : The temperature gauge needle is about halfway
between the cold mark and the beginning of the band at
115 F (46 C) and about at the beginning of the band at
160F(71C).
(5) Accelerate engine to 1500 rpm. Carburetor ported vacuum should be indicated on vacuum gauge. If not,
replace EGR CTO switch.
(1)
(2)
(3)
(4)
(5)
TO EGR
VALVE
TO EGR
CTO E PORT
ATMOSPHERIC
V E N T FILTER
SPACER
RemovalSix-Cylinder
^
RESTRICTION
InstallationSix-Cylinder
Fig. 1J-74
A42015
cooling
RemovalEight-Cylinder Engine
Remvil
(1) Remove vacuum lines from exhaust back-pressure sensor valve and EGR valve.
(2) Remove two attaching nuts from EGR valve.
(3) Remove EGR valve and exhaust back-pressure
sensor assembly.
(4) Clean intake manifold and back-pressure sensor
ports and all mating surfaces.
Installation
(1) Install replacement gasket on intake manifold
and position exhaust back-pressure sensor on top of
gasket.
NOTE: Exhaust back-pressure sensor assembly should
extend toward the left side on eight-cylinder engines.
(2) Install replacement gasket on exhaust backpressure sensor spacer and install EGR valve.
(3) Install support bracket to valve portion of sensor and tighten screws.
(4) Install two attaching nuts and tighten to 13 footpounds (18 Nm) torque.
(5) Attach vacuum lines to exhaust back-pressure
sensor valve and EGR valve.
NOTE: Vacuum line from CTO switch must be connected to nipple with 0.030-inch (0.762 mm) restriction.
RESTRICTOR PLATES
NOTE: Restrietor plates are used only on vehicles
equipped with the non-integral back-pressure sensor.
The restrietor plate (fig. 1J-75) is located between the
exhaust back-pressure sensor spacer and the intake
manifold, mounted between gaskets. The stainless steel
restrietor plate is calibrated for a particular engine/
exhaust system and should never be altered or replaced
with a restrietor plate of different calibration.
AJ43044
Fig. 1J-75
Reslricfor Piafe
POSITIVE CRANKCASE
VENTILATION (PCV)
SYSTEM
Page
Components
General
1J-42
1J-41
The PCV system prevents crankcase vapors from entering the atmosphere. Filtered air is directed into the
Pige
Operation PCV Air Ifriet Filter
PCV Valve Test
1J-42
1J-42
1J-42
FUEL SYSTEMS
NON-VENTED
HOSE TO
MANIFOLD
VACUUM
SOURCE
AT
COMPONENTS
The PCV system consists of an air inlet filter, a flowcontrol (PCV) valve and associated hoses (fig. 1J-76 and
1J-77).
The air inlet filter' is located inside the air cleaner
housing on six-cylinder engines. It is contained in the oil
filler cap on eight-cylinder engines.
NON-VENTED
MANIFOLD
V A C U U M HOSE
Fig. U - 7 7
Fig. 1J-76
OPERATION
Air flow through the PCV system is controlled primarily by manifold vacuum. There are two basic operating modes. When manifold vacuum is relatively high,
as at idle or at cruising speed, fresh air is drawn through
the air intake filter into the crankcase. After circulating
through the crankcase, the vapor-filled air is drawn
FUEL SYSTEMS
1J-43
MOULDED
HOSES
Fig. 1 J - 7 8
Yellow
Six-Cylinder
1.30-1.90 (.0Q3-.005)
2.70-3.79 (.007-.010)
7
5
Eight-Cylinder
1.21-2.26 (.003-.006)
3.30-4.39 (.009-.012)
3
2
1.34-1.63 (.003-.004)
16
13
Fig. 1 J - 7 9
1.28-2.56 (.003-.007)
80586
Ii-Cftinier
A polyurethane foam PCV air inlet filter is located in
a filter retainer in the air cleaner.
deteriorated.
"ZD
c o N T R O t t g
Mm mLmmmii
Page
Pl|S
General
Operation
1J-43
U-44
OENERAL
The Thermostatically Controlled Air Cleaner (TAC)
System provides pre-warmed air to the carburetor air
cleaner during engine warm-up, while under-hood air
Testing
1J-44
Thermal Sensor
U-44
temperature is low. Warm intake air permits the carburetor to be calibrated leaner, reducing hydrocarbon
emissions. It also improves engine warm-up and minimizes carburetor icing.
FUEL SYSTEMS
For 1979, all Jeep vehicles are equipped with a vacuum-operated TAC system.
This system consists of a heat shroud at the exhaust
manifold, a hot air hose, a special air cleaner assembly
equipped with a thermal sensor, and a vacuum motor
and air valve assembly (fig. 1J-80). The air cleaner snorkel is attached by flexible hose to the ambient air inlet at
the front of the engine compartment.
AIR BLEED
V A L V E (OPEN)
THERMAL
SENSOR
TESTING
SNORKEL
A I R V A L V E CLOSED
( H E A T OFF POSITION)
A I R V A L V E OPEN
( H E A T ON POSITION)
HEATED
AIR
THERMAL SENSOR
Fig. 1J-80
TAC SystemTypical
iipiiciffliif
OPERATION
The position of the heat valve is controlled by manifold vacuum acting against a spring. Manifold vacuum is
controlled by a temperature-sensitive switch in the air
cleaner housing.
disconnect vacuum
sensor. Remove senand gasket. Press reinstall air cleaner.
FUEL SYSTEMS
1J-4S
C A R B U R E T O R BOWL
COOLING S Y S T E M
Page
Pap
Cooling Fan Replacement
Oeflector Replacement
General
1J-45
1J-46
1J-45
lose Replacement
1J-45
Operation
Timer Replacement
Sensor Replacement
Vent Replacement
GENERAL
After engine shut down the carburetor bowl cooling
system automatically cools the carburetor bowl when
the underhood temperature is above a pre-determined
temperature. The length of cooling time is also controlled by a preset timer (relay). The system reduces fuel
percolation during high heat soak periods.
Components are:.
Cooling fandraws in cool ambient air for bowl
cooling.
Ductdirects cooling air to the base of the
carburetor.
Timer (Relay)directs current to the cooling fan
(through the sensor) for a pre-determined amount of
time.
Sensoracts an an on/off switch for cooling fan
current (this is a heat sensitive device placed in an
area of underhood heat).
Deflectorattached to carburetor bowl and directs
air flow at bowl.
Ventattached to fan and protects fan assembly
from foreign matter.
OPERATION
When the ignition switch is cycled (engine started,
and then the ignition switch turned to the Off position),
the timer directs current to the fan through the sensor.
If the underhood temperature is above the sensor
switching temperature, the circuit is closed and the cooling fan operates. If during carburetor cooling operation
the underhood temperature falls below the sensor temperature calibration, the sensor opens the circuit and the
fan stops. The timer turns off the fan after a preset time
interval regardless of underhood temperature.
In the event of an engine re-start during fan cooling
operation, the fan turns off and the timer resets.
ORANGE
GREEN W/TR
ALTERNATOR
Fig. 1J-81
FRONT
90196
TIMER REPLACEMENT
Reioval
(1) Open hood.
(2) Disconnect negative battery cable.
(3) Remove leads at starter solenoid and ignition
coil feed.
(4) Cut straps and remove timer assembly.
Installation
(1) Connect leads to ignition coil feed and starter
solenoid.
(2) Secure timer assembly with tiedown straps.
(3) Connect negative battery cable.
(4) Close hood.
HOSE REPLACEMENT
Installation
Romoval
1J-45
1J-45
1J-46
1J-46
1J-46
F U E L SYSTEMS
Installation
(1) Install hose to carburetor and fan.
(2) Install air cleaner.
(3) Close hood.
(1)
(2)
(3)
(4)
SENSOR REPLACEMENT
Removal
(1) Open hood.
(2) Unplug sensor.
(3) Cut strap retaining sensor.
VENT REPLACEMENT
Removal
Installation
(1) Install sensor and secure with strap.
(2) Plug in sensor to timer lead.
(3) Close hood.
DEFLECTOR REPLACEMENT
:
Install deflector.
Install duct to reflector.
Install air cleaner.
Close hood.
Removal
(1) Open hood.
(2) Remove air cleaner.
(1)
(2)
(3)
(4)
Open hood.
Remove duct from fan.
Unplug fan and remove screws.
Remove vent and fan.
(1)
(2)
(3)
(4)
Fan operates
1. Short sensor
2. Start engine
3. Turn ignition switch off
1.
2.
3.
4.
FUEL SYSTEMS
Tools
J-23738
H A N D OPERATED
V A C U U M PUMP
1J47
NOTES
1K-1
Pap
Ah- Guard Systaa
Page
Exhaust Manifolds, i u f f l i r s , mi Pipes
1K-9
1K-13
Tools
wmmmmm ssm
Fill
Exhaust Manifold
Geiarai
Heat Valve
Muffler
1K-6
1K-1
1K-7
1K-8
GENERAL
The basic exhaust system on all vehicles consists of
exhaust manifold(s), front exhaust pipe, catalytic converter, muffler and tailpipe.
All six-cylinder CJ models use a catalytic converter
(fig. 1K-1). Six-cylinder CJ models for California use a
monolithic catalytic converter and a pellet-type catalytic
converter (fig. 1K-1). All eight-cylinder CJ models use a
single pellet-type catalytic converter (fig. 1K-2).
Cherokee, Wagoneer and Truck models use a single
pellet-type catalytic converter (fig. 1K-3 through 1K-6).
The exhaust system must be properly aligned to prevent stress, leakage, and grounding. If the system
grounds on any body panel, it may amplify objectionable
noises originating from the engine or the body. When
inspecting an exhaust system, check for cracked or loose
joints, stripped screw threads, and corrosion damage.
Check for worn or broken hangers. Eeplace all parts that
are badly corroded or damaged. Do not attempt to
repair.
1K-1
liC-15
PIPES
Pip
Pipes m - 9
Restricted Exhaust System Diagnosis 1K-1
Specifications 1K-9
1K-2
EXHAUST SYSTEMS
to
HEAT
SHIELD
Fig. 1K-1
EXHAUST SYTEMS
1K-3
80230
Fig. 1K-2
TAILPIPE
Fig. 1K-3
TRANSMISSION
Fig. 1K-4
AUTOMATIC
TRANSMISSION
EXHAUST SYTEMS
1K-5
AUTOMATIC
3-SPEED
TRANSMISSION
80137
Fig. 1K-5
TAILPIPE
HEAT V A L V E
GASKET
WASHER
3-SPEED
TRANSMISSION
4-SPEED
TRANSMISSION
AUTOMATIC
TRANSMISSION
Fig. 1K-6
80138
1K-6
EXHAUST SYSTEMS
EXHAUST MANIFOLD
ReplacementSix-Cylinder Engine
Removal
Fig. 1K-7
Manifold Assembly
(2) Install choke clean air tube into bottom of exhaust manifold and install tube clip.
(3) Position replacement intake manifold gasket on
cylinder head and install manifold assembly. Tighten
manifold attaching bolts and nuts in sequence (fig. 1K-8)
to 23 foot-pounds (31 Nm) torque.
(4) Install flange gasket and connect exhaust pipe to
manifold flange. Use replacement nuts.
(5) Install carburetor to intake manifold. Connect
fuel line and hose from vapor canister.
(6)* Install air conditioning idler assembly, if
removed.
(7) Install air pump, if removed.
(8) Install air pump/power steering pump mounting bracket, if removed.
^ (9) Install diverter valve. Connect hoses to air pump
and checWalve. Connect vacuum hose to manifold.
(10) Install drive belts and tighten to specification.
Refer to Chapter 1CCooling Systems.
(11) Install spark CTO vacuum tubes. Connect TCS
wiring, if removed.
(12) Connect vacuum line at EGR valve.
EXHAUST SYTEMS
(13) Install throttle return spring and carburetor
control shaft.
(14) Connect accelerator cable and PCV hose.
(15) Install choke heater tube and clean air tube to
carburetor.
(16) Start engine and check for vacuum or exhaust
leaks.
(17) Install air cleaner.
10
Fig. 1K-8
1K-7
HEAT VALVE
Six-Cylinder Engine
A thermostatically controlled heat valve in the exhaust manifold directs exhaust heat to the floor of the
intake manifold for rapid fuel vaporization during engine warmup. The valve is in the heat On position,
directing exhaust heat to the intake manifold, when the
counterweight is in the extreme counterclockwise position when viewed from the counterweight end (fig. 1K9). As the engine reaches operating temperature, the
thermostatic spring heats up and loses tension, allowing
the counterweight to move the valve to the heat Off
position (fig. 1K-10).
leplacementEight-Cylinder Engine
Removal
AJ43059
Fig. 1K-9
Installation
43060
Fig. 1K-10
1K-8
EXHAUST SYSTEMS
COUNTERWEIGHT
Replacement
Eight-Cylinder Engine
A thermostatically controlled heat valve mounted between the right exhaust manifold and exhaust pipe directs exhaust heat to the intake manifold for rapid fuel
vaporization during engine warmup. When the counterweight is in the horizontal position, the valve is in the
heat On position, directing exhaust heat through the
intake manifold crossover passage (fig. 1K-11). The exhaust heat crosses through the intake manifold and discharges into the left exhaust manifold until the engine
reaches operating temperature. At this time, the thermostatic spring loses its tension and the counterweight
moves downward, moving the valve to the heat Off
position and allowing the exhaust heat to discharge
through the right exhaust pipe.
Check the manifold heat valve for free movement and
lubricate every 30,000 miles (48 000 km) with Jeep Heat
Valve Lubricant, or equivalent.
Replacement
Fig. 1K-11
in Heat On PositionEight-Cylinder
MUFFLE!
Replacement
Removal
Removal
Installation
Installation
SPECIFICATIONS
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
^
Exhaust and Intake Manifold Screws and Nuts
Six-Cylinder .
Exhaust Manifold Screws Eight-Cylinder
Center (2)
Outer (4)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
23
18-28
31
24-38
25
20-30
12-18
27
34
20
15-25
27-41
20-34
20-34
15
Metric (N- m)
20
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
70295
1K-12
GENERAL
This system incorporates a belt-driven air pump, diverter (bypass) valve, air injection manifold(s) and connecting hoses (fig. 1K-12 and 1K-13).
Air is discharged from the air pump to the diverter
valve which directs it to the air distribution manifold(s)
or dumps it through a bypass port, depending on engine
Page
General
1K-9
Specifications 1K-13
1K-10
EXHAUST SYSTEMS
VACUUM
SENSING
LINE
MANIFOLD
VACUUM
SOURCE
A I R PUMP
TO D I V E R T E R
V A L V E HOSE
A I R INJECTION
MANIFOLD
CHECK
VALVE
^DIVERTER
"
VALVE
DIVERTER
BRACKET
DIVERTER VALVE
INJECTION HOSE
-TO-AIR
43040
Fig. 1K-12
V A C U U M SENSING
LINE (TO M A N I F O L D
V A C U U M SOURCE)
The front bearing supports the rotor shaft. The bearing is secured in position by plastic injected around
grooves in the housing and bearing outer race.
The rear cover supports the vane pivot pin, rear bearing inner race and exhaust tube. Dowel pins pressed into
the housing correctly position the end cover which is
fastened by four screws.
The rotor positions and drives the two vanes. A
stamped steel liner supports the carbon shoes and shoe
springs which seal the vanes and rotor. The two plastic
vanes are molded to hubs which support bearings that
rotate on the pivot pin. The pulley drive hub is pressed
on the rotor shaft, and threaded holes in the hub provide
for attachment of a pulley.
R E A R COVER
V E N T HOLE
(DO NOT OIL)
CHECK
VALVE
FILTER F A N
MANIFOLD
AIR PUMP-TODIVERTER
V A L V E HOSE
HOSE D I V E R T E R
VALVE-TO-AIR
INJECTION M A N I F O L D
(CALIF. ONLY)
AIR PUMP
42006
ROTOR S H A F T A N D
DRIVE HUB
4200?
AIR PUMP
Fig. 1K-14 Air Pump
Ceipoiiits
The same air pump is used for six-cylinder and eightcylinder engines. The major components of the air pump
are enclosed in a die-cast aluminum housing. A filter fan
assembly, rotor shaft and drive hub are visible on the
pump exterior (fig. 1K-14).-The pump is designed for long life and is serviceable
only by replacement. Do not remove the rear housing
Operation
The pump vanes are located 180 apart and rotate
around the pivot pin which is located on the centerline of
the pump housing. The rotor which drives the vanes
rotates off the centerline of the pump housing. This
creates changes in the distance between the outside of
EXHAUST SYTEMS
the rotor and the inner wall of the pump housings during rotor rotation. As the leading vane moves past the
intake opening, it is moving from a small area to a large
area. This creates a partial vacuum which draws air into
the pump. As the vanes and rotor continue to rotate, the
trailing vane passes the intake and traps the air between
the vanes. The vanes and rotor move the air into a
smaller area. This begins to compress the air. Compression continues until the leading vane passes the
exhaust opening. There the compressed air passes out of
the pump and on to the rest of the Air Guard System.
Servico Precaytions
The following is a list of service precautions to prevent
damage to the air pump.
Do not attempt to prevent pulley from rotating by
inserting tools into the centrifugal filter fan.
Do not operate engine with pump belt removed or
disconnected except for noise diagnosis.
Do not attempt to lubricate.
Do not clean centrifugal filter.
Do not disassemble pump or remove rear cover.
Do not exceed 20 foot-pounds (27 Nm) torque on
mounting bolts.
D o not pry on aluminum housing to adjust belt
tension.
Do not clamp pump in vise.
Do not permit liquids to enter pump when steam- or
pressure-cleaning engine.
Sorwiio Prooolyres
RemovalSix-Cylinder Engine
(2)
(3)
(4)
(5)
1K-11
InstallationSix-Cylinder Engine
DIVERTER(BYPASS) V A L V E
General
A diverter valve is used in all Air Guard applications.
The valves for six-cylinder and eight-cylinder engines
differ only in the number of outlets. The six-cylinder
diverter valve has one outlet and the eight-cylinder diverter valve has two for California certification and one
outlet for 49-state models (on left side). A high flow
diverter is used on some applications where greater air
flow is required for emission control.
The valve momentarily diverts air pump output from
reaching the exhaust manifolds during rapid deceleration. It also acts as a pressure release when air pump
output is excessive. An internal silencer is incorporated
in the diverter housing to muffle the airflow.
Operation
In a rapid deceleration condition, high intake manifold vacuum is applied to the diaphragm in the diverter.
When the vacuum signal is 20 inches of mercury or
more, the spring tension of the diaphragm is overcome.
1K-12
EXHAUST SYSTEMS
DIAPHRAGM
DIAPHRAGM
Diverter Replacement
The diverter valve is not serviceable and must be
replaced if defective. The valve is attached to a bracket
or suspended by the hoses between the air pump and air
injection manifolds. Removal involves disconnecting the
hoses, the vacuum sensing line and bracket clamp, if
used. Installation entails connecting the hoses, vacuum
line and bracket clamp, if used.
PRESSURE
RELIEF O U T L E T
(METERING
V A L V E IN
BYPASS
POSITION)
A5Q277
RemovalSix-Cylinior Engine
Oiwerter Test
(1) Start engine and run at idle.
(2) Check diverter vents. Little or no air should flow
from vents.
(3) Accelerate engine to 2000 to 3000 rpm and rapidly close throttle. A strong flow of air should pass from
the diverter vents for approximately 5 seconds. The high
flow diverter used on some engines should vent for ap-
EXHAUST SYTEMS
1K-13
InstallationSix-Cylinder Englno
NOTE: Some resistance to removal may be encountered due to carbon build-up on the screws.
air
injection
InstallationEight-Cylinder Engine
(1) Install air injection manifold using replacement
sealing gasket on either side of each opening.
(2) Install injection screws to exhaust manifold.
Tighten screws to 38 foot-pounds (52 N*m) torque.
(3) Connect air delivery hose to check valve.
RomovalElght-Cylindor Engine
(1) Disconnect air delivery hose at check valve.
(2) Remove injection screws.
SPECIFICATIONS
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
Metric (N- m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
20
27
15-22
20-30
20
38
27
52
15-20
30-45
20-27
41-61
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
70296
CATALYTIC CONVERTER
SYSTEM
Page
Catalyst Replacement
1K-14
General
1K-13
Page
Operation
1K-14
OENERAL
Converter Types
The monolithic converter contains a mixture of platinum and palladium catalyzing agents is coated on an
extruded material resembling a honeycomb. The front
pipe and the monolithic converter are constructed as a
unit. The catalyst is not serviceable.
The pellet-type converter contains beads of alumina
coated with platinum and palladium catalyzing agents.
Thousands of pellets are contained in a stainless steel
1K-14
EXHAUST SYSTEMS
OPERATION
8 0 4 3 2
Fig. IK-IS
CATALYST REPLACEMENT
Monolithic Converter
The entire unit must be replaced if defective.
The monolithic converter is removed by disconnecting
at the exhaust manifold and removing at the pellet type
converter. Clean mating surface of manifold. Use replacement seal if required.
Pellot-Typo Convortor
The threaded plug used in previous years has been
replaced with a pressed-in plug for 1979. A replacement
kit consists of bridge, plug, washer and screw (fig. 1K16).
(1) Raise vehicle.
(2) Place hose of Vacuum Pump Tool J-25077 on
exhaust pipe and tighten clamp (fig. 1K-17).
(3) Connect shop air (80 psi minimum) to fitting on
vacuum pump.
(4) Remove plug from bottom of converter.
(a) Drive small chisel between plug and converter housing. Do not damage housing.
(b) Continue driving chisel into plug to deform.
(c) Repeat steps (a) and (b) several places
Fig. 1K-17
Vacuum Pump
EXHAUST SYTEMS
11-11
NOTE: If any pellets come out of the tailpipe, the converter is defective and must be replaced.
Fig. 1K-18
Vibrator Tool
Tools
* *
70452
NOTES
1L-1
POWER PLANT
INSTRUMENTATION
SECTION INDEX
Circuits and Schematics
and Repair Simplification (DARS) Charts
General Information
SpecificationsCherokee
Page
Page
1L-41
1140
1L-42
SpecificationsCJ
SpecificationsTruck
SpecificationsWagoneer
Tools
1L-7
11-1
1142
1L-42
1L-44
GENERAL INFORMATION
Page
Constant Voltage Regulator (CVR) Replacement
Gauge Replacement
Instrument Cluster Replacement
1L-7
1L-5
1L-4
Page
Operation
Printed Circuit Replacement
1H
11-7
GENERAL
This chapter is divided into three sub-sections. The
first sub-section, General Information, contains verbal
descriptions of all instrumentation, operating principles, test procedures and replacement procedures. The
second sub-section, Diagnosis and Repair Simplification
(DARS) Charts, contains pictorial guides for diagnosing
instrumentation malfunctions. The third sub-section,
Circuits and Schematics, contains specifications, cluster
illustrations, cluster schematics and separate schematics for each gauge circuit.
Power plant instrumentation includes all instrument
panel gauges used to monitor engine-related systems
i n c l u d e d in t h i s v o l u m e . R e f e r t o C h a p t e r
3CInstrument Panels and Components for speedometer, odometer, clock, illumination lamps, turn signal
indicators and high beam indicator. Instrumentation
covered in this chapter includes: ammeter, constant
voltage regulator (CVR), fuel gauge, oil pressure gauge,
tachometer, temperature gauge and voltmeter (fig. 1L-1
and 1L-2). These gauges are all electrically operated.
OPERATION
Ammeter
The ammeter is standard on Cherokee, Wagoneer and
Truck. It is not available on CJ models.
The ammeter is an instrument used to indicate current flow into or out of the battery. Whenever electrical
loads in the vehicle are greater than the alternator can
supply, current flows from the battery, and the ammeter indicates discharge (-). Whenever alternator output
is greater than the electrical loads of the vehicle, the
excess current is available to charge the battery, and the
ammeter indicates charge (+). If the battery is fully
charged, the voltage regulator reduces alternator output
to meet only immediate vehicle electrical loads. When
this happens, the ammeter indicates zero.
The ammeter is connected between the battery and
the alternator in order to indicate current flow into and
out of the battery.
1L-2
TACHOMETER
O I L PRESSURE
GAUGE
BRAKE
VOLTMETER
TEMPERATURE
GAUGE
EMERGENCY
DRIVE
F U E L GAUGE
80317
Fig. 1L-1
FUEL
GAUGE
BRAKES
FASTEN
BELTS
Fig. 1L-2
CJ Instrumentation
LEFT
TURN
TEMPERATURE
GAUGE
Tachometer
OIL
PRESSURE
GAUGE
RIGHT
TURN
HIGH BEAM
The oil pressure gauge system consists of a CVRpowered gauge, a variable-resistance sending unit, appropriate wiring and the CVR. The gauge needle is attached to a bimetal strip which responds to temperature
changes. A heating coil wrapped around the bimetal
provides heat to operate the bimetal. Current flows from
the CVR, through the heating coil and is grounded
through the sending unit on the engine.
^f
R
v
AMMETER
G E N C Y
Temperature Gauge
Cherokee-Wagoneer-Truck Instrumentation
Fuel Gauge
Fuel gauges on all models operate on regulated voltage provided by the constant voltage regulator (CVR).
The fuel gauge system consists of the gauge, a variableresistance sending unit in the fuel tank, appropriate
wiring and the CVR.
The gauge needle is attached to a bimetal coil which
responds to temperature changes. A heating coil
wrapped around the bimetal provides heat to operate
the bimetal. Current flows from the CVR through the
heating coil, and is grounded through the sending unit in
the fuel tank. The sending unit offers high resistance at
low fuel level and very low resistance at high fuel level.
Oil Pressure Gauge
The oil pressure gauge is standard on all Jeep vehicles.
CJ Models
The oil pressure gauge system consists of a magnetictype gauge, a variable-resistance sending unit and appropriate wiring. Battery voltage is applied to two coils
in the gauge. One coil is connected directly to ground.
Voltmeter
The voltmeter is standard equipment on CJ models
only. It is not available on other models. The voltmeter
indicates regulated voltage. This provides an indication
of the charging system's ability to keep the battery
charged. Continuous readings in either high or low red
bands indicates improper regulation, broken or slipping
alternator drive belt, shorted alternator diode(s) or defective battery. Low readings in the green band are
normal at idle or after prolonged engine cranking. Continuous readings in the low green band indicate faulty
operation.
INSTRUMENTATION DIAGNOSIS
General
Improper operation of electrical gauges is usually
traced to faulty continuity of wiring (including printed
circuits), improperly calibrated components or high resistance caused by loose or corroded connections.
A common diagnostic procedure is to bypass a suspected component, wire, or connection with a jumper
wire. If the system functions properly with the jumper
installed, the problem usually is within the bypassed
item.
Test Equipment
Several gauge tests require Universal Gauge Tester J24538. This instrument provides variable resistance over
a wide range of ohm readings. If the tester is not available, a suitable substitute can be made with an accurate
ohmmeter and a spare fuel tank sending unit.
(1) Attach one lead of ohmmeter to sending unit
terminal.
(2) Attach other ohmmeter lead to sending unit
ground wire.
(3) Refer to Sending Unit Resistance Requirements
chart for resistance values that apply to gauge being
tested. Chart is included in specifications. Move float
arm and mark appropriate resistance values on sending
unit case.
(4) Disconnect ohmmeter. Fasten jumper wire to
sending unit terminal. Tester is now calibrated and
ready to use.
Printel Circuit Test
The following procedure is used to pinpoint suspected
breaks or shorts in the conducting foil.
(1) Remove instrument cluster from vehicle and remove all bulbs and gauges. Refer to Instrument Cluster
Replacement for procedures.
(2) Connect test lamp or ohmmeter lead to correct
pin terminal for circuit to be tested. Trace each circuit
from pin to bulb or gauge in that circuit.
N O T E : Use ohmmeter or Test Lamp J-21008. When
using an ohmmeter, use low scale (0 to 10 ohms) and
adjust meter to zero reading.
(3) Check for continuity at each uncoated position
in circuit. Test lamp should light or ohmmeter should
read zero ohms at each position.
(4) Trace circuit leading away from bulb or gauge to
terminal pin or ground screw.
(5) Check for continuity in circuit at each uncoated
postion. Test lamp should light or ohmmeter should read
zero ohms.
(6) Connect test lamp or ohmmeter lead to ground
pin terminal and other lead to cluster metal case. Test
lamp should light or ohmmeter should read zero ohms.
1L 3
1L-4
Needle pulsates.
Refer to DARS chart 4 or 5 for a systematic method of
finding the causes of these problems.
(3) Compare indication of test voltmeter with indication of vehicle voltmeter. Replace voltmeter if readings vary more than tolerance listed in Specifications.
Calibration Test
Tachometer Diagnosis
Cherokee-Wagoneer-Truck Models
Removal
Voltmeter
(1) Connect voltmeter of known accuracy across
battery terminals.
(2) Turn ignition switch On.
Ammeter
(1) Remove cluster.
(2) Remove printed
assembly.
Cherokee-Wagoneer-Truck Models
GAUGE REPLACEMENT
circuit
board
and
1L-5
gauge
Oil
Pressure
Gauge
Fuel Gauge
CJ Models
CJ Models
Tachometer
(1) Disconnect wires:
(a) Black ground wire
(b) Orange illumination wire from fuse block
(c) Red and red w / t wires from main harness
(2) Remove screw and retaining cup.
(3) Remove tachometer from instrument panel.
1L-6
Tomperatun Gauge
CJ Models
(3)
(4)
(5)
(6)
lamp.
Removal
(1) Remove instrument cluster.
(2) Remove radio noise suppressor (connector strip
when not equipped with radio).
(3) Remove all lamps from cluster. Twist counterclockwise to remove.
(4) Remove circuit board and gauge assembly.
(5) Remove retaining nuts from ammeter and oil
pressure gauges.
(6) Lift ammeter, oil pressure gauge and plate out
of cluster as assembly.
(7) Remove retaining nuts from fuel and temperature gauges. Remove large ground screw from circuit
board above speedometer.
(8) Remove speedometer, fuel gauge, and temperature gauge as assembly.
Installation
Install cluster.
CJ Models
Voltmeter
(1) Disconnect illumination lamp and wire connectors. Note wire locations for installation.
(2) Remove retaining nuts and bracket behind instrument panel.
Clerokee-Wagoieer-Truik Models
The CVR is contained in the temperature gauge case.
If CVR is defective, replace temperature gauge.
1L-7
DIAGNOSIS A N D R E P A I R
SIMPLIFICATION ( D A R S )
CHARTS
Page
Pi|i
Fuel Gauge
Fuel Gauge and Temperature Gauge Both Malfunction
Fuse Blown
1L-8
11*19
1 U 7
1L-21
1L-26
11*32
1L-8
Note: Refer to Chapter A General Information for details on how to use this DARS chart.
Chart 1
P R O B L E M : F U E L GAUGE N O T
FUNCTIONING P R O P E R L Y
SEQUENCE
STEP
m NOTE POSITION OF
FUEL GAUGE NEEDLE
# T U R N I G N I T I O N ON A N D
W A I T 2 M I N U T E S FOR
GAUGE T O W A R M UP
RESULT
# OBSERVE NEEDLE
N E E D L E DOES
NOT M O V E
NEEDLE
MOVES
BEFORE S T A R T I N G TEST:
01
ENGINE MUST BE W A R M
NEEDLE MOVES
TO M A X I M U M
A N D STAYS
FUEL T A N K MUST BE
NEITHER COMPLETELY FULL
NOR COMPLETELY EMPTY
N E E D L E PULSATES
MORE T H A N W I D T H
OF N E E D L E
REPLACE
CVR
GO T O
* CHART 2
STEP 1
FUSE BLOWN
FUSE N O T BLOWN
TEMPERATURE
GAUGE NEEDLE
DOES N O T M O V E
OBSERVE
TEMPERATURE
GAUGE
o
GO TO
- CHART 3
STEP 1
CJ
MODELS"
TEMPERATURE
GAUGE NEEDLE
INDICATES PROPERLY
CHEROKEE
WAGONEER
TRUCK MODELS
8 0 3 1 1 A
STEP
1L-9
Chart 1
RESULT
SEQUENCE
STOP
G R O U N D SENDER
T E R M I N A L OF G A U G E
NEEDLE DOES
NOT M O V E
L O C A T E A N D REPAIR
OPEN C I R C U I T IN
SENDER WIRE
STOP.
8 0 3 1 1 B
11-10
Chart 1
SEQUENCE
STEP
# R E M O V E CLUSTER
@ D O N O T DISCONNECT I N S T R U M E N T
CLUSTER W I R I N G CONNECTOR
RESULT
CHECK FOR
PRESENCE OF
VOLTAGE AT
GAUGE INPUT
STOP
VOLTAGE
NOT PRESENT
REPLACE
C I R C U I T BOARD
OK
V O L T A G E PRESENT
GROUND
SENDER
TERMINAL
OF GAUGE
NEEDLE DOES
NOT MOVE
STOP
NEEDLE MOVES
REPAIR OPEN
CIRCUIT IN
SENDER WIRE
G R O U N D FUEL
GAUGE PIN T E R M I N A L
ON C I R C U I T BOARD
'STOP
NEEDLE DOES
NOT M O V E
REPLACE
CIRCUIT
BOARD
CHECK
G R O U N D STRAP
GROUND
NOT OK
BROKEN
MISSING
CORRODED
SCREWS LOOSE, MISSING
(OK)
G R O U N D OK
N E E D L E DROPS
FROM M A X I M U M
STOP
REPAIR
GROUND
NEEDLE REMAINS
AT MAXIMUM
8 0 3 1 1 C
Chart 1
RESULT
SEQUENCE
STEP
1L-11
DISCONNECT S E N D I N G U N I T
WIRE F R O M SENDING U N I T
N E E D L E DROPS
FROM M A X I M U M
NEEDLE R E M A I N S
AT MAXIMUM
T U R N IGNITION ON
ADJUST TESTER TO
SELECT O H M V A L U E S
LISTED I N S E N D I N G
U N I T RESISTANCE
REQUIREMENTS CHART.
OBSERVE FUEL
GAUGE I N D I C A T I O N A T
EACH O H M S E T T I N G .
GAUGE I N D I C A T I O N S
NOT A C C U R A T E
A T EACH O H M SETTING
OK
GAUGE I N D I C A T I O N S
ACCURATE A T
EACH O H M S E T T I N G
OBSERVE T E M P E R A T U R E GAUGE
TEMPLRATURE
GAUGE
NEEDLE IS A T
MAXIMUM
ST0P
REPAIR CLUSTER G R O U N D
OR REPLACE CVR
TEMPERATURE
GAUGE
NEEDLE
INDICATES
NORMALLY
STOP
REPLACE FUEL GAUGE
8 0 3 1 1 D
STEP
Chart 1
RESULT
SEQUENCE
CHECK FUEL
T A N K FOR
DEFORMATION
OK
FUEL T A N K
NOT DEFORMED
(OK)
FUEL T A N K
DEFORMED
STOP
REPAIR
OR
REPLACE
FUEL T A N K
CHECK SENDING U N I T A N D
T A N K FOR LOOSE SOLDER
OK
NO LOOSE
SOLDER
STOP
REPLACE
SENDING
UNIT
O3]
LOOSE
SOLDER
PRESENT
DISCONNECT
BATTERY
N E G A T I V E CABLE
STOP
REMOVE
LOOSE
SOLDER
REMOVE I N S T R U M E N T
CLUSTER. DO NOT
DISCONNECT WIRE
HARNESS
NEEDLE DROPS
FROM M A X I M U M
CONNECT JUMPER
(.WIRE BETWEEN
IICLUSTER G R O U N D
A N D BODY
i t
NEEDLE
REMAINS A T
MAXIMUM
CONNECT B A T T E R Y
N E G A T I V E CABLE
REPAIR I N S T R U M E N T
G R O U N D PANEL
STOP
8 0 3 1 1 E
Chart 1
RESULT
SEQUENCE
STEP
1L-13
DISCONNECT
S E N D I N G U N I T WIRE
FROM CLUSTER
STOP
NEEDLE DROPS
FROM M A X I M U M
REPAIR OR REPLACE
SENDING U N I T WIRE
i STOP
REPLACE GAUGE
(CJ)
NEEDLE R E M A I N S
AT MAXIMUM
STOP
REPLACE C I R C U I T BOARD
* (CHEROKEE, WAGONEER,
TRUCK)
0
CJ
GAUGE I N D I C A T I O N S
NOT ACCURATE A T
EACH O H M S E T T I N G
CHEROKEE
WAGONEER
TRUCK
T U R N I G N I T I O N ON
ADJUST TESTER TO
SELECT O H M V A L U E S
LISTED I N SENDING
U N I T RESISTANCE
REQUIREMENTS CHART.
OBSERVE FUEL
GAUGE I N D I C A T I O N A T
EACH O H M SETTING.
OK
GAUGE INDICATIONS
A C C U R A T E A T EACH
OHM SETTING
STOP
REPLACE
SENDING
UNIT
8 0 3 1 1 F
1L-14
Chart 1
SEQUENCE
STEP
RESULT
REMOVE I N S T R U M E N T CLUSTER
A N D DISCONNECT
I N S T R U M E N T WIRES
DISCONNECT
BATTERY
N E G A T I V E CABLE
CHECK GAUGE N U T S
FOR CORROSION. REPLACE
IF NECESSARY A N D
TIGHTEN
CONNECT JUMPER
WIRE IN SERIES
W I T H 3 AMP
FUSE BETWEEN
BATTERY
VOLTAGE
A N D GAUGE
l-TERMINAL
CONNECT
BATTERY
NEGATIVE
CABLE
CONNECT
JUMPER
WIRE F R O M
CLUSTER
CASE T O
GROUND
CONNECT ONE
TESTER LEAD
TO FUEL
GAUGE SENDING
UNIT
TERMINAL AND
OTHER LEAD
TO G R O U N D
GAUGE I N D I C A T I O N S
ACCURATE
A T EACH O H M S E T T I N G
REPLACE SENDING
U N I T WIRE
GAUGE I N D I C A T I O N S
NOT O B T A I N E D
A T EACH O H M S E T T I N G
A L L READINGS
H I G H OR A L L
READINGS LOW
GAUGE I N D I C A T I O N S
NOT ACCURATE A T EACH
OHM SETTING
SOME READINGS
. H I G H OR LOW,
SOME
ACCURATE
REPLACE
GAUGE
8 0 3 1 1 G
STEP
1L-1S
Chart 1
RESULT
SEQUENCE
R E M O V E I N S T R U M E N T CLUSTER
A N D DISCONNECT
I N S T R U M E N T WIRE HARNESS
DISCONNECT
BATTERY
NEGATIVE CABLE
CONNECT JUMPER
WIRE I N SERIES W I T H
3 A M P FUSE BETWEEN
BATTERY VOLTAGE AND
I G N I T I O N FEED PIN T E R M I N A L
CONNECT ONE
TESTER L E A D
TO FUEL
GAUGE S E N D I N G
U N I T PIN
TERMINAL AND
OTHER LEAD
TO G R O U N D
STOP
(OK
GAUGE I N D I C A T I O N S A C C U R A T E
A T EACH O H M S E T T I N G
REPLACE SENDING
U N I T WIRE
GAUGE I N D I C A T I O N S
A C C U R A T E A T EACH
O H M SETTING
(Of
ALL READINGS
- H I G H OR A L L
R E A D I N G S LOW
GAUGE I N D I C A T I O N S
NOT A C C U R A T E A T EACH
OHM SETTING
OK
GAUGE
INDICATIONS
N O T ACCURATE
A T EACH O H M
SETTING
SOME R E A D I N G S
H I G H OR LOW,
"SOME
ACCURATE
STOP
REPLACE GAUGE
8 0 3 1 1 H
1L-16
Chart 1
RESULT
SEQUENCE
STEP
REPLACE
CIRCUIT
BOARD
OHMMETER
CONNECT O H M M E T E R LEADS TO GAUGE
INPUT T E R M I N A L A N D GAUGE SENDER T E R M I N A L
COMPARE O H M M E T E R
R E A D I N G W I T H V A L U E S LISTED
IN GAUGE RESISTANCE V A L U E S C H A R T
GAUGE
RESISTANCE
CORRECT
GAUGE
RESISTANCE
INCORRECT
REPLACE
CVR
REPLACE
GAUGE
80311J
1L-17
Chart 2
STEP
RESULT
SEQUENCE
OK
CONNECT
SHORT
CHECKER
J-8681
SHORT NOT
INDICATED
SHORT
INDICATED
CHECK FOR
INTERMITTENT SHORT
STOP!
R E D I G N I T I O N FEED T O GAUGES
REPAIR AS
NECESSARY
T R A N S M I S S I O N KICKDOWN CIRCUIT
DISCONNECT A U T O M A T I C
T R A N S M I S S I O N KICKDOWN
SWITCH
SHORT
INDICATED
SHORT NOT
INDICATED
REMOVE
INSTRUMENT
CLUSTER
REPLACE
KICKDOWN
SWITCH
DISCONNECT I N S T R U M E N T
WIRE HARNESS CONNECTOR
FROM P R I N T E D C I R C U I T
(CHEROKEE, WAGONEER, TRUCK)
OR FROM GAUGES (CJ)
OK
CONNECT
BATTERY
NEGATIVE
CABLE
SHORT
INDICATED
-ORT MOT
INDICATED
CHEROKEE
. WAGONEER .
TRUCK
CJ
1L-18
Chart 2
SEQUENCE
;TEP
RESULT
CHECK W I R I N G W I T H SHORT
CHECKER TO F I N D SHORT
REPLACE SHORTED
WIRE HARNESS
CHECK C I R C U I T BOARD
FOR OBVIOUS D A M A G E
OK
C I R C U I T BOARD
NOT D A M A G E D
REPLACE CVR
C I R C U I T BOARD
DAMAGED
D E T E R M I N E CAUSE OF
D A M A G E : CVR OR
GAUGE F A U L T Y
REPLACE C I R C U I T
BOARD A N D
F A U L T Y COMPONENT
CHECK I N S T R U M E N T CLUSTER
A N D I N D I V I D U A L GAUGES FOR
OBVIOUS D A M A G E
OK
DAMAGE
NOT E V I D E N T
h0
DAMAGE
EVIDENT
REPLACE CVR
(A
REPLACE
DAMAGED
COMPONENT
1L-19
fflaot
IL"
AND TRUCK)
STEP
RESULT
SEQUENCE
CONNECT V O L T M E T E R TO
I N P U T SIDE O F 3 - A M P G A U G E
FUSE A N D TO G R O U N D
WRITE DOWN
VOLTMETE R
INDICATION
CONNECT VOLTMETER
TO IGNITION FEED WIRE
FEMALE CONNECTOR
IN I N S T R U M E N T W I R E
HARNESS CONNECTOR
AND TO GOOD GROUND
^
if
//
CONNECT
,i B A T T E R Y
NEGATIVE
CABLE
VOLTMETER
INDICATION
DIFFERENT
FROM STEP 1
VOLTMETER
INDICATION
SAME AS
STEP 1
CHEROKEE
WAGONEER
TRUCK
DISCONNECT
INSTRUMENT
WIRE HARNESS
CONNECTOR
CJ
REPAIR OR REPLACE
INSTRUMENT PANEL
WIRE HARNESS
STOP
C H E C K G A U G E N U T S FOR
A N D CORROSION
REPLACE, T I G H T E N
OR C L E A N AS R E Q U I R E D
CONNECT JUMPER
WIRES A N D VOLTMETER
I VOLTMETER
INDICATION
S A M E AS
STEP 1
VOLTMETER
INDICATION
DIFFERENT
F R O M STEP 1
80313A
1L-20
Chart 3
RESULT
SEQUENCE
STEP
(INTEGRAL WITH
TEMPERATURE
GAUGE)
CHECK R A D I O NOISE
SUPPRESSOR OR
CONNECTOR STRIP
FOR PROPER
ATTACHMENT
USING SAME
TEST SET-UP
AS STEP 4
MOVE VOLTMETER
CONNECTOR FROM
CVR T E R M I N A L
T O R A D I O NOISE SUPPRESSOR
OR CONNECTOR STRIP
OUTPUT T E R M I N A L
VOLTMETER
INDICATION
SAME AS
STEP 1
VOLTMETER
INDICATION
DIFFERENT
FROM
STEP 1
REPLACE
CVR
(INTEGRAL WITH
F U E L GAUGE)
REPLACE
CIRCUIT
BOARD
REPLACE
R A D I O NOISE
SUPPRESSOR
OR CONNECTOR
STRIP
8 0 3 1 3 B
Chart 4
P R O B L E M : OIL P R E S S U R E GAUGE
NOT FUNCTIONING PROPERLY (CJ)
STEP
SEQUENCE
NOTE POSITION
O I L GAUGE N E E D L E
1L-21
RESULT
S T A R T ENGINE
OBSERVE NEEDLE
NEEDLE DOES
NOT M O V E
NEEDLE
MOVES
BEFORE S T A R T I N G TEST.
OIL PAN MUST BE
F I L L E D TO SPECIFICATION
<3>
FUEL T A N K MUST BE
N E I T H E R COMPLETELY F U L L
NOR COMPLETELY EMPTY
NEEDLE MOVES
TO M A X I M U M
A N D STAYS
OBSERVE
FUEL
GAUGE
FUEL GAUGE
NEEDLE DOES
NOT MOVE
6
FUEL GAUGE
NEEDLE
INDICATES
PROPERLY
(A
FUSE N O T BLOWN
I STOP
LOCATE A N D REPAIR
FAULT IN IGNITION
FEED T O INSTRUMENTS
80314A
1L-22
Chart 4
SEQUENCE
STEP
REMOVE O I L G A U G E
L E A V E GAUGE WIRES
CONNECTED
RESULT
TURN
IGNITION
ON
CONNECT JUMPER
WIRE; F R O M G A U G E
G R O U N D S T U D TO
GOOD B O D Y G R O U N D
VOLTAGE
NOT PRESENT
[STOP
LOCATE A N D REPAIR
F A U L T IN I G N I T I O N
FEED T O O I L GAUGE
VOLTAGE
PRESENT
OK
[STOP
N E E D L E MOVES
LOCATE A N D
REPAIR OPEN
IN SENDER
CIRCUIT
'STOP
N E E D L E DOES
NOT M O V E
(6m
BROKEN
MISSING
CORRODED
SCREW LOOSE, MISSING
GROUND
NOT OK
(OKH
G R O U N D OK
80314B
STEP
1L-23
Chart 4
RESULT
SEQUENCE
REPAIR
GROUND
STOP
NEEDLE
REMAINS
AT MAXIMUM
START
ENGINE
DISCONNECT
SENDING U N I T
"WIRE
NEEDLE DROPS
FROM M A X I M U M
m
NEEDLE R E M A I N S
AT MAXIMUM
REPLACE GAUGE
STOP
GAUGE I N D I C A T I O N S
ACCURATE
A T EACH O H M SETTING
REPLACE
SENDING U N I T
STOP
80314C
1L-24
hart 4
STEP
SEQUENCE
RESULT
NEEDLE
REMAINS
AT MAXIMUM
GAUGE I N D I C A T I O N S
NOT ACCURATE A T EACH
O H M SETTING
GAUGE I N D I C A T I O N S
ACCURATE A T
EACH OHM SETTING
REPLACE
SENDING
UNIT
80314D
STEP
1L-25
Chart 4
RESULT
SEQUENCE
CHECK
TERMINAL
STUDS FOR
CORROSION
CONNECT
BATTERY
NEGATIVE
CABLE
CONNECT JUMPER WIRE
FROM G A U G E
GROUND STUD
TO BODY GROUND
CONNECT ONE
TESTER L E A D
TO OIL
GAUGE SENDING
UNITS-TERMINAL
STUD AND
OTHER L E A D
TO GROUND
G A U G E INDICATIONS
NOT OBTAINED
l
A T E A C H OHM S E T T I N G ^
OKJ
G A U G E INDICATIONS
ACCURATE
A T EACH OHM SETTING
lOm
^
G A U G E INDICATIONS
NOT A C C U R A T E A T
EACH OHM SETTING
# i
'
V l
. REPLACE
GAUGE
REPLACE
GAUGE
80314E
1L-26
Chart 5
STEP
SMOTE POSITION OF
OIL GAUGE NEEDLE
m S T A R T ENGINE A N D
W A I T 2 M I N U T E S FOR
GAUGE TO W A R M UP
RESULT
m OBSERVE NEEDLE
NEEDLE DOES
NOT M O V E
NEEDLE
MOVES
BEFORE S T A R T I N G TEST:
3 >
FUEL T A N K MUST BE
N E I T H E R COMPLETELY F U L L
NOR COMPLETELY EMPTY
NEEDLE M O V E S
TO M A X I M U M
A N D STAYS
NEEDLE PULSATES
MORE T H A N W I D T H
OF N E E D L E
GOTO
- CHART 2
STEP 1
GO TO
CHART 3
STEP 1
OBSERVE
FUEL
GAUGE
80315A
STEP
Chart 5
RESULT
SEQUENCE
VOLTAGE
NOT PRESENT
CHECK
GAUGE
NUTS
FOR LOOSENESS
A N D CORROSION
U-27
--lizzzzz~:::\;
STOP
REPLACE
C I R C U I T BOARD
OK
V O L T A G E PRESENT
6
GROUND
SENDER
TERMINAL
OF GAUGE
NEEDLE DOES
NOT M O V E
STOP
REPAIR OPEN
CIRCUIT IN
SENDER WIRE
[STOP
I GROUND
GAUGE PIN T E R M I N A L
ON C I R C U I T BOARD
(6G
CHECK
G R O U N D STRAP
GROUND
NOT OK
BROKEN
MISSING
CORRODED
SCREWS LOOSE, MISSING
OK
G R O U N D OK
N E E D L E DROPS
FROM M A X I M U M
STOP
REPAIR
GROUND
NEEDLE REMAINS
AT M A X I M U M
80315B
1L-28
Chart 5
SEQUENCE
STEP
DISCONNECT
.SENDING U N I T
WIRE F R O M
SENDING U N I T
RESULT
N E E D L E DROPS
FROM M A X I M U M
NEEDLE REMAINS
AT MAXIMUM
GAUGE I N D I C A T I O N S
NOT A C C U R A T E
AT EACH O H M SETTING
(OK
GAUGE I N D I C A T I O N S
A C C U R A T E AT
EACH O H M SETTING
REPLACE
SENDING U N I T
lj
FUEL
GAUGE
NEEDLE
INDICATES
NORMALLY
STOP
80315C
STEP
1L-29
Chart 5
RESULT
SEQUENCE
REMOVE I N S T R U M E N T
CLUSTER. DO NOT
DISCONNECT WIRE
HARNESS
DISCONNECT
BATTERY
N E G A T I V E CABLE
NEEDLE DROPS
FROM M A X I M U M
CONNECT JUMPER
| WIRE BETWEEN
(CLUSTER G R O U N D
A N D BODY
NEEDLE
REMAINS A T
MAXIMUM
CONNECT BATTERY
N E G A T I V E CABLE
REPAIR I N S T R U M E N T
PANEL G R O U N D
I DISCONNECT SENDING
i U N I T WIRE F R O M CLUSTER
NEEDLE DROPS
FROM M A X I M U M
REPAIR OR REPLACE
S E N D I N G U N I T WIRE
NEEDLE REMAINS
AT M A X I M U M
REPLACE C I R C U I T
BOARD
DISCONNECT
SENDING
U N I T WIRE
T U R N I G N I T I O N ON
ADJUST TESTER TO
SELECT O H M V A L U E S
LISTED I N SENDING
U N I T RESISTANCE
R E Q U I R E M E N T S CHART.
OBSERVE FUEL
GAUGE I N D I C A T I O N A T
EACH O H M SETTING.
GAUGE I N D I C A T I O N S
NOT ACCURATE A T
EACH O H M SETTING
GAUGE I N D I C A T I O N S
ACCURATE A T EACH
OHM SETTING
# ^
I O K J
'
REPLACE
SENDING
UNIT
80315D
1L-30
STEP
Charts
RESULT
SEQUENCE
DISCONNECT
BATTERY
N E G A T I V E CABLE
REMOVE I N S T R U M E N T CLUSTER
A N D DISCONNECT
I N S T R U M E N T WIRE HARNESS
CONNECT JUMPER
W I R E I N SERIES W I T H
3 AMP FUSE BETWEEN
BATTERY VOLTAGE A N D
I G N I T I O N FEED PIN T E R M I N A L
CONNECT ONE
TESTER L E A D
TO OIL
GAUGE SENDING
U N I T PIN
TERMINAL AND
OTHER L E A D
TO G R O U N D
OK
GAUGE I N D I C A T I O N S ACCURATE
A T EACH O H M SETTING
REPLACE SENDING
U N I T WIRE
REPEAT TEST W I T H L E A D
J
M O V E D FROM PIN T E R M I N A L J_
TO GAUGE S- T E R M I N A L
GAUGE I N D I C A T I O N S
A C C U R A T E A T EACH
O H M SETTING
GAUGE I N D I C A T I O N S
NOT O B T A I N E D
A T EACH O H M SETTING
A L L READINGS
- H I G H OR A L L
READINGS LOW
GAUGE I N D I C A T I O N S
NOT ACCURATE A T EACH
O H M SETTING
GAUGE
INDICATIONS
NOT ACCURATE
A T EACH O H M
SETTING
SOME READINGS
H I G H OR LOW,
"SOME
ACCURATE
REPLACE GAUGE
80315E
Chart 5
SEQUENCE
HEP
RESULT
REPLACE
GAUGE
OHMMETER
CONNECT O H M M E T E R L E A D S TO G A U G E
INPUT T E R M I N A L A N D G A U G E SENDER T E R M I N A L
COMPARE O H M M E T E R
READING WITH V A L U E S LISTED
m G A U G E RESISTANCE V A L U E S C H A R T
OK
GAUGE
RESISTANCE
CORRECT
GAUGE
RESISTANCE
INCORRECT
REPLACE
CVR
REPLACE
GAUGE
80315F
1 L-3
Chart 6
P R O B L E M : T E M P E R A T U R E GAUGE
NOT FUNCTIONING PROPERLY
SEI
STEP
O NOTE POSITION OF
T E M P E R A T U R E GAUGE
NEEDLE
) T U R N I G N I T I O N ON A N D
W A I T 2 M I N U T E S FOR
G A U G E T O W A R M UP
RESULT
OBSERVE N E E D L E
NEEDLE DOES
NOT M O V E
NEEDLE
MOVES
BEFORE S T A R T I N G TEST:
j x
r
W
w
>
'
ENGINE MUST BE W A R M
NEEDLE M O V E S
TO M A X I M U M
AND STAYS
FUEL T A N K MUST BE
N E I T H E R COMPLETELY F U L L
NOR COMPLETELY EMPTY
NEEDLE PULSATES
MORE T H A N W I D T H
OF N E E D L E
REPLACE
CVR
GO TO
- CHART 2
STEP 1
CHECK 3-AMP FUSE
A T FUSE PANEL
FUSE BLOWN
ikr. j
GO TO
CHART 3
STEP 1
FUEL GAUGE N E E D L E
DOES NOT M O V E
# OBSERVE
FUEL GAUGE
CJ
" MODELS"
STEP
SEQUENCE
Chart 6
RESULT
80316B
1L-34
STEP
SEQUENCE
WIRE F R O M S E N D I N G U N I T
AT M A X I M U M
Chart 6
RESULT
1L-35
Chart 6
STEP
SEQUENCE
iULT
CONNECT ONE TESTER
LEAD TO GROUND
A N D ONE L E A D
TO S E N D I N G
U N I T WIRE
T U R N I G N I T I O N ON
ADJUST TESTER T O
SELECT O H M V A L U E S
LISTED I N S E N D I N G
U N I T RESISTANCE
REQUIREMENTS CHART.
OBSERVE G A U G E
INDICATION A T '
EACH O H M S E T T I N G .
GAUGE INDICATIONS
NOT ACCURATE
A T EACH O H M S E T T I N G
GAUGE INDICATIONS
ACCURATE A T
EACH O H M SETTING
OBSERVE F U E L GAUGE
(1)
1L-36
Chart 6
RESULT
SEQUENCE
STEP
REPAIR I N S T R U M E N T
PANEL G R O U N D
DISCONNECT
SENDING U N I T W I R E
FROM CLUSTER
N E E D L E DROPS
FROM M A X I M U M
REPAIR OR REPLACE
SENDING U N I T W I R E
NEEDLE R E M A I N S
AT MAXIMUM
REPLACE C I R C U I T BOARD
(CHEROKEE, WAGONEER,
TRUCK)
T U R N I G N I T I O N ON
m ADJUST TESTER T O
SELECT O H M V A L U E S
LISTED IN SENDING
U N I T RESISTANCE
REQUIREMENTS C H A R T .
OBSERVE G A U G E
INDICATION AT
EACH OHM S E T T I N G .
CHEROKEE
WAGONEERTRUCK
GAUGE I N D I C A T I O N S
N O T ACCURATE A T
EACH O H M SETTING
OK
GAUGE I N D I C A T I O N S
ACCURATE A T EACH
O H M SETTING
REPLACE
SENDING
UNIT
80316E
1L-37
Chart 6
STEP
SEQUENCE
RESULT
R E M O V E I N S T R U M E N T CLUSTER
A N D DISCONNECT
INSTRUMENT WIRES
DISCONNECT
BATTERY
NEGATIVE CABLE
CHECK G A U G E NUTS
FOR C O R R O S I O N . REPLACE
F NECESSARY A N D
TIGHTEN
CONNECT JUMPER
WIRE I N SERIES
W I T H 3 AMP
FUSE BETWEEN
BATTERY
VOLTAGE
A N D F U E L GAUGE
1-TERMINAL
CONNECT
BATTERY
NEGATIVE
CABLE
CONNECT
JUMPER
WIRE F R O M
CLUSTER
CASE TO
GROUND
C O N N E C T ONE
TESTER L E A D
TO TEMPERATURE
GAUGE SENDING
UNIT
TERMINAL AND
OTHER LEAD
TO GROUND
GAUGE I N D I C A T I O N S
ACCURATE
A T EACH O H M S E T T I N G
REPLACE SENDING
U N I T WIRE
GAUGE I N D I C A T I O N S
NOT OBTAINED
A T EACH O H M S E T T I N G
ALL READINGS
- H I G H OR A L L
READINGS LOW
GAUGE I N D I C A T I O N S
NOT A C C U R A T E A T EACH
OHM SETTING
SOME R E A D I N G S
. H I G H OR LOW,
SOME
ACCURATE
REPLACE
GAUGE
80316F
1L-38
Chart 6
RESULT
SEQUENCE
STEP
R E M O V E I N S T R U M E N T CLUSTER
A N D DISCONNECT
I N S T R U M E N T WIRE HARNESS
DISCONNECT
BATTERY
N E G A T I V E CABLE
CHECK GAUGE N U T S
FOR CORROSION. REPLACE
IF NECESSARY A N D
TIGHTEN
CONNECT JUMPER
WIRE I N SERIES W I T H
3 A M P FUSE BETWEEN
BATTERY VOLTAGE A N D
I G N I T I O N FEED PIN T E R M I N A L
CONNECT JUMPER W I R E
F R O M CLUSTER CASE TO
GROUND
CONNECT ONE
TESTER LEAD TO
TEMPERATURE
GAUGE SENDING
U N I T PIN T E R M I N A L
A N D OTHER LEAD
TO G R O U N D
G A U G E I N D I C A T I O N S ACCURATE
A T EACH O H M S E T T I N G
'STOP
OK
OK
REPLACE SENDING
UNIT WIRE
REPEAT TEST W I T H L E A D
M O V E D FROM PIN T E R M I N A L
TO GAUGE S- T E R M I N A L
GAUGE I N D I C A T I O N S
A C C U R A T E A T EACH
OHM SETTING
GAUGE INDICATIONS
NOT OBTAINED
A T EACH O H M SETTING
A L L READINGS
- H I G H OR A L L
READINGS LOW
GAUGE INDICATIONS
N O T A C C U R A T E A T EACH
OHM SETTING
GAUGE
INDICATIONS
NOT ACCURATE
A T EACH O H M
SETTING
SOME R E A D I N G S
H I G H OR LOW,
'SOME
ACCURATE
[STOP
REPLACE GAUGE
80316G
Chart 6
RESULT
SEQUENCE
STEP
1L-39
-STOP
REPLACE
GAUGE
OHMMETER
CONNECT O H M M E T E R L E A D S TO G A U G E
INPUT T E R M I N A L A N D G A U G E SENDER T E R M I N A L
COMPARE O H M M E T E R
R E A D I N G W I T H V A L U E S LISTED
IN G A U G E RESISTANCE V A L U E S C H A R T
OK
GAUGE
RESISTANCE
CORRECT
GAUGE
RESISTANCE
INCORRECT
REPLACE
CVR
REPLACE
GAUGE
80316H
1L-40
CIRCUITS A N D
SCHEMATICS
Pap
Cherokee
CJ
Truck
Wagoneer
Pip
1L-44
1L-41
1L-44
11-44
SpecificationsCherokee
SpecificationsCJ
SpecificationsTruck
SpecificationsWagoneer
1L-43
11-40
1L-43
1L-43
SPECIFICATIONSCJ MODELS
Fuel Gauge Sending Unit Resistance (Ohms)
E'
1/2
73
23
10
BEGINNING
OF B A N D
END
OF B A N D
73
36
13
80670
80674
OHMS
S to Ground
68 to 72
S to I
19 to 21
S to A
19 to 21
ZERO
to A
I to Ground
49 to 51
A to Ground
49 to 51
ACTUAL
INDICATED
500
380 to 620
1500
1380 to 1620
4500
4330 to 4620
80671
80675
20
40
60
80
OHMS
234-246
149-157
100.5-105.5
65-69
32.5-34.5
80672
INDICATED
12.4
11.7 to 12.3
14.4
13.8 to 14 2
19 t o
21
ohms
NOTE: Indicated Readings are Observed f r o m Drivers Seat
80673
80676
O I L PRESSURE
GAUGE
VOLTMETER
FUEL GAUGE
(BUILT-IN CVR)
TACHOMETER
LAMPS
T E R M I N A L STUDS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
TEMPERATURE
GAUGE
1L-41
A
B
C
D
E
F
O I L GAUGE S - T E R M I N A L
O I L GAUGE l - T E R M I N A L
O I L GAUGE G R O U N D
VOLTMETER +-TERMINAL
VOLTMETER GROUND
F U E L GAUGE S-TERMINAL
F U E L GAUGE A - T E R M I N A L
FUEL GAUGE l - T E R M I N A L
T E M P E R A T U R E GAUGE S-TERMINAL
T E M P E R A T U R E GAUGE A - T E R M I N A L
ILLUMINATION
H I G H BEAM
RIGHT TURN
EMERGENCY D R I V E
BRAKE
LEFT T U R N
OTHER
T1 T A C H O M E T E R LEAD
T 2 T A C H O M E T E R LEAD
80125
Instrument ClusterCJ
Tachometer CircuitCJ
1L-42
O I L PRESSURE
GAUGE
3 AMP
FUSE
IGNITION
SWITCH
RED
DASH
CONNECTOR
STARTER
SOLENOID
SPLICE
RED
-PINK
FUEL GAUGE
SENDING U N I T
OIL PRESSURE
SENDING U N I T
8 0 2 8 7
8 0 2 8 8
TEMPERATURE
GAUGE
VOLTMETER
CVR INSIDE
FUEL GAUGE
YELLOW-
SPLICE
"P"
-REDIGNITION
SWITCH
DASH
CONNECTOR
12
STARTER
SOLENOID
SPLICE
-RED-
T E M P E R A T U R E GAUGE
SENDING U N I T
8 0 2 9 0
8 0 2 8 9
Voltmeter CircuitCJ
Ammeter Calibrations
ACTUAL
INDICATED
-60
-48 to -72
0 Needle Width
0
+60
+48 to +72
80677
1/2
73
23
10
80670
19 t o 21
ohms
80673
10
60
80
OHMS
69-77
35-38
13-15
9.5-10.5
80678
BEGINNING
OF BAND
END
OF BAND
73
36
13
9
80674
OHMS
S to Ground
68 to 72
S to I
19 to 21
S to A
19 t o 21
to A
ZERO
I to Ground
49 to 51
A to Ground
49 to 51
80671
1L-43
1L-44
PIN T E R M I N A L S
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
EMERGENCY D R I V E
NOT USED
OIL GAUGE
GROUND
ILLUMINATION
H I G H BEAM
FUEL GAUGE
BRAKE
FASTEN BELTS
T E M P E R A T U R E GAUGE
IGNITION
LEFT T U R N
RIGHT TURN
I G N I T I O N FEED SIDE
OF R A D I O SUPPRESSION
15. R A D I O SUPPRESSION TO CVR
NOT USED
ILLUMINATION
HIGH BEAM
FUEL GAUGE
LAMPS
A
B
C
D
E
F
G
H
LEFT TURN
ILLUMINATION
R I G H T T U R N INDICATOR
LEFT T U R N INDICATOR
BRAKE I N D I C A T O R
EMERGENCY D R I V E I N D I C A T O R
FASTEN BELT I N D I C A T O R
NOT USED
H I G H BEAM I N D I C A T O R
RIGHT TURN
IGNITION FEED
SIDE OF RADIO
SUPPRESSION
OTHER
RADIO
SUPPRESSION
TO CVR
AMMETER
M2
A1
51
A2
52
A3
53
I
80127
O I L GAUGE A T E R M I N A L
OIL GAUGE S T E R M I N A L
FUEL GAUGE A T E R M I N A L
FUEL GAUGE S T E R M I N A L
T E M P E R A T U R E GAUGE A T E R M I N A L
T E M P E R A T U R E GAUGE S T E R M I N A L
CVR I T E R M I N A L (CVR INSIDE
T E M P E R A T U R E GAUGE)
M1 A M M E T E R STUD
M 2 A M M E T E R STUD
GR G R O U N D SCREW
80126
-?AR
-~zz7sr-\
"
WI
P R I N T E D CIRCUIT
AMMETER
rum
-YELLOW-
FUEL
GAUGE
CVR
RED
DASH
CONNECTOR
55
SPLICE " B " TO
A L L VEHICLE
CIRCUITS
5
O
AMP
FUSE
z
E
mJ
-YELLOW-
UJ
DASH
CONNECTOR
SPLICE
ALTERNATOR
STARTER
SOLENOID
55
10
SPLICE
*-
-YELLOW
FRAME
HARNESS
CONNECTOR
-PINK
))
t^AA^r"
FUEL G A U G E
SENDING U N I T
80293
80291
A m m e t e r Circuit
Cherokee-Wagoneer-Truck Models
PRINTED CIRCUIT
PRINTED CIRCUIT
AMMETER
~\J\J1
YELLOW
2*x
AMMETER
TEMPERATURE
GAUGE
CVR
SPLICE
"C"
IGNITION
SWITCH
RED
W/T "
fi>
IGNITION
SWITCH
RED
//
UJ
A.
YELLOW-
D
CL
DASH
CONNECTOR
L^-RE
J %'
RED
SPLICE
"B"
STARTER
SOLENOID
55
-YELLOW
SPLICE
4k
7*r
STARTER
SOLENOID
SPLICE
*
-YELLOW
YELLOW
L-PURPLE W/T-
PURPLESENDING U N I T
YELLOW
$> \/\y$\/
SENDING U N I T
80294
80292
Tools
J-24538
FUEL A N D T E M P E R A T U R E
GAUGE TESTER
Navigation Tools: Click on the "Chapter" below, or use the Bookmarks to the left.
SECTION 2
Clutch
Manual Transmission
2B
Automatic Transmission | | | | |
Transfer Case ' 2 D
CHAPTER
Propeller Shaft
2E
Axles
2F
^ Brakes
2G
2H
Steering Columns
Manual Steering Gear
El
ES
2L
Steering Linkage
2M
Suspension
ZA-1
CLUTC
SECTION INDEX
Page
General Information
ZA-1
Clutch Service
ZA-8
Page
2A-6
2A-1
2A-1
GENERAL INFORMATION
Page
Clutch Adjustments
Clutch Component Service
Clutch Linkage
2A-6
2A-8
2A-6
GENERAL
The clutch assembly used in Jeep vehicles consists of a
single dry-disc driven plate and a spring and lever-type
clutch cover (fig. 2A-1).
Two clutch cover styles are used. A 10.5 inch (26.7 cm)
diameter direct spring pressure cover is used in CJ models with six- or eight-cylinder engines. An 11.0 inch (27.9
cm) diameter semi-centrifugal cover is used on Cherokee
and Truck models with eight-cylinder engine. Cherokee
and Truck models with six-cylinder engine use an 11.0
inch (27.9 cm) direct spring pressure cover.
The two clutch covers are similar in appearance and
construction consisting of a pressure plate, release levers, lever pivots, apply springs, and outer cover.
Both covers apply spring pressure directly against the
pressure plate to maintain engagement. However, the
semi-centrifugal cover also utilizes six rollers, located
between the pressure plate and cover, to exert additional
apply force at higher engine speeds. At these speeds,
centrifugal force moves the rollers outward wedging
them between the cover and pressure plate to increase
apply force.
The driven plate consists of a steel hub with integral
cushion springs and clutch friction material which is
riveted to the hub (fig. 2A-1). The function of the cushion springs is to absorb excessive torque loads and provide smoother clutch engagement.
The clutch release mechanism consists of a throwout
bearing located on the transmission front bearing cap
and a forked lever mounted on a ball and pivot installed
in the clutch housing. A spring, attached to the lever and
anchored to the ball pivot, is used to maintain lever-topivot ball contact.
SERVICE DIAGNOSIS
Clutch Chatter
Clutch chatter can be described as a shaking or shuddering sensation felt throughout the vehicle. Chatter
2A-2 CLUTCH
CRANKSHAFT
SPRING
RETAINER
(CKE, T R K . O N L Y )
Fig. 2A-1
CJ
CHEROKEE - TRUCK
80117
Fig. 2A-2
90031
Clutch Assembly
CLUTCH
2A-3
2A-4
CLUTCH
(2) Shift transmission into neutral but do not release clutch pedal.
(3) Wait 5 to 10 seconds and shift transmission into
reverse. If shift is smooth with no gear clash, clutch
operation is normal. If shifting into reverse produces
gear clash, proceed to next step.
(4) Raise vehicle on hoist. Check clutch linkage for
binding, worn, broken or bent components. Lubricate or
replace as necessary. If components are in good operating condition, proceed to next step. If one or more
problems were discovered and repaired, lower vehicle
and repeat steps (1) through (3). If clutch now operates
correctly, stop repair. If clutch drag persists, proceed to
next step.
(5) Remove transmission and clutch components.
Refer to Clutch Removal.
N O T E : Whenever the transmission is removed, also
remove the pilot bushing lubricating wick, soak the wick
in engine oil, and reinstall the wick before assembly.
(6) Observe wear pattern on driven plate. If wear
pattern is uneven (e.g., two areas heavily worn on one
side, two only partially wrrn on opposite side), or has
opposing wear patterns on front and reverse side, the
driven plate is warped and should be replaced.
(7) Inspect clutch cover assembly. If clutch cover
assembly has worn, bent, or broken release levers or
lever pivots, is heavily scored, or warped, replace clutch
cover assembly. If cover assembly does not exhibit any
of these conditions, do not replace it.
(a) Clean oil and dirt from clutch cover with
solvent and allow cover to air dry.
(b) Sand pressure plate surface lightly using
fine emery cloth.
(c) Lubricate cover release lever pivots with
chassis grease.
(12) Apply thin film of chassis grease to transmission clutch shaft splines. Do not apply grease to shaft
pilot hub.
(13) Install pilot bushing and lubricating wick.
(14) Install clutch components and transmission. Refer to Clutch Installation.
(15) Lower vehicle.
(9) Inspect crankshaft pilot bushing for heavy scoring, angular wear pattern, or discoloration. Replace as
necessary. Be sure to soak bushing in engine oil before
installation.
CLUTCH
2A-5
the
21-8
CLUTCH
Oiyfeli Noises
CLUTCH ADJUSTMENTS
There are two clutch adjustments required: clutch
pedal free play and clutch cover release lever height.
Clutch pedal free-play should be checked and adjusted
at the intervals specified in the Mechanical Maintainence Schedule, Chapter B, or whenever diagnosis indicates adjustment is needed. Refer to Clutch Pedal Free
Play Adjustment in this section.
Clutch cover release lever height should be checked
and adjusted whenever the cover is removed or replaced
during service operations, or whenever diagnosis indicates adjustment is needed. Refer to the Clutch Service section in this chapter.
CLUTCH PEDAL FREE PLAY ADJUSTMENT
Shift
CLUTCH LINKAGE
The suspended-type clutch pedal is connected to the
throwout lever through the clutch push rod, bellcrank
outer and inner levers, and release rod (fig. 2A-3 and fig.
2A-4). The throwout bearing is mounted on the transmission front bearing cap and acts directly against the
clutch cover release levers to engage and disengage the
clutch. The bearing is actuated by a throwout lever
mounted in the clutch housing. The lever pivots on a
steel ball mounted inside the clutch housing.
The bellcrank pivots on ball studs mounted in the
inner and outer support brackets (fig. 2A-3 and fig. 2A4). Idler bushings, installed in each end of the bellcrank
provide bearing surfaces for the ball studs.
CLUTCH
2A-7
CLUTCH
PUSH
ROD
PEDAL SHAFT
BEARINGS
RETURN
SPRING
OVERCENTER
SPRING
THROWOUT
LEVER
PROTECTIVE
BOOT
OUTER
SUPPORT
BRACKET
Fig. 2A-3
PEDAL
SHAFT
60566
BUSHING
\
\
PEDAL
SHAFT
^
INNER
SUPPORT
BRACKET
WAVE
WASHER
OUTER
SUPPORT
BRACKET
Fig. 21-4
SPRING'
8 0 1 1 6
2A-8
CLUTCH
Page
Clutch Cover Release Lever Adjustment
Clutch Housing Alignment
Clutch Inspection and Service
Clutch Installation
Clutch Pedal Overcenter Spring ReplacementCJ
2A-11
2A-10
2A-9
2A-8
2A-12
CLUTCH REMOVAL
(1) Remove transmission as outlined in Chapter 2B.
(2) Remove starter motor.
(3) Remove throwout bearing.
(4) Remove clutch housing.
(5) Mark position of clutch cover on flywheel for
assembly alignment reference.
(6) Loosen clutch cover attaching bolts one or two
turns at a time and in rotation to relieve spring tension
on cover.
CAUTION: The clutch cover bolts must be loosened
evenly and in rotation to avoid cover distortion. The
cover is a steel stamping and could be warped if improperly removed resulting in clutch chatter when installed.
(7) Remove clutch cover bolts and remove cover and
driven plate from flywheel.
NOTE: Observe which side of the driven plate faces the
flywheel before removing the plate. Paint or chalk alignment marks on the plate for assembly reference.
(8) Remove pilot bushing lubricating wick and soak
wick in engine oil.
(9) Inspect and service clutch components as outlined under Clutch Component Inspection.
, ..
Page
Clutch Pedal and Overcenter Spring Replacement- -Cherokee-Truck
Clutch Removal
Specifications
2A-13
2A-8
2A-14
2A-15
(3) Insert Clutch Alignment Tool J-22056 (Cherokee-Truck), or Alignment Tool J-25353 (CJ), or spare
clutch shaft in driven plate hub and mount assembled
plate and tool on flywheel. Be sure tool is fully seated in
pilot bushing.
CAUTION: Be sure the correct side of the driven plate
faces the flywheel. Refer to the reference marks placed
on the driven plate during clutch removal.
(4) Position clutch cover on . flywheel and over
driven plate and alignment tool. Align cover and flywheel according to reference marks made during clutch
removal and install cover attaching bolts finger tight
only.
(5) Tighten cover attaching bolts alternately and
evenly to 40 foot-pounds (54 Nm) torque. Be sure to
maintain cover-to-plate alignment while tightening
bolts.
CAUTION: The cover attaching bolts must be tightened alternately and evenly to avoid distorting the
cover.
(6) Install clutch housing and tighten housing attaching bolts to specified torque. Refer to Specifications.
(7) Install starter motor.
(8) Install throwout bearing (fig. 2A-2). On Cherokee and Truck models, be sure wave washer is installed
on throwout lever. On CJ models, be sure bearing tension springs are engaged in throwout lever.
(9) Install transmission as outlined in Chapter 2B.
CLUTCH 2A-9
CLUTCH INSPECTION AND SERVICE
Driven Plate
Inspect the friction material for excessive wear, or
charred, cracked, broken or loose friction material.
Check the driven plate steel hub and cushion springs for
distortion, cracks, or breakage. Replace the driven plate
if it exhibits any of these conditions.
N O T E : Do not replace the driven plate if the cushion
springs only appear loose. This is a normal condition
when the plate is removed from the vehicle and the
springs are not under load.
Clutch Cover
Inspect the cover for cracks, distortion, broken or
collapsed apply springs and for broken, bent, loose, or
excessively worn release levers. Inspect the pressure
plate surface for deep scores, cracks, heat checking or
discoloration, and for evidence of warping (use a
straightedge to check pressure plate surface flatness).
Replace the cover as an assembly if it exhibits any of
these conditions.
N O T E : The centrifugal rollers in the clutch cover may
rattle when the cover is removed and not under load. Do
not replace the cover if this occurs, it is a normal
condition.
Throwout Bearing
Two throwout bearings are used on Jeep vehicles. On
Cherokee-Truck models, a spring-type wave washer is
used to retain the throwout lever on the bearing. On CJ
models, the bearing is retained on the lever by tension
springs.
CAUTION: The throwout bearings used on Jeep vehicles are permanently lubricated during manufacture.
Do not wash or immerse the bearings in solvent as the
bearing lubricant could be dissolved. Clean the bearing
by wiping it with shop towels.
Inspect the bearing for excessive wear and deep scoring on the release lever contact surface, looseness on the
sleeve, or discoloration which indicates overheating.
Check the sleeve bore for excessive wear or burrs which
could cause it to bind on the front bearing cap. Rotate
the bearing on the sleeve. The bearing must rotate freely
and not bind. When rotating the bearing, also listen for
grinding or grating sounds which indicate that the internal rollers are worn or damaged. On CJ models, check
the bearing tension springs for distortion or breakage.
Replace the bearing if it exhibits any of these conditions.
Flywheel
Inspect the flywheel surfaces for cracks, deep scoring,
excessive wear, heat checking, discoloration, and excessive face runout or distortion. Check face runout using a
dial indicator. Runout must not exceed 0.005 inch (0.12
mm) with the crankshaft end play held to zero. Use a
straight edge to check surface flatness. Inspect the ring
gear teeth for cracks, breakage, or excessive wear. If the
ring gear teeth are severely milled (worn), also check the
starter motor drive teeth for similar wear or damage.
Check the flywheel attaching bolt torque and tighten the
bolts to 105 foot-pounds (142 Nm) torque if necessary.
Replace the flywheel if it exhibits any of the conditions
just desribed.
2A-10 CLUTCH
CLUTCH HOUSING ALIGNMENT
Clutch housing misalignment is caused by excessive
face or bore runout of the clutch housing or housing-totransmission adapter. Misalignment will cause improper clutch release, driven plate failure, front transmission bearing failure, premature crankshaft pilot
bushing wear, and clutch noise and vibration. In severe
cases, misalignment will also cause gear jump-out on
deceleration. If these malfunctions occur, the rear face
and bore of the clutch housing or housing-to-transmission adapter must be checked for excessive runout.
Fig. 2A-6
41478
Fig. 2A-5
M o u i A | Dial
tatotor
CLUTCH 2A-11
NOTE: Any change in face alignment will also change
bore alignment. In some cases, it is possible to correct
bore alignment simply by correcting face alignment
Where it is impossible to correct bore alignment to a
maximum of 0.010 inch (0.25 mm) runout (after changing face alignment), replace the clutch housing.
2fl-7
2A-12
CLUTCH
42575
Fig. 2A-8
Fig. 2A-9
CLUTCH 2A-13
Installation
(1) Mount clutch pedal on pedal shaft if removed.
(2) Connect overcenter spring to clutch pedal and
pedal support bracket.
(3) Rotate clutch pedal on pedal shaft until pedal
stop bracket clears brake pedal.
(4) Install clutch pedal completely on pedal shaft.
Use plastic mallet to tap pedal onto shaft.
(5) Install snap ring on clutch pedal end of pedal
shaft.
(6) Position pedal support bracket assembly in
vehicle.
(7) Connect brakelight wires to brakelight switch.
(8) Align pedal support bracket with dash panel and
install support bracket lower attaching bolts to hold
bracket in position. Install bolts from inside vehicle.
(9) Align steering column mounting bracket with
pedal support bracket and install column mounting
bracket bolts finger tight only.
(10) On vehicles with power brakes:
(a) Remove wire securing power unit to grille
support rod.
(b) Position power unit bracket over pedal support bracket bolts and install nuts on bolts to hold power
unit in place.
(c) Install pedal support bracket upper attaching bolt and nut from engine compartment side of dash
panel. Tighten bolt and nut finger tight only.
(d) Remove pedal support bracket lower attaching bolts installed previously and reinstall bolts from
engine compartment side of dash panel. Tighten bolts
finger tight only.
(11) On vehicles with nonpower brakes:
(a) Install pedal support bracket attaching bolts
and nuts. Tighten bolts finger tight only.
(b) Position master cylinder on dash panel and
install cylinder attaching bolts and nuts. Tighten bolts
to 35 foot-pounds (47 Nm) torque.
(12) Connect brake pedal push rod to brake pedal.
Use replacement cotter pin only to retain pedal.
(13) Tighten pedal support bracket attaching bolts
securely.
(14) Install steering column toe plates. Tighten toe
plate screws to 12 foot-pounds (16 N*m) torque.
(15) Tighten bolts attaching steering column mounting bracket to support bracket to 20 foot-pounds (27
Nm) torque.
(16) Install steering column bezel.
(17) Install fuse panel on dash panel.
(18) Install headlamp indicator in instrument panel
and connect wires to indicator.
REPLACEMENTCHEROKEE-TRUCK
Overcenter Spring
Overcenter Spring Removal
2A-14
CLUTCH
SPECIFICATIONS
Clutch Specifications
Engine
Model
(CID)
CJ-5/CJ-7
232,258,
304
Cherokee,
Wagoneer,
Truck,
258
Clutch
Diameter
Release Lever
Pedal Free Play
Height
(Above Gauge
Hub)
3/16
(27.9 cm)
(4.7 mm)
3/8 to 5/8
(9.5to15.8mm)
360
60567
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
Metric (N-m)
USA (ft-lbs.)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
19
47
54
16-22
41-54
47-61
14
35
40
12-16
30-40
35-45
47
61
41-54
54-68
35
45
30-40
40-50
41
41
61
20
54
45
24
74
34-47
34-47
54-68
16-23
47-61
41-49
16-34
68-81
30
30
45
15
40
33
18
55
25-35
25-35
40-50
12-17
35-45
30-36
12-25
50-60
All Torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified. Refer to the Standard Torque Specifications and
Capscrew Markings Chart in Section A of this manual for any torque specifications not listed above.
60568
CLUTCH
2A-15
Tools
J-8001
DIAL
INDICATOR
SET .
J-1048
CLUTCH
GAUGE
PLATE
J-22056 OR J-25353
ALIGNING
TOOL
J-23330
CLUTCH L E V E R
H E I G H T GAUGE
42578
NOTES
2B-1
MANUAL
TRANSMISSION
SECTION INDEX
Page
Page
Model T-18A 4-Spted
Tools
2B-20
2B-29
GENERAL INFORMATION
Page
Backup Lamp Switch
General
Identification
Service Diagnosis
TCS Switch
Transmission Installation
Transmission Lubricants
Transmission Removal
2B-1
2B-1
2B-1
2B-2
GENERAL
Three manual transmission models are used in Jeep
vehicles; they are Models T-150, T-15A, and T-18A.
Models T-150 and T-15A are 3-speed, constant mesh
units providing synchromesh engagement in all forward
gear ranges. Model T-18A is a 4-speed, constant mesh
unit providing synchromesh engagement in second,
third, and fourth gear ranges only. First gear is not
synchronized in this transmission.
Model T-150 is used in CJ models with six- or eightcylinder engines. Model T-15A is used in Cherokee and
Truck models with six- or eight-cylinder engines and
model T-18A is used in all models with six or eightcylinder engines.
The three transmission models are all floor shift
units. Column shift units are not available in any Jeep
model.
The entire shift mechanism on all transmission models is located within the shift control housing which also
serves as the transmission top cover. The shift mechanism does not require adjustment and can be serviced
independently of the transmission.
BACKUP LAMP SWITCH
* A spring and plunger-type backup lamp switch is used
on all models. The switch is located in the shift control
housing and is actuated by the first-reverse shift rail on
Models T-150 and T-15A and by the reverse shift rail on
Model T-18A. The switch does not require adjustment
and is serviced as an assembly only.
20-1
2B-4
2B-1
2B-3
TCS SWITCH
A nonadjustable, spring and plunger-type switch is
used on models equipped with TCS (transmission controlled spark). The switch is located in the shift control
housing and is actuated by the second-third shift rail on
Models T-150 and T-15A and by the third-fourth rail on
Model T-18A. The switch is activated in direct drive gear
range only.
IDENTIFICATION
An identification tag displaying the Jeep part number
is attached to the shift control housing. The information
on this tag is necessary to obtain correct replacement
parts should replacement become necessary. Be sure the
tag is securely attached in the original location after
completing all service operations.
TRANSMISSION LUBRICANT
The recommended lubricant for all transmission models is SAE 90 Gear Lubricant. This lubricant grade
should be used during all service and maintenance
operations.
N O T E : Do not use gear lubricants containing lead,
chlorine, or sulphur compounds.
When refilling or adding lubricant to the transmission, fill the transmission until the lubricant level is at
the lower edge of the fill plug hole only. Lubricant capacities for the three transmission models are:
T-1502-3/4 Pints (1.30 liters).
T-15A2-3/4 Pints (1.30 liters).
T-18A6-1/2 Pints (3.07 liters),
2B-2
MANUAL TRANSMISSION
Service Diagnosis
Possible Cause
Condition
Correction
LOCKS IN TWO
GEARS
(1)
(i)
HARD SHIFTING
(1)
(i)
(2)
(2)
Replace synchronizer(s).
(3)
Incorrect lubricant.
(3)
Replace lubricant.
(1)
(1)
Replace synchronizer(s).
(2)
Incorrect lubricant.
(2)
Replace lubricant.
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(7)
(8)
(8)
Replace bearings.
(9)
(9)
Replace bushing.
(1)
(1)
Replace gears.
(2)
(2)
Replace fork.
(3)
JUMPS OUT OF
GEAR
(1)
(1)
LUBRICANT LEAKS
INTO TRANSFER
CASE CAUSING
UNDERFILL IN
TRANSMISSION
AND OVERFILL
IN TRANSFER CASE
(1)
(1)
Replace seal.
60565
SHIFT LEVER K N O B .
SHIFT
LEVER,
SPRING
SEAT
GASKET
SHIFT CONTROL LEVER
HOUSING ASSEMBLY
J41034
Fig. 2B-1
3-Spead Transmission
J41035
214
MANUAL TRANSMISSION
TRANSMISSION INSTALLATION
(1) Install lubricating wick in pilot bushing.
(2) If removed, install wave washer on throwout
lever, position throwout bearing in lever, and center
bearing over clutch cover release levers.
CAUTION; Protect the transmission
clutch
splines and maintain throwout bearing alignment
installing the transmission.
shaft
when
Pip
Assembly
Cleaning and Inspection
Disassembly
DISASSEMBLY-
- . \
2B-7
2B-7
2B-4
Page
Shift Control Housing
Specifications
2B-11
2B-12
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
1. M A I N S H A F T R E T A I N I N G SNAP RlNG
2. S Y N C H R O N I Z E R B L O C K I N G RINGS (3)
3. SECOND-THIRD S Y N C H R O N I Z E R S L E E V E
4. SECOND-THIRD S Y N C H R O N I Z E R INSERT SPRING (2!
5. SECOND-THIRD H U B
6. SECOND-THIRD S Y N C H R O N I Z E R INSERT (3)
7. SECOND GEAR
8. FIRST GEAR R E T A I N I N G SNAP R I N G
9. FIRST GEAR T A B B E D T H R U S T WASHER
10. FIRST GEAR
1 1 . FIRST-REVERSE S Y N C H R O N I Z E R INSERT SPRING
12. FIRST-REVERSE SLEEVE A N D GEAR
13. FIRST-REVERSE H U B R E T A I N I N G SNAP R I N G
14. FIRST-REVERSE S Y N C H R O N I Z E R INSERT (3)
15. FIRST-REVERSE HUB
16. C O U N T E R S H A F T ACCESS PLUG
17. M A I N S H A F T
18. M A I N S H A F T SPACER
19. REAR BEARING ADAPTER LOCK RING
20. OIL SLINGER/SPACER
2 1 . REAR BEARING A N D ADAPTER ASSEMBLY
22. WASHER
LOCKNUT
ROLL PIN
REVERSE IDLER GEAR S H A F T
T H R U S T WASHER
BUSHING (PART OF IDLER GEAR)
REVERSE IDLER GEAR
TRANSMISSION CASE
T H R U S T WASHER (2)
B E A R I N G RETAINER (2)
C O U N T E R S H A F T NEEDLE BEARINGS (50)
C O U N T E R S H A F T GEAR
F R O N T BEARING CAP
BOLT (4)
F R O N T BEARING CAP OIL SEAL
GASKET
F R O N T BEARING RETAINER SNAP RING
F R O N T BEARING LOCKRING
F R O N T BEARING
C L U T C H SHAFT
M A I N S H A F T PILOT ROLLER BEARINGS
ROLL PIN
COUNTERSHAFT
60548
Fig. 21-3
W i l l i T160Exploded Vtaw
2B-6
MANUAL TRANSMISSION
REAR B E A R I N G
3/16 INCH D I A M E T E R
PIN PUNCH
ADAPTER
mm
F I L L PLUG H O L E
's4P^7
60549.;
60552
TOOL
J-25232
C O U N T E R S H A F T ACCESS PLUG
60550
Fig. 2B-5
Countershaft Removal-Installation
REVERSE I D L E R
GEAR S H A F T
COUNTERBORE
A L I G N R O L L PIN
WITH C O U N T E R B O R E
WHEN I N S T A L L I N G
BEARING
REMOVER
T O O L J-6654-01
PULLER
SCREWS
60553 I
MANUAL T 1 1 1 S 1 1 S S I 0 N
(2) Remove insert springs from second-third synchronizer, remove three inserts, and separate sleeve
from synchronizer hub (fig. 2B-3).
(3) Remove snap ring and tabbed thrust washer
from shaft and remove first gear and blocking ring.
(4) Remove first-reverse hub retaining snap ring.
Case
(5)
inserts
(6)
shaft.
(7)
press.
Inspection
Inspect the transmission components. Replace any
components that exhibit the following conditions:
2B7
ASSEMBLY
(1) Lubricate reverse idler gear shaft bore and
bushings with transmission lubricant.
(2) Coat transmission case reverse idler gear thrust
washer surfaces with petroleum jelly and install thrust
washers in case.
N O T E : Be sure to engage the locating tabs on the
thrust washers in the locating slots in the case.
(3) Install reverse idler gear. Align gear bore,
thrust washers, case bores, and install reverse idler gear
shaft from rear of case. Be sure to align and seat roll pin
in shaft into counterbore in rear of case (fig. 2B-8).
(4) Measure reverse idler gear end play by inserting
feeler gauge between thrust washer and gear. End play
should be 0.004 to 0.018 inch (0.10 to 0.45 mm). If end
play exceeds 0.018 inch (0.45 mm), remove idler gear and
replace thrust washers.
(5) Coat needle bearings and bearing bores in
countershaft gear with petroleum jelly. Insert Arbor
Tool J-25232 in bore of gear and install 25 needle bearings and one retainer in each end of gear (fig. 2B-3).
(6) Coat countershaft gear thrust washer surfaces
with petroleum jelly and position thrust washers in
case. .
N O T E : Be sure to engage the locating tabs on the
thrust washers in the locating slots in the case.
(7) Insert countershaft into rear case bore just far
enough to hold rear thrust washer in position. This will
prevent thrust washer from being displaced when
countershaft gear is installed.
2B-8
MANUAL TRANSMISSION
-wwamiim^:
Countershaft
Arbor
Tool J-
'
-jm
FIRST-REVERSE
NOTE: The countershaft gear must remain at the bottom of the case to provide sufficient clearance for ins tallation of the main shaft and clutch shaft assemblies.
(10) Coat all mainshaft splines and machined surfaces with transmission lubricant and start first-reverse
synchronizer hub on output shaft splines by hand. End
of hub with slots should face front of shaft. Use arbor
press to complete hub installation on shaft and install
retaining snap ring in most rearward groove (fig. 2B-9).
FIRST-REVERSE
SYNCHRONIZER
60555
Fig. 2 1 - 1 0
Fig. 2B-9
FIRST-REVERSE
SLEEVE A N D GEAR
FIRST
GEAR
Fig. Z B - 1 1
60556
SECOND
GEAR
Fig. 2 B - 1 4
BLOCKING
RING
Fig. 2 B - 1 2
ALIGNMENT
MARKS
60557
INSERT SPRING
(UNDER LIP OF
INSERTS)
SLEEVE
60558
Fig. 2 B - 1 3
2B-10
MANUAL TRANSMISSION
(27) Coat bearing bore of clutch shaft with petroleum jelly and install 15 roller bearings in clutch shaft
bore.
(34) Raise countershaft gear with wire loop (fig. 2B16), align bore in countershaft gear with front thrust
washer and countershaft, and start countershaft into
gear using plastic hammer (fig. 2B-16).
Fig. 2B-16
Countershaft Installation
MANUAL TRANSMISSION
SHIFT CONTROL HOUSING
2B-11
Disassembly
(1) Remove backup lamp switch and TCS switch if
equipped.
(2) Unthread shift lever cap and remove cap, gasket, spring seat and shift lever as assembly (fig. 2B-17).
WASHER
(7) Rotate first-reverse shift fork away from housing notch until roll pin is accessible. Drive roll pin out of
fork and rail using pin punch. Remove shift fork and roll
pin.
NOTE: The shift fork roll pin hole is offset. Mark the
position of the shift fork for assembly reference.
(8) Remove first-reverse shift rail using brass drift
or hammer. Catch shift rail plug as rail forces plug from
housing. Do not lose poppet ball during removal. Cover
housing shift tower and poppet ball holes with cloth or
tape before removing rail.
(9) Remove poppet balls, springs, and interlock
plunger from housing.
SPRING
RETAINER
SHIFT
LEVER
SPRING
Assembly
SHIFT
RAIL
(FIRSTREVERSE)
POPPET
SPRING
springs and
detent plug in
60562
Fig. 2B-17
21-12
MANUAL TRANSMISSION
SPECIFICATIONS
Transmission Specifications
Model. . .
T150
. . . . .Synchromesh
Type . . . .
3 Forward, 1 Reverse
Speeds . . ,
Gear Ratios
. .
2.99:1
First . .
.1.75:1
Second .
. . . .
1.00:1
Third. .
.
3.17:1
Reverse.
End Play Tolerances:
Countershaft Gear to Case . .0.004 to 0.018 inch (0.10 to 0.45 mm)
Reverse Idler Gear T o Case .0.004 to 0.018 inch (0.10 to 0.45 mm)
Mainshaft Gear Train . . . . .0.004 to 0.018 inch (0.10 to 0.45 mm)
Lubricant Capacity
2-3/4 Pints (1.30 liters)
Lubricant Type . .
SAE 9 0 Gear Lubricant
80118
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Service
Set-To
Torque
Backup Lamp Switch
Drain Plug
Fill Plug
Front Bearing Cap Bolt. . . . . . . . . . . . . . . . . . . . .
Shift Control Housing-to-Case B o l t .
Transfer Case Drive Gear Locknut
Transfer Case-to-Transmission Case Bolts
TCS Switch
.
...
.
.
.
18
15
15
33
22
150
30
18
Metric (N-m)
Service
In-Use
Recheck
Torque
15-20
10-20
10-20
30-36
20-25
145-155
25-35 .
15-20
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
24
20
20
45
30
203
41
24
20-27
14-27
14-27
41-49
27-34
197-210
34-47
20-27
All torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Marking chart in Chapter A for torque values not listed above.
80119
MODEL T-1SA
3-SPEED TRANSMISSION
Page
Page
Assembly
Cleaning and Inspection
2B-16
2B-15
DISASSEMBLY
(1) Remove bolts attaching transfer case to transmission and remove transfer case from transmission.
(2) Remove and discard transfer case-to-transmission gasket.
(3) Remove nut and washer attaching transfer case
drive gear to main shaft (fig. 2B-18).
2B-18
Specifications
2B-19
MANUAL TRANSMISSION
1. SECOND-THIRD S Y N C H R O N I Z E R SNAP R I N G
2. BLOCKING RINGS (3)
3. S Y N C H R O N I Z E R SPRINGS (2)
4. SECOND-THIRD S Y N C H R O N I Z E R ASSEMBLY
5. SECOND-THIRD C L U T C H HUB
6. SECOND-THIRD S H I F T I N G PLATE (3)
7. SECOND-THIRD CLUTCH SLEEVE
8. SECOND GEAR
9. M A I N S H A F T PILOT BEARING ROLLERS (21)
10. M A I N S H A F T
11. FIRST GEAR
12. FIRST GEAR S Y N C H R O N I Z E R ASSEMBLY
13. FIRST-REVERSE CLUTCH SLEEVE
14. S Y N C H R O N I Z E R SPRING (1)
15. FIRST GEAR CLUTCH HUB
16. FIRST GEAR S H I F T I N G PLATE (3)
17. FIRST GEAR SNAP RING
18. REVERSE GEAR BUSHING ( I N C L U D E D W I T H REVERSE GEAR)
19. REVERSE GEAR
20. COUNTERSHAFT GEAR T H R U S T WASHER (REAR)
2 1 . COUNTERSHAFT GEAR BEARING WASHER (4)
22. C O U N T E R S H A F T GEAR BEARING ROLLERS (44)
23. C O U N T E R S H A F T GEAR BEARING SPACER
24. C O U N T E R S H A F T GEAR
25. COUNTERSHAFT-REVERSE IDLER S H A F T LOCKPLATE
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
2B-13
COUNTERSHAFT
C O U N T E R S H A F T GEAR T H R U S T WASHER (FRONT)
REVERSE IDLER GEAR T H R U S T WASHER (2)
REVERSE IDLER GEAR
REVERSE IDLER GEAR BUSHING ROLLERS
REVERSE IDLER GEAR S H A F T
MAINSHAFTLOCKNUT
M A I N S H A F T WASHER
M A I N S H A F T BEARING SPACER
REAR BEARING ADAPTER
REAR BEARING LOCK RING
REAR BEARING
TRANSMISSION CASE
F I L L PLUG
D R A I N PLUG
CLUTCH SHAFT
FRONT BEARING RETAINER
FRONT BEARING
F R O N T BEARING LOCK RING
FRONT BEARING SNAP RING
F R O N T BEARING CAP GASKET
F R O N T BEARING CAP OIL SEAL
F R O N T BEARING CAP
F R O N T BEARING CAP BOLT
LOCK WASHER
60243
Fig. 21-18
2B-14
MANUAL TRANSMISSION
42581
Fig. 21=1 i
GEAR
Fig. 2B-22
42586
Fig. 2B-21
tar
Bearing Removal
Countershaft Removal/Installation
Fig. 2B-23
S N A P
MAINSHAFT
SNAP
RING
R I N G
G R O O V E
CLUTCH
SLEEVE
F I R S T
SHIFTER
PLATE
SYNCHRONIZER
SPRING ( 1 )
G E A R
SYNCHRONIZER
Fig. 21-24
42590
Fig. 2B-Z6
Inspection
Inspect the transmission components. Replace any
components exhibiting the following conditions:
PLATES
Case
42589
ASSEMBLY
(1) Lubricate all parts with transmission lubricant
unless noted otherwise.
(2) Install reverse idler gear, roller bearings, and
thrust washer using tool J-25203.
(3) Install reverse idler gear shaft. Shaft will force
tool J-25203 out during installation. Be sure slotted end
of shaft is correctly aligned with lock plate.
(4) Install center spacer and Arbor Tool J-25199 in
countershaft gear bore.
(5) Install bearing washer at each end of center
spacer. Slide washers over arbor tool until seated
against spacer.
(6) Install 22 roller bearings at each end of countershaft gear and install bearing washer over roller bearings at each end of gear (fig. 2B-27 and 2B-28).
COUNTERSHAFT
GEAR
COUNTERSHAFT
BEARING
ROLLERS
COUNTERSHAFT
WASHERS
WASHERS
Fig. 21-28
COUNTERSHAFT
GEAR SPACER
J42592
Bearing/Spacer/Washer Location
WASHER
REVERSE
IDLER
SHAFT
PLATE
COUNTERSHAFT
42593
Fig. 21-2?
MANUAL TRANSMISSION
"'wmww
-"japwr
"Twmm?
witfgr--
'wvmtw
-wsmssr-
2B-17
~ "z^pf,}
Fig. 2B-31
TOOL
J-22828
TOOL
4 2597
Fig. 2B-32
2B-18
MANUAL TRANSMISSION
OIL
SEAL
42598
Fig. 2B-33
Disassemblf
(1) Remove TCS switch, if equipped, and backup
lamp switch.
(2) Remove shift rail plugs from rear of housing
(fig. 2B-34). Remove plugs by driving them sideways
(into bore) then prying out.
(3) Move first-reverse shift rail to first gear
position.
(4) Remove roll pin from first-reverse shift fork and
rail.
Fig. 2B-34
MANUAL TRANSMISSION
Assembly
(1) Install shift lever and retainer spring.
N O T E : The small end of the spring cone should be
against the lever ball. Be sure the spring is snapped in
behind the cover shoulders.
(2) Slide second-third shift rail into housing to poppet boss.
(3) Insert poppet spring and ball.
(4) Compress ball and spring and slide rail just
through boss.
(5) Rotate rail to position shift lever slot toward
center of housing.
(6) Install second-third fork with flanged side of
fork toward front of housing.
(7) Install roll pin.
2149
SPECIFICATIONS
Transmission Specifications
Model.
Type
Speeds
Gear Ratios:
First
Second
Third .
Reverse
End Play Tolerances
T15A
Synchromesh
3 Forward, 1 Reverse
2.997:1
1.832:1
1.000:1
2.997:1
A l l end play controlled by
selective thickness snap rings.
Use thickest snap rings available.
2-3/4 Pints (1.30 liters)
. SAE 90 Gear Lubricant
Lubricant Capacity
Lubricant Type
80120
Torque Specifications
Service Set'-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
. .
.
. . . . .
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
18
15
15
15
12
150
30
18
15-20
10-20
10-20
12-18
10-15
145-155
25-35
15-20
Metric (N-m)
Service
Set-To
. Torque
24
20
20
20
16
203
41
24
Service
In-Use
Recheck
Torque
20-27
14-27
14-27
16-24
14-20
197-210
34-47
. 20-27
All torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Marking chart in Chapter A for torque values not listed above.
80121
2B-20
MANUAL TRANSMISSION
4^mm
TSJIMSMISSION
Page
Assembly
Cleaning and inspection
Disassembly
Page
Shift Control Housing
Specifications
21-23
2B-22
2B-20
21-27
2B-28
DISASSEMBLY
Legend
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
M A I N S H A F T PILOT B E A R I N G R O L L E R SPACER
T H I R D - F O U R T H B L O C K I N G RING
T H I R D - F O U R T H R E T A I N I N G RING
T H I R D - F O U R T H S Y N C H R O N I Z E R SNAP RING
T H I R D - F O U R T H S H I F T I N G P L A T E (3)
THIRD-FOURTH CLUTCH HUB
T H I R D - F O U R T H R E T A I N I N G RING
T H I R D - F O U R T H C L U T C H SLEEVE
T H I R D - F O U R T H B L O C K I N G RING
T H I R D - F O U R T H GEAR S Y N C H R O N I Z E R ASSEMBLY
T H I R D GEAR
M A I N S H A F T SNAP RING
SECOND GEAR T H R U S T WASHER
SECOND GEAR
.
:
MAINSHAFT
SECOND GEAR B L O C K I N G RING
M A I N S H A F T SNAP RING
FIRST-SECOND C L U T C H HUB
FIRST-SECOND S H I F T I N G P L A T E (3)
POPPET B A L L (3)
POPPET SPRING (3)
FIRST-SECOND INSERT SPRING
M A I N S H A F T SNAP RING
FIRST-SECOND C L U T C H SLEEVE
SECOND GEAR S Y N C H R O N I Z E R ASSEMBLY
C O U N T E R S H A F T GEAR T H R U S T WASHER (STEEL) (REAR)
C O U N T E R S H A F T GEAR T H R U S T WASHER
(STEEL B A C K E D BRONZE) (REAR)
C O U N T E R S H A F T GEAR B E A R I N G WASHER
C O U N T E R S H A F T GEAR B E A R I N G R O L L E R S (88)
C O U N T E R S H A F T GEAR B E A R I N G SPACER
C O U N T E R S H A F T GEAR
C O U N T E R S H A F T GEAR T H R U S T WASHER (FRONT)
REVERSE S H I F T I N G A R M
REVERSE S H I F T I N G A R M SHOE
F I L L E R PLUG
D R A I N PLUG
LOCKWASHER
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
B O L T (TRANSMISSION-TO-CLUTCH HOUSING)
C-WASHER
REVERSE IDLER GEAR SNAP RING
REVERSE IDLER GEAR T H R U S T WASHER
REVERSE IDLER S H A F T SLEEVE
REVERSE IDLER GEAR B E A R I N G ROLLERS (74)
REVERSE IDLER GEAR B E A R I N G WASHER
REVERSE IDLER GEAR
LOCKWASHER (6)
A D A P T E R PLATE BOLTS (6)
D R I V E GEAR L O C K N U T
WASHER
A D A P T E R PLATE
COUNTERSHAFT-REVERSE IDLER S H A F T L O C K P L A T E
REVERSE IDLER GEAR S H A F T
COUNTERSHAFT
A D A P T E R PLATE G A S K E T
A D A P T E R PLATE S E A L
SPEEDOMETER GEAR SPACER
REAR B E A R I N G L O C A T I N G SNAP RING
REAR B E A R I N G
REVERSE S H I F T I N G A R M PIVOT PIN
REVERSE S H I F T I N G A R M PIVOT
REVERSE S H I F T I N G A R M PIVOT O-RING
WASHER (6)
SIDE COVER B O L T (6)
SIDE COVER
TRANSMISSION CASE
M A I N S H A F T PILOT B E A R I N G ROLLERS (22)
CLUTCH SHAFT
FRONT B E A R I N G R E T A I N E R WASHER
FRONT B E A R I N G
FRONT B E A R I N G L O C A T I N G SNAP RING
F R O N T B E A R I N G LOCK RING
FRONT B E A R I N G CAP G A S K E T
FRONT B E A R I N G CAP
FRONT B E A R I N G CAP BOLTS (4)
LOCKWASHER (4)
60242
2B-22
MANUAL TRANSMISSION
(29) Remove power takeoff cover.
(30) Remove fill plug and drain plug.
Fig. 2B-36
MANUAL TRANSMISSION
ASSEMBLY
NOTE; Prefabricate all components
jelly during assembly.
with
petroleum
2B-23
(3) Position first-second clutch hub on top of thirdfourth hub so lock ball holes in first-second hub are in
uppermost position (fig. 2B-37).
(4) Align scribe marks on first-second hub and
sleeve and install sleeve on hub (fig. 2B-38). Allow sleeve
to bottom against work bench.
(5) Install each shifting plate, poppet spring, and
lock ball assembly one at a time as follows (fig. 2B-38):
(a) Install shifting plate in hub slot.
(b) Insert poppet spring through plate.
(c) Position lock ball on poppet spring, and
compress ball and spring (fig. 2B-38).
(d) Maintain pressure on ball and spring and
slide shifting plate downward in hub slot until ball is
held in position by clutch sleeve.
(6) Install remaining shift plates, poppet springs
and lock balls as described in previous step.
(7) Complete synchronizer assembly by pressing
down on hub and pulling up on sleeve.
42606
Fig. ZB-38
42605
Fig. 21-37
2B-24
MANUAL TRANSMISSION
GROOVE
TO R E A R
Fig. 2B-39
42609
Fig. 2 B 4 1
42608
Fig. 2B-40
42610
Fig. 2B-42
MANUAL TRANSMISSION
INCORRECT
2B-25
CORRECT
J42611
Fig. 2B-43
42612
Fig. 2B-44
2B-26
MANUAL TRANSMISSION
REVERSE S H I F T
FORK
REVERSE S H I F T
GATE A N D
PLUNGER PIN
SHIFT RAIL
POPPET BORES
THIRD-FOURTH
S H I F T FORK
THIRD-FOURTH
S H I F T RAI
ROLL PIN
INTERLOCK PLUNGER
R O L L PIN
I
I
FIRST-SECOND
S H I F T FORK
FIRST-SECOND
S H I F T GATE
POPPET
BALLS
FIRST-SECOND
SHIFT RAIL
R O L L PIN
POPPET SPRINGS
ROLL PIN
90146
Fig. 2B-45
MANUAL TRANSMISSION
2B-27
N O T E : The front
four thicknesses.
in
Assembly
(1) Install replacement breather in housing if
removed.
(2) Install spring and plunger in reverse shift gate.
Compress plunger and install plunger retaining clip.
(3) Insert reverse shift rail into housing. Install reverse shift fork on rail and slide rail up to but not into
shift rail poppet bore.
(4) Install poppet spring and ball in reverse shift
rail poppet bore. Compress ball and spring using punch
and slide rail through bore.
(5) Install reverse shift gate on opposite end of shift
rail and slide rail into housing until poppet ball engages
in rail notch. Install shift gate so plunger pin boss faces
rear of housing (fig. 2B-46).
(6) Align and install roll pins that fasten reverse
shift fork and shift gate to shift rail.
(7) Install interlock plungers in pockets located between housing shift rail poppet bores.
2B-28
MANUAL TRANSMISSION
90147
SPECIFICATIONS
Transmission Specifications
Model
Type
Speeds
Gear Ratios:
First
Second
Third
Fourth
Reverse
End Play Tolerances
Lubricant Capacity
Lubricant Type
T18A
Synchromesh
4 Forward, 1 Reverse
6.32:1
.3.09:1
1.69:1
1.00:1
7.44:1
A l l end play controlled by
selective thickness snap rings.
Use thickest snap rings available.
6-1/2 Pints (3.07 liters)
SAE 90 Gear Lubricant
80122
MANUAL TRANSMISSION
ZB-29
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
Metric (N-m)
. . . . .
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
18
15
15
15
12
150
30
18
15-20
10-20
10-20
12-18
10-15
145-155
25-35
15-20
24
20
20
20
16
203
41
24
20-27
14-27
14-27
16-24
14-20
197-210
34-47
20-27
A l l torque values given in newton-meters and foot-pounds w i t h dry fits unless otherwise specified.
Refer t o the Standard Torque Specifications and Capscrew Marking chart in Chapter A f o r torque values not listed above.
80123
Tools
J-25232
ARBOR TOOL
J-26852
MAINSHAFT REAR
SEAL INSTALLER
J-6654-01
B E A R I N G REMOVER
J-25233
F R O N T B E A R I N G CAP
SEAL INSTALLER
80660
2B-30
MANUAL TRANSMISSION
Tools
J-26092
BEARING INSTALLER TOOL
J-25200
THRUST YOKE TOOL
J-25203
REVERSE I D L E R GEAR
ARBOR TOOL
J-22828
BEARING INSTALLER
80661
NOTES
NOTES
2C-1
AUTOMATIC
TRANSMISSION
SECTION INDEX
Pegs
Page
2C-6
2C-29
General Information
2C-1
Tools
2C-81
2C-25
GENERAL INFORMATION
Page
General
Hydraulic System Operation
Identification
Page
2C-1
2C-3
2C-1
GENERAL
The automatic transmission used in all Jeep models is
a fully automatic, hydraulically operated, three-speed
unit combining a torque converter and compound planetary gear system. The transmission case and converter
housing are a one-piece aluminum casting (fig. 2C-1).
The transmission consists of a three element torque
converter, two planetary gear sets, three multiple disc
clutches, two roller clutches, and two bands, all of which
combine to provide one reverse and three forward gear
ratios. The hydraulic system consists of a single oil
pump, two band actuating servos, a valve body, and a
governor valve.
A mechanical linkage is used to select desired gear
range. Shift speed and quality are controlled by a vacuum modulator connected between the engine and
transmission, and by a centrifugal governor valve
mounted on the output shaft. An electrically operated
detent solenoid valve and detent switch provide detent
downshift capabilities.
Power Flow
The direct transmission-to-engine connection is
through the torque converter, which is connected to the
engine crankshaft by a driveplate. In operation, engine
torque is transmitted through the converter to the turbine shaft and then to the main shaft through multiple
disc clutches in the transmission. From the mainshaft,
engine torque is further transmitted through the com-
2C-1
2C-2
2C-5
IDENTIFICATION
The transmission serial number is stamped on a metal
plate attached to the right side of the transmission case.
The serial number must be included in any communication involving parts ordering or requests for transmission information.
Venting
The transmission is vented through a plastic tube
mounted in the transmission case. The tube is located
just above the vacuum modulator.
2C-2
J
AUTOMATIC TRANSMISSION
U
^ g
m
m m m
Flg. 2C-1
&
^ T ^ - F I ^ - ^ r - -
- l ^ T O R -
Torqui Conwirtir
The three-element torque converter consists of a
pump or driving member, a turbine or driven member
and a stator assembly. The stator is mounted on a oneway roller clutch which allows the stator to turn in a
clockwise direction only (fig. 2C-2). The converter is
welded together during manufacture and cannot be disassembled for service.
As oil passes through the turbine, it travels in such a
direction that if it were not redirected by the stator it
would hit the rear of the converter pump blades and
impede pumping action (fig. 2C-2). At low turbine rotating speeds, oil is redirected by the stator to the converter
pump to assist the converter pump in multiplying engine torque.
As turbine rotating speed increases, the direction of
the oil leaving the turbine changes and flows against the
rear side of the stator vanes in a clockwise direction.
Since the stator is now impeding the smooth flow of oil,
the stator roller clutch releases allowing the stator to
revolve freely on the stator shaft. When the stator freewheels, there is no further multiplication of engine
torque within the converter which has now achieved
AUTOMATIC TRANSMISSON
TURBINE
STATOR
2C-3
C O N V E R T E R PUMP
Roller' ditches
A roller clutch permits rotation of a unit in one direction only. Roller clutches are used to lock one member of
each planetary gear set for gear reduction. The intermediate roller clutch is effective in second gear D or 2range only. The low roller clutch is effective in first gear
D or 1-range only. In direct drive (third gear), the roller
clutches allow free rotation of all members.
TURBINE
SHAFT
J42425
Fig. 2G-2
Torqisa Converter
Vacuui Modulator
The engine-to-transmission vacuum signal is provided
by the vacuum modulator which consists of an evacuated metal bellows, a diaphragm, and two springs. The
bellows and one spring apply a force which acts on the
modulator valve to increase modulator pressure. Engine
vacuum and the second spring act in the opposite direction to decrease modulator pressure. Low engine vacuum results in high modulator pressure, while high
engine vacuum results in low modulator pressure.
Governor
60523
Fig. 2C-3
Detent Switch
2C-4
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSON
1-2 Accumulator
In first gear, 1-2 accumulator oil charges the rear
servo accumulator preparatory to application of the intermediate clutch on 1-2 upshifts. Line oil pressure is
directed to the 1-2 accumulator valve and is further
regulated to become 1-2 accumulator oil. Modulator
pressure is directed to the 1-2 accumulator valve, causing 1-2 accumulator pressure to become sensitive to engine torque. This provides smoother shifts in response to
engine torque output.
Detent oil is directed to the 1-2 accumulator valve to
raise 1-2 accumulator pressure during detent 1-2 shifts
to improve clutch life. In Drive-1 range, oil is directed to
the 1-2 accumulator valve to raise 1-2 accumulator pressure to the same value line pressure. This increased
pressure, directed to the rear servo accumulator piston,
resists servo apply pressure and slows down the apply of
the rear band for a smoother manual shift to Drive-1
range first gear, or for a 2-1 downshift in Drive-1 range.
Detent and Detent Regulator Valves
When the accelerator pedal is fully depressed, the
detent valve train replaces the modulator as a controller
2C-5
Park-Neutral
In Park and Neutral, pump supplied oil is routed to
and from the release side of the front servo through the
manual valve; then through the detent regulator valve,
modulator valve orifice, and back to the sump. Clutch
and band application does not occur in either of these
gearshift lever positions.
TOWING
Emergency Towing
If the vehicle is to be towed with the front or rear
wheels off the ground, towing speed must be limited to
30 mph (48 km/h) and the vehicle towed for a distance
no greater than 15 miles (24 km).
2C-6
AUTOMATIC TRANSMISSION
rear wheels and tow the vehicle with the front wheels
raised. Or, disconnect the rear propeller shaft at the axle
yoke (be sure to mark the shaft and yoke for assembly
alignment reference), secure the shaft to the underside
of the vehicle and tow with the front wheels raised.
Recreational Towing
Jeep vehicles can be towed behind a recreational vehicle such as a motor home, however, the following
instructions must be followed explicitly in order to avoid
damaging driveline components. In addition, be sure to
check and comply with federal, state and local requirements/ordinances regarding vehicle lighting, tow bars
and trailer hitches.
Automatic Transmission Without Quadra-Trac Low Range Unit
DIAGNOSIS A N D T E S T
PROCEDURES
Page
Page
Clutch and Band Application Chart
Converter Housing Leak Diagnosis
Control Valve and Governor Test
Diagnosis Charts
Diagnosis Guides
Fluid Level and Condition
Hydraulic Flow Charts
2C-8
2C-12
2C-9
2C-13
2C-21
2C-7
2C-S3
PRELIMINARY DIAGNOSIS
In all automatic transmission repair, the logical and
2C-I
2C-11
2C-11
2C-6
2C-8
2C-10
2C-23
proper procedure is diagnosis before disassembly. A systematic diagnosis procedure is necessary and practical
for two important reasons. First, in locating the cause of
AUTOMATIC TRANSMISSON
a malfunction and second, to avoid repair delays resulting from incorrect or unnecessary repairs.
Jeep automatic transmission malfunctions may be
caused by one or more of the following general
conditions:
Poor engine performance.
Loss of vacuum or insufficient vacuum.
Loss of electrical signal.
Incorrect fluid level.
Incorrect linkage, switch, or band adjustment.
Hydraulic system malfunctions.
Mechanical component malfunctions.
Two basic preliminary diagnosis procedures are required. One for vehicles in operating condition (can be
driven) and one for vehicles not in operating condition
(cannot be driven).
2C-7
2C-8
AUTOMATIC TRANSMISSION
is operating
(77C).
temperature
of approximately
170F
Forward Clutch
Direct Clutch
D
1
Front Band
Intermediate Clutch
(8) If fluid level is low, add fluid as necessary, reinstall and seat dipstick, and check for leaks.
CAUTION: Do not overfill the transmission. Overfilling will result in fluid foaming (aeration) and consequent loss of fluid from the vent and fill tube. In
addition, foaming will cause fluid overheating, oxidation, and varnish buildup, which can interfere with
valve, clutch, and servo operation.
Lo Clutch Roller
m
43007
Fluid Condition
mm
Intermediate Sprag
Rear Band
firmer
1-Range
AUTOMATIC TRANgffliSSON
1-RangeOverrun Braking
(1) Shift transmission into 2-range and increase vehicle speed to 30-40 mph (48-64 km/h).
(2) Close throttle and shift transmission, into 1range. A 2-1 downshift should occur at 40-20 mph (64-32
km/h). A 2-1 downshift at closed throttle will be accompanied by increased engine rpm, and an engine braking
effect should be noticed.
NOTE: If a pressure test gauge has been installed, line
pressure should be approximately 150 psi (1 084 kPa)
after
downshifting.
Reverse Range
2C-9
2C-10
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION
20-11
NEUTRAL
BRAKES
APPLIED
1000 RPM
DRIVE
IDLE
OIL
PRESSURE
DRIVE
BRAKES
APPLIED
1000 RPM
DRIVE - 1
BRAKES
APPLIED
1000 RPM
REVERSE
BRAKES
APPLIED
1000 RPM
DETENT
SWITCH A C T I V A T E D
OIL
PRESSURE
OIL
PRESSURE
OIL
PRESSURE
OIL
PRESSURE
OIL
PRESSURE
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
NORMAL
HIGH
HIGH
NORMAL
NORMAL
NORMAL
HIGH
HIGH
HIGH
NORMAL
HIGH
SLIPPING-REVERSE
NORMAL
NORMAL
NORMAL
NORMAL
LOW
NORMAL
DROP
NORMAL
O I L LEAK I N F E E D
SYSTEM TO THE
DIRECT CLUTCH
SLIPPING1ST G E A R
NORMAL
NOT DETENT
DOWNSHIFTS
NORMAL
MALFUNCTION
NO 1-2 UPSHIFT
AND/OR D E L A Y E D
UPSHIFT
DRIVE-BRAKES
APPLIED 1000 RPM
PRESSURE DROP
OCCURS W H I L E
E N G I N E RPM
INCREASES F R O M
1000 T O 3 0 0 0 RPM
WHEELS FREE
TO M O V E *
10 PSI DROP
OR M O R E
POSSIBLE CAUSE
OF M A L F U N C T I O N
OIL
PRESSURE
NORMAL
MALFUNCTION IN
C O N T R O L V A L V E ASSY.
NORMAL
MALFUNCTION IN
G O V E R N O R OR
GOVERNOR FEED
SYSTEM
DROP
HIGH
MALFUNCTION IN
DETENT SYSTEM
10 PSI D R O P
O R M O R E (69 KPa)
DRIVE
30 MPH
CLOSED
THROTTLE
MALFUNCTION IN
M O D U L A T O R OR
V A C U U M F E E D SYSTEM
TO MODULATOR
LOW T O
LOW T O
NORMAL
NORMAL
LOW T O
NORMAL
NORMAL
LOW T O
NORMAL
LOW T O
NORMAL
O I L LEAK IN F E E D
SYSTEM TO THE
FORWARD CLUTCH
NORMAL
NORMAL
NORMAL
NORMAL
LOW
NORMAL
NORMAL
MALFUNCTION IN
DETENT SYSTEM
J 4 3 0 0 9
governor pipe or screen in control valve or case, or governor pipes loose in case holes.
(12) If line pressures are high, proceed to High Line
Pressure Check.
10IULIT0ITEST
(1) Check for presence of transmission fluid in modulator using pipe cleaner. Insert pipe cleaner into modulator vacuum connector pipe as far as possible.
Withdraw pipe cleaner and check for presence of transmission fluid on pipe cleaner.
(2) Replace modulator if fluid is found in connector
pipe (fig. 2C-4). Transmission fluid may be lost through
diaphragm and burned in engine.
2C-12
AUTOMATIC TRANSMISSION
HOUSING'
70895
Fig. 2C-4
Vacuum Modulator
(4) Test holding ability of modulator vacuum diaphragm. Apply and maintain 21 inches vacuum to modulator for at least 30 seconds and check for plunger
movement. Replace modulator if diaphragm will not
hold vacuum for at least 30 seconds.
Plunger Cylinder Concentricity Check
converter housing. However, if total seal failure occurs, fluid will be deposited inside the converter
housing only, near the housing outside diameter.
Oil Pump Bodyleaks from the pump body follow
the same path as do pump seal leaks, or they may
flow down the pump body face and into the converter housing.
Oil Pump-to-Case Boltleaks past any one of these
bolts are deposited on the inside of the converter
housing only and not on the converter itself.
Oil Pump-to-Case Gasketleaks past the gasket are
deposited inside the converter housing only.
Converter Drain Plugleaks past the plug threads
are deposited on the converter, converter drive plate,
and inside the converter housing near the drive
plate.
Engine oil leaks are sometimes mistaken for transmission oil pump seal leaks. The following areas should
be inspected to determine the actual leak source:
Cylinder Head Cover and Gasketleaks past the
cover or gasket may flow down the engine block and
onto the converter housing. Or, they may seep into
the converter housing between the housing and engine block.
Oil Gallery Plugoil leaking past the plug will flow
down the rear face of the engine block and into the
bottom of the converter housing.
Crankshaft Rear Main Sealleaks past the seal
collect on the converter drive plate and are thrown
off onto the inside of the converter housing.
Fluid leaks from components located forward of the
transmission, such as the power steering pump, could
result in fluid collecting on the converter housing exterior due to road draft-blow back.
Engine oil or transmission fluid leaks can sometimes
be differentiated by the coloration of these two lubricants. Engine oil usually has a brownish-green cast to it
while transmission fluid is usually red or reddish orange
in color.
CRANKSHAFT
CRANKSHAFT
SEAL LEAK
OIL PUMP
SEAL LEAK
OIL PUMP
TO-CASE BOLT
LEAK
OIL PUMP
GASKET LEAK
DRIVE
PLATE
CONVERTER
ASSEMBLY
CONVERTER
D R A I N PLUG
LEAK
Fig. ZC-5
TRANSMISSION
CONVERTER
HOUSING
IMPELLER
80189
AUTOMATIC TRANSMISSON
2C-13
ARSH UPSHIFT
Note: Poor engine performance can also cause this symtom.
STEP
SEQUENCE
RESULT
CHECK F L U I D L E V E L
ADD FLUID
AS NECESSARY
OK
DISCONNECT D E T E N T
WIRE A T
TRANSMISSION
LIGHT
"ON"
ADJUST OR
REPLACE
D E T E N T SWITCH
CONNECT TEST
LIGHT FROM
D E T E N T WIRE
TO G R O U N D
LIGHT "OFF"
CHECK M O D U L A T O R
HOSE A N D PIPE
FOR LEAKS OR
RESTRICTIONS
REPAIR AS
NECESSARY
(OK
CHECK FOR
OIL I N M O D U L A T O R
OIL
NO OIL
REPLACE
MODULATOR
CONNECT V A C U U M GAGE
TO M O D U L A T O R E N D OF PIPE
90173A
20-14
AUTOMATIC TRANSMISSION
SEQUENCE
STEP
RESULT
LESS T H A N 1 3 " OR V A C U U M
RESPONDS SLOWLY TO
T H R O T T L E CHANGE
START ENGINE
REPAIR LEAK
OR RESTRICTION
IN V A C U U M HOSE,
PIPE, OR F I T T I N G
SHIFT LEVER
IN " P "
R E A D GAGE W H I L E
MOVING THROTTLE
LINKAGE
MORE T H A N 1 3 " A N D
V A C U U M RESPONDS Q U I C K L Y
TO T H R O T T L E CHANGE
APPLY V A C U U M A N D
W A T C H FOR M O V E M E N T
OF PLUNGER
PLUNGER MOVES
A T LESS T H A N
8 " OR MORE
THAN 20" VACUUM
PLUNGER MOVES
BETWEEN 8 " A N D
20" VACUUM
MODULATOR V A L V E
OK
CONNECT T A C H A N D
O I L PRESSURE
GAGE
RAISE V E H I C L E
WHEELS O F F
FLOOR
S T A R T ENGINE
S H I F T TO
"DRIVE"
DISCONNECT
A N D PLUG
MODULATOR
HOSE
90173B
AUTOMATIC TRANSMISSON
STEP
SEQUENCE
60 TO 90 PSI
2C-15
RESULT
REPAIR V A L V E
BODY
90173C
2C-16
AUTOMATIC TRANSMISSION
DIAGNOSIS AND REPAIR SIMPLIFICATION (DARS) CHARTS
Note: Refer to Chapter A General Information for details on how to use this DARS chart.
;tep
RESULT
ENGINE I D L I N G
SHIFT LEVER
IN " P "
R E M O V E DIPSTICK A N D
FEEL F L U I D T E M P E R A T U R E
WIPE DIPSTICK C L E A N
A N D REINSERT
R E M O V E DIPSTICK A N D
NOTE R E A D I N G
TRANSMISSION OK
Add
1 Pt
A D D OR REMOVE F L U I D
TO M A K E L E V E L OK FOR
TEMPERATURE
0*0
T R A N S M I S S I O N NOT OK
SLIPS A T START-UP
IN A L L R A N G E S A N D
DURING ACCELERATION
F R O M A N Y SPEED
SLIPS A T S H I F T
POINTS REVERSE
iOK
CONNECT V A C U U M
GAGE T O M O D U L A T O R
END OF PIPE
90173D
AUTOMATIC TRANSMISSQN
STEP
SEQUENCE
2C-17
RESULT
REMOVE TRANSMISSION
FOR REPAIRS
90173E
2C-18
AUTOMATIC TRANSMISSION
DIAGNOSIS AND REPAIR SIMPLIFICATION (DARS) CHARTS
Note: Refer to Chapter A - General Information for details on how to use this DARS chart.
BIS-
RIVE/REVERSE
SEQUENCE
STEP
ENGINE
IDLING
S H I F T LEVER
IN " P "
REMOVE DIPSTICK
A N D FEEL F L U I D
TEMPERATURE
RESULT
WIPE DIPSTICK
CLEAN AND
REINSERT
REMOVE DIPSTICK A N D
NOTE R E A D I N G
TRANSMISSION
OK
Add 1 Pt
A D D OR R E M O V E
F L U I D TO M A K E
L E V E L OK FOR
TEMPERATURE
OK
TRANSMISSION
NOT OK
CHECK M A N U A L L I N K A G E
ADJUSTMENT
ADJUST AS
NECESSARY
REMOVE TRANSMISSION
FOR REPAIRS
PROBLEM:
STEP
RESULT
STOP
RADIO " O N " AM
N E A R 1400
OFF STATION)
POP
REPAIR D E T E N T V A L V E
T R A I N ( V A L V E BODY)
MOVE ACCELERATOR
TO FLOOR A N D L I S T E N
FOR " P O P " IN R A D I O
AS A C C E L E R A T O R IS
RELEASED
NO POP OR NO R A D I O
!ST0P
REPAIR AS
NECESSARY
REPLACE
FUSE
FUSE OK
[STOP
FUSE O K
DEPRESS
ACCELERATOR
FUSE
BLOWS
REPAIR SHORT IN
D E T E N T C I R C U I T OR
REPLACE D E T E N T
SOLENOID
FUSE OK
ADJUST OR
REPLACE
D E T E N T SWITCH
BLOCK A C C E L E R A T O R
P E D A L F U L L OPEN
DISCONNECT
DETENT
WIRE A T
TRANSMISSION
CONNECT
L I G H T FROM
D E T E N T WIRE
TO G R O U N D
LIGHT " O N "
'STOP
T R A N S M I S S I O N OK
REPLACE
DETENT
SOLENOID
I STOP
T R A N S M I S S I O N N O T OK
REPAIR D E T E N T V A L V E
T R A I N ( V A L V E BODY)
90173G
-.
Diagnosis Chart
TRANSMISSION
NOISY
C A U T I O N : Before checking transmission for what is believed to be transmission noise, make certain the noise is not from the water pump, alternator, air
conditioner, power steering, etc. These components can be isolated by removing
the proper belt and running the engine not more than two minutes at one time.
PUMP C A V I T A T I O N
Oi! level low.
Plugged or restricted filter.*
Intake pipe O-ring damaged.
Intake pipe split, porosity in case intake
pipe bore.
Water in o i l .
Porosity or voids at trans, case {pump face)
intake port.
Pump to case gasket off location.
PUMP ASSEMBLY
Gears damaged, or defective, driving gear
assembled backwards.
Crescent interference.
Buzzing noise orifice cup plug in pressure
regulator damaged or missing.
Seal rings damaged or w o r n .
43016
AUTOMATIC TRAN3MIS3GN
-21
Diagnosis Chart
D R I V E IN N E U T R A L
W O N T
H O L D I N P A R K OR W O N T RELEA3E
FROM PARK
INTERNAL LINKAGE
Manual valve disconnected or end b r o k e n ,
inside detent lever pin broken.
PUMP ASSEMBLY
Trans, lube pressure leaking into forward
clutch apply passage.
INTERNAL LINKAGE
1. Parking brake rod assy. (Check actuator
for chamfer).
2. Parking pawl broken, chamfer omitted.
3. Parking brake bracket loose, burr or
rough edges, or incorrectly installed.
4. Parking pawl return spring missing,
broken or incorrectly hooked.
FORWARD CLUTCH
Burned plates check cause.
Incorrect clutch plate usage.
43015
DIAGNOSIS GUIDES
Filler pipe O-ring seal damaged or missing; misalignment of filler pipe bracket to engine, loading
one side of O-ring.
Modulator O-ring seal damaged or improperly
installed.
2C-22
AUTOMATIC TRANSMISSION
@ Transmission overfilled.
Water in fluid.
Filter O-ring damaged or improperly assembled
causing oil to foam.
Foreign material between pump and case or between
pump cover and body holding pump halves apart.
Case porous or pump face improperly machined.
Pump-to-case gasket mispositioned.
Pump breather hole blocked or missing.
Hole in intake pipe.
Check ball in forward clutch housing stuck open or
missing.
Oil Cooler Lines
Diaphragm defective.
Causes of Burned Clutch Plates
Forward Clutch
Direct Clutch
Oil Pump
AUTOMATIC TRANSMISSON
Transmission Case
Pump
Line
2C-23
Pressure
Vacuum Leak
Modulator
off
Hole in diaphragm.
Stuck valve.
Water in modulator.
Modulator inoperative.
Detent System
D e t e n t s w i t c h p l u n g e r s t u c k , s h o r t e d , or
misadjusted.
Detent wiring shorted.
Detent solenoid stuck open.
Detent feed orifice in valve body spacer plate
blocked.
Detent solenoid loose.
Detent valve bore plug damaged.
Detent regulator valve pin short.
Hole in line.
Loose fitting.
Restricted orifice or incorrect orifice size.
Carbon buildup at modulator vacuum fitting.
Pinched line.
Grease in pipe (delayed or no upshift cold).
TEST SPECIFICATIONS
Hydraulic Pressure Test Specifications
Gear Range
Neutral
1000
Yes
D-Range
Yes
D-Range
1000
Yes
1-Range
1000
Yes
Reverse
1000
Yes
D-Range w i t h
detent & switch on
1000
Yes
D-Range
30 MPH on speedometer
w i t h throttle closed
No
80142
2C-24
AUTOMATIC TRANSMISSION
Gear Range
D-Range*
1000
No
D-Range*
3000
No
D-Range**
1000
No
D-Range***
1000
No
80143
Series
Transmission
400-JS
400-JM
400-JK
400-JR
258
304
360
258
360
3.54
Tire Size
J-10 Truck
400-JC
Engine
Axle
Wagoneer
Cherokee
4.09
3.54
4.09
3.07
3.54
3.54
3.73
4.09
4.09
H78 x15
HR78 x 15
8.00 x 16.5
8.75 x 16.5
9.50 x 16.5
H R 7 8 x 15
H 7 8 x 15
HR78 x 15
H78 x 15
HR78 x 15
728
728
728
707
677
728
F78 x 15
F78 x 15
H78 x 15
HR78 x 15
H R 7 8 x 15
750
750
3.54
4.09
Closed Throttle:
1-2
23
10-18
2-10
8-16
11-19
2-10
9-17
6-14
20-28
5-13
17-25
4-12
15-23
12-20
4-12
10-18
4-12
10-18
3-11
9-17
3-11
8-16
1-2
23
6-16
17-27
5-15
14-24
6-16
25-35
5-15
21-31
18-28
41-51
16-24
36-44
11-21
25-35
9-19
21-31
9-19
32-42
9-19
3242
8-18
30-40
7-17
27-37
1-2
2-3
16-26
33-43
13-23
28-38
19-29
41-51
16-26
35-45
30-40
52-62
25-35
45-55
20-30
39-49
16-26
33-43
23-33
45-55
23-33
44-54
21-31
42-52
19-29
38-48
24-36
20-32
29-41
56-68
49-61
21-33
42-54
31-43
61-73
30-42
54-66
36-48
65-77
26-38
38-48
24-36
46-58
31-43
43-55
60-72
28-40
57-69
26-38
52-64
3-11
3-11
3-11
Part Throttle:
To Detent:
Kickdown:
Wide Open Throttle
3-1
10-22
8-20
20-32
12-24
24-36
23-35
22-34
35-47
44-56
61-73
17-29
52-64
15-27
41-53
11-23
52-64
9-21
3-2
47-59
40-52
59-71
57-69
54-66
20-32
50-62
3-2
26-38
22-34
34-46
29 41
43-55
36-48
32-44
27-39
31-43
30 42
29-41
26-38
Kickdown:
Part Throttle
60624
IN-VEHICLE SERVICE
AND ADJUSTMENT
Control aiv8 and Oil Filter
Potent Solenoid
Governor
Manual Linkage
Pagt
Page
2C-27
2C-27
2C-27
2C-25
Modulator 2C-28
Neutral Switch 2C-26
Parking Linkage 2C-28
Pressure Regulator Valve 2C-26
MANUAL LMKABE
Ai|istfflMt
(1)
(2)
(3)
enough
6).
QUADRANT
QUADRANT
80140
Fig. 2C-6
2C-26
AUTOMATIC TII1S1ISSI01
NEUTRAL SWITCH
Aljistient
(1) Apply parking brake.
(2) Check and adjust manual linkage if necessary.
(3) Remove neutral switch from steering column.
Switch is located at base of column (fig. 2C-6).
(4) Place gearshift lever in Park and lock column.
(5) Move neutral switch actuating lever until lever
aligns with letter "P" stamped on back of switch.
(6) Insert 3/32 (2.38 mm) drill in hole located below
letter " N " stamped on back of switch.
(7) Move switch actuating lever until it stops
against drill.
(8) Position neutral switch on column, install
switch attaching screws, and remove drill.
(9) Check switch operation. Engine should start in
Park and Neutral positions only. Backup lamp should
light when gearshift lever is in Reverse position only.
Fig. 2C-8
Installation
FOR I D E N T I F I C A T I O N - S Q U A R E D
O F F PRESSURE R E G . BOSS
Fig. 2C-7
t
J
A
3
^
0
AUTOMATIC TRANSMISSON
DETENT SOLENOID
Removal
(1) Raise vehicle.
(2) Position drain pan under transmission.
(3) Remove oil pan and oil filter.
(4) Remove and discard oil pan gasket and remove
and discard intake pipe O-ring seal if seal was not removed with filter and intake pipe.
(5) Disconnect detent solenoid lead at electrical connector in case.
(6) Remove bolts attaching solenoid to valve body
and remove solenoid.
Installation
(1) Position solenoid on valve body and install solenoid attaching bolts. Tighten bolts to 7 foot-pounds (10
Nm) torque.
(2) Connect solenoid wire to electrical connector in
case.
(3) Install O-ring seal on intake pipe.
(4) Install intake pipe and filter.
(5) Install oil pan gasket and oil pan. Tighten oil pan
bolts to 12 foot-pounds (16 Nm) torque.
(6) Lower vehicle.
(7) Fill transmission with Jeep transmission fluid,
Dexron, or equivalent.
2C-27
Installation
(1) Position control valve-to-spacer plate gasket on
control valve.
(2) Install governor pipes and manual valve in valve
body.
(3) Install governor screen in governor pipe.
(4) Remove shim stock or feeler gauge from between spacer plate and front servo piston. Install control
valve and governor pipes. Be sure governor pipes are
aligned in case bores.
(5) Install control valve attaching bolts. Tighten
bolts alternately and evenly to 8 foot-pounds (11 N*m)
torque.
(6) Install detent roller spring assembly.
(7) Connect detent solenoid wire to electrical connector in case.
(8) Install O-ring on intake pipe and install oil filter
and intake pipe.
(9) Position gasket on oil pan and install oil pan.
Tighten oil pan bolts to 12 foot-pounds (16 N*m) torque.
(10) Lower vehicle.
(11) Fill transmission with Jeep transmission fluid,
Dexron, or equivalent.
GOVERNOR
Roioval
(1) Raise vehicle.
(2) Position drain pan under transmission oil pan.
(3) Remove oil pan and oil filter.
(4) Remove and discard intake pipe O-ring and oil
pan gasket.
2C 28
AUTOMATIC TRANSMISSION
Installation
Installation
(1) Install governor assembly.
(2) Install gasket, cover, and
screws.
(3) Lower vehicle.
cover
attaching
MODULATOR
Rovnoval
(1) Raise vehicle.
(2) Disconnect vacuum hose from modulator.
(3) Remove modulator adapter attaching screw and
retainer (fig. 2C-9).
PARKING LINKAGE
Removal
(1) Raise vehicle.
(2) Disconnect manual linkage and remove manual
lever from manual shaft.
NOTE: The manual lever attaching nut is a metric size
nut
(3) Remove oil pan and oil filter. Discard pan
gasket.
(4) Unthread jamnut retaining detent lever on manual shaft (fig. 2C-10).
PARKING
PAWL
80144
Fig. 2C-9
Modulator Assembly
LEVER
Fig. 20-10
SEAL
Parking Linkage
80141
AUTOMATIC TRANSMISSON
(5) Remove
using pliers).
(6) Remove
(7) Remove
assembly.
(8) Remove
and bracket.
(9) Remove
(10) Remove
(11) Remove
ing pawl.
Installation
(1) Install parking pawl, parking pawl shaft, and
cup plug. Apply nonhardening sealant to cup plug before
installation.
2C-29
OUT-OF-VEHICLE SERVICE
A N D OVERHAUL
Page
Band Adjustment
Bushing Replacement
Specifications
Subassembly Overhaul
Torque Converter
2C-32
2C-64
2C-79
2040
2C-30
TRANSMISSION REMOVAL
(1) Remove transmission dipstick.
(2) If radiator is equipped with shroud, remove
bolts attaching shroud to core support.
(3) Raise vehicle on hoist.
(4) Mark front and rear universal joints and axle
yokes for assembly reference.
(5) On Cherokee, Wagoneer and Truck models, remove parking brake cable jamnut and adjuster nut, remove clip attaching parking brake cable to crossmember
and pull cable out of crossmember.
(6) On Cherokee and Wagoneer models with low
range reduction unit, remove reduction unit shift lever
from shift shaft and remove reduction unit.
(7) On CJ and Truck models with low range reduction upit, disconnect shift rod at reduction unit shift
lever and remove reduction unit.
(8) Disconnect speedometer cable.
(9) Mark Emergency Drive control vacuum lines for
assembly reference and disconnect lines.
(10) Disconnect Emergency Drive indicator lamp
wire.
(11) Remove bolt attaching vacuum line routing
bracket to rear of transfer case.
(12) Disconnect detent solenoid wire at transmission
case connecter.
Page
Transmission Assembly
Transmission Disassembly
Transmission Installation
Transmission Removal
2C-71
20-30
2C-30
2C-29
2C-30
AUTOMATIC TRANSMISSION
TORQUE CONVERTER
With the transmission removed and mounted on a
transmission jack, remove the torque converter by pulling it straight out of the converter housing.
N O T E : It is not necessary to replace the converter
when a transmission malfunction has occurred unless
the converter has malfunctioned or is damaged. However, it is recommended that the transmission and converter be properly cleaned, oil filter replaced and cooler
and cooler lines flushed after any problem that generates sludge, dirt, or chips.
TRANSMISSION DISASSEMBLY
(1) Remove transfer case.
(2) Install Holding Fixture J-8763-01 on transmission case with modulator positioned on side of holding
fixture nearest bench.
CAUTION: Do not overtighten the holding
clamp screw. This will bind the center support.
fixture
AUTOMATIC TRANSMISSON
Fig. 20-13
Fig. ZC-11
2C-31
Fig. 20-14
Fig. 2E-12
2C-S2
AUTOMATIC TRANSMISSION
^^^^^^^^^^^^^^^^^^^^^^
Rear Servo
Removal
Fifj. 1C-15
G O V E R N O R
P I P E S (2)
C O N T R O L
V A L V E
Band Adjustment
In the Jeep automatic transmission, only the rear
band is adjustable. The front band does not have any
provision for adjustment.
Rear band adjustment is determined by band apply
pin length. Three different length apply pins are available for adjustment purposes.
N O T E : The required length apply pin must be selected
before the transmission is completely
disassembled.
This is necessary because the rear servo, rear band, and
geartrain must be in the installed position in order to
measure and select the pin length needed.
Fig. 2C-17
AUTOMATIC TRANSMISSON
2C 33
REAR S R V O
2C-19
Fig. 20-21
l i a r l u i Ad|ustmenl
2CS4
AUTOMATIC TRANSMISSION
Fig. 2C-25
Fig. 2C-23
Fig.
Fig. 2C-26
AUTOMATIC TRANSMISSON
20-35
THICKNESS
0.060
0.071
0.082
0.093
0.104
0.115
0.126
to
to
to
to
to
to
to
0.064
0.075
0.086
0.097
0.108
0.119
0.130
(1.52-1.62
(1.80-1.90
(2.08-2.18
(2.36-2.46
(2.64-2.74
(2.92-3.02
(3.20-3.30
COLOR/NO.
mm)
mm)
mm)
mm)
mm)
mm)
mm)
Yellow
Blue
Red
Brown
Green
Black
Purple
- 0
- 1
- 2
3
4
- 5
6
Fig. 2C-27
80682
90002
Fig. 2C-28
2G-36
AUTOMATIC TRANSMISSION
Fig. 2C-31
shaft-to-case
seal
using
Fig. 2C-30
Fig. 2C-32
AUTOMATIC T1AIS1SSSOI
Fig. 2C-35
Removal
Fig. 20-34
Fig. 2C-36
2C-37
2G-38
AUTOMATIC TRANSMISSION
Thickness
(Inch)
0.074
0.082
0.090
0.098
0.106
0.114
to
to
to
to
to
to
0.078
0.086
0.094
0.102
0.110
0.118
(1.87-1.98
(2.08-2.18
(2.28-2.38
(2.48-2.59
(2.69-2.79
(2.89-2.99
mm)
mm)
mm)
mm)
mm)
mm)
None
1 Tab Side
2 Tab Side
1 Tab OD
2 Tabs OD
3 Tabs OD
1
2
3
4
5
6
70519
Intermediate Clutch
Removal
Fig. 2C-37
Fig. 2G-38
Fig. 2C-39
Fig. 2C-40
Removal
Fig. 2G-42
tofer
0.040-1 NCH
thrust
90006
Fig. 2C-41
rig. 2C-43
2C-40
AUTOMATIC TRANSMISSION
SURASSEMRLY OVERHAUL
Center Support i l l Gear Unit
(1) Lift and remove center support from gear unit
(fig. 2C-45).
(2) Remove thrust washer located between center
support and reaction carrier (fig. 2C-46).
(3) Remove center support-to-sun gear races and
thrust bearing.
(4) Remove reaction carrier and roller clutch from
output carrier as assembly (fig. 2C-47).
(5) Remove front internal gear ring from output
carrier (fig. 2C-48).
(6) Remove sun gear from output carrier (fig. 2C48).
(7) Remove plastic or metal thrust washer located
between reaction carrier and output carrier.
NOTE: The plastic washer is factory installed
Service replacement washers are made of metal.
42468
Fig. 2C-45
Removing
Center Support
only.
90007
Fig. 2C-46
AUTOMATIC TRANSMISSON
Fig. 2C-48
Fig. 20-50
2C-41
2C-42
AUTOMATIC TRANSMISSION
Gewirner >
All governor components, except the driven gear, are
select-fit components and are individually calibrated assemblies. The governor, including the driven gear, is
serviced as a complete assembly only. However, the
driven gear may be serviced separately if required.
In order to replace the driven gear, it is necessary to
disassemble the governor assembly.
NOTE: Disassembly may also become necessary if dirt
or foreign material has entered the governor causing
improper operation.
Disassembly
(1) Cut off one end of each governor weight pin and
remove pins, thrust cap, weights and springs (fig. 2C51).
NOTE: The governor weights are interchangeable
side to side and need not be identified.
from
Wash all parts in clean solvent, air dry the parts and
blow out all passages using compressed air.
Inspect the governor sleeve for nicks, burrs, scoring,
or galling.
Check the governor sleeve for free operation in the
case bore.
Inspect the governor valve for nicks, burrs, scoring or
galling.
Check the governor valve for free operation in the
governor sleeve bore. Inspect the governor driven gear
for nicks, burrs or damage.
Fig. 2C-51
Fig. 2C-52
Fig. 2C-53
AUTOMATIC TRANSMISSON
2C-43
Fig. 2C-55
J42476
Fig. 2C-54
J42475
Fig. 2C-56
Governor Assembly
2C44
AUTOMATIC TRANSMISSION
Front Servo
N O T E : Do not remove the teflon ail seal ring from the
front servo piston unless the seal ring requires replacement. Service oil seal rings are aluminum instead of
teflon.
Wit
T E F L O N O I L SEAL R I N G
RETAINER RING
S E R V O PIN
SERVO SPRING
\
\
S E R V O PISTON
SPRING R E T A I N E R
J 4 3 0 2 2
Fig. 2C-57
J42478
Fig. 2C-59
Rear Servo-Accumlater
Disassembly
(1) Install spring retainer with cap facing downward and install spring, and flat washer on servo pin
(fig.2C-60).
AUTOMATIC TRAHSMISSON
2C-45
PISTON
E-RING
R E T A I N E R
A C C U M U L A T O R
PISTON
TOOL
'J-22259-01
S E R V O OIL
SEAL
OIL SEAL
SPRING
R E T A I N E R
S E R V O
PIN
J42480
J43023
2C-60
Fig.2C-61E-RingRetainerRemoval
Control Valve
Disassembly
OIL
SEAL
RING
(TEFLON)
A C C U M U L A T O R
SPRING
A C C U M U L A T O R
E-RING
PISTON
RETAINER
Fig.
2042
2C-46
AUTOMATIC TRANSMISSION
J42483
Fig. 2C-63
DH>
mmmmmum
USED IN
MODELS
JS, JM, J R
ONLY
i t
1.
2.
3.
4.
5.
6.
7.
8.
9.
USED IN
MODELS
JC, J K
ONLY
Control Valve
Manual Valve
Retaining Pin
1-2 Bushing
1 -2 Regulator Valve
1-2 Regulator Spring
1-2 Detent Valve
1-2 Valve
2-3 Valve
w { 7 ^) |
<S=3
I '
L.
r "
ess
10.
11.
11
12.
13.
14.
15.
16.
2-3 Spring
2-3 Modulator Valve
2-3 Modulator Valve
2-3 Valve Spring
(Not used in JC Model)
2-3 Bushing
Retaining Pin
Retaining Pin
Bore Plug
Fig. 2C-64
17.
18.
19.
20.
21.
22.
23.
3-2 Spring .
'
Spacer
3-2 Valve
1-2 Accumulator Primary
Spring (Used in Models
JM, JS, JR only)
1-2 Accumulator Valve
Bore Plug
Retaining Pin
24.
25.
26.
27.
28.
29.
30.
Retaining Pin
Bore Plug
Detent Valve
Detent Regulator
Spacer
Detent Spring
1-2 Accumulator
Secondary Spring
(Used in Model JC only)
4 2 4 8 2
AUTOMATIC TBANSMISSON
2C-47
Oil Pump
PRESSURE
REGULATOR
-VALVE
PUMP
COVER
90009
Fig. 2C-66
'if
DRIVE
GEAR
DRIVEN
GEAR
RETAINING
PIN
BORE
PLUG
SPRING
RETAINER
WASHER
SNAP
RING
90010
PRESSURE
BOOST
BUSHING
PRESSURE
BOOST
VALVE
Fig. 2C-65
OIL
PUMP
COVER
Fig. 2C-67
J42484
Inspection
Fig. 2C-68
2C-48
AUTOMATIC TRANSMISSION
EXHAUST
MODULATOR
OR
HOLE
VENT
Fig. 20-70
\.
CONVERTSF
\
J42488
\-COOLER
RETURN
J43024
Fig. 2C-IS
Assambiy
tangs
AUTOMATIC TRANSMISSON
2C-49
Disassembly
90011
Fig. 2C-74
2C-50
AUTOMATIC TRANSMISSION
C A U T I O N : Production-built transmissions use a direct clutch piston without a check ball. The forward and
direct clutch pistons are similar in appearance. Be sure
the forward clutch piston is identified during disassembly so it will be installed correctly. Also, the produc tion- built forward clutch piston will be aluminum or
stamped steel.
(10) Remove center piston seal from forward clutch
housing (fig. 2C-77).
42495
Fig. 2C-77
Inspection
Fig. 2G-75
J42494
Fig 2C-76
AUTOMATIC TRANSMISSON
transmission build date before ordering a replacement
part. Refer to the transmission serial number stamped
on the ID tag attached to the right-side of the transmission case. The first two digits of the serial number
denote the build date.
Assembly
2C-51
(7) Press short-spline end of turbine shaft into forward clutch housing using arbor press if shaft was
removed.
(8) Place thrust washers on forward clutch hub. Be
sure bronze washer is installed on side of hub facing
forward clutch housing. Use petroleum jelly to retain
washers.
(9) Install hub and washers in clutch housing (fig.
2C-79).
(10) Install four composition-faced, three flat steel,
and one waved steel clutch plate (plate with U-notches)
in clutch housing. Install waved steel plate first, then
alternately install composition-faced plates and flat
steel plates (fig. 2C-80 and 2C-81).
Fig. 2C-79
(6) Compress springs using Clutch Spring Compressor J-25148 and arbor press and install spring retainer-to-piston snap ring.
20-52
AUTOMATIC TRANSMISSION
Fig. 20-81
IDENTIFICATION
IDENTIFICATION
V NOTCH
USAGE:
OPTIONAL
IDENTIFICATION
NONE
U NOTCH
USAGE! OPTIONAL
USAGE! OPTIONAL
Fig. 2C-82
AUTOMATIC T1A1SIISSOI
2C-53
90014
Fig. 2C-83
42502
Disassembly
F!|. 2C-84
DIRECT C L U T C H
PISTON RELEASE
SPRINGS
NOTE , Some transmission models use five composition-faced and five steel clutch plates. Refer to the
Clutch Plate Application Chart at the end of this section
for details.
(5) Using Clutch Spring Compressor Tool J-25149
and arbor press, compress spring retainer and remove
snap ring attaching spring retainer to direct clutch
housing.
(6) Remove spring retainer, release springs, and
piston (fig. 2C-88).
INTERMEDIATE
ROLLER
CLUTCH
DIRECT
CLUTCH
INNER
SEAL
INTERMEDIATE
CLUTCH
RETAINER
SNAP
RING
DIRECT C L U T C H
SPRING R E T A I N E R
DIRECT
CLUTCH
OUTER
SEAL
DIRECT
CLUTCH
CENTER
SEAL
DIRECT
CLUTCH
HOUSING
AND
RACE
ASSEMBLY
INTERMEDIATE
CLUTCH
OUTER
RACE
90015
20-54
AUTOMATIC TRANSMISSION
so it will be installed correctly. The service replacement
direct clutch piston contains a check ball. Also, the production-built direct clutch piston will be aluminum or
stamped steel.
(7) Remove outer seal and inner seal from piston
(fig. 2C-85).
(8) Remove center seal from direct clutch housing.
Inspection
Fig. 2C-86
Inspect the roller clutch for damaged rollers and inspect the inner cam and outer races (inner cam on clutch
housing) for scratches or wear.
Inspect the direct clutch housing for cracks, wear,
restricted oil passages, or wear of the clutch plate drive
lugs.
Inspect the composition-faced and steel plates for
signs of wear or burning. Inspect the backing plate for
scratches or other damage. Inspect the piston for cracks
and for free operation of the check ball. Inspect the
springs for distortion or signs of collapse.
NOTE: If one or more of these springs require replacement, discard all of them and install 16 service replacement springs.
J42506
Fig. 2C-87
Assembly
with
J42508.
Fig. 2C-88
NOTE: Production-bullt
transmissions use a direct
clutch piston without a check ball The forward and
direct clutch pistons are similar in appearance. Be sure
the direct clutch piston is identified during disassembly
Fig. 2C-89
AUTOMATIC TRANSMISSON
2C-55
Fig. 2C-90
Fig. 2C-93
Fig. 2C-91
Fig. 2C-92
2C-56
AUTOMATIC T1A1SMIISI01
INTERMEDIATE CLUTCH
Fig. 2C-96
Fig. 2C-94
INTERMEDIATE CLUTCH
R O L L E R ASSEMBLY
\
DIRECT C L U T C H
HOUSING A N D
C A M ASSEMBLY
^^loiiBSIlii \ ^
Fig. 2C-97
Retainer Installation
J42513
Fig.2C-95
Fig. 2C-98
AUTOMATIC TRANSMISSON
Center Support
2C-57
Disassembly
rings are
hook-type
(2) Compress spring retainer to center support assembly, remove snap ring, and carefully release pressure on spring retainer.
(3) Remove spring retainer, three release springs,
intermediate clutch spring guide and piston.
(4) Remove inner and outer seals from intermediate
clutch piston.
NOTE: Do not remove the three screws attaching the
roller clutch inner race to the center support.
Inspection
Fig. 20-99
support
2C-58
AUTOMATIC TRANSMISSION
INTERMEDIATE
CLUTCH PISTON
I N T E R M E D I A T E CLUTCH
SPRING GUIDE
CLUTCH
INNER SEAL
42521
42518
Fig. 2C-100
Fig. 2C-103
INTERMEDIATE
CLUTCH PISTON
CLUTCH
OUTER
SEAL
Fig. 2C-101
42519
SPRING
RETAINER
TOOL
J-21363
CENTER
SUPPORT
90017
90019
Fig. 2C-102
Fig. 2C-105
AUTOMATIC TRANSMISSION
2C-59
'
Fig. 2C-106
J42524
REACTION
CARRIER
Fig. 2C-108
Fig. 2C-107
Fig 2C-109
2C-60
AUTOMATIC TRANSMISSION
Fig. 2C-110
90021
Fig. 2 C - 1 1 2
42528
Fig. 2 G - 1 1 1
Fig. 20-113
AUTOMATIC TRANSMISSON
2C-61
Main Shaft
Inspection
Inspect the lining for cracks, flaking, burning, or looseness. Check the band for cracks or distortion and check
the end of the band for damage at the anchor lugs or
apply lugs. Replace any b a n d e x h i b i t i n g t h e s e
conditions.
intension Housing
Inspection
Fig 2 C - 1 1 4
Output Shaft
Inspection
Inspect the gear for cracks, the gear teeth for damage
or wear, and the splines for damage.
2C-62
AUTOMATIC TRANSMISSION
w
,_
ir
^"-tt
Apply suction to the vacuum tube and check for diaphragm leaks.
Inspection
--
Transmission Case
Inspection
Fig. 2C-115
42534
Fig. 2C-116
AUTOMATIC TRANSMISSON
2C-63
DRIVE
Fig. 2C-118
Torqui Convertar
Fig. 2C-119
Inspection
(1) Install and tighten Leak Detecting Fixture J21369 on torque converter housing (fig. 2C-119).
(2) Apply 80 psi air pressure to fixture.
(3) Submerge housing in water and check for leaks.
2C-64
AUTOMATIC TRANSMISSION
RUSHING REPLACEMENT
INSTALLER
Fig. 2C-121
CAUTION: To avoid damaging the shaft bearing journal surface, the vise must be equipped with protective
jaws and must not be overtightened.
(3) Thread Remover J-21465-16 into bushing. Remove bushing by bumping outward with Slide Hammer
J-2619 (fig. 2C-120).
(4) Remove output shaft from vise.
(5) Clean flange bushing bore.
(6) Position output shaft on wood blocks so flange
faces upward and shaft downward.
(7) - Assemble Installer J-21465-1 and Driver Handle
J-8092.
(8) Position replacement bushing on Installer J21465-1.
(2) Assemble Adapter J-2619-4, Slide Hammer J2619, and Remover J-2146545 (fig. 2C-122).
(3) Thread Remover J-21465-15 into bushing. Remove bushing by bumping outward with Slide Hammer
J-2619 (fig. 2C-122). Reposition shaft in vise and repeat
procedure to remove opposite bushing.
(4) Remove shaft from vise.
(5) Clean shaft bushing bores.
SLIDE H A M M E R
J-2619
80146
Fig. 20-120
ADAPTER
SLIDE
HAMMER
J-2619
Fig. 20-122
80148
AUTOMATIC TRANSMISSON
(6) Assemble Installer J-21465-5 and Driver Handle
J-8092 and position replacement bushing on Installer J21465-5.
(7) Support shaft on wood block (fig. 2C-123).
(8) Center bushing in shaft bore and drive bushing
into bore until installer tool bottoms (fig. 2C-123). Reposition shaft in vise and repeat procedure to install opposite bushing.
(9) Flush shaft with solvent to remove any chips or
shavings generated by bushing installation.
Fig. 2C-123
2C-65
Fig. 20-124
2C66
AUTOMATIC TRANSMISSION
VIEWB
Fig. 2C-125
Fig. 2C-126
AUTOMATIC TRANSMISSON
2C-67
Fig. 20-128
Fig. 20-127
(2) Assemble Adapter J-2619-4, Slide Hammer J2619, and Remover J-21465-15 (fig. 2C-129).
(3) Thread Remover J-21465-15 into bushing. Remove bushing by bumping outward with Slide Hammer
J-2619 (fig. 2C-129).
(4) Remove shaft and pump cover assembly from
vise. Support assembly on wood block. Position wood
block under pump cover seal ring hub.
(5) Clean bushing bore.
2C-68
AUTOMATIC TRANSMISSION
SLIDE
HAMMER
J-2619
80156
Fig. 20-129
80157
Fig. 20-130
automatic Tinsiissei m m
Fig. 2C-133
2C-70
AUTOMATIC TRANSMISSION
80162
AUTOMATIC TRANSMISSON
TRANSMISSION ASSEMBLY
NOTE: When assembling the transmission and subassembly units, lubricate all bushings, bearings and
bearing thrust surfaces with transmission fluid and lubricate both sides of all thrust washers with petroleum
jelly.
2C-71
washer on output carrier with washer tabs facing downward and located in corresponding pockets of carrier.
Use petroleum jelly to retain parts.
Fig. 2C-138
Fig. 2C-137
42540
Fig. 2C-139
2C-72
.
AUTOMATIC TRANSMISSION
;asr:~7MZ^zz^BBCZZZ^
lammr-
N O T E : Service replacement
90027
Fig. 2C-140
Fig. 2C-142
Fig. 2C-141
AUTOMATIC TRANSMISSON
2C-73
(20) Insert rear spline (longest spline) of sun gearshaft into sun gear spline.
N O T E : When the reaction carrier is held stationary,
the center support should turn counterclockwise only.
(21) Using Gear Assembly Clamp Set J-21795, clamp
gear unit assembly together until it is installed.
(22) Install output shaft-to-case thrust washer and
seat washer so washer tabs are inserted into corresponding holes of shaft (fig. 2C-147). Use petroleum jelly to
retain thrust washer.
N O T E : Do not use aplastic thrust
washer.
J 4 2 5 4 4
Fig. 2C-143
Fig. ZC-144
42468
Fig. 20-146
Fig. 2C-14S
Fig. 2C-147
2C-I4
AUTOMATIC TIAISMISSiOl
Fig. 2C-149
Fig. 2C-148
A D J A C E N T TO B A N D
ANCHOR PIN
90029
Fig. 2C-150
AUTOMATIC TRANSMISSON
2C-75
Fig. 2C-151
Thickness
(Inch)
0.074
0.082
0.090
0.098
0.106
0.114
to
to
to
to
to
to
0.078 (1.87-1.98
0.086 (2.08-2.18
0.094 (2.28-2.38
0.102 (2.48-2.59
0.110 (2.69-2.79
0.118 (2.89-2.99
Notches and/or
Numeral
mm)
mm)
mm)
mm)
mm)
mm)
None
1 Tab Side
2 Tab Side
1 Tab OD
2 Tabs OD
3 Tabs OD
1
2
3
4
5
6
70519
Front lend
Install front band with band anchor hole positioned
over band anchor pin and band apply lug facing servo
hole.
Manual Linkage
Fig. 2C-152
2C-76
AUTOMATIC TRANSMISSION
(4) Install forward clutch and turbine shaft. Position direct clutch hub so end of main shaft will bottom
on end of forward clutch hub. When forward clutch is
seated, it will be approximately 1-1/4 inch (31.75 mm)
from case oil pump face.
Oil Pump
(1) Fabricate guide pins by grinding heads from two
spare 5/16-18 valve body bolts.
(2) Install, guide pins in pump mounting bolt holes
of transmission case.
(3) Position oil pump gasket on pump face of transmission case. Use petroleum jelly to retain gasket.
(4) Install pump assembly and all but one pump
attaching bolt and washer. Omit bolt and washer from
either 5 or 10 o'clock position.
(5) Tighten installed pump attaching bolts to 22
foot-pounds (30 Nm) torque.
Fig. 2C-153
J42554J
Fig. 2G-154
Direct Clutcft-^orward
(1) Install direct clutch and intermediate roller
clutch assembly.
(2) Rotate direct clutch housing until outer race of
roller clutch contacts intermediate clutch plates and hub
of clutch housing contacts sun gear shaft.
N O T E : Use Clutch Plate Alignment Tool J-21+396 to
align the plates to ease installation. However, if an
alignment tool is not available, it may be helpful to
remove the composition plates and steel plates from the
direct clutch housing while seating the assembly.
(3) Install forward clutch hub-to-direct clutch housing thrust washer on hub of forward clutch if not installed previously. Use petroleum jelly to retain washer.
Fig. 2G-155
(7) Measure front unit end play, and replace selective washer if necessary.
(8) Install remaining oil pump attaching bolt and
washer. Tighten bolt to 22 foot-pounds (30 N*m) torque.
AUTOMATIC TRANSMISSON
Fig. 2C-158
Fig. 2C-156
2C-77
lnrSirvi
(1) Install proper length band-apply pin. Refer to
Band Adjustment-Rear Band Apply Pin Selection.
(2) Install rear accumulator spring (fig. 2C-159).
Fig. 2C-159
(3) Lubricate rear servo assembly with transmission fluid and install servo assembly.
20-157
2C-78
AUTOMATIC TRANSMISSION
Oil Filter-Oil Pan
Fig. 2C-160
Fig. 2C-162
Modulator-Moditator Valve
Governor
Fig. 2C-161
Transfer Case
(1) Install replacement extension housing-to-transfer case gasket.
(2) Inspect transfer case output shaft seals. Replace
seals if damaged.
(3) Install transfer case on transmission. Tighten
transfer case attaching bolts to 42 foot-pounds (57 N*m)
torque.
SPECIFICATIONS
Transmission Specifications
Fig. 2C-163
Extension Housing
(1) Position replacement gasket on extension
housing.
(2) Position extension housing and and gasket on
transmission and install housing attaching bolts.
(3) Tighten housing attaching bolts to 20 footpounds (27 Nm) torque.
(4) Install snap ring on bearing.
(5) Slide bearing onto output shaft and start bearing into extension housing.
(6) Seat bearing in housing using plastic tip
hammer.
Model.
400
Ratios:
Low. . .
2.4815 to 1
Intermediate
1.4815 to 1
High
1 to 1
Reverse
2-.0769 to 1
Converter Stall Ratio
2.4 to 1
Oil Capacity
22 pt. (10.4 liters)
Modulator
. Vacuum Control
Converter Elements
3
Cooling
Water
Carrier Pinion End Play
0.009 to 0.024 inch (0.22-0.60 mm)
Pump Face to Rotor End Play. . 0 . 0 0 0 8 to 0.0035 inch (0.02-0.07 mm)
Front Unit End Play
0.003 to 0.024 inch (0.07-0.60 mm)
Bushing Clearance (Max.)
.0.008 inch (0.20 mm)
70520A
Torque Specifications
Service Set-To Torques should be used when assembling components.
J42561
Metric (N-m)
Service
Set-To
Torque
Service
Set-To
Torque
34
14
11
41
14
27
27
5
11
27
27
18
27
27
27
27
25
10
8
30
10
20
20
4
8
20
20
13
20
20
20
20
47
57
35
42
27
20
All torque values given in newton-meters and foot-pounds with dry fits
unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Markings
Chart in Section A of this manual for any torque specifications not
listed above.
70520B
2C-80
AUTOMATIC TRANSMISSION
Trans.
Model
258
Direct Clutch
Flat
Steel
Plates*
Waved
Steel
Plates
Composition
Plates
Flat
Steel
Plates
400-JC
304
400-JS
Cherokee
and
Wagoneer
360
400-J M
J-10 Truck
258
400-JK
J-10 and
J-20 Truck
360
400-J R
Series
Intermediate Clutch
Composition
Plates
Flat
Steel
Plates
Waved
Steel
Plates
Composition
Plates
Waved
Steel
Plates
CJ-7
<
AUTOMATIC TRANSMISSON
2C-81
Tools
J3
J-8763-01 TRANSMISSION
HOLDING FIXTURE
J-21368 A L I G N M E N T STRAP
PUMP A N D BODY
J-21363 I N T E R M E D I A T E C L U T C H
INNER S E A L
PROTECTOR
J-21795
GEAR ASSEMBLY
REMOVING AND
INSTALLING TOOL
J-25118 S L I D E
HAMMERS
J-25149 D I R E C T C L U T C H
SPRING COMPRESSOR
J-21885 A C C U M U L A T O R PISTON
RETAINER RING REMOVER-INSTALLER
J-21370-5 P I N - R E A R B A N D APPLY
J-246B4
COMPRESSOR T O O L
J-23093 CENTER SUPPORT
L O C A T I N G TOOL
J-25148 F O R W A R D C L U T C H
SPRING COMPRESSOR
J-21364
REAR U N I T
A N D PUMP
PROTECTOR
HUB
J-21362 F O R W A R D A N D DIRECT
C L U T C H INNER S E A L PROTECTOR
J-21409 F O R W A R D C L U T C H
OUTER SEAL PROTECTOR
42564
2C-82
AUTOMATIC TRANSMISSION
Tools (Continued)
J-2619-4
ADAPTER
J-21465-1
INSTALLER
J-21465-3
INSTALLER
J-8092
DRIVER
HANDLE
J-21465-8
REMOVER
INSTALLER
J-21465-9
ADAPTER RING
J-21465-6
REMOVER
INSTALLER
J-21465-13
DRIVER HANDLE
EXTENSION
J-21465-15
REMOVER
J-5907
OIL PRESSURE GAUGE
J-23108
V A C U U M GAUGE
J-21465-16
REMOVER
HYDRAULIC
FLOW C H A R T S
AUTOMATIC TRANSMISSION
2C-85
2C-86
AUTOMATIC TRANSMISSION
M A I N L I N E PRESSURE
INTAKE PRESSURE
CONVERTER PRESSURE
GOVERNOR PRESSURE
MODULATOR PRESSURE
DETENT PRESSURE
1-2 ACCUMULATOR PRESSURE I
GOVERNOR ASSEMBLY
VACUUM
MODULATOR ASSEMBLY
STRAINER ASSEMBLY
2D-1
SECTION
INDEX
Pip
21-1
21=12
M j i i W ! i t
& m
General
Identification
In-Vehicle Service
Oit-of-Vellile Service
Power Flow
Service Diagnosis
IlEITiFiClTill
21-39
Page
21-9
21-11
21-11
21-2
21-1
mm
2D-1
21-1
21-3
21-1
21-1
21-3
GENERAL
Tools
POWER FLOW
TO
FRONT
AXLE
J428'
Fig. 2 1 - 1
Neutral
2D-2
TRANSFER CASE
Fig. 2D-4
CJ M O D E L S
Fig. 2D-5
Fig. 2D-3
Toine
If the vehicle is disabled and must be towed with the
front wheels off the ground, towing speed and distance
must be limited. Towing speed must not exceed 30 mph
(48 k m / h ) for a distance no greater than 15 miles (24
km).
Ignition Key Available: Shift transmission and
transfer case into Neutral. Vehicle can now be towed
with all four wheels on the ground or with front or rear
wheels raised. If vehicle is equipped with locking hubs,
set them in LOCK position.
Ignition Key Not Available and Vehicle is Unlocked: Shift transmission and transfer case into Neu-
CHEROKEE A N D T R U C K
J42352
Jeep vehicles can be towed behind a recreational vehicle such as a motor home, but be sure you comply with
the following instructions to avoid damage to drivetrain
components. Be sure to check federal, state, and local
laws.
Manual Transmission
Turn ignition key to Off position to unlock steering
wheel.
Shift transmission and transfer case into Neutral
position.
Turn locking hubs to LOCK position, if equipped.
TRANSFER-CUE- 11-3
L
IN-VEHICLE SERVICE
Shift Rod Oil Seal Replacement
Cherokee-Truck
Condition
J U M P S OUT O F 2 WD
Possible Cause
(1) Main shaft gear disengaged
from r e a r output shaft
Correction
(1) Check torque on main shaft
gear nut.
sliding gear.
(2) Shift lever torsion spring
not holding.
J U M P S OUT OF 4 W D H I G H
sliding gear.
(3) Shift lever torsion spring -
not holding.
(4) Rear shift rod poppet spring
not holding.
70540
214
TRANSFER CASE
(2) Remove bolts attaching transfer case shift housing to support tube and pull shift lever straight back to
4H position.
(3) Raise vehicle.
(4) On models with eight-cylinder engine, place support stand under transmission and remove r e a r
crossmember.
(5) Disconnect front propeller shaft at transfer case
yoke. Mark shaft and yoke for assembly alignment
reference.
(6) Remove clevis pins connecting control links to
transfer case shift rods.
(7) On models with 3-speed transmission, remove
transfer case shift housing from support tube using
brass drift and hammer.
(8) Remove shift rod seal using tool J-25175 (fig. 2D6).
(9) Install replacement seal using Thimble and
Driver Tools J-25167 (fig. 2D-7).
(10) On models with 3-speed transmission, install
transfer case shift housing on support tube.
(11) Install clevis pins connecting control links to
transfer case shift rods. Use replacement cotter pins to
secure pins.
(12) Connect propeller shaft to transfer case yoke.
Align shaft and yoke using alignment marks made during disassembly.
(13) On models with eight-cylinder engine, install
rear crossmember and remove transmission support
stand.
(14) Lower vehicle.
(15) On models with 3-speed transmission, install
shift housing-to-support tube attaching bolts and install
shift lever boot and knob.
Fig. 20-6
Fig. 20-7
C J Models
TOOL
J-251! 7B
(4) Remove transfer case yoke nut and washer using tool J-8614-01 (fig. 2D-8).
(5) Remove transfer case yoke using tools J-861401,02,03 (fig. 2D-9).
(6) Remove oil seal using tool J-25180 (fig. 2D-10).
(7) Install replacement seal using tool J-25160.
(8) Install yoke, washer, and nut. Tighten nut to 140
foot-pounds (163 Nm) torque. Use tool J-8614-01 to hold
yoke while tightening nut.
Removal
TRANSFER CASE
2D-5
Disassembly
Fig. 21=1
'i^m
Yoke Removal
/A'
Installation
J42359
II
(1) Install bearing cap and install bearing cap-totransfer case bolts. Tighten bolts to 30 foot-pounds (41
Nm) torque.
20-6
TRANSFER CASE
mpmmw
REAR B E A R I N G CAP
*m?mmw
w-mpmr
*mgmmp
R E A R PROPELLER
^raaEiarar
R E A R OUTPUT S H A F T
Fig. 20-11
OUT-OF-VIHiCLE SERVICE
' '
Drive
TRANSFER IASE
1 . S H I F T ROD - R E A R OUTPUT
SHAFT SHIFT FORK
2. S H I F T ROD - F R O N T OUTPUT
S H A F T SHI FT F O R K
3. S H I F T ROD O I L S E A L
4 . I N T E R L O C K PLUG
5. I N T E R L O C K
6. POPPET B A L L SPRING
7. POPPET B A L L
8. F R O N T B E A R I N G CAP
9. F R O N T B E A R I N G CAP G A S K E T
10. F R O N T O U T P U T S H A F T T H R U S T WASHER
11. FRONT OUTPUT SHAFT GEAR
12. F R O N T O U T P U T S H A F T S L I D I N G G E A R
13. SETSCREW
14. F R O N T O U T P U T S H A F T S H I F T F O R K
15. F R O N T O U T P U T S H A F T
16. F R O N T O U T P U T S H A F T SPACER
17. F R O N T O U T P U T S H A F T F R O N T B E A R I N G CUP
18. F R O N T O U T P U T S H A F T F R O N T B E A R I N G
19. F I L L E R PLUG
20. T R A N S F E R CASE
2 1 . T H I M B L E COVER
22. F R O N T O U T P U T S H A F T R E A R B E A R I N G
23. F R O N T O U T P U T S H A F T R E A R B E A R I N G CUP
24. F R O N T O U T P U T S H A F T R E A R B E A R I N G CUP SHIMS
25. COVER P L A T E
26. I N T E R M E D I A T E S H A F T
27. I N T E R M E D I A T E S H A F T O-RING
28. LOCK P L A T E
29. LOCK P L A T E B O L T
30. R E A R O U T P U T S H A F T FRONT B E A R I N G
Fig. 20-12
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
REAR O U T P U T S H A F T F R O N T B E A R I N G CUP
SPEEDOMETER D R I V E GEAR
REAR O U T P U T S H A F T B E A R I N G S H I M
REAR B E A R I N G CAP G A S K E T
REAR B E A R I N G CAP
BREATHER
REAR O U T P U T S H A F T REAR B E A R I N G CUP
REAR O U T P U T S H A F T REAR B E A R I N G
REAR B E A R I N G CAP O I L S E A L
REAR Y O K E
REAR Y O K E WASHER
REAR Y O K E N U T
SPEEDOMETER SLEEVE
SPEEDOMETER D R I V E N G E A R
SPEEDOMETER BUSHING
B O T T O M COVER G A S K E T
B O T T O M COVER
D R A I N PLUG
REAR O U T P U T S H A F T
REAR O U T P U T S H A F T S L I D I N G GEAR
M A I N S H A F T GEAR
SETSCREW
REAR O U T P U T S H A F T S H I F T F O R K
I N T E R M E D I A T E GEAR T H R U S T WASHER
I N T E R M E D I A T E G E A R B E A R I N G SPACER
I N T E R M E D I A T E GEAR S H A F T N E E D L E B E A R I N G S
I N T E R M E D I A T E GEAR B E A R I N G SPACER
I N T E R M E D I A T E GEAR
I N T E R M E D I A T E GEAR S H A F T N E E D L E B E A R I N G S
I N T E R M E D I A T E GEAR B E A R I N G SPACER
I N T E R M E D I A T E GEAR T H R U S T WASHER
FRONT B E A R I N G CAP
21-8
TRANSFER CASE
TOOL
J-25142
\
Fig. 21-13
Asssmblf
2044
Enl Play
Removal
NOTE: The rear washer can be held in place by starting the intermediate shaft into the case and positioning
the washer on the shaft. Hold the front washer in position using petroleum jelly.
NOTE: On vehicles with eight-cylinder engine and hspeed transmission, the transfer case must be removed
in order to remove the control case.
21-11
TRANSFER CASE
S H I F T L E V E R KNOB
LOCKNUT
DUST COVER
CAPSCREW A N D
LOCKWASHER
S H I F T ROD L I N K
(
S H I F T R O D PAWL
F U L C R U M BALL
R E T A I N E R A N D PIN
H I G H / L O W RANGE
S H I F T ROD
COTTER P I N
C L E V I S PIN
4 WD/NEUTRAL
SHIFT ROD
S H I F T LEVER
C O N T R O L CASE
S H I F T FORK
LOCK SCREW
COVER GASKET
SUPPORT TUBE
SHIFT LEVER
rORSION SPRING
COVER
T O R S I O N SPRING
R E T A I N E R ROD
Fig. ZD-15
isassembly
'"
J42364
'
the
Installation
(1) Place shift lever in 4H position.
(2) Install control case on support tube but do not
install bolts.
(3) Attach control case shift rods to shift rod links
with clevis pins.
(4) Install and tighten shift control case-to-support
tube lockscrews.
(5) Install boot, trim ring, and shift lever knob.
Fig. ZD-16
Shift Positions
SPECIFICATIONS
Model 20 Transfer Case Specifications
Type
Make .
Model
Gear Ratio:
High. .
Low.
Two-Wheel Drive
Lubricants
Four-Position
Spicer
20
1:1
2.03:1
1:1
60631
21*12
TRANSFER CASE
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
120
30
14
14
30
14
30
30
90-150
28-32
12-15
12-15
28-32
12-15
28-32
28-32
163
41
19
19
41
19
41
41
122-203
38-43
16-20
16-20
38-43
16-20
38-43
38-43
A l l torque values given in newton-meters and foot-pounds w i t h d r y fits unless otherwise specified.
Refer t o the Standard Torque Specifications and Capscrew Marking chart in Chapter A f o r torque values not listed above.
60632
QUADRA-TRAC
T R A N S F E R CASE
Page
general
Lubrication
Operation
Reduction Unit Service
Service Diagnosis
Page
Specifications
Towing
Transfer Case ServiceIn-Vehicle
Transfer Case ServiceQut-of-Wehicle
20-12
20-21
20-12
20-22
20-17
GENERAL
20-38
20-16
20-28
20-32
OPERATION
Transfer Case
1-13
FRONT
AXLE
Limited slip differentia!
in Quadra-Trac transmits
engine torque to both front
and rear axles as determined
by traction available. O p t i m u m
traction is maintained, resulting
in m a x i m u m c o n t r o l .
QUADRA-TRAC
T R A N S F E R CASE
80346
Fig. 2D-18
Emtrpiif Iriwi
Emergency Drive is a vacuum operated control system which locks the front and rear wheel drives together
resulting in undifferentiated four wheel drive. This feature allows the vehicle to be moved from a high centered
condition, permits continued operation in two wheel
drive in the event of an axle or propeller shaft failure,
and assists in maintaining traction in soft sand or mud,
or on extremely icy surfaces.
CAUTION: Emergency Drive is provided for extreme
situations only and must not be used for normal operation. The Quadra-Trac Transfer Case is designed to
80254
TRANSFER CASE
SEE O W N E R S M A N U A L FOR D E T A I L S
60610
Fig. 2D-20
side fills with engine vacuum, atmospheric pressure acting upon the opposite side of the diaphragm moves the
diaphragm piston and shift fork inward. As the fork
moves inward, it moves the lockup hub into engagment
with the case rear end cap. At this point, the hub is now
splined to both output shafts through the case rear end
cap. This results in a direct axle-to-axle connection
which nullifys differential action.
As the control diaphragm piston moves inward, it
contacts the indicator switch plunger ball forcing the
ball and plunger upward closing the switch internal
contacts. This completes the electrical circuit to the indicator light which illuminates signalling the operator
that Emergency Drive is engaged.
When the glove box switch is turned to the normal
4WD position, vacuum is applied to the release side of
the control diaphragm. Atmospheric pressure on the
opposite side of the diaphragm moves the piston and
shift fork outward disengaging the lockup hub from the
case rear end cap. As the piston moves outward, contact
between the indicator switch plunger ball and piston is
broken. The switch ball and plunger are then returned to
the open position by internal spring pressure. This opens
the circuit between indicator light and switch causing
the light to go off.
If a front or rear propeller shaft assembly or front or
rear axle shaft failure should ever occur, activating
Emergency Drive will permit two wheel drive operation
until repairs can be made.
Engaging Emergency Drive
2145
Reduction Unit
The reduction unit consists of an aluminum case containing a planetary geartrain and reduction engagement
gears. The pinion gears, sun gear, and lock plate are
located within the internal tooth ring gear. The unit is
engaged/disengaged by a floor mounted shift lever and
linkage.
When engaged, the shift fork moves the shift collar
into engagement with the collar plate hub. This locks the
engagement and planetary gears together through the
collar plate and pinion cage lockplate which are splined
to the ring gear. Engine torque is transmitted to the
reduction unit through the sun gear which is connected
to the transfer case drive sprocket by the drive hub and
lock sleeve.
For operation during unusually severe on or off-road
conditions, the reduction unit provides maximum engine
braking and additional torque at low speeds. When engaged, the unit provides a gear reduction ratio of 2.57:1.
2D-16
TRANSFER CASE
Release accelerator pedal when vehicle speed is approximately 10-15 mph (16-24 km/h).
Shift transmission into Neutral while vehicle is still
moving.
W h e n vehicle speed drops below 5 mph (8 km/h),
move reduction unit shift lever all the way forward
(CJ-7 models) or all the way upward (CherokeeWagoneer-Truck Models). Do not stop at the Neutral
(center) position, which is for towing use only.
Release accelerator pedal when vehicle speed is approximately 15-20 mph (24-32 km/h).
When vehicle speed drops to 5-10 mph (8-16 km/h),
shift automatic transmission into Neutral.
While vehicle is still moving, move the reduction
unit shift lever all the way to the rear on CJ-7 models, or all the way down on Cherokee-WagoneerTruck models. Do not stop at the Neutral (center)
position on any model when disengaging the unit.
TOliNI
If the vehicle is inoperative and must be towed with
either the front or rear wheels raised, towing speed
must be limited to 30 mph (48 k m / h ) or less and for a
distance no greater than 15 miles (24 km).
Automatic Transmission with Quadra-Trac Less Reduction
Unit
Ignition Key Available: Turn ignition key to Off
position to unlock steering column and gearshift selector
linkage. Place transmission gearshift lever in N (Neutral). If vehicle is to be towed with all four wheels on the
ground, disconnect both propeller shafts from axle
yokes (mark propeller shafts and yokes for assembly
alignment reference), secure shafts to underside of vehicle, and proceed with towing. If vehicle is to be towed
with front end raised, disconnect rear propeller shaft
only (mark shaft and yoke for assembly alignment reference) and secure shaft to underside of vehicle.
. Ignition Key Not Available: Place dolly under rear
wheels and tow vehicle with front end raised; or, disconnect rear propeller shaft at rear axle yoke (mark
shaft and yoke for assembly alignment reference), secure shaft to underside of vehicle, and tow with front
wheels raised.
Automatic Transmission with Quadra-Trac and Reduction
Unit
Fig. 20-21
1NSFERCASE
SERVICE DIAGNOSIS
The majority of Quadra-Trac operational problems
are a result of incorrect lubricant or lubricant level,
mismatched tires, uneven tire inflation pressures, insufficient vacuum, incorrect use of Emergency Drive, or
improper operation by the driver.
When diagnosing Quadra-Trac problems, follow the
preliminary diagnosis procedure and consult the Service
Diagnosis Charts before removal or disassembly. A
proper diagnosis will not only help to locate the problem
cause, it will also help to avoid unnecessary or ineffective repairs.
Preliminary Diagnosis
(1) Inspect all tires. Tires must be same type, size,
make, and tread design.
(2) Check tire inflation pressure. Tires must be inflated to recommended pressures and not vary more
than 1/2 to 1 psi (3.45 to 6.895 kPa).
(3) Check lubricant level and condition. If lubricant
level is low, add as necessary and check for leaks. If level
is high, drain to correct level. If lubricant is severely
discolored and smells burnt, drain sample and check for
particles and debris.
(4) If complaint was based on noisy operation, road
test and check for stick slip condition or excessive play
in drive chain. Refer to Stick-Slip Condition, Torque
Bias Check, Drive Chain Tension Inspection, and Service
Diagnosis charts.
(5) If complaint was based on incorrect Emergency
Drive operation, check unit operation first, then refer to
Emergency Drive Diagnosis.
2D-17
Stlck-Sllp Condition
When the differential brake cones tend to stick and
release suddenly or release at differing torque values, it
is caused by a condition similar to torque windup in a
conventional transfer case. This condition is refered to
as "stick-slip."
Sudden release of the brake cones under this condition
results in a pulsating clunking, rasping, or grunt-type
noise. This is a low-frequency noise which is most noticeable at slow speeds, such as when slowly turning a
corner, or when maneuvering to park the vehicle.
Stick-slip noise will not occur when the vehicle is
driven straight-ahead. However, if a noise similar to
stick-slip, but much louder, occurs during straight
ahead driving, inspect the drive chain for excessive
looseness.
Proper lubricant is important in preventing stick-slip
noise. Use Jeep Quadra-Trac lubricant or equivalent
only. Multigrade, detergent-type oils must never be
used. Stick-slip caused by improper lubricants may be
corrected by draining the transfer case and reduction
unit, if equipped, and refilling with the specified
lubricant.
NOTE: If a vehicle has not been driven for a week or
more, stick-slip noise may occur during initial operation.
This condition is considered normal and should be of no
concern, as the noise will usually disappear with continued driving.
Correction
Possible Cause
Condition
(1)
(1)
(2)
(2)
(3)
Incorrect or insufficient
lubricant.
(3)
(4)
(4)
2D-18
TRANSFER CASE
Service DiagnosisQuadra-Trac T r a n s f e r Case ( C o n t i n u e d )
Correction
Possible Cause
Condition
FRONT OR REAR O F
VEHICLE TENDS TO
WANDER OR PULL AT
TIMES WHEN DRIVING
IN STRAIGHT AHEAD
DIRECTION
(1)
(1)
(1)
Incorrect or insufficient
lubricant.
(1)
(2)
(2)
(3)
(3)
EMERGENCY DRIVE
WON'T ENGAGE OR
DISENGAGE
(1)
(1)
(2)
(2)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(1)
(1)
(2)
(2)
REDUCTION UNIT
W O N T ENGAGE OR
DISENGAGE
LUBRICANT LEAKS
PAST SEALS,
GASKETS, OR OUT
OF VENT
80688B
s o ?
No vacuum.
Replace hose.
No vacuum
through switch.
Hose OK.
Vacuum through
switch OK.
No click is heard.
Click is heard.
Replace control
diaphragm.
Hose OK.
2D-20
TRANSFER CASE
No vacuum.
Vacuum OK.
Hose OK
I
Repair or replace
hose.
No click is heard.
Replace control
diaphragm.
Click is heard.
TRANSFER CASE
Lubrication
The Quadra-Trac transfer case lubricant must be
changed periodically at the intervals specified in the
Maintenance Schedule. In addition, if a stick-slip condition occurs, the transfer case and reduction unit, if
equipped, lubricant must be changed. U s e Jeep
Quadra-Trac lubricant or equivalent only whenever
a lubricant change is necessary.
If a stick-slip condition has developed, check for mismatched tires or uneven tire pressure before changing
lubricant; then drain and refill the transfer case and
reduction unit, if equipped, as follows:
With Reduction Unit:
2D-21
The torque bias test is a method for checking differential brake cone preload. This test measures the torque at
which the differential brake cones will release.
(1) Be sure Emergency Drive is not engaged. Differential must be free to operate and must not be locked.
(2) Shift transmission into Neutral.
(3) Disconnect rear propeller shaft at transfer case
yoke.
(4) Have helper apply brakes firmly to lock front
wheels.
(5) Assemble socket and torque wrench with minimum capacity of 200 foot-pounds (271 N*m).
(6) Install socket and torque wrench on transfer
case rear yoke retaining nut.
(7) Apply torque in tightening direction (clockwise)
to retaining nut. Differential brake cones should release
when 80 to 170 foot-pounds (108 to 230 N*m) of torque is
applied.
NOTE: If the brake cones release at a torque valve of
80 foot-pounds (108 N m) or less, the differential unit
may require replacement If the cones do not release
when 170 foot-pounds (230 N m) torque or more is applied, improper lubricant may be the cause. Refer to
Stick-Slip Condition and Lubrication in this section.
9
HOUSING B O L T
T R A N S F E R CASE
(LOOSEN A L L F I V E
D R A I N PLUG
TO D R A I N U N I T )
Fig. 20-22
(1) Remove transfer case drain plug, drain lubricant, and reinstall drain plug.
(2) Remove chain inspection plug.
(3) Thread Chain Tension Gauge J-25162 into inspection hole until gauge stops against case (fig. 2D-23).
(4) Tension gauge plunger should protrude past
outer end of checking tool (fig. 2D-23). If gauge plunger
is flush or below end of gauge, replace drive chain.
2D 22
TRANSFER CASE
Fig. 20-23
J42371
Fig. 20-24
Fig. 20-25
(7) Remove following components as assembly: direct drive sleeve and needle bearing, shift collar hub and
needle bearing, reduction collar hub, and ring gear and
needle bearings (fig. 2D-30).
NOTE: If necessary, the reduction collar plate hub and
reduction collar plate can be separated from the ring
gear by removing the retaining snap rings.
(8) Remove pinion cage lock plate and needle
bearings.
(9) Remove sun gear and main shaft from pinion
cage (fig. 2D-31). Do not attempt to disassemble sun
gear and main shaft.
SUN GEAR
EXPANSION PLUG
COLLAR
PLATE HUB
S H I F T FORK
R E T A I N I N G PIN
POPPET B A L L
A N D SPRING
P I N I O N CAGE
PINION CAGE LOCK PLATE
TAPER PLUG
SHIFT RAIL
SPRING PIN
, M A I N SHAFT
(p)
>v
O-RING
CONTROL LEVER
S H I F T C O L L A R HUB
D I R E C T D R I V E SLEEVE
COLLAR HUB
POWER T A K E O F F COVER
Fig.
COVER G A S K E T ^
20-26
J42374
2D-24
TRANSFER CASE
Fig. 2D-27
SOS25
Housing Removal/Installation
Fig. 21=21
S i f t Collar Ramoval
Fig. 2D-30
TRANSFER CASE
<wmr~
-way. ..
Tgggg
FE-AR
2D-25
" "~wt
Fig. 2D-32
Fig. 2D-33
20-26
TRANSFER CASE
PINS
HOLES
MUST
A L I G N :
',, *
'
" \
J42382
Hp
J42381
l i l i i t i i i Unit Assembly
(1) Install reduction holding plate in case. Holding
plate locating pins must face interior of case and index
in case (fig. 2D^36).
N O T E : Be sure to align the shift fork locating pin holes
in the holding plate and housing (fig. 2D-36).
(2) Install reduction holding plate retaining snap
ring. Snap ring tabs must face forward. Be sure snap
ring seats completely in groove and clears shift fork.
(3) Install shift fork locating pin. Be sure pin is
inserted completely through holding plate and is seated
in housing.
Fig. 2D-37
TRANSFER CASE
USE P!M AS
COMPRESSOR
T O O L
21-
F L A T ON
PIH FLUSH
W I T H FORK
l i l t
J42385
Fig. 21-39
COLLAR HUB
SHIFT
COLLAR
HUB
NEEDLE
BEARINGJA 2388
J4-2384
Fig. 21-40
Fig. 21-38
I M kft&riujm
- i s ? ,-iliir 111
COLLAR
PLATE
COLLAR
PLATE HUB
J42387
Fig 2041
NEEDLE
BEARING
(2)
COLLAR
J42389
Fig. 2042
TRANSFER CASE
(6) Mark emergency drive control diaphragm vacuum hoses for assembly reference and disconnect hoses.
(7) Disconnect emergency drive indicator switch
wire.
(8) Disconnect speedometer cable.
(9) Remove emergency drive indicator switch.
(10) Disengage parking brake cable guide from pivot
on right-side frame rail.
(11) On CJ-7 models, place support stand under
transmission and remove rear crossmember.
(12) Remove bolts attaching rear cover assembly to
front cover.
SEAL RING
20-29
(13) Remove rear cover assembly. Slide cover assembly backward until disengaged with transmission output
shaft and front output shaft.
D R I V E SLEEVE
SNAP RING
F R O N T COVER
CONTROL
DIAPHRAGM
ANNULAR BEARING
THRUST WASHER
F R O N T OUTPUT SHAFT
REAR O U T P U T S H A F T
A N N U L A R BEARING
J42391
OUTPUT S H A F T O I L SEAL
Fig. 2043
WOOD
BLOCK
Fig. 21-45
J42393
Differentia! mi Mm Sprockets
(3) Install drive chain on drive sprocket and differential sprocket (fig. 2D-46).
N O T E : The differential sprocket may be serviced without disassembling any of the other components. Refer to
Transfer Case Disassembly.
Fig. 2 1 4 1
WOOD
. BLOCK
Fig. 2 1 4 4
J42392
!9-31
Fig. 2D-49
Fig 20-47
Fig. 2D-48
(1) Apply 1/16 inch (1.58 mm) wide bead of siliconetype sealer to mating surface of transfer case front
cover.
(2) Install two 3 / 8 4 6 by 2 inch (5.08 cm) long pilot
studs in front cover.
(3) Move rear cover assembly forward and into engagement with front output shaft and transmission output shaft.
N O T E : If necessary, rotate the rear output
slightly to engage the two sets of splines.
shaft
2B-32
TRANSFER CASE
TRANSFER CASE
2D 33
hearings,
removing
BORE
TRANSFER
CASE
FRONT
COVER
Sibassembly Overhail
80698
Fig. 20-58
Differential Sprocket
Fig. 20-51
42402
2D-34
TRANSFER CASE
together and
identify
normal condition. Replace the assembly only if any component is galled, deeply scored, cracked, broken, or excessively worn.
The thrust washers should be smooth and should conform to their mating surfaces. Distortion or galling is
not acceptable. The shaft should be straight and fit
tightly in the sprocket. A polished wear pattern is normal. Galling, grooves, or wear on the shaft is not
acceptable.
The side gear teeth should be free of chip marks.
However, a rough machined look is normal. The thrust
surfaces and shaft splines may be highly polished with
some slightly tarnished spots, however, this is normal.
Galling or measureable wear is not acceptable.
Brake Cones
Inspection
Assembly
together and
identify
thrust
Cleaning
N O T E : During assembly, all bearing and thrust surfaces must be prefabricated with Jeep Quadra-Trac Lubricant or equivalent only.
(1) Slide pinion mate shaft into differential
sprocket to depth of 3 inches (7.62 cm).
(2) Install pinion mate thrust washers and gears on
shaft in proper order (fig. 2D-43).
(3) Align pinion mate shaft lockpin hole with lockpin hole in case sprocket. Drive pinion mate shaft into
sprocket until lockpin holes are aligned.
N O T E : Alignment can be checked by looking through
the lockpin hole in the sprocket.
(4) Slide pinion mate gears apart until side gears
press washers against sprocket (fig. 2D-53).
(5) Mesh appropriate (front or rear) side gear with
pinion mate gears.
(6) Position appropriate brake cone over side gear
and in sprocket.
TRANSFER CASE
M A T C H E D REAR SET
MATCHED
F R O N T SET
20-85
SMALL
THRUST
WASHER
PRELOAD
SPRINGS
LARGE
THRUST
WASHER
BRAKE
CONE
SIDE
GEAR
SIDE
GEAR
BRAKE
CONE
LARGE
THRUST
WASHER
PRELOAD
SPRINGS
SMALL
THRUST
WASHER
SPROCKET CASE
42403
Fig. 2D-53
Rearing Repiaceient
Needle Bearings
To remove the differential front and rear needle bearings and drive sprocket front needle bearing, use Bearing Remover Tool J-25159 (fig. 2D-54).
Use tool J-25212 (less tool J-25212-1) to install the
differential front and rear needle bearings (fig. 2D-55).
Use tool J-25212 with tool J-25212-1 inserted into the
case bore to install the drive sprocket front needle
bearing.
N O T E : The drive sprocket oil seals must be removed in
order for the pilot adapter to enter the case bore (fig. 2D56).
Fig. 2D-54
2D-36
TRANSFER CASE
- 4
Fig. 20-57
Fig. 2D-55
Fig. 2D-58
Annular Bearings
Fig. 21=56
Mm
NOTE: The front and rear output shaft annular bearings are retained in the transfer case front and rear
covers by snap rings. The outer snap ring for each bearing is a select-fit part available in four thickness ranges
which are: 0.060 to 0.063 inch (1.52 to 1.60 mm), 0.06k to
0.066 inch (1.62 to 1.67 mm), 0.067 to 0.069 inch (1.70 to
1.75 mm), and 0.070 to 0.072 inch (1.77 to 1.82 mm). The
inner snap ring for the bearings should always be 0.060
to 0.063 inch (1.52 to 1.60 mm) thick.
(1) Remove output shaft yoke seal.
NOTE: If the rear bearing is being replaced, also remove the speedometer gear.
* (2) Remove outer snap ring.
(3) Remove annular bearing. Bearing is not a pressfit in bore and can be removed by hand. However, if
bearing is tight or if bore is scratched, use brass drift to
remove bearing.
TRANSFER CASE
A.-
-K
~sz:.. z z : 3 . _ z z z z i z ' _ z z z z J Z Z Z Z Z ^
zazi
~^
-.-.
- A . ' - .. ~ar
HL:
"
-Z-XZi -
2D-37
A- ^ ^ Z W Z J
L O N G SIDE
T O REAR
TO FRONT
Fig. 2D-60
Removal
-ZZ-JEZ-..zlzzz.
J42410
Installation
(1) Lubricate shifting shoes with Quadra-Trac lubricant, or equivalent, and install shoes in shift fork.
(2) Install lockup hub in shift fork (fig. 2D-60).
Fig. 2D-53
2D-38
TRANSFER CASE
(13) Apply 1/16-inch (1.58 mm) thick bead of silicone-type sealer to mating surfaces of transfer case
front and rear covers.
(14) Install front output shaft and thrust washer in
cover.
(15) Align and install front cover assembly on rear
cover assembly.
(16) Install front cover-to-rear cover attaching bolts.
Tighten bolts alternately and evenly to 20 foot-pounds
(27 N*m) torque.
CAUTION: Do not exceed the maximum
torque for the attaching bolts.
Fig. 2D-61
specified
SPECIFICATIONS
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Service
Service
In-Use
Set-To
Recheck
Torque
Torque
Transfer Case
Breather
. .
Chain Measuring Access Hole Plug
Differential End Cap Bolts
Drain Plug
Fill Plug
Lock-Up Cover t o Transfer Case
Emergency Drive Indicator Switch
Output Shaft Nut
Power Takeoff Cover t o Transfer Case Bolt:
3/8-16 Bolts
5/16-18 Bolts
Speedometer Adapter
.
Front Cover-to-Rear Cover Bolts.
. .
Transfer Case to Transmission Extension Bolt.
Reduction U n i t
Fill Plug
Reduction Power Takeoff Cover t o Case. . . .
Reduction Unit to Transfer Case Bolt:
3/8-16 B o l t / N u t
5/16-18 B o l t / N u t
Shift Lever t o Shaft Nut
Metric (N-m)
Service
Service
In-Use
Set-To
Recheck
Torque
Torque
8
12
27
20
20
10
12
120
6-10
6-14
24-30
15-25
15-25
8-10
10-15
90-150
11
16
37
27
27
14
16
163
8-14
8-19
33-41
20-34
20-34
11-14
14-20
122-203
20
15
25
20
40
15-25
10-20
20-30
15-25
30-50
27
20
34
27
54
20-34
14-27
27-41
20-34
41-68
20
20
15-25
15-25
27
27
20-34
20-34
20
10
20
15-25
8-10
15-25
27
14
27
20-34
11-14
20-34
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Marking chart in Chapter A for torque values not listed above.
60634
TRANSFER CASE
General Specifications
2D-39
Lubricants
Quadra-Trac Lubricant
or equivalent
60635
60633
Tools
J-25175 S H I F T R O D O I L S E A L
REMOVER TOOLS
J-25160 OUTPUT S H A F T
O I L SEAL INSTALLER
J-8614-01 Y O K E
HOLDING WRENCH
42413
2141
TRANSFER CASE
Tools (continued)
J-25213 SEAL
INSTALLER
J-25161 B E A R I N G REMOVER
A N D INSTALLER
I
w
J-25213-1 SLEEVE
J-8614-02 A N D -03
Y O K E REMOVER
TOOLS
BOLTS
(USED WITH
J-8614-01)
3S%
J-25180
OUTPUT S H A F T
SEAL R E M O V E R
J-25162 C H A I N GAUGE
59 BEARING PULLER
42414
J-25122 H A N D L E
2E 1
ROPELLER
SECTION INDEX
Page
Driveline Vibration
General
Lubrication
Propeller Shaft Service
2E-3
2E-1
2E-9
2E-10
GENERAL
Jeep vehicles use tubular propeller shafts to transmit
engine torque from the transfer case to the front and
rear axles. Universal joints connect each shaft to the
transfer case and axle yokes. A splined slip yoke is used
at one end of each propeller shaft to compensate for
variations in shaft length caused by suspension spring
movement.
Because of the various driveline combinations available on Jeep vehicles, several different propeller shaft
and universal joint designs are required.
Page
Specifications
Tools
Universal Joint Angle Measurement and Ad|ustment
Universal Joint Service
2E-12
2E-13
2E-9
2E-10
The front propeller shaft on CJ-7, Cherokee, Wagoneer, and Truck models with automatic transmission is
connected to the axle yoke with a single cardan universal
joint and to the transfer case yoke with a double cardan
universal joint (fig. 2E-1).
The front propeller shaft on CJ models with manual
transmission is connected to both the axle and transfer
case yokes with single cardan universal joints. A slip
yoke is used at the axle end of the shaft (fig. 2E-2).
The rear propeller shaft on Cherokee and Wagoneer
models with automatic transmission and Truck models
with manual or automatic transmission is connected to
both the axle and transfer case yokes with single cardan
universal joints. A slip yoke is used at the transfer case
end of the shaft (fig. 2E-3).
The rear propeller shaft on Cherokee models with
manual transmission is connected to the transfer case
80329
3E:
80330
80331
Fig. 2E-3
80332
Fig. ZE-4
RETAINING
BEARING
CAP
SOCKET
BALL
RETAINER
SEAL
NEEDLE
. BEARINGS
SOCKET
SPRING
LINK
YOKE
THRUST
WASHER
PROPELLER
SHAFT
YOKE
Fig. 2E-6
SOCKET
NEEDLE
BEARINGS
FRONT
SPIDER
TRUNNION
CAP
WASHER
TRUNNION
BALL
PROTECTIVE
BOOT
PROPELLER
SHAFT
TRUNNION
HOUSING
BOOT
RETAINING
STRAPS
80335
Rg. 2E-7
tions are heard or sensed above normal road and background noise and may be accompanied by mechanical
vibration. In some cases, audible vibration occurs as a
droning or drumming noise while in other cases, it produces a buffeting sensation that is felt or sensed by the
driver rather than heard.
Driveline vibration may be caused by the front or rear
propeller shafts, axle or transfer case yokes, universal
joints, incorrect front or rear pinion angles, loose engine-transmission-transfer case mountings, or engine
driven accessories. Mechanical vibration is usually
caused by a damaged or worn driveline component. Audible vibrations are usually caused by an incorrect universal joint angle or binding universal joints and are
most noticeable in the 40-60 mph (64-97 km/h) speed
range.
Vibration caused by a propeller shaft may be the
result of:
Undercoating on the shaft tube
Excessive shaft runout
Cracked or broken shaft seam welds
Dented, bent, or twisted shaft tube
Worn or damaged shaft bearing yokes
Loose universal joint clamp strap bolts, U-bolt nuts,
or flange bolts
Tight, loose, or binding slip yoke
Tight, worn, binding, or damaged universal joint
Loose yoke retaining nut
Vibration caused by universal joints may be the result
of:
Loose U-bolt nuts, clamp strap bolts, or flange bolts
Tight, loose, binding, or worn slip yoke
Worn or damaged universal joint spider
Worn or damaged needle bearings or bearing caps
Vibration caused by axle, transfer case, engine, or
suspension components may be the result of:
Loose yoke retaining nut
Excessive yoke runout
Incorrect universal joint angle
Bent, worn, broken, or loose torque reaction bracket
or engine rear crossmember
Damaged or loose suspension springs or suspension
components
Loose engine or transmission/transfer case support
cushions or crossmembers, broken spring mounting
pad (on axle), broken spring center bolt, or damaged
engine driven accessories or drive belts.
DRIVELINEVIBRATION
Driveline vibration can be divided into two categories:
audible or mechanical. Mechanical vibrations produce
visible motion in the fenders, rear view mirror, instrument panel, or steering wheel, or can be felt through
the seats, floorpan, or steering wheel. Audible vibra-
2E-4
PROPELLER SHAFT
Driveline Vibration Diagnosis arid Repair (DARS) Charts
Note:
Refer t o Chapter
A General
DARS
chart.
STEP
RESULT
WHEEL/TIRE CONDITION
1.
2.
3.
CHECK A N D CORRECT T I R E I N F L A T I O N
PRESSURES AS N E E D E D .
. C O R R E C T I O N NEEDED R O A D TEST
CORRECTION
NOT NEEDED
OK
CORRECTION
NEEDED
ROAD TEST
R O A D TEST
D R I V E 5 - 1 0 MPH ABOVE V I B R A T I O N
R A N G E - T H E N - S H I F T TO N E U T R A L ,
LET ENGINE I D L E A N D C O A S T - T H R O U G H
V I B R A T I O N RANGE.
V I B R A T I O N GONE
.OK)(stop
VIBRATES DURING
'COAST-THROUGH
(o-s^Q
ROAD
TEST '
V I B R A T I O N STOPS
D U R I N G COASTTHROUGH
(IN NEUTRAL)
W H E E L / T I R E BALANCE
A D D BALANCE
WEIGHTS HERE
A D D BALANCE
WEIGHTS HERE
f
OF
SPINDLE
HEAVY
SPOT
OF
SPINDLE
T I R E OR WHEEL T R A M P ,
OR WHEEL HOP
CORRECTIVE WEIGHT
LOCATION
STATIC U N B A L A N C E
CORRECT AS
NECESSARY
A N D R O A D TEST
( M A X . WHEEL W E I G H T
ALLOWANCE PER WHEEL
IS 1 0 - OUNCES)
H E A V Y SPOT
WHEEL S H I M M Y
AND VIBRATION
CORRECTIVE
WEIGHT
LOCATION
D Y N A M I C UNBALANCE
IF CORRECTION
p WAS NEEDEDREPEAT ROAD TEST
ROAD TEST OR
NO CORRECTION
NEEDED.
80787A
m?nm mm 2E-5
SEQUENCE
STEP
RESULT
CHECK
TIRE R A D I A L
RUNOUT:
RADIAL TIRES
0.080
CONVENTIONAL TIRES
0.105
TIRE L A T E R A L
RUNOUT:
ALL TIRES
WHEEL
[LATERALLY
DIAL
INDICATOR
0.100
RUNOUT:
0.045
LATERAL/RADIAL
NO CORRECTION
NEEDED
CHECK
' WHEEL R U N O U T
LATERALLY
CORRECTION
NEEDED
REPAIR O R
REPLACE AS
NECESSARY
RADIALLY
ROAD
TEST
ROAD TEST
y / V
J
OK
NO CHANGE IN
VIBRATION LEVEL
{in
WORN, BINDING
BRINELLED
U-JOINTS
WORN, LOOSE
BINDING SLIP
YOKE
BENT
TUBE
EXCESSIVE
UNDERCOATING
ON
TUBE
\
i
REPAIR O R REPLACE
R O AiDl
D TEST
SHAFT
(OK'
STOP
80787B
2E-6
^
PROPELLER SHAFT
^
H E
SEQUENCE
STEP
r
RESULT
T O O L J-28488
MAXIMUM ALLOWABLE
R U N O U T A T EITHER
Y O K E IS 0.006 (0.15 mm)
IF R U N O U T IS 0.007 OR M O R E ,
R E I N D E X Y O K E , A N D RECHECK
R U N O U T . REPLACE Y O K E IF
R E I N D E X I N G DOES NOT
CORRECT R U N O U T .
R O A D TEST
REPLACEMENT Y O K E R U N O U T
S H O U L D BE CHECKED A L S O .
REINDEX SHAFT
1 8 0 A N D RECHECK
RUNOUT.
MAXIMUM ALLOWABLE
R U N O U T SPECIFICATIONS A R E :
F R O N T / R E A R . . . 0.015 (0.38 mm)
CENTER
0.020 (0.51 mm)
REPLACE S H A F T
R O A D TEST
80787C
PROPELLER SHAFf
STEP
SEQUENCE
21
RESULT
AXLE
PINION
UPWARD
ANGLE
R O A D TEST
REAR A X L E PINION A N G L E
MUST BE / T O V / 2 ( 1 PREFERRED) BELOW ENGINE
A N G L E . USE APPROPRIATE
SHIMS TO CORRECT A N G L E
1
1.
REMOVE F R O N T PROPELLER S H A F T ( A L I G N
M A R K S H A F T A N D A X L E Y O K E S FOR A S S E M B L Y
REFERENCE).
2.
R O A D TEST W I T H Q U A D R A - T R A C I N EMERGENCY
D R I V E - O R - M O D E L 20 IN 4 H W I T H F R O N T HUBS
L O C K E D ( I F EQUIPPED).
R O A D TEST
V I B R A T I O N GONE OR
N O T I C E A B L Y REDUCED
NO C H A N G E I N
VIBRATION LEVEL
CHECK F R O N T PROPELLER
SHAFT CONDITION
WORN, BINDING
BRINELLED
U-JOINT
W O R N , LOOSE
BINDING
SLIP Y O K E
BENT
TUBE
EXCESSIVE P A I N T
OR U N D E R C O A T I N G
ON TUBE
R O A D TEST
80787D
2E-8
PROPELLER SHAFT
SEQUENCE
STEP
RESULT
IF R U N O U T IS 0.007 OR M O R E , R E I N D E X
Y O K E A N D RECHECK R U N O U T . REPLACE
Y O K E IF R E I N D E X I N G DOES N O T CORRECT
RUNOUT.*
MAXIMUM ALLOWABLE
R U N O U T A T ESTHER
Y O K E IS 0.006 (0.15 mm)
f
ROAD TEST
REPLACEMENT Y O K E R U N O U T
SHOULD BE CHECKED A L S O
3 >
CHECK F R O N T PROPELLER S H A F T
R U N O U T USING D I A L I N D I C A T O R
M A X I M U M ALLOWABLE RUNOUT
SPECIFICATIONS A R E :
FRONT/REAR
CENTER
. . . . .
CHECK F R O N T A X L E P I N I O N A N D F R O N T
PROPELLER S H A F T A N G L E S
FRONT A X L E PINION A N G L E
MUST BE Vz TO VAP ( 1 PREFERRED) A B O V E F R O N T PRO
PELLER S H A F T A N G L E . USE
APPROPRIATE SHIMS TO
O B T A I N CORRECT A N G L E
ENGINE
DOWNWARD*
ANGLE
b-HrHSTOP
80787E
PROPELLER SHAFT
UNIVERSAL JOINT
ADJUSTMENT
ANGLE
MEASUREMENT
AND
2E-9
LUDRIOATION
The propeller shaft slip yoke and universal joints on
all Jeep vehicles require periodic lubrication. Refer to
the Maintenance Schedule in Chapter B for specific
details.
Lubricant Type
2E-10
PROPELLER SHAFT
Removal-Rear Shaft
(1) Raise vehicle.
(2) Mark propeller shaft, transfer case yoke or
flange, and axle yoke for assembly alignment reference.
(3) Disconnect shaft at transfer case and axle yokes
and remove shaft.
Installation-Rear Shaft
(1) Align reference marks on propeller shaft yokes
and install shaft.
(2) Tighten universal joint U-bolt nuts or clamp
strap bolts to 15 foot-pounds (20 Nm) torque. Tighten
flange bolts (on ball and trunnion joint) to 35 footpounds (47 Nm) torque.
(3) Lower vehicle.
90143
illVERSAL JOINT-SERVICE . .
"
Disassembly-Single C i f l i t Joint
"'
T O O L J - 25512 - 2
90144
Installation-Front Shaft
(1) Align reference marks on propeller shaft and
yokes and install propeller shaft.
(2) Tighten universal joint U-bolts to 15 footpounds (20 Nm) torque.
(3) Lower vehicle.
TRUNNION
'PIN
PROPELLER
SHAFT
DIMENSIONS
A AND B
MUST NOT
V A R Y BY
MORE T H A N
0.006 - INCH
(0.15 mm)
8 0 7 1 6
SPECIFICATIONS
Universal Joint Angle Chart
Rear
Front
Set-To
OK Range
Set-To
Wagoneer
Cherokee
(Quadra-Trac)
7-9
4-6
Cherokee
(Dana 20)
7-9
4-6
Truck
(Model 25)
7-9
330'
230'-430'
Truck
(Model 45)
7-9
4-6
OK Range
70556
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Service
Set-To
Torque
Pinion Yoke N u t :
Axle Model 30-44
Axle Model 60
A M C - J e e p Axle
. . . .
Service
In-Use
Recheck
Torque
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
* Torque
285
210
271-298
200-220
352
250-270
339-366
260
A d d 5 in-lbs. (0.56 N-m) torque measured at
disassembly. Refer to Pinion Seal and Yoke
Replacement, Chapter 2F- A M C - J e e p Axle.
18-24
15
13-18
20
34-61
25-45
47
35
14-24
13
10-18
18
All Torques values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
80336
nOPELLER SHAFT
Tools
LUBE F I T T I N G
ADAPTER TOOL
J-25512-2
NOTES
2E-13
NOTES
2F-1
Pap
Axles Testing mi Diagnosis
Front Axis
Rear Axle
2F-1
2F-2
ZF-14
mm M M
Standard Differentia!
Tools
Trac-Lok Differential
2F-21
2F-50
2F-40
wMsimmm
Pip
litterTrac-Lok Differential
Seieral
Otler Axle Conditions
Tin Noise list
Wheel Bearing Test
2F-2
2F-2
2F-2
iZF-1
I 2F-2
i2F-1
I2M
1E1ERAL
Because certain types of tire tread wear or tread patterns may produce objectionable noises, drive the vehicle on various types of road surfaces and listen for a
change in the noise. If the noise varies with the type of
road surface, the tires may be causing the noise.
AXLE TESTS
Before testing the axle, drive the vehicle a distance
sufficient to warm the axles and axle lubricant. During
the test, operate the transmission and transfer case in
every gear combination.
2F-2
AXLES
BACKLASH
Excessive driveline backlash may be the result of
backlash in the transmission, transfer case, propeller
shaft yokes or slip joint splines, universal joints, ring
and pinion gears, differential gears, front axle shaft
splines or universal joints, or rear axle shaft splines.
CHATTERTRAC-LOK DIFFERENTIAL
Trac-Lok chatter is usually caused by using non-recommended lubricants. If chatter occurs, drain and refill
the axle with Jeep Trac-Lok lubricant or equivalent
only.
OTHER A X L E CONDITIONS
FRONT AXLE
Page
Axle Housing Service
Axle Identification
Axle Installation
Axle Removal
Axle Shaft
Axle Shaft Seal
Axle Shaft Universal Joint
Front Wheel Alignment
General
2F-4
2F4
2F-12
2F-12
2F-6
2F-11
2F-8
2F-4
2F-3
Page
High Steering Effort 2F-4
Pinion Seal and Yoke 2F-5
Specifications 2F-13
Spindle) Bearing 2F-11
Steering Knuckle Installation 2F-10
Steering Knuckle Removal 2F-9
Steering Knuckle Ball Studs | 2F-9
Turning Angle Adjustment 2F-12
AXLES. 2F-3
GENERAL
A drive-type front axle with steering knuckles and
hypoid differential gears is used on all Jeep models.
Engine torque is transmitted to the wheels through full
floating, two-piece axle shafts which have connecting
universal joints (fig. 2F-1). The axle shafts revolve
within and are supported by the steering knuckles. Open
end steering knuckles which pivot on ball studs are used
on all Jeep front axles.
MODEL 44
A X L E HUB COMPONENTS
F I L L PLUG
A X L E HOUSING COVER
A X L E HOUSING COVER GASKET
DIFFERENTIAL BEARING
CAP BOLT
DIFFERENTIAL BEARING
CAP
6. D I F F E R E N T I A L BEARING
CUP (2)
7. P I N I O N M A T E SHAFT
8. T H R U S T WASHER
9. D I F F E R E N T I A L SIDE
GEAR
10. D I F F E R E N T I A L P I N I O N
GEAR
1 1 . T H R U S T WASHER
12. R I N G GEAR M O U N T I N G
BOLTS
13. D I F F E R E N T I A L BEARING (2)
14. D I F F E R E N T I A L BEARING
PRELOAD SHIMS
15. D I F F E R E N T I A L CASE
16. P I N I O N MATE S H A F T PIN
17. R I N G GEAR
18. P I N I O N GEAR
19. SLINGER
20. P I N I O N BEARING
M O D E L 30
A X L E HUB COMPONENTS
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
P I N I O N B E A R I N G CUP
P I N I O N DEPTH SHIMS
BAFFLE
A X L E HOUSING
P I N I O N PRELOAD SHIMS
O I L SEAL
DUST CAP
YOKE
WASHER
PINION NUT
UPPER BALL STUD SPLIT
R I N G SEAT
32. UPPER BALL STUD N U T
33. COTTER PIN
34. LOWER BALL STUD JAMNUT
Fig 2F-1
38 pARING
%
39'jgEARING CUP
40. f l U B
41.-INNER LOCKNUT
42. WASHER
43. OUTER LOCKNUT
44.,SPRING CUP
45. PRESSURE SPRING
46. D R I V E GEAR
47. SNAP RING
48. HUB CAP
49. SPINDLE BEARING
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
WASHER
SEAL
SEAL SEAT
A X L E SHAFT
STEERING KNUCKLE
STEERING STOP BOLT
LOWER BALL STUD
SNAP RING
T I E ROD
T I E ROD END N U T
SPINDLE
SEAL
BEARING
BEARING CUP
HUB
TABBED WASHER
INNERLOCKNUT
LOCK WASHER
OUTERLOCKNUT
GASKET
D R I V E FLANGE
SNAP RING
HUB CAP
2F-4
j
AXLES
t
-..
, _ . .
;
r-r-r
- - ^ - - ^ - 7 . : ^ : , ^ ; ^
A1LE i l E I T i F l C I T i l l
On Model 44 front axles, the axle code number is cast
into the upper surface of the reinforcing rib at the left
side of the axle housing (fig. 2F-2).
On Model 30 front axles, the axle code number is cast
into the bottom surface of the differential housing.
The axle build date and manufacturers build date are
stamped on the right-side axle tube adjacent to the axle
housing cover.
The axle build date is decoded as follows: The first
number represents the month, the second number the
day of the month, the third number the year, the letter
the shift, and the last number is the assembly line. If
there are two build dates, the latter date will indicate
when the brake components were installed.
The gear ratio tag attached to the left side of the axle
housing cover indicates the Jeep manufacturing reference part number and the numerical tooth combination
of the ring and pinion gears.
The front axle housing should be inspected periodically for weld cracks or other damage that could cause
loss of lubricant, affect driving characteristics, or result
in front end misalignment.
AXLES
2F.5
limewal
(1) Raise vehicle.
(2) Mark propeller shaft and yoke for assembly
alignment reference and disconnect propeller shaft from
yoke.
(3) Remove pinion nut and washer using socket,
breaker bar, and tool J-8614-01 (fig. 2F-3).
(4) Remove yoke using tools J-8614-01, -02, -03 (fig.
2F-4).
(5) Remove pinion seal using tool J-25180.
Installation
(1) Install replacement seal using tool J-25104.
(2) Install yoke.
(3) Install pinion washer and nut. Tighten nut to
210 foot-pounds (285 N*m) torque.
(4) Align reference marks on propeller shaft and
yoke and connect shaft to yoke. Tighten shaft-to-yoke
attaching bolts or nuts to 16 foot-pounds (22 N*m)
torque.
(5) Lower vehicle.
2F-6 AXLES
throughout 2 or 3 bolt removal and installation procedures. If it becomes necessary to recoat the drive
flange bolts, recoat them with Loctite 21>2 AdhesiveSealant or equivalent Be sure to clean the bolt threads
and threaded holes thoroughly before applying
afresh
coat of sealant
TOOL
J-8614-01
illlltllKlll
7053S;
InstallstionCJ Meitls
"700."""
J-8614-03,
BHR&
' TOOL
J-86 " 4-02
TOOL
J-8614-01 t
7o539}
Fig. 2 F - 4
AXLE SHAFT
RemovalCJ Models
'
RemovalWagoneer-Cherokee-Truck Models
(1) Raise vehicle.
(2) Remove disc brake caliper. Refer to Chapter 2G.
(3) Remove rotor hub cap.
(4) Remove axle shaft snap ring, drive gear, pressure spring, and spring retainer.
(5) Remove outer locknut, washer, and inner locknut using tool J-6893.
(6) Remove rotor. Spring retainer and outer bearing
are removed with rotor.
AXLES
InstallationCherokee-Wagonser-Truck Models
(1) Install axle shaft. Insert splined end of axle
shaft in differential side gear and push shaft into place.
(2) Install spindle.
(3) Install support shield and rotor.
(4) Install inner wheel bearing locknut (nut has peg
on one side). Tighten locknut just enough to remove end
play.
(5) Install wheel and tire but do not tighten wheel
nuts completely.
(6) Tighten inner locknut to 50 foot-pounds (68
N m ) torque and rotate wheel while tightening locknut
to seat bearings.
(7) Loosen and retighten inner locknut to 35 footpounds (47 N*m) torque. Rotate wheel while tightening
locknut to maintain established bearing seating.
(8) Back off inner locknut 1/3 turn.
(9) Install washer so inner tab is aligned with
spindle keyway. Be sure peg on inner locknut engages in
nearest hole in washer.
(10) Install outer locknut and tighten nut to minimum of 50 foot-pounds (68 Nm) torque.
(11) Remove wheel and tire.
(12) Install spring retainer, pressure spring, and
drive gear.
#
2F-7
h
(5) Repeat above step to remove remaining bearings
and remove bearing cross-journal by sliding it to one
side and lifting out.
(6) Wash all parts in solvent and inspect parts after
cleaning. Replace any part that shows extensive wear or
damage.
(7) Pack bearing cups one-third full of bearing lubricant and install bearing rollers.
(8) Insert bearings into axle shaft yoke half and
seat them firmly against bearing shoulders.
(9)' Install bearing cross-journal while holding bearings in a vertical position to prevent bearings from dropping out.
- (10) Press bearing cup on journal from oppp^Jte side
until firmly seated.
~
(11) Repeat steps (9) and (10) on opposite journal.
(12) Install snap rings on bearing cups.
/<n
B E A R I N G CUP
2F-8
AXLES
90068B
Fig. 2F-6
41067
AXLES
2F-9
(3) On CJ models, install Adapter J-25211-4 on nutend of puller screw so adapter shoulder faces nut-end of
screw.
(4) On all models, thread puller frame halfway onto
puller screw. Insert nut-end of screw through lower ball
stud hole in steering knuckle. Position puller frame
against knuckle and puller screw against Button J25211-3 (fig. 2F-9). On CJ models, be sure Adapter J25211-4 is positioned between puller frame and steering
knuckle.
(5) Tighten puller screw to press upper ball stud out
of knuckle.
(6) Remove tools used to press upper ball stud from
knuckle. Do not disassemble screw and frame of Puller
J-25215 at this time. Tools will be used, as assembled, to
install lower ball stud.
41070
Fig. 2F-7
2F-10
AXLES
_______
Fig. 2F-8
Fig. 2F-9
Fig. 2F-10
Fig. 2F-11
UpperBall
Stud
Installation
Fig. 2 F - 1 2
Steering
Knmlite ImUMlm
Fig. 2 F - 1 3
iipiicsiiif
N O T E : Front axle spindles are equipped with a needle
roller bearing which is located in the spindle flange bore
(fig.2F-15).
(1) Wrap machined surfaces of spindle with tape
and mount spindle in vise. Do not clamp spindle in vise
until protective tape is applied to spindle surfaces.
(2) Remove needle bearing using internal-type
puller.
2F-12
AXLES
m*
(3) Clean dirt and foreign matter from spindle bearing surface.
(4) Install replacement bearing using bearing
driver.
(5) Pack needle bearing with wheel bearing grease.
BEAREMG
J41079
Fig. 2F-15
AXLE REMOVAL
(1) Raise and support front end. Position frame
stands under frame rails at rear of front springs.
(2) Remove wheels.
(3) Mark propeller shaft and axle yoke for assembly
alignment reference.
(4) Disconnect propeller shaft at axle yoke. Secure
shaft to frame rail using wire.
(5) Disconnect connecting rod at steering knuckles.
(6) Disconnect shock absorbers at axle housing.
(7) On vehicles equipped with sway bar, remove
nuts attaching sway bar connecting links to spring tie
plates.
(8) Disconnect breather tube from axle housing.
(9) Disconnect sway bar link bolts at spring clips.
(10) Remove disc brake calipers, rotors, and brake
shields. Refer to Chapter 2G.
(11) Remove U-bolts and tie plates.
(12) Support axle assembly on hydraulic jack and
raise jack slightly to relieve spring tension.
(13) Loosen nuts attaching spring pivot bolts to
springs.
(14) Remove bolts attaching front spring shackles to
springs and lower springs to floor.
(15) Remove hydraulic jack and axle assembly from
underneath vehicle.
~mm:r
namr.
" <dp_er
-i
AILE illlAlLIIill
(1) Support axle assembly on hydraulic jack and
move assembly into position underneath vehicle.
(2) Raise springs and install shackle bolts in front
springs and shackles. Install shackle bolt retaining nuts
hand-tight.
(3) Lower hydraulic jack until axle is supported by
front springs and rotate axle into position on springs.
(4) Install spring U-bolts and tie plates.
(5) On vehicles equipped with sway bar, mount
sway bar connecting links on tie plates.
(6) Tighten spring shackle bolts to 24 foot-pounds
(33 N*m) torque on CJ models and 100 foot-pounds (136
Nm) torque on all other models.
AXLES
2H3
SPECIFICATIONS
Front Axle Specifications
Axle Type:
Model 3 0 / 4 4 .
Front A x l e Lubricants:
Axle Application;
Model 30 Front Axle
Model 44 Front Axle
Axle Ring Gear Diameter:
Model 30
Model 4 4 .
CJ-5, CJ-7
Cherokee, Wagoneer, Truck
7.125-inches (18.09 cm)
8.500-inches (21.59 cm)
Lubricant Capacity:
Model 3 0
Model 4 4 . .
Turning Angle:
CJ-5, CJ-7
Cherokee, Wagoneer, Truck
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
. . .
. ., .
. . ., .
. .
. . . . .
.
.
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
20
15-25
27
20-34
40 min.
70 m i n .
_
_
54 m i n .
95 m i n .
85
75
115 min.
102 min.
40 min.
60 min.
45
100
80-120
54 m i n .
81 m i n .
61
136
48-68
109-163
24
100
18-30
80-120
33
136
24-41
109-163
100
55
50
100
15
80
85-105
45-65
163
75
68
136
20
109
115-142
61-81
_
35-50
13-18
65-90
18-24
88-122
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Markings Chart in Section A of this manual for any torque specifications not listed above.
80322
2F-14
AXLES
REAR AXLE
Page
Axis Housing
Axle HubAMC/Jeep Axle
Axle Shaft and BearingAMC/Jeep Axle
Axle Shaft and BearingModel 44 and 60 Axle
General
2F-14
2F-15
2P-16
2F-17
2F-14
identification
2F-14
2F-18
2F-19
2F-19
2F-19
0E1E1AL
CJ models are equipped with the AMC/Jeep semifloating rear axle with tapered axle shafts. This axle has
an 8-7/8 inch (22.50 cm) diameter ring gear.
Cherokee, Wagoneer, and Truck models use the Model
44F semi-floating rear axle which has flanged axle
shafts. Truck models rated from 6800 to 8400 GVWR
(3084 to 3810 kg) use the Model 60 full-floating rear axle.
Refer to the Power Train Combination Chart in Chapter
A for further information.
IDENTIFICATION
AIC/JeepAiIe
The axle ratio identification code letter is located on
the axle housing tube boss, adjacent to the dowel hole
(fig. 2F-16).
Fig. 2F-16
Ratio
Pinion/Drive
Gear Teeth
Standard
3.07
14/43
Trac-Lok
3.54:1,
11/39
Standard
3.54:1
11/39
Trac-Lok
3.07
14/43
60650
PART NUMBER
42299
Fig. 2F-17
A1LE HOUSING
The rear axle housing should be checked periodically
for weld cracks and other damage that may cause loss of
lubricant or affect driving characteristics.
AXLES
2F-l|
70544
Fig. 2F-18
Inspoction
Inspect the hub for loose or distorted wheel lug studs.
Inspect the keyway and tapered center bore for wear,
damaged serrations, or cracks. Replace the hub if worn
or damaged.
Installation
NOTE: The procedures for installing an original hub
and for installing a replacement hub are different. The
installation procedures for both hub-types are as
follows:
2F-19
41420
2F-16
AXLES
(1) If axle shaft bearing is to be replaced, pack bearing with generous amount of wheel bearing lubricant
and press bearing onto shaft. Small diameter of bearing
must face toward outer tapered end of shaft.
(2) Coat inner seal with light lubricating oil.
(3) Coat outer surface of seal metal retainer with
nonhardening sealer.
(4) Install inner oil seal using Seal Installer J-21788
(fig. 2F-22).
(5) Install axle shaft. Align shaft splines with differential side gear splines and insert shaft into gear.
(6) Install outer bearing cup.
(7) Inspect brake support plate for elongated bolt
holes. Replace support plate if necessary.
Fig. 2F-20
Installation
NOTE: Tapered shaft axle bearings do not have any
provision for lubrication after assembly and must be
packed with a high quality wheel bearing lubricant before installation.
AXLES
IMJ*
RemovalModel 44 Axle
(I) Raise and support vehicle and remove wheels.
(2). Remove brakedrum.'
(3) Remove nuts attaching support plate and retainer to axle tube flange using access hole in axle shaft
flange.
(4) Assemble Adapter Tool J-21579 and Slide Hammer J-2619-01, install tools on axle shaft flange, and
remove axle shaft (fig. 2F-24).
(5) Remove axle shaft oil seal from axle housing
tube.
(6) Wipe seal bore in axle housing tube clean and
install seal using tool J-25135.
"41423
InstallationModel 44 Axle
Fig. 2F-23
^F-18
MLES
TOOL
J-2619-01
Fig. 2F-26
70543
Fig. 2F-24
R8moaiMeie! 60
NOTE: It is not necessary to raise the rear wheels in
order to remove the rear axle shafts on Model 60 fullfloating rear axles.
(1) Remove axle flange nuts, lockwashers, and split
washers retaining axle shaft flange.
(2) Remove axle shaft from housing.
tastallatlofrr-Model'60'Axle
AXLES
(15) Check torque required to turn pinion, gear Pinion must be turned several revolutions to obtain accurate torque reading. Refer to torque reading recorded
during disassembly and add 5 inch-pounds (0.6 N*m)
for proper amount of torque.
(16) If preload torque is less than desired amount,
which should equal disassembly torque reading plus 5
inch-pounds (0.6 N*m), tighten pinion nut slightly and
recheck torque.
(17) Repeat gradual tightening procedure until desired torque is attained. Do not loosen and retighten
nut.
TOOL
J-22661
2F4I
Fig. 2F-28
41428
Installation
(1) Install replacement pinion seal using tool J25104.
(2) Install yoke on pinion.
(3) Install pinion washer and nut. Tighten nut to
210 foot-pounds (285 N*m) torque on Model 44 axle and
260 foot-pounds (352 N*m) torque on Model 60 axle.
(4) Align index marks on propeller shaft and yoke
and install shaft. Tighten U-bolt nuts to 16 foot-pounds
(22 N*m) torque or tighten flange bolts to 35 foot-pounds
(47 Nm) torque.
(5) Remove supports and lower vehicle.
Fig. 2F-27
41427
2F-2Q
AXLES
SPECIFICATIONS
Drive-type, semi-floating
axle w i t h flanged axle shafts.
Drive-type, full-floating axle
with flange-type axle.
Drive-type, semi-floating
axle w i t h tapered axle shaft.
AMC/Jeep
A x l e Application:
Model 44 Rear Axle
Model 6 0 Rear Axle
AMC/Jeep Rear Axle
Axle Ring Gear Diameter:
Model 4 4 .
Model 60
AMC/Jeep
Rear Axle Lubricants:
Standard Differential
Cherokee-Wagoneer-J-10 Truck
J-20 Truck
. . . CJ
8.500-inches (21.59 cm)
9.750-inches (24.38 cm)
8.875-inches (22.19 cm)
Jeep Axle Lubricant or
equivalent of SAE 90
A.P.I. Grade GL-5 quality, or
axle lubricant grade MIL-L-2105 B.
. Jeep Trac-Lok Axle
Lubricant or equivalent only.
Trac-Lok Differential
Lubricant Capacity:
Model 4 4 .
Model 6 0
AMC/Jeep
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Metric (IM-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
250 m i n .
20
15-25
339 m i n .
27
20-34
30
50
32
25-35
45-55
25-40
41
68
43
34-47
61-75
34-47
210
260
17-25 in-lbs
45
200-220
250-270
271-298
339-366
35-50
285
353
2-3
61
100
55
85-105
45-65
136
75
115-142
61-88
24
100
100
32 in-lbs
15
15
35
18-30
80-120
80-120
24-40 in-lbs
13-18
13-18
25-45
33
136
136
4
20
20
47
24-41
115-163
115-163
3-5
18-24
18-24
34-61
80
120
80
65-80
110-150
65-90
108
163
108
88-108
149-203
88-108
47-68
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
80325
AXLES 2F-21
STANDARD DIFFERENTIAL
Page
Differentia! Operation
Differential OverhaulAMC/Jeep Axle
Page
Differential OverhaulAxle Models 3 0 4 4 4 0
General
2F-21
2F-21
GENERAL
2F-30
2F-21
DIFFERENTIAL OPERATION
The differential gear system divides the torque between the axle shafts and allows them to rotate at different speeds when turning corners.
Each differential side gear is splined to an axle shaft.
The pinion gears are mounted on a pinion mate shaft
and are free to rotate on the shaft. The pinion gear is
fitted in a bore in the differential case and is positioned
at a right angle to the axle shafts.
In operation, power flow occurs as follows: The pinion
gear rotates the ring gear. The ring gear, which is bolted
to the differential case, rotates the case. The differential
pinion gears, which are mounted on the pinion mate
shaft, which is fitted in the case, rotate the side gears.
The side gears, which are splined to the axle shafts,
rotate the shafts.
During straight-ahead driving, the differential pinion
gears do not rotate on the pinion mate shaft. This occurs
because input torque applied to the gears is divided and
distributed equally between the two side gears. As a
result, the pinion gears revolve with the pinion mate
shaft but do not rotate around it (fig. 2F-29).
When turning corners, the outside wheel must travel
a greater distance than the inside wheel in order to
complete the turn. This difference must be compensated
for in order to prevent the wheels from scuffing and
sliding through the turn. To accomplish this, the differential becomes effective allowing the axle shafts to rotate at unequal speeds (fig. 2F-30). In this instance, the
input torque applied to the pinion gears is not divided
equally. The pinion gears now rotate around the pinion
mate shaft in opposite directions. This allows the side
gear and axle shaft attached to the outside wheel to
rotate at a faster speed.
PINION GEARS
WITH CASE
Fig. 2F-29
ROTATE
A50113
AXLE
OUTER WHEEL
110% CASE SPEED
100% D I F F E R E N T I A L
CASE SPEED
INNER WHEEL
90% CASE SPEED
Fig. 2F-30
2F-22
AXLES
P I N I O N F R O N T BEARING
PINION
NUT
F I L L PLUG
DIFFERENTIAL
SIDE G E A R
YOKE
T H R U S T BLOCK
.
DIFFERENTIAL
PINION GEAR
COLLAPSIBLE
SPACER
NVENT
ASSEMBLY
SEAL
RETAINER"
6 0 6 5 3
Fig. 2F-31
Fig. 2F-32
AXLES
2F-23
Fig. 2F-34
(1) Remove rear bearing cup using Driver Handle J8092 and Cup Remover J-21786.
(2) Remove pinion gear depth adjustment shims
from cup bore in housing.
N O T E : The pinion gear depth adjustment shims are
located under the rear bearing cup. Tag these shims for
assembly reference.
(3) Remove front bearing cup using Driver Handle
J-8092 and Cup Remover J-21787.
Differential Assembly
Pinion Qear Depth measurement and Ad|ustment
Ring and pinion sets are factory tested to detect machining variances. Tests are started at a standard setting which is then varied to obtain the most desirable
tooth contact pattern and quiet operation. When this
setting is determined, the ring and pinion gear are etched with identifying numbers (fig. 2F-36).
The ring gear receives one number. The pinion gear
receives two numbers which are separated by a plus (+)
or minus (-) sign.
The second number on the pinion gear indicates pinion
position, in relation to the centerline of the axle shafts,
where tooth contact was best and gear operation was
quietest. This number represents pinion depth variance
and indicates the amount, in thousandths of an inch,
that the gear set varied from the standard setting. The
number on the ring gear and first number on the pinion
gear identify the gears as a matched set. Do not attempt
to use a ring and pinion set having differing numbers.
This is not a matched set.
The standard setting for AMC/Jeep axles is 2.547
inches (6.46 cm). If the pinion is marked +2, the gear set
varied from standard by +0.002 inches (0.05 mm) and
will require 0.002 inch (0.05 mm) less shims than a gear
set marked zero (0). When a gear set is marked plus (+),
the distance from the pinion end face to the axle shaft
centerline must be more than the standard setting. If
the pinion gear is marked -3, the gear set varied from
standard by 0.003 inches (0.07 mm) and will require
0.003 (0.07 mm) more shims than a set marked zero (0).
When a set is marked minus (-), the distance from the
pinion end face to the axle shaft centerline must be less
than the standard setting. Refer to Figure 2F-35 for an
illustration of the standard setting dimension.
N O T E : On some factory installed gear sets, an additional 0.010 or 0.020 inches (0.25 or 0.50 mm) may have
been machined off the pinion gear buttonface. This does
not affect gear operation but does affect pinion gear
marking and depth measurement. Pinion gears machined in this fashion have different identifying
numbers. For example, if the pinion is marked +23, the
number 2 indicates that 0.020 (0.50 mm) was removed
from the pinion button face and the number 3 indicates
that variance from the standard setting is +0.003 (0.07
mm). If the pinion is marked +16, the number 1 indicates that 0.010 (0.25 mm) was removed from the
pinion buttonface and the number 6 indicates that variance from the standard setting is +0.006 (0.15 mm).
Gear sets with additional amounts machined off the
pinion button face are factory installed items exclusively. All service replacement gear sets will be machined
to standard
settings
only. In
addition,
replacement gear sets marked + or -0.009 (0.22 mm) or
more, or sets with mismatched identifying
numbers
must be returned to the parts distribution center. Do not
attempt to install these gear sets.
AXLES
2F-25
2 . 5 4 7 INCHES
* (64.69mm)
AMC/JEEP A X L E
STANDARD
SETTING
DIMENSION
AXLE SHAFT
CENTERLINE
COLLAPSIBLE
SPACER
A41439
Fig.
41435
Fig. 2F-36
ZF-26
AXLES
Pinion Variance Chart
Old Pinion
Marking
-3
-2
-1
+1
+4
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+3
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
+1
+0.005
+0.004
+0.003
+0.002
+0.001
+0.004
+0.003
+0.002
+0.001
-1
+0.003
+0.002
+0.001
-2
+0.002
+0.001
-3
+0.001
-4
-0.001
+2
+4
+2
+3
+0.002
+0.001
-0.001
-0.001
-0.002
-0.001
-0.002
-0.003
-0.001
-0.002
-0.003
-0.004
-0.001
-0.002
-0.003
-0.004
-0.005
-0.001
-0.002
-0.003
-0.004
-0.005
-0.006
-0.001
-0.002
-0.003
-0.004
-0.005
-0.006
-0.007
-0.002
-0.003
-0.004
-0.005
-0.006
-0.007
-0.008
80702
Fig. 2F-37
AXLES
N O T E J To avoid false readings, do not allow the gauge
anvil to contact the pinion gear at any point.
(15) Assemble Clamp J-5223-24 a n d Bolt J-5223-29
and mount on axle housing (fig. 2F-38). Use one axle
housing cover bolt to attach clamp to housing.
(16) Extend clamp bolt until it presses against gauge
block with enough force to prevent gauge block from
moving.
(17) Loosen gauge block thumbscrew to release
plunger. When plunger contacts arbor tool, tighten
thumbscrew to lock plunger in position. Do not disturb
plunger after locking in place.
(18) Remove clamp and bolt assembly from axle
housing.
(19) Remove gauge block and measure distance from
end of anvil to end of plunger using 3 inch (7.62 cm)
micrometer (fig. 2F-39). This dimension represents
measured pinion depth. Record this dimension for assembly reference.
(20) Remove bearing caps and remove arbor tool and
discs from housing.
(21) Remove pinion gear, rear bearing cup, and pinion depth shim from housing.
(22) Measure thickness of depth shim used in step
(10). Add this dimension to measured pinion depth obtained in step (8). From this total, subtract desired pinion depth. Result represents correct shim thickness
required.
2F-27
set-
28).
(5) Install pinion yoke and replacement pinion nut.
Tighten pinion nut finger-tight only.
(6) Tighten pinion nut only enough to remove end
play and seat pinion bearings. Use tool J-22575 to
tighten nut and use tool J-8614-01 to hold yoke while
tightening nut. Rotate pinion while tightening nut to
seat bearings evenly.
2F-28
AXLES
GAUGE
BLOCK
\,
J-5223-20
CLAMP A N D BOLT
J-5223-24, -29
Fig. ZF-38
41437
GAUGE
BLOCK
J-5223-20
prying.
THUMBSCREW
41438
Fig. 2F-39
AXLES
J-8001
Fig. 2F-40
Fig. 2F-42
2F-29
41444
Fig. 2F-41
N O T E : Differential
bearings must be preloaded to
compensate for heat and loads during operation. Correct
preload is 0.008 inch (0.20 mm). The differential bearings are preloaded by increasing the shim pack thickness
at each side of the differential by 0.001+ inch (0.10 mm).
(1) Remove differential assembly from housing. Be
sure to keep differential bearing shim packs together for
proper assembly.
(2) Reinstall differential bearing shims in axle
housing bearing bores.
(3) Install differential bearing cups on differential
bearings. Cups should cover differential bearing rollers
completely.
2F-30
AXLES
the shims by
hammering
Fig. 2F-44
Differential Installation
Differential D s s a s s e i l l f
NOTE: It is not necessary to remove the axle assembly
to overhaul the differential. All differential service operations can be performed with the axle mounted in the
vehicle.
(1) Raise vehicle.
(2) Remove wheels, brake drums, and axle shafts.
(3) Remove axle housing cover (fig. 2F-45,2F-46).
(4) Mark differential bearing caps with centerpunch for assembly alignment reference.
(5) Loosen differential bearing cap bolts until only 2
or 3 threads are engaged.
(6) Install Axle Housing Spreader Tool J-24385-01.
Be sure to install holddown clamps to keep spreader tool
in position (fig. 2F-47).
(7) Mount Dial Indicator Set J-8001 on axle housing
(fig. 2F-47). Zero indicator and be sure indicator stylus
contacts one side of opening in housing.
(8) Spread housing no more than 0.020 inch (0.50
mm) using spreader tool. Measure amount housing is
spread with dial indicator.
Fig. 2F-43
Checking Backlash
AlLES^2f-31
(1) Assemble and install Bearing Remover Set J25100 on bearing and gear (fig. 2F-49).
(2) Insert bearing remover adapters into remover
base from top and position adapters 180 apart (fig. 2F49).
(3) Tighten remover tool forcing screw and remove
bearing.
Pinion Rear Bearing RemovalModel 60 Axle
DIFFERENTIAL
SIDE GEAR
J42304
2F-32
AXLES
SLINGER
LjlD
^/<*Sia<
DIFFERENTIAL
CASE
S
DIFFERENTIAL
B E A R I N G SHIMS
SHIMS
DIFFERENTIAL
BEARING
B E A R I N G CUP
\ ^
P I N I O N DEPTH
SHIMS
N I O N F R O N T BEARING CUP
BEARING
PINION G E A
PINION M A T E
SHAFT
DUST CAP
SEAL
1^0
PINION
PRELOAD
_
SHIMS
P I N I O N REAR BEARING CUP
P I N I O N REAR BEARING
HOUSING
SEAL
f
I
RETAINER
B E A R I N G RETAINER RING
THRUST
WASHERS
AXLE SHAFT
DIFFERENTIAL
P I N I O N GEAR
J42305
Fig. 2F-46
SPREADER
J-24385-01
HOLDDOWN
CLAMPS
J42307
Fig. 2 F 4 8
DIAL INDICATOR
J-8001
J42306
Fig. 2F-47
(1) Assemble and install Bearing Remover Set J25100 on bearing and case. Remover tools are positioned
in manner similar to pinion bearing removal. Refer to
figure 2F-49 for tool setup.
(2) Install two bearing adapters in remover tool
base. Insert adapters into one side of tool base from top
and reposition adapters 180 degrees apart (fig. 2F-49).
(3) Install remover tool button in differential case
and center remover tool forcing screw in button.
(4) Tighten remover tool forcing screw and remove
bearing.
(5) Repeat operations to remove opposite bearing.
AXLES
2F-33
REMOVER
J-22912-01
90180
Fig. 2F-51
TOOL
BASE
Fig. 2F-49
42310
REMOVER
J-22912-01
90179
fig. 2F-50
2F-34
AXLES
DIFFERENTIAL BEARING
S H I M PACKS
Fig. 2F-52
J42312
AXLES
2F-3S
Fig. 2F-53
2F-36
AXLES
- r r - a E ^ ;
M " ~ ~ Z I W 1
set-
The following examples illustrate the procedure for determining correct shim thickness.
Example IPinion Depth Variance is Plus (+) Model 44
Axle
Step 1Determine desired pinion depth.
Add pinion depth variance (marked on pinion gear) to
standard setting. Result is desired pinion depth.
Standard Setting
.............
Pinion Depth Variance
Desired Pinion Depth =
Add measured pinion depth to measured shim thickness. Result equals total measured pinion depth.
Measured Pinion Depth......
Starter Shim Thickness..........
Total Measured Pinon Depth
AXLES
Fig. 2F-56
Fig. 2F-54
G A U G E BLOCK
J-5223-20
Fig. 2F-55
2F-37
2F-38
AXLES
N O T E : When overhauling a Model U front axle differential, check the axle shaft inner oil seals. If seal replacement is required, pry out the old seals and install
new seals using tool J-25111 (fig. 2F-58).
(13) Mount Spreader Tool J-24385-01 and Dial Indicator Set J-8001 on housing. Spread housing no more
than 0.020 inch (0.50 mm) (fig. 2F-47). Do not exceed
0.020 inch (0.50 mm) to avoid damaging housing.
Fig. 2F-57
J42319
Fig. 2F-58
J42320
Fig. 2F-59
tort
& g G Backlash
AXLES ZF-39
SPECIFICATIONS
Differential Specifications
Model 30 Front Axle
Metric
USA
015 in
.000-.006 in
005-.009 in
0.38 m m
0.000-0.15 mm
0.12-0.22 m m
15-25 in-lbs.
20-40 in-lbs.
2-3 N-m
2-5 N-m
0.15 in
.000-.006 in
.005-.010 in
0.38 m m
0.000-0.15 mm
0.12-0.25 mm
10-20 in-lbs.
20-40 in-lbs.
1-2 N-m
2-5 N-m
.015 in
.000-.006 in
.005-.009 in
0.38 m m
0.000-0.15 mm
0.12-0.15 m m
10-20 in-lbs.
20-40 in-lbs.
1-2 N-m
2-5 N-m
004-.008 in
(.006 in
desired)
17-25 in-lbs.
008 in
002 in max.
005-.009 in
(.008 in
desired)
0.10-0.20 m m
(0.15 m m
desired)
2-3 N-m
0.20 m m
0.05 m m max.
0.12-0.15 m m
(0.20 m m
desired)
2.547 in
64-69 m m
Model 60 Axle
Differential Bearing Preload
Differential Side Gear-to-Case Clearance
Drive Gear-to-Pinion Backlash
Drive Pinion Bearing Break-Away
Original Bearings
New Bearings
60657B
Torque Specifications
Service
S@t-To
Torque
Axle Housing Cover Bolts . . .
Differential Bearing Cap Bolts.
Ring Gear-to-Case Bolts . . . .
Lower Ball Stud Nut
Pinion Nut
Universal Joint U-Bolts. . . . .
Upper Ball Stud Nut
Upper Ball Stud Seat
Wheel-to-Hub Nuts . . . . . . .
20
40
55
80 m i n .
210
15
100 m i n .
50 m i n .
80
Metric (N-m)
Service
In-Use
Recheck
Torque
15-25
35-50
45-65
200-220
13-18
65-90
Service
Set-To
Torque
27
54
75
108 m i n .
271
20
136 m i n .
68 m i n .
108
Service
In-Use
Recheck
Torque
20-34
47-68
61-88
285-298
18-24
88-122
2F-40
AXLES
Service
Set-To
Torque
20
30
SO
8
35
55
80 m i n .
210
100 m i n .
50 min.
35
15
80
Metric (N-m)
15-25
25-35
70-90
5-10
30-40
45-65
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
20-34
34-47
95-122
7-14
41-54
61-81
25-45
13-18
65-90
27
41
108
11
47
75
108 m i n .
271
136 min.
68 min.
47
20
108
15-25
45-55
70-90
100-110
250-270
25-45
13-18
110-125
27
68
108
142
352
47
20
163
20-34
61-75
95-122
135-149
339-366
34-61
18-24
149-169
150-190 in-lbs
90-105 in-lbs
80-95
95-115
25-40
250 m i n .
13-18
10-18
19
11
10
142
43
339 min.
20
18
17-21
10-12
9-11
135-149
34-54
18-24
14-24
200-220
285-298
34-61
18-24
88-122
Model 60 Axle
20
50
80
105
260
35
15
120
AMC/Jeep Axle
(Semi-Floating Tapered Shaft)
Axle Housing Cover Bolts
Brake Tube-to-Rear Wheel Cylinder
Differential Bearing Cap Bolts
Ring Gear-to-Case B o l t . .
Rear Brake Support Plate Bolts
Axle Shaft-to-Hub Nuts
Universal Joint U-Bolts.
Clamp Strap Bolts
..
170 in-lbs
97 in-lbs
87
105
32
250 m i n .
15
13
All torque values given in foot-pounds and newton meters with dry fits unless otherwise specified.
Refer to the Standard Torque Specifications and Capscrew Markings Chart in Section A of this manual for any torque specifications not listed above.
60657A
TRAC-LOK DIFFERENTIAL
Page
Diagnosis
General
Lubrication
Overhaul
Service Replacement
Specifications
2F-41
2F-40
2F-41
2F-40
2F-42
2F-46
2F-46
GE1E1AL
OPERATION
AXLES
2F-41
LUBRICATION
The Trac-Lok differential requires a special lubricant.
Ordinary multipurpose gear lubricants m u s t not be
used. Use Jeep Trac-Lok Lubricant or equivalent only.
In addition, the only acceptable method for cleaning the
Trac-Lok differential is by disassembling the unit and
wiping it clean with shop towels.
NOTE: Trac-Lok differentials are serviced at the same
time intervals as standard
differentials.
OIACNOSIS
If noisy or rough operation such as chatter occurs
when turning corners, the most probable cause is incorrect or contaminated lubricant. Before removing the
Trac-Lok unit for repair, drain, flush, and refill the axle
with the specified lubricant. Refer to the lubricant
change procedure under Lubrication. A complete lubricant drain and refill with the specified lubricant will
usually correct chatter.
JVERHAUL
Jisasseiblf
(1) Remove Trac-Lok differential from axle housing. Removal procedures are same as outlined for standard differential. Refer to Figure 2F-60 for parts
nomenclature.
(2) Install one axle shaft in vise with spline end
facing upward and tighten vise. Do not allow more than
2-3/4 inch (6.98 cm) of shaft to extend above top of vise
(fig. 2F-61). This prevents shaft from fully entering side
gear, causing interference with step plate tool used to
remove differential gears.
(3) Mount differential case on axle shaft with ring
gear bolt heads facing upward (fig. 2F-62),
(4) Remove and discard ring gear bolts.
(5) Place shop towels under ring gear to protect
gear when it is removed from case (fig. 2F-62).
(6) Remove ring gear from case using rawhide
hammer.
(7) Remove differential case from axle shaft and
remove ring gear.
(8) Remount differential case on axle shaft.
mmm
N O T E : It may be necessary to adjust the tension applied to the Belleville springs by the forcing screw before the gears can be rotated in the case.
(18) Retain -upper side gear and clutch-pack in case
by holding hand on bottom of rotating tool while removing forcing screw. Remove rotating tool, upper side gear,
and clutch pack.
(19) Remove differential case from axle shaft. Invert
case with flange or ring gear side up and remove step
plate tool, lower side gear, and clutch pack from case.
Remove retainer clips from both clutch packs to allow
separation of plates and discs (fig. 2F-68).
Fig. 2F-62
Inspection
Clutch Plates and Disc
If any one member of either clutch pack shows evidence of excessive wear or scoring, the complete clutch
pack must be replaced on both sides.
Fig. 2F-63
if l i t
Hlf^li?
j J42323
fF-fiy
Fig. 2F-64
2F-44
AXLES
lifferential Side and Pinion lears
Fig. 2F-66
Fig. 2F-69
DIFFERENTIAL ASSEMBLY
Fig. 2F-67
Pinion l i a r Removal
Fig. 2F-68
AXLES
(22) Align ring gear and case bolt holes and install
ring gear bolts finger-tight only.
(23) Remount case on axle shaft and tighten bolts
evenly. On Model 30 and 44 axles, tighten bolts to 55
foot-pounds (75 N*m) torque. On Model 60 axles, tighten
bolts to 105 foot-pounds (142 Nm) torque.
(24) Install differential in axle housing. Follow service procedures previously outlined for conventional axles
to complete differential and axle assembly servicing.
Fig. 2F-70
2F-45
FI|. 2F-71
2F-46
AXLES
TOOL
J-8646-2
TOOL
J-23781-7
J-23781
J42338
J42336
Fig. 2F-72
Fig. 2F-74
J42337
Fig. 2F-73
J42339
Fig. 2F-75
SERVICE REPLACEMENT
If the Trac-Lok unit must be replaced as an assembly,
replace the unit as follows:
(1) Remove differential bearings and shims. Mark
or tag each bearing and shim pack for assembly
reference.
(2) Remove ring gear from case.
(3) Install original ring gear on replacement differential assembly. Be sure gear flange on replacement
case is free of nicks or burrs.
(4) Inspect shims and bearings which were removed. If shims and bearings are worn or damaged,
SPECIFICATIONS
Axle Specifications
Model 30 Front Axle
Differential Bearing Preload
Differential Side Gear-to-Case Clearance .
Ring Gear
Pinion Bearing Break-Away Preload
Original Bearings
New Bearings . . .
USA
Metric
015 in
.000-.006 in
.005-.009 in
0.38 mm
0.000-0.15 mm
0.12-0.22 mm
15-25 in-lbs.
20-40 in-lbs.
2-3 N-m
2-5 N-m
AXLES
2F-47
Metric
USA
.
..
. . .
. .
0.15 in
.000-.006 in
.005-.010 in
0.38 m m
0.000-0.15 m m
0.12-0.25 m m
10-20 in-lbs.
20-40 in-lbs.
1-2 N-m
2-5 N-m
.015 in
000-.006 in
.005-.009 in
0.38 m m
0.000-0.15 m m
0.12-0.15 m m
10-20 in-lbs.
20-40 in-lbs.
1-2 N-m
2-5 N-m
004-.008 in
(.006 in
desired)
17-25 in-lbs.
.008 in
.002 in max.
.005-.009 in
(.008 in
desired)
2.547 in
0.10-0.20 m m
(0.15 m m
desired)
2-3 N-m
0.20 m m
0.05 m m max.
0.12-0.15 m m
(0.20 m m
desired)
64-69 m m
Model 60 Axle
Differential Bearing Preload
Differential Side Gear-to-Case Clearance
Drive Gear-to-Pinion Backlash.
Drive Pinion Bearing Break-Away
Original Bearings
New Bearings
. .
60657B
Torque Specifications
Model 30 Front Axle
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
Metric (N-m)
Service
Set-To
Torque
Axle Housing Cover Bolts
Differential Bearing Cap Bolts
Ring Gear-to-Case Bolts
Lower Ball Stud Nut
Pinion Nut
Universal Joint U-Bolts. . . . .
Upper Ball Stud Nut
Upper Ball Stud Seat
Wheel-to-Hub Nuts
- -
. ..
20
4
Service
In-Use
Recheck
Torque
65-90
27
54
75
108 m i n .
271
20
136 m i n .
68 m i n .
108
15-25
25-35
70-90
5-10
30-40
45-65
200-220
25-45
27
41
108
11
47
75
108 m i n .
271
136 m i n .
68 m i n .
47
15-25
35-50
45-65
80 m i n .
2
100 m i n .
80
5
Service
Set-To
Torque
200-220
13-18
m i n
Service
In-Use
Recheck
Torque
20-34
47-68
61-88
285-298
18-24
88-122
- - - -
20
30
80
8
35
55
80 m i n .
210
100 m i n .
50 m i n .
35
Wheel-to-Hub Nuts
80
1 3
"
1 8
65-90
108
20-34
34-47
95-122
7-14
41-54
61-81
285-298
34-61
1 8
2 4
88-122
2F-48
AXLES
Metric (N-m)
Model 60 Axle
Axle Housing Cover Bolts .
Support Plate Bolts/Nuts
Differential Bearing Cap Bolts
Ring Gear-to-Case Bolts . ..
Pinion N u t .
Universal Joint Flange Bolts.
Universal Joint U-Bolts.
Wheel-to-Hub Nuts
. .
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
20
50
80
105
260
35
15
120
15-25
45-55
70-90
100-110
250-270
25-45
13-18
110-125
27
68
108
142
352
47
20
163
20-34
61-75
95-122
135-149
339-366
34-61
18-24
149-169
150-190 in-lbs
90-105 in-lbs
80-95
95-115
25-40
250 m i n .
13-18
10-18
19
11
10
142
43
339 m i n .
20
18
17-21
10-12
9-11
135-149
34-54
18-24
14-24
AMC/Jeep Axle
(Semi-Floating Tapered Shaft)
Axle Housing Cover Bolts . .
Brake Tube-to-Rear Wheel Cylinder
Differential Bearing Cap Bolts
Ring Gear-to-Case B o l t . .
Rear Brake Support Plate Bolts
Axle Shaft-to-Hub Nuts
Universal Joint U-Bolts. . . .
Clamp Strap Bolts
170 in-lbs
97 in-lbs
87
105
32
250 m i n .
15
13
-.
A l l torque values given in foot-pounds and newton meters w i t h dry fits unless otherwise specified.
Refer t o the Standard Torque Specifications and Capscrew Markings Chart in Section A of this manual for any torque specifications not listed above.
60657A
Tools
K B
J-25180 PULLER
J-25211-3 B U T T O N
J-25133 PULLER
J-25215 PULLER
0k
J-25158 WRENCH
NUT
' ' %,
J-8614-2
J-8614-3
Y O K E REMOVER
TOOLS
J-25211-2 CUP
J-25211-4 ADAPTER
J-25211-1 PLATE
J-8614-01
YOKE HOLDING TOOL
80323
AXLES
2F-49
Tools (Continued)
J-22575
P I N I O N N U T SOCKET
J-2498
AXLE SHAFT REMOVER
J-22661 REAR P I N I O N
OIL SEAL I N S T A L L E R
J-8614-2
J-8614-3
Y O K E REMOVER
TOOLS
J-8001
D I A L I N D I C A T O R SET
J-21788
A X L E SHAFT OIL
SEAL I N S T A L L E R
J-2092 A X L E E N D
PLAY C H E C K I N G TOOL
J-23674
A X L E SHAFT BEARING
REMOVER-INSTALLER
J-9233
P I N I O N OIL SEAL REMOVER
J-25109-01
A X L E HUB PULLER
J-21579
A X L E S H A F T PULLER
J-2619-01 SLIDE H A M M E R
J-25135-01
80326
ZF-50
AXLES
Tools (Continued)
dm
J-21787
PINION FRONT
B E A R I N G CUP
REMOVER
J-5223-24
CLAMP
J-21786
P I N I O N REAR
BEARING REMOVER
J-5223-20
GAUGE BLOCK
A N D PLUNGER
J-5223-29
BOLT
J-8608
P I N I O N REAR BEARING
CUP INSTALLER
O
O
J-24433
P I N I O N BEARING
INSTALLER SLEEVE
J-5223-25 OR -26
DISCS
J-8611-01
PINION FRONT
BEARING CUP
INSTALLER
J-21784
DIFFERENTIAL
BEARING INSTALLER
J-5223-4
ARBOR
J-5223-03
P I N I O N DEPTH S E T T I N G GAUGE SET
J-22697 P I N I O N REAR
BEARING INSTALLER
J-9233
P I N I O N SEAL REMOVER
WHS? . . : : J t 5 f c
151
\
J-22912-01
BEARING R E M O V E R
/
J-22661
PINION SEAL
INSTALLER
J-2497-01
DIFFERENTIAL BEARING
PULLER SET
J-5590
P I N I O N BEARING
INSTALLER SLEEVE
J-25111
F R O N T A X L E INNER
SEAL INSTALLER
J-25157 INSTALLER
J-25122 D R I V E R H A N D L E
80327A
AXLES
2F-51
Tools (continued)
J-7079-2
DRIVER H A N D L E (NON-THREADED)
J-24385-01
A X L E HOUSING SPREADER
J-8092
DRIVER HANDLE (THREADED)
J-24430
BEARING INSTALLER
80327B
4%
J-8646-2 FORCING SCREW A N D
J-23781-3GEAR R O T A T I N G T O O L
J-23781-7
STEP PLATE
80328
NOTES
26-1
BRAKES
SECTION INDEX
Pap
Brake Hydraulle System
Disc Brakes
Drum Brakes
26-20
26-39
26-32
GENERAL INFORMATION
Page
Brake Diagnosis
Brakelamp Switch
Brakelining Inspection
Brake Pedal
Brake Warning Lamp
26-1
26-17
26-17
26-14
26-14
lENEIAl
Jeep vehicles are equipped with single piston, floating
caliper front disc brakes and self energizing rear drum
brakes.
Two different disc brake calipers are used. The caliper
used on CJ models slides on abutement surfaces machined into the caliper and caliper support bracket. The
caliper used on Cherokee, Wagoneer and Truck models
slides on pivot bolts installed in the support shield and
bracket assembly. Refer to the Brake Size and Application Chart for size and application details.
Two different drum brake units are used. They are
similar in construction and operation but differ in
method of automatic adjustment. Eear drum brakes on
CJ models have cable operated automatic adjusters
while rear drum brakes on Cherokee, Wagoneer and
Truck models have linkage operated adjusters.
A dual reservoir master cylinder that provides separate hydraulic systems for the front and rear brake
units is used on all models.
A three-function combination valve is used on all Jeep
models. The valve consists of a one-piece housing containing a front brake metering valve, pressure differential warning valve, and rear brake proportioning valve.
Three power brake units are used. CJ models with
optional power assist brakes use an 8 inch (20.8 cm)
Page
General 21-1
Paring Brake Adjustment 26-1 i
Parking Brake Cables 21-18
Service Brake Adjustment 21-17
Specifications 26-19
2G-2
BRAKES
Test 2
Bleed system.
Test 3
Depress brake pedal and hold foot pressure on
pedal. If vehicle is equipped with power brakes,
stop engine and deplete all vacuum reserve in
system. Hold pressure for three minutes.
60778
BRAKES
2G-3
Test 5
70894
SLOW RETURN O F
BRAKE PEDAL
GRABBING OR
DRAGGING BRAKES
Correction
Possible Cause
(1)
(1)
(2)
(2)
(3)
(3)
(1)
(1)
(2)
(2)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
Service D i a g n o s i s - D r y m Brakes
Condition
LOW PEDAL OR
PEDAL GOES TO
TOE BOARD
Possible Cause
Correction
(1)
(1)
(2)
(2)
Adjust brakes.
(3)
(3)
(4)
(4)
MAKES
28-5
Possible Cause
Condition
LOW PEDAL OR
PEDAL GOES TO
TOE BOARD
(Continued)
SPRINGY, SPONGY
PEDAL
Correction
(5)
(5)
(6)
(6)
(7)
Air in system.
(7)
Bleed system.
(8).
(8)
(1)
(1).
(2)
Improper brake
(2)
(3)
(4)
(5)
(5)
(6)
Hoses-lines collapsed,
(3)
Improper l i n i n g
cylinder.
fluid.
thickness or
location.
(4)
specification)
kinked,
cylinder compensator
m Master
port blocked.
EXCESSIVE PEDAL
PRESSURE
REQUIRED TO
STOP VEHICLE
leaking.
(7)
a)
(1)
Adjust brakes.
(2)
Incorrect lining.
(2)
(3)
(3)
(4)
Improper fluid.
(4)
(5)
(6)
(7)
Linings watersoaked.
(7)
(8)
Glazed linings.
(8)
Replace linings.
(9)
Bell-mouthed, barrel-shaped,
or scored drums.
(9)
26-6
BRAKES
Possible Cause
Condition
LIGHT PEDAL
PRESSURE-BRAKES
TOO SEVERE
PULSATING BRAKE
PEDAL
BRAKE FADE
Correction
(1)
(1)
Adjust brakes.
(2)
(2)
(3)
A small a m o u n t of grease or
fluid on linings.
(3)
(4)
(4)
(5)
(5)
(6)
Incorrect lining.
(6)
(7)
(7)
(8)
Bell-mouthed, barrel-shaped, or
scored drums.
(8)
(9)
(9)
(1)
Drums out-of-round.
(1)
(2)
(2)
Tighten.
(3)
(3)
Replace or adjust.
(4)
(4)
(5)
(5)
(6)
(6)
(1)
Incorrect lining.
(2)
(2)
(3)
(3)
(1)
(1)
(2)
Improper fluid.
(2)
(3)
(3)
60637C
BRAKES
26-7
BRAKE PEDAL
TRAVEL DECREASING
Correction
Possible Cause
Condition
(4)
(4)
(5)
(5)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(7)
(8)
(8)
(9)
(9)
(1)
Contaminated linings.
(1)
(2)
(2)
Possible Cause
Condition
BRAKES GRAB OR
WON'T HOLD IN
WET WEATHER
BRAKES SQUEAK
(1)
Linings water-soaked.
(1)
(2)
(2)
Clean drums.
(3)
(3)
(4)
Scored drums.
(4)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
Drums distorted.
(4)
(5)
(5)
Lubricate.
(6)
(6)
(7)
(7)
Adjust bearings.
(8)
Charred lining.
(8)
Replace lining.
(9)
(9)
Tighten.
Correction
(1)
(1)
(2)
(2)
(3)
Dirty lining.
(3)
Replace lining.
(4)
(4)
Overhaul cylinders.
(5)
(5)
Replace springs.
(6)
(6)
BRAKES
26-9
Condition
VEHICLE PULLS TO
ONE SIDE
Possible Cause
Correction
(1)
(1)
(2)
Adjustment n o t correct.
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(7)
(8)
(8)
()
(9)
(10)
Out-of-round drums.
(10)
(11)
Brake dragging.
(11)
(12)
(12)
(13)
(13)
(14)
Unequal camber.
(14)
(15)
(15)
(16)
(16)
(17)
(17)
Replace.
60637F
Possible Cause
Condition
BRAKES CHATTER
SHOE CLICK
Correction
(1)
Incorrect lining-to-drum
clearance.
(i)
Adjust to recommended
clearances.
(2)
(2)
(3)
(3)
(4)
(4)
Replace.
(5)
(5)
Adjust.
(6)
Drums out-of-round.
(6)
(7)
(7)
Straighten or replace.
(8)
(8)
(1)
(1)
(2)
(2)
Replace springs.
(3)
Shoe bent.
(3)
(4)
(4)
BRAKE CHATTER OR
ROUGHNESS. BRAKE
PEDAL PULSATES
Correction
Possible Cause
Condition
(1)
(i)
(2)
(2)
(3)
(3)
(4)
(4)
BRAKES
2G-11
Condition
Correction
BRAKE CHATTER OR
ROUGHNESS. BRAKE
PEDAL PULSATES
(Continued)
(5)
(5)
(6)
(6)
Replace shoes.
EXCESSIVE PEDAL
E F F O R T REQUIRED
(1)
(1)
(2)
(2)
(3)
Lining worn.
(3)
(4)
(4)
Rebuild caliper.
(5)
(5)
(6)
(6)
(1)
(1)
(2)
Leak in system.
(2)
(3)
Air in system.
(3)
Bleed brakes.
(4)
(4)
(5)
Worn lining.
(5)
Replace linings. If wear is excessive or premature, check for incorrect lining, sticking caliper
pistons, binding park brake
cables, shoe drag on support
plate, weak return springs on
drum brakes, improper rear
brake adjustment.
(6)
(6)
Replace as required.
(7)
(7)
(8)
(8)
(1)
(1)
EXCESSIVE PEDAL
TRAVEL
DRAGGING BRAKES
NOTE: A very light
drag occuring after
releasing the brake
pedal is a characteristic of disc brakes.
60638B
2G-12
BRAKES
Condition
GRABBING BRAKES
Correction
Possible Cause
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(7)
(8)
(8)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(1)
(1)
Inflate to spec.
(2)
(2)
(3)
(3)
BRAKES
Sermm
Condition
2G-13
Possible Cause
Correction
(4)
Malfunction in caliper.
(4)
(5)
(5)
(6)
(6)
(7)
Loose calipers.
(7)
(8)
(8)
F r o n t end o u t of alignment.
(9)
- (9)
(10)
(10)
(11)
(11)
(1)
(1)
(2)
(2)
SPONGY PEDAL
(1)
Air in system.
(1)
(2)
(2)
(3)
Calipers lopse.
(3)
(4)
(4)
60638D
26-14
BRAKES
Condition
SPONGY PEDAL
(Continued)
Possible Cause
Correction
(5)
(5)
(6)
(6)
60638E
BRAKE PEDAL *
A suspended brake pedal is used on all models. The
pedal is attached to the pedal support bracket by a pivot
bolt (fig. 2G-1 and 2G-2). The pivot bolt serves as both
attaching part and pivoting member for the pedal.
PIVOT
BOLT
LOCKNUT
BRAKE LAMP
SWITCH
PIVOT
LOCKNUT
SPACER
WASHER
BRAKE
PEDAL
80337
WASHER
Fig. 2G-2
80338
Fig. 21-1
models and under normal circumstances should not require further attention. Power brake equipped vehicles
utilize a single push rod in the power unit which is also
preset at manufacture and is not adjustable. When replacing a power unit, use the push rod supplied with the
replacement power unit as it has been properly gauged
for use with the replacement unit. Pedal free play for
power brake equipped vehicles is the same as for vehicles with nonpower brakes.
BRAKES 26-15
differential between front and rear brake hydraulic systems should ever occur.
On vehicles with a parking brake warning system, the
lamp also functions as a signal device to alert the driver
when the parking brakes are applied.
In the parking brake signal mode, the lamp is activated by a mechanically operated switch mounted on the
parking brake lever assembly. In the brake hydraulic
pressure differential warning mode, the lamp is activated by a plunger-type switch located in the combination valve.
If a pressure loss should occur in either the front or
rear brake hydraulic systems, a pressure differential of
70 to 300 psi (483 to 2 068 kPa) will cause a piston in the
pressure differential section of the combination valve to
shuttle toward the low pressure side of the valve. As the
piston moves toward this side of the valve, ramps on the
piston contact the differential switch plunger forcing it
upward and closing the switch internal contacts. This
completes the electrical circuit between switch and
warning lamp causing the lamp to light. Unless the
ignition lock cylinder is turned to the OFF position, the
lamp will remain illuminated until the cause of the
CLIP
HANDLE
80340
Fig. 2G-3
20-16 BRAKES
W I T H M O D E L 60 REAR A X L E
80339
Fig. 2G-4
BRAKES 2G-17
(7) On Cherokee, Wagoneer and Truck models, install fuel tank skid plate if removed.
(8) Tighten cable adjuster locknuts and adjust parking brakes as outlined in this chapter.
(9) Lower vehicle.
RemovalFront Cable
(1) Raise vehicle.
(2) Remove equalizer from front cable.
(3) On CJ models, remove clip retaining cable to
frame bracket.
(4) On Cherokee, Wagoneer and Truck models, remove clip retaining cable to rear crossmember.
(5) Lower vehicle.
(6) Disconnect front cable return spring at parking
brake lever assembly if equipped.
(7) Roll carpet back and remove front cable ferruleto-parking brake lever assembly retaining clip.
(8) Disengage cable end from parking brake lever
assembly.
(9) Remove cable.
(10) If cable is to be replaced, remove insulator or
grommet from lever end of cable.
InstallationFront Cable
(1) Install front cable through floorpan and install
cable grommet or insulator in floorpan.
(2) Install cable ferrule-to-parking brake lever assembly retaining clip and reposition carpet.
(3) Engage cable end in parking brake lever assembly and install cable return spring if equipped.
(4) On CJ models, install clip retaining cable to
frame bracket.
(5) On Cherokee, Wagoneer and Truck models, install clip retaining cable to rear crossmember.
(6) Raise vehicle.
(7) Install cable equalizer and locknuts. On CJ models, be sure cable is properly positioned in frame bracket
as well as equalizer (fig. 2G-3).
(8) Adjust parking brakes as outlined in this
section.
(9) Lower vehicle.
BRAKELAIP SWITCH
The brakelamp switch is mounted on a flange attached to the brake pedal support bracket (fig. 2G-2). A
spring-loaded plunger in the switch opens and closes the
stoplamp circuit.
When the brake pedal is in the released position, the
pedal arm contacts the switch plunger, holding it in the
off position. When the brake pedal is pressed, the spring
loaded plunger extends with brake pedal movement until the switch is in the On position.
BRAKELINING INSPECTION
Disc Brakes
The brakelining should be inspected whenever the
wheels are removed for tire rotation or at the intervals
specified in the Maintenance Schedule.
2G-18
BRAKES
"I,
TOOL
J-21177
CALIPER
SUPPORT
J41113)
Fig. 20-7
VIEW B
Fig. 28-5
J41139
N O T E : The disc brakes hoes used on Cherokee, Wagoneer and Truck models have a wear sensor attached to the
inboard brakeshoe. When the lining wears
sufficiently,
the sensor contacts the rotor making a high pitched
noise to warn the driver that replacement is necessary.
Drum Brakes
Inspect the rear drum brakelining whenever the rear
wheels and drums are removed or at the intervals specified in the Mechanical Maintenance Schedule. Bonded
linings should be replaced whenever the lining has worn
to a thickness of 1/16 inch (1.58 mm) or less. Riveted
linings should be replaced whenever the lining has worn
to within 1/32 inch (0.79 mm) of the rivet heads.
Fig. l i - i
BRAKES
28-19
SPECIFICATIONS
Brake Size and Application Chart
Rear Brakes
Front Brakes
Model
Master Cylinder
Bore Diameter
Brake Size
Ana Type
Caliper Piston
Diameter
Brake Size
And Type
Wheel Cyl.
Diameter
Power Brake
Unit Type
CJ
1.00
(25.4 mm)
11.7 Disc.
(29.7 cm)
2.6
Single Piston
(6.60 cm)
10 x 1.75 D r u m
(25.4 x 4.44 cm)
.875
(22.2 mm)
8.00
Single Diaphragm
(20.3 cm)
Cherokee
Wagoneer
1.125
(28.5 mm)
12.0 Disc.
(30.48 cm)
2.937
Single Piston
(7.45 cm)
1 1 x 2 Drum
(27.94 x 5.08 cm)
.937
(23.79 mm)
9 1/2
Single Diaphragm
(24.13 cm)
J-10 Truck
1.125
(28.5 mm)
12.0 Disc.
(30.48 cm)
2.937
Single Piston
(7.45 cm)
1 1 x 2 Drum
(27.94 x 5.08 cm)
937
(23.79 mm)
9 1/2
Single Diaphragm
(24.13 cm)
J-20 Truck
6800 GVW
1.125
(28.5 mm)
12.5 Disc.
(31.75 cm)
2.937
Single Piston
(7.45 cm)
12 x 2.5 D r u m
(30.48 x 6.35 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
J-20 Truck
7600 GVW
1.125
(28.5 mm)
12.5 Disc.
(31.75 cm)
2.937
Single Piston
(7.45 cm)
12 x 2.5 D r u m
(30.48 x 6.35 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
J-20 Truck
8400 GVW
1.125
(28 5 mm)
12.5 Disc.
(31 75 cm)
2.937
Single Piston
(7.45 cm)
12 x 2.5 D r u m
( 3 0 . 4 8 x 6 . 3 5 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
4 1 1 0 2
Torque Specifications
USA (ft.-lbs.)
Service
Set - to
Torque
Brakeline-to-Caliper Fitting Bolt (Cke, Wag, Trk)
Bleeder Screw (1/4 - 28)
, ..
Bleeder Screw (3/8 - 24)
Brake Support Plate Mounting Bolts/Nuts (J-20 Trk)
Brake Support Plate Mounting Bolts/Nuts (Cke, Wag, J10 Trk)
Brake Support Plate Mounting Bolts/Nuts (CJ)
Caliper Anchor Bracket t o Steering Knuckle (CJ)
Master Cylinder Mounting Bolts/Nuts
Master Cylinder-to-Power Unit Mounting Nuts
Power Brake Unit-to-Dash Mounting Bolts/Nuts
Brake Line-to-Caliper Fitting Bolt (CJ)
Brake Line-to-Wheel Cylinder Fitting
Parking Brake Cable Clamp-to-Support Plate Bolts (5/16 - 18)
Wheel Nuts (CJ)
Wheel Nuts (Cke, Wag, Trk) .
Wheel Nuts (8400 GVW Trk)
Brake Pedal-to-Power Unit Push Rod B o l t / N u t
Caliper Mounting Bolts (Cke, Wag, Trk)
Caliper Support Key Retaining Screw (CJ) .
Disc. Brake Shield Bolts (Cke, Wag, Trk)
Disc. Brake Shield Nuts (Cke, Wag, Trk)
Wheel Bearing Outer Locknut (All)
Wheel Bearing Inner Locknut (Bearing Adjuster):
CJ
Cke, Wag, T r k
.
160 in-lbs.
4 5 in-lbs.
90 in-lbs.
50
45
33
85
30
25
22
25
160 in-lbs.
10
75
75
130
35
35
15
8
35
50(min.)
In - Use
Recheck
Torque
1 2 0 - 2 0 0 in-lbs.
4 0 - 50 in-lbs.
4 0 - 140 in-lbs.
45-55
35-55
30-35
75-95
25-35
20-30
18-25
20 - 30
1 2 0 - 2 0 0 in-lbs.
8 - 12
65-90
65-80
110-150
25- 40
30-40
1 5 - 18
5 - 10
30-40
Metric ( N m)
Service
Set - to
Torque
18
5
10
68
61
45
115
41
34
30
34
.18
14
102
102
176
47
47
20
11
47
68 (min.)
In - Use
Recheck
Torque
14 23
5- 6
5 16
61 - 75
47 - 75
41 - 4 7
102-129
34-47
27-41
24-34
27-41
14 23
11 - 16
88-122
8 8 - 108
149-203
3 4 - 54
41 - 54
20-24
7 - 14
41 - 54
Tighten to 50 ft-lbs. (68 N-m) and back off 1/3 turn while rotating wheel.
Tighten to 50 ft-lbs. (68 N-m), loosen and retighten to 35 ft-lbs.
(47 N-m), then back off 1/3 turn - all while rotating wheel.
60647
2G-20
BRAKES
BRAKE
HYDRAULIC SYSTEM
Page
Brake Bleeding 2G-26
Brake Fluid 2G-20
Brake Fluid Level 2G-21
Combination Valve 28-24
General 2G-20
GENEIIL
The brake hydraulic system consists of the dual reservoir master cylinder, combination valve, front disc
brake calipers, rear drum brake wheel cylinders, and the
connecting brake lines, hoses, and fittings (fig. 2G-8).
The hydraulic system is a closed system and must
remain free of contaminants in order to function properly. When servicing the system, prevent the entry of
contaminants by capping all lines and ports, and by
avoiding the use of cleaning solvents that have a mineral
oil base.
CAUTION: Never use gasoline, kerosene, carbon tetrachloride, paint thinner, alcohol, or any similar fluid
containing mineral oil, to clean or lubricate hydraulic
Page
2G-21
2G-21
2G-27
26-23
system components. These materials will cause swelling, deterioration, and premature aging of rubber parts.
Use brake fluid or brake cleaning solvent only.
To determine if dirt, moisture, or mineral oil base
fluids have contaminated the hydraulic fluid, drain off a
sample and check for suspended particles, discoloration,
or separation of the fluid into distinct layers. Layering
indicates the presence of water or mineral oil. If system
contamination should occur, drain and flush the entire
brake hydraulic system with an approved brake fluid
only.
l U I I FLU
.,
BRAKES
2G-21
MASTER CYLINDER
A dual reservoir master cylinder is used on all Jeep
vehicles. The hydraulic system for the front brakes is
completely separate from the rear brakes. In the event
of hydraulic brake failure in the front system, the rear
hydraulic brakes will still operate. If a failure occurs in
the rear brakes, the front brakes will still operate.
The dual master cylinder has two outlet ports, two
fluid reservoirs, and two hydraulic pistons which are
operated in tandem by a single push rod.
When the master cylinder fluid reservoirs are filled
and the front and rear brake systems purged of air,
there is a solid column of fluid on the forward side of
both the primary and secondary pistons.
During brake application, fluid is displaced by the
master cylinder pistons into the front caliper and rear
wheel cylinders to activate the brakes. At brake release,
fluid returns from the calipers and wheel cylinders to
the master cylinder reservoirs.
26-22 BRAKES
Fig. ZG-9
BRAKES 28-23
primary piston inward (using push rod) and install piston snap ring in groove of master cylinder bore.
(8) On CJ models with nonpower brakes, install
boot if removed.
(9) Install replacement diaphragm seal on master
cylinder cover.
Installation
WHEEL CYLINDER
SECONDARY
PISTON ASSEMBLY
60240
Fig. 21-10
Master Cylinder
Cherokee-Wagoneer-Truok Models
Assembly
(1) Install replacement tube seats (if removed) using spare tube fitting nuts to press seats into place. Do
not allow seats to become cocked during installation. Be
sure seats are bottomed. Remove tube fitting nuts and
check for burrs or chips. Remove burrs or chips. Rinse
master cylinder in brake cleaning solvent and blow out
all passages with compressed air.
(2) Install piston cups on secondary piston. Piston
cup installed in groove at end of piston should have lip
facing away from piston. Install next cup so lip faces
piston (fig. 2G-9 and 2G-10).
(3) Install seal protector, piston seal, spring retainer, and return spring on secondary piston (fig. 2G-9
and 2G-10). Install piston seal so lip faces interior of
master cylinder bore when assembly is installed. Be
sure return spring seats against retainer and that retainer is located inside lip of piston seal.
(4) Lubricate master cylinder bore and secondary
piston seal and cups with clean brake fluid and install
secondary piston assembly in cylinder bore.
(5) Lubricate seals on new primary piston assembly
with clean brake fluid and install assembly in master
cylinder bore.
(6) On models with power brakes, press primary
piston inward using wooden dowel and install piston
snap ring in groove of master cylinder bore.
(7) On CJ models with nonpower brakes, press
Remowal
(1) Remove wheels, brakedrums, and brakeshoes.
Refer to Drum Brake Section for procedure.
(2) Disconnect brake line at wheel cylinder. Do not
bend line away from cylinder. When cylinder is removed, line will separate from cylinder easily.
(3) Remove cylinder-to-support plate bolts and remove cylinder.
Overhaul
(1) Remove brakeshoe links and dust boots.
(2) Push pistons, piston cups, and compression
spring and expanders out of piston bore. Discard piston
cups, they are not reusable.
(3) Clean all cylinder components using brake
cleaning solvent or brake fluid only.
26-24
BRAKES
COMPRESSION
SPRING A N D
EXPANDERS
CJ M O D E L S
LINK
COMPRESSION
SPRING A N D
EXPANDERS
BLEEDER
SCREW
DUST
BOOT
PISTON
PISTON CUP
WHEEL
CYLINDER
80398
CHEROKEE, WAGONEER
TRUCK MODELS
Fig. 2G-11
Wheel Cylinder
CAUTION: Do not clean brake parts with solvents containing mineral oil such as gasoline, carbon tetrachloride, kerosene, alcohol, paint thinner or similar fluids.
Mineral oil causes swelling, deterioration, and premature aging of all rubber parts in the hydraulic system. Use clean brake fluid or an approved
brake
cleaning solvent only.
(4) Inspect wheel cylinder and pistons. Replace cylinder if bore or pistons are scored, corroded, rusted,
pitted, worn, or cracked. If bore or pistons are only
discolored, or stained, polish bore or pistons lightly using crocus cloth only. Do not polish cylinder bore in
lengthwise direction, polish by rotating cylinder around
crocus cloth supported on fingers.
CAUTION: Do not hone the wheel cylinders
time or for any reason.
at any
(5) Inspect bleeder screw and screw threads in cylinder. Screw must turn freely. Replace screw if damaged or replace cylinder if cylinder threads are
damaged.
(6) Inspect compression spring and integral expanders. Replace spring if broken, distorted, lacks tension,
or if expanders are damaged in any way.
(7) Inspect rubber dust boots. Replace boots if cut,
torn, cracked, distorted.
(8) If cylinder bore or pistons were polished, clean
them using brake fluid or brake cleaning solvent and dry
using compressed air.
(9) Lubricate cylinder bore and all cylinder internal
components with new brake fluid. Do not lubricate dust
boots. Install them dry only.
(10) Position replacement piston cups on compression expanders and install assembled parts in cylinder bore. Be sure expanders are seated in piston cups
and that cups are installed with lips facing one another
and toward interior of cylinder bore.
(11) Install pistons in cylinder bore. Be sure pistons
are installed with flat sides facing interior of bore.
(12) Install dust boots.
Installation
(1) Clean wheel cylinder mounting surface of support plate.
(2) Clean brake line fitting and threads.
(3) Start brake line fitting into cylinder. Do not
tighten fitting completely.
(4) Position cylinder on support plate and install
cylinder mounting bolts. Tighten bolts to 18 foot-pounds
(24 N*m) torque.
(5) Insert brakeshoe connecting links through dust
boots and into into pistons.
(6) Install Wheel Cylinder Clamp Tool J-8002 over
cylinder to retain internal components in cylinder.
(7) Tighten wheel cylinder brake line fitting.
COMBINATION VALVE
A three-function combination valve is used on all Jeep
models. The valve consists of a one-piece housing containing a front brake metering valve, a pressure differential warning valve, and a rear brake proportioning
valve. The combination valve also serves as the junction
block for the front brakes.
Two different combination valves are used. Some
models may be equipped with the type-W valve (fig. 2G12), while other models may be equipped with the typeD valve (fig. 2G-13). Although the two valve types differ
in external appearance and in internal component design, valve function and operation is the same for both.
Combination valve location is the same for all models.
The valve is mounted on the inner side of the left frame
rail adjacent to the transmission (fig. 2G-14).
BRAKES
FRONT
INLET
PORT
FRONT
OUTLET
PORT
WARNING
VALVE
SWITCH
26-15
REAR
INLET
PORT
REAR
OUTLET
PORT
METERING
VALVE
DUST COVER
,FRONT
OUTLET
PORT
70569
Fig. 2 6 - 1 2
I
METERING V A L V E
DIFFERENTIAL
WARNING
VALVE SWITCH
SWITCH
FRONT I
"""J"
FRONT " ) " L
SWITCH
7
OUTLET
< PLUNGER
PORT
'
E
P O H
PROPORTIONER
VALVE
;
REAR INLET
PORT
REAR
OUTLET
PORT
BOOT
METERING
VALVE
STEM
FRONT OUTLET
PORT
PROPORTIONER
PISTON
Fig. 2 6 - 1 4
41120
Fig. 26-13
Combn
iao
tin Viha Ipntlon
NOTE: The type D and W combination valves are hydraulic self-reset types which do not require manual
recentering.
2G-26 BRAKES
BRAKE BLEEB11G
General
The brake hydraulic system must be purged of air
whenever a line has been disconnected or if air has
entered the system.
In most cases, it will be necessary to bleed only that
portion of the hydraulic system (front or rear) being
serviced. However, if a firm brake pedal cannot be obtained, or if diagnosis indicates the need, the entire
system must be bled.
Brake bleeding can be performed manually or with
pressure equipment. Bleeder screws are provided at the
calipers and wheel cylinders to simplify the bleeding
procedure.
Fig. 2G-16 Metering Valve Tool Installation
(1) Remove all accumulated dirt from master cylinder and cover.
(2) Remove master cylinder cover.
(3) Fill master cylinder if required and install
cover.
(4) On vehicles equipped with type-W combination
valve, remove dust cover from metering valve stem and
install tool J-26869 on stem to hold valve open (fig. 2G15).
7 0 5 7 0
Fig. 2a-1B
(7) Remove master cylinder cover and refill as required. Fill reservoir to within 1/4 inch (6.35 mm) of
reservoir rim. Install cover. Make sure cover retainer is
in place.
(8) Remove metering valve tool.
(9) Test brake operation before moving vehicle.
BRAKES 26-27
(6) On vehicles with type-W combination valve, remove dust cover from metering valve stem and install
tool J-26869 on stem to hold valve open (fig. 2G-15).
(7) On vehicles equipped with type-D combination
valve, loosen valve front mounting bolt and insert
slotted end of tool J-23709 under bolt. Push metering
valve stem inward (using tool) to hold valve open and
tighten mounting bolt to secure tool (fig. 2G-16).
(8) Bleed brake system in following sequence:
(a) right rear wheel
(b) left rear wheel
(c) right front wheel
(d) left front wheel
(e) master cylinder brake line connections
NOTE: When using pressure equipment, the bleeding
procedure is the same as outlined in the Manual Bleeding Procedure except that a helper is not required to
apply the brake pedal The pressure bleeder develops
enough system pressure to permit bleeding without the
use of the brake pedal
Fi|. ?(M7
(9) When system has been purged of all air, turn off
pressure bleeder and close bleeder fluid release valve.
(10) Disconnect pressure bleeder hose at adapter fitting and remove master cylinder cover adapter.
(11) Refill master cylinder reservoirs to within 1/4
inch (6.35 mm) of reservoir rims.
(12) Install cover and rubber diaphragm seal. Make
sure cover retainer is in place.
(13) On vehicles equipped with type-W combination
valve, remove tool J-26869 from metering valve stem
and install dust cover. On vehicles equipped with type-D
combination valve, loosen valve front mounting bolt,
remove tool J-23709, and retighten mounting bolt.
(14) Test brake operation before moving vehicle.
SPECIFICATIONS
Fluid S p e c i f i c a t i o n s
Brake Fluid
2G-28 BRAKES
Master Cylinder
Bore Diameter
Rear Brakes
Brake Size
And Type
Caliper Piston
Diameter
Brake Size
And Type
Wheel Cyl.
Diameter
Power Brake
Unit Type
CJ
1.00
(25.4 mm)
1 1 . 7 Disc.
(29.7 cm)
2.6
Single Piston
(6.60 cm)
10 x 1.75 Drum
(25.4 x 4.44 cm)
.875
(22.2 mm)
8.00
Single Diaphragm
(20.3 cm)
Cherokee
Wagoneer
1.125
(28.5 mm)
12.0 Disc.
(30.48 cm)
2.937
Single Piston
(7.45 cm)
1 1 x 2 Drum
(27.94 x 5.08 cm)
.937
(23.79 mm)
9 1/2
Single Diaphragm
(24.13 cm)
J-10 Truck
1.125
(28.5 mm)
12.0 Disc.
(30.48 cm)
2.937
Single Piston
(7.45 cm)
1 1 x 2 Drum
(27.94 x 5.08 cm)
.937
(23.79 mm)
9 1/2
Single Diaphragm
(24.13 cm)
J-20 Truck
6800 GVW
1.125
(28.5 mm)
12.5 Disc.
(31.75cm)
2.937
Single Piston
(7.45 cm)
1 2 x 2.5 Drum
(30.48x6.35 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
J-20 Truck
7600 GVW
1.125
(28.5 mm)
12.5 Disc.
(31.75 cm)
2.937
Single Piston
(7.45 cm)
12 x 2.5 Drum
(30.48x6.35 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
J-20 Truck
8400 GVW
1.125
(28.5 mm)
12.5 Disc.
(31.75 cm)
2.937
Single Piston
(7.45 cm)
1 2 x 2.5 Drum
(30.48 x 6.35 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
41102
Torque Specifications
USA (ft.-lbs.)
Service
Set - to
Torque
In - Use
Recheck
Torque
Metric (N-m)
Service
Set - to
Torque
In - Us
Recheck
Torque
BRAKES
2G-29
2G-29
2G-31
2G-31
Pip
Power Unit Removal
Power Unit Service
Specifications
2G-31
2G-31
26-31
GENERAL
Three power units are used on Jeep vehicles. An 8-inch
single diaphragm unit is used on CJ models (fig. 2G-18).
A 9-1/2 single diaphragm unit is used on Cherokee,
Wagoneer and J-10 Truck models (fig. 2G-19) and a 9-1/2
tandem diaphragm unit is used on J-20 Truck models.
The power units consist of a two-piece outer shell
containing the single or dual diaphragms, air inlet valve,
air filter, control valve, power piston, reaction plate and
master cylinder push rod, and vacuum check valve (fig
2G-20 and 2G-21).
Fig. 21=18
Piwer Unit
The power unit utilizes a combination of engine vacuum and atmospheric pressure to increase brake apply
force without increasing brake pedal efforts.
In the neutral (non-applied) position, a vacuum is
present within the chamber formed by the two halves of
the outer shell and on both sides of the power piston and
diaphragm.
20-30
BRAKES
Fig. 26-20
80383
Fig. 26-21
PowerUnit
TandemDiaphragm
(Typical)
BRAKES
of the power piston to develop atmospheric air pressure
on the power piston.
2G-31
SPECIFICATIONS
Brake Size and Application Chart
Front Brakes
Model
Master Cylinder
Bore Diameter
Rear Brakes
Brake Size
And Type
Caliper Piston
Diameter
Brake Size
And Type
Wheel Cyl.
Diameter
Power Brake
Unit Type
CJ
1.00
(25.4 mm)
11.7 Disc.
(29.7 cm)
2.6
Single Piston
(6.60 cm)
10 x 1.75 Drum
(25.4 x 4.44 cm)
.875
(22.2 mm)
8.00
Single Diaphragm
(20.3 cm)
Cherokee
Wagoneer
1.125
(28.5 mm)
12.0 Disc.
(30.48 cm)
2.937
Single Piston
(7.45 cm)
1 1 x 2 Drum
(27.94 x 5.08 cm)
.937
(23.79 mm)
9 1/2
Single Diaphragm
(24.13 cm)
J-10 Truck
1.125
(28.5 mm)
12.0 Disc.
(30.48 cm)
2.937
Single Piston
(7.45 cm)
1 1 x 2 Drum
(27.94 x 5.08 cm)
.937
(23.79 mm)
9 1/2
Single Diaphragm
(24.13 cm)
J-20 Truck
6800 GVW
1.125
(28.5 mm)
12.5 Disc.
(31.75 cm)
2.937
Single Piston
(7.45 cm)
12 x 2.5 Drum
(30.48 x 6.35 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
J-20 Truck
7600 GVW
1.125
(28.5 mm)
12.5 Disc.
(31.75 cm)
2.937
Single Piston
(7.45 cm)
12 x 2.5 Drum
(30.48 x 6.35 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
J-20 Truck
8400 GVW
1.125
(28.5 mm)
12.5 Disc.
(31.75 cm)
2.937
Single Piston
(7.45 cm)
12 x 2.5 Drum
(30.48 x 6.35 cm)
1.125
(28.5 mm)
9 1/2
Tandem Diaphragm
(24.13 cm)
41102
20 32
BRAKES
Torque Specifications
USA (ft.-lbs.)
Service
Set - t o
Torque
Brakeline-to-Caliper Fitting Bolt (Cke, Wag, Trk)
Bleeder Screw (1/4 - 28)
,
Bleeder Screw (3/8 - 24)
Brake Support Plate Mounting Bolts/Nuts (J-20 Trk)
Brake Support Plate Mounting Bolts/Nuts (Cke, Wag, J10 Trk)
Brake Support Plate Mounting Bolts/Nuts (CJ)
Caliper Anchor Bracket to Steering Knuckle (CJ)
Master Cylinder Mounting Bolts/Nirts
Master Cylinder-to-Power Unit Mounting Nuts
Power Brake Unit-to-Dash Mounting Bolts/Nuts
Brake Line-to-Caliper Fitting Bolt (CJ)
Brake Line-to-Wheel Cylinder Fitting
Parking Brake Cable Clamp-to-Support Plate Bolts (5/16 - 18)
Wheel Nuts (CJ)
Wheel Nuts (Cke, Wag, Trk)
Wheel Nuts (8400 GVW Trk) . .
:
Brake Pedal-to-Power Unit Push Rod B o l t / N u t
Caliper Mounting Bolts (Cke, Wag, Trk) .
Caliper Support Key Retaining Screw (CJ)
Disc. Brake Shield Bolts (Cke, Wag, Trk)
Disc. Brake Shield Nuts (Cke, Wag, Trk)
Wheel Bearing Outer Locknut (All) .
Wheel Bearing Inner Locknut (Bearing Adjuster):
CJ
Cke, Wag, Trk
160 in-lbs.
45 in-lbs.
90 in-lbs.
50
45
33
85
30
25
22
25
160 in-lbs.
10
75
75
130
35
35
15
8
35
50(min.)
In - Use
Recheck
Torque
1 2 0 - 200 in-lbs.
4 0 - 50 in-lbs.
4 0 - 140 in-lbs.
4 5 - 55
3 5 - 55
30-35
75-95
25-35
20-30
1 8 - 25
20-30
1 2 0 - 200 in-lbs.
8 - 12
65-90
65-80
110-150
25-40
30-40
1 5 - 18
5 - 10
30-40
Metric (N-m)
Service
Set - to
Torque
18
5
10
68
61
45
115
41
34
30
34
18
14
102
102
176
47
47
20
11
47
68 (min.)
In - Use
Recheck
Torque
1 4 - 23
5- 6
5 - 16
61 - 75
47 - 75
41 - 47
1 0 2 - 129
34-47
27-41
24-34
27-41
1 4 - 23
11-16
88 - 122
88-108
149-203
3 4 - 54
41 - 54
2 0 - 24
7 - 14
41 - 54
Tighten to 50 ft-lbs. (68 N-m) and back off 1/3 turn while rotating wheel.
Tighten to 50 ft-lbs. (68 N-m), loosen and retighten to 35 ft-lbs.
(47 N-m), then back off 1/3 turn - all while rotating wheel.
60647
Page
Page
Brake ServiceCJ Models
Brake Service- -Cherokee-Wagoneer-Truck Models
General
2G-34
2G-36
21-32
GENERAL
Two different drum brake units are used on Jeep
vehicles. The brakes used on CJ models have a cable
operated automatic adjuster mechanism, while the
brakes used on Cherokee, Wagoneer, and Truck models
have a linkage operated automatic adjuster mechanism.
Although the units differ slightly in construction, operation and service procedures for both units are similar.
Each drum brake unit consists of a support plate, a
primary and a secondary brakeshoe, two brakeshoe return springs, an adjusting screw assembly, two holddown springs, automatic adjuster components, and a
wheel cylinder assembly (figs. 2G-22 and 2G-23).
2G-32
2G-38
BRAKES
i
- - .v i d
-A-
Fig. 21-22
#~~zir~~-:
:~~
A _Z1
:,Z
al
zzzzzzzr~^:
26-33
:
Wear Coipensation
The automatic adjuster mechanism continuously
maintains correct lining-to-drum operating clearance by
adjusting the brakes in small increments in direct proportion to lining wear. This continuous adjustment prevents a gradual increase in brake pedal travel as the
linings wear. The adjuster mechanism also adds the
safety feature of maintaining adequate pedal reserve
during the service life of the lining.
-J
28-34
BRAKES
SUPPORT PLATE
A C T U A T I N G LEVER
R E T U R N SPRING
60241
Fig.
S E C O N D A R Y SHOE
R E T U R N SPRING
^PVS
P R I M A R Y SHOE
R E T U R N SPRING
TER
AJ41387
2G-36
BRAKES
1
l^^^^^^^m
>
~ " W ~
"
' W
: f
JF
Disassembly
(1) Raise vehicle.
(2) Remove rear wheels and drums.
(3) Release parking brake and loosen locknuts at
parking brake equalizer to relieve cable tension before
removing rear drums.
(4) On Truck models with Model 60 full-floating
rear axle, remove two screws that locate rear drums on
hubs (fig. 2G-25).
(5) Remove primary brakeshoe return spring (fig.
2G-28).
J41135
Fig. 20-25
BRAKES
26-37
28-38
BRAKES
SPECIFICATIONS
General Specifications
Brake Drum Radial Runout L i m i t
0.005 inches (0.12 mm)
Brake Drum Internal Diameter L i m i t :
CJ Models
10.060 inches (25.5 cm}
CherokeeWagoneerJ-10 Truck . . . 11.060 inches (28.09 cm)
J-20 Truck
12.060 inches (30.6 cm)
Brake Lining Wear Limits:
Riveted Lining
Replace when worn t o w i t h i n
1/32 inch (0.79mm) of rivet heads.
Bonded Lining
Replace when worn t o thickness of
approximately 1/16 inch (1.58 mm) or less.
80393
Torque Specifications
USA (ft. -lbs.)
Service
Set - to
Torque
Brakeline-to-Caliper Fitting Bolt (Cke, Wag, Trk)
Bleeder Screw (1/4 - 28)
Bleeder Screw (3/8 - 24)
Brake Support Plate Mounting Bolts/Nuts (J-20 Trk) .
Brake Support Plate Mounting Bolts/Nuts (Cke, Wag, J10 Trk)
Brake Support Plate Mounting Bolts/Nuts (CJ)
Caliper Anchor Bracket to Steering Knuckle (CJ) .
Master Cylinder Mounting Bolts/Nuts
Master Cylinder-to-Power Unit Mounting Nuts
Power Brake Unit-to-Dash Mounting Bolts/Nuts
Brake Line-to-Caliper Fitting Bolt (CJ)
Brake Line-to-Wheel Cylinder Fitting
Parking Brake Cable Clamp-to-Support Plate Bolts (5/16 - 18) .
Wheel Nuts (CJ)
.
Wheel Nuts (Cke, Wag, T r k ) .
Wheel Nuts (8400 GVW Trk)
Brake Pedal-to-Power Unit Push Rod B o l t / N u t
Caliper Mounting Bolts (Cke, Wag, Trk) . .
Caliper Support Key Retaining Screw (CJ)
Disc. Brake Shield Bolts (Cke, Wag, Trk)
Disc. Brake Shield Nuts (Cke, Wag, Trk)
Wheel Bearing Outer Locknut (All)
Wheel Bearing Inner Locknut (Bearing Adjuster):
CJ
Cke, Wag, Trk . . .
.
.......
160
45
90
50
45
33
85
30
25
22
25
160
10
75
75
in-lbs.
in-lbs.
in-lbs.
in-lbs.
130
35
35
15
8
35
50(min.)
Metric (N-m)
In - Use
Recheck
Torque
1204040453530752520182012086565110253015530-
200 in-lbs.
50 in-lbs.
140 in-lbs.
55
55
35
95
35
30
25
30
200 in-lbs.
12
90
80
150
40
40
18
10
40
Service
Set - to
Torque
18
5
10
68
61
45
115
41
34
30
34
18
14
102
102
176
47
47
20
11
47
68 (min.)
In - Use
Recheck
Torque
14 - 2 3
5 -6
5 - 16
61 - 75
47 - 75
41 - 47
102 - 129
34 - 47
27 - 4 1
24 - 34
27 - 4 1
14 - 2 3
11
88
88
149
34
41
20
7
41
16
122
108
203
54
54
24
14
54
Tighten to 50 ft-lbs. (68 N-m) and back off 1/3 turn while rotating wheel.
Tighten to 50 ft-lbs. (68 N-m), loosen and retighten to 35 ft-lbs.
(47 N-m), then back off 1/3 turn - all while rotating wheel.
60647
BRAKES
26-39
DISC B R A K E S
Brakeshoe ReplacementCJ
Brakeshoe ReplacementCherokee-Wagoneer-Truck
Caliper OverhaulCJ
Caliper OverhaulCherokee-Wagoneer-Truck
Models
Models
Models
Models
General
2G-45
2G-42
2G-48
2G-43
2G-39
GENERAL
Jeep vehicles are equipped with single piston, floating
caliper front disc brakes. Two different calipers are
used. On CJ models, the caliper is positioned on abutement surfaces machined into the leading and trailing
edges of the caliper anchor bracket (fig. 2G-27). On Cherokee, Wagoneer, and Truck models, the caliper is positioned on mounting bolts located in the caliper support
bracket (fig. 2G-28). Although the two caliper designs
differ in construction, caliper operation and service procedures are similar.
Fig. 21-27
2G-40
2G-50
2G-53
2G-40
BRAKES
HUB CAP
60239
Fig 2G-28
Disc
Opinion
The significant feature of disc brake operation is that
the caliper is free to slide laterally on the mounting bolts
or anchor plate abutement surfaces.
When the brakes are applied, fluid pressure is exerted
equally against the piston and piston bore surfaces.
Pressure applied to the piston is transmitted to the
BRAKES
2G 41
tends, additional brake fluid flows into the bore to compensate for the increase in bore volume caused by piston
extension (fig. 2G-29).
l e i r Ceipeisition
Fig. 2G-30
Cherokee-Wagoneer-Truck Models
The piston seal maintains operating clearance between the rotor and lining and adjusts for wear during
each brake application. When the brakes are applied, the
seal is deflected by hydraulic pressure and by friction
between the piston and seal. When hydraulic pressure is
released, the seal reverts to its original shape and retracts the piston just enough to provide the necessary
operating clearance.
As the linings wear, piston travel begins to exceed the
seal deflection limit. The piston then moves outward
through the seal just far enough to compensate for lining wear and reestablish normal seal deflection (fig. 2G31).
RELEASED
APPLIED
A 4 1 3 9 1
Fig. 21-31
21-42
BRAKES
ClERIKEE-lAiwicci-
mi
. ir Removal
mm
(12) Lubricate replacement bushings, sleeves, bushing grooves, and small ends of mounting bolts with
silicone lubricant
(13) Install rubber bushings in caliper mounting
ears.
CAUTION: Do not use the original old bushings
sleeves. Use replacement parts only.
I^^^B^^^ ^^^^^^^^SBtfH^K
%
26-32
Caliper f l t i i i S l i i l i l t Removal
urns
or
(14) Install sleeves in inboard mounting ears of caliper. Position sleeves with sleeve end facing shoe and
lining flush with machined surface of mounting ear.
(15) Install support spring on inboard shoe. Place
single tang end of spring over notch in shoe (fig. 2G-34).
(16) Install inboard shoe in caliper (fig. 2G-35). Be
sure shoe is flush against piston and that support spring
is fully seated in piston (fig. 2G-35).
BRAKES
28-43
CHER0KEE-1AG0NEER-TRUCK
Removal
WARNING
SENSOR
J 4 H 1 7
Fig. 2G-34
NOTE POSITION
OF SUPPORT
J41118
Fig. 2G-35
Disassembly
(1) Clean caliper exterior with brake cleaning
solvent.
(2) Drain remaining fluid from caliper and place
caliper on clean work surface.
(3) Pad caliper interior with clean shop cloths (fig.
2G-36).
(4) Insert air nozzle into caliper fluid inlet hole and
slowly apply just enough air pressure to ease piston out
of bore (fig. 2G-36).
WARNING: Do not, under any circumstances, place
fingers in front of the piston in an attempt to catch or
protect it. In addition, use only enough air pressure to
ease the piston out of the bore. Excessive air pressure
can eject the piston with enough force to cause damage
or injury.
2G-44 BRAKES
Fig. 2G-37
J41162
28-36
Pistol R a n m l
J41130
Fig. 2G-38
CAUTION: Do not use emery cloth or similar abrasives on the piston bore. If the bore does not clean up
with crocus cloth, replace the caliper. Clean the caliper
thoroughly with brake fluid or brake cleaning solvent if
the bore was polished.
Asseiblf
BRAKES
2G-40
TOOL
J-22904
D U S T
PORTION
B O O T
J41133
Fig. 2 1 4 1
JHHH|
Sosllng M
Iml to Gounlerbore
Installation
FOLD FACES
OPEN END OF
PISTON
LIP PORTION
OF FOLD SEATS
IN G R O O V E I N
PISTON
J41131
Fig. 28-39
Fig. 2 1 4 0
S i i p p i i f l i s t l i l t Mi
l i Place
2G-46
BRAKES
Fig. 2G-44
42872
Fig. 2 8 4 2
Fig. 2G-43
BRAKES 21-4?
Fig. 2847
mm^
Fig. 28-43
Abutment Surfaces
^ 4.
. (11) Remove anti-rattle spring from inboard brakeshoe (fig. 2G-46). Note spring position for assembly
reference.
(12) Remove outboard brakeshoe from caliper.
(13) Clean caliper interior using shop cloths only.
^H^^HHHHIHIiHiHKHl
A42879
Fig. 2848
CAUTION? Be very careful to avoid tearing or dislodging the dust boot when installing the caliper. A
damaged or displaced boot mil expose the caliper piston
to road splash resulting in corrosion and eventual piston
siezure.
(20) Align caliper and anchor plate and insert support key and spring between abutment surfaces at trailing end of caliper (fig. 2G-43).
28-48 SHAKES
(21) Complete installation of support key and spring
using hammer and punch.
(22) Install support key retaining screw and tighten
screw to 15 foot-pounds (20 N*m) torque. Be sure screw
is properly seated in support key notch before
tightening.
(23) Fill master cylinder reservoir to within 1/4 inch
(6.35 mm) of reservoir rim.
(24) Press firmly on brake pedal several times to seat
shoes.
tatafTi
tote*!
installation
Fig. 2G-S0
brakes
m-m
Disassembly
.Cleaning t i l Inspection
Remove rust and corrosion from the caliper and anchor plate abutement surfaces using a wire brush and
fine grit sandpaper and lubricate these surfaces with
molydisulphide grease (fig. 2G-47).
Clean the caliper and piston with brake cleaning solvent and dry both parts using filtered compressed air.
Be sure to blow out all passages in the caliper.
Inspect the caliper piston for damage. Replace the
piston if worn, scored, pitted, or corroded.
Inspect the caliper for damage. Replace the caliper if
the bore or seal grooves are worn, nicked, pitted, or
badly corroded. Minor corrosion in the bore can be removed using a fiber brush only.
Inspect the anti-rattle spring, support key, support
key spring, and support key retaining screw. Replace
any parts that are damaged or worn. Replace the support spring and anti-rattle springs if they are flattened,
distorted, or lack tension.
42886A
A42884
Fig. 2G-51
Fig. 2G-53
Assembly
(1) Lubricate piston bore and replacement piston
seal with brake fluid.
(2) Install piston seal in bore. Work seal into groove
using fingers only.
(3) Install bleeder screw and protective cap.
(4) Install caliper piston and replacement dust boot
using Installer Tool J-24837. Refer to Piston and Boot
Replacement with Installer Tool J-24837.
NOTE: If a boot installer tool is not available, refer to
Piston and Boot Installation without Installer Tool.
Piston and Boot Installation with Installer Tool J-24837
A42885
Fig. 2G-52
26-50
r^t^y-
BRAKES
JEZT
T"j:. ~::.z:zjez
"~' - '
^ v -
^ ^ - ^
~&
Installation
42886B
Piston instaiiation
(1) Check rotor lateral runout and thickness variation. Inspect rotor for scoring, cracks, and broken ventilating ribs. Refer to Rotor Service for procedures.
(2) Install brakeshoes and caliper. Refer to Brakeshoe ReplacementCJ Models.
(3) Install replacement washers on brake line connector or fitting and connect brake line to caliper.
Tighten brake line bolt to 160 inch-pounds (18 N*m)
torque. Or, if equipped with brake line fitting, tighten
fitting to 25 foot-pounds (34 N m ) torque.
(4) Fill master cylinder to within 1/4 inch (6.35
mm) of reservoir rims.
(5) Press brake pedal firmly several times to seat
brakeshoes.
(6) Refill master cylinder if necessary and bleed
brakes. Refer to Brake Bleeding.
(7) Install wheels.
(8) Lower vehicle.
(9) Check brake operation before moving vehicle.
#
ROTOR SERVICE
The hub and rotor are cast as a single unit. The hub
contains the wheel bearings and wheel mounting studs.
The hollow-cast rotor section has integral ventilating
fins and provides the contact surfaces that the brakeshoes are pressed against.
The hub and rotor are serviced as an assembly only. If
either section is damaged, replace the complete
assembly.
Rotor service is extremely important because rotor
tolerances must be accurate to ensure proper brake operation. Rotor service involves inspection, measurement, and refinishing or replacement where indicated.
Inspection
(1) Raise vehicle and remove wheels.
BRAKES
26-51
42889
Fig. ZG-S5
Clocking Lateral l u o i t
leasireient
(1) Tighten wheel bearing adjusting nuts enough to
remove all end play from front wheel bearings.
(2) Measure rotor lateral (face) runout:
(a) Mount dial indicator on support stand or
wheel spindle so indicator stylus contacts rotor outboard
surface approximately one inch from outer edge (fig. 2G55).
(b) Turn rotor 360 degrees and note indicator
reading.
(c) Lateral runout must not exceed 0.005 inch
(0.12 mm). Lateral runout will cause rotor wobble resulting in chatter, vibration, pedal pulsation, and excessive pedal travel (wobbling rotor will contact brakeshoes
and knock caliper pistons back into bore).
(d) If lateral runout exceeds tolerances, replace
or refinish rotor.
(3) Measure rotor thickness variation:
(a) Using micrometer or two dial indicators,
measure rotor thickness at four equally spaced points
around rotor circumference (fig. 2G-56). Take measurements approximately one inch (2.54 cm) in from outer
edge of rotor.
(b) Thickness variation must not exceed 0.001
inch (0.02 mm) on any model. Thickness variations can
cause pedal pulsation and vibration during brake
applications.
(c) If thickness variation exceeds tolerance, replace or refinish rotor.
(4) Measure hub-to-bore runout. Wheel mounting
surface of hub must be square with centerline of bearing
cup bore to within 0.010 inch (0.25 mm) on all models
(fig. 2G-57).
42890
Fig. 2G-56
26-52
BRAKES
f l i i i r s i t i i i i i Cresslifil Pattern)
Rotor Replacement Thickness
M O U N T ON
B E A R I N G CUPS
WHEN MEASURING
42887
Fig. 2G-57
Checking H u b - M e r e Runout
Rotor Reftnising
If the rotor surfaces are within specified tolerances
and are only lightly scored or rusty and scaled, a brake
lathe and flat sanding discs are all that is needed to
restore the surface finish.
If the rotor surfaces are heavily scored or not within
tolerance, the rotor will have to be turned in a brake
lathe to restore the surface finish and meet required
tolerances. When machining a rotor, be sure to follow
the lathe manufacturers operating instructions
explicitly.
The correct rotor surface finish is 15 to 80 micro
inches for CJ models and 20 to 60 micro inches for all
other models. The finished rotor surface must form a
nondirectional C r o s s h a t c h pattern. A directional type of
pattern is not desirable. After machining a rotor, use
flat sanding discs to generate the desired microfinish
and Crosshatch pattern (fig. 2G-58).
When rotor resurfacing or refinishing operations are
completed, recheck lateral runout, thickness variation,
and overall thickness to be sure the rotor meets all
specified tolerances.
BRAKES
fltffloval
(1) Remove wheel cover, if equipped, and loosen
wheel retaining nuts.
(2) Raise vehicle.
(3) Remove wheels.
(4) Remove caliper. Refer to Brakeshoe ReplacementCherokee-Wagoneer-Truck Models.
(5) Remove rotor hub cap.
(6) Remove drive gear snap ring and remove drive
gear, pressure spring, and spring cup.
(7) Straighten lip of outer locknut retaining washer.
(8) Remove wheel bearing outer and inner locknuts
and retaining washers using tool J-6893.
(9) Remove rotor.
(10) Remove wheel bearings from rotor.
Installation
(1) Lubricate wheel bearings with EP-type, waterproof wheel bearing lubricant.
(2) Install wheel bearings and replacement grease
seal in rotor.
(3) Install rotor.
(4) Install inner locknut using tool J-6893.
NOTE: The bearing adjuster inner locknut has a locating peg on one side. When installed, this peg must face
away from the bearing.
26-53
SPECIFICATIONS
General Specifications
Caliper Piston Diameter:
CJ Models . . . . . . . . . .
...........
2.6 inches (6.60 cm)
Cherokee-Wagoneer-Truck
2.94 inches (7.45 cm)
Minimum Rotor Thickness:
CJ Models
815 inches (20.7 mm)
Cherokee-Wagoneer-Truck .
1.21 5 inches (30.86 mm)
Rotor Diameter:
CJ Models
11.7 inches (29.7 cm)
Cherokee-Wagoneer-J10 Truck
12.0 inches (30.48 cm)
J-20 Truck
12.5 inches (31.75 cm)
Rotor Hub-To-Bore Runout Limit
0.010 inches (0.25 m m )
Rotor Lateral Runout Limit .
0.005 inches (0.12 m m )
Rotor Thickness Variation
0.001 inches (0.02 mm)
80395
21-14
HUES
T o r q u e Specifications
Service Set-To T o r q u e s s h o u l d b
U S A f f t . lbs.)
Metric (N-m)
Service
In-Use
Service
Set-To
Torque
Recheck
Torque
35
15
160 in-lbs.
8
35
50
75
75
130
'
30-40
15-18
150-170 in-lbs.
5-10
.
30-40
50-55
65-80
65-80'
110-150
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
47
20
18
11
47
68
41-54
20-24
17-19
7-14
41-54
68-75
102
102
176
88-108
88-108
149-203
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
80396
Tools
J-8057
B R A K E SPRING TOOL
J-21177
DRUM BRAKE
CLEARANCE GAUGE
J-8002
WHEEL C Y L I N D E R CLAMPS
J-22904
DUST BOOT I N S T A L L E R
J-24837
CALIPER
INSTALLER
80394
J-23709
METERING V A L V E TOOL
(TYPED VALVE)
J-8001
D I A L I N D I C A T O R SET
J-26869
METERING V A L V E TOOL
(TYPE-W V A L V E )
J-25133
FRONT HUB
F L A N G E PULLER
80397
2H"1
SECTION
INDEX
Page
CE1ERAL
Jeep vehicles are equipped with American and Metric
size, tubeless-type, pneumatic tires available in load
ranges SL, B, C, and D. Standard equipment tires are of
bias-ply or bias-belted construction. Radial-ply tires are
available as an option on most models.
Standard equipment wheels are safety rim, drop center-types constructed entirely of steel. Optional wheels,
which are available on most models, consist of forged
aluminum wheels, wide rim spoke-type sport wheels,
and chrome plated styled steel wheels.
Original equipment wheels and tires are tested and
selected to provide the best all around performance for
normal operation. To obtain optimum wheel/tire performance, tire inflation pressures must be maintained
at recommended levels and wheel/tire condition should
be checked regularly. This is especially important on
vehicles equipped with the Quadra-Trac full-time four
wheel drive transfer case.
TIRE CONSTRUCTION
Three types of tire construction are currently in use.
They are referred to as bias-ply, bias-belted, and radialply construction. The description for each constructiontype is derived from the method used to position the tire
cord plies in relation to the tread centerline.
Tire Rotation
Tire Roughness
Tire Size and Load Rating
Vibration
Wheels
Wheel Balancing
Wheel Bearing Adjustment
Maintenance and Condition
2H-5
2H-7
2H-2
2H-9
2H-5
2H-5
2H-5
2H-5
Bias-Belted Construction
Bias-belted tires are constructed basically the same as
bias-ply tires. However, in addition to the angled body
cord plies, they also have belts that encircle the tire.
These belts are located under the tire tread and extend
from tread shoulder-to-tread shoulder (fig. 2H-1).
Radial-Ply Construction
Radial-ply tires, like bias-belted tires, also have belts
under the tread which encircle the tire and extend from
* tread shoulder-to-tread shoulder. However, these tires
are constructed with the body cord plies at right angles
to the tread centerline. The plies cross the tread centerline at an angle of approximately 90 degrees (fig. 2H-1).
Because the body cord plies radiate from the tread centerline, this type of construction is designated radialpiy.
Identifying Tire-Types
Bias-Ply Construction
2H-2
BELTS
R A D I A L - PLY
- - -
_ - ~
BELTS
SIZES
" 8 3 " PROFILE R A T I O
BIAS - PLY
SIZES
" 7 8 " PROFILE R A T I O
BIAS - BELTED
70189
70223
Fig. 2 1 - 2
lire
Size a i l
Profile
litlo
Fig. 2H-3
2H-3
both. If this type of wear occurs and the tires are serviceable, rotate the tires and inflate them to recommended levels when they are cool.
Rapid wear at the tread center is usually caused by
overinflation or lack of rotation or a combination of
both. If this type of wear occurs and the tires are still
serviceable, rotate the tires and inflate them to recommended levels when they are cool.
Cracked treads are usually caused by underinflation
or excessive high speed operation or a combination of
both. Tires with cracked treads should be replaced and
the replacement tires properly maintained to avoid a
recurrence.
Excessive wear of one tread shoulder may be caused
by excessive speed on turns or by incorrect camber.
Incorrect negative camber will wear the inboard tire
shoulder while incorrect positive will wear the outboard
shoulder. If this type of wear occurs, check camber. If
camber is incorrect, the front axle housing may need to
be replaced. If camber is within specified limits, caution
the owner about excessive speed on turns. If the tires are
serviceable, rotate them and adjust inflation pressures
to recommended levels.
Incorrect toe-in will cause the tire tread surface to
develop a feathered edge. One side of the tread will be
rounded while the opposite side develops a feathered
edge. This type of wear indicates that the tire is side
slipping and scuffing as it moves over the road surface.
A feathered edge that faces toward the vehicle indicates excessive toe-in. A feathered edge that faces
away from the vehicle indicates excessive toe-out. The
direction in which a feathered edge has developed can be
determined by passing a hand over the tire tread surface. Bent steering knuckle arms can also cause this type
of wear.
If a feathered edge develops, check and correct toe-in
as necessary and rotate the tires if they are serviceable.
214
Bias-belted wide tread tires have an initial wear characteristic that is unique to this type of tire. It occurs as a
fairly rapid but even wear of the second and sixth tread
ribs (fig. 2H-4). Wear may occur at only one of the ribs
or at both ribs simultaneously. In some cases, a slight
cupping of these ribs may also develop in addition to
wear. Although wear develops rapidly, the degree of
wear is relatively light.
This wear characteristic is a normal condition with
wide tread bias-belted tires and and is related to the
tread deflection properties of these tires. When the
tread is pressed against the road surface, all tread ribs
do not support equal portions, of weight. The outer and
center ribs support the most weight while the second
and sixth ribs support the least. Because of the lighter
load on the second and sixth ribs, they are able to deflect
more and tend to slip and scrub slightly as the tire
rotates. This action causes more wear on these ribs.
Wear on the second and sixth ribs cannot be reduced
by over or underinflating the tires. Maximum benefit in
minimizing wear is obtained only by adhering to the
specifications recommended for tire inflation pressures,
tire rotation, and front wheel alignment.
TREAD
S T I L L GOOD
TREAD
WORN OUT
70224
Fig. 2H-5
A number of states have statutes concerning minimum permissable tread depths and use these indicators
as the tire wear limit.
Clean tires using a mild soap and water solution only
and rinse thoroughly with water. Do not use caustic
solutions or abrasive materials. To clean white sidewalls
and raised letters and numbers, use an approved whitewall cleaner only. Do not use steel wool, wire brushes, or
materials having a mineral oil base such as gasoline,
paint thinner, or turpentine. These materials are harmful to the tires and will also discolor the white sidewalls
and raised figures.
F T R E A D RIB WEAR I
50516
Fig. 2H-4
TIRE REPAIR
Punctured tires should be removed from the wheel
and permanently repaired from the inside using a combination repair plug and vulcanized patch. When repairing punctures, always follow the manufacturers
instructions for repair kit installation.
Punctures in the tread area only are repairable (fig.
2H-6). Never attempt to repair punctures in the tire
shoulders or sidewalls. In addition, never attempt to
repair any tire that has sustained the following damage:
Bulges or blisters
Ply separations
Broken, cut, or cracked beads
Fabric cracks or cuts
Tires worn to the fabric or if wear indicators are
visible
Punctures larger than 1/4 inch (6.35 mm) in
diameter
2H-5
70225
Fig. 2H-6
T i n Repair Area
TIRE ROTATION
' .
To equalize wear, tires should be rotated at the intervals specified in the Mechanical Maintenance Schedule.
The first rotation is the most important in setting the
stage for even tread wear. After rotation, adjust tire
inflation pressures to the levels recommended in the
Tire Inflation Pressure Chart.
Radial tires are not rotated in the same manner as
conventional tires. Conventional tires are rotated in a
crossing pattern. Radial tires are rotated on the same
side, front-to-rear (fig. 2H-7).
WHEELS
The standard equipment wheels used on Jeep vehicles
are safety rim, drop center, J-type wheels of all-steel
construction. Optional wheels include chrome-plated
styled steel wheels, wide rim spoke-type steel wheels,
and forged aluminum wheels.
Steel wheels are of two-piece construction consisting
of a rim and center section (spider). The two sections are
welded together to form a seamless, air-tight assembly.
Fig. 2 1 - 7
Tire flotation
Wheel condition should be checked frequently. Replace any wheel that is cracked, bent, severely dented,
has excessive runout, or has broken welds. The tire
inflation valve should also be inspected frequently for
wear, leaks, cuts, or looseness and should be replaced if
damaged or worn.
Clean all wheels with a mild soap and water solution
only and rinse thoroughly with water. Never use abrasive or caustic materials, especially on aluminum or
chrome plated wheels as the surface will be etched or the
plating severely damaged. After cleaning aluminum or
chrome plated wheels, apply a coating of protective wax
to preserve the finish and lustre.
2H-6
WHEEL 1ALANCINI
Wheel balancing may be performed using on or offvehicle equipment. However, when using on-vehicle balancing equipment, observe the following precautions:
On vehicles with a Trac-Lok rear axle, do not use onvehicle equipment to balance the rear wheels. Instead, remove the wheels and balance them off the
vehicle using a two-plane, dynamic balancer.
Before balancing wheels on a vehicle equipped with
a Model 20 transfer case, shift the transmission and
transfer case into neutral.
Before balancing wheels on a vehicle equipped with
a Quadra-Trac transfer case, disconnect the front or
rear propeller shafts as required.
Because of their unique construction, radial tires are
sometimes less responsive to certain balancing techniques. In some cases, dynamic two-plane, off-vehicle
type balancing equipment will provide the most satisfactory results with radial tires.
When balancing aluminum or chrome plated wheels,
take care to avoid damaging the wheel surface when
installing balance weights. Use self-adhering type
weights on aluminum wheels only and install them on
the back side of the wheel whenever possible.
Fig. 2H-8
2H-7
OIL
SEAL
INNER
BEARING
CUP
NUT
CONE W A S H E R ,
/r\
OUTER
BEARING
CUP
NUT
INNER
BEARING
HUB A N D
BRAKE
The wheel bearings used in Model 44 rear axles (Cherokee, Wagoneer, J-10 Truck) or AMC/Jeep rear axles
WHEEL
NUT
OUTER
BEARING
J42295
Fig. 2H-10
2H-8
R0JJ1HIESS
Tire Thump
Thump noise is caused by the tire moving over irregularities in the road or by irregularities in the tire
itself. The sound coincides with each wheel revolution.
To determine which tire is causing thump, inflate all
tires to 45 psi (310 kPa) temporarily and drive over the
same roads. If thump stops, reduce the pressure in one
tire at a time and repeat the road test. Perform this
procedure until all tires have been tested and each test is
made with three tires at high pressure and one tire at
recommended pressure. When thump develops again,
the tire just reduced to normal inflation pressure is the
problem tire.
N O T E : Although the procedure for diagnosing thump
is quite effective with conventional tires, it is considerably less effective with radial tires.
Tire Tramp
Tramp is caused by wheel/tire static unbalance or by
excessive lateral runout of the tire or wheel.
The most effective method for checking static balance
is by using off-vehicle balancing equipment.
Static balance is the result of an equal distribution of
wheel and tire weight about the circumference of the
tire. In this case, weight is distributed about the spindle
in such a manner that the assembly lacks the tendency
to rotate by itself when mounted on the arbor of a
balancing machine.
Static unbalance occurs when an unequal portion of
weight is concentrated at one point on the tire and wheel
(fig. 2H-11). It causes a vibratory-type pounding action
which is referred to as tramp or hop.
Dynamic balance is the result of an equal distribution
of wheel/tire weight around the plane of rotation (fig.
2H-12). This causes the wheel to rotate smoothly about
the axis that bisects the wheel and tire centerline.
Dynamic unbalance occurs when unequal forces are
concentrated at opposing points on the tire circumference. It will cause shimmy and vibration at medium
and high speeds (fig. 2H-12).
The most effective method for balancing wheels and
tires is by using equipment that will correct both static
and dynamic balance. Dynamic, two-plane balancing
equipment is preferable.
2H-9
A D D BALANCE
WEIGHTS HERE
CORRECTIVE WEIGHT
LOCATION
T I R E OR WHEEL TRAMP,
OR WHEEL HOP
70227
Fig. 2H-11
Static Unbalance
A D D BALANCE
WEIGHTS HERE
H E A V Y SPOT
WHEEL S H I M M Y
AND VIBRATION
/
CORRECTIVE WEIGHT
LOCATION
70226
Fig. 2H-12
Dynamic Unbalance
41412
RADIALLY
Fig. 2H-13
LATERALLY
Tire Runout
2H-10
Vibration. Sonsitlwlty
Mechanical and audible vibrations are sensitive to
changes in engine torque, vehicle speed, or engine speed.
They usually occur within one, or sometimes two welldefined ranges in terms of vehicle speed, engine rpm,
and torque application.
Torque Sensitive
Fig. 2H-14
LATERALLY
VIBRATION
Vibration may be caused by tire and wheel unbalance
or runout, incorrect wheel bearing adjustment, loose or
worn suspension or steering components, worn or defective tires, certain tire tread patterns, incorrect universal
joint angles, worn universal joints, excessive propeller
shaft runout or yoke runout, rotor or brakedrum runout,
loose engine or transmission supports, or by engine operated accessories.
Vibration Types
There are two types of vibration which are referred to
as mechanical and audible.
This means that the vibration occurs at varying vehicle speeds when a different transmission gear is selected. It can sometimes be isolated by increasing or
decreasing engine speed with the transmission in
neutral.
Vibration Diagnosis
A proper vibration diagnosis should always begin
with a road test, corrective measures should not be
attempted until the vibration type, magnitude, and
speed range have been established by a road test.
Road Test
or bearing ends of spiders are worn, damaged, overtightened, or loose, they will cause mechanical vibration
at almost any speed. Torque and vehicle speed sensitive
vibration.
PSYPropeller Shaft and Yokes. Not a cause of vibration below 35 mph (56 km/h). Excessive runout, unbalance, missing balance weights, undercoating on shaft
tube, dents or bends in tube will cause mechanical vibration at 35 mph (56 km/h) and above. Torque and vehicle
speed sensitive vibration.
WBWheel Bearings. Loose bearings cause shimmylike vehicle speed sensitive mechanical vibration at 35
mph (56 k m / h ) and above. Rough or damaged bearings
will also generate growl noise at low speed or whine
noise at high speed.
ANAxle Noise. Axle not a cause of vibration unless
axle shaft is bent or front axle shaft U-Joint is damaged.
Worn or damaged axle gears or bearings will cause noise
in varying speed ranges in relation to amount of engine
torque applied.
SSCSuspension and Steering Components. Worn,
damaged, or loose suspension components (steering
damper, steering knuckles, pitman arm, springs, spring
U-bolts or center bolts, shocks, tie rod ends, etc.) can
cause mechanical or audible vibrations at many speeds.
Can be torque and vehicle speed sensitive.
EAEngine Driven Accessories. Loose or broken AC
compressor, power steering pump, water pump, air
pump, alternator, etc. can cause engine speed sensitive
mechanical vibration. Usually apparent when transmission is shifted into neutral and engine rpm increased.
ADBAccessory Drive Belts. Loose, worn belts can
cause engine speed sensitive audible vibration that
sounds like droning, fluttering, or rumbling noise.
DEMDamaged Engine or Transmission Mounts. If
loose, worn, or broken can allow engine, transmission, or
engine accessories to contact body causing noise and
vibration.
ESExhaust System. Loose or broken components may
contact body causing noise. In addition, mispositioned
components (e.g., muffler, converter, pipes, hangers)
may also contact body or driveline components causing
noise.
2H-1Z
Correction Codes For Mechanical Vibrations Within Specific MPH (km/h) Ranges
Vibration
Sensitivity
10
(16 km)
20
(32 km)
30
(48 km)
40
(64 km)
wv n
70
(112 km)
80
(128 km)
90
(144 km)
psy
- _l
Engine
Speed
Sensitive
60
(96 km)
Vehicle
Speed
Sensitive
Torque
Sensitive
50
(80 km)
A R. 1
UJ d
JA-#-
JA-*~
EA
DEM
... ,
p O
Correction Codes For Audible Vibrations Within Specific MPH (km/h) Ranges
Vibration
Sensitivity
10
(16 km)
20
(32 km)
30
(48 km)
50
(80 km)
'
1
U JM
JU and W 4
Vehicle
Speed
Sensitive
60
(96 km)
70
(112 km)
80
(128 km)
90
(144 km)
"" PSY
Torque
Sensitive
Engine
Speed
Sensitive
40
(64 km)
DB
IJJ and T E D
(i
"
EA d
DEM
41 3 7 1
Norma 1 Load
Model
CJ-5
&
CJ-7
Cherokee
&
Wagoneer
GVW
Rating
lbs
kg
3750
&
4150
1700
&
1882
6200 2812
2812
6800 3084
J-20 Truck
Sustained Driving
Maximum Load ?
Under 6 5 mph
(105 km/h)
Sustained Driving
Under 65 m p h
(105 km/h)
Tire
Size
Load
Range
Front
Rear
Front
Rear
Front
Rear
Front
Rear
9-15
H78-15
L78-15
B
B&D
B
30
24
24
30
24
24
20
20
20
20
20
20
35
28
24
35
28
24
25
24
20
25
24
20
G78-15
H78-15
H78-15
HR78-15
HR78-15
L78-15
P225/75R-15
10-15
D
B
D
B
c
30
26
26
26
26
24
26
30
30
26
26
26
26
24
26
30
26
22
22
22
22
20
22
20
26
22
22
22
22
20
22
20
40*
32*
36
32*
36
32
35*
40*
40*
32*
36
32*
36
32
35*
40*
38
32
32
32
32
28
32
30
38
32
32
32
32
28
32
30
15x6
15 x 6
15x6
15x6
15x6
15x8
15x6
15 x 8
Aluminum
Wheel
is
15x7
32
28
28
26
26
26
30
32
28
28
26
26
26
30
28
24
24
22
22
22
20
28
24
24
22
22
22
20
40*
32*
36
32*
36
35*
40*
40*
32*
36
32*
36
35*
40*
38
32
32
32
32
32
30
38
32
32
32
32
32
30
15x6
15x6
15x6
15x6
15x6
15 x 6
15x8
Aluminum
Wheel
is
15x7
40
45
40
45
30
35
30
35
50*
55*
55*
70*
40
45
45
60
G78-15
H78-15
H78-15
HR78-15
HR78-15
P225/75R-15
10-15
8.75-16.5
9.50-16.5
B
B
D
B
D
B
c
B
c
D
Over 65 mph
(105 k m / h )
Over 6 5 mph
(105 k m / h )
Wheel Size
15x8
15 x 5.50
15x8
16.5 x 6
16.5 x 6.75
7600 3447
9.50-16.5
45
35
36
55*
70*
45
60
16.5 x 6.75
9.50-16.5
D
D
45
8400 3810
45
45
35
35
55*
70*
45
60
16.5 x 6.75
Cherokee &
Wagoneer
6200 2812
with
Snow Plow
Package
H78-15
26
26
22
22
40*
40*
38
38
J-10 Truck
with
Snow Plow
Package
H78-15
6200 2812
28
28
24
24
40*
40*
15x6
Aluminum
Wheel
is
15x7
38
38
15x6
N O T E : Inflate tires while cold, before running. D o not reduce pressure if tires are w a r m .
*Speed limited t o 7 4 m p h ( 1 1 9 k m / h ) .
(1) N o r m a l Load: Frequently selected accessories plus driver and t w o passengers. For CJ models, driver and one passenger.
(2) M a x i m u m Load: Gross Vehicle Weight Rating ( G V W R ) .
(3) SL is approximate metric tire equivalent of load range B.
(4) Sustained driving over 7 4 m p h ( 1 1 9 k m / h ) for Cherokee and Wagoneer except where indicated by asterisk ( * ) .
90145
2H-14
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
35
15
30-40
15-18
47
20
41-54
20-24
75
75
130
65-80
65-90
110-150
102
102
176
88-108
88-122
149-203
50
50 min.
68
68 min.
Tighten to 50 foot-pounds (68 N-m) torque and
back locknut off 1/3 turn while rotating wheel.
50
50 min.
68 min.
68
Tighten to 50 foot-pounds (68 N-m ), then loosen
and retighten locknut to 35 foot-pounds (47 N-m)
and back off nut 1/3 turn while rotating wheel.
0.105
0.080
0.100
0.045
0.045
inch
inch
inch
inch
inch
2.66
2.03
2.54
1.14
1.14
mm
mm
mm
mm
mm
All Torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
80419
2J-1
STEERING
COLUMNS
S E C T I O N INDEX
General
Ignition Lock Cylinder
Ignition Switch
Neutral Safety Switch
Service Diagnosis
Specifications
Sport Steering Wheel Skirt Replacement
Standard Column OverhaulAutomatic Transmission
Standard Column OverhaulManual Transmission
2J-1
2J-38
2J-37
2J-37
ZJ-1
2J-41
ZJ-11
2J-20
2J-13
1ENERAL
Three different steering column designs are used on
Jeep vehicles. Models with automatic transmission use a
non-tilt column with column mounted gearshift mechanism. Models with manual transmission use a non-tilt
column with ignition key release lever. A six position tilt
column is available as an option on all models.
All steering columns used on Jeep vehicles have antitheft and energy absorbing features. Each column is
designed to compress under impact.
The ignition lock cylinder, ignition switch, and neutral
safety switch are mounted on the column. When the lock
cylinder is turned to LOCK position, the ignition switch
and steering shaft cannot be operated. On models with
2J-10
2J-13
2J-11
2J-10
2J-10
2J-3G
2J-24
2J-41
2J-36
automatic transmission, the lock mechanism also prevents operation of the column mounted gearshift
mechanism.
A center slip-type (telescoping) intermediate shaft is
used on all models. It is attached to the steering gear
with a flexible coupling and to the steering column with
a universal joint.
SERVICE llAeiOSIS
When diagnosing steering column malfunctions, refer
to the Service Diagnosis Charts for the probable cause
and correction procedures. To simplify chart use, they
are divided into the various sub-systems within the column and include: ignition system, lock mechanism, turn
signal switch, electrical, tilt column, and steering
column.
2J-2
STEERING COLUMNS
Lock System
Condition
Possible Cause
Correction
(1)
a)
HIGH E F F O R T (HIGH
E F F O R T REQUIRED
TO TURN IGNITION
KEY AND LOCK
CYLINDER)
(1)
(i)
(2)
(2)
(3)
(3)
(4)
(4)
Remove burr.
(5)
(5)
Replace shaft.
(6)
(6)
(7)
(7)
Replace rod.
(8)
(8)
Straighten or replace.
(9)
(9)
(1)
(1)
Straighten or replace.
(2)
(2)
Straighten or replace.
(1)
(1)
Adjust switch.
(2)
(2)
LOCK CYLINDER
CAN BE REMOVED
WITHOUT DEPRESSING RETAINER
(1)
(1)
(2)
(2)
Remove burr.
HIGH E F F O R T ON
LOCK CYLINDER
BETWEEN " O F F "
AND "OFF-LOCK"
(1)
(1)
(2)
(2)
Remove burr.
(3)
(3)
Adjust linkage.
WILL STICK IN
"START"
KEY CANNOT BE
REMOVED IN
"OFF-LOCK"
60659A
STEERING COLUMNS
2J-3
S t e e r i n g Column
NOISE IN COLUMN
Correction
Possible Cause
Condition
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
Align column.
(7)
(7)
Replace coupling.
(8)
(8)
(9)
(9)
(1)
(10)
HIGH STEERING
SHAFT E F F O R T
(10)
(1)
Column misaligned.
(1)
Align column.
(2)
(2)
Replace as required.
(3)
(3)
Repair or replace.
(4)
(4)
(5)
(5)
Replace bearings.
60659C
2J-4
STEERING COLUMNS
Condition
Possible Cause
Correction
(1)
(1)
Tighten bolts.
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
Replace shoes.
(6)
(6)
(7)
(7)
(8)
(8)
Tighten screws.
(1)
(1)
(2)
(2)
Tighten screws.
STEERING WHEEL
LOOSE-EVERY
OTHER TILT
POSITION (TILT
COLUMN ONLY)
(1)
(1)
STEERING COLUMN
NOT LOCKING IN
ANY TILT POSITION
(TILT COLUMN ONLY)
(1)
(1)
(2)
(2)
(3)
(3)
Replace springs.
(1)
(1)
(2)
(2)
LASH IN MOUNTED
COLUMN ASSEMBLY
HOUSING LOOSE
(TILT COLUMN ONLY)
NOISE WHEN
TILTING COLUMN
(TILT COLUMN ONLY)
STEERING COLUMNS
2J-5
Condition
Possible Cause
Correction
(1)
(1)
(1)
(1)
Align column.
(2)
(2)
Assemble correctly.
(3)
(3)
(1)
(2)
Adjust linkage.
(3)
(3)
60659E
2J-6
STEERING COLUMNS
Ignition System
Condition
IGNITION SWITCH
ELECTRICALLY
INOPERATIVE
IGNITION SWITCH
WILL NOT ACTUATE
MECHANICALLY
IGNITION SWITCH
CANNOT BE ADJUSTED CORRECTLY
Possible Cause
Correction
(1)
(1)
(2)
(2)
Repair or replace.
(3)
(3)
(1)
(1)
Adjust switch.
(2)
(2)
(1)
(1)
Replace switch.
(2)
(2)
(3)
(3)
(1)
(1)
60659B
Turn Signal
Correction
Possible Cause
Condition
(1)
a)
Tighten screws.
(2)
(2)
Replace switch.
(3)
(3)
60659F
STEERING COLUMNS
2J-7
Possible Cause
Condition
Correction
(1)
(1)
(2)
(2)
Replace switch.
(3)
(3)
(4)
(4)
(5)
(5)
(1)
(1)
Replace switch.
(2)
(2)
Replace or reposition as
required.
(3)
Jammed wires.
(3)
(1)
(1)
(2)
Defective switch.
(2)
Replace switch.
HAZARD SWITCH
CANNOT BE
PULLED OUT
(1)
(1)
NO TURN
SIGNAL LIGHTS
(1)
(1)
(2)
(2)
Replace fuse.
(3)
(3)
Connect securely.
(4)
(4)
(5)
(5)
TURN SIGNAL
DIFFICULT TO
OPERATE
TURN SIGNAL
WILL NOT INDICATE
LANE CHANGE
TURN SIGNAL
WILL NOT STAY
IN TURN POSITION
60659G
2J-8
STEEMN8 COLUMNS
Condition
INSTRUMENT PANEL
TURN INDICATOR
LIGHTS ON BUT NOT
FLASHING
TURN INDICATIOR
PANEL LIGHTS
NOT FLASHING
Possible Cause
Correction
(1)
(1)
Replace bulb.
(2)
(2)
(3)
Inoperative flasher.
(3)
Replace flasher.
(4)
(4)
Connect securely.
(5)
(5)
(6)
(1)
(1)
Connect securely.
(2)
(2)
(3)
(3)
(1)
(1)
Replace bulbs.
(2)
(2)
Replace socket.
(3)
(3)
60659H
STEERING COLUMNS
2J-9
Condition
TURN SIGNAL
LIGHTS FLASH
VERY SLOWLY
HAZARD SIGNAL
LIGHTS WILL NOT
FLASH-TURN
SIGNAL FUNCTIONS
NORMALLY
Possible Cause
Correction
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
Connect securely.
(5)
(5)
(1)
Blown fuse.
(1)
Replace fuse.
(2)
(2)
(3)
Loose chassis-to-column
harness connection.
(3)
Connect securely.
(4)
(4)
(5)
(5)
606591
2J-10
STEERING COLUMNS
C l i r i k i s - l i i i i i i r - T f i i l Models
CJ Models
STEERING COLUMNS
Cherokee-Wagoneer-Truck Models
(1) Align reference marks on steering shaft and
steering wheel and install wheel.
(2) On models with sport steering wheel, install
contact plate, horn button receiver, and receiver bushing. Be sure to install receiver so horn button locating
notch is at 12 o'clock position.
(3) Install steering wheel washer and nut. Tighten
nut to 30 foot-pounds (41 N*m) torque.
(4) On models with standard steering wheel, insert
spring and horn wire in cancelling cam yoke. Seat horn
wire retainer in cam yoke and connect opposite end of
wire to steering wheel switch.
(5) Install horn button.
(6) Connect battery negative cable.
(7) Reset clock if equipped.
CANCELING CAM
2J 11
HORN BUTTON
90188
Fig. ZJ-3
CAUTION: Do not attempt to separate the intermediate shaft and steering column at this time. If separated, the plastic
connector
injected
into the
intermediate shaft could be damaged.
(4) On Cherokee and Wagoneer models with air conditioning, remove left air duct extension.
(5) Remove steering column-to-instrument panel
bezel. On Cherokee, Wagoneer, and Truck models,
screws attaching two halves of bezel are located behind
lower bezel half.
(6) Remove bolts attaching steering column mounting bracket to instrument panel.
(7) Remove bolts attaching steering column mounting bracket to steering column and remove bracket.
2J-12
STEERING COLUMNS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
STEERING WHEEL N U T
WASHER
LOCK PLATE COVER
STEERING S H A F T SNAP RING
LOCKPLATE
RETAINER
H O R N CONTACT PIN
SPRING
CANCELING CAM
UPPER BEARING P R E L O A D SPRING
THRUST WASHER
T U R N S I G N A L SWITCH SCREW (3)
T U R N S I G N A L SWITCH
TURN SIGNAL LEVER KNOB
TURN SIGNAL LEVER
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
connector if equipped.
(11) On vehicles with automatic transmission, disc o n n e c t wiring harness connector at neutral safety
switch.
(12) Separate steering column from intermediate
shaft and remove steering column.
T U R N S I G N A L L E V E R SCREW
UPPER B E A R I N G
HOUSING R E T A I N I N G SCREW (4)
HOUSING
RACK P R E L O A D SPRING
KEY RELEASE LEVER SPRING
W A V E WASHER
LOCK B O L T
LOCK R A C K
REMOTE ROD
SPRING WASHER
KEY RELEASE LEVER
H A Z A R D W A R N I N G SWITCH KNOB
LOCK SECTOR
LOCK C Y L I N D E R
Fig. 2J-4
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
STEERING COLUMNS
2J-13
Fig. 2 J - 5
Stwing
STANDARD COLUMN
TRANSMISSION
OVERHAUL MANUAL
Column Disassemlly
NOTE: Steering column removal is not necessary if
only the lock plate cover, lock plate, steering shaft snap
ring, canceling cam, turn signal switch, upper bearing
preload spring, or lock cylinder are to be serviced (fig.
2J-3). However, the column must be removed in order to
service any of the remaining components. If the column
is removed, remove the column-to-ins trument panel
mounting bracket and install Support Fixture J-23071+
(fig. 2J-5). Mount the column in a vise by clamping the
support fixture flange in the vise.
(1) Place front wheels in straight-ahead position.
(2) Disconnect battery negative cable.
(3) Cover painted areas of column.
(4) Remove steering wheel.
(5) Remove lock plate cover. Use two screwdrivers
to pry cover off lock plate and out of column.
(6) Compress lock plate and unseat steering shaft
snap ring as follows:
(a) Inspect and identify steering shaft nut
thread type. Metric shafts have identifying groove in
steering wheel locating splines (fig. 2J-2). American
thread shafts do not have this groove.
(b) If shaft has American threads, use tool J23653 as is to compress lockplate and unseat snap ring
(fig. 2J-6).
(c) If shaft has metric threads, replace compressor tool standard forcing screw with Metric Forcing
Screw J-23653-4 before installing tool on steering shaft.
2J-14
STEERING COLUMNS
Fig. 2J-7
Fig. 2J-6
WARNING: The lock plate is under strong spring tension. Do not attempt to remove the steering shaft snap
ring without using the compressor tool.
(7) Remove lock plate compressor tool and snap
ring. Discard snap ring.
C A U T I O N : When the steering shaft snap ring is removed, the shaft is free in the column. During bench
overhaul, remove the shaft by pulling it out from the
lower end of column. Do not allow the shaft to fall out
whenever the column is removed from the vehicle.
(8) Remove lock plate, canceling cam, upper bearing
preload spring, and thrust washer from shaft.
(9) Remove hazard warning switch knob. Press
knob inward and unthread knob from column.
(10) On vehicles without Cruise Command, remove
turn signal lever attaching screw and remove lever.
(11) On vehicles with Cruise Command, disconnect
two of four wires at switch connector. Fold wires back
along harness. Tape wires to harness and tape length of
string to harness to aid removal.
(12) Unhook turn signal switch wire harness connector from bracket at lower end of steering column.
(13) Disconnect instrument panel harness connector
from turn signal switch harness connector by lifting
plastic lock tab on connector and separating connectors.
(fig.2J-7).
(14) Wrap tape around turn signal switch harness
connector to prevent snagging during removal.
Fig. 2J 8
(17) Turn ignition lock cylinder (clockwise) two detent positions beyond Off-LOCK position.
(18) Compress lock cylinder retaining tab using thinbladed screwdriver and remove lock cylinder from
column.
N O T E : The lock cylinder retaining tab is accessible
through the slot adjacent to the turn signal switch
mounting boss (fig. 2J-9). If the retaining tab is not
visible through the slot, scrape or knock any casting
flash out of the slot to provide access.
Fig. 2J-10
(19) Remove ignition switch from lower end of column (fig. 2J-10).
(20) Remove screws attaching housing and shroud to
column jacket (fig. 2J-11) and remove housing and
shroud.
Z c M 2
^Dioving Shroud
??m States
2J-16
STEERING COLUMNS
Fig. 2J-16
Fig. 2J-14
STEERING COLUMNS
(27) Remove column from vehicle, if necessary, and
mount column in vise using Support Fixture Tool J23074 (fig. 2J-5).
(28) Remove s t e e r i n g s h a f t if not removed
previously.
(29) Remove spring clip from lower bearing retainer
and remove retainer, bearing, and adapter.
2J-17
LOCK R A C K BLOCK T O O T H
Column Assembly
CAUTION: Use only the specified screws, bolts, and
nuts when servicing the column and tighten all fasteners to recommended torque values only to maintain the
energy-absorbing (compressing) action of the column.
Incorrect length screws or bolts can prevent the column
from compressing under impact The bolts and nuts that
attach the column mounting bracket to the column and
instrument panel must also be tightened to the proper
torque so that the bracket will break away under
impact.
(1) Coat all friction and bearing surfaces with
chassis grease before assembly.
(2) Install lock sector on sector shaft. Install sector
through lock cylinder hole in housing (fig. 2J-17). Use
blunt tool to press sector onto shaft. Be sure sector turns
freely after installation.
60673
Fig. 2J-18
mm
RACK
SIP::
Fig. 2J-19
Fig. 2J-17
60674
Sector Installation
j SPR8WG
Fig. 2J-20
60675
Srttoltoi
2J-18
STEERING COLUMNS
Fig. 2J-21
60679
Fig. 2J-23
Fig. 2J-22
STEERING COLUMNS
2J-19
Fig. 2J-25
Fig. 2J-24
2J-20
STEERING COLUMNS
STANDARi COLUMN
TRANSMISSION
OVERHAULAUTOMATIC
Column Dlsassomblf
N O T E : Steering column removal is not necessary if
only the lock plate cover, lock plate, steering shaft snap
ring, upper bearing preload spring, canceling cam, turn
signal switch, or lock cylinder are to be serviced. However, the column must be removed in order to service
any of the remaining components. If the column must be
removed, remove the column mounting bracket and install Support Fixture J-2307J+ (fig. 2J-5). Mount the column in a vise by clamping the support fixture flange in
the vise.
HOUSING
HORN CONTACT
RETAINER, PIN,
AND SPRING
PRELOAD
SPRING
STEERING
SHAFT
SNAP
RING
STEERING
WHEEL
NUT
CLAMP
I N T E R M E D I A T E SHAFT ASSEMBLY
80438
Fig. 2J-26
STEERING COLUMNS
(b) If shaft has American threads, use Compressor Tool J-23653, as is, to compress lock plate and
unseat snap ring (fig. 2J-6).
(c) If shaft has metric nut threads, replace compressor tool standard forcing screw with Metric Forcing
Screw J-23653-4 before installing tool on steering shaft.
WARNING: The lock plate is under strong spring tension. Do not attempt to remove the snap ring without using
the compressor tool.
(8) Remove lock plate compressor tool and remove
steering shaft snap ring. Discard snap ring.
CAUTION: When the snap ring is removed, the steering shaft is free in the column. If the column is removed
for bench overhaul, do not let the shaft fall out when the
column is moved.
(9) Remove lock plate, canceling cam, upper bearing
preload spring, and thrust washer (fig. 2J-26).
(10) On vehicles without Cruise Command, remove
turn signal lever attaching screw and remove lever.
(11) On vehicles with Cruise Command, remove
wires from switch terminal. Fold two of four wires back
along harness. Tape wires in place and tape length of
string to harness to aid removal.
(12) Push inward on hazard warning switch knob
and unthread knob in counterclockwise direction.
(13) Place gearshift lever in Park position. Remove
lever retaining pin using punch and remove lever.
(14) Unhook turn signal switch wire harness connector from column.
(15) Disconnect turn signal switch harness connector
from instrument panel harness connector (fig. 2J-7). Lift
connector lock tab to separate connectors.
(16) Using stiff wire or paper clip, compress lock tab
retaining shift quadrant light wire in connnector block
and disconnect wire.
TAPE HARNESS TO
P R E V E N T SNAGGING
Fig. 2J-27
2J-21
Fig, 2,3-28
1km
Gyp PoalEan
2J-22
STEERING COLUMNS
SHIFT GATE
LOCK
COUNTERSUNK
SCREW ( 2 )
RACK
PRELOAD
SPRING
COLUMN
J A C K E T TUBE
(UPPER END) *
LOCK
SECTOR
42051
Fig. 2J-29
Housing Components
NOTCH
(TYPICAL)
(26) Remove lock bolt and lock rack and remove rack
preload spring (fig. 2J-29).
(27) Remove lock sector from sector shaft using
blunt punch (fig. 2J-19). Note lock sector position for
assembly reference and remove sector through lock cylinder hole in housing.
(28) Remove shift gate lock from upper housing. Examine shift gate lock detents for wear. Replace lock if
excessively worn.
(29) Remove shift quadrant. Quadrant is retained by
two clips which must be pried out with small punch (fig.
2J-30).
Fig. 2J-31
NYLON
THRUST
WASHER
S M I
SPRANG
BEARING
( M E T A L FACE
TOWARDS
RETAINER)
SNAP
RINQ
RETAINER
N O T E : FLOOR S H I F T STEERING C O L U M N S
H A V E NO T H R U S T WASHER OR SPRING
AJ42055
'
JHHHHHHHHHHr
AJ42059
Column Assembly
(1) Apply chassis grease to all friction and bearing
surfaces.
(2) Install shift tube.
(3) Install nylon washer in lower end of shift tube
with flat side of washer facing upper end of tube (fig. 2J32).
COLUMNS
2J-23
PLATE
'DOGLEG
OPENING
ill
TURN
SIGNAL
CANCELING
CAW S H A F T
Fig. 2J-33
2J-24
STEERING G0LI11S
, REMOTE R O D H O L E
SPRING POCKET
SWITCH
SLIDER
ACCESSORY
OFF-LOCK
OFF-UNLOCK
2 POSITIONS TO T H E
R I G H T OF ACCESSORY
Fig.
2J-35
A C T U A T O R ROD H O L E
60683
J-2'J 354-1;
AJ67076
% 2J-36
jPUNCH
RELEASE
LEVER
AJ67072
Fig.
taioval
PIN
PUNCH
HOUSING
LOCK
SHOES
LOCX
SHOE ^
AJ67073
PIN
Fil.
2J-26
STEERING COLUMNS
AJ70199
Fig. 2J-40
RETAINER
AJ70202
Fig. 2J-39
AJ70200
Fig. 2J-41
Mmw
Plate Removal
Column Assembly
(1) Coat all bearing and friction surfaces with
chassis grease.
(2) Mount shift bowl on column jacket.
(3) Install shift tube spring, wave washer, and retainer plate in shift bowl.
(4) Install shift tube through lower end of column
jacket and align tube spline with shift bowl keyway.
(5) Insert Installer Tools J-23073-2 and -4 in shift
tube (fig. 2J-43). Spring-loaded lower foot of tool must
engage shift tube inner shoulder and tool guide must be
seated in shift tube.
STEERING COLUMNS
LOCK
LOCK PLATE
CANCELING
CAM
PLATE
COVER
2J-27
LOCK RACK
STEERING S
SHAFT
SNAP
t RING
INTERMEDIATE SHAFT
ASSEMBLY
50286
S H I F T TUBE
Fig. 2J-42
Tilt Steering
: ,TAINER
Fig.
2J43
Positioning
REMOTE
RC*?
AJ70205
Fig. 2 J 4 5
Fig. 2J-44
Pulling
STEERING COLUMNS
LOCK SECTOR
LOCK
2J-29
NOTE: Be sure the switch actuating lever pivot is correctly aligned and seated in the housing pivot boss before installing the switch attaching screws.
(43) Install mounting bracket on column. Tighten
bracket-to-column bolts to 20 foot-pounds (27 N*m)
torque.
(44) Position column mounting bracket on instrument panel and install bracket-to-instrument panel
attaching bolts. Tighten bolts to 20 foot-pounds (27
N*m) torque.
(45) Tighten toe plate bolts to 10 foot-pounds (14
Nm) torque.
(46) Install upper bearing race, bearing seat, preload
spring, and canceling cam on steering shaft.
(47) Align lock plate splines with steering shaft
splines and install lock plate. Canceling cam shaft must
protrude through opening in lock plate (fig. 2J-34).
(48) Install replacement steering shaft snap ring on
sleeve of Compressor Tool J-23653 and install tool on
steering shaft (fig. 2J-25).
AJ70204
Fig. 2 J 4 6
2J-30
STEERING COLUMNS
Column Disassembly
(1) Place front wheels in straight-ahead position.
(2) Disconnect battery negative cable.
r\r> is
SHOE
RELEASE LEVER
PIN
UPPER
BEARING
/RELEASE
PIN
LOWER
/LEVER
BEARING
/SPRING
/^S.ONSPmi
/
OCK
TURN SIGNAL
SWITCH
STEERING SHAFT
SNAP RING
S F P T O R
COLUMN
MOUNTING
BRACKET
COLUMN
SPRING
CLIP
BEARING ADAPTER
Fig. 2J-47
BRACKET
MOUNTING
BOLTS
80568
STEERING COLUMNS
.->-: - ,
vwr...
- -
2J-31
mm
Fig. 2J-49
80571
Fig. 2J-50
Cover Removal
B E A R I N G RACE
Fly. 2J-51
Fig. 2J-53
Housing Removal
HOUSING
Fig. 2J-52
Fig. 2J-54
guide is under
strong
STEERING COLUMNS
2J-33
LOCK
80576
Fig. 2 J - I 7
80579
Fig. 2 J - I S
Fig. 2J-56
(35) Remove tilt lever pin- from housing using tool J22635 or pin punch (fig. 2J-37).
(36) Remove lock shoe pin from housing using tool J22635 or pin punch (fig. 2J-38) and remove lock shoes,
springs, and wedge.
(37) Remove housing upper and lower bearings and
races only if damaged or worn. If bearings and races
must be replaced, remove bearings and races using hammer and punch.
NOTE: Discard the housing bearings and races if removed. They are not reusable.
(38) Disconnect steering shaft at intermediate shaft
coupling.
(39) Remove steering shaft through upper end of column (fig. 2J-58).
SUPPORT
Fig. 2J-61
Fig. 2J-59
Fig. 2 J - 8 0
S l n i l Removal/Installation
Support Removal/installation
Fig. 2J-62
C i l i n Assembly
(1) Lubricate all bearing, friction, and thrust surfaces with chassis grease.
(2) Install bearing assembly, bearing retainer, and
snap ring in lower end of column (fig. 2J-47).
(3) Install key release lever spring on lever and install assembled lever and spring in shroud (fig. 2J-62).
, (4) Align and install shroud on column jacket (fig.
2J-61).
STEERING COLUMNS
Fig. 2J-63
Support Installation
(5) Install retainer plate (fig. 2J-60). Tip plate toward 12 o'clock position, slide it under jacket opening,
and seat It in column jacket notches.
(6) Align column jacket "V" notch with corresponding "V" on support and Install support In column (fig. 2J63). Press key release lever downward while pressing
support into place to seat support fully.
(7) Install all support attaching screws finger tight;
Then tighten screws alternately and evenly to 60 inchpounds (81 Nm) torque (fig. 2J-59).
(8) Install remote rod in support. Guide rod through
upper end of shroud and insert it into rod slot in
support.
(9) Install steering shaft in column (fig. 2J-58).
(10) Install replacement bearings in housing, if removed. Be sure to lubricate bearings with chassis grease
before installation.
(11) Install lock shoes, lock shoe springs, and lock
shoe pin in housing. Use 0.180 inch (4.5 mm) diameter
rod to align lock shoes and pin during installation.
(12) Install release lever, lever spring, and lever pin
in housing. Insert wedges between housing and lever to
relieve spring tension and ease pin installation (fig. 2J57).
(13) Install sector shaft in housing. Lightly tap shaft
into housing using punch.
(14) Install lock sector on shaft. Lightly tap sector
onto shaft until shaft snap ring groove is exposed and
install sector retaining snap ring.
(15) Install lock bolt in housing and engage bolt in
lock sector cam surface (fig. 2L-56).
(16) Install lock rack, rack preload spring, and replacement shim (if used) in housing. Square block tooth
of rack must engage square block tooth of sector (fig. 2356).
2J-35
2J-36
STEERIKG COLUMNS
Fig. 2J-64
Adlustmant.
(1) Adjust
necessary.
transmission
manual
linkage
if
Remoiil
(1) Disconnect battery negative cable.
(2) Disconnect switch harness connector at switch.
(3) Remove switch attaching screws and remove
switch from column.
Installation
(1) Position switch on column and install attaching
screws finger-tight only.
(2) Connect harness connector to switch terminals.
(3) Adjust switch. Refer to Adjustment.
(4) Tighten switch attaching screws to 35 inchpounds (4 Nm) torque.
(5) Connect battery negative cable.
IGNITION SWITCH
Removal
(1) Insert key in lock cylinder and turn cylinder to
Off-Unlock position.
(2) Disconnect battery negative cable.
(3) Disconnect harness connectors at switch.
(4) Remove switch attaching screws.
(5) Disengage remote rod from switch slider and
remove switch from column.
Installation
(1) Move switch slider to Accessory position (fig. 2J64).
(2) Move switch slider back two clicks to Off-Unlock
position (fig. 2J-64).
(3) Engage remote rod in switch slider and position
switch on column. Do not move slider when positioning
switch on column jacket.
(.4) Install and tighten switch attaching screws to 35
inch-pounds (4 Nm) torque.
(5) Connect harness connectors to switch.
(6) Connect battery negative cable.
2J-38
STEElIlf
WARNING: The lock plate is under strong spring pressure. Do not attempt to remove the steering shaft snap
ring without using the compressor tool.
steering
A41061
Fig.
2J-66
Fig, U41
RETAINER
Fig. 2J-65
2J-40
STEERING COLUMNS
Fig. 2J-69
POSITIONS
12345
KEY CODES
AJ41049
Fig. 2J-68
W A V E WASHER
Fig. 2J-70
Assembly
(1) Insert key completely into lock cylinder then
pull key out two notches.
(2) Install wave washer and anti-theft ring on lock
cylinder (fig. 2J-70).
(3) Grasp lock sleeve with left thumb and forefinger
and hold nylon stop in lock sleeve upward with forefinger (fig. 2J-70).
(4) Grasp lock cylinder with right thumb and forefinger, align anti-theft ring tang and lock cylinder side
bar with slot in wall of lock sleeve, and insert cylinder
into sleeve (fig. 2J-70).
(5) Push key completely into cylinder and turn key
clockwise to lock cylinder in sleeve.
SPECIFICATIONS
Torque Specifications
Service Set-To Torques s h o u l d be used when assembling components.
Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Metric (Nm)
Service Set-To
Torque
Service In-Use
Recheck Torque
Service Set-To
Torque
Service In-Use
Recheck Torque
30
45
45
20
20
60 in-lbs.
100 in-los.
5 in-lbs.
60 in-lbs.
100 in-lbs.
35 in-lbs.
35 in-lbs.
18 in-lbs.
30
60 in-lbs.
35 in-lbs.
10
15 in-lbs.
35 in-lbs.
25-35
40-55
40-55
15-25
15-25
50-65 in-lbs.
95-105 in-lbs.
3-7 in-lbs.
55-65 in-lbs.
95-105 in-lbs.
30-40 in-lbs.
30-40 in-lbs.
14-22 in-lbs.
25-35
50-65 in-lbs.
30-40 in-lbs.
10-18
12-20 in-lbs.
28-40 in-lbs.
41
61
61
27
27
7
11
0.56
7
11
4
4
2
41
7
4
14
2
4
34-47
54-75
54-75
20-34
20-34
5-7
10-12
0.34-0.79
5-7
10-12
3-5
3-5
2-3
34-47
5-7
3-5
14-24
1-3
3-5
80629
All Torque values given in foot-pounds with dry fits unless otherwise specified.
Tools
l
J-23072
SHIFT TUBE REMOVER
J-22635
PIN REMOVER AND
INSTALLER
J-23653
LOCK PLATE
COMPRESSOR
J-23073
SHIFT TUBE
INSTALLER
'MM*
liiBiii
J-22569
STEERING SHAFT SNAP RING
REMOVER AND INSTALLER
J-21232
STEERING WHEEL
PULLER
J-21854-1 PIVOT
PIN PULLER
J-23074
STEERING COLUMN
HOLDING FIXTURE
50408A
NOTES
2K-1
MANUAL
RING GEAR
SECTION INDEX
Pap
General Information
Steering GearLeft Hand Drive Vehicles
Page
Steering GearRight Hand Drive Vehicles 2K-11
Tools 2K-14
2K-1
2K-3
GENERAL INFORMATION
Page
General
Service Diagnosis
2K-1
2K-2
GENERAL
Two different manual steering gear units are used in
Jeep vehicles. Left hand drive models use a recirculating
ball-type gear (fig. 2K-1). Eight hand drive models use a
worm and roller-type gear (fig. 2K-2).
In the recirculating ball gear, the wormshaft and ball
nut are in line with the steering shaft in the column. The
ball nut is mounted on the wormshaft and is driven
through steel ball bearings which circulate in spiral
grooves machined in the wormshaft and ball nut. The
bearings act as a rolling thread between the wormshaft
and ball nut. The ball nut is directly engaged by the
pitman shaft teeth.
WORM SHAFT
BALLS A N D
WORM
GUIDES
ADJUSTER
2K-3
BEARING
PITMAN SHAFT
Fig. 2K-1
Specifications
LOCKNUT
J42693
Fig. 2K-2
ZK-2
Service Diagnosis
HARD STEERING
LOOSE STEERING
EXCESSIVE
ROAD SHOCK
Correction
Possible Cause
Condition
(1)
(1)
Adjust.
(2)
Lack of lubrication.
(2)
(3)
(3)
Replace.
(4)
(4)
Adjust or replace.
(5)
(5)
Replace.
(6)
(6)
Replace bearings.
(7)
(7)
(8)
(8)
(9)
(9)
(10)
(10)
(11)
(11)
(12)
(12)
(13)
(13)
(14)
(14)
(1)
(1)
Replace.
(2)
(2)
Replace.
(3)
(3)
Replace.
(4)
(4)
Adjust.
(1)
U-bolts loose.
(1)
Repair as necessary.
(2)
(2)
Repair as necessary.
(3)
(3)
Replace.
60701 A
2K-3
Possible Cause
Condition
TURNING RADIUS
SHORT ONE
SIDE
Correction
(1)
(1)
Repair as necessary.
(2)
Axle shifted.
(2)
Repair as necessary.
(3)
(3)
Replace.
60701B
SPECIFICATIONS
Steering Gear Specifications
Left Hand Drive Vehicles:
Gear-Type
.
Ratio . . . . . . . . . . .
Bearings
Upper
Lower
Adjustments:
Worm Bearing Preload
Pitman Shaft Overcenter
Drag Torque
Recirculating Ball
24:1
Ball
Ball
. . 8 in-lbs.
(0.90 N-m)
4-10 in-lbs.
(0.45-1.13 N-m) in addition to
8 in-lbs. (0.90 N-m) w o r m
bearing preload for a total of
18 in-lbs. (2.03 N-m) maximum
.0.002 in. (0.05 mm)
Adjustments:
Worm Bearing Preload
. 2-5 in-lbs.
(0.23-0.56 N-m)
7-12 in-lbs.
(0.79-1.36 N-m)
0.010 in.
(0.25 mm)
80435B
80435A
2K-8
2K-4
2K-4
REMOVAL
(1) Remove intermediate shaft-to-wormshaft coupling clamp bolt and disconnect intermediate shaft.
(2) Remove pitman arm nut and lockwasher.
(3) Remove pitman arm from steering gear pitman
shaft using Puller J-6632 (fig. 2K-3).
(4) On Cherokee, Wagoneer and Truck models, remove bolts attaching steering gear to frame and remove
gear.
(5) On CJ models:
(a) Raise left side of vehicle slightly to relieve
tension on left front spring and place support stand
under frame.
Page
Removal
Specifications
Subassembly Overhaul
2K-3
2K-10
2K-6
2K-4
42065
Fig. 2K-3
INBOARD
N O T E : After the steering gear is installed, it may produce a slightly rough feel. To eliminate this roughness,
turn the gear full left and right for 10 to 15 complete
cycles.
OISASSEMPLY
Fig. 21-4
ilSTILLilll
N O T E : Proper retention of the steering gear is important Some of the following steps in gear installation
require the application ofLocktite or similar material to
2K-5
ADJUSTER
SCREW
NUT
WORM
BEARING
ADJUSTER,
LOCKNUT '
ADJUSTER
SCREW
SHIM
WORMSHAFT
LOWER
B E A R I N G CUP
WORMSHAFT
LOWER
BEARING
LOWER
BEARING
RETAINER
WORMSHAFT
WORMSHAFT
UPPER
BEARING
WORM
BEARING
ADJUSTER
HOUSING
0
BALL
GUIDE
CLAMP
SCREWS
BALLS
BALL
GUIDE
CLAMP
WORMSHAFT
UPPER
BEARING
CUP
WORMSHAFT
SEAL
90162
Fig. 2K-5
Fig. 2K-6
ZK-6
i-"iw
m? ~
law
'
".-.^______zi_zr^!^
JBASSEMBLY If E1HAUL
^s^'
~ ;
mm
(1) Place clean shop cloths on workbench and position wormshaft and ball nut on cloths.
(2) Remove upper bearing from wormshaft.
(3) Remove ball guide clamp attaching screws and
remove clamp.
(4) Remove ball guides. Separate guide halves and
retain ball bearings that stayed in guides during
removal.
(5) Remove remaining ball bearings from ball nut
circuits. Position ball nut over shop cloths and rotate
wormshaft back and forth until bearings drop out onto
cloth.
with
WORMSHAFT
UPPER END
42073
guide
teeth
side.
shaft
90164
Fig. 2K-7
the
the
Fig. 2K-8
2K-7
Assembly
TOOL
J-5755
BEARING
90166
^ -
2K-8
(1) If wormshaft upper bearing cup is to be replaced, remove old cup using hammer and brass punch
(fig. 2K-14).
(2) Install replacement bearing cup using Installer
J-5755 (fig. 2K-15).
NOTE: Do not install the wormshaft or pitman shaft
seals at this time. Refer to Assembly and Adjustment.
90169
Fig. 2K-14
Fig. 2K-15
PITMAN
SHAFT
S E A
!r
SCREWDRIVER
90167
Fig. 2K-12
90168
Fig. 2K-13
CAUTION: Be
"
"
t'
q-
~~7r.:..w
deep side of the ball nut teeth facing the side cover
opening.
(4) Install worm bearing adjuster in housing and
tighten adjuster only enough to remove wormshaft end
play.
(5) Install locknut on worm bearing adjuster but do
not tighten locknut at this time.
(6) Pack steering gear housing with as much chassis
grease as possible.
NOTE: In order to pack the maximum amount of
grease into the housing, the ball nut must be moved back
and forth for better access to the housing interior. Rotate the wormshaft in one direction until ball nut travel
ceases. Pack the unobstructed housing end full of
grease; then rotate the shaft in the opposite direction
and repeat the packing procedure.
(7) Place ball nut in centered position. Rotate
wormshaft from stop to stop and count total number of
turns. Turn wormshaft back 1/2 number of turns to
center ball nut.
(8) Lubricate pitman shaft with chassis grease and
install shaft in housing. Engage center tooth of shaft in
center groove of ball nut (fig. 2K-16).
(9) Coat replacement side cover gasket with chassis
grease and position gasket on housing side cover
opening.
(10) Install end play shim on adjuster screw and
thread screw into side cover to depth of 2-3 threads.
(11) Slide adjuster screw into pitman shaft T-slot
and turn screw counterclockwise to thread it into cover.
Stop turning screw when side cover almost contacts
gasket.
- (12) Align gear housing and side cover bolt holes and
install cover attaching bolts finger tight only (do not
attempt to seat cover on housing by tightening bolts).
(13) Tighten adjuster screw until it bottoms and
back off screw 1/2 turn.
(14) Tighten side cover bolts to 30 foot-pounds (41
Nm) torque.
(15) Install pitman shaft and wormshaft seals as
follows:
(a) Wrap 0.005 inch (0.1 mm) thick shim stock
(or single layer of thinnest tape available) around shaft
splines and threads. Shim stock (or tape) will serve as
seal protecter when seals are installed.
(b) Lubricate seals with chassis grease. Slide
each seal over protective material and down shaft until
seal contacts housing.
(c) Start seals into housing seal seats by hand.
Complete seal installation by tapping seals into place
using plastic mallet. Be sure each seal is fully seated in
housing.
'ari~
jgr.~~~
2K-9
Z J Z D
42074
Fig. 21-1
Adjustment
The recirculating ball gear requires two adjustments
which are, worm bearing preload and pitman shaft overcenter drag torque.
Worm bearing preload is controlled by the amount of
compression force exerted on the wormshaft bearings by
the worm bearing adjuster.
Pitman shaft overcenter drag torque is controlled by
the pitman shaft adjuster screw which determines the
clearance between the ball nut and pitman shaft sector
teeth.
CAUTION: The following adjustment
procedures
must be performed exactly as described and in the sequence outlined. Failure to do so can result in damage to
the gear internal components and improper steering response. Always adjust worm bearing preload first and
pitman shaft overcenter drag torque last.
2K-1Q
l i r a Infill Preload
Adjustment
(6) Hold adjuster screw in position using screwdriver and tighten adjuster screw locknut to 23 footpounds (31 N*m) torque. Do not allow screw to turn
when tightening locknut.
N O T E : If the adjuster screw is allowed to turn when
the locknut is tightened, the entire drag torque adjustment procedure will have to be performed once again.
(7) Recheck overcenter drag torque and readjust if
necessary.
TOOL
90172
Fig. 21-18
SPECIFICATIONS
Steering Gear Specifications
Left Hand Drive Vehicles
Left Hand Drive Vehicles:
Gear-Type
Ratio .
Bearings
Upper
Lower
Adjustments:
Worm Bearing Preload
Pitman Shaft Overcenter
Drag Torque .
A D JUSTING
WRENCH
AND
SOCKET
90171
21-17
Recirculating Ball
24:1
Ball
Ball
8 in-lbs.
(0.90 N-m)
4-10 in-lbs.
(0.45-1.13 N-m) in addition to
8 in-lbs. (0.90 N-m) worm
bearing preload for a total of
16 in-lbs. (1.8 N-m) maximum
. .0.002 in. (0.05 mm)
80435A
2K-11
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
45
185
70
55
70
30
20
23
18
90
20
40-50
160-210
60-80
50-60
60-80
25-35
18-25
18-27
16-20
70-110
18-25
61
251
95
75
95
41
27
31
24
122
27
54-68
217-285
81-108
68-81
81-108
34-47
24-41
24-37
22-27
95-149
24-34
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
60704
STEERING GEARRIGHT
H A N D D R I V E VEHICLES
Page
Assembly and Adjustment
Cleaning and Inspection
Disassembly
2K-12
2K-12
2K-11
REMOVAL
(1) Remove gear-to-column flexible coupling alienhead clamping screw.
(2) Disconnect steering connecting rod at steering
arm.
(3) Remove bolts attaching steering gear to frame.
(4) Remove gear by sliding gear slightly forward
and to right and lifting gear out of engine compartment.
INSTALLAT101
(1) Position gear on frame and install gear mounting bolts.
(2) Attach steering connecting rod to steering arm.
(3) Align and engage steering gear wormshaft with
steering column and install flexible coupling clamp bolt.
OlSASSEMSLf
(1) Clean exterior of steering gear with solvent.
(2) Remove fill plug from housing (fig. 2K-19) and
drain lubricant from gear.
(3) Paint assembly alignment reference marks on
steering arm and roller gear and shaft assembly.
(4) Remove nut and lockwasher from roller gear
shaft (fig. ZK-19).
Page
Installation
Removal
Specifications
2K-11
2K-11
2K-13
(5) Remove steering arm from roller gear shaft using pitman arm puller.
CAUTION: Do not use a hammer or wedge to remove
the steering arm from the roller gear shaft. This will
damage the gear and shaft assembly.
(6) Remove nicks or burrs from exposed portions of
roller gear and shaft assembly and from worm gear and
shaft assembly using fine-tooth file or emery cloth.
(7) Remove side cover attaching bolts.
(8) Remove side cover, cover gasket, and roller gear
and shaft from housing as an assembly.
(9) Remove locknut from roller shaft adjustment
screw.
(10) Turn roller shaft adjustment screw clockwise
until screw is completely unthreaded from side cover
and separate roller gear and shaft assembly from cover.
(11) Remove end cover attaching bolts and remove
end cover and shims from housing.
(12) Remove worm gear and shaft assembly.
(13) Remove upper and lower bearing cups and bearings from worm gear and shaft.
(14) Remove worm gear shaft and roller gear shaft
oil seals from housing. Discard both seals.
2K-12
WORM S H A F T
OIL SEAL
R O L L E R GEAR
S H A F T O I L SEAL
STEERING A R M
UPPER B A L L B E A R I N G
LOWER B A L L B E A R I N G
NEEDLE
BEARING
R O L L E R GEAR A N D
S H A F T ASSEMBLY
SPACER
W O R M GEAR A N D
S H A F T ASSEMBLY
END COVER
NEEDLE
BEARING
LOWER
B E A R I N G CUP
LOCKNUT
Fig. 2K-19
. SHIMS
42703
(2) Press each seal into housing seal bore using suitable diameter tool that will contact seal bore of housing
around entire perimeter of bore.
(3) Lubricate worm gear and shaft assembly and
upper bearing and bearing cup with Gear Lubricant
MIL-L2105B, Grade SAE 80 or equivalent.
(4) Install upper bearing and bearing cup on worm
gear shaft.
(5) Install worm gear and shaft assembly in gear
housing. Do not damage oil seal when installing shaft.
(6) Lubricate lower end of worm gear and shaft
assembly and lower bearing and bearing cup with Gear
Lubricant MIL-L-2105B, Grade SAE 80 or equivalent.
(7) Install lower bearing, bearing cup, and spacer on
lower end of worm gear shaft.
(8) Install shims and end cover on steering gear
housing and install cover attaching bolts. Do not tighten
bolts completely at this time.
(9) Position side cover on roller gear shaft adjustment screw.
(10) Thread screw counterclockwise into cover until
end of roller gear shaft just touches inner face of cover.
(11) Install locknut on adjustment screw finger-tight
only.
(12) Install gasket on side cover.
(13) Lubricate roller gear and shaft assembly with
Gear Lubricant MIL-L-2105B, Grade SAE 80 or
equivalent.
(14) Install roller gear and shaft assembly in housing. Do not damage roller gear shaft oil seal when installing assembly.
(15) Mesh roller gear and worm gear.
(16) Install side cover attaching bolts. Tighten bolts
to 20 foot-pounds (27 Nm) torque.
(17) Clamp exposed portion of roller gear and shaft
assembly in vise equipped with protective jaws.
(18) Align assembly reference marks on roller gear
shaft and steering arm and install steering arm on
splined end of shaft.
2K-13
SPECIFICATIONS
Steering Gear SpecificationsRight Hand Drive Vehicles
Right Hand Drive Vehicles:
Gear-Type
Ratio
Bearings
Upper
Lower
Lever Shaft
. .
Ball
Ball
Roller and Bushing
Adjustments:
Worm Bearing Preload
2-5 in-lbs.
(0.23-0.56 N-m)
7-12 in-lbs.
(0.79-1.36 N-m)
0.010 in.
(0.25 mm)
80435B
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
1 n-Use
Recheck
Torque
45
185
70
55
70
30
20
23
18
90
20
40-50
160-210
60-80
50-60
60-80
25-35
18-25
18-27
16-20
70-110
18-25
61
251
95
75
95
41
27
31
24
122
27
54-68
217-285
81-108
68-81
81-108
34-47
24-41
24-37
22-27
95-149
24-34
A l l torque values given in foot-pounds and newton-meters w i t h dry fits unless otherwise specified.
60704
2K-14
Tools
TORQUE WRENCH
J-77S4
SLIDE HAMMER
J-2619-01
J-6632
PITMAN ARM
PULLER
SECTION INDEX
Paga
Page
General Information
Power Steering Gear
2L-1
2L-19
23.-44
GENERAL INFORMATION
Page
Pap
2L-1
Periodic Maintenance
2L-1
21-1S
2L-10
GENERAL
The power steering system consists of a power steering gear, hydraulic pump, and interconnecting hoses.
The system fluid supply is contained in a reservoir
mounted on the pump. Fluid from the pump is supplied
to the gear through the interconnecting pressure and
return hoses. The pump is operated by a drive belt
mounted on pulleys attached to the pump shaft and
engine crankshaft.
Two different ratio steering gear units are used. CJ
models use a constant ratio gear with a 17.5:1 steering
ratio. Cherokee, Wagoneer and Truck models use a variable ratio gear with a 16:1 ratio on center and 13:1 ratio
at full lock.
Although the steering ratios of the two units differ,
exterior appearance and service procedures for both
units are the same. However, the internal components of
the two gears are not interchangeable.
A vane-type power steering pump with a combination
flow control/relief valve is used on all models. Two valve
calibrations are used. On CJ models, the valve is calibrated to open at 1100 psi (7 584 kPa). On Cherokee,
Wagoneer, and Truck models, the valve is calibrated to
open at 1500 psi (10 342 kPa).
The power steering gear is designed to operate manually if a system malfunction should ever occur. This
feature provides the driver with continued steering control of the vehicle. In this condition, the gear operates
like a manual steering gear; hydraulic fluid is bypassed
through the gear valve body to allow manual operation.
Service Diagnosis
SpieifiBiiioifs
21-15
21-5
2L-'3?
SIDE
COVER
GEAR
HOUSING
ADJUSTER
PLUG
TORSION
STUB
SHAFT
TORSION BAR
STUB S H A F T SEAL
UPPER T H R U S T
BEARING
RACK PISTON
SEAL RING
PITMAN SHAFT
80450
Fig. 21-1
System operating pressures are maintained by a combination flow control/relief valve located in the pump
(fig. 2L-2). The relief section of the valve prevents exces-,
sive system pressure buildup.
I f draulic Assist
An open center, three position, rotary-type valve body
is used to control fluid flow within the gear (fig. 2L-1).
Pump supplied fluid enters the valve body through a
pressure port in the gear housing. The valve then directs
fluid to the rack piston through passages in the housing.
The valve body, spool valve, torsion bar, and stub
shaft (which is pinned to the torsion bar) are connected
to the front wheels through mechanical linkage.
. Because of the pressure exerted on the front wheels by
vehicle weight, the wheels and valve body tend to resist
RESERVOIR
2L-3
Fig. 2L-2
2L-4
RACK PISTON
AJ42078
Fig. 21-3
R E T U R N OIL
O I L PRESSURE
PORT
OIL RETURN
TO UPPER SIDE
OF RACK PISTON
WORM S H A F T
H I G H PRESSURE
LOW PRESSURE
V A L V E BODY
RACK PISTON
AJ42079
Fig. 2L-4
2L-6
Because of this relationship, the steering ratio remains a nearly constant 16:1 for the first 40 degrees of
steering wheel movement in either direction from
center.
Turning the steering wheel further reduces the length
of the lever. This moves the point of contact down the
side of the center tooth decreasing the radius.and providing a steering ratio of 13:1 at full lock.
CONSTANT RATIO
Fig. 2L-5
VARIABLE RATIO
AJ41064
SERVICE DIAGNOSIS
When diagnosing suspected power steering system
malfunctions, refer to the Service Diagnosis Charts in
this section for probable causes and indicated repair
procedures.
To avoid ineffective or unneccessary repair, do not
attempt to correct a malfunction until an accurate diagnosis has been made. Utilize the diagnosis charts, hydraulic pressure test and leak diagnosis procedures
before servicing the gear or pump.
Possible Cause
Condition
Correction
HISSING NOISE IN
STEERING GEAR
(1)
(1)
RATTLE OR CHUCKLE
NOISE IN STEERING
GEAR
(1)
(1)
2L-7
RATTLE OR CHUCKLE
NOISE IN STEERING
GEAR (CONTINUED)
Correction
Possible Cause
Condition
(2)
(2)
(3)
(3)
(4)
Adjust t o specifications.
(4)
(5)
SQUAWK NOISE IN
STEERING GEAR
WHEN TURNING OR
RECOVERING FROM A
TURN
(1)
(1)
CHIRP NOISE IN
STEERING PUMP
(1)
(1.)
BELT SQUEAL
(PARTICULARLY
NOTICEABLE AT FULL
WHEEL TRAVEL AND
STAND STILL
PARKING)
(1)
(1)
GROWL NOISE IN
STEERING PUMP
(1)
(1)
GROWL NOISE IN
STEERING PUMP
(PARTICULARLY
NOTICEABLE AT
STAND STILL
PARKING)
(1)
(1)
(2)
(2)
Replace parts.
GROAN NOISE IN
STEERING PUMP
RATTLE NOISE IN
STEERING PUMP
(1)
(1)
(2)
(2)
(1)
(1)
Install properly.
(2)
(2)
2L-8
Correction
Possible Cause
Condition
WHINE NOISE IN
STEERING PUMP
(1)
(1)
POOR RETURN O F
STEERING WHEEL TO
CENTER
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(7)
Replace bearings.
(8)
(8)
(9)
(9)
(10)
(10)
(1)
(1)
(2)
(2)
Adjust to specifications.
(3)
(3)
Replace valve.
MOMENTARY
INCREASE IN E F F O R T
WHEN TURNING
WHEEL FAST TO
RIGHT OR LEFT
(1)
(1)
(2)
(2)
(3)
(3)
2L-9
STEERING WHEEL
SURGES OR JERKS
WHEN TURNING WITH
ENGINE RUNNING
ESPECIALLY DURING
PARKING
LOOSE STEERING
HARD STEERING OR
LACK OF ASSIST
Correction
Possible Cause
Condition
(1)
(1)
Fill as required.
(2)
Loose p u m p belt.
(2)
(3)
Insufficient p u m p pressure.
(3)
(4)
(4)
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(1)
Loose p u m p belt.
(1)
(2)
(2)
(3)
(3)
(4)
(5)
(6)
(7)
2L-10
Correction
Possible Cause
Condition
FOAMING AERATED
POWEE STEERING
FLUID, LOW FLUID
LEVEL AND
POSSIBLE LOW
PRESSURE
(1)
(1)
(1)
(1)
(2)
(2)
Correct.
(3)
(3)
(4)
(4)
(5)
(5)
Install properly.
(6)
(6)
(7)
(7)
Replace part.
(1)
(1)
(2)
(2)
LEAK DIAGNOSIS
The actual source of power steering system fluid leaks
should always be determined before attempting repair.
Because innaccurate diagnosis can lead to ineffective
repair, proper inspection procedures are necessary. The
most common fluid leak sources are shown in figures
2L-6, 2L-7, and 2L-8.
Inspection Procedure
(1) Raise front of vehicle.
(2) Clean exterior surfaces of steering gear, pump,
hoses, and fittings thoroughly.
mwm
Leak Diagnosis and CorrectionSteering Gear
N O T E : Refer to figures 2L-6 and 2L-7 for an
tion of steering gear leak sources.
illustra-
21-11
RESERVOIR
RESERVOIR
" O " RING
PUMP SHAFT
SEAL
F I T T I N G " O " RING A N D
STUD/BOLT " O " RINGS
RETURN HOSE A N D CLAMPS
ADJUSTER PLUG
" O " RING
PRESSURE PORT
TORSION BAR
" O " RING
PRESSURE A N D R E T U R N PORT SEATS
STUB S H A F T
SEAL
A D J U S T I N G SCREW LOCK N U T
HOUSING
B A L L PLUG
END COVER " O " RING
PITMAN SHAFT
SEAL
GEAR
HOUSING
80076
Fig.
214
Points
2L-12
Leak Points
Pay particular attention to the exact source of leakage. Due to the proximity of the various seals, an incorrect diagnosis will result in ineffective repair.
Corrective Action
Replace adjuster plug O-ring seal
Replace Dust and stub shaft seals.,
Fig. ZL-7
Fig. 2L-7
A -
A
m
ZL-14
Corrective Action
If leak persists after tightening fitting nut to specified
torque:
.
a. Loosen nut and rotate tubing to reseat. Tighten nut
again and recheck. If leak persists, replace connector seats and hose.
b. Remove hose and check sealing face for cracks. If
flare is cracked, replace hose. If not cracked, replace
connector seats.
c. Replace brass connector seats and reface tube flare.
Check threads in pump housing and on fitting nut. If
nut threads are damaged, replace both housing and
nut.
Tighten fitting to specified torque. If leak persists, Replace both O-ring seals
Replace reservoir O-ring. u.
Replace pump shaft seal. -
8(5078
Sg^x^^ LtiM
Test Procedure
(1) Check condition of power steering fluid. Drain
and replace fluid if it contains small amount of dirt or
contaminant. If fluid is exceptionally dirty, contaminated, or full of debris or foreign material, gear and
pump should be disassembled and serviced.
(2) If fluid is full of bubbles, bleed power steering
system. Refer to Fluid Level and Initial Operation in
Power Steering Pump section.
(3) Check and adjust pump drive belt tension if
necessary.
(4) Position drip pan under pump.
(5) Disconnect pressure hose at pump. Keep hose
end raised to avoid excessive fluid loss.
(6) Connect pressure hose to Test Gauge J-21567.
Refer to Pump Diagnosis Charts.
(7) Connect test gauge hose to pump. Refer to Hydraulic Pressure Test Procedure.
(8) Open test gauge valve completely. Turn valve
counterclockwise to open.
(9) Fill pump reservoir with power steering fluid.
(10) Shift transmission into neutral, apply parking
brakes, start engine, and operate engine until power
steering fluid reaches normal operating temperature.
(11) Record pump initial output pressure registered
on test gauge. Pressure should be 80-125 psi (552-862
kPa) with gauge valve open completely.
(12) Check pump maximum output pressure as follows: Close gauge valve completely for 2-3 seconds; then
open valve completely. Perform this procedure three
times in succession and record highest pressure developed each time valve is closed.
CAUTION: Do not hold the gauge valve closed for
more than five seconds at a time as pump damage could
occur.
2L-15
(13) On CJ models, maximum pump output pressures should be in 1000-1100 psi (6 895-7 584 kPa) range
and not vary by more than 50 psi (345 kPa). On all other
models, pressures should be in 1400-1500 psi (9 65310 342 kPa) range and also not vary by more than 50 psi
(345 kPa).
For example if recorded pressures on CJ models were
1050-1060-1070 ' (7 240-7 309-7 378 kPa), or 1450-14801470 (9 99840 205-10 136 kPa) on Cherokee, Wagoneer
and Truck models, maximum pressures are within allowable variance and pump operation is within limits.
(14) If maximum pressures were within specified
high ranges but varied by more than 50 psi (345 kPa),
flow control valve is sticking. Remove and clean valve
and remove any surface imperfections with crocus cloth.
(15) If pump flow control valve was serviced, repeat
pressure test to check valve operation before proceeding.
(16) Turn steering wheel right and left. Contact
steering stops in both directions and record highest pressure developed when each stop is contacted. If pressures
are 1000-1100 psi (6 895-7 584 kPa) on CJ models, or
1400-1500 psi (9 653-10 342 kPa) on all other models,
pump is operating properly.
CAUTION: Do not hold the steering wheel against the
steering stops for more than 5 seconds at a time as pump
damge could occur.
PERIODIC MAINTENANCE
'
2L-16
CHECK F L U I D LEVEL,
ADD FLUID
IF NECESSARY
DISCONNECT HOSE
A T GEAR A N D
CHECK POPPET
V A L V E FOR FREE
OPERATION
REPAIR OR
REPLACE AS
NECESSARY
A L L THREE R E A D I N G S MUST
BE A B O V E SPEC. A N D W I T H I N
50 PSI (345 kPa) OF EACH OTHER
PRESSURES OK
CLOSE V A L V E F U L L Y T H R E E T I M E S ,
RECORDING HIGHEST PRESSURE EACH T I M E
CAUTION
| DO NOT L E A V E V A L V E CLOSED FOR MORE T H A N
5 SECONDS AS T H E PUMP C O U L D BE D A M A G E D
SEQUENCE
STEP
REMOVE A N D C L E A N
FLOW C O N T R O L V A L V E
REMOVE A N Y BURRS
W I T H CROCUS C L O T H
OR FINE HONE
CHECK F L U I D
CONDITION
FLUID DIRTY
DISASSEMBLE PUMP
A N D GEAR A N D CLEAN.
REASSEMBLE
REPLACE FLOW
CONTROL V A L V E
PRESSURES OK
RECHECK
PRESSURES
(SEE STEP 4)
PRESSURES
LOW
REPLACE R O T A T I N G
GROUP
(OK
COMPARE PRESSURESL E F T A N D RIGHT.
PRESSURE R E A D I N G
MUST BE SAME AS
H I G H PRESSURE STEP 4
WITH V A L V E OPEN
T U R N STEERING WHEEL
A L L THE WAY LEFT A N D
RIGHT. RECORD HIGHEST
PRESSURE A T EACH STOP
DISASSEMBLE GEAR
A N D CHECK FOR
INTERNAL LEAKS
MOST L I K E L Y A R E A S
A R E CIRCLED
PRESSURE OK
LEFT
RIGHT
RECHECK F L U I D
L E V E L A D D IF
NECESSARY
80084B
2L-18
SPECIFICATIONS
.Needle Roller
.Needle Roller
Needle Roller
Use Jeep Power Steering Fluid or
equivalent only. Do not use
transmission f l u i d .
Power Steering System Fluid Capacity
1-1/4 pints
(0.59 liters)
Steering Gear Adjustment:
Worm Bearing Preload . . . 4 to 10 inch-pounds (0.45 t o 1.13 N-m)
rotating torque. Refer t o
Steering Gear Adjustment.
Pitman Shaft Overcenter Drag Torque
(New gear w i t h less than 400 miles service) . . . .4 to 8 inch-pounds
(0.45 to 0.90 N-m) in addition
to w o r m bearing preload
but not t o exceed total of
14 inch-pounds (1.58 N-m)
(Used gear w i t h over 400 miles service)
4 to 5 inch-pounds
(0.45 to 0.56 N-m) in addition
to w o r m bearing preload but
not to exceed total of 18 inchpounds (2.03 N-m)
Steering Ratio
CJ.
. 17.5:1 constant ratio
Cke-Wag-Trk.
. . 13/16:1 variable ratio
Value Body
Three-way, open center, rotary-type.
Pump Type
80499
Metric (N)
New Belt*
Used Belt
New Belt*
Used Belt
125-155
125-155
125-155
65-75
125-155
125-155
125-155
90-115
90-115
90-115
60-70
90-115
90-115
90-115
556-689
556-689
556-689
291-334
556-689
556-689
556-689
400-512
400-512
400-512
267-311
400-512
400-512
400-512
*New belt specifications apply only to replacement belts. Once a belt has been tensioned and run, it is considered a used belt and should be adjusted
to used belt specifications.
80503
g e n i u s
mrm,
mm
Page
2L-39
2L-19
21-19
2L-32
2L-21
2L-20
21-24
2L-36
21-22
GENERAL
Although service and adjustment procedures for constant and variable ratio steering gears are the same, do
not attempt to interchange gear internal components.
When servicing a gear, perform all repair operations
on a clean work surface only. Small amounts of foreign
material or contaminants can cause a malfunction after
assembly. Clean all parts in clean-filtered solvent only
and dry all parts, except bearings, using filtered compressed air. Use lint-free paper towels or cloths only to
dry bearings.
During assembly operations, use the recommended
torque values and adjusment specifications only. Failure to adhere to these specifications can result in accelerated wear and unsatisfactory gear operation.
W-VEHICLE SERVICE
Steering Gear Adjustment
Because of the complexity involved in adjusting worm
bearing preload and pitman shaft overcenter drag
torque plus the friction effect of hydraulic fluid, the
steering gear must be adjusted off the vehicle only.
Refer to Worm Bearing Preload and Pitman Shaft Overcenter Drag Torque Adjustment under Steering Gear
Assembly and Adjustment.
i
PULLER
J-6632
steering
fluid
only in the
42065
2L-20
p^^^^,~~~_~~^.^-~~-
TT\
w T r
r " ""yvr
"
r-^--^--
,-
r-yr;
-y
^ g ^ r ^ T T ^ r ^
BACKUP
"
-y-:
;~"?v-T1
(15) Install pitman arm on shaft and install replacement pitman arm nut and lockwasher. Tighten nut to
185 foot-pounds (251 N*m) torque. Stake nut in two
places to retain it.
(16) Lower vehicle.
(17) Fill power steering pump reservoir to correct
level with power steering fluid.
(18) Start and idle engine for at least three minutes.
Do not turn steering wheel during this time.
(19) Turn steering wheel left and right and check for
leaks. Add additional fluid as necessary.
S I N G L E LIP
D O U B L E LIP
SEAL
SEAL
Fig. 2L-10
60188
(12) Seat single lip seal and washer using Snap Ring
Tool J-21553. Install seal and washer only far enough to
provide clearance for remaining seal, backup washer,
retaining ring, and for clearance between seals. Do not
allow seal to bottom in housing bore.
CAUTION: To ensure proper seal action, be sure to
allow enough space for clearance between the two seals.
(13) Install double lip seal and backup washer in
housing bore using tool J-21553. Install seal only far
enough into bore to allow clearance for retaining ring.
(14) Install retaining ring using Snap Ring Tool J4245. Be sure ring is fully seated.
On Cherokee, Wagoneer and Truck models, the position of the steering gear prevents on-vehicle replacement of the end plug O-ring seal (fig. 2L-11).
>
LOCK NUT
SIDE COVER -
DAMPER
O-RING
GASKET -
ADJUSTER
P L U G LOCK
NUT
BALL R E T U R N
GUIDE H A L V E S
RETAINING
RING
DUST SEAL
OIL SEAL
O-RING
PITMAN A R M N U T
42099
Fig. 2 L - 1 1
(3) On CJ models, remove clamp bolt and nut attaching intermediate shaft coupling to steering gear
stub shaft and disconnect intermediate shaft.
(4) Paint alignment marks on pitman shaft and pitman arm for assembly reference.
(5) Remove and discard pitman arm nut and
lockwasher.
(6) Remove pitman arm using tool J-6632 (fig. 2L9).
(7) On Cherokee, Wagoneer, and Truck models, remove steering gear-to-frame mounting bolts and remove
gear.
(8) On CJ models, remove gear as follows:
(a) Raise left side of vehicle slightly to relieve
tension on left front spring and place support stand
under franue.
(b) Remove three lower steering gear mounting
bracket-to-frame bolts.
(c) Remove two upper steering gear mounting
bracket-to-crossmember bolts and remove steering gear
and mounting brackets as assembly.
(d) Remove mounting bracket-to-gear attaching
bolts and remove upper and lower mounting brackets
from steering gear.
21-22
I.
, <
li-iliHH^P *
42100
Fig. 2 U 2
Fig. ZL-13
2L-23
RACK PISTON
PITMAN SHAFT
A D J U S T I N G SCREW
LOCKNUT
80019
Fig. 2 U 5
' SPAMMER
WRENCH
J-7624
60189
Fig. 2 L - 1 4
, A4209
Fig. 2 L - 1 6
Adjuster Plug
ffiniwii
(c) Remove rack piston and arbor tool as assembly (fig. 2L-15).
(16) Remove adjuster plug locknut using brass drift
and hammer.
(17) Remove adjuster plug using Spanner Tool J-7624
(fig. 2L-16).
(18) Remove valve body from housing. Grasp stub
shaft and pull outward to remove.
(19) Remove wormshaft lower thrust bearing and .
bearing races from housing if not removed previously.
2L-24
Fig. 21-18
Fig. 2 L - 1 7
Inspect the housing bore. Replace the housing if severely worn, scored, or pitted. However, slight scratches
or minor corrosion can be removed using crocus cloth.
Inspect the pressure and return port hose connector
seats and check the poppet check valve in the pressure
port. Replace the seats if cracked, loose, cocked, worn, or
scored. Replace the check valve if scored, chipped,
cracked, or distorted. If seat or valve replacement is
necessary, refer to Hose Connector Seat and Check
Valve Replacement.
Inspect the housing ball plug (fig. 2L-19). Reseat the
ball if fluid leaked past the ball before disassembly or if
it has risen above the housing surface. If necessary,
drive the ball into the housing until it is flush with, or
1/16 inch (1.58 mm) below the housing surface. Secure
the ball by staking the housing around it. Replace the
housing if the ball is loose or cannot be reseated.
Inspect all retaining ring, bearing, and seal surfaces
in the housing. Replace the housing if any surface is
worn or damaged.
Hose Connector Seat and Check Valve Replacement
21-25
42123
Fig. 2 1 - 1 9
Fig. 2L-2Q
11-11
42108
Fig. 2L-23
RETAINING
RING
Adjuster Plug
THRUST
WASHER
RETAINER
6 0 1 9 2
Fig. 2L-24
Disassembly
(1) Remove thrust bearing retainer using screwdriver (fig. 2L-23). Discard retainer. Do not damage
needle bearing bore when removing retainer.
X.
Fig. 2L-26
Fig. 2L-25
2L-27
' A 4 2 1 1 1
2L-28
Valve Body
VALVE
BODY
Disassembly
60193
STUB
SHAFT
SHAFT
CAP
SPOOL
VALVE
TORSION
BAR
SPOOL V A L V E
L O C A T I N G PIN
O-RINGS (3)
I N S T A L L E D UNDER
T E F L O N RINGS
STUB S H A F T
O-RING'
60194
42113
Fig. 2L-30
Valve Body
CI@iiii| m l Inspection
Wash the valve body components In clean solvent and
blow out all fluid passages using filtered, compressed
air.
If the torsion bar is broken or loose, or if the torsion
seal leaked prior to disassembly, replace the entire valve
body as an assembly.
If the spool valve locating pin is broken or the valve
body is cracked, worn, or broken, replace the entire
valve body as an assembly.
NOTE: Tiny flat spots on either side of the spool valve
locating pin are normal.
Fig. 2L-31
2L-29
(4) Lubricate replacement spool valve damper 0 ring with petroleum jelly and install O-ring on spool
valve.
(5) Insert spool valve in valve body. Do not attempt
to force spool valve into place.
(6) Push spool valve through valve body until spool
valve locating pin hole is visible at opposite end of valve
body and spool valve is flush with notched end of valve
body.
(7) Install stub shaft in spool valve and valve body.
Be sure stub shaft locating pin is aligned with spool
valve locating hole (fig. 2L-29).
(8) Align notch in stub shaft cap with stub shaft
locating pin in valve body and press stub shaft and spool
valve into valve body (fig. 2L-32).
Assembly
2L-30
^^^^^
^^^^^^
^^^^^
^^
"
ADJUSTER SCREW
Fig. 2L-32
Fig. 2L-33
Clean the shaft and cover with solvent and wipe them
dry with lint free cloths.
Inspect the side cover bearing and mating surfaces for
wear, distortion, scoring, or distortion. Replace the
cover if it exhibits any of these conditions.
Inspect the pitman shaft bearing and seal surfaces
and sector teeth for cracks, wear, pitting, or scoring (fig.
2L-33). Inspect the adjuster screw for looseness, damaged threads, or distortion. Replace the pitman shaft if
any of these conditions are noted. However, light scoring, corrosion, or scratches on the shaft surfaces may be
removed using crocus cloth.
2L-31
:?
RETURN
GUIDE
CLAMP
SEAL RING
80493
y
42753
Fig. 21-34
2L-32
STUB
SHAFT
ARBOR
:i
TOOL
J-21552
LOWER
THRUST
BEARING
TOPS O F
CONES
MUST FACE
4 CONICAL T H R U S T
B E A R I N G RACES
BOTTOM OF
GEAR
A 4 2 1 0 3
Fig 2L-37
W O R M S H A F T L O C A T I N G PIN
SUPPORT BLOCK
Fig. 2L-36
42121
80494
Fig. 2L-38
FLUID
RETURN
PORT
80495
Fig. 2L-39
21-33
Fig. 2L-40
2L-34
Fif. 2141
instil! Hoisini
T U R N
EVEN
Fig. 2L-42
Remarking Housing
43
A T
A N
RATE
2L-3S
(1) Turn pitman shaft adjuster screw counterclockwise until screw is fully extended, then turn screw
back 1/2 turn clockwise.
(2) Rotate stub shaft from stop-to-stop and count
total number of turns.
(3) Starting from either stop, turn stub shaft back
1/2 total number of turns. This is gear center.
NOTE: When the gear is centered, the flat on the stub
shaft should face upward and be parallel with the side
cover (fig. 2L-44). In addition, the master spline on the
pitman shaft should be in line with the adjuster screw
(fig. 2L-J>5).
Fig. 2L-45
Fig. ZL-44
Fig. 2L-46
2L-36
SPECIFICATIONS
Needle Roller
Needle Roller
Needle Roller
Use Jeep Power Steering Fluid or
equivalent only. Do not use
transmission f l u i d .
Power Steering System Fluid Capacity
1-1/4 pints
(0.59 liters)
80499
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
Metric (N m)
. . . . . . .
. . . . . . .
.
. . . . . . .
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
85
45
30
70
55
30
30
70
185
33
6
50
40
75-95
40-50
25-35
60-80
50-65
25-35
25-35
60-80
170-210
27-37
4-10
45-55
30-45
115
61
41
95
75
41
31
95
251
45
8
68
54
102-129
54-68
34-47
81-108
68-88
34-47
34-47
81-108
230-285
37-50
5-14
61-75
41-61
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
80500
POWER STEERING P U M P
Page
Fluid Level ani Initial Operation
In-Vehicle Service
Pump Assembly
Pump Disassembly
Page
21-39
ZL-37
2L-41
2L-40
Pump Installation
Pump Removal
Specifications
2L-40
2L-39
21-43
IN-VEHICLE SERVICE
Pump Shaft Seal and Pump Pulley
Removal
42917
FI|.2L-47
Fig. 2 1 4 8
2L-38
..'4';%
ff
1 tension!
;GAUGE
* J-23600 |
TOOL
J-25033
42918
Fig. 21-50
??L"&V
Installation
Fig. 2L-52
2L-39
PUMP REMOVAL
(1) Loosen pump adjusting bracket bolts and nuts
and remove pump belt. Also remove air pump belt if
equipped.
(2) Disconnect pressure and return hoses at pump.
Cap hoses to prevent dirt entry.
(3) On models with eight-cylinder engine, remove
bolts attaching pump front mounting bracket to engine
and remove pump and bracket as assembly.
PUMP INSTALLATION
(1) On models with eight-cylinder engine, install
front mounting bracket on pump.
(2) On all models, position pump in mounting
bracket on engine and install pump-to-bracket attaching
bolts and nuts.
(3) Fill pump reservoir with power steering fluid
and turn pump pulley counterclockwise until bubbles no
longer appear in fluid.
(4) Install pump drive belt. Also install air pump
drive belt if equipped.
(5) Adjust belt tension. Pull back on adjuster
bracket with breaker bar until belt is tight. Tighten
adjusting bracket bolts.
(6) Check and adjust belt tension using Tension
Gauge J-23600 (fig. 2L-51). Refer to Belt Tension
Adjustment.
(7) Tighten all pump mounting bolts to 30 footpounds (41 Nm) torque.
(8) Fill pump reservoir and bleed air from power
steering system. Refer to Fluid Level and Initial
Operation.
POMP DISASSEMBLY
Fig. 2L-S3
'
Fig. 2L-54
2L-41
COUNTERSUNK
H O L E (FOR U N I O N S E A L )
COUNTERSUNK
H O L E (FOR
M O U N T I N G STUD
SEAL)
\
HOUSING
CORE PLUGS
// v . A
RESERVOIR
CRING SEAL
GROOVE
^
GROOVE 1
(FOR END P L A T E
R E T A I N I N G RING)
GHOOVE 3
(FOR SEAL)
GROOVE 2
<
>
F
A42132
PUMP ASSEMBLY
CAUTION: Do not allow dirt to enter the pump during
assembly. All parts must be clean and lubricated before
installation. Perform all assembly operations on a clean
work surface or a surface covered with clean, lint free
ARROW
TOWARDS
REAR
SHAFT
RETAINING
RING
60198
2L-42
DOWEL PIN
HOLE
CROSSOVER
HOLE
ARROW
ARROW
PUMP
RING
42135
42134
Fig. 21-5/
Fig. 2L-58
Fig. 2L-59
2L-43
SPECIFICITIONS
Power Steering P u m p Specifications
Pump Type
Fig. 21-61
Flow Control Mm
mi Spring Installation
2L-44
.
.
Metric (N)
New Belt*
Used Belt
New Belt*
Used Belt
125-155
125-155
125-155
65-75
125-155
125-155
125-155
90-115
90-115
90-115
60-70
90-115
90-115
90-115
556-689
556-689
556-689
291-334
556-689
556-689
556-689
400-512
400-512
400-512
267-311
400-512
400-512
400-512
*New belt specifications apply only to replacement belts. Once a belt has been tensioned and run, it is considered a used belt and should be adjusted
to used belt specifications.
80503
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
30
35
35
35
35
25-35
30-40
30-40
30-40
30-40
41
47
47
47
47
34-47
41-54
41-54
41-54
41-54
Hose Fittings
. . . .
Pump Adjusting Bolts-Nuts . .
Pump Mounting Bracket Bolts.
Pump Mounting Studs . . . . .
Pump Union Fitting
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
80504
Toois
J-4245
SNAP-RING PLIERS
J-21553
P I T M A N S H A F T SEAL
INSTALLER
J-6222
ADJUSTER PLUG
SEAL PROTECTOR
J-21552
RACK-PISTON ARBOR
J-6221
ADJUSTER PLUG
BEARING R E M O V E R
AND INSTALLER
J-21567
PRESSURE TESTING GAUGE
ASSEMBLY
J-21554
ADJUSTER PLUG
SEAL
INSTALLER
J-23600
BELT TENSION
* GAUGE
J-8642
SHAFT SEAL
PROTECTOR
CONNECTOR
SEAT I N S T A L L E R
J-8841
SEAL INSTALLER
J-8092
HANDLE
J-21551
PITMAN SHAFT
BEARING R E M O V E R
A N D INSTALLER
J-7754
T O R Q U E WRENCH
(0-25 INCH POUNDS)
J-6632
PITMAN ARM
PULLER
J-7624
SPANNER
WRENCH
8 0 5 0 1
H I
J-25034
REMOVER
J-8842
SEAL REMOVER
J-25033
INSTALLER
70356
2M-1
STEERING
LINKAGE
Page
Connecting Rod
Front Wheel Alignment
Front Wheel Shimmy
leneral
Page
21-3
Specifications
Steering Damper
Steering Wheel Spoke Alignment
Tie Rod
21-4
2M-5
2M-1
21-6
21-3
21-5
21-3
1ENERAL
The steering linkage consists of a steering gear pitman arm, a connecting rod, a tie rod, a steering damper,
and an integral steering arm and steering knuckle. Ball
ends and adjusting tubes are used on the tie rod and
connecting rod for toe-in adjustment and steering wheel
alignment (fig. 2M-1 and 2M-2).
Fig. 2 1 - 1
Steering LinkageCherokee-Wagoneer-Truck
2M-2
STEERING LINKAGE
.
^ '&zmx&'
.^^agB,^
Fig. 2 1 - 2
end. The steering damper is connected to a bracket clamped to the center of the tie rod.
The connecting rod (fig. 2M-4) is threaded on one end
and has a ball-end assembly at the opposite end. An
adjusting tube and removable ball end complete the
connecting rod assembly. On Cherokee, Wagoneer and
Truck models, the end having the integral ball end assembly is connected to the tie rod. On CJ models, it is
attached to the right hand steering arm. The threaded
end, with the adjusting tube and removable ball end, is
attached to the pitman arm.
STEERING LINKAGE
21-1
Til 111
RffllOVal
(1) Remove cotter plus and retaining nuts at both
ends of tie rod and from end of connecting rod where it
attaches to tie rod.
(2) Remove nut attaching steering damper push rod
to tie rod bracket and move damper aside.
(3) Remove tie rod ends from steering arms - and
connecting rod using puller.
'
\
NOTE; After removal, the tie rod ends can he removed
by loosening the adjusting tube clamp bolts and unthreading the ends.
Installation
(1) Attach tie rod ends to steering arms. Tighten
nuts to 50 foot-pounds (68 N*m) torque and install replacement cotter pins.
(2) Attach connecting rod to tie rod. Tighten nut to
80 foot-pounds (81 N*m) torque on CJ models and 70
foot-pounds (95 Nm) torque on Cherokee, Wagoneer
and Track. Install replacement cotter pin in retaining
nut.
(3) Attach steering damper to tie rod bracket.
(4) Adjust toe-in as necessary.
J42704
Fig. 2 1 - 1
Steering DamperCherokee-Wagoneer-Truck
STEERING
DAMPER-TOTIE ROD
BRACKET
Connecting Rii
The steering connecting rod can be removed by removing the cotter pins and nuts from both ball ends and
removing the rod. The steering connecting rod ball stud
ends cannot be disassembled for service.
When installing the steering connecting rod, place the
wheels in the straight-ahead position and place the
steering arm parallel to the centerline of the vehicle. The
steering gear pitman arm must be indexed with the
alignment marks on the pitman arm and steering gear
shaft and the steering gear must be centered. When the
steering arm is correctly positioned, install the connecting rod.
Steering i n p s r
The steering damper used on Cherokee, Wagoneer and
Truck models has mounting eyelets at each end (fig. 2M5). The damper used on CJ models has a mounting eyelet
at the body end only as the push rod is threaded to
accept a mounting bracket retaining nut (fig. 2M-6).The
body end of the damper attaches to a stud on a bracket
mounted between the left axle spring and axle spring
pad. The push rod end is attached to a bracket that is
clamped to the tie rod.
The steering damper is serviced as an assembly only.
If damaged or leaking, replace the damper. However,
the rubber mounting bushings used in the damper eyelets or on the push rod can be replaced individually if
necessary. .
'
Fig. 2M-6
Removal
ZM-4
STEERING LINKAGE
Camber
Refer to figure 2M-8. Correct wheel camber of 1-1/2
is preset in the front axle at the time of manufacture
and cannot be altered by adjustment. It is important
that camber be the same on both front wheels. Camber
angle should be checked using wheel alignment
equipment.
CAUTION: Do not attempt to adjust the camber angle
by heating or bending the axle or any suspension components. If camber is incorrect, the components) causing an incorrect camber angle should be replaced.
NOTE: Be sure all front suspension and steering system nuts and bolts are tight before checking wheel
alignment.
(9) Check caster, camber and toe-in.
Tii-li
J42706
Fig. 2 1 - 8
Caster
Refer to figure 2M-9. Axle caster is preset at + 3 for
CJ models and + 4 for Cherokee, Wagoneer and Truck
models. Caster should be checked using wheel alignment
VERTICAL
! [ ^ C A S T E R ANGLE
J42705
Fig. 2 M - 7
Fig. 2 1 - 9
J42707
STEERING LINKAGE
2M-5
2M-6
STEERING LINKAGE
SPECIFICATIONS
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Service
In-Use
Recheck
. Torque
Service
Set-To
Torque
Connecting Rod Clamp Bolt CJ
Connecting Rod Clamp Bolts Cke, Wag, T r k
Connecting Rod End-to-Tie Rod Nut (5/8-18)
Connecting Rod End-to-Pitman A r m Nut (9/16-18)
Pitman A r m to Pitman Shaft Nut
Steering Damper Locknuts Cke, Wag, Trk
Steering Damper Bracket U-Bolts CJ.
Steering Damper Locknut (3/8-24) CJ
Steering Damper Locknut (7/16-20) CJ
. .
Upper Ball Stud Retaining Nut and Lower Bolt Stud Jam Nut
Upper Ball Stud Split Ring Seat
Tie Rod Clamp Bolt (5/16-24) CJ
Tie Rod Clamp Bolt (7/16-14) Cke, Wag, T r k .
Tie Rod Stud Nuts - CJ
Tie Rod Stud Nuts - Cke, Wag, Trk
Wheel Nuts - CJ .
.
Wheel Nuts - Cke, Wag, J-10 T r k . . .
Wheel Nuts - J-20 Trk .
."
.
. . .
.
.......
. . . . . .
.
Metric (N-m).
12
30
70 min.
60 m i n .
185
30
12
22
30
100
50
12
30
40 min.
60 m i n .
105
75
125
10-15
25-35
#
*
160-210
24-36
8-15
16-28
24-36
10-15
25-35
*
90-115
65-80
100-150
Service
Set-To
Torque
16
41
95 m i n .
81 m i n .
251
41
16
30
41
136
68
16
41
54 m i n .
81 m i n .
142
102
169
Service
In-Use
Recheck
Torque
14-20
34-47
*
*
217-285
33-49
11-20
22-38
33-49
14-20
34-47
*
*
122-156
88-108
136-203
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
Tightened to castellated nut slot only. Do not loosen nut to obtain desired torque.
90070
8-1/2
. +3(+1)
+4(+1)
+1-1 /2(+1 / 2 )
3/64 to 3/32-inch
(1.19 t o 2.38 mm)
3 1 t o 32
3 7 to 3 8
80436
2N-1
SECTION
Page
Front Axle Windup Bumper
F r i l l Spring
general
l i i r Spring
-asm."
Page
2N-1
2N-3
2SJ-1
214
Shook Absorbers
Spring Bustling R e p l a c e d
Stabilizer lir
Torque Specifimthm
2N-1
2N7
2N3
2N-8
GENEiAL
Jeep vehicles are equipped with semi-elliptic leaf
springs and double-action hydraulic shock absorbers at
front and rear. A front axle stabilizer bar is standard on
Cherokee, Wagoneer, and J-10 Truck models with radial
tires and on 8400 GVWR J-20 Truck models and CJ
models with the molded hard top. A front stabilizer bar
is optional on all other Jeep models.
Front and rear suspension springs are mounted parallel to the frame side rails. The forward end of the front
springs and the rear end of the rear springs are attached
to the frame by pivoting shackles. The opposite spring
ends are attached to the frame by fixed pivot bolts. All
spring ends have silent block-type rubber , bushings
which do not require lubrication.
The front springs are mounted below the axle on all
Jeep vehicles. CJ models use multi-leaf front springs
(fig. 2N-1). Cherokee, Wagoneer, and Truck models use
tapered-leaf or multi-leaf front springs (fig. 2N-2).
The multi-leaf rear springs used on CJ models are
mounted below the axle (fig. 2N-3).
The rear springs used on Cherokee, Wagoneer, and
Truck models are either multi-leaf or tapered-leaf
springs and are mounted above the axle (fig. 2N-4).
The leaf springs on all Jeep models are attached to the
axle by U-bolts and tie plates and are positioned on the
axle by spring saddles welded to the axle tubes. Spring
center bolts and spring clips are used to align and hold
the spring leaves in position. If the vehicle is used for
severe, off-road operation, the springs should be examined periodically for broken or shifted leaves, loose or
missing clips, and broken center bolts.
Squeaking noises can be generated when movement
between the spring bushings and metal parts occurs.
This noise can usually be eliminated by tightening the
spring attaching bolts to the specified torque. However,
SHOCK ABSORBERS
The hydraulic, dual-action shock absorbers used on
Jeep vehicles are designed to control suspension spring
movement. The shock absorber upper ends are attached
to brackets located on the frame rails. The lower ends
are attached to the spring tie plate or axle tube. Rubber
bushings installed in the shock mounting eyes dampen
out road shock and noise.
Squeak noises from the shock bushings can be generated if movement between the bushings and metal parts
occurs. This noise can usually be eliminated by tightening the shock mounting nuts. However, if squeak
noises persist, check for damaged or worn bushings or
damaged shock mounting components. Repair as necessary if any of these conditions are discovered.
2N-2
SUSPENSION
a malfunction occurs, the shock absorber must be replaced as an assembly. To test a unit, hold it in an
upright position and work the shock piston up and down
four or five times. Shock action throughout each stroke
should be smooth and produce an equal amount of resistance in each direction.
SUSPENSION
n r
BF
~w
-^F
>w
'*gF
~W
TP
-^r
Tip
*W
IT
W " ~ T
2N-3
'T~f:
BUSHINGS
SHOCK
ABSORBER
SPRING
SHACKLE
BUSHING
SPRING EYE
BUSHING
TIE PLATE
REBOUND CLIP
60892
Fig. 21-2
STA11L1ZE11A1
..
FRONT SPRING
Removal
(1) Raise vehicle.
(2) Support vehicle using safety stands placed under frame rails.
(3) Position hydraulic jack under axle and raise axle
to relieve springs of axle weight.
(4) Disconnect stabilizer bar if equipped.
(5) Remove spring U-bolts and tie plates.
(6) Remove bolt attaching spring front eye to
shackle.
(7) Remove bolt attaching spring rear eye to spring
hanger.
(8) Remove spring.
N O T E : The spring can be disassembled by removing
the spring rebound clips and spring center bolt If the
spring bushings are to be removed, refer to Spring Bushing Replacement
2N-4
SUSPENSION
SHACKLE
PLATE
SPRING
HANGER
U-BOLT
REBOUND CLIPS
SPRING EYE
BUSHING
TIE PLATE
BUSHINGS
60693
Fig. 2N-3
Installation
(1) Position spring rear eye in hanger bracket and
loosely install attaching bolt and nut. Do not tighten
bolt at this time.
(2) Position spring front eye in shackle and loosely
install attaching bolt and nut. Do not tighten bolt at this
time.
(3) Position axle on spring and install spring tie
2N-6
SUSPENSION
mmmmM~JT'
ZEZZZJZ
"XTTJZT:
M A I N LEAF
REBOUND CLIP
C E N T E R BOLT
J42640
CONNECTING
LINK PIN
BRACKET
CONNECTING
LINK
CLAMP
J42641
Installation
REAR SPRING
Spring Mounted Below Axle
Removal
SUSPENSION
Spring Mounted Above Axis
Removal
2N-7
(3) Install one flat washer and one hex nut on rod
behind socket (fig. 2N-9).
(4) Install 2 inch (5.08 cm) long section of suitable
size pipe on opposite end of threaded rod. Pipe will serve
as bushing receiver.
NOTE: The inside diameter of the pipe must be large
enough to accommodate the bushing but still seat
against the spring eye surface properly.
(5) Install flat washer and hex nut on rod to secure
pipe section. Be sure flat washer is large enough in
diameter to support and maintain alignment of pipe
section.
(6) Tighten both hex nuts finger-tight and align all
components.
NOTE: Be sure socket is positioned in the spring eye
and aligns with the bushing. The pipe section must butt
against the spring eye surface so the bushing can pass
through it. The socket will act as a press ram and press
the bushing out of the spring eye.
3/8 H E X N U T
1
2 INCH LONG
PIPE SECTION
60697
Fig. 21-9
2N-8
SUSPENSION
Large Bushing
(1) Insert 1/2 by 11 Inch (1.27 by 27.9 cm) length of
threaded rod halfway through bushing.
(2) Install suitable size deep socket on one end of
rod with open end of socket toward bushing. Socket will
serve as bushing driver.
NOTE: The socket must be large enough in diameter to
bear against the metal outer sleeve on the bushing but
still be small enough to pass through the spring eye.
(3) Install one flat washer and one hex nut on rod
behind socket (fig. 2N-10).
60698
SPECIFICATIONS
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
35
45
100
24
100
55
100
35
85
85
130
35
55
25-40
35-50
80-120
18-30
85-105
45-65
80-120
27-45
65-90
65-90
110-150
25-40
48-62
47
61
136
33
136
75
136
47
115
115
176
47
75
34-54
47-68
108-163
24-41
115-142
61-88
108-163
37-61
88-122
88-122
149-203
34-54
65-84
A l l torque values given in foot-pounds and newton-meters w i t h dry fits unless otherwise specified.
60699
Water Leak/Wind
Section 2 - Chassis
3C
3D
~3e"
3F
3G
LitigatesTailgates
Doors ~
Rear Quarter 3K
Luggage Racks 3L
Seat Assemblies 3M
CHAPTE
INDEX
Section 1 - Power Plant
3A
3B
WindshieldRear Window
HeadliningHardtop EnclosureExterior Decals and Overlays
Lighting Systems
Horn Systems
Windshield Wipers
Tailgate Window Defogger
Radio Sound Systems
SECTION 3
fu-
3A-1
Page
General
3A-1
31-7
3A-5
GENERAL
The problem of water leaks is closely related to dust
leakage due to the fact that, under certain conditions,
water can enter the vehicle body at any point where dirt
and dust can enter.
The key to correcting any water leak problem is complete and accurate diagnosis. To do this a thorough
check of the following five general causes of leakage
must be accomplished:
Maladjusted components
I m p r o p e r l y i n s t a l l e d , m i s r o u t e d or f a u l t y
weatherstrips
Omission of sealers
Misfitted panels
Missing body plugs
Leaks can be deceiving. The point where water is
detected may not be the point where it entered the
vehicle.
Spraf list
The first thing to do on any water leak problem, is to
pin-point the leak. The best way to do this is to perform
a water spray test.
Sit inside the vehicle and have someone spray water
over the suspected leak area. Always start spraying
along the bottom. By starting at the bottom, the exact
level at which the leaks occur will be determined. If
water was sprayed at the highest point, water would be
at all suspect areas and it would be difficult to determine the exact problem area.
Pill
Water in Front Passenger Compartment
Water on Front or Rear Seats
Water in Rear Passenger Compartment
3A-2
3A-4
3A-6
Do not rush the water spray test. The water may have
to flow awhile before it shows up. Try to simulate as
close as possible the effect of wind-driven water.
Ultrasonic Test
Another way to test the vehicle for water leaks is use
the Listener Tool J-23455-01. This tool makes use of the
fact that ultrasonic energy (high frequency sound) has
certain properties that are similar to those of fluids
(liquids and gases). Ultrasonic energy does not penetrate .
solids, such as glass or metal. It is, however, transmitted
through cracks and openings, such as those that cause
body, water, or air leaks.
An operating ultrasonic generator placed inside an
automotive body will fill the vehicle with sound energy.
This energy will leak at the same locations that permit
water and air leaks. The water path or opening must be
dry since the ultrasonic sound will be blocked if an
opening or hole is full of water.
An ultrasonic generator and detector gun form an
ideal combination for determining the location and mag- '
nitude of water and air leaks. The ultrasonic leak detec- .
tor can be used effectively as a diagnostic tool realizing
it is not an exact tool and has certain limitations.
Light Test
Another method of finding water leaks is the light
test. This method is good for finding sealer skips in the
sheet metal joints and seams, particularly in the wheelhouse area. Sit inside the vehicle and have someone pass
3A-2
a bright light along the seams and joints from under the
vehicle.
Water/list Strtaks
Another thing to look for in diagnosing water leaks is
a pattern of rust or water streaks on interior sheet metal
and trim. For instance, a symptom of rear window leakage or inadequately sealed coach joint is water dripping
into the rear compartment. This will show up as water
or rust streaks on the rear compartment trim or
wheelhouse.
For the various materials to adhere and form an effective bond, it is essential that they are applied to clean,
dry surfaces. After a water test, dry the joint or seam
with clean dry compressed air then wipe the joint, or
seam, with a cloth dampened in 3M General Purpose
Adhesive Cleaner, or equivalent.
(3) If leaks are noted, dry out suspect area as described under Bonding Surface Preparation.
(4) Seal windshield as described in detail in Chapter
3N.
(5) Repeat spray test to ensure that an effective
repair has been made.
(6) Install windshield reveal mouldings.
Ultrasonic Diagnosis and Repair
(4) If leaks are noted, dry out suspect area as described above under Bonding Surface Preparation.
(5) Straighten any distorted flanges.
(6) Seal suspect spot weld burn holes and dash
panel joints using 3M Ail-Around Autobody Sealant, or
equivalent.
N O T E : Use care not to direct sealer into air ducts.
(7) Seal interior plenumn chamber leaks by attaching a length of flexible plastic hose to nozzle of applicator gun specified for use with 3M Joint and Seam
Sealer, or equivalent.
(8) Check all grommets to be sure they are correctly
installed. If necessary, apply sealant to ensure a water
tight seal.
(9) Make sure that all suspect components and attaching hardware are properly installed. If necessary,
apply sealant to ensure a water tight seal.
(10) Repeat spray test to ensure that an effective
repair has been made.
(11) Properly position sound insulation material and
carpet, if equipped.
(12) Close hood.
3A-3
(11) Make sure that all suspect components and attaching hardware are properly installed. If necessary,
apply above sealant to ensure a water tight seal.
(12) Repeat ultrasonic test to ensure that an effective repair has been made.
(13) Properly position sound insulation material and
carpet, if equipped.
(14) Close hood.
3A-4
(1) Perform the following spray test using guidelines described under Spray Test above.
^^^^ r
1ATER0PF IEADL1NER
Luggage Racks
Spray Diagnosis and Repair
3A-6
3A-7
NOTE: Before starting rear quarter window leak diagnosis, ensure that the rear quarter windows are properly
adjusted.
Spray Diagnosis and Repair
(1) Perform the following spray test using guidelines described under Spray Test above.
(a) Start a lower corner of liftgate or tailgate,
spray water between lower edge and body panel.
(b) Move slowly up to top of liftgate, or tailgate.
(c) Move to opposite lower corner and spray
between edge and adjacent body panel.
(d) Move slowly up to top of liftgate, or tailgate.
(e) Finally, test top edge to adjacent body
panel.
(2) If leaks are noted, dry out suspect area as described above under Bonding Surface Preparation.
(3) Examine rubber sealers for damage, distortion
or incorrect installation. Damaged or distorted rubber
sealers should be replaced, as outlined in Chapter 3H.
(4) Correct improperly installed rubber sealers as
outlined in Chapter 3H.
(5) In instances of leakage from spot weld burn
holes, apply 3M All-Around Autobody Sealant, or equivalent, and touch up with matching body color when dry.
(6) Repeat spray test to ensure that an effective
repair has been made.
3A-8
(10) Seal large suspect joints or seams using 3M Underseal Rubberized Undercoating, or equivalent.
(11) Examine suspect area for loose or missing body
plugs.
(a) Check for hardened sealer or road dirt preventing plug from seating.
(b) Check plug hole to be sure that it is not
distorted.
(c) If necessary, reshape floorpan or extension
panels locally and add a bead of sealant around hole to
ensure a satisfactory water tight seal.
(12) Replace damaged or distorted lamp housing gas-
3A-9
31-10
Lifigates-Tailgates Adjustments
3A-10
Read Test
Static Test
Window Adjustments
itiera! 3A-9
lEliiAL
A systematic diagnosis is necessary to isolate interior
wind noises. The spot where the noise is heard may not
be where the trouble really originates. Before proceeding with a noise diagnosis, consider the forces that
act on the vehicle to generate wind noise.
Air impacts the windshield and is forced around the
A-pillar and along the sides of the vehicle. This air
motion causes a low pressure area that moves along
with the vehicle near the A-pillar and along the sides of
the body.
At the same time, air rammed into the vehicle interior
by forward motion enters through the heating and ventilating to build a positive pressure inside the vehicle
which tends to force the window glass outward.
To maintain a weather-tight, noise-free seal against
these two forces, the doors and glass must be properly
maintained and adjusted.
STATIC TEST
Before beginning a static test, visually inspect the fit
of the doors, liftgates, tailgates and glass. Proper door,
liftgate, tailgate and glass adjustments will cure most
interior wind noise problems. Also, thoroughly inspect
all weatherstrips to make sure they are not damaged or
incorrectly installed. Correct improperly installed, misrouted or faulty weatherstrips.
Close all the doors, windows, and vents and turn the
blower motor on high. Use a stethoscope to listen for air
leakage in the suspected area. If the air leakage appears
to be excessive compared with the other side of the
vehicle, perform the necessary repairs to correct the air
leakage and recheck the repaired area.
3A-9
3A-9
3A-10
ROAD TEST
If the wind noise was not located and corrected during
the static test, it will be necessary to road test the
vehicle. Also, the vehicle should be road tested after
repairs are completed to verify that the problem has
3A-10
WATER
LEAK/m M E
i B g M l REPAIR
-,
DOOR ADJUSTMENTS
Refer to Chapter 3J for detailed procedures on door
adjustments.
LIFTGATE-TAILGATE ADJUSTMENTS
Refer to Chapter 3H for detailed procedures on liftgate-tailgate adjustments.
WINDOW ADJUSTMENTS
Refer to Chapter 3J and 3K for detailed procedures on
window adjustments.
- : ^ - t - W ^
. ; ~ r P 7 T ^ ^ ^ ^ ^
^ ^ ? - ^ 7 7 T ^ F ^
Page
Page
Body Mouldings 3A-11
Fender Mouldings 3 1 - 1 1
General 3A-10
GENERAL '
Noises generated by loose or unseated mouldings,
trim, vibrating grille components, etc., can be difficult
to diagnose. The most common noise is generally called a
"tea kettle" whistle and is usually due to air flowing,
under instead of around or over a moulding.
RIA1 TEST
There is no way to simulate the air flow that makes
exterior wind whistles, so a road test is usually necessary. Take along a roll of body tape to help isolate the
problem areas when they are located on the road test. It
is usually helpful to have an assistant drive the vehicle
or locate the noise. Road test the vehicle with the front
windows up and then down, to be sure the noise is
coming from outside the vehicle. Also, drive the vehicle
in both directions, as the prevailing wind could influence
Grille Area
Luggage Racks
Road Test
3A-10
3A-11
3A-10
GRILLE AREA
A process of elimination is the only system to use in
locating a wind whistle in the grille area. Make a wind
FENDER
Fender mouldings that are not properly aligned or
tightly seated to the fender can cause a wind whistle. If
this is the case, apply body tape to the suspected moulding and road test the vehicle. If the wind whistle has
been eliminated with the body tape, align and tighten
the moulding or fill the gap with a clear sealer.
BODY
Body or windshield reveal mouldings that are not
properly aligned or tightly seated can allow air to flow
LUGGAGE RACKS
Luggage racks present a problem area similar to the
grille area covered above. Make a deflector from cardboard, large enough to cover one-half the frontal area of
the luggage rack. Tape the deflector to the luggage rack
and road test the vehicle. If the wind whistle is still
there, move the deflector to the other side and repeat the
road test. After determining which side of the luggage
rack is causing the wind whistle, apply body tape to all
mouldings, supports and rails. Continue the road test
and progressively remove tape segments until the wind
whistle has been isolated. Align and tighten the mouldings, supports and rails or fill the gap(s) with clear
sealer.
Tools
70429
S310N
3B-1
META t REPAIR
AND PAINTING
SECTION
INDEX
Pigi
Finishing letal Replacement Parts
Finishing Plastic Trim Parts
Metal Repair
31-2
3B-3
3B-1
METAL REPAIR
The information contained herein provides instructions for bulge, crease and dent repair. The terms are
defined as follows:
Bulge-An impression in the metal from inside to
outside.
CreaseA depression in the metal up to 1/2-inch to
2 inches long or longer.
DentA depression in the metal larger than 1/4inch by 1/4-inch.
(1) Wash damaged area with mild detergent and
water to remove dirt.
(2) Clean repair area using wax and silicone remover, such as DuPont Prep-Sol, Ditzler Acryli-Clean,
or equivalent.
(3) Use a grinder to remove paint and to outline
damaged area.
(a) Use a grade 24 disc for initial grinding.
(b) Follow up with a grade 50 disc to prevent
coarse scratches from showing up in final finish.
(4) A bulge may require application of heat to
shrink metal.
(a) Heat metal bulge with an oxygen-acetylene
torch and immediately upset bulge area with a hammer
and dolly.
(b) Do not attempt to hammer bulge below original contour completely while metal is hot or metal will
be overshrunk.
(5) To restore contour of a bulge, crease or dent
after straightening and grinding, apply plastic body
filler, such as DuPont Polyester Autobody Filler, Ditzler
"999" Body Filler, 3M Plastic Filler, or equivalent. For
best results, mix plastic body filler and hardener according to manufacturer's instructions.
(6) Apply plastic filler with a plastic spreader. Use
firm pressure to aid in removing air bubbles which will
show up as pinholes.
Page
Metallic Color Guide
Paint Repair With Acrylic Enamel
Painting Tips
31-2
3B-1
3B-2
Painting Tips
70427
70428
undercoating.
313
Flexible Vinyl
Plastic Parts
painting
NOTES
3C-1
SECTION
INDEX
Page
rip
Cherokee-Wagoneer-Truck Instrument Panel
CJ Instrument Panel
3C-4
Page
Page
Cigar Lighter
Click
Crash Pal
General
Glove Box Assembly
3C-1
Instrument Cluster
Instrument Illumination
Instrument Panel
Speedometer
3C-4
3C4
3G-2
3C-1
3C-3
3C-1
3C-3
3C-1
3C-3
INSTRUMENT CLUSTER
GENERAL
Removal
CJ instrument panels are of formed sheet metal construction and are reinforced with braces and fastened to
adjacent body panels with screws.
A crash pad is available for CJ models and is attached
to the instrument panel (fig. 3C-1).
Installation
(1) Connect cluster lamps and electrical connectors.
(2) Position cluster on instrument panel and install
attaching screws.
(3) Connect speedometer cable.
(4) Connect battery negative cable.
INSTRUMENT PANEL
Removal
Fig. 3C-1
instrument Panel
3C-2
CRASH PAD
Removal
Hardtop
The glove box door hinge mounting holes are elongated to provide adjustment. The hinge screws may be
loosened and the door moved in the desired direction to
fit the door opening.
(1) Remove hinge-to-instrument panel attaching
screws.
(2) Remove door and hinge assembly.
Installation
INSTRUMENT ILLUMINATION
Instrument panel illumination is provided by three
bulbs in the instrument cluster, six molded lamps in the
instrument panel, and one bulb each in the voltmeter
and oil gauge. Protection for the panel bulbs and lamps
is provided by the 3-amp fuse located in the fuse panel.
The 3-amp fuse is fed from the headlamp switch through
a rheostat.
Do not pull on the bulb wires to remove the bulb
socket. Grasp the socket and pull straight out.
To remove the molded lamps, remove the wire connectors. Squeeze the lamp together at the top and bottom to release the small retaining tabs. Push the lamp
3C-3
SPEEDOMETER
Indication
(mph)
167
9 to 11
500
30 to 32.5
1000
60 to 63
1500
90 to 94
60599
anti-backup
spring
for
proper
3C-4
CLOCK
HOLD
THIS END
Fig. 3C-S
^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^AJ4?236
^^B
AdvaBeeEEeg Odometer Reads
^S^eamcml Oilyf
Hold the fifth separator and rotate the last five numerals in their normal direction until the desired sixth
digit is obtained. When the desired sixth digit is obtained, align the fourth separator in line with the fifth
separator. Rotate the last four numerals, repeating the
process until the desired total mileage is obtained. When
installing the odometer, the separators must straddle a
cross bar to maintain proper number alignment.
CIGAR LIGHTER
The cigar lighter is attaching to the bottom of the
instrument panel on all CJ models.
The lighter can be removed by removing the battery
feed wire and ground wire and unscrewing the shell that
surrounds the lighter.
The lighter circuit is protected with a 10-amp fuse
located at the fuse panel.
Page
Cigar Lighter
Clock
Page
3C-7
3C-7
Crash Pad
3C-5
Sineral
Glove Box I s s w l l f
3C-4
3C-S
Instrument Cluster
Instrument Illumination
Instrument Panel
Speedometer
3C-5
3C-6
3C-5
3C-7
GENERAL
Fig. 3C4
Instrument Panel
Installation
(1) Position cluster on instrument panel.
(2) Connect blend air door control cable.
(3) Connect electrical connectors and heater vacuum hoses.
(4) Install cluster attaching screws.
(5) Connect speedometer cable.
(6) Connect battery negative cable.
(7) Remove covering on steering column.
(8) Check heater and gauge operation.
INSTRUMENT PANEL
Removal
(1) Disconnect battery negative cable.
(2) Remove instrument panel crash pad, as outlined
in this chapter.
(3) Remove evaporator assembly and ducts, if
equipped with air conditioning.
(4) Remove instrument cluster.
(5) Remove radio, if equipped.
(6) Remove parking brake lever assembly.
(7) Remove air vent cables.
(8) Disconnect electrical connectors and remove
courtesy lights.
(9) Disconnect defroster hoses.
(10) Remove steering column trim panel.
(11) Remove bolt from center of brace and lower
steering column.
(12) Remove instrument panel attaching screws and
remove panel.
Installation
(1) Position instrument panel and install attaching
screws.
(2) Raise steering column and install bolt in center
of brace.
(3) Install steering column trim panel.
(4) Connect defroster hoses.
(5) Connect electrical connectors and courtesy
lights.
3C-5
CRASH PAD
Removal
(1) Remove windshield and windshield weatherstrip to expose crash pad retaining screws at base of
windshield (refer to Windshield RemovalChapter 3N).
(2) Remove instrument cluster.
(3) Remove glove box.
(4) Remove ashtray and retainer.
(5) Remove radio, if equipped.
(6) Remove crash pad-to-instrument panel attaching screws and nuts.
N O T E : The nuts are accessible through the cluster, ash
receiver, and glove box openings.
Installation
(1) Position crash pad on instrument panel.
(2) Install attaching screws and nuts.
(3) Install radio, if equipped.
(4) Install ashtray and retainer.
(5) Install glove box.
(6) Install instrument cluster.
(7) Install windshield weatherstrip and windshield
(refer to Windshield InstallationChapter 3N).
Installation
(1)
(2)
screws.
(3)
(4)
Removal
The glove box door hinge mounting holes are elongated to provide adjustment. The hinge screws may be
loosened and the door moved in the desired direction to
fit the door opening.
(1) Remove hinge-to-instrument panel attaching
screws.
N O T E : On vehicles equipped with air conditioning, the
evaporator housing must be lowered to obtain access to
the hinge-to4nstrument panel attaching screws.
(2) Remove door-to-hinge attaching screws.
(3) Remove hinges and glove box door.
Installation
INSTRUMENT ILLUMINATION
Four bulbs provide lighting for the instrument cluster
(fig. 3C-5) and two bulbs illuminate the heater control
panel. Panel lights are fed from the fuse panel through
the headlamp switch rheostat. To replace instrument
cluster bulbs, reach up behind the cluster, twist the bulb
socket counterclockwise (viewed from the rear) and pull
out. To replace the heater control panel bulb, pry the
bulb socket down to free the spring clip which attaches
the socket to the panel.
Striker Adjustment
The glove box door lock striker is attached to the
instrument panel opening with sheet metal screws. The
striker can be moved in or out for door closing
adjustment.
PRINTED CIRCUIT
T O CLUSTER CASE
G R O U N D SCREWS
HEATER C O N T R O L PANEL
BULBS G R O U N D W I R E
CONNECTION
FUEL G A U G E
PANEL
RIGHT
TURN
BRAKE
OIL GAUGE
HEATER C O N T R O L
PANEL
TEMP
CONTROL
LEVER
EMERGENCY
DRIVE
NOT USED
NOT USED
AMMETER
PANEL
PANEL
HI-BEAM
SPEEDOMETE R
TEMP GAUGE
PAN E L
TEMP
GAUGE
Fig. 3G-5
' R A D I O NOISE
SUPPRESSOR
CVR
TERMINAL
70499
SPEEDOMETER
HOLD
THIS E N D
SIXTH
DIGIT
'
FIFTH
SEPARATOR
*
SEPARATOR
R
Speedometer Calibration
Shaft Speed
(rpm)
Indication
(mph)
167
9 t o 11
500
30 t o 32.5
1000
60 t o 63
1500
9 0 t o 94
42236
Fig. 3C-6
Install
Install
Install
Install
anti-backup
spring
for
proper
CLOCK
The clock is attached to the instrument panel with two
nuts.
If the vehicle is not equipped with air conditioning,
the clock may be removed by reaching behind the instrument panel and removing the nuts.
If the vehicle is equipped with air conditioning, access
to the clock can be obtained by removing the glove box
liner attaching screws and pulling down the top portion
To reset the hands of the clock, pull out the adj"**"'
ment knob and rotate. Hands of a
fast-running^ &
should be turned backward, and slow-runninr
ks
forward. Allow 24-hours between adjustme^' ^ * k
speed will then be corrected automatically
two adjustments.
0(
c i o c
oc
c e r o
CIGAR LIGHTER
l
NOTES
30-1
HEATER
SECTION INDEX
Cherokee-Wagoneer-Truck Heater
CJ Heater
3D-6
3D-1
CJHEATER
Page
Blower lofor
Control Cables
Defroster Duct
Fan Control Switch
Fresh Air Intake Duct
MAX RIGHT
OFF LEFT
AIR
OFF HEAT VENT
WIPERS WASHES
TEMP
DEF
60357
Fig. 30-1
General
Heater and Defroster Operation
Heater Core
System Controls
3D-5
GENERAL
ry
tnn
3D-4
30-4
30-5
30-4
30-2
3D-1
30-2
30-4
30-1
with a controlled amount of cool, fresh air which bypasses the heater core. System controls and operation
are described in this section.
When servicing a malfunctioning heater system, refer
to the Service Diagnosis for a list of the possible causes
and recommended service procedures.
SYSTEM CONTROLS
The heater and defroster controls consist of a fan
control switch and three push-pull knobs and cable assemblies which are located on the instrument panel (fig.
3D-1).
The air control is a dual function control. When the
control is pulled to the first position (Heat), it opens a
door in the fresh air inlet to allow air to enter the heater.
When the control is pulled completely out (Vent), it
opens two additional doors (one in the left end of the
fresh air inlet and one on the right side of the heater) to
allow fresh air to enter the passenger compartment. A
new fresh air duct has been added to direct fresh air to
the driver's side.
The defrost control knob operates a door in the heater
housing which regulates heater and defroster operation
by directing the flow of air through the defroster hose or
floor outlet.
The temperature control knob adjusts the amount of
airflow around the heater core and through the heater
core air passages. This regulates the degree of heat entering the passenger compartment.
The fan control is a four-position control switch (Off,
Low, Med and High), which regulates the blower
motor and airflow for heat and defrost.
3D-2
HEATER
.HOSE
SCREW
BLOWER
MOTOR
CLAMP
DEFROSTER DUCT
HEATER
HOUSING
Fig. 30-2
HEATER
Fig. 3D-3
3D-3
Service Diagnosis
FAN MOTOR
WILL NOT RUN
AT ANY SPEED
(1)
(2)
(3)
(4)
(5)
(6)
(1)
(2)
(1)
(2)
(1)
(2)
(3)
(4)
WILL NOT D E F R O S T
Correction
Possible Cause
Condition
(1)
(2)
Blown fuse
Loose connection
Poor ground
Faulty switch
Faulty m o t o r
Faulty resistor
Faulty switch
Faulty resistor
Intake blocked
Fan n o t secured t o
motor shaft
Coolant does n o t reach
proper temperature
Heater core blocked
internally
Heater core air-bound
Blend-air door n o t in
proper position
Control cable adjustment
incorrect
Defroster hose damaged
(1)
(2)
(3)
(4)
(5)
(6)
(1)
(2)
(1)
(2)
Replace fuse
Inspect and tighten
Clean and tighten
Replace switch
Replace m o t o r
Replace resistor
Replace switch
Replace resistor
Clean intake
Tighten securely
30-4
HEATER
F i l CONTROL SWITCH
Replacement
(1) Disconnect cable from door and housing.
Removal
(1) Rotate knob until slot in neck of knob is visible.
Insert a small bladed screwdriver in the slot and depress
spring metal clip toward knob. This will relieve tension
on the spring metal clip and allow knob to slide off shaft
(fig.SD-4).
Removal
Fig. 3 0 4
installation
Iistilatiei
(1) Connect wires and position
instrument panel.
(2) Install trim ring and retaining nut.
(3) Install control knob.
switch
in
CONTROL CABLES
Adjustment
The only cable that is adjustable is the cable from the
air inlet linkage to the passenger vent door at the right
side of the heater. This cable has a turnbuckle adjustment located approximately six inches above the cable
attachment to the right side of the heater. Adjust this
cable until the passenger vent door is closed when the air
control knob is pushed in.
N O T E : If the cable is adjusted beyond the closed door
position it will cause a bind in the linkage and may
prevent the driver's vent door from closing.
^-
BLOWER M010R
The heater housing assembly must be removed to
replace the blower motor.
HEATE1
Removal
(1) Remove heater assembly as outlined above.
(2) Remove blower motor assembly-to-heater housing attaching screws and remove blower motor
assembly.
(13)
(14)
(15)
(16)
30-5
Installation
(1) Position blower motor assembly to heater housing and install attaching screws.
(2) Reinstall heater assembly as outlined above..
(3) Check blower m o t o r and h e a t e r control
operation.
DEFROSTER DUCT
Removal
(1.) Disconnect negative battery cable.
(2) Drain two quarts of antifreeze from radiator.
(3) Remove heater hoses.
(4) Remove drain tube from heater housing.
(5) Remove screws attaching evaporator housing to
instrument panel and lower housing. .
(6) Disconnect wiring from A / C switch.
(7) Remove screw attaching heater motor housing
to bracket.
(8) Remove nuts attaching heater housing-to-dash
panel from engine compartment.
(9) Disconnnect speedometer cable.
(10) Remove glove box.
(11) Tilt heater housing assembly back and pull to
rear and lower housing. *
(12) Disconnect heater control cables.
(13) Remove fresh air cover panel from cowl.
(14) Remove fresh air intake duct assembly.
(15) Lower windshield.
(16) Remove screws from defroster duct and remove
defroster duct and tube.
Installation
(1) Position defroster duct and install attaching
screws and tube.
(2) Raise windshield and secure.
(3) Install fresh air intake duct assembly.
(4) Install fresh air cover panel on cowl.
(5) Install heater control cables.
(6) Position heater housing assembly on dash panel.
(7) Install nuts attaching heater housing to dash
panel.
(8) Install glove box.
(9) Install speedometer cable.
(10) Install screw attaching heater housing to
bracket.
(11) Connect wiring to A/C switch.
(12) Install evaporator housing to instrument panel.
Installation
(1) Position defroster duct and install attaching
screws and tube.
(2) Raise windshield and secure.
(3) Install fresh air intake duct assembly.
(4) Install fresh air cover panel on cowl.
(5) Install heater control cables.
(6) Position heater housing assembly on dash panel.
(7) Install nuts attaching heater housing to dash
panel.
(8) Install glove box.
(9) Install speedometer cable.
(10) Install screw attaching heater housing to
bracket.
(11) Connect wiring to A/C switch.
(12) Install evaporator housing to instrument panel.
(13) Connect drain tube to heater housing.
(14) Connect heater hoses.
(15) Refill radiator.
(16) Connect negative battery cable.
3D-6
HEATER
Blower Motor
Control Cable
Fresh Air Ventilation
General
GENERAL
The blend-air type heater and defroster system is used
on all Cherokee, Wagoneer and Truck models. The
blend-air method of heating uses a constant flow system
with engine coolant continuously flowing through the
heater core. The temperature of the heated air entering
the passenger compartment is controlled by regulating
the quantity of air which flows through the heater core
air passages, then blending it with a controlled amount
of cool, fresh air which bypasses the heater core. System
controls and operation are described in this section.
When servicing a malfunctioning heater system, refer
to the Service Diagnosis for a list of the possible causes
and recommended service procedures.
SYSTEM CONTROLS
The heater and defroster controls consists of a fan
control switch, a vacuum control switch operated by
three pushbuttons, and a slide temperature control lever
(fig.3D-5).
SCREW
TUBE
FAN
CONTROL
SWITCH
VACUUM
CONTROL
SWITCH
TUBE
DEFROST
TUBE
TEMPERATURE
CONTROL
CABLE
HEAT
CLIP
Fig. 3D-5
TEMPERATURE
CONTROL
SWITCH
J 4 2 6 3 5
3D-6
3D-7
3D-9
3D-6
HEATER 3D-7
JK-i
- . I Z Z Z A G Z U I
:IASIG~ZZIZZ^^
y:mm
Installation
(1)
(2)
(3)
(4)
(5)
(6)
(LOUVER)
Fig. 30-7
J42630
Service Diagnosis
Possible Cause
Condition
FAN MOTOR
WILL NOT RUN
AT ANY SPEED
(1)
(2)
(3)
(4)
(5)
(6)
(1)
(2)
(1)
(2)
(3)
Blown fuse
Loose connection
Poor ground
Faulty switch
Faulty m o t o r
Faulty resistor
Faulty switch
Faulty resistor
Intake blocked
Fan n o t secured t o
m o t o r shaft
Inlet door n o t opening
Correction
(1)
(2)
(3)
(4)
(5)
(6)
(1)
(2)
(1)
(2)
Replace fuse
Inspect and tighten
Clean and tighten
Replace switch
Replace m o t o r
Replace resistor
Replace switch
Replace resistor
Clean intake
Tighten securely
i
80587B
CONTROL CABLE
Adjustment
Replacement
(1)
(2)
(3)
(4)
(5)
switch.
location
HEATER
(17)
(18)
(19)
(20)
(21)
(22)
(23)
HEATER CORE
Removes
(1) Drain approximately two quarts of coolant from
radiator.
(2) Disconnect temperature control cable from
blend-air door.
(3) Disconnect heater hoses at heater core.
(4) Disconnect blower motor resistor wires.
(5) Remove heater core housing to dash panel attaching nuts.
(6) Remove heater core housing assembly.
(7) Remove attaching screws holding housing
halves together and separate housing.
(8) Remove heater core to housing attaching screws
and remove core.
3D-9
Installation
(1) Position heater core in housing and install attaching screws.
(2) Seal and assemble two halves of heater core
housing and install attaching screws.
(3) Position heater core housing on dash panel and
install attaching nuts.
(4) Connect heater resistor wires.
(5) Connect heater hoses.
(6) Connect temperature control cable to blend air
door.
(7) Replace coolant.
(8) Check heater operation.
1L01ER I0T0R
Removal
(1) Disconnect blower motor electrical connector.
(2) Remove blower motor-to-blower motor housing
attaching screws and remove blower motor and fan
assembly.
installation
(1)
blower
(2)
(3)
NOTES
3E-1
ME
CONDITIONING
SECTION INDEX
Pag
Cherokee-Wagoneer-Truck Models 3E-25
CJ Models 3E-22
General Information 3E-1
3E-2
3E 21
GENERAL INFORMATION
Pill
Pl|l
System Components
3E-1
SYSTEM COMPONENTS
CompressorThe compressor is a two-cylinder, beltdriven pump used to circulate and increase the pressure
of the refrigerant in the system.
CondenserThe condenser is mounted in front of the
radiator to allow air to flow over the cooling fins and
remove heat from the refrigerant. As the refrigerant
passes through the condenser, it liquifies (condenses).
Receiver/DrierThe receiver/drier is a reservoir
used to store the precise amount of refrigerant required
by the system. The refrigerant level in the receiver/drier, must be adequate to provide a steady flow of
refrigerant to the expansion valve. The receiver/drier
contains a desiccant to remove moisture from the system. The receiver/drier must be replaced anytime the
system has been open to atmosphere due to a system
component failure. If the charge is lost, the receiver/drier opening should be tightly capped immediately.
Expansion ValveThe thermostatic expansion valve
is located at the inlet of the evaporator. It meters the
refrigerant to the evaporator to maintain proper flow
for the various evaporator heat load requirements encountered during operation. The metering action of the
expansion valve is controlled by the temperature sensing bulb mounted on the outlet (suction) line of the
evaporator.
System Operation
31-1
SYSTEM OPERATION
The compressor increases the pressure and temperature of the system refrigerant (fig. 3E-1). The heated
refrigerant vapor is then pumped into the condenser
where it cools by giving off heat to air passing over the
condenser fins. As the refrigerant cools in the condenser, it condenses into a liquid. Still under high pressure, the liquid refrigerant passes into the receiver. The
receiver acts as a reservoir to furnish refrigerant to the
expansion valve at all times. From the receiver, the high
pressure liquid refrigerant passes to the expansion
valve. The expansion valve meters refrigerant into the
evaporator where a low pressure is maintained by the
suction side of the compressor. As it enters the evaporator, the refrigerant immediately begins to boil by absorbing heat from the air passing over the evaporator
core. Having given up its heat to boil the refrigerant, the
air is cooled and passes into the passenger compartment
of the vehicle. From the evaporator the vaporized refrigerant is drawn back to the compressor to repeat the
cycle.
3E-2
AIR CONDITIONING
THERMOSTAT
EXPANSION
THERMAL
TO F A N SWITCH
VALVE
BULB
EXPANSION V A L V E
TO
MAGNETIC
CLUTCH
SIGHT
GLASS
COMPOUND
GAUGE
SUCTION
GAUGE
CONNECTION
SUCTION
RECEIVER
DRYER
SERVICE
VALVE
COMPRESSOR
SCREEN
LOW PRESSURE G A S
T H E R M A L BULB PRESSURE
LOW PRESSURE L I Q U I D
Fig. 3E-1
41488
Refrigeration Cycle
GENERAL SERVICE
PROCEDURES
Compressor 3E-11
General
3E-2
Sight Glass
3E-6
GENERAL
to touch
Refrigerant will tarnish bright metal and chrome surfaces. Avoid splashing refrigerant on any surface. Refrigerant in combination with moisture is very corrosive
and can cause great damage to all metal surfaces.
SERVICE VALVES
The discharge and suction service valves are mounted
on the compressor cylinder head and are used for diagnosis, charging, discharging, evacuating, and component
removal.
The service valves are three-position valves (fig. 3E-2).
The normal operating position, shown in figure 3E-2,
View B, has the valve stem turned counterclockwise to
the back-seated (full-out) position.
- When the valve stem is turned clockwise to the frontseated (full-in) position (fig. 3E-2, View A), the compressor is isolated from the system. This position is used
when removing the compressor or when checking compressor oil level.
1 - TO SERVICE PORT
2 - T O HOSE
3 - T O COMPRESSOR
area.
V I E W C - MiDiPOSlTIONEP
AJ41483
H I G H SIDE GAUGE
MANIFOLD
Manifold
The gauges are connected into the air conditioning
system through a manifold (fig. 3E-3). The manifold has
three connections. The low side hose and fitting is connected directly below the low side gauge. The high side
hose and fitting is connected below the high side gauge.
AIR CONDITIONING
3E-5
Relative
Humidity
(percent)
20
30
40
50
60
70
80
90
Surrounding
Air
Temperature
(F)
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
Engine
Speed
(RPM)
Maximum
Desirable
Center
Register
Discharge
Air Temp.
( F)
Suction
Pressure
PSI
(REF)
Head
Pressure
PSI
( + 2 5 PSI)
40
41
42
43
11
15
20
23
177
208
226
255
40
41
42
44
12
16
22
26
181
214
234
267
40
42
43
44
13
18
23
26
185
220
243
278
40
42
44
46
14
19
25
27
189
226
25'1
289
41
43
45
46
15
21
25
28
193
233
259
300
41
43
45
46
16
22
26
29
198
238
267
312
1500
42
44
47
18
23
27
202
244
277
1500
42
47
48
19
24
28
206
250
284
1500
1500
1500
1500
1500
1500
'Operate engine with transmission in neutral. Keep vehicle out of direct sunlight.
70143
3E-B
AIR CONDITIONING
mm suss
A sight glass Is Incorporated In the receiver-to-evaporator hose at the receiver end (fig. 3E-4) or in the top of
the receiver/drier. The sight glass provides a visual
check of the system refrigerant level A continuous
stream of bubbles will appear in the sight glass of a
system which is NOT properly charged. Properly
charged and completely discharged systems will appear
similar through the sight glass because of .a lack of
bubbles. To distinguish between the two situations;
cycle the magnetic clutch OFF and ON with the engine
running at 1500 rpm. During the time the clutch is off,
bubbles will appear if the refrigerant is in the system
and will disappear when the clutch is on. If no bubbles
appear when cycling the magnetic clutch, there is no
refrigerant in the system since some bubbles would appear in a fully charged system. If the system is discharged, it will be necessary to leak test, repair as
required, evacuate, and charge the system.
mm
jCOMPOUND
GAUGE
SERV5CE
VALVE
'HIGH
i PRESSURE
^GAUGE
>
P
EVACUATING SYSTEM
^^^^^^^^^^^^^^^801781
CJ
m/E^^^^^/^j/^SjSt 80385 j
CHEROKEE-WAGONEER-TRUCK
DISCHARGING SYSTEM
Refrigerant should be discharged from the system
before replacing any part in the system except when
servicing the compressor.
(1) Connect pressure gauge and manifold assembly
to proper service valves.
(2) Turn both manifold hand valves to maximum
counterclockwise (open) position.
(3) Open both service valves a slight amount (from
back seated position) and allow refrigerant to discharge
slowly from system (fig. 3E-5).
off. At an ambient temperature of 75F, when the desired vacuum of 29.5 inches of H g is reached, water will
boil at approximately 54F and a complete boiling off of
all moisture in the system is assured when this vacuum
reading has been reached.
At altitudes higher than sea level, it will not be possible to obtain a vacuum reading of 29.5 inches of Hg on
the low side compound gauge. For each 1,000 feet of
altitude, the vacuum gauge must be corrected by one
inch of Hg to compensate for a change in atmospheric
pressure. For example, at altitudes of 1,000 feet, a gauge
reading of 28.5 inches of Hg will be the same as a gauge
reading of 29.5 inches of Hg at sea level. When this
vacuum is reached, a minimum of 30 minutes should be
allowed in evacuating the system to ensure complete
moisture removal.
COMPOUND!./HIGHPRESSURE!
'
GAUGE
GAUGE
I DISCHARGE;
J CENTER
';.
<"
;SUCTION ;
-SERVICE
'
!SERVICE
. SERVBCE
VALVE
'
!HOSE
; VALVE
Fig. 3E-6
The J-23500-01 Portable Air Conditioning Service Station (fig. 3E-7) is a completely portable station equipped
with vacuum pump, metering-charging cylinder, refrigerant supply, gauges, hoses and hand control valves.
'
.
' -
;' j 7 0 5 2 5
(2) Connect red charging hose to compressor discharge service on compressor and connect blue charging
hose to compressor- suction service valve.
(3) Open both discharge and suction service valves
to mid position. Fully open high and low pressure valves
on charging station.
(4) Connect power pack cord to HOv wall outlet.
(5) Connect vacuum pump power cord to 110 volt
pump receptacle on power pack, and switch vacuum
pump on.
(6) Completely open vacuum pump valve.
(7) Operate pump until blue compound gauge on
manifold indicates 29 inches of vacuum. Continue to
operate pump for 30 minutes after system reaches 29
inches. It is recommended that a thermistor vacuum
gauge be used to obtain a more precise vacuum reading.
(8) Fill charging cylinder, as described below, while
system is evacuating.
(9) After evacuating system, close valve on vacuum
pump and stop pump. Observe blue compound gauge to
determine if a leak exists. System is now ready for
charging.
/
3E-8
AIR CONDITIONING
M I C
RED H I G H
PRESSURE
GAUGE
HIGH
PRESSURE
VALVE
CYLINDER
GAUGE
TOP
CYLINDER
VALVE
CHARGING
CYLINDER
PLASTIC
SHROUD
LIQUID
SIGHT
GLASS
REFRIGERANT
CONTROL
VALVES
REFRIGERANT
HEATER
SWITCH
8 0 6 8 3
OR FUMES
poisonous.
FROM
THE
HA-
AIES CONDITIONING
3E-9
(3) Move flexible probe slowly under suspected connections, joints, and seals. R-12 refregerant is heavier
than air, leaks may be detected more readily on lower
side of areas being checked.
(4) When a leak is found, its presence will be indicated by the white signal light.
NOTE: If probe tip is held too long on the leak, the
white signal light will go out.
(5) Repair leaks, as required.
(6) Evacuate system after all leaks are corrected.
(7) Charge system.
CHARGING T H E SYSTEM
Before making a complete charge, check the compressor oil level, leak test if necessary, and evacuate the
system.
Charge Capacity
The recommended charge for the respective systems
is as follows: CJ2-1/2 pounds R-12; Cherokee, Wagoneer and Truck2-1/4 pounds R-12. Capacities are also
indicated on a decal attached to compressor.
Charging Procedure with J-6272-02
Opener
Multl-Rifriginil Can
eyes.
(1) Connect Pressure Gauge and Manifold Assembly J-23575 and evacuate system. Keep both service
valves in mid or cracked position.
(2) Close both gauge hand valves.
(3) Disconnect service hose from vacuum pump and
connect it to center of Multi- Refrigerant Can Opener J6272-02. Close four petcock valves on dispenser.
(4) Attach necessary number of refrigerant cans to
opener. Refer to Charge Capacity for proper weight of
refrigerant necessary to charge vehicle being serviced.
(5) Open one petcock valve. Loosen center service
hose at Pressure Gauge and Manifold Assembly allowing refrigerant to purge air from line. Tighten service
hose connection and close petcock valve.
-.W
COMPRESSOR
The compressor is the belt-driven, two-cylinder reciprocating type. It is attached to the engine with a mounting bracket as shown in figures 3E-10 and 3E-11.
W ~ "
"
~ ~ ~ W ~
W " !
IDLER
Fig. 31*11
Compressor MountingSii-Cflliiir
Fig. 3E-10
Compressor MountingElght-Cylleadr
3E-12 J R C l l i l T l O i i l
Compressor InstallationEight-Cylinder
(1) Install mounting bracket to compressor.
(2) Install compressor and bracket assembly to
engine.
(3) Install alternator mounting bracket, if removed.
(4) Install compressor drive belt(s) and adjust to
proper tension.
(5) Attach compressor service valves and lines.
(6) Purge compressor of air and open service valves.
(7) Connect clutch wire.
Compressor RemoalSii-Cyiinder
(1) Isolate compressor.
(2) Remove both service valves and cap compressor
and valves.
(3) Loosen compressor belt and move aside.
(4) Remove alternator belt and adjusting bolt.
(5) Remove upper alternator mounting bolt.
(6) Loosen lower alternator mounting nut.
(7) Remove back idler.
(8) Remove compressor mounting nuts and remove
compressor.
It is not necessary to discharge the system for compressor removal. The compressor can be isolated from
the remainder of the system, eliminating the need for
recharging when performing compressor service.
(1) Connect Pressure Gauge and Manifold Assembly J-23575.
(2) Close both gauge hand valves and mid-position
(crack) both service valves.
(3) Start engine and operate air conditioning.
(4) Turn suction service valve slowly clockwise toward front-seated position. When suction pressure is
reduced to zero or less, stop engine and compressor and
quickly finish front-seating suction service valve.
(5) Front-seat discharge service valve.
(6) Loosen oil check plug slowly to release any internal pressure in compressor. The compressor is now isolated from remainder of system. Service valves can be
removed from compressor.
Compressor RemovalEight-Cylinder
Compressor InstallationSix-Cylinder
(1) Position compressor and install mounting nuts.
(2) Install back idler.
(3) Install alternator upper mounting bolt.
(4) Tighten lower mounting nut.
(5) Install alternator adjusting bolt.
(6) Install alternator drive belt and adjust to proper
tension.
(7) Install compressor drive belt and adjust to
proper tension.
(8) Attach compressor service valves and lines.
(9) Purge compressor of air and open service valves.
(10) Connect clutch wire.
AIR CONDITIONING
COMPRESSOR
Fig. 3E-12
3E-13
O I L CHECK
AJ41500
3E-14
AIR CONDITIONING
Fig. 3E-13
AIR CONDITIONING
3E-15
.MAX
1-3/16
MIN
13/16
1-3/4 V ^
\ ^
T H I S E N D FOR
HORIZONTALLY
MOUNTED
COMPRESSORS
A J 4 1 5 0 2
Fig.
3E-14
Fig.
3E-1S
T H I S END FOR
VERTICALLY
MOUNTED
COMPRESSORS
I' '*
M I N 7/8
A J 4 1 5 0 3
3E-16
AIR CONDITIONING
FLUSHING SYSTEM
Electrical Diagnosis
Flushing Procedure
state.
eyes.
MAGNETIC CLUTCH
The magnetic clutch consists of a stationary electromagnetic coil and a rotating pulley and plate assembly.
The electromagnetic coil is mounted on four bosses on
the compressor. The pulley and plate assembly is
mounted on the compressor shaft. When the air conditioner is off, the pulley is free to turn on the clutch hub
bearing. When the clutch is energized, the plate is magnetically attracted to the pulley and turns the compressor crankshaft.
Clutch Renewal
(1) Remove compressor belt(s).
(2) Energize the clutch or use a spanner wrench to
hold clutch plate while removing the clutch-to-shaft attaching bolt and washer.
(3) Install a 5/8 inch by 11 standard thread bolt in
the threaded center of the clutch plate.
(4) Tighten bolt and pull clutch from shaft.
CAUTION: Do not pry on clutch to remove.
(5) Remove four capscrews which attach magnetic
coil and disconnect coil wire. Remove coil.
Clutch Installation
(1) Install magnetic coil with four special capscrews
provided with replacement unit. These capscrews are
used to ensure coil is positioned properly on compressor.
(2) Tighten capscrews to 7 to 10 foot-pounds (9 to 13
Nm) torque.
(3) Align clutch assembly with key and install
clutch on shaft.
(4) Install clutch-to-shaft attaching washer and bolt
and tighten to 20 foot-pounds (27 N*m) torque. Connect
clutch coil wire and energize clutch to hold unit when
tightening.
(5) Install compressor belt(s) and adjust belt tension to specifications.
System Troubleshooting
PRELIMINARY
DIAGNOSIS
CONTROLS
AIR LEAKS
MAGNETIC CLUTCH
BLOWER
AIR DISCHARGE
Check A d j u s t m e n t s
Check
Refer t o Magnetic
Check at all
C O N N E C T I N G DUCTS
Vents
Clutch Troubleshooting
speeds
D o o r seals
Charts
W i n d o w seals
REFRIGERATION
SYSTEM
DIAGNOSIS
CHECK DISCHARGE A I R T E M P E R A T U R E
Set t h e r m o s t a t at m a x cool
Set engine speed at 1 5 0 0 r p m
C h e c k discharge air t e m p e r a t u r e w i t h
thermometer
Discharge air t e m p e r a t u r e must correspond t o a m b i e n t air t e m p e r a t u r e
as s h o w n in N o r m a l O p e r a t i n g T e m p eratures a n d Pressures Chart
S y s t e m cools
S y s t e m does
S y s t e m cycles
a n d cycles
not cool or
but at incorrect
Check t h e r m o s t a t
properly
cycle
temperature
capillary t u b e f o r
proper i n s t a l l a t i o n .
Install correctly a n d
recheck discharge
air t e m p e r a t u r e .
Install gauges a n d
check pressures
t o diagnose p r o b -
l e m . See Pressure
Diagnosis Chart t o
correct.
System cycles
but at incorrect
temperature
Replace
Road test t o verify proper o p e r a t i o n
thermostat
70526
3E-18
AIR CONDITIONING
2 . Place t h e i g n i t i o n s w i t c h in o n p o s i t i o n .
3.
Clutch inoperative
C o n n e c t a j u m p e r w i r e f r o m t h e b a t t e r y t o t h e c l u t c h lead
harness w i r e t e r m i n a l in t h e engine c o m p a r t m e n t .
C l u t c h inoperative
C l u t c h operates
C l u t c h Coil F a u l t y
Clutch inoperative.
C l u t c h operates
Clutch operates.
Clutch inoperative.
Open circuit in
light blue wire.
C l u t c h operates
Clutch inoperative
Faulty thermostat.
Clutch operates.
C l u t c h operates
C o n n e c t j u m p e r w i r e t o center ( f e e d )
terminal on fan switch.
Clutch inoperative
Clutch inoperative.
Open circuit
in brown wire.
C l u t c h operates
Clutch inoperative
Wire t o switch f a u l t y
Switch defective
70527
AIR CONDITIONING
3E-19
Correction
Possible Cause
Condition
(1)
Broken valves.
a)
(2)
Overcharged.
(2)
(3)
(3)
(4)
Piston slap.
(4)
Replace compressor.
(5)
Broken rings.
(5)
Replace compressor.
(1)
(1)
(2)
Clutch loose.
(2)
Tighten clutch.
(3)
Overcharged.
(3)
(4)
Pulley misaligned.
(4)
Align pulley.
CONDENSATION
DRIPPING
IN PASSENGER
COMPARTMENT
(1)
(1)
(2)
Insulation removed or
improperly installed.
(2)
FROZEN
EVAPORATOR COIL
(1)
Faulty thermostat.
(!)
Replace thermostat.
(2)
(2)
COMPRESSOR NOISE
EXCESSIVE
VIBRATION
70522
3E-20
AIR CONDITIONING
Possible Cause
Condition
Correction
(1)
System refrigerant l o w .
(1)
(.1)
(1)
(2)
(2)
(3)
Expansion valve.
(3)
(4)
(4)
(1)
(1)
(2)
Air in system.
(2)
(3)
Expansion valve.
(3)
(4)
(4)
(1)
Expansion valve.
(1)
(2)
(2)
(3)
Restriction in receiver.
(3)
Replace receiver.
(4)
Restriction in condenser.
(4)
Replace condenser.
(1)
Air in system.
(1)
(2)
Moisture in system.
(2)
70523
3E-22
AID CONDITIONING
CJ A I R C O N D I T I O N I N G
Pill
Condenser and Receiver/Dryer Assembly
Control Operation
Control Panel
GENERAL
When driving at normal highway speeds the CJ air
conditioning system (fig. 3E-16) will provide maximum
efficiency. However, when operating under stop-and-go
city driving conditions, a slight reduction in cooling efficiency generally will be experienced.
FAN CONTROL
KNOB
Page
3E-23
3E-22
3E-22
TEMPERATURE
C O N T R O L KNOB
3E-23
3E-25
3E-22
ADJUSTABLE A! R
OUTLETLOUVERS
Fig. 3E-16
Fan Switch
The fan switch may be serviced by removing the access plate located on the lower evaporator core housing
below the control panel.
AIR CONDITIONING
(3)
(4)
(5)
(6)
3E-23
slowly
to prevent
loss of
compressor oil
(2) Disconnect evaporator and condenser lines from
receiver/dryer.
(?) Remove attaching screws from receiver/dryer
bracket and remove receiver/dryer.
Installation
Fi|.3E-17
could
cause
the thermostat
to
Removal
(1) Discharge refrigerant from system.
slowly
to prevent
loss of
compressor oil.
to
Fig. 3 E - 1 8
3E-24
AIR CONDITIONING
Fig. 3E-19
AIR CONDITIONING
N O T E ; It
service the
be lowered
the blower
Installation
(1) Push hoses through grommet opening, and install grommet by pushing toward engine compartment
of vehicle and fasten to dash panel- with two attaching
screws.
(2) Raise evaporator and install evaporator-housing-to-instrument-panel attaching screws and the evaporator-to-mounting-bracket screw.
(3) Install hose clamps and grommet attaching
screws.
(4) Connect receiver/dryer-to-evaporator hose.
3E-25
Page
Condenser and Receiver/Dryer Assembly
Control Operation
Control Panel
3E-26
3E-26
3E-26
GENERAL
When driving at normal highway speeds the Jeep air
conditioning system will provide maximum efficiency.
However, when operating under stop-and-go city driving
conditions a slight reduction in cooling efficiency generally will be experienced.
It is recommended that intermediate temperature and
high fan setting be used for average city driving and
intermediate temperature and medium fan setting for
highway driving.
The air conditioning system, as shown for the Wagoneer in figure 3E-20, is applicable to Cherokee and Truck
models.
When driving at relatively high speed for an extended
period of time, the cooling coil may possibly frost over,
resulting in a temporary loss of cooling. Should this
occur, simply turn the TEMP knob to OFF and allow the
blower to operate for a few minutes to allow the cooling
coil to defrost. Then turn the TEMP knob to a setting
which is not as cold as the setting at which frosting
occurred.
3E-27
3E-Z7
3E-25
ADJUSTABLE
OUTLET
AIR
LOUVERS
Fig. 3E-20
3E-26
AIR CONDITIONING
CONTROL PANEL
Fan Switch
The fan switch may be serviced by removing the access plate located on the lower evaporator core housing
below the control panel.
INSULATION
CONTROL OPERATION
CAPILLARY
TUBE - INSERT
INTO COIL M I N .
2 INCHES
41094
Fig. 3 E - 2 1
Removal
(1) Discharge refrigerant from system.
NOTE: Discharge
compressor oil
system
slowly
to prevent
loss of
AIR CONDITIONING
3E-27
Installation
(1) If removed, install receiver/dryer to condenser.
(2) Place condenser in position and connect receiver/dryer-to-evaporator hose at receiver/dryer.
(3) Install condenser attaching screws.
(4) Connect pressure line at condenser.
(5) Install radiator and fan shroud.
(6) Fill radiator.
(7) Evacuate, leak test, and charge system.
RECEIVER/DRYER
Removal
(1) Discharge refrigerant from system.
N O T E : Discharge
compressor nV7
system
slowly
to prevent
loss of
J41092
Fig. 3E-22
Quick-Disconnect Coupling
(5) Remove
evaporator
housing-to-instrument
panel attaching screws and evaporator housing-tomounting bracket screw (fig. 3E-23).
Installation
(1) Install receiver/dryer to radiator support
bracket.
(2) Install evaporator and condenser lines to
receiver/dryer.
(3) Remove block and install inner panel bolt.
(4) Install grille.
(5) Install headlamp assembly.
(6) Install headlamp trim ring.
(7) Evacuate, charge system and leak test.
SCREW (1)
J41093
3E-28
AIR CONDITIONING
Installation
(1) Push hoses through grommet opening, and Install grommet by pushing toward engine compartment
of vehicle and fasten to dash panel with two attaching
screws.
(2) Raise evaporator and install evaporator-housing-to-instrument-panel attaching screws and evaporator-to-mounting-bracket screw.
(3) Install hose clamps and grommet attaching
screws.
(4) Connect receiver-to-evaporator hose at quickdisconnect coupling.
(5) Connect inlet (suction) line to compressor.
(6) Evacuate, leak test, and charge system.
Fig. 3E-24
3F-1
Page
3F-1
3F-15
3F-11
3F-S
3F-1
Grilles
Panels
Boll Bars
Swlngout Spare Tire Carriers
Tools
3F-8
3F-7
3F-14
3F-13
3F-1I
BODIES
Page
Body Construction
Page
3F-1
Body Mouldings
3F-1
BODY CONSTRUCTION
General
Jeep vehicles are of all-steel construction, with insulated body mounting points that provide a secure attachment to the chassis frame.
All major body panels are of heavy gauge steel, reinforced, flanged, and welded. The bodies are completely
detachable from the chassis unit and are insulated from
the frame by body spacers placed between the body and
frame and held in position with body bolts.
Spacers are located between the body and chassis
mounting points to insulate against vibrations and road
noises.
Periodic inspection is necessary to determine the condition of body spacers and holddown bolts. Worn, loose,
Frame Alignment
Frame Construction
Page
3F-7
3F-1
BODY MOULDINGS
Trim Mouliings
Trim mouldings on the front fenders, front and rear
doors and rear quarter are attached with adhesive backing, screws and snap-in clips. To replace mouldings,
remove attaching screws and use a wedge-shaped fiber
stick to pry mouldings from body.
FRAMES
FRAME CONSTRUCTION
The frame is the foundation and structural center of
the vehicle. In addition to carrying the load, it mounts
and supports the power unit while maintaining correct
Page
Frame Straightening
3F-7
relationship and alignment of the power train. This relationship assures normal functioning of the units and
freedom from excessive wear, stress, and strain. The
frame is constructed of heavy channel steel side rails
3F-2
ABCDFGHJ-
12.51
17.50
5.20
12.19
15.73
14.57
40.61
46.16
43.50
KMSIPQR
S-
Fig. 3F-1
31.26
41.52
37.84
9.39
13.75
27.50
39.06
60581
3F-3
3F-4
A
B-
CD
E-
F-
GHJ -
KL -
12.05
5.46
10.60
9.94
N
P Q
16.17
10.82
R
S -
14.03
45.26
57.25
24.68
69.00
T U -
V-
wX -
Fig. 3F-3
59.63
46.76
23.38
47.02
17.88
43.54
45.88
42.50
11.52
32.40
35.22
60583
A
B-
c-
DE F GHJ K-
11.97
5.39
11.35
9.94
16.80
12.55
16.78
45.23
57.22
96.80
Fig. 3F-4
L
M-
Np QR
S T
48.79
23.38
45.72
45.92
42.52
32.40
17.69
46.75
17.06
11.52
3F-S
3F-6
A
B
c-
DE
F
G-
HJ K
11.97
5.39
11.35
9.94
15.92
12.57
16.78
4523
56.47
96.80
Fig. 3 F - 5
\ I
DATUM LINE
60.79
23.38
45.72
45.92
42.52
32.40
17.69
46.75
17.06
11.52
60585
3F-7
The most efficient method of checking frame alignment is with a frame alignment machine.
NOTE: The following procedure is adequate for checking most frame dimensions. However, if torsional twist
or frame rail height is in question, the vehicle must be
checked on an alignment machine using datum gauges.
Follow alignment machine manufacturer's
instructions.
If a frame straightening machine is not available,
frame alignment may be determined by using the "X" or
diagonal method. Figures 3F-1 through 3F-5 provide all
frame dimensions.
The most convenient method of checking frame dimensions is to locate with a plumb-bob and chalk mark
on a level floor all dimensional points from which measurements are taken. This is known as "plumb-bobbing"
the frame. If working on a cement floor, clean it so t h a t
the chalk marks will be visible underneath the frame. If
working on a wooden floor, lay sheets of paper underneath the vehicle. Drop a plumb-bob from each point
indicated in figures 3F-1 through 3F-5, marking the
floor directly underneath the point. Satisfactory checking depends on t h e accuracy of the marks in relation to
the frame.
To check points that have been marked, carefully
move the vehicle away from the layout on the floor, and
proceed as follows:
Check the frame at front and rear end using corresponding marks on the floor. If widths correspond to
frame specifications, draw a centerline the full length of
FRAME STRAIGHTENING
A bent or twisted frame may be straightened, provided the extend of misalignment is not excessive.
Severely damaged frame parts should be replaced.
PANELS
Doors
Geneial
3F-7
3F 7
Radiator Grilles
Rear Quarter Panels
3F-8
3F-8
GENERAL
Replacement
DOORS
Galvanized Panels
For protection against rust, panels vulnerable to corrosion on Cherokee, Wagoneer, and Truck vehicles are
galvanized. A conversion coating must be applied to
these panels prior to painting to ensure good adhesion of
the paint.
3F-8
Fig. 3F-8
RADIATOR GRILLES
CJ Models
The CJ grille and the support and baffle are welded
together to form a maximum-strength radiator guard
(fig.3F-9).
Fig. 3F-6
Fig. 3F-9
Removal
42646
Fig. 3F-7
3F-9
Installation
(1) Position guard panel and connect electrical wiring at headlamp sealed beam unit and parking lamps.
(2) If equipped with air conditioning, remove caps
from fittings and connect line to condenser.
(3) Position radiator support rods in radiator grille
guard support brackets and install attaching hardware.
Fig. 3 F - 1 0
Grille PanelCherokee-Wagoneer-Truck
FENDERS
Page
Page
Cherokee-Wagoneer-Truck Models
a
Models
3F-10
Fender Extensions
3F-10
3F-9
CJ MODELS
Replacement
(1) Remove or disconnect all items attached to
apron of fender.
(2) Disconnect ^electrical connector at side marker
lamp.
(3) Remove rocker panel moulding, if equipped.
3F-10
CHEROKEE-WAGONEER-TRUCK MODELS
Removal
(1) Remove front bumper.
(2) Remove headlamp to gain access through
opening.
(3) Reach through headlamp opening and remove
bolts and washers attaching fender to grille face panel.
(4) Remove side marker lamp reflector lens and disconnect lamp socket assembly from lens.
(5) Remove bolts and washers attaching fender to
grille face panel.
(6) Disconnect brace at fender (fig. 3F-13).
Installation
(1) Spread sealer evenly over and along surfaces
where fender and apron make metal-to-metal contact
with other sheet metal parts.
(2) Install apron and fender in place with fingertightened bolts until all bolts and washers have been
installed. Tighten all nuts and bolts.
(3) Install and reconnect all items removed from
fender and apron, such as wiring harness, electrical
components.
(4) Secure items, such as headlight, grille and front
bumper, which were released or removed to facilitate
removal of fender and apron.
CJ FENDER EITENSIONS
iiiOfiS
(1) Remove screws attaching fender extension to
fender (fig. 3F-14).
(2) Remove extension from fender.
EXTENSION
Fig. 3F-14
80429
Installation
Fig. 3F-13
3F-11
BUMPERS
PiP
Pljl
GENERAL
Front bumpers on CJ models are of one-piece construction. When vehicle is equipped with rear mounted
spare, two separate bumperettes are used.
Front bumpers on the Cherokee, Wagoneer, and Truck
models are one-piece chromed aluminum. Rear bumpers
are the same construction and are used on the Cherokee
and Wagoneer. Trucks, when equipped with a rear
bumper, have a one-piece step bumper.
Front bumper guards are available as an option on
standard bumpers on all models except CJ.
BUMPER
RAIL
FRONT BUMPERS
Installation
CJ Models
Removal
(1) Remove nuts and bolts attaching front bumper
rail (fig. 3F-15) to frame extensions.
(2) Remove f r o n t b u m p e r rail from f r a m e
extensions.
Cherokee-Wagoneer-Truck Models
Removal
(1) Remove vertical bumper guard (fig. 3F-16) from
bumper end rail, if equipped.
3F-12
Installation
BUMPERETTE
N O T E : Do not tighten attaching hardware until complete bumper is assembled on vehicle frame and properly aligned.
(2) Position bumper rail on brackets and install attaching bolts and nuts.
(3) Align bumper assembly and tighten all attaching hardware.
(4) Install horizontal bumper guard, if equipped.
(5) Install vertical bumper guard, if equipped.
Fig. 3F-17
80430
Installation
Cherokee-Wagonur
Removal
REAR BUMPERS
CJ Models
Removal
(1) Remove nuts and bolts attaching rear bumperettes (fig. 3F-17) to vehicle frame.
(2) Remove rear bumperettes from vehicle frame.
Fig. 3F-18
3F-13
ARM
Installation
ANTI-SLIP
TAPE
NOTE: Do not tighten attaching hardware until complete bumper is assembled on vehicle frame and properly aligned.
(2) Position bumper rail on brackets and install attaching bolts and nuts.
.
(3) Align bumper assembly and tighten all attaching hardware.
(4) Install horizontal bumper guards on bumper end
rails, if equipped.
80425
Fig. 3F-19
Installation
Truck Models
(1) Position arms on vehicle frame and install attaching bolts, washers and nuts.
Removal
NOTE: Do not tighten attaching hardware until complete bumper is installed on vehicle frame and properly
aligned.
(2) Position step bumper on arms and install attaching bolts, washers and nuts.
(3) Align bumper assembly and tighten all attaching hardware.
(4) Connect license lamp wiring to vehicle wiring.
Installation
(1) Position spring, washer and handle in carrier
and install attaching pin.
(2) Position hinge spacer washers and carrier in
upper and lower hinges and latch handle in latch
bracket.
(3) Install hinge pin bolts and nuts in upper and
lower hinges.
(4) Install spare tire on carrier.
3F-14
ROLL B A R S
Page
CJ Models
3F-14
CJ MODELS
lliliil
'
Page
Installation
(1) Position roll bar on body and align bolt holes
with body.
(2) Position spacers between body side panels and
Truck Models
3F-14
demon!
(1) Remove off-road driving lamps from roll bar, if
equipped.
3F-15
80440
FIg.3F-21
Installation
(1) Position anti-squeak material and roll bar assembly on pick up box.
Fig. 3F-22
BRUSH GUARDS
CHEROKEE-TRUCK MODELS
Removal
(1) Remove bolts and washers attaching brush
guard (fig. 3F-23) to frame rails.
(2) Remove nuts and bolts attaching brush guard to
bumper bolts and remove brush guard.
Installation
(1) Position brush guard on bumper and install attaching bolts and nuts.
N O T E : Do not tighten attaching hardware until complete brush guard is assembled on vehicle and properly
aligned.
3F-1
Fig. 3F-28
J-25359-02
T O R X BIT A N D SOCKET SET
70119
36-1
hoods
SECTION INDEX
1
Page
Hood Bumper
Hood Lock
QwrokM-Waioflter-Trocfc
36-3
36-3
36-1
31=1
. _
7-77-71
CJ MODELS
liniral
Alignment
F O O T M A N LOOP
'
HINGE
HOOD
The hood hinge mounting holes are oversized to permit adjustment when aligning the hood.'
N O T E : If the hood must be moved to either side, the
hood lock striker, hood lever lock, and safety hook assembly, according to vehicle model, must first be
loosened.
(1) Loosen hinge mounting screws slightly on one
side and tap hinge in opposite direction hood is to be
moved.
(2) Tighten screws.
(3) Repeat procedure on opposite hinge.
(4) Hook lock striker, hook lever lock, and safety
hook assembly must be adjusted to ensure positive
locking,,
(5) Shim between hinge and hood with caster and
camber shims or flat washers at the rear screw if hood is
low in relation to the cowl top.
(6) Shim at the front screw if the hood is too high at
the cowl
CHEROKEE-WAGONEER-TRUCK MODELS
SAFETY
HOOK
SPRING
BRACKET
REINFORCEMENT
i " PLATE
SIDE CATCH
Fig. 36-1
J 4 2 6 5 2
General
The Cherokee, Wagoneer, and Truck hood consists of
an outer flanged panel with reinforcements welded at
front, rear and both sides.
3G-2
HOODS
Fig. 3G-2
Alignment
The hood hinge mounting holes are oversized to permit adjustment when aligning the hood.
N O T E : If the hood must be moved to either side, the
hood lock striker, hood lever lock, and safety hook assembly, according to vehicle model, must first be
loosened.
(1) Loosen hinge mounting screws slightly on one
side and tap hinge in opposite direction hood is to be
moved.
(2) Tighten screws.
(3) Repeat procedure on opposite hinge.
HOODS
(4) Hook lock striker, hook lever lock, and safetyhook assembly must be adjusted to ensure positive
locking.
(5) Shim between hinge and hood with shims or flat
washers at the rear screw if hood is low in relation to the
cowl top.
(6) Shim at the front screw if the hood is too high at
the cowl.
HOOD LOCK
CJ Models
The CJ hood is secured to the front fenders by two
hood retaining latches. To release, pull the latches
straight up and turn slightly at the end of travel. The
hood now may be raised with the release of the safety
catch by inserting fingers between the grille bars to the
right of center and by pulling to the left on the catch. To
30-3
secure the hood in the raised position, remove the support bar from its retaining clip and insert the free end
into the support bar bracket.
Cherokee-Wagoneer-Truck Models
The hood lock and safety catch incorporates a release
system, whereby the release lever operates the hood lock
and the safety catch.
The hood lock release latch is located in upper horizontal opening at center of grille. To release the latch, rotate
release lever and lift hood while holding lever in the
released position.
HOOD DUMPER
The hood bumpers on CJ Models are located across the
top of the radiator grille guard and are not adjustable.
The hood bumpers on the Cherokee, Wagoneer, and
Truck are adjustable. Rubber caps must be removed to
adjust the bumper screws.
NOTES
LIFTGATES TAILGATES
Page
C J - 7 Liftgate
3H-1
C J - 7 Tailgate
3H-4
Cherokee-Wagoneer Tailgates
3H-5
Truck Tailgate
3H-11
C J - 5 Tailgate
3H-4
Liftgate Removal
Sealing System
Support System
Window System
3H-3
3H-1
3H-3
3H-1
CJ-7 L I F T G A T E S
Liftgate Alignment
Hinge System
Liftgate Installation
Lock System
3H-3
3H-3
3H-3
3H-2
SEALING SYSTEM
Rubber Sealer
The liftgate rubber sealer is made of molded latex
foam with a smooth rubber skin on the outside.
Plastic retainers are used to retain the rubber sealer
to the liftgate. Barbs on the retainers depress when
inserted in the holes and spread when fully inserted.
Maintenance of Rubber Sealers
WINDOW SYSTEM
Replacement
(1) Unlock rubber weatherstrip (fig. 3H-1) using
wood wand or fiber stick.
(2) Use fiber stick to break seal betwen glass and
rubber weatherstrip.
(3) Push glass and weather strip toward outside of
vehicle. Remove glass.
(4) Remove weatherstrip from liftgate opening.
(5) Inspect weatherstrip and clean sealer from glass
cavity and flange cavity.
NOTE: Inspect for uneven surfaces or irregularities in
the opening flange that could cause stress damage to the
glass.
LSFTGATESTAILGATES
3H-2
LIFTGATE
HINGE
RUBBER
SEALER
SUPPORT
LATCH
CYLINDER
70509
GLASS
Fig. 3H-1
Liftgate Components
the
LOCK SYSTEM
Qytstde Handle Riplicmifnt
(1) Remove screws attaching remote control to liftgate using Torx Bit Tool J-25359-02.
(2) Remove nuts attaching outside handle to liftgate and remove handle.
N O T E : The replacement outside handle is furnished
without the lock cylinder. The lock cylinder is furnished
uncoded without keys.
(3) Code existing door lock key to replacement
cylinder.
(a) Insert key in replacement cylinder.
(b) File tumblers until flush with cylinder body.
(c) Remove and install key, and check that tumblers are flush with body.
LIFTGATESTAILGATES
(d) Install cylinder in replacement outside
handle.
(4) Position outside handle in liftgate and install
attaching nuts.
(5) Position remote control on liftgate and install
attaching screws using Torx Bit Tool J-25359-02.
Latch Replacement
(1) Loosen screw attaching remote control cable to
latch. Disconnect cable from screw.
(2) Remove screws attaching latch (fig. 3H-1) to
liftgate using Torx Bit Tool J-25359-02. Remove latch.
(3) Position latch on liftgate and install attaching
screws using Torx Bit Tool J-25359-02.
(4) Connect remote control cable to latch screw and
tighten screw.
Striker Adjustment
The strikers provide durable retention points for the
latches and prevent movement of the liftgate. Strikers
may be moved in or out to compensate for body and
enclosure variations. Use Torx Bit Tool J-25359-02 for
removal and adjustment.
SUPPORT SYSTE1
Replacement
(1) Open liftgate, support to prevent closing, and
remove lockpins from support attaching screws.
(2) Remove screws attaching supports and remove
supports.
(3) Install supports and attaching screws.
(4) Install lockpins on support attaching screws.
HINGE SYSTEM
Replacement
(1) Open liftgate, support to prevent closing, and
remove lockpins from liftgate support attaching screws.
(2) Remove screws attaching supports to liftgate
and fold supports downward.
WARNING: Never remove supports with
liftgate
closed. The supports are under spring tension and may
cause damage or personal injury if removed with liftgate closed. After removal, do not attempt to dismantle
or repair the supports.
3H-3
3H4
LIFTGATESTAILGATES
GENERAL
REMOVAL .
. -
INSTALLATION
(1) Hold tailgate at approximately 45 degrees from
full up position and engage right hinge.
(2) Rotate tailgate an additional few degrees and
then engage left hinge.
ADJUSTMENT
(1) Loosen hinge attaching bolts and slide body half
of hinge up, down, or to the side as needed.
(2) Tighten bolts.
AILGATE
GENERAL
REMOVAL
(1) Remove screws and wave washers attaching
support cables to tailgate.
(2) With tailgate closed, remove screws attaching
hinges to tailgate using Torx Bit Tool J-25359-02. Disengage latches and remove tailgate.
INSTALLATION
'
ADJUSTMENT
(1) Loosen hinge-to-body attaching screws and
align tailgate to body opening.
HINGE REPLACEMENT
(1) Remove all hinge attaching screws using Torx
Bit Tool J-25359-02 and remove hinge.
(2) Clean replacement hinge in a suitable solvent
and blow dry with compressed air.
(3) Paint hinge to match body with Jeep exterior
spray paint.
(4) Lubricate hinge with 3M 4-Way Spray lubricant
or equivalent.
(5) Position hinge on body and tailgate and install
attaching screws using Torx Bit Tool J-25359-02.
RUBBER SEALER
The tailgate rubber sealer is made of molded latex
foam with a smooth rubber skin on the outside.
Plastic retainers are used to retain the rubber sealer
to the tailgate. Barbs on the retainers depress when
inserted in the holes and spread when fully inserted.
LIFTGATESTAILGATES
Sl-I
Replacement
CHEROKEE - WAGONEER
TAILGATES
Page
Adjustment
General
leplacement
Installation
Page
Lock System
Power Tail gate Window System
iio r:\ivai
Window System
3H-5*
3H-S
3H-e
3H-7
3H-7
3H-8
31-1
3H-7
GENERAL
Hinges
ADJUSTMENT
Dovetail Assemblies
Tailgate adjustment is similar to side door adjustments; proper alignment is obtained by changing the
position of the hinges relative to the body and tailgate.
On models equipped with carpeting, remove carpeting to
gain access to hinge cover plates. Cherokee and Wagoneer vehicles have hinge cover plates in the body floor and
tailgate for easy access to hinge screws (fig. 3H-2). The
dovetail assemblies, which stabilize the tailgate and
function as an overslam bumper, are adjusted by bringing the dovetail studs into alignment with the dovetail
cap. The dovetail studs are located on the body pillars
near the striker plates, and are adjustable. The dovetail
caps are located on the tailgate and are nonadjustable.
3H-6
LIFTGATESTAILGATES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Hexagon Screw
Lower Channel
Weatherstrip
Tailgate Glass
Run Channel
Upper Cushion
Weatherstrip
Glass Frame
Channel Sealer
Tapping Screw
Bottom Channel
Stud Retainer
Window Regulator
Remote Control
Release Handle
Oval Head Screw
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Outer Panel
Tailgate
Machine Screw
Speed Nut
Plastic Rivet
Tailgate Sealer
Machine Screw
Bracket Bumper
Stop Bracket
Machine Screw
Torque Rod
Cover Gasket
Access Cover
Tapping Screw
Tapping Screw
Fig. 3H-2
HINGE REPLACEMENT
(1) Open tailgate. If vehicle is equipped with cargo
area floor covering, remove mouldings and place floor
covering aside.
(2) Remove access hole cover plates from body and
tailgate.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
Cover Plate
Hinge Screw
Body Half Hinge
Hinge Pin
Tailgate Half Hinge
Plastic Rivet
Dust Seal
Arm Bumper
Shoulder Bolt
Spring Washer
Arm Sleeve
Support Arm
Lock Washer
Dovetail Cap
Tapping Screw
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
Machine Screw
Tailgate Striker
Striker Shim
Machine Screw
Lock Washer
Tailgate Dovetail
Hexagon Nut
Dovetail Stud
Machine Screw
Tailgate Latch
Machine Screw
Machine Screw
Handle Gasket
Regulator Handle
Machine Screw
J41006
LIFT6ATESTAILGATES
(3) Raise tailgate to vertical position to unload
counterbalance torque rods, and pry rods from clip
welded to body half of hinge.
(4) Using a wax pencil, mark outline of existing
hinge(s) on body and tailgate for reference.
(5) Support tailgate in horizontal position, remove
screws attaching hinge(s), and remove hinge(s).
(6) Clean replacement hinges in a suitable solvent
and blow dry with compressed air.
CAUTION: Do not immerse hinge in solvent
(7) Color coat hinges to match body.
(8) Lubricate hinges with 3M 4-Way Spray lubricant, or equivalent.
(9) Install replacement hinge(s), being careful to
align with wax pencil marks. Tighten screws to 15 to 20
foot-pounds (20 to 27 Nm) torque.
(10) Raise tailgate to vertical position and install
counterbalance torque rods in welded clips on body half
of hinges.
(11) Check t a i l g a t e a l i g n m e n t and a d j u s t if
necessary.
(12) Install access hole cover plates on body and tailgate and, if equipped, replace cargo area floor covering
and mouldings.
REMOVAL
(1) Remove carpeting from tailgate, if equipped.
(2) Remove tailgate access cover plate and disconnect wiring.
(3) Remove carpeting, if equipped, to gain access to
hinge access hole cover plates.
(4) Remove hinge access hole cover plates on body.
(5) Close tailgate and drive out hinge pins.
(6) With tailgate in a vertical position, counterbalance torque rods are unloaded and can be removed
from the clip which is attached to the body half of the
hinge.
(7) Remove screws holding lower end of support
arms to tailgate.
INSTALLATION
(1) Attach support arms to tailgate and raise tailgate to a vertical position in tailgate opening.
(2) Insert curved end of one torque rod in hole at
bottom edge of tailgate and* right-angle tapered end of
rod in clip which is attached to body half of the hinge.
Attach other torque rod in same manner.
(3) Install hinge pins with head of pin on inboardside of hinge.
(4) Install hinge access hole cover plates on body.
(5) Install carpeting, if equipped.
(6) Connect wiring and replace tailgate access cover
plate and carpeting, if equipped.
(7) Adjust tailgate.
3H-7
LOCK SYSTEM
Latch Replacement
(1) Lower tailgate and move tailgate glass to the
extreme out position so remote control assembly will be
accessible. Tailgate glass should be supported to relieve
stress on its lower edge.
(2) Remove carpeting from tailgate, if .equipped.
(3) Remove access cover and remove screws attaching ends of remote control rods to tailgate.
(4) Remove screws attaching latch assemblies to
ends of gate and remove latch assemblies.
1IND01 SYSTEM
'
./'
'
'
'
Glass Replacement
Tailgate glass is operated by a double-arm window
regulator which is connected directly to an outside window regulator handle. The complete window assembly
will slide up and out of the run channels when the pins
at the ends of the regulator arms are withdrawn from
the slot in the lifter channel.
(1) Remove access cover on inside tailgate panel and
pry off retainers with a screwdriver.
N O T E : Retainers can be damaged when removed and
their condition should be checked. When installing retainers, the tabs must be firmly locked in groove of pin.
If difficulty is experienced when installing retainers,
they were probably damaged during removal and should,
be replaced.
(2) When installing tailgate glass, check glass assembly and regulator separately to make sure that both
operate freely before connecting the two together.
3H-8
LIFTGATESTAILGATES
J42660
Operation
Instrument Panel Switch
Genera!
A new electrically operated tailgate window is offered on Cherokee and Wagoneer models. When checking for tailgate window motor operation, be sure
instrument panel switch black lead is properly
grounded. The tailgate motor grounds through this,
switch. It is necessary to isolate the problem to one of
the two operating circuits: (1) tailgate window operation
from instrument panel switch and (2) tailgate window
operation from tailgate window switch.
LIFTGATESTAILGATES 3H-9
TAILGATE MOTOR
48B TAN 12
TAILGATE SWITCH
30 AMP
CIRCUIT
TAILGATE
SWITCH
FEED
30 AMP
CIRCUIT
LP.
SWITCH
FEED
GROUND
53 - RED - 12
A - BLACK - 18
I N S T R U M E N T PANEL
TAILGATE WINDOW
SWITCH
9G-BLACK - 18
4 7 - B R O W N - 14
4 7 - B R O W N - 14
48 - TAN - 14
9G
BLACK-GROUND
48
T A N - UP
47
BROWN
46
RED-W/TR-HOT
48 - TAN -12
47 - BROWN - 12
DOWN
Fig. 3H-4
46-RED-W/TR-12
43197
3H-10
LIFTGATESTAILGATES
N O T E : Be sure instrument
panel tailgate
switch black lead is properly grounded. The
motor grounds through this switch.
window
tailgate
Safety Switch
A safety switch, mounted in the upper left side of the
tailgate, prevents operating the glass when the tailgate
is in the open position to avoid possible damage to glass
channels and regulator.
Circuit Dreaders
The electric tailgate regulator motor and wiring harness are protected by two 30-ampere circuit breakers
located in the fuse panel.
N O T E : Be sure instrument
panel tailgate
switch black lead is properly grounded. The
motor grounds through this switch.
window
tailgate
Wiring Harness
The tailgate circuit is a two-section wire harness: the
body section, which is routed along the left side of the
vehicle, and the section in the tailgate. The two harnesses are connected at the rear body crossmember.
LIFTGATESTAILGATES
3H-11
iindow Switch
Installation
Key Loci
Regulator
Removal
Motor
Removal
(1)
(2)
(3)
above.
(4)
TRUCK TAILGATE
GENERAL
The tailgate on the pickup box is hinged at both sides.
It is necessary to lower the tailgate for access to the
cross-recessed countersunk attaching screws.
The tailgate on the pickup box is held in the up or
closed position with spring-loaded latches at the top of
the gate. A paddle handle, located in the center of the
tailgate operates the latches at each side through connecting rods.
Pin type hinges are located on the sides of the pickup
box. The hinge pin brackets are attached with crossrecessed countersunk attaching screws and cage nuts for
easier adjusting.,
The left side hinge pin is a solid round bar. The right
side pin is similar but with two flat surfaces which
correspond with a notch and the two flat surfaces allow
the tailgate to be removed quickly from the tailgate
opening.
To remove, open and lower the tailgate. Remove the
side supports and then raise the tailgate to about 45
degrees from horizontal. Disengage the right side hinge
and move the tailgate to the right to disengage the left
side hinge.
3H-12 LIFTGATES-TAILGATES
90186
3J-1
DOORS
SECTION INDEX
Cherokee-Wagoneer Rear Doors
Cherokee-Wagoneer-Truck Front Doors
Page
3J-9
3J-4
Page
3J-1
3J-12
CJ-7 W I T H H A R D T O P
ENCLOSURE
Door Trim
Hinge System
Lock System
Page
3J-1
3J-3
3J-3
Sealing System
Window System
Page
3J-1
3J-2
POOR TRIM
Removal
l l i l o w Reguliter Handle
Peer Assist H i R i i
Removal
(1) Remove screws attaching door assist handle using Torx Bit Tool J-25359-02.
(2) Remove handle from door.
Installation
SEALI1G S Y S T E M
Installation
Trip Panel
Trim panels consist of fiber board composition covered with a vinyl material. They are fastened to the door
with spring clips inserted into holes in the door inner
panel.
Water Shield
The water shield is attached to the door inner panel
with adhesive. To remove water shield, use a putty knife
between shield and door inner panel to break adhesive
bond.
When installing water shield, be sure the slit lower
portion is tucked inside the door panel at the access
opening and that the shield is bonded securely to the
door inner panel.
312
DOORS
Ribbsr Soalor
The door rubber sealer is made of molded latex foam
with a smooth rubber skin on the outside.
Plastic retainers are used to retain the rubber sealer
to the door below the belt line. Barbs on the retainer
depress when inserted in the holes and spread when
fully inserted. Above the belt line, the sealer is retained
in a channel formed in the upper door frame.
/
FASTENER
\ SCREW
Fig. 3 J - 1
Replacement
DIVISION
CHANNEL
LOWER
I ADJUSTING!
60579
Removal
WINDOW SYSTEM
Installation
Door Gloss
Adjustment
NOTE: Movement of division channel fore and aft reduces or increases free play between channels.
DOORS
3J-3
LOCISISTEI
Removal
Installation
Latch Replacement
(1) Remove screws attaching door latch to door using Torx Bit Tool J-25359-02 and remove latch.
(2) Lubricate door latch with 3M 4-Way Spray lubricant, or equivalent.
(3) Position door latch on door and install attaching
screws using Torx Bit Tool J-25359-02.
HINBE SYSTEM
Adjustments
Installation
Replacement
Window Regulator
Removal
3J-4
DOORS
pencil marks, and install screws using Torx Bit Tool J25359-02.
(7) Position hinge on body, align carefully with pencil marks, and install screws using Torx Bit Tool J25359-02.
(8) Check door alignment. Adjust if necessary (refer
to Door Adjustment).
Page
Sealing System 3J-4
Window System 3J-5
DOOR TRIM
(3)
(4)
remote
(5)
SEALING SYSTEM
Trim Panel
Water Shield
Trim panels consist of fiber board composition covered with a vinyl material. They are fastened to the door
with spring clips inserted into holes in the door inner
panel and screws along the bottom edge.
Removal
Rubber Sealer
The door rubber sealer is made of molded latex foam
with a smooth rubber skin on the outside.
The door rubber sealer is attached to the body opening
around the door opening.
Maintenance of Rubber Sealers
Cold weather may cause the rubber sealer to harden
and lose resiliency. When servicing, use a dampened
cloth to clean rubber sealer. Remove dirt from all points
where the rubber sealer contacts the door. Apply AMC/
Jeep Silicone Lubricant, or equivalent, to a dampened
cloth and apply to rubber sealer.
DOORS
CAUTION: Do not use graphite, brake fluid, or wax on
rubber sealer.
Replacement
Replacement rubber sealers are coated with powder to
prevent stickiness in storage. Remove all powder with a
dampened cloth before installation.
(1) Carefully remove rubber sealer from door
opening.
(2) Remove dust and dirt from rubber sealer, door
and body opening.
3J-5
WINDOW SYSTEM
Door Glass
Removal
FRAME
WEATHERSTRIP
GLASS
PIVOT
ASSEMBLY
HANDLE
LOCKING ROD
Fig. 3J-2
4 2 6 5 4
3J-6
DOORS
(6) Remove screws attaching remote control assembly to door panel and lower to bottom of door.
(7) Lower door glass and remove retaining clip.
(8) Lower glass to bottom of door.
(9) Push lower end of division channel toward front
of door to release glass from channel.
(10) Move glass toward front of door to release it
from rear channel.
(11) Rotate glass vertically 90 and guide it between
inner and outer door panels.
Installation
Vent Window
Installation
Glass Replacement
Window Regulator
Removal
LOCK SYSTEM
Removal
Outside Handle
Removal
DOORS
3J7
Key Lock
Removal
(1)
tension
(2)
(3)
Position lock cylinder in door, making sure exrod is inserted in square hole in latch.
Install lock cylinder retainer.
Install rubber sealer with retaining pins.
Fig. 3J-3
3J-8
DOORS
Locking Rod
Removal
(1)
(2)
(3)
(4)
locking
Installation
Door Adjustments
HIN8E SYSTEM
Replacement
(1) Remove trim panel and water shield.
(2) Disconnect door speaker wiring, if equipped.
(3) Mark outline of existing hinges on body pillar
and door for reference with wax pencil.
(4) Position door in holding fixture.
(5) Remove all hinge-to-body screws.
(6) Remove door from vehicle.
(7) Remove all hinge-to-door screws and remove
hinges.
(8) Clean replacement hinges in a suitable solvent
and blow dry with compressed air.
DOORS
3J-9
CHEROKEE - WAGONEER
REAR DOORS
Pill
Door Trim
Hinge System
Lock System
Pip
3J-9
3J-12
3J-11
Sealing System
Window System
3J-9
3J-10
DOOR TRIM
SEALING SYSTEM
Water Shield
Trim Panel
Trim panels consist of fiber board composition covered with a vinyl material. They are fastened to the door
with spring clips inserted into holes in the door inner
panel and screws along the bottom edge.
Rubber Sealer
The door rubber sealer is made of molded latex foam
with a smooth rubber skin on the outside.
The rubber sealer is attached to the door body
opening.
Removal
Maintenance of Rubber Sealers
Installation
Replacement
Replacement rubber sealers are coated with powder to
prevent stickiness in storage. Remove all powder with a
dampened cloth before installation.
(1) Carefully remove rubber sealer from door
opening.
(2) Remove dust and dirt from rubber sealer, door
and body.
(3) Install upper front corner of sealer to door opening first.
(4) Complete installation of rubber sealer to remainder of door opening.
3J-10
DOORS
WINDOW SYSTEM
Door Glass
Removal
CHANNEL
Fig. 3J-4
DOORS
3J-11
LOCK S f S T E i
Went Window
Removal
Outside Handle
Removal
Locking Rod
Installation
Removal
Window Regulator
Removal
(1) Position regulator on inner door panel and secure with attaching screws.
(2) Install regulator pin in glass channel and install
retaining clip.
(3) Install water shield and door trim panel.
Removal
(1)
(2)
(3)
locking
installation
3J-12
DOORS
Deer Adjustments
HINGE SYSTEM
Replacement
(1) Scribe outline of hinges on body pillar and doorfor reference.
(2) Position door in holding fixture.
(3) Remove all hinge screws using Torx Bit Tool J25359-02 and remove hinges. Retain shims.
(4) Clean replacement hinges in a suitable solvent
and blow dry with compressed air.
CAUTION: Do not immerse hinge in solvent
(5) Color-coat hinges to match body.
(6) Lubricate hinges with 3M 4-Way Spray lubricant, or equivalent.
(7) Position hinges on door with original shims,
being careful to align with wax pencil marks, and install
screws using Torx Bit Tool J-25359-02. Tighten screws to
12 to 18 foot-pounds (16 to 24 N*m) torque.
(8) Remove door holding fixture.
(9) Check door alignment. Adjust if necessary (refer
to Door Adjustments).
Tools
70119
J-25359-02
TORX BIT A N D
SOCKET SET
J-2631-01
TRIM PAD
DEPRESSOR
J-21104-01
WEATHERSTRIP
REMOVER
3K-1
REAR
QUARTER
SECTION I N D E X
Page
Pivot Vent WindowCherokee 3K-1
Stationary Window2-Door Cherokee 3K-2
Stationary Window4-Door Cherokee-Wagoneer 3K-2
Page
Stationary WindowCJ-7 with Hardtop Enclosure
Trim Panel
3K-2
31-1
TRIM PANEL
NOTE: If weatherstrip
Removal
GLASS
FRAME
MYLAR
Installation
(1) Inspect all panel attaching clips; replace any
that are bent. To prevent damage to trim panel, do not
hammer or exert excessive force on clips.
(2) Install trim panel attaching screws.
(3) Install armrest and armrest metal overlay strip,
if equipped.
(4) Install ash receiver holder and ash receiver, if
equipped.
FILLER
STRIP
WEATHERSTRIP
WEATHERSTRIP
J42657
Installation
(1) Lubricate weatherstrip with soap and water
solution.
(2) Place window frame and weatherstrip assembly
into position in window opening.
3K-2
REAR QUARTER
STATIONARY
ENCLOSURE
WINDOWCJ-7
WITH
HARDTOP
Reiotal
(1) Unlock rubber weatherstrip using wood wand or
fiber stick.
(2) Use fiber stick to break seal between glass and
rubber weatherstrip.
(3) Push glass and weatherstrip toward outside of
vehicle. Remove glass.
(4) Remove weatherstrip from opening.
Installation
(1) Inspect weatherstrip and clean sealer from glass
cavity and flange cavity.
N O T E : Inspect for uneven surfaces or irregularities in
the opening flange that could cause stress damage to the
glass.
(2) Before installing weatherstrip on flange, apply a
3/16-inch bead of 3M Auto Bedding and Glazing Compound or equivalent in weatherstrip flange cavity using
a pressure-type applicator.
(3) Install weatherstrip on liftgate opening flange.
(4) Apply a liberal amount of liquid soap solution to
glass cavity of weatherstrip.
(5) Position glass into upper glass cavity and into
each side. Position wooden wand under glass and lift up
and into lower cavity. Check for equal side clearance.
(6) Use wooden wand to lock weatherstrip.
NOTE: Soap solution should be removed from
weatherstrip and glass before installing sealer.
the
STATIONARY W 1 N D 0 W - 4 - D 0 0 R CHER0KEE-WA60NEER
Removal
(1) Remove interior garnish mouldings from
around window and break seal loose between weatherstrip and body panels.
(2) Push glass toward inside of vehicle.
(3) Remove weatherstrip from around glass and
clean old sealer from glass cavity and flange cavity.
Installation
(1) Before installing glass in weatherstrip, apply a
3/16-inch bead of 3M Windshield Sealer or equivalent in
glass cavity completely around weatherstrip using a
pressure type applicator (fig. 3K-2).
REAR QUARTER
window opening with ends of cord hanging outside vehicle (fig. 3K-3).
(4) Pull on ends of cord to pull lip of weatherstrip
over body panel. With cord removed, weatherstrip
should be positioned correctly.
Fig. 3K-3
Fig. 3K-2
3K-3
Tools
60580
NOTES
3L-1
LUGGAGE
RACKS
SECTION INDEX
Page
Page
Adjustable End Rail
General
Roof Slat
31-2
3L-1
3L-Z
GENERAL
The luggage rack (fig. 3L-1) consists of side rails,
adjustable end rails, end and center supports, and roof
mounted slats. A spanner wrench, located in the vehicle
glove box, facilitates securing the adjustable end rails.
Side Rail
Specifications
Support
3L-2
3L-2
3L-2
SCREW
SCREW
SLAT
GASKET
LARGE
DIAMETER
OF CROSS R A I L
TO FACE F R O N T
J41007
Fig 3 M
Luggage Rack
3L-2
LUGGAGE RACKS
SUPPORT
Removal
N O T E : Do not apply extreme pressure to support attaching screws during removal or installation as this
may cause the well nuts to drop between the roof panel
and headliner.
Installation
(1) Position support on side rail.
(2) Position support and gasket on roof.
(3) Coat screw threads with 3M Drip-Chek Sealer or
equivalent, and install screws. Tighten screws to 28
inch-pounds (3 N*m) torque.
(4) Install screw(s) attaching support to side rail.
"
Removal
(1) Remove screws attaching end supports to side
rails.
(2) Remove attaching screws from end supports.
N O T E : Do not apply extreme pressure to support attaching screws during removal or installation as this
may cause the well nuts to drop between the roof panel
and headliner.
(3) Remove end supports and gaskets from roof.
(4) Loosen adjustable end rail lock nuts and remove
adjustable end rail from side rails.
Installation
(1) Position adjustable end rail in side rails.
(2) Position end supports on side rails.
(3) Position end supports and gaskets on roof.
(4) Coat screw threads with 3M Drip-Chek Sealer or
equivalent, and install screws. Tighten screws to 28
inch-pounds (3 Nm) torque.
(5) Install screws attaching end supports to side
rails.
(6) Tighten adjustable end rail lock nuts.
SIDE RAIL
Removal
(1) Remove screws attaching side rail to supports.
ROOF SLAT
Removal
(1) Remove screws attaching roof slat to roof.
(2) Use 3M Release Agent or equivalent to soften
adhesive bond.
(a) Using snorkel tube, spray between roof slat
and roof panel.
(b) Allow 2 to 3 minutes for penetration and
softening of adhesive bond.
(3) Carefully pry roof slat up from roof using a
wooden or fiber stick.
(4) Remove roof slat.
Installation
CAUTION: Exercise care not to damage painted surface when using cleaning solvents. To determine if a
solvent will damage the paint, test solvent on a hidden
area of the vehicle.
(1) Clean adhesive residue and wax from surface
with cloth dampened with 3M General Purpose Adhesive Cleaner or equivalent.
N O T E : Surface must be clean and dry for roof slat to
adhere.
(2) Heat metal to minimum 68F with heat gun J25070 or heat lamp.
CAUTION: Do not install roof slats on fresh paint that
has not been properly cured.
(3) Peel backing paper from roof slat and position
on roof.
(4) Firmly press roof slat to roof with roller or
heavy hand pressure.
(5) Install screws attaching roof slat to roof.
LUGGAGE RACKS
J-25359-02
T O R X BIT A N D SOCKET SET
3L-3
70119
70301
NOTES
3M-1
SEAT
ASSEMBLIES
SECTION INDEX
Front Seats
Page
3M-1
Rear Seats
3M-7
CJ Console
CJ 2 / 3 - 1 / 3 Style Seats
Seat Belt
3M-5
3M-1
3M-6
FRONTSEATS
Cherokee-Wagoneer-Truck Bench Seats
Cherokee-Wagoneer-Truck Bucket Seats
CJ Bucket Seats
31-4
3IW-4
31-1
GENERAL
CJ BUCKET SEATS
On all Truck models, the bench seatback swings forward for access to the seatback storage area. The seatback locks automatically in the fully upright position to
prevent it from tilting forward in the event of sudden
stops. To release the seatback lock, pull up on the seatback release.
The fore-and-aft seat adjuster mechanism for Cherokee-Wagoneer-Truck models and left front CJ seats has
a turnbuckle to allow for slight dimensional variances
during production assembly of seats and seat support
components. The turnbuckle permits the seat sliding
and latching components to be adjusted for trouble-free
operation. Adjustment of the turnbuckle is covered in
this chapter.
All seat belts utilize quick-release buckle latches.
Cherokee and Wagoneer models are equipped with three
sets of rear seat belts; the two outboard seat belt retractors are anchored on the wheelhousings.
Removal
(1) Remove screws (fig. 3M-1) attaching supports
and braces to floorpan.
(2) Remove seat assembly from vehicle.
Installation
(1) Position seat assembly in vehicle.
(2) Install screws attaching supports and braces to
floorpan. Tighten screws to 15 foot-pounds (20 Nm)
torque.
3M-2
SEAT ASSEMBLIES
SEAT
70506
Fig. 3M-1
SEAT ASSEMBLIES
1/3 SEAT
Fig. 3M-2
3M-3
314
SEAT ASSEMBLIES
Installation
(1) Position seat assembly in vehicle.
(2) Install screws attaching supports and/or braces
to floorpan. Tighten screws to 15 foot-pounds (20 Nm)
torque.
60620
Fig*3i"3
Installation
SEAT ASSEMBLIES
On bench seats and bucket seats, a latch wire connects
the right and left spring-loaded locking levers, facilitating the simultaneous unlocking or locking of both
seat adjusting slides.
3M-5
Removal
(1) Remove screws attaching supports to floorpan.
(2) Remove seat assembly from vehicle.
Installation
(1) Position seat assembly in vehicle.
(2) Install screws attaching supports to floorpan.
Tighten screws to 20 foot-pounds (27 Nm) torque.
Adfustment
(1) Locate turnbuckle under the bench seat (fig. 3M4). Loosen turnbuckle wingnut.
(2) Tighten turnbuckle until slack is removed from
wire.
(3) Back off turnbuckle three turns.
(4) Secure wingnut up against turnbuckle.
(5) Check for proper seat adjustment operation. If
right side of seat will not release, increase tension by
tightening turnbuckle. If right side of seat will not lock
in place, decrease tension by loosening turnbuckle.
Fig. 3M-5
Removal
(1) Open console cover.
(2) Remove screws attaching console to floorpan.
(3) Remove console assembly from vehicle.
installation
(1) Position console assembly in vehicle.
(2) Align drain hole with hole in floorpan and install attaching screws.
(3) Close and latch console cover.
Console Cover Seal
The console cover seal is attached to the console. The
foam seal may be replaced after opening the cover.
Console Cover Lock
Lock Cylinder Removal
Fig. 3M-4
CJ FLOOR CONSOLE
The beverage container type floor console (fig. 3M-5),
available only with bucket seat equipped models, is fabricated from molded plastic material. The floor console
cover is provided with a lock and two depressions designed to hold beverage containers. The bottom of the
floor console is equipped with a hole, in the rear, allowing ice water to drain onto the ground.
M 4
SEAT ASSEMBLIES
SEAT SELTS
Removal
(1) Remove seat belt anchor bolt with Torx Bit Tool
J-25359-02.
(2) Remove seat belt.
(3) Remove shoulder belt guide cover from guide, if
equipped.
(4) Remove guide bolt with Torx Bit Tool J-2535902.
(5) Obtain access to seat belt retractors by removing trim covers.
(6) Remove seat belt retractors anchor bolts with
Torx Bit Tool J-25359-02.
Installation
(1) Install seat belt and seat belt retractor anchor
bolts. Tighten to 25 to 35 foot-pounds (34 to 47 N*m)
torque.
(2) Position shoulder belt guide on B-pillar and install bolt with Torx Bit Tool J-25359-02.
(3) Install shoulder belt guide cover.
(4) Install seat belt retractor trim cover.
REAR SEATS
Cherokee-Wagoneer Seats
CJ Seats
CJ SEATS
3M-6
3M-6
Seat Belts
3M-7
Removal
(1) Remove bolts attaching rear seat assembly to
floorpan.
(2) Remove rear seat assembly from vehicle.
Installation
(1) Position rear seat assembly in vehicle.
(2) Install bolts attaching rear seat assembly to
floorpan.
CHEROKEE-WAGONEER SEATS
'
Fig. 3M-6
Hi
MOUNTING
HINGES
Warn
KflM
WWmm
RUBBER
BUMPERS
70561
Fig. 3 M - 7
70562
liiBfil
LATCH LEVER
Installation
STR'KER
70563
Fig. 31-8
Adjusttnont
(1) Tilt seat back forward and loosen striker bolt to
allow forced movement of striker.
(2) Raise seat back to upright position and tap strik e r i n t o p o s i t i o n for m a x i m u m l a t c h / s t r i k e r
engagement.
(3) Unlatch seat back carefully so as not to change
striker position and tighten striker securely.
(4) Check striker/latch operation.
SEAT BELTS
Removal
(1) Remove seat belt anchor bolt with Torx Bit Tool
J-25359-02.
3M-8
SEAT ASSEMBLIES
Installation
(1) Install seat belt and seat belt retractor anchor
bolts. Tighten to 25 to 35 foot-pounds (34 to 47 N*m)
torque.
(2) Position shoulder belt guide on B-pillar and install bolt with Torx Bit Tool J-25359-02.
(3) Install shoulder belt guide cover.
(4) Install seat belt retractor trim cover.
Tools
mm
mm
70119
3N-1
WINDSHIELD <= ^
H
REAR WINDOW % P i i
SECTION INDEX
Page
Rear Window
Page
3N-6
Windshield
3N-1
General
Rear View Mirror Bracket
Tools
3N-1
3N-5
3N-7
WINDSHIELD
Page
Cherokee-Wagoneer-Truck Wlndshiatd Glass
CJ Folding Windshield
CJ Windshield Glass
Page
3N-2
3N-1
3N-2
GENERAL
The windshields on all models consist of two sheets of
plate glass laminated together to form a one-piece safety
glass.
All CJ windshields are retained in their openings by
rubber weatherstrips (channels).
New for 1979, all Cherokee-Wagoneer-Truck model
windshields are bonded to the rubber weatherstrip and
the rubber weatherstrip is bonded to the body opening to
improve glass retention and sealing.
The safety type glass is designed with adequate clearance to prevent stress and strains. When replacing
cracked glass resulting from causes other than a direct
blow or a known instance of temporary misalignment, it
is very important that the cause of the breakage be
determined and the condition corrected.
The inside rear view mirror bracket for all models is
bonded directly to the windshield glass with a polyvinylbutyral compound through a heat-induction process.
Service replacement windshield glass may have the
rear view mirror bracket bonded to the windshield glass.
In this case, the mirror is simply transferred from the
damaged windshield to the bracket on the replacement
windshield.
If the replacement windshield does not have a bonded
mirror bracket or if the bonded bracket has been lost, a
service kit is available for bracket installation. The kit is
available from your local parts distribution center and
consists of a replacement bracket and a firm-setting,
two-component adhesive. Installation instructions are
included in the kit, and also in this section.
N O T E : Do not attempt
to remount
bracket. Use a new bracket kit.
the
original
CJ FOLDING WINDSHIELD
The windshield and frame assembly may be lowered
to the hood by removing the knobs at each side of the
windshield. When in the lowered position, always secure
the windshield by passing the strap at the top of the
windshield through the footman loop on the hood and
drawing the strap up firmly.
Removal
(1) Remove necessary top components from windshield frame.
(2) Disconnect wiper motor wiring harness from
switch.
(3) Remove windshield hinge-to-frame attaching
screws using Torx Bit Tool J-25359-02.
(4) Remove windshield holddown knobs and remove
windshield frame.
Installation
(.1) Position windshield frame on vehicle and install
windshield hinge-to-frame attaching screws using Torx
Bit Tool J-25359-02.
(2) Install windshield holddown knobs.
(3) Connect wiper motor wiring harness to switch.
(4) Install necessary top components to windshield
frame.
'
. .
Installation
(1) Using 3M Auto Bedding and Glazing Compound
or equivalent, apply a 1/16-inch bead of sealer completely around weatherstrip in flange cavity.
(2) Install weatherstrip on glass. Split in weatherstrip should be centered on bottom edge of glass.
(3) Beginnning at bottom of glass, work weatherstrip over flange using a fibre or wooden wand.
(4) Apply 3M Windshield Sealer or equivalent, between weatherstrip and outside of glass around entire
perimeter.
(5) Clean off excess sealer.
(6) Install inside rear view mirror on bracket.
(7) Install defroster ducts and sun visors.
(8) Install windshield wiper arms.
(9) Test windshield installation for water leaks.
NOTE: Methyl-ethyl-ketone
(MEK), tuloul (toluene),
and Grow Chemical Solvent GS-35 are usually available
from chemical houses listed under SOLVENTS in the
Yellow Pages of the telephone directory. If not available
locally in small quantities, these solvents may be obtained from mail order chemical houses such as E. H.
Sargent & Co. and Fisher Scientific, which have salesservice centers throughout the country. This is neither a
complete list, nor a recommendation for the exclusive
use of the chemical houses listed.
Water Leaks
Water leaks around windshields installed with urethane adhesive can be corrected without removing the
windshield glass.
NOTE: If the windshield is structurally sound in the
body opening, without large breaks in the bond, water
leaks may be corrected by using a liquid butyl sealer
such as 3M Windo-Weld Resealant or equivalent. When
the windshield is not structurally sound in the body
opening, the following procedure will apply and will
require one Windshield Glass Installation Kit.
(1) Remove windshield reveal moulding, if
equipped.
(2) Water test around the entire sealing area of
windshield.
(a) Always begin water spray at lowest point
and allow sufficient saturation before moving water
spray upward.
(b) To best simulate normal conditions that
cause water leaks, i.e., rain or washing, water test with
a spray pattern rather than a heavy, solid stream of
water which can create misleading symptoms.
WINDSHIELD-REAR WINDOW
3N-3
Removal
(1) Cover adjoining painted surfaces to protect
finish.
(2) Remove windshield wiper arms using a wide
blade screwdriver.
(3) On vehicles with stainless steel mouldings, perform the following steps.
(a) Remove moulding screws on the top and bottom of side mouldings.
(b) Remove top corner moulding by lifting bottom and pulling outboard.
(c) Tip side mouldings toward center of vehicle
and lift off.
(d) Remove top moulding.
(4) Slide center moulding clip to left or right and
remove bottom mouldings. This will expose the locking
type weatherstrip.
(5) Use a wedge-shaped fiber or hardwood stick or
wand as shown in figure 3N-1 to unlock the weatherstrip
as shown in figures 3N-2 and 3N-3. (The locking type
weatherstrip without mouldings is shown in figure
3N-3.)
J42670
Fig. 31-1
U N L O C K E D POSITION
L O C K E D POSITION
UPPER F L A N G E
SEALER
SEALER
GLASS
MOULDING
GROOVE
MOULDING
GROOVE
jLjt
LOWER SECTION
U N L O C K E D POSITION
Fig. 3N-2
LOWER SECTION
L O C K E D POSITION
60613
GLASS
LOCKED POSITION
UNLOCKED
POSITION
GLASS OPENING
FLANGE.
WEATHERSTRIP
Fig. 3N-3
60614
314
WINDSHIELDREAR WINDOW
(6) Unlock rubber weatherstrip starting at the bottom with a fiber stick or wand as shown in figure 3N-4.
1/2 INCH
MASKING
TAPE
80421
Fig. 3N-5
RUBBER
WEATHERSTRIP
J42673
Fig. 3 N 4
(7)
(8)
erstrip,
flange.
(9)
(10)
flange.
Installation
(9) Apply smooth, continuous bead of urethane adhesive material inside of rubber weatherstrip body
flange cavity. Bead should be 1/8-inch in diameter.
(10) Install rubber weatherstrip on windshield opening flange.
(11) Apply a liberal amount of soap and water solution to edge of windshield glass.
(12) Place a 1/8-inch diameter cord in bottom glass
cavity of rubber weatherstrip.
WINDSHIELDREAR WINDOW
M A S K I N G TAPE
f i g ; 31-6
3N-5
N O T E : Urethane adhesive material begins to cure after 15-minute exposure to air and moisture.
(20) Water test windshield immediately using cold
water spray. Do not direct hard stream of water on fresh
urethane adhesive material. If leaks are encountered,
apply extra urethane adhesive material with pointed
nozzle.
(21) Bottom mouldings are installed one at a time. To
facilitate installation, place a 1/8-inch diameter cord in
weatherstrip moulding retaining groove along entire
6 0 6 1 1
Fig. 31-7
3N-6
WINDSHIELDREAR WINDOW
MOUNTING
BRACKET
J41066
Fig. 31-8
(Inches)Cherokee-Wagoneer-Truck Models
EMM WINDOW
GENERAL
Truck Models
SPECfiCJtTiOIS
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft. lbs.)
Service
Set-To
Torque
In-Use
Recheck
Torque
15
12-20
All Torque values given in newton-meters and inch-pounds with dry fits unless otherwise specified.
Metric (N-m)
Service
Set-To
Torque
In-Use
Recheck
Torque
1-2
70272
WINDSHIELDREAR WINDOW
Tools
J-25359-02
T O R X B I T A N D SOCKET SET
3N-7
NOTES
3P-1
Hardtop Enolosure
Page
3P-7
3P-11
Headlining
3P-2
3P-1
Intricate Decals
3M0
Tools
3P-14
HEADLINING
Page
Cherokee-Wagoneer Models
3P-1
Geieral
3P-1
0E1E1AL
The headlining used in Cherokee, Wagoneer and
Truck models is made of laminated polystyrene backing
board which is finished, depending on the model, with
either a plastic coating, a soft vinyl covering or a close
knit fabric. Lines scored into the backing board allow
the headlining to be shaped to fit the contour of the roof
while providing added strength for self-support.
CHE10KEE-WAG0IEE1MOOELS
iomovat
(1) Remove sun visors, escutcheons and center
support.
(2) Remove windshield moulding and end caps.
(3) Remove rear opening moulding and end caps.
(4) Remove plastic trim center moulding and end
cap retainers.
(5) Remove lens from dome lamp and cargo lamp.
Remove screws attaching lamp to roof bows. Remove
and disconnect cargo lamp switch.
(6) Remove coat hooks.
(7) Free rear headlining from J-moulding by pulling
down carefully at the center, while pushing up on either
outside edge.
(8) Push cargo lamp through die-cut opening in
headlining.
(9) Remove rear headlining through tailgate
opening.
Page
Trick Mollis
3P-2
(10) Free front headlining from J-moulding by pulling down carefully at the center, while pushing up on
outside edges.
(11) Remove front headlining through tailgate
opening.
Installation
(1) Position front headlining in vehicle and insert
left side into J-moulding.
(2) Pull dome lamp through die-cut opening in
headlining and align front headlining to vehicle roof.
(3) Pull down carefully at center of front headlining
and insert right side of headlining into J-moulding.
(4) Position rear headlining in vehicle and insert
left side into J-moulding.
(5) Pull cargo lamp through die-cut opening in rear
headlining and align rear headlining to vehicle roof.
(6) Pull down carefully at center of rear headlining
while pushing up on right edge, and insert right side of
headlining into J-moulding.
(7) Check alignment of front headlining using sun
visor and dome lamp holes and leading edge of headlining as guide. Adjust fore or aft as required.
(8) Check alignment of rear headlining using the
trailing edge as a guide. Adjust fore or aft as required.
(9) Secure dome lamp and cargo lamp to roof bows
and install lamp lenses. Install and connect cargo lamp
switch.
(10) Install plastic center mouldings and end cap
retainers.
3P-2
(11) Install
(12) Install
(13) Install
(14) Install
support.
coat hooks.
rear opening moulding and end caps.
windshield moulding and end caps.
escutcheons, sun visors and center
Roof low ^
Noise from the headliner may be caused by improperly adjusted roof bows.
(1) Remove headliner
(2) Loosen roof bow* attaching screws, using Torx
Bit J-25359-02.
(3) Insert screwdriver through hole in roof bow and
raise roof bow against roof panel.
(4) Tighten roof bow attaching screws using Torx
Bit J-25359-02.
(5) Install headliner.
TRUCK MODELS
Removal
(1) Remove sun visors and center support.
(2) Remove lens from dome lamp. Remove screws
attaching dome lamp to rear window panel.
Installation
(1) Position headlining in vehicle and insert left side
into J-mouldings.
(2) Pull dome lamp through die-cut opening and
align headlining to vehicle roof.
(3) Pull down carefully at center of headlining
while pushing up on right edge, and insert right side of
headlining into J-moulding.
(4) Check alignment of the headlining using the sun
visor and dome lamp holes and headlining leading edge
as guides. Adjust fore and aft as necessary.
(5) Secure dome lamp to rear window panel and
install dome lamp lens.
(6) Install windshield moulding and end cap.
(7) Install sun visors and center support.
H A R D T O P ENCLOSURE
Pl|!
General
Installation
Removal
Page
3P-2
3P-2
3P-2
GENERAL
A lightweight, removable hardtop enclosure is available for the CJ-7. The top is constructed of injection
molded polycarbonate. The hardtop enclosure and steel
liftgate are painted with a special spatter finish polyurethane enamel.
REMOVAL
(1) Remove screws attaching hardtop enclosure to
windshield frame (fig. 3P-1).
(2) Remove nuts, washers and screws attaching
hardtop enclosure to rear quarter panels.
(3) Remove hardtop enclosure from vehicle.
C A U T I O N : When removing hardtop enclosure, avoid
damaging foam sealer installed between the hardtop
enclosure and rear quarter panels.
INSTALLATION
(1) Inspect tabular windshield seal, bonded to hardtop enclosure, for damage. Replace if necessary.
Repair
Sun Roof
ap-2
SP-6
REPAIR
In the event of top damage, the following material will
be required for use with these repair procedures:
Paint Repair Kit (White)*
Paint Repair Kit (Brown)*
Paint Repair Kit (Black)*
Structural Adhesive (3M Brand or equivalent)
*Paint repair kits are available from parts distribution
centers. The paint repair kits consist of:
One quart spatter enamel
One quart sealer coat
3P-3
HARDTOP
ENCLOSURE
Fig. 3P-1
70508
Dent Repair
(1) Use a grinder to remove paint and to outline
damaged area.
(a) Use a grade 24 disc for initial grinding.
(b) Follow up with a grade 50 disc to prevent
coarse scratches from showing up in final finish.
3P-4
NOTE; Edges should be beveled on the inside and outside on the enclosure to ensure sufficient surface area
for bonding.
(3) Clamp broken piece into place leaving a 1/16inch gap along break line.
(4) Mix Structural Adhesive, according to manufacturer's instructions, apply liberally to break as shown in
figure 3P-4.
Fig. 3P-2
Fig. 3P-4
Fracture Repair
(1) Use a grinder to remove paint from both sides,
and to outline damaged area.
(2) Stop-drill crack(s) using 1/8-inch drill bit as
shown in figure 3P-5.
(3) Bevel edges of crack(s) on both sides, using a
rotary file.
NOTE: Edges should be beveled on the inside and outside of the enclosure to ensure sufficient surface area for
good bonding.
Fig. 3P-3
3P-5
60822
Fig. 3P-6
60820
Fig. 3P-8
Paint Repair
(1) Clean repair area using wax and silicone remover or such as DuPont Prep-Sol or Ditzler AcryliClean.
(2) Featheredge affected area as described in the
following steps:
(a) For rough featheredging, use a grade 80 disc
on a random disc sander.
(b) For final featheredging, use a grade 180 disc
on a random disc sander or 220 grade paper on a hand
sanding block.
(3) Mix sealer according to instruction sheet in kit.
60821
Fig. 3P-7
(5) Mix Structural Adhesive, according to manufacturer's instructions, and apply liberally to crack(s) from
inside and outside of enclosure as shown in figure 3P-8.
(6) Use an air file or hand file board and sanding
block for shaping of Structural Adhesive.
(a) For initial shaping, use a grade 24 paper.
(b) For shaping and sanding contours in Struc-
3P-6
SON ROOF
A sun roof (fig. 3P-9) is available on CJ-7 models
equipped with the hardtop option. The sun roof is raised
by turning the operator knob clockwise. To remove the
sun roof completely, raise the operator arms until the
plastic safety stop contacts the opposite operator arm.
Slide the safety stop up the operator arm and pull the
operator arm forward, to disengage the arms from the
aluminum glass frame. Remove glass and frame assembly from the metal roof frame by rotating glass and
frame assembly forward until hinges disengage from
the metal frame.
Bliss/Frame Assembly
Removal
Fig. 3P-9
(1) Pry the sun roof screw vinyl cover from the
clamp ring.
(2) Remove self-tapping screws and lower retaining
ring.
(3) Break the sealant bond between metal frame
and roof and remove metal frame from roof..'
3P-7
Installation
Operator
EXTERIOR DECALS
Page
Page
General
Repair
3P-7
3P-7
Replacement
3P-7
REPAIRS
GENERAL
Exterior decals and stripes are made of tough, durable, weather-resistant solid vinyl and have a pressuresensitive back. The pressure-sensitive back is protected
by a paper backing which is removed at installation. The
front (or face) of stripes and decals may be covered with
an easy-release paper for protection during shipment or
storage. The paper should be removed after installation.
REPLACEMENT'
Preparation
The temperature of the workroom should be between
65F and 90F. Decals should not be replaced in temperatures below 65F.
The following equipment and materials are necessary
for a quality installation:
Woodgrain and Stripe Remover3M, or equivalent
Adhesive Remover3M, or equivalent
Liquid detergent (Joy, Vel, or equivalent)
Wax and silicone remover (3M General Purpose
Adhesive Cleaner, xylol, or equivalent)
Isopropyl alcohol (rubbing alcohol)
Squeegee (4 to 5 inches wide, plastic or hard rubber)
Heat Gun J-25020 or infrared heat bulb with extension cord
Clean wiping rags or paper towels
, Sharp knife, single-edge razor blade or X-acto knife
Scissors
Sharp needle or pin
Grease pencil
3P-8
Removal
(1) Clean repair surfaces, adjacent panels and openings as required.
(2) Remove decal overlapping parts from affected
panel.
(3) Mask off area surrounding the panel.
(4) Spray 3M Woodgrain and Stripe Remover, or
equivalent, on flange area first. Then spray entire decal
to be removed (fig. 3P-10). Move spray back and forth
across entire decal in a smooth steady motion. Make
sure entire decal is coated with remover.
Fig. 3P-11
Fig. 3P-10
Fig. 3P-12
3Mis
3P-9
(10) After five minutes, use squeegee to remove adhesive residue (fig. 3P-13).
Fig. 3P-14
Fig. 3P-13
AJ41187
Fig. 3P-15
Installation
(1) Clean painted surface with wax and silicone remover. Use 3M General Purpose Adhesive Cleaner, or
equivalent. Wipe surface with clean cloth and allow to
dry.
Fig. 3P-16
Lifting Decal
(5) Remove approximately 6 inches of paper backing from one end (fig. 3P-17).
Fig 3P-17
3MQ
fillMMIjYS
effectiveness
Fig. 3P-19
3P-11
EXTERIOR WOODGRAIN
OVERLAYS
Pap
General
Installation
Preparation
3P-11
3P-13
3P-11
GENERAL
Exterior woodgrain overlay panels are made of a
tough, durable, weather-resistant, opaque cast vinyl and
have a pressure-sensitive back. The pressure-sensitive
back is protected by a paper backing which is removed at
installation. The woodgrain is embedded in the cast
vinyl for a longer lasting, attractive appearance. In addition, the rear panels are retroreflective; that is, light is
reflected back to its source by means of thousands of
tiny glass beads impregnated in the cast vinyl.
REPAIRS
Small nicks, bruises or scratches can be touched up
with paint in much the same manner as painted surfaces. Proper color match can be obtained by blending
small amounts of appropriate paint colors, then spotpainting the affected area of the overlay.
To repair blisters or air bubbles, pierce them with a
sharp needle or pin. Work the trapped air out through
the pin hole and press the overlay firmly against the
panel. It may be necessary to preheat the panel slightly
with Heat Gun J-25070 to soften the adhesive. Heat also
may be applied to remove small wrinkles, irregularities,
or bridging which may occur in the corners of the fuel
tank filler opening.
N O T E : Whenever the material must be stretched, do
not slit or cut the overlay. Simply apply heat and press
or squeegee the overlay smoothly and firmly into place.
PREPARATION
Workroom temperature should be between 65F and
90F. Overlays should not be replaced in temperatures
below 65F.
The following equipment and materials are necessary
for a quality overlay installation.
Woodgrain and Stripe Remover3M, or equivalent
Adhesive Remover3M, or equivalent
Liquid detergent (Joy, Vel, or equivalent)
Wax and silicone remover (3M General Purpose
Adhesive Cleaner, or equivalent)
Isopropyl alcohol (rubbing alcohol)
Squeegee (4 to 5 inches wide, plastic or hard rubber)
Water bucket and sponge
Pip
Removal
Repairs
Vinyl Moulding Replacement
3P-12
3P-11
3P-11
3P-12
REMOVAL
(1) Clean repair surfaces, adjacent panels and openings as required.
(2) Remove overlay, reveal mouldings, door handles, lock assembly, side marker lamps or other overlapping parts from the affected panel.
(3) Mask off area surrounding the panel.
(4) Spray 3M Woodgrain and Stripe Remover, or
equivalent, on flange area first. Then spray entire overlay to be removed (fig. 3P-20). Move spray can back and
forth across entire overlay in a smooth steady motion.
Make sure entire overlay is coated with remover.
Fig. 3P-21
Fig. 3P-20
Fig. 3P-22
3P-13
Fig. 3P-23
INSTALLATION
(1) Scuff-sand painted surface with No. 220 or No.
400 sandpaper by dry sanding. Freshly painted surfaces
must be thoroughly dry. Residual solvents in fresh paint
may cause overlay to blister.
(2) Clean painted surfaces with wax and silicone
remover (3M General Purpose Adhesive Cleaner, or
equivalent). Wipe surface with clean cloth and allow to
dry.
(3) Position overlay on repair panel surface, and
mark approximate outline on overlay with a grease pencil. Ensure that 1/2-inch excess is allowed to be wrapped
around the door and fender areas. With scissors, cut
overlay to approximate size. Overlay should be cut so
that upper and lower edges extend halfway into area
covered by mouldings.
(4) Place overlay on a clean, flat surface with protective paper backing side up. Bend a corner of the
overlay toward the decorative face side, and with a flick
of the finger, separate the paper backing from the overlay. Hold overlay firmly to the surface of a table and
remove the paper backing. Under hot, humid conditions,
a slight jerking motion aids in removing paper backing.
(5) Using clean sponge, apply ample wetting solution to overlay adhesive and to repair panel surface. The
wetting solution permits ease of movement of the overlay while positioning it on a panel surface.
(6) Immediately apply wetted overlay to the repair
panel surface. Position overlay in the center of the area
to be covered with at least 1/2 inch extending beyond
edges. Apply wetting solution to woodgrain surface of
overlay to allow squeegee to slip during application.
(7) Squeegee from the center to edges of overlay
with firm strokes to remove all air bubbles and wetting
solution and to assure bonding of overlay to painted
surface. On large overlays, the following steps will simplify installation:
(a) Squeegee a short, 4 to 6-inch horizontal section of overlay at center of panel. Lift right or left side of
overlay, position it straight and close to panel, and
squeegee toward lifting edge. Avoid stretching overlay
at lifted end; squeegee progressively from middle with
firm, overlapping strokes.
(b) Lift upper area of overlay (up to bonded
area) and, working upward from bonded section at center, squeegee overlay into place.
(c) Lift lower area of overlay (up to bonded
area) and working downward from bonded section at
center, squeegee overlay into place.
NOTE: If a wrinkle is trapped during squeegee operations, stop immediately. Carefully lift affected section.
Realign section to panel and progressively
remove
wrinkle. Do not lift overlay if only a few bubbles are
trapped.
(8) Notch corner or curved edges of overlay where
necessary and trim off excess material.
(9) Allow 1/2-inch extra material beyond edges that
are to be wrapped around flange areas.
CAUTION: Use extreme care to avoid spilling isopropyl alcohol (rubbing alcohol) on trim or painted surfaces. Wipe spills immediately as alcohol will discolor
trim or painted surfaces on prolonged contact
(10) To activate adhesive, wipe adhesive side of overlay with isopropyl alcohol.
(11) Warm overlay at edges by passing a heat source,
such as Heat Gun J-25070, over the surface to soften it.
(12) Firmly press overlay into position with fingertips, a cloth, and finally a squeegee, alternately warming and pressing it until complete adhesion is obtained.
NOTE: Avoid undue pulling or stretching
overlay as tearing could result
at ends of
3M4
Tools
70301
3R-1
LIGHTING
SYSTEMS
SECTION INDEX
Page
Chassis Wiring Harness
Exterior Lighting Systems
3R-14
3R-1
-3R-12
3R-6
3R-10
3R-4
3R-5
3R-9
3R-9
3R-17
E X T E R I O R LIGHTING
SYSTEMS
Backup Lamps and Switches
Cargo Lamp
Directional Signal Switch
Engine Compartment Lamp
General
Headlamps
3R-6
3R-7
3R-7
3R-11
3R-1
3R-1
GENERAL
The wiring of the lighting systems is shown in the
wiring diagrams which indicate the various units in
relation to their positions in the vehicle. The wires in the
various circuits are different colors or are marked by
tracers.
All models have a 20-amp circuit breaker built into
the switch for light system protection.
The upper and lower headlamp beams are controlled
by a foot switch located on the toeboard.
HEADLAMPS
All models are equipped with a single headlamp
system.
The round headlamp used with the CJ system is identified by the number 2 embossed on the sealed beam
face. The new large rectangular headlamp system is
used on all Cherokee, Wagoneer and Truck models. All
lamps contain two elements: one low beam and one high
beam.
I t plicinttnt
Each sealed beam headlamp can be replaced only as a
complete unit.
CJ Models
31-2
LilHTlil SYSTEMS
VERTICAL
ADJUSTMENT
HORIZONTAL
ADJUSTMENT
VERTICAL TAPE
LAMP CENTER
HORIZONTAL
VERTICAL
LEFT
CENTERLINE
VERTICAL TAPE
RIGHT LAMP
"CENTER
TAPE
J42727
HEIGHT OF
CENTERS
ZONE OF GREATEST
INTENSITY
LAMP
25
FEET
J42728
Fig 3R-1
Fig. 3R-2
Headlamp Aiming
(15) Turn screw clockwise until top edge of high intensity area is even with horizontal line.
(16) Turn horizontal aiming screw counterclockwise
until beam is off centering tape.
(17) Turn same screw clockwise until left edge of
high intensity area is 2 inches to right of lamp centerline
(fig.3R-l).
(18) Cover lamp that has been aimed and aim other
lamp using same procedure.
Headlamp Switch
The switch is a two-position switch containing a
rheostat for controlling instrument panel light brightness (fig. 3R-3). Rotating the knob clockwise dims the
panel lights. Rotating the knob fully counterclockwise
turns on the dome and courtesy lamps.
Headlamp Switch Replacement
LIGHTING SYSTEMS
WIRING
HARNESS
PLUG
INPUT
TERMINAL
3R-3
OUTPUT
TERMINALS
T E R M I N A L JUNCTION
DOME L I G H T SWITCH
J42730
Fig. 3R-4
RETAINING NUT
J42729
Fig. 3R-3
Headlamp Switch
314
LIGHTING SYSTEMS
Models
The parking lamps are mounted in the radiator guard
panel just below the headlamps (fig. 3R-5). The lamps
are on when headlamp switch knob is pulled out.
Parking and Directional Bulb
(1)
(2)
(3)
(4)
Cherokee-Wagoneer-Truck Models
The parking lamps are mounted in the panel just
above the bumper (fig. 3R-6).
The front side marker lamps flash in unison with the
front directional indicator bulb when the headlamps are
not on. When the headlamps are on, the side markers
flash alternately with the front directional signal lamps.
Side markers and parking lamps come on when the
headlamp switch is pulled out to any position.
To replace parking lamp bulbs on Cherokee, Wagoneer
and Truck models, remove the lens and gasket to gain
access to the bulb.
To replace side marker lamps, remove the lamp assembly. Twist the socket 1/4-turn counterclockwise to
remove. Remove the bulb by pulling it straight out from
the socket.
Fig. 3R-6 Headlamp, Parking, Directional and Side Marker LampsCherokee-Wagoneer-Truck Models
LIGHTING SYSTEMS
Fig. 3R-7
3R-5
Rear Directional, Stop, Backup, Taillamps and Side Marker LampsCJ Models
CJ Models
HARNESS
T A I L STOP
DIRECTIONAL
IBULB
Cherokee
Refer to figure 3R-8 for parts identification.
Fig. 3R-8
BACKUP
BULB
J42735
3R-6
LIGHTING SYSTEMS
Wagoneer
Refer to figure 3R-9 for parts identification.
Truck
The lamp assemblies are mounted in the pickup box
end caps (fig. 3R-10).
Taillamp Bulb Replacement
LIGHTING SYSTEMS
Fig. 3 1 4 0
3R-7
CARGO I AMP
A cargo lamp is offered on some Truck models (fig.
3R-11). The cargo lamp bulb is replaced by removing the
outer lens.
GASKET
J42739
Fig. 3R-11
Cargo LampTruck
Switch Removal
(1) Disconnect battery negative cable.
3R-8
LIGHTING SYSTEMS
AJ42231
DIRECTIONAL
SIGNAL
ACTUATING
LEVER
Fig. 3 1 - 1 2 Lock Plato Snap Ring Removal
Fig. 3R-13
DIRECTIONAL
S I G N A L SWITCH
ASSEMBLY
LIGHTING SYSTEMS
(9) Remove Lock Plate Compressor Tool, snap ring,
lock plate, directional signal canceling cam, upper bearing preload spring and thrust washer from steering
shaft.
(10) Place directional signal actuating lever in right
turn position and remove lever.
(11) Depress hazard warning light switch, located on
right side of column adjacent to the key lock, and remove button by turning in a counterclockwise direction.
(12) Remove directional signal wire harness connector block from its mounting bracket on right side of
lower column.
NOTE: On vehicles equipped with automatic transmission, use a stiff wire, such as a paper clip, to depress the
lock tab which retains the shift quadrant lamp wire in
the connector block.
(13) Remove directional signal switch retaining
screws and pull directional signal switch and wire harness from column (fig. 3R-13).
Switch Installation
(1) Guide wire harness into position and carefully
align switch assembly.
3R-9
STOPLAMP SWITCH
The stoplamp switch is self-adjusting and is the same
for all models. The switch is retained in its mounting
bracket by a spring clip which engages the threaded
portion of the switch housing (fig. 3R-14). The switch
may be removed by pulling straight out of the mounting
bracket and retainer.
BRACKET
CONNECTOR
70533
Fig. 31-14
Stoplamp Switch
31-11
LIGHTING SYSTEMS
Adjustment
(1) Depress brake pedal and hold in depressed
position.
(2) Push stoplamp switch completely into mounting
bracket until switch bottoms.
(3) Release brake pedal and allow it to return to
undepressed position. Brake pedal will push switch to
properly adjusted position.
(4) Check switch operation. Stoplamps should operate after 3/8 inch to 5/8 inch of pedal travel.
Stoplamp Switch Electrical Test
This test requires a voltmeter.
(1) Ground one lead of voltmeter.
(2) Probe each connection of stoplamp switch with
other lead of voltmeter.
(a) With switch plunger depressed (brake not
applied), one switch connector should indicate voltage
and the other should not.
(b) With switch plunger released (brake applied), both switch leads should show voltage.
OFF-ROAD DRIVING LAMPS
The off-road driving lamps (fig. 3R-15) are installed
on Truck models equipped with an roll bar. The fuse
holder and switch (fig. 3R-16) are located on the instrument panel to the left of the steering column.
N O T E : On California vehicles, the fuse must
moved from the fuse holder for street use.
be re-
Fig. 31-16
Aiming Lamps
(1) Position vehicle on a flat surface, facing and
approximately 25 feet from a wall.
(2) Remove lamp stone shields.
(3) Install fuse in fuse holder, if removed.
(4) Loosen lamp attaching bolts. Turn ignition
switch and lamp switch on, adjust lamp beams as
follows:
mm SYSTEMS 3R-11
STONE S H I E L D
L E N S & REFLECTOR
80635
Fig. 31=17
Switch Replacement .
(1) Disconnect electrical leads from switch and note
or tag leads so they may be installed in the correct
position.
(2) Compress sides of switch body and remove
switch from bracket (fig. 3R-18).
BULB
(3) Install replacement switch in bracket and connect electrical leads to switch terminals as noted above.
ENGINE COMPARTMENT L A i P
This optional lamp obtains current at the battery terminal of the s t a r t e r solenoid. A single wire incorporating a fusible link for protection passes current
to the lamp assembly. The lamp assembly has a mercury
switch which completes the circuit through the hood
assembly when the hood is open. When the hood is
closed, the mercury within the lamp assembly opens the
circuit and the lamp does not light (fig. 3R-19).
HOLDER
ENGINE COMPARTMENT
LAMP ASSEMBLY
BULB
SPLICE
SWITCH
STARTER
jf^w_p[ |KI
SOLENOID ^
BATTERY
^
BRACKET
N E G
POSH|J
DC
CONNECTOR
. . . . .
BLACK
DLAG
t i R\ O U N D S
THROUGH
HOOD
ASSEMBLY
60426
8 0 6 3 6
Fig. 3 1 - 1 8
3R-12
LIGHTING SYSTEMS
INTERIOR LIGHTING
SYSTEM
Page
Cargo Lamps
Courtesy Lamps/Dome Lamps
Dome/Reading Lamp
Page
31-13
3R-12
3R-12
Glove I n Lamp
Instrument Cluster Lamps
Lighted Vanity Mirror
3R-13
3R-13
3R-13
To install, align the lens tab with the proper slots and
snap it into place.
CJ Models
Truck Models
Cherokee-Wagoneer Models
The courtesy and dome lamps operate when the doors
are opened. The door pillar switch provides a ground for
the circuit.
Battery feed is from the headlamp switch. When the
doors are closed, the dome and courtesy lamps are operated by rotating the headlamp switch knob counterclockwise to the stop. The ground for the lamps is then
through the headlamp switch. The standard round dome
lamp lens has three irregularly spaced barbed tabs that
are inserted into slots in the dome lamp base to retain it.
The lens is removed by pulling it downward or by prying
it down with a small screwdriver (fig. 3R-21).
Fig. 3R-22
00ME/REA01NGMMP
Cherokee-Wagoneer Models
Fig. 3R-21
SWITCH
IB
Fi|. 31-24 Ufjiisi Vanity MirrorQrarokee-Wagoneer M e l s
CA1G0 LAMP
C l i r o k i i - l i p n i r Models
seat position. The reading lamps are operated individually by a sliding switch located next to each lamp (fig.
3R-23). The reading lamps are grounded through the
lamp assembly attaching screws to the roof bow. Refer
to Wiring Diagrams at the end of this manual for
details.
" .
3R-14
LIGHTING SYSTEMS
CHASSIS WIRING H A R N E S S
Pap
Pap
Circuit Breakers
3R-16
Specifications
3R-17
Fuse Panel
Ignition Switch
31-18
3R-15
3R-14
START
ON
LOCKQ
ACC-O I
Fusible Links
Fusible links are harness wires covered with a special
non-flammable insulation. The links protect circuits
which are not normally fused due to carrying high amperage loads or because of their location in the chassis.
They are used to prevent major harness damage in the
event a short circuit, short to ground or overload condition occurs.
All Jeep models are equipped with fusible links, located in the engine compartment, which protect the
circuits shown in the Wiring Diagrams.
Each link is of a fixed value for the specific load.
Replacement links are listed in the parts catalog.
CASE
GND.
60140
Fig 3R-25
LIGHTING SYSTEMS
(4) Following the wiring diagram, determine which
circuit(s) may have caused the failure. Test the circuit(s)
using an ohmmeter or test light until ground condition
is located and corrected.
(5) Unsolder link from harness, solder replacement
link to harness wire(s).
N O T E : Solder joint MUST be made with rosin core
solder only. DO NOT use acid or acid core solder. Protect
harness wires from damage when soldering.
(6) Tape harness using plastic electrical tape.
(7) Route wire as originally installed and make
connection.
(8) Connect battery negative cable and check operation of the circuit(s) involved.
IGNITION SWITCH
The ignition switch is mounted on the lower section of
the steering column and is connected to the key lock
assembly by a remote lock rod.
31*11
(1; Place key lock in OffLOCK position and remove two switch attaching screws.
(2) Disconnect switch from remote rod.
(3) Disconnect harness connector and remove
switch from steering column.
Testing
The ignition switch terminals are shown in figure 3R25.
To test the ignition switch circuitry and continuity,
place the slide bar in the position to be tested and use
either an ohmmeter or Continuity Light J-21008.
Ignition switch slide bar positions can be easily identified by first locating the alignment hole located in the
flat portion of the switch adjacent to the terminals.
Starting from the alignment hole end of the switch, the
switch positions are: Accessory, OffLOCK, Off, On,
and Start. Each position has a detent stop except
START which is spring loaded to release when the key is
released.
JG1
STEERING
COLUMN
STEERING WHEEL
STANDARD COLUMN
S T E E R I N G WHEEL
TILT COLUMN
I G N I T I O N SWITCH
POSITION
CIRCUIT
START
CONNECTED
GROUNDED
ON
1-1 & B 1
A & B-2
1-3 & B-3
CONNECTED
CONNECTED
CONNECTED
OFF
OPEN
OFF-LOCK
ACCESSORY
OPEN
A & B-2
B-1, B-2 & B-3 (COMMON C O N N E C T I O N )
Fig. 3R-26
CONNECTED
A42215
3R-16
LIGHTING SYSTEMS
Installation
Standard Column
Tilt Column
90199
Fig. 3R-27
CIRCUIT BREAKERS
F1SE PANEL
The fuse panel is located on the passenger compartment side of the dash panel, attached to the main
harness connector.
CJ Modols
Headlamps are protected by a 20-ampere circuit
breaker located in the headlamp switch.
LIGHTING SYSTEMS
QaQftDp]
c
i|_JI_JI
\DpOtojj]
CZZDCZ]
D liDp D gjDa Do
7T
3R-17
D afl Da
TT
o,
REAR VIEW
FRONT
Fig. 3R-28
VIEW
90200
Cherokee-Wagoneer-Truck Models
Headlamps are protected by a 20-ampere circuit
breaker located in the headlamp switch.
The tailgate window circuits are protected by two 30ampere circuit breakers located in the fuse panel.
One circuit breaker is used in the instrument panel
switch circuit and the other is used in the tailgate key
operated switch circuit.
Torque Specifications
Service Set-To Torques should be used when assembling components.
Service In-Use Recheck Torques should be used for checking a pre-torqued item.
All Torque values given in inch-pounds with dry fits unless otherwise specified.
70377B
3R-18
LIGHTING SYSTEMS
Tools
S E A L REMOVER
(STEERING WHEEL" P U L L E R )
J-23653-LOCK
P L A T E COMPRESSOR
J-21008
CONTINUITY LIGHT
42271B
3S-1
HORN
SYSTEMS
SECTION INDEX
Page
General
Horn Ad|ustment
3S-1
3S-2
Page
Horn System Dlangosls mi Repair
Specifications
3S-1
3S-2
GENERAL
RED W/T
HORN
TO M A I N
HARNESS
B L A C K W/T
80264
Fig 3S-1
A fusible link is incorporated in the main wiring harness to furnish protection against major harness
damage.
When a grounded circuit or overload occurs in the
horn circuit, damage will be limited to the fusible link.
(7) If horn does not operate, ground number 2 terminal and connect a jumper lead from horn relay terminals 1 to 3.
(8) If horn now operates, a faulty horn relay is
indicated.
(9) If it does not operate, check wiring and connections between the horn relay terminal number 3 and
horn for continuity.
(10) Connect a jumper lead from horn base to the
vehicle chassis or engine and repeat the above tests.
(11) If horn now operates, remove attaching screw,
horn and mounting bracket, clean mating surfaces.
(12) Install horn, mounting bracket and attaching
screw, tightened screw to 15 foot-pounds (20 Nm)
torque.
(13) If horn still does not operate, horn is inoperative
and must be replaced.
3S-2
HORN SYSTEMS
GROUND
HORN
HORN ADJUSTMENT
Adjust current by turning the adjusting screw
counterclockwise to decrease the current until the specified current is reached. Current adjustment is very sensitive. Therefore, care must be taken not to turn the
horn adjustment screw too far. Turn only 1/10 of a turn
at one time.
(1) Check for normal battery voltage (about 12.6
volts).
(2) Connect ammeter in series between horn and
battery and read current as shown in figure 3S-2.
(3) Adjust current to 4.5 amps.
BATTERY
AMMETER
Fig. 3S-2
42233
SPECIFICATIONS
Electrical Specifications
Item
Current Flow
Horn
4-5 Amps
70446
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (ft.lbs.)
Metric (N-m)
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
Service
Set-To
Torque
Service
In-Use
Recheck
Torque
15
8-17
20
11-23
All Torque values given in newton-meters and foot-pounds with dry fits unless otherwise specified.
70445
3T-1
WINDSHIELD
WIPERS
SECTION INDEX
Page
Cherokee-Wagoneer-Truck Windshield Wipers
3T-4
CJ Windshield Wipers
3T-1
CJ W I N D S H I E L D W I P E R
Page
General
Washer Pimp
Page
3T-1
3T-2
3T-2
3T-8
3T-2
3T-2
3T-1
GENERAL
Fig. 31-1
Installation
(1) Install pivot shaft body and linkage in windshield frame.
(2) Connect wiper motor drive link to left wiper
pivot.
(3) Install right and left access hole covers.
(4) Raise windshield to upright position and install
right and left windshield holddown knobs.
(5) Install nuts attaching pivots to windshield
frame.
(6) Install right and left wiper arms.
(7) Install necessary top components on windshield
frame.
Fig. 3T-2
Installation
Fig. 3T-3
Selector Position
Off or Park
B-1
Low Speed
B-2
High Speed
B-3
Wash
B-W
80343
Fig. 3T-4
Troubleshooting Procedures
The wiper motor may be operated independently of
the switch to aid in determining defective components.
NOTE: The wiper motor must be grounded for proper
operation and during all wiper tests.
With ignition switch on, check for 12 volts at switch
terminal B. If 12-volt test lamp lights but wiper motor
does not operate, connect a jumper wire from ground
strap on motor to a good body ground. If motor still does
WASHER PU1P
The electric washer pump assembly is mounted in the
water reservoir. The impeller motor case is grounded to
the body sheet metal by a black ground wire. It is energized by a yellow feed wire from the single blade terminal on the control switch.
3T-4
WINDSHIELD WIPERS
Intermittent governor
Tools
Specifications
Page
3T-14
3T-6
Windshield Washers
Wiper Arm Replacement
Wiper Blade Element Replacement
Wiper Blade Replacement
Wiper Mtter
Wiper Pivot Shaft Body and Linkage
3T-4
3T-15
3T-18
3T-18
3T-18
3T-4
3T-4
3T-4
3T-15
3T-5
GENERAL
The new two-speed electric windshield wipers and
electric washers are standard equipment. An optional
intermittent wiper system provides a pause between
wipe cycles for use during conditions of very light
precipitation.
The controls for the windshield wipers are mounted
on the instrument panel to the left of the steering
column.
The electric wipers are operated by turning the control knob to the right. For intermittent operation, turn
knob to the left. Electric washers are actuated by depressing the wiper control knob.
The wiper arms are actuated by a link and pivot
assembly attached to the wiper motor.
The wiper motor is mounted to an adapter plate
mounted to dash panel.
The wiper arms move in a tandem-like action and
park to the right side of the vehicle.
BLADE
INSTALLATION
Fig. 3T-5
BLADE
FRAME
LEVER
RUBBER B L A D E
41524
Fig. 3T-6
WINDSHIELD WIPERS
3T-5
PASSENGER SIDE
2-7/8 INCHES
D R I V E R ' S SIDE
2-1/4 INCHES
41104
Fig. 3T-7
BLADE
NUT
CLIP
GASKET
LEFT PIVOT
SHAFT BODY
SCREW
W A V E WASHER
BOLT
J41045
Fig. 3T-8
31-1
WINDSHIELD WIPERS
installation
iiiiiisislii^ciiCiiTif
This section is a guide to troubleshooting the windshield wiper system used on Cherokee, Wagoneer and
Truck models. It consists of two parts: Diagnosis Charts
and Circuitry Illustrations.
Service Diagnosis
W I N D S H I E L D WIPERS DO N O T O P E R A T E OR
O P E R A T E A T O N E SPEED O N L Y
BOTH SPEEDS
SYSTEM IS FREE
H I G H OR LOW SPEED
HIGH SPEED:
BLUE W/TR
AND GROUND
BLUE A N D
GROUND
NO L I G H T
NO C O N T I N U I T Y OF C I R C U I T R Y TO THE WIPER
MOTOR - CHECK I G N I T I O N SWITCH, WIPER SWITCH,
HARNESS, A N D T E R M I N A L S FOR OPEN CIRCUITS.
L I G H T ON
CHECK FOR LOOSE OR M I S A L I G N E D CONNECTION BETWEEN W I R I N G HARNESS PLUG A N D MOTOR PLUG CHECK MOTOR G R O U N D STRAP CONNECTIONS.
70259
WINDSHIELD WIPERS
3T-7
W I N D S H I E L D WIPERS DO N O T PARK
V E R I F Y THE C O M P L A I N T .
DISCONNECT THE WIPER MOTOR A N D DO THE FORLOWING A T THE WIPER MOTOR PLUG.
1. CONNECT THE B L A C K TO THE WHITE L E A D .
2. FEED 12 V O L T S D I R E C T L Y TO THE RED L E A D .
PARKS OK
NO PARK
NO L I G H T A N D / O R
NO C O N T I N U I T Y
NOT OK
OK
70260
WINDSHIELD WIPERS
3T-8
WIPER M O T O R Q U I T S W H I L E WIPING
WITH
ENGINE
OPERATE
(5)
CYCLES
A N D
STOPS S U D D E N L Y
OPERATES
(CIRCUIT
57
IDLING A N D
WIPERS
A T
CONSISTING
SECONDS
BLOWER
HIGH
M O T O R
SPEED SETTING
OF
SECONDS
ON
OF
FIVE
WATER
D R Y I N G .
OR
STRUGGLES T O A
I N T E R M I T T E N T L Y
BREAKER
HIGH
FOR
STOP (STALLED
OPENS)
i
*TEST CIRCUIT
COMPLETE
M O T O R )
i
CLEAN
BREAKER.
GLASS
REPLACE
* * R E P E A T
STILL STOPS D U R I N G
5 CYCLE
A N D / O R
WIPER
BLADES.
TEST.
STILL STOPS D U R I N G
TEST
TEST
i
REPLACE
BLADES.
*TEST CIRCUIT
* * R E P E A T
5 M I N U T E
(5 C Y C L E )
STILL STOPS D U R I N G
BREAKER.
TEST.
TEST.
I
REPLACE
CIRCUIT
* *
A L L O W
H A N D
BREAKER
M O T O R
CAN
IS I N T E G R A L
TO COOL
T O
140
BE H E L D A G A I N S T
WITH
F OR
M O T O R
I N S T R U M E N T
LOWER
PANEL
M O T O R .
SWITCH.
BEFORE S T A R T I N G
W I T H O U T
REPEAT
TESTS.
IF M O T O R
IS 140
F OR
LOWER,
THE
DISCOMFORT.
70261
WINDSHIELD WIPERS
3T-9
V E R I F Y THE C O N D I T I O N .
DO B L A D E S STOP A N D S T A R T IN M I D D L E OF C Y C L E ,
ERATICALLY?
YES
NO
TEST C I R C U I T B R E A K E R . *
NOT OK
OK
REPLACE SWITCH.
NOT OK
OK
REPLACE G O V E R N O R .
3T 10
WINDSHIELD WIPERS
V E R I F Y THE C O N D I T I O N .
NOT OK
OK
REPLACE WIPER SWITCH.
OK
NOT OK
OK
REPLACE G O V E R N O R .
70263
WINDSHIELD WIPERS
3T-11
W I N D S H I E L D WASHER DOES N O T O P E R A T E
V E R I h Y THE C O N D I T I O N .
OK
OK
REPLACE FUSE
LIGHT
ON
NO L I G H T
70264
3T-12
WINDSHIELD WIPERS
RED W/TR
RED W/TR
4\
WIPER
SWITCH
NOTE: WIPER SWITCH
OPERATES TWO
SETS OF CONTACTS
SIMULTANEOUSLY
FUSE
PANEL
SWITCH
POSITIONS
P - OFF
L - LOW
H - HIGH
WASHER
PUMP
WIPER
MOTOR
NOTE: IN R U N M O D E ,
MOTOR SWITCH
CONTACTS M O V E TO
INTERMITTENT
PARK POSITION
ONCE E V E R Y MOTOR
R E V O L U T I O N TO
PROVIDE PARK
FUNCTION.
Fig. 3T-9
70265
WINDSHIELD WIPERS
3T-13
E
Q
UJ
GROUND T H R O U G H I N S T R U M E N T
PANEL.
CC
I
Q
UJ
INTERMITTENT
GOVERNOR
cc
H
Q
UJ
CC
\|/'
FUSE
BLOCK
NOTE: IN RUN M O D E ,
MOTOR SWITCH
CONTACTS M O V E TO
INTERMITTENT
PARK POSITION
ONCE EVERY MOTOR
R E V O L U T I O N TO
PROVIDE PARK
FUNCTION.
1
a
WIPER MOTOR
Fig. 3T-10
70266
3T-14
WINDSHIELD WIPERS
CONTROL SWITCH
Removal
A one-way friction spring in the control knob retains
it to control switch shaft. This one-way spring allows
knob to be installed but prevents its removal unless
spring tension is released.
(1) Disconnect battery negative cable.
(2) To remove, locate small notch at base of knob
and insert a small screwdriver at that point. Apply
pressure to release spring and pull knob from shaft.
(3) Remove slotted trim nut from front of switch.
(4) Push switch through instrument panel, disconnect from harness and remove.
Installation
(1) Connect switch to harness and push through
instrument panel.
(2) Install slotted trim nut on front of switch and
tighten.
(3) Align control knob and push on shaft.
(4) Connect battery negative cable.
Switch Test
(1) Check wiper switch continuity using Continuity
Light J-21008 or an ohmmeter. Continuity should exist
between terminals at various switch positions as shown
in figure 3T-11.
(2) Variable resistance between number. 4 and 5 terminals of an intermittent wiper system must be checked
with an ohmmeter. This resistance controls governor
operation for intermittent wiping. If intermittent wipe
cycle is not operating, but system does operate at both
low and high speed, resistance between number 4 and 5
terminals should be checked. With switch control knob
rotated to full counterclockwise position, ohmmeter
should indicate 5600 to 8400 ohms. As control knob is
rotated in a clockwise direction, resistance should decrease to a minimum of 100 to 900 ohms.
(3) If continuity and resistance do not check out as
specified, switch must be replaced. Check wiring for
proper continuity if switch tests indicate proper
operation.
Standard
Intermittent
Off or Park
1-2
3-4
1-2
4-5
Low Speed
1-2-3
1-2
4-5 to Case
4-5
1-2-3
High Speed
1-2-5
4-5 to Case
4-5
1-2
4-5 to Case
. ^-Variable Resist.
" 1-9K to 7 K
Intermittent
Wash
1-2
6-7
41528
GREEN
Connect switch to tester as shown in figure 3T-12. Adjust current draw until it equals circuit breaker rating.
Leave switch connected to tester for 10 minutes. Current
reading on ammeter should remain at rated current. If
circuit breaker opens during ten minute period, replace
wiper switch assembly.
1-2
6-7
WINDSHIELD WIPEBS
Test 2
Connect switch as shown in figure 3T-12. Adjust current
draw until it is twice switch rating. Current reading on
ammeter should drop to zero within 15 seconds. If it
takes longer than 15 seconds for circuit breaker to open
(current reading drops to zero), replace wiper switch
assembly.
INTERMITTENT GOVERNOR
"
To check the intermittent governor accurately requires electronic testing equipment. However, if the intermittent wipe cycle is not satisfactory, check related
components such as the motor, control switch, and connecting wires. If all components function properly, install a new governor.
The electronic governor assembly is contained in a
two-inch cube which is attached to an instrument panel
bracket adjacent to the wiper control switch. The 6-inch
governor lead plugs into the wiper control switch and
the shorter, 4-inch lead plugs into the instrument panel
harness (fig. 3T-13).
Fig. 3T-13
3145
41526
Fig. 3T-14
Intermittent Governor
WIPER I0T0R
Removal
(1) Remove screws attaching motor adapter plate to
dash panel.
(2) Separate wiper wiring harness connector at
motor.
(3) Pull motor and linkage out of opening to expose
drive link-to-crank stud retaining clip. Raise up lock tab
of clip with a flat blade screwdriver and slide clip off
stud.
(4) Remove wiper motor assembly.
Installation
(1) Position wiper motor assembly and insert crank
stud into drive link bushing.
41530
Fig. 3T-15
3T-16
WINDSHIELD WIPERS
Park Tist
(1) Disconnect motor from harness connection.
Temporarily contact a battery feed to either blue or blue
w/tracer wire to move wiper arms and blades away
from normal park position.
(2) Insert jumper wire from white to black wire
terminals (fig. 3T-16).
Assemhlf
Fig. 3T-16
Part Tiit
Disassemlf
CAUTION: The motor field consis ts of two permanent
ceramic-type magnets which can be damaged by pounding on the motor housing or the magnets.
NOTE: Mark position of drive crank with respect to
output shaft for correct assembly.
(1) Remove drive crank attaching nut, drive crank,
spring washer, and plain washer (fig. 3T-17).
(2) Remove screws attaching mounting bracket to
motor. Separate bracket from motor and remove screw
attaching ground strap to bracket.
(3) Remove screws attaching gear housing cover to
housing. Remove cover and gasket.
WINDSHIELD WIPERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
NUT
DRIVE CRANK
SEAL
BRACKET
SCREW
G R O U N D STRAP
SPRING WASHER
PLAIN WASHER
GROMMET
GEAR HOUSING
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Fig. 3T-17
SHAFT
SWITCH WASHER
SWITCH LEVER
OUTPUT GEAR A N D S H A F T
END PLAY SPRING
IDLER GEAR A N D P I N I O N
GASKET
SCREW
COVER
PUSH N U T
BRUSHES A N D HARNESS
(12) Install motor housing on armature, holding armature worm gear to prevent magnetic field from pulling armature out of position in gear housing.
(13) Align indicator marks on motor housing and
gear housing before inserting through-bolts.
'" (14) Install through-bolts securing motor housing to
gear housing.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
3T-17
END H E A D
ARMATURE
BALL
MOTOR HOUSING
BOLT
SCREW
BRUSH
SPRING
PARKING LEVER PIN
SCREW
SEAL
41532
3T-18
WINDSHIELD WIPERS
(18) Install grommets in mounting bracket and secure motor assembly to bracket with attaching screws.
Tighten attaching screws to 23 inch-pounds (3 Nm)
torque.
(19) Install plain washer and spring washer on output shaft, position drive crank on output shaft in the
marked position from which it was removed, and install
nut. Tighten nut to 120 inch-pounds (14 Nm) torque.
TAG WIRE
WINDSHIELD WASHERS
The electric pump assembly is mounted in the bottom
of the water reservoir. The impeller motor case is
grounded to the car body by a ground wire. It is energized by a feed wire from the No. 6 and 7 terminals on
the control switch.
80490
SPECIFICATIONS
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a pre-torqued item.
USA (in.lbs.)
Metric (N-m)
Service
Set-To
Torque
In-Use
Recheck
Torque
Service
Set-To
Torque
In-Use
Recheck
Torque
23
118
15-35
100-135
3
13
2-4
11-15
All Torque values given in newton-meters and inch-pounds with dry fits unless otherwise specified.
70269
Tools
J-21008
CONTINUITY LIGHT
J-25359-02
T O R X BIT A N D
SOCKET SET
70119
3U-1
TAILGATE
WINDOW
DEFOGGER
SECTION INDEX
General
Grid Repair
3U-1
30=3
GENERAL
The electrically-heated tailgate window grid consists
of two vertical bus bars and horizontal rows of heating
elements of silver-bearing, ceramic enamel compound
that is fused to the inside surface of the tailgate glass. A
control switch, pilot lamp, timer-relay and wire harness
complete the circuit.
Testing
70503
Fig. 3U-1
3U-2
3U-2
With the control switch on the instrument panel activated and ignition switch On, the relay contacts close.
The timer in the relay operates the defogger for 8 to 12
minutes, depending on the ambient temperature, or un. til the control switch or ignition switch is turned Off.
The pilot lamp indicates system operation.
NOTE: The defogger switch and the electric
window switch are serviced as an assembly.
tailgate
TESTING
Switch Test
(1) Turn ignition switch On and press defogger
switch.
(2) Disconnect optional equipment wiring harness
at connector under" dash. Connect a 12-volt test lamp
from purple wire (89) to a good ground (fig. 3U-1). Test
lamp should light.
(3) Shut off defogger switch and test lamp should
not light.
(4) To test indicator light, disconnect orange wire
from lamp. Connect a jumper wire from accessory terminal of new fuse panel to orange wire. With ignition
switch turned to Accessory position, the lamp should
light.
Grid Test
When a grid is inoperable due to an open circuit, the
area of glass normally cleared by that grid will remain
fogged or iced until adequately warmed by the adjacent
grids. Use the following procedure to locate a broken
grid.
(1) With engine running at idle, press tailgate window defogger switch. Defogger lamp should light, indicating defogger operation.
Relay Test
NOTE: Terminals on the relay are labeled X, L and P.
(1) Attach negative lead of voltmeter to ground.
Probe red w / t r wire (X-terminal) with voltmeter positive lead. Voltmeter should indicate battery voltage regardless of ignition switch position.
If no voltage is indicated, operate the tailgate window.
(The tailgate window and rear window defogger are fed
by the same wire.) If the window operated, the wire
between the window switch and relay is open.
(2) Probe orange wire (L-terminal) with voltmeter
positive lead. No voltage should be indicated.
(3) Turn ignition switch to On or Accessory position. Voltmeter should indicate voltage. If no voltage is
indicated, relay is defective, or is not receiving voltage
from purple wire (P-terminal).
If relay activates properly, it should remain energized
8 to 12 minutes before opening (ignition switch must
remain On). If the time period is too short or excessively
long, relay is defective.
(4) If relay did not energize, connect jumper wire to
known good 12-volt source in tailgate and probe relay Pterminal. If relay clicks when probed, trace purple wire
for open or short.
If relay does not click when probed by jumper, check
relay ground and repair if necessary. If relay still fails to
operate, it is defective.
DC
70504
Fig. 3U-2 Voltmeter Connections and Voltage Prop for Grid Continuity
Grid Repair
Once a broken or open grid Is located, repairs can be
accomplished using the grid repair kit in accordance
with the following procedure.
(1) Using suitable marking pencil, mark location of
broken or open grid on exterior surface of glass.
(2) Using fine steel wool, lightly rub area to be
repaired (inside of tailgate window). Clean area with
isopropyl alcohol (rubbing alcohol).
(3) Attach two strips of cellulose tape (inside of
tailgate window) above and below break in grid as
shown in figure 3U-3.
BREAK
IN G R I D
TAPE
NOTE: GAP MUST
B E EXACT W I D T H
Fig. 3U-3
3U 3
NOTES
3V-1
IIIII
TEMS
SECTION INDEX
Pile
Page
Antenna 3V-11
Antenna Trimmer 3V-2
Bull Replacement 3V-10
CB Radio Diagnosis 3V-9
CB Radios 3V-3
Controls 3V-2
Genera! 3V-1
Radio Interference Oiaposis 3V-6
3V-4
3V-9
3V-13
3V-13
3V-12
3V-13
3V-13
3V-11
GENERAL'
CAUTION: Do not operate the CB radio with the antenna disconnected. Radio damage can result.
The radio manufactured date, model and serial number are stamped on the radio case.
Radio Polarity
When servicing the radio, the A (power) lead must be
connected to the positive side of the power source. If
connected to the negative side, the radio will not operate
and damage to components will result.
The radio is grounded internally. The ground return
circuit is completed by grounding the radio chassis to
the instrument panel. When testing on the bench, a
ground jumper wire must be attached between the radio
chassis and the negative terminal of a 12-volt battery or
power supply to complete the power circuit.
3V-2
ANTENNA TRIMMER
Antenna trimmer adjustment is necessary to match
the vehicle radio circuit to the vehicle antenna. The
adjustment should be made after installation of a radio
or antenna, or after repair to a radio. The adjustment
also should be checked whenever radio reception is
unsatisfactory.
BASS
Adjuster Location
A M and AM/FM radio: just above the tuning
control.
AM/FM stereo with tape player: in the tape cartridge slot.
AM/FM/CB: just left of pushbuttons on face plate.
VOLUME
Trimmer Adjustment
The trimmer adjustment should be made when the
radio is tuned to a very weak station. It is not necessary
to be able to receive an understandable station. The
object is to obtain the greatest volume while the volume
control is at a medium setting.
(1) Switch radio to the AM broadcast band.
(2) Turn on radio and allow to warm up for several
seconds.
(3) Turn station control knob to 1400 KC range and
obtain a radio station signal. Turn to medium volume.
(4) On AM and AM/FM radios, remove inner and
outer station tuning control knobs (radios without tape
player). On AM/FM/Tape radios, open tape door. On
AM/FM/CB radio the AM adjustment is on the face of
the radio. The CB adjustment procedure is found in the
Tuning Antenna Splitter section.
(5) Engage small slotted screw head with standard
screwdriver.
(6) Turn screw left or right until the greatest volume can be obtained without touching the volume
control.
(7) Install inner and outer tuning control knobs, if
removed.
CONTROLS
AM Radio
The AM radio (fig. 3V-1) has one dash-mounted
speaker as standard equipment. The dial bulb is c o n trolled by the on-off switch; therefore, the bulb has no
brilliance control.
PUSHBUTTON
STATION
TUNING
80202
Fig. SV-1
A I Radio Controls
Y E L L O W STEREO
INDICATOR L I G H T
P U L L FOR B A L A N C E
LEFT
VOLUMF
RIGHT
MANUAL
STATION
TUNING
OFF
PI Jeep
88 Hi 92 196^1001 1041 108
O D
REAR
FRONT
TREBLE
FADER
PROGRAM
SLIDE SWITCH ^ A M
TONE
PUSHBUTTON
STATION
TUNING
Fig. 3V-2
PROGRAM
INDICATORS
80203
STEREO I N D I C A T O R L I G H T
FM P R O G R A M
ADVANCE
STATION
TAPE T R A C K S
INDICATOR
Fig. 3V-3
TAPE
CARTRIDGE
SLOT
80250
ci l i n o s .
ERASER
END OF
PENCIL
. '
C I Radio Controls
ANTENNA
TRIMER
\ i (if
LEFTRIGHT,
BALANCE
Fig. 3V-4
3V-3
CB Operation
To Receive
3V-4
CHANNEL
SELECTOR KNOB
RADIO
FUNCTION
CONTROL
CHANNEL
INDICATOR
ON
* \ VOLUME
TONE
TREBLE
BASS
PUSH &
TURN
8 0 2 3 9 A
AM and FM Reception
AM-
LEFT/RIGHT
BALANCE
BAND - F M
SWITCH
/ F T \
STEREO
INDICATOR
LIGHT
ON
REAR 1 FRONT
STATION
n,Ai
OFF
U 1
VOLUME
T
T
REEBBL L
TR
EE
K
\
N E
BASS ^ \\
BAbb
PUSH &
TURN
*
y
ANTENNA
TRIMMER
MANUAL
STATION
TUNING
PUSHBUTTON
STATION
TUNING
80239B
Fig.
'
AM/FM/CB ladliAM/FM/Ciitrois
UPPER
ATMOSPHERE
:SKY:
REFLECTED
SIGNAL
' / , - . SIGNAL W
>
"REFLECTED
SIGNAL
3V-5
TRANSMITTER
GROUND
AJ42239
SIGNAL
Fig. 3V-7
AM RacaptionLong Distance;
UPPER
ATMOSPHERE
GROUND
SIGNAL
SKY
//'
GROUND
SIGNAL
SIGNAL
/
!
i l
' ^
ill i i''
( ( y ^
11 i i l i i
AJ42242
I | ii i i i i j i
If i i i i'-i! i i
Fig. 3V-10
Multipath Reception
AJ42240
Fig. 3V-8
RECEPTION COULD BE
RECEPTION IS G O O D I N T H I S
POOR IN THIS A R E A AS
A R E A AS T H E R E A R E N O OB-
S I G N A L IS B L O C K E D
STRUCTIONS BETWEEN
BY HILLS, MOUNTAINS,
FM
ETC.
STATION A N D RADIO.
^
AJ42245
Fig. 3V-9
FM Fading
3V-6
CB Radio Reception
The range of CB broadcasts and reception depends on
weather conditions, amount of air traffic, strength and
condition of transmitter and receiver, and the adjustment of antenna and splitter box. Range also depends on
the movement between the transmitter and receiver.
Reception will be clearer in open spaces with little air
traffic than in congested metropolitan areas. Hilly terrain may also affect operation. Electrical interference
affects reception similar to AM broadcasts.
Reception should not be fuzzy or screechy unless the
network is congested.
12 INCHES
CLIPS
AJ42243
Fig. 3V-11
Lay the screen across the top of the dash and attach
the clips to body grounds. If the noise is diminished or
disappears, the noise is being radiated up through the
dash.
To determine exactly where the noise source is, a
useful noise probe can be improvised from an antenna
lead-in cable.
To make the probe, cut or remove the lead-in from the
antenna at the antenna, remove approximately 2 inches
of the outer plastic covering and the woven wire shield
(fig. 3V-12).
COAXIAL
SHIELD '
Interference EntryAntenna
Disconnect the antenna. If this causes the noise to
stop, the problem is reduced to three possibilities:
A defective antenna; refer to Radio Antenna Ohmmeter Tests
Noise radiated upward from the dash
Noise radiated from the engine compartment
Noise Radiated Upward from Dash
CENTER
CONDUCTOR WIRE
ANTENNA LEAD IN
WITH ANTENNA BASE
CONNECTOR REMOVED
WHITE
PLASTIC
INSULATOR
CUT 2-INCHES
OF COAXIAL "*
SHIELD
AJ42244
FI.3V-12
3V-7
3V-8
.5
S M A L L CLIP
M F D
CAPACITOR
Fig. 3V-13
In general, any adjacent metal parts which are separated by mastic or paint must be connected together
electrically.
Effective bonding requires more than physically clean
surfaces and self-tapping screws. Tooth-type lockwashers must be used to cut into the surface layers of
metal. Grounding straps must be as short and as heavy
as possible.
A-line noise is normally the result of:
Alternator whine (A-line)
Wiring harness too close to ignition wiring
Radio noise suppressor
Poor radio grounding
Alternator Whine (A-Line)
A noise suppressor is installed on Cherokee, Wagoneer and Truck models equipped with a radio. This suppressor (choke) is plugged into the back of the cluster on
a printed circuit board. Be sure the choke has not been
installed over the copper strip installed on vehicles not
originally equipped with a radio.
Tap on the instrument panel with the ignition in the
On position and the Acc position to activate the CVR
point movement. If noise only occurs in the On position,
repair noise suppressor as follows:
(1) Remove radio choke.
(2) Remove plastic covering.
(3) Unsolder one end of coil wire and remove approxiately 6-1/2 inches of wire.
(4) Resolder wire end.
(5) Wrap coil with several turns of plastic electrical
tape and install choke.
Fig. 3V-14
3V-9
Defective Radio
CB RADIO DIAGNOSIS
80669
Fig. 3V-15
RADIO REPLACEMENT
CJModils
NOTES
Function
Setting
Test
Step
1
Watts
Int.
Frequency
MHZ
Int.
Press-Self
Test
HBJ^
Watts RF
Int.
Key Mic.
03.0 M i n .
Frequency
MHZ
Int.
Key Mic.
See Freq.
Chart
Frequency
MHZ
Int.
PressReceiver
Test
(Channel 20)
Jfc^
JPP^
Frequency
MHZ
Int.
Key Mic.
Press-Mod.
Test
SWR
Int.
Key Mic.
1.00-1.20
SWR
Ext.
Key Mic.
1.00-3.50
RADIO
CB
MAX.
.26.9663
26.9637
^ 26.9763
^ 26.9747
26.9863
^ 26.9837
27.0063
^ 27.0037
U v 5
Q
u
Q
u
12.0-16.0
Special Notes
CAUTION:
Instructions
Press-Battery
Volts
R A D I O UNDER TEST
CONTROL SETTINGS
- *Readings
Min.-Max.
Antenna
5
o
<
27.0163
^ 27.0137
<
n R
U D
n 7 <
m
0
<
MAX.
MIN.
.27.0263
^ 27.0237
> 27.0363
27.0337
.27.0563
27.0537
27.0663
^ 27.0637
<
<
10<27.0763
^27.0737
, u
<
. MAX.
MIN.
.... . 27.0863
'^27.0837
.27.1063
^27.1037
. . . . 27.1163
' ^ 27.1137
27.1263
'^27.1237
27.1363
'^27.1337
r
C
1 f i
27.1563
27.1537
^ 27.1663
'^27.1637
27.1763
27.1737
27.1863
27.1837
27.2063
^ 27.2037
1 7 <
l z
1 R < r
FREQUENCY CHART
. MAX.
< MIN.
w
H
vBHJpr
MAX.
MIN.
.27.2163
-27.2137
^ 27.2263
^ 27.2237
-.27.2363
^ 27.2337
27.2463
^ 27.2437
r
C
u
H
z , <
Z D
9 9 s
z /
9
Z
2
z
<
-.27.2563
z d < . 27.2537
9 E
. MAX.
MIN.
.27.2663
^27.2637
27.2763
^27.2737
a .27.2863
^27.2837
.27.2963
^ 27.2937
27.3063
27.3037
9 1
<
<
z o
<
. MAX.
MIN.
.27.3163
^*27.3137
~
27.3263
^ 27.3237
~ .27.3363
^ 27.3337
27.3463
^^27.3437
~ . 27.3563
27.3537
J ,
r
C
H
H
<
MAX.
MIN.
~- .27.3663
^27.3637
.27.3763
^27.3737
^ .27.3863
27.3837
~ .27.3963
27.3937
27.4063
^ 27.4037
J D <
J /
<
80700
(8)
(9)
panel.
(10)
knobs.
(11)
Cherokee-Wagoneer-Truck Models
(1) Open glove box door and remove glove box liner
and lock striker.
(2) Disconnect microphone lead from radio, if
equipped.
(3) Disconnect antenna lead(s).
(4) Disconnect feed wire from fuse panel.
(5) Disconnect speaker leads from radio.
(6) Disconnect rear support bracket from radio.
(7) Remove radio control knobs and attaching nuts.
(8) Push radio back to clear instrument panel and
remove it through glove box opening.
(9) Install radio in instrument panel.
(10)
(11)
(12)
. (13)
(14)
(15)
(16)
BULB REPLACEMENT
All Models
N O T E : AM/FM/CB radio bulb replacement is accomplished by exchanging the radio.
(1) Remove radio.
(2) Remove radio dial cover retainers and cover.
(3) Rotate manual tuning control to move pointer to
extreme left or right.
(4) Remove dial light reflector clips and deflector.
(5) Remove bulb and bulb diffuser.
(6)
(7)
(8)
(9)
Install
Install
Install
Install
mmmm;.
ANTENNA
AM/FM/CB Radio
VSWR is a measurement of the magnetic fields which
reflect back into the antenna. Besides limiting the range
of the transmitter, these also cause a heat build-up
which can damage the transmitter circuitry. A high
VSWR reading indicates a high level of reflected magnetic fields. A reading less than 2.0:1 is excellent. A
reading above 3.5:1 is excessive and requires adjustment
(seeVSWR Reading by CB Channels chart). VSWR
readings can vary depending upon atmospheric conditions. VSWR can also vary with respect to surrounding
objects that affect reflection and conductivity.
o-
0-2
CBCHANNELS
0-1
-O O
1
6
11
16
26
31
36
0-3
O
0~
thru 5
thru 10
thru 15
thru 2 5
thru 30
thru 35
thru 40
VSWR R E A D I N G
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
3.5
3.0
2.5
2.0
2.5
3.0
3.5
1
1
1
1
1
1
1
80662
AJ42258
Tuning the CB antenna or splitterbox involves reducing the SWR level by using a VSWR meter or the Amserv AMX 386S Mobile CB Tester and chart covering
operating instructions for Amserv AMX 386S Mobile CB
Tester. Trim the antenna/splitterbox as follows:
3V-1Z
ANTENNA
BASE
ADJUSTMENT
3.5-
SWR
READING
1.5
10
20
30
40
CHANNELS
SPLITTER ADJUSTMENTS
80703
Fig. 31-18
SPEAKERS
Speakers have an impedance of either 3.2 or 8 ohms. A
speaker should be replaced with a speaker having the
proper part number. If the exact replacement is not
available, select a speaker which matches the ohm value
stamped on the radio chassis with a black ink stamp.
AM/FM stereo radios are more critical in the selection
of a speaker than are AM radios. A noticeable deterioration in sound will be noticed if the correct speaker is not
used.
Stereo speakers are paired together for a truer stereo
sound, right front with right rear, left front with left
rear.
Speaker Repairs
A speaker, once it has been damaged, is usually not
repairable and should be replaced. Defective speakers
usually have one or more of the following symptoms:
Loose mounting.
Screws or other objects stuck to back of magnet.
Audio distortion, particularly on the low frequency
notes and at high volume.
Rattles and buzzes caused by foreign material hitting or rubbing against the speaker cone.
Raspy noises caused by foreign matter inside the
speaker restricting free movement of the speaker
cone.
M u f f l e d s o u n d c a u s e d by s p e a k e r o p e n i n g
obstruction.
Use a light to check the speaker opening(s).
If the entire speaker is not visible through the speaker
grille openings, remove the obstruction as follows:
3V-13
CJ Models
(1) Disconnect speaker feed wires at radio connector and each individual speaker.
NOTE: When reconnecting the speaker harness to the
radio, be sure the antenna lead-in cable is fully engaged
in the radio socket
(2) Connect one lead of an ohmmeter to the speaker
feed wire and the other lead to a good ground. An infinity reading should be indicated. Check each individual speaker wire in this manner.
(3) If resistance is indicated on the ohmmeter, the
wire being checked is grounded.
NOTE: Grounded speaker harnesses are
caused by screws piercing wire harness.
SPECIFICATIONS
1/1892
Cherokee-Wagoneer-Truck
1/1893
generally
70320
Short Condition
(1) Disconnect speaker feed wires at the radio connector and at each individual speaker.
(2) Connect ohmmeter leads to speaker feed wires
at the radio connector.
(3) An infinity reading should be indicated.
(4) If resistance is indicated on ohmmeter, the feed
wires being checked are shorted.
Tools
Speaker Test
Speakers may be isolated for grounds by testing the
impedance with an ohmmeter. Connect ohmmeter between the two speaker leads. The specified value should
match the ohm value stamped on the radio chassis.
J-22683-01
STERO TEST TAPE
70319
NOTES
ALPHABETICAL
INDEX
Air
Air
Air
Air
Air
Air
Air
Air
Air
Conditioning, C J
C o n d i t i o n i n g compressor
C o n d i t i o n i n g compressor oil level, c h e c k i n g
C o n d i t i o n i n g , compressor, p u r g i n g o f air
C o n d i t i o n i n g compressor v a l v e leak diagnoisis
C o n d i t i o n i n g , general service procedures
C o n d i t i o n i n g leaks, checking for
C o n d i t i o n i n g , m a g n e t i c clutch
Conditioning normal operating temperatures
A b n o r m a l tire w e a r
A c r y l i c e n a m e l , paint r e p a i r , w i t h
A d a p t e r , b e a r i n g , rear, r e m o v a l
A d j u s t a b l e end r a i l , luggage rack
A d j u s t i n g d i f f e r e n t i a l b e a r i n g sideplay
A d j u s t m e n t , assembly a n d , p o w e r steering gear
A d j u s t m e n t , a u t o m a t i c transmission l i n k a g e - all
2H-3
3B-1
2B-6
3L-2
2F-29
2L-32
models
Adjustment,
Adjustment,
Adjustment,
Adjustment,
Adjustment,
Adjustment,
B-12
2C-32
2L-38
2A-11
2A-6
2F-28
a n d pressures
A i r Conditioning
assembly
A i r Conditioning
A i r Conditioning
A i r Conditioning
A i r Conditioning
A i r Conditioning
2F-37
2F-36
IE-13
Air
Air
Air
Air
b a n d , a u t o m a t i c transmission
belt tension, p o w e r steering p u m p
clutch cover release lever
c l u t c h pedal free p l a y
differential bearing
differential b e a r i n g preload a n d ring
gear backlash
A d j u s t m e n t , differential side gear
A d j u s t m e n t , d r i v e belt, a l t e r n a t o r
A d j u s t m e n t , f r o n t seat
3M-5
Adjustment, horn
3S-2
A d j u s t m e n t , m e a s u r e m e n t a n d , universal j o i n t a n g l e . . . . 2 E - 9
A d j u s t m e n t , m e a s u r e m e n t , pinion d e p t h
2F-34
Adjustment, parking brake
2G-15
A d j u s t m e n t , p i n i o n b e a r i n g preload
2F-36
A d j u s t m e n t , pinion gear b e a r i n g preload
2F-27
A d j u s t m e n t , pinion installation a n d d e p t h
2F-35
A d j u s t m e n t procedures, c a r b u r e t o r m o d e l 2 1 0 0 , 2venturi
A d j u s t m e n t procedures, c a r b u r e t o r m o d e l 2 1 5 0 , 2-
1J-29
venturi
A d j u s t m e n t procedures, m o d e l B B D 2 - v e n t u r i
carburetor
A d j u s t m e n t , r i n g a n d pinion gear backlash
A d j u s t m e n t , service b r a k e
A d j u s t m e n t , striker
A d j u s t m e n t , t u r n i n g angle
A d j u s t m e n t , wheel b e a r i n g
A d j u s t m e n t s , clutch
Adjustments, Cruise C o m m a n d
A d v a n c e mechanism, distributor
A i m i n g , headlamp
A i m i n g lamps
A i r cleaner
A i r cleaner
A i r cleaner, t h e r m o s t a t i c a l l y c o n t r o l l e d , ( T A C )
system
A i r Conditioning
A i r Conditioning
A i r C o n d i t i o n i n g checking compressor oil level
A i r Conditioning, Cherokee, Wagoneer, T r u c k
A i r Conditioning, C J
1J-35
1J-17
2F-28
2G-17
3H-3
2F-12
2H-6
2A-6
1H-11
1 A-18
3R-2
3R-10
1J-1
1A-18
1J-43
3E-15
3E-1
3E-15
3E-25
3E-22
3E-22
3E-11
3E-15
3E-15
3E-11
3E-2
3E-8
3E-16
3E-5
pressure g a u g e a n d m a n i f o l d
sight glass
system c h a r g i n g
system c o m p o n e n t s
system, discharging
system, evacuating
C o n d i t i o n i n g system f l u s h i n g
C o n d i t i o n i n g system o p e r a t i o n
C o n d i t i o n i n g , system pressures, c h e c k i n g
C o n d i t i o n i n g system t r o u b l e shooting
3E-4
3E-6
3E-9
3E-1
3E-6
3E-6
3E-16
3E-1
3E-4
3E-17
A i r C o n d i t i o n i n g tools
A i r injection m a n i f o l d s
A i r p u m p noise diagnosis
A l i g n m e n t , c l u t c h housing
Alignment, frame
A l i g n m e n t , f r o n t wheel
A l i g n m e n t , f r o n t wheel
Alignment, hood, Cherokee, Wagoneer, T r u c k
models
A l i g n m e n t , h o o d , C J models
A l i g n m e n t specifications, f r o n t wheel
A l i g n m e n t , steering wheel spoke
Alternator components
A l t e r n a t o r d r i v e belt a d j u s t m e n t
3E-21
1K-12
1K-11
2A-10
3F-7
2M-4
2F-4
A l t e r n a t o r overhaul
A l t e r n a t o r replacement
A l t e r n a t o r testing, off-vehicle
IE-10
1E-9
1E-7
A M a n d F M reception
A M / F M / C B r a d i o - A M / F M controls
A M / F M / C B r a d i o - C B controls
A M / F M m u l t i p l e x tape radio
A M / F M stero r a d i o controls
A M radio
A M r a d i o controls
AMC/Jeep
A M C / J e e p axle
A M C / J e e p rear a x l e - C J models
Ammeter
A m m e t e r diagnosis
A n g l e adjustment, turning
A n t e n n a , interference e n t r y
3V-4
3V-4
3V-4
3V-2
3V-2
3V-2
3V-2
2F-14
2F-17
2F-22
1L-1
1L-3
2F-12
3V-6
A n t e n n a , radio
Antenna trimmer
3V-11
3V-2
3G-2
3G-1
2M-6
2M-5
1E-11
1E-13
ALPHABETICAL INDEX
2E-1
2E-2
2B-16
3T-2
3H-5
2B-7
2B-23
2K-8
2K-13
2C-71
2A-2
2B-23
2F-44
2F-34
2F-24
2F-28
2F-3
3C-5
3C-3
2L-41
2C-1
2C-71
2C-32
2C-8
2C-80
2C-6
2C-13
2C-21
2C-30
B-14
2C-7
2C-83
2C-9
2C-11
2C-3
B-12
2F-22
B-8
B-9
2F-3
2F-14
2F-4
2F-15
2F-4
2F-14
2F-32
2F-18
2F-31
2F-2
2F-2
2F-14
2F-6
2F-16
2F-17
2F-18
2F-17
2F-7
2F-6
2F-16
2F-6
2F-18
2F-6
2F-11
2F-8
2F-47
2F-13
2F-46
2F-46
2F-47
2F-1
2F-48
2F-39
2F-1
2C-29
2C-8
2C-25
2C-79
2C-40
2C-10
2C-23
2C-81
2F-2
2F-14
2F-22
ALPHABETICAL INDEX
2F-9
2C-32
2N-3
1D-1
ID-3
1D-7
1D-6
1D-2
1D-1
1 D-6
ID-5
2H-6
2A-2
2F-16
2B-17
2B-14
2B-17
2B-7
2B-14
22F-16
2F-31
2F-31
2F-11
2F-29
B-8
1C-14
1C-23
2L-38
2L-44
1C-23
1C-14
3M-6
3M-8
3M-4
2G-26
2F-37
2F-28
3D-4
3F-1
B-9
3F-1
1J-6
2G-17
B-9
2G-26
B-11
2G-1
2G-20
2G-21
2G-20
B-11
B-10
2G-21
B-11
Brake, parking
Brake pedal
Brake service-Cherokee-Wagoneer-Truck models,
drum brakes
Brake service-CJ models, drum brakes
Brake size and application chart
Brake specifications
Brake tools
Brake warning lamp
Brakelamp switch
Brakelining inspection
Brakes
Brakes...........
Brakes, disc
Brakes, drum
Brakes rear self-adjusting mechanism
Brakeshoe replacement-Cherokee-Wagoneer-Truck
models, disc brake
Brakeshoe replacement-CJ models, disc brake
Breakers, circuit
Breakers, tailgate circuit
Brush guards
Bucket seats, Cherokee,Wagoneer, and Truck
Bucket seats-CJ
Bulb replacement, radio
Bumper, front axle windup
Bumper, front axle windup
Bumper, hood
Bumpers....
Bumpers, front
Bushing replacement, spring
B-11
2G-14
2G-36
2G-34
2G-19
2G-19
2G-54
2G-14
2G-17
2G-17
2G-1
B-9
2G-39
2G-32
B-11
2G-42
2G-45
3R-16
3H-10
3F-15
3M-4
3M-2
3V-10
2N-6
2N-1
3G-3
3F-11
3F-11
2N-7
C
Cables, control
Cables, parking brake
Calibration, speedometer, Cherokee, Wagoneer,
Truck
Calibration, speedometer, CJ
California emission components, light duty
Caliper overhaul-Cherokee-Wagoneer-Truck
models, disc brake
Caliper overhaul-CJ models, disc brake
Camber
Camshaft and bearings, eight-cylinder
Camshaft and bearings, six-cylinder........
Canister, charcoal, and hoses
Cap and rotor
Cap, radiator pressure
Capacities, fluid
Capacity, fuel tank
Capacity, tire inflation pressure and
3D-4
2G-16
3C-7
3C-3
1A-2
2G-43
2G-48
2M-4
1B-43
1 B-8
1J-5
1G-3
1C-2
B-15
U-9
2H-2
ALPHABETICAL INDEX
1J-8
1J-17
1J-29
1J-35
1J-45
1J-46
1 J-20
1J-34
1 J-10
1J-9
1 J-20
1J-33
1J-12
1J-24
1 J-34
1J-13
1J-25
1J-19
1J-32
1J-33
1 J-35
3R-7
3R-13
3F-13
2F-44
2D-9
2B-15
2D-1
B-13
2B-7
2M-4
B-15
A-l
3V-3
3V-3
3V-9
3V-10
3V-6
3V-3
1J-5
1A-21
ID-3
IE-1
1E-1
1E-4
1E-2
1E-14
1E-14
IE-14
1E-3
3E-9
3E-9
2G-19
2F-34
2F-26
A-2
2H-13
2E-12
2H-12
A-6
2C-83
2E-4
A-2
B-8
B-4
3R-14
1J-6
1 J-6
1K-12
2F-30
3E-8
2F-29
2F-37
3E-4
3E-25
A-3
3P-1
3J-9
3M-7
3H-4
3H-5
3M-4
3M-4
3C-7
3J-4
3D-6
3C-6
3C-4
3G-1
3N-2
3T-4
1 J-32
1 J-19
3C-7
3C-4
3T-14
3R-16
A L P H A B E T I C A L INDEX
Circuit breakers
Circuitry test, Cruise Command
Circuitry,Power tailgate window-CherokeeWagoneer models
Circuits, BBD 2-venturi carburetor
Circuits, carburetor model 2100, 2-venturi
CJ Air Conditioning
.
CJ bucket seats
CJ clock
CJ fender extensions
CJ floor console
CJ folding windshield
CJ heater
CJ instrument illumination
CJ instrument panel
CJ models
CJ Models
CJ models bumpers, rear
CJ models, hoods....
CJ seats
CJ speedometer
CJ windshield glass
CJ windshield wiper
Cj 2/3-1/3 style seats
CJ-5 tailgate
CJ-5 tailgates
CJ-7 liftgate
CJ-7 tailgates
CJ-7 with hardtop enclosure
Cleaner, air
Cleaner, air
Clearance, checking side gear
Clock, Cherokee, Wagoneer, Truck
Clock, CJ
Cluster, instrument, Cherokee, Wagoneer, Truck
Cluster, instrument CJ
Clutch..
Clutch adjustments
Clutch and band application chart, automatic
transmission
Clutch assembly
Clutch chatter
Clutch cover release lever adjustment
Clutch drag or inadequate release
Clutch housing alignment
Clutch housing alignment specifications
Clutch lever and linkage
Clutch linkage
Clutch linkage lubrication
Clutch, magnetic, Air Conditioning
Clutch noises
Clutch pack and side gear installation
Clutch pack, side gear, removal
Clutch pedal free play adjustment
3H-10
1H-6
3H-9
1 J-10
1 J-20
3E-22
3M-1
3C-4
3F-10
3M-5
3N-1
3D-1
3C-3
3C-1
A-8
A-3
3F-12
3G-1
3M-7
3C-3
3N-2
3T-1
3M-1
3H-4
3H-4
3H-1
3H-4
3J-1
1 J-l
1A-18
2F-37
3C-7
3C-4
3C-5
3C-1
2A-1
2A-6
2C-8
2A-2
2A-1
2A-11
2A-4
2A-10
2A-14
B-12
2A-6
2A-8
3E-16
2A-6
2F-45
2F-44
2A-6
A L P H A B E T I C A L INDEX
n s r - M ^ ^ ^ ^ ^ ^ ^ ^ W
w w
g g n r g e :
Control cables
Control switch
Control system, fuel vapor
Control unit
Control, washer and wiper
Controls, radio
Conversion of English and Metric Measures
Converter, catalytic
Converter housing leak diagnosis
Converter, torque
Cooland recovery system
Coolant
Coolant freezing point test
Cooling system, carburetor bowl
Cooling system components
Cooling system diagnosis
Cooling system diagnosis, carburetor bowl
Cooling system leakage
Cooling system operation
Cooling system specifications
Cooling system specifications
Cooling systems
Cooling systems components
Cooling systems diagnosis
Cooling systems torque specifications
Core, heater
Core, heater
Countershaft gear arbor tool installed
Countershaft installation
Countershaft removal-installation
Countershaft removal/installation T15A
Countershaft roll pin removal-installation
Courtesy lamps/dome lamps
Crankshaft, eight-cylinder
Crankshaft end play measurement, eight-cylinder
Crankshaft end play measurement, six-cylinder
Crankshaft main bearings, eight-cylinder
Crankshaft main bearings, six-cylinder
Crankshaft, six cylinder
Crash pad, Cherokee, Wagoneer, Track
Crash pad,CJ
Cruise Command
Cruise Command adjustments
Cruise Command circuitry tests
Cruise Command operation
Cruise Command service diagnosis
Cruise Command switch, turn signal and,
Cruise Command trouble shooting
CTO operation
CTO switch, EGR
CTO test, EGR
Cylinder block, eight-cylinder
Cylinder block, six-cylinder
Cylinder bore reconditioning, eight-cylinder
3D-4
3T-14
1J-5
\G-l
3T-2
3V-2
A-10
B-15
2C-12
2C-2
1C-3
1C-16
1C-12
1J-45
1C-21
1C-5
1J-46
1C-11
1C-4
1C-21
1C-22
1C-1
1C-2
1C-6
1C-22
3D-4
1C-4
2B-16
2B-10
2B-6
2B-14
2B-6
3R-12
1B-64
1B-64
1B-28
1B-64
1B-28
1B-28
3C-5
3C-2
1H-1
1H-11
1H-6
1H-2
1H-9
2J-36
1H-5
1C-5
U-39
U-40
1B-68
1B-32
1B-68
1 B-68
1 B-33
1B-51
1B-16
1 B-52
IB-16
1 A-11
1A-13
2J-38
2G-21
2G-23
D
Damper, steering
DARS charts starter voltage drop test
Decimal equivalents
Definitions of frequently used terms
Defroster and heater
Defroster duct
Depth adjustment, pinion gear
Depth gauge tools, pinion installing
Description and operation Power Steering Gear and
Amp
Description of maintenance services
Diagnosis, Air conditioning compressor valve leak
Diagnosis, air pump noise
Diagnosis and circuitry
Diagnosis and repair, horn system
Diagnosis and Repair Simplification (DARS)
Charts
Diagnosis and repair simplification (DARS) charts,
charging system
Diagnosis and repair water leak/wind noise
Diagnosis and test procedures, automatic
transmission
Diagnosis, brake power unit
Diagnosis, brakes
Diagnosis, carburetor bowl cooling system
Diagnosis chart, vibration
Diagnosis charts, automatic transmission
Diagnosis, clutch service
Diagnosis, converter housing leak
Diagnosis, cooling system
Diagnosis, cooling systems
Diagnosis, cylinder leakage test
Diagnosis, disc brakes
Diagnosis, driveline vibration
Diagnosis, drum brakes
Diagnosis, emergency drive system service
Diagnosis, full failure
2M-3
1F-6
A-14
3V-4
3D-7
3D-5
2F-25
2F-28
2L-1
B-5
3E-11
1K-11
3T-6
3S-1
A-l
1E-4
3A-l
2C-6
2G-31
2G-1
1 J-46
2H-12
2C-13
2A-1
2C-12
1C-5
1C-6
1 A-13
2G-10
2E-3
2G-4
2D-19
1G-4
A L P H A B E T I C A L INDEX
1 A-1
2C-21
1G-5
2L-10
1 A-2
1 A-3
1 A-6
2L-6
2G-4
2D-17
3V-6
1K-1
2D-3
1G-14
1F-4
2-J-l
2F-1
2F-41
2H-10
1 A-11
2F-44
2F-34
2F-24
2F-28
2F-34
2F-38
2F-29
2F-29
2F-37
2F-22
2F-32
2F-33
2F-44
2F-28
2F-30
2F-21
2F-30
2F-21
2F-21
2F-21
2F-21
2F-21
2F-21
2F-30
2F-30
2F-44
2F-36
2F-39
2F-21
2F-40
B-11
3R-3
3R-8
3R-8
3R-7
2C-30
2F-30
2F-21
2L-22
2L-40
2K-4
2K-12
B-11
2G-43
2G-48
B-11
2G-50
2G-5 3
2G-39
2G-10
2G-42
2G-45
3E-6
3E-6
1G-2
1 A-18
1G-14
1G-18
1G-1
1A-22
1G-15
1 A-16
1G-18
1A-24
1K-11
1K-12
1K-12
3R-12
B-10
3J-1
3 J-9
3J-4
3J-1
3J-1
3F-7
B-13
B-13
3H-5
IE-13
B-7
2L-44
1C-14
2D-21
2E-3
A L P H A B E T I C A L INDEX
2E-3
2E-4
2G-34
2G-38
2G-32
2G-36
2G-4
1C-5
3D-5
3D-5
1 J-40
1 J-37
B-7
1K-6
1 B-51
1A-21
1K-9
1A-21
B-12
1K-1
3F-10
3A-10
3P-11
E
EGR-CTO switch
EGR-CTO test
EGR system-eight-cylinder-typical
EGR system-eight-cylinder-with external,nonintegral back-pressure sensor
EGR system-six-cyiinder-typical
EGR valve
EGR valve maintenance-Cherokee-Wagoneer-Truck
EGR valve test
EGR valve with integral back-pressure sensor
EGR valve without back-pressure sensor
Eight-cylinder engine
Eight-cylinder engine
Eight-cylinder engine specifications
Emergency drive, Quadra-Trac
Emergency drive system service diagnosis
Emergency towing
Emission components-California light duty
Emission components-49-state light duty
End play, main shaft
End play measuring, axle shaft-AMC/Jeep axle
Engine block heater
Engine block heater
Engine compartment lamp
Engine drive belt arrangement...
Engine drive belt tension
Engine, eight-cylinder
Engine flushing
Engine idle speed and mixture setting procedures
Engine maintenance schedule
Engine maintenance schedule
Engine oil viscosity
Engine spark knock (ping) diagnosis
Evacuating Air Conditioning, system
Evacuating system, Air Conditioning
Exhaust back-pressure sensor-non-integral
U-39
U-40
1J-37
1 J-37
1 J-37
U-38
. U-39
U-38
1J-38
1 J-38
1K-8
1B-36
1B-70
2D-13
2D-19
2C-5
1 A-2
1A-l
2B-9
2F-17
1C-17
1C-4
3R-11
1C-23
1C-23
1K-8
1C-17
1 A-19
1 A-14
B-2
B-7
1G-14
3E-6
3E-6
1J-40
Fan..
Fan and alternator belt adjustment
Fan control switch
Fasteners, Torx-Head
Fenders.....
Fill hole, manual steering gear
Fill plugs, Quadra-Trac, transfer case, and low range
reduction unit
Filler cap, fuel tank
Filler neck, fuel tank
Filter, charcoal canister
Filter, fuel
Filter, fuel
Filter maintenance, PCV air
Filter, oil...............
Filter, PCV
Filter, PCV air inlet
Filters, fuel
Finishing metal replacement parts
Finishing plastic trim parts
First gear synchronizer assembly
First gear synchronizer hub snap ring removal/
installation
First gear thrust washer installation
First-reverse hubFirst-reverse hub insert installation
First second synchronizer assembly
First-second synchronizer installation
Floor console components
Flow charts, automatic transmission hydraulic
Fluid, brake....
Fluid capacities
Fluid change, manual transmission case
Fluid change, Quadra-Trac
Fluid changes, automatic transmission...
Fluid level and condition, automatic transmission
1C-2
1C-14
3D-4
A-3
3F-9
B-12
B-14
1J-5
1J-3
1 A-21
1A-18
B-7
1J-42
B-7
B-8
1A-20
U-2
3B-2
3B-3
2B-15
2B-15
2B-9
2B-8
2B-8
2B-23
2B-24
3M-5
2C-83
2G-20
B-15
B-14
B-13
B-14
2C-7
ALPHABETICAL INDEX
3F-1
Fresh air intake duct
3D-5
Fresh air ventilation
3D-7
Fresh air ventilation
3D-2
Front axle-all models
2F-2
Front axle assembly
2F-3
Front axle specifications
2F-13
Front axle windup bumper
2N-6
Front axle windup bumper
2N-1
Front bearing cap oil seal
2B-18
Front bearing cap oil seal installation
2B-10
Front bearing installation
2B-17
Front bearing removal T15A!
2B-14
Front brake linings - CJ models
B-10
Front brake linings-Cherokee-Wagoneer-Truck
models
B-11
Front bumpers
3F-11
Front end shimmy
2M-5
Front seat adjustment
3M-5
Front seats
3M-1
Front spring,
2N-3
Front spring and shock absorber-CherokeeWagoneerTruck
2N-3
Front spring and shock absorber-CJ
2N-2
Front towing-front end raised
A-8
Front wheel alignment
2M-4
Front wheel alignment
2F-4
Front wheel alignment specifications
2M-6
Fuel economy tests
1 J-9
Fuel filter
1A-18
Fuel filter..
B-7
Fuel filters
U-2
Fuel gauge.
1L-2
Fuel gauge
1J-7
Fuel gauge diagnosis
1L-3
Fuel pump
U-8
Fuel pump
1 J-7
Fuel pump capacity test,
U-8
Fuel pump pressure test
U-8
1J-8
1 J-9
U-8
B-1
1 J-6
1J-47
U-1
1A-18
U-2
1J-4
U-3
1J-4
U-9
U-5
U-3
U-3
1A-20
U-5
U-5
1 J-7
1G-4
3R-16
3R-14
G
Galvanized panels
Gauge, automatic transmission test
Gauge, fuel....
Gauge replacement
Gauge, temperature
Gear and synchronizer assemblies
Gear assembly, power steering..
Gear, main shaft, disassembly
Gear, manual steering
Gear, power steering
Gear, power steering
Gear, reverse idler
Gear, reverse idler, removal/installation
Gear rotating tool installation
Gear, second, installation
Gear train, main shaft-disassembly
Gears, differential side and pinion
General
General
General Dimensions (Inches)
General information
General service and diagnosis
General service procedures, A i r Conditioning
General specifications, brake fluid
General specifications, disc brake
General specifications, drum brakes..
3F-7
2C-10
U-7
1L-5
1C-3
2B-7
2L-21
2B-14
B-12
2L-19
2L-2
2B-23
2B-14
2F-44
2B-9
2B-6
2F-44
2K-1
2F-21
A-13
2K-1
1A-1
3E-2
2G-27
2G-53
2G-38
ALPHABETICAL INDEX
2D-39
3U-1
3P-6
3P-6
3C-5
3C-3
3R-13
B-9
3F-8
3F-15
3B-2
H
Hard top enclosure, CJ-7
Harness, chassis wiring
Harness, tailgate wiring
Hazard warning flasher
Headlamp aiming
Headlamp aiming procedure
Headlamp switch
Headlamp switch replacement
Headlamps
Headlining
3J-1
3R-14
3H-10
3R-9
3R-2
3R-2
3R-2
3R-2
3R-1
3P-1
3P-1
1K-7
B-7
1 A-21
3D-1
3D-7
3D-6
3D-2
3D-6
3D-1
3D-7
3D-4
1C-4
1C-17
1C-4
3D-1
B-1
1 D-6
2F-4
3H-3
3J-12
3J-8
3J-3
3H-5
3G-2
3G-1
3G-1
Hood alignment, CJ models
Hood and related parts-Cherokee-Wagoneer-Truck
3G-2
models
3G-1
Hood and related parts-CJ models
3G-3
Hood bumper
.. B-9
Hood hinge - CJ models
.. B-9
Hood-latch - CJ models
3G-3
Hood lock
3G-1
Hoods
3S-2
Horn adjustment
3S-1
Horn circuit schematic
Horn system diagnosis and repair
3S-1
Horn system specifications
3S-2
Horn systems....
3S-1
Hoses
1C-2
Hoses.......
1C-16
Housing assembly, shift control lever-3-speed
transmission
2B-3
Housing assembly, shift control lever-4-speed
transmission
2B-3
Housing, axle
2F-14
Housing, shift control
2B-18
Housing, spreading axle
2F-32
Housing, taillamp
3R-6
Housing, 4-speed shift control
2B-27
How to use this manual
A-l
Hub, axle-AMC/Jeep axle
2F-15
Hub, first-reverse
2B-8
Hub, supporting first-second clutch..
2B-23
Hydraulic flow charts, automatic transmission
2C-83
Hydraulic pressure test analysis, automatic
transmission
2C-11
Hydraulic pressure test, automatic transmission
2C-9
Hydraulic pressure test, power steering gear and
pump
2L-15
Hydraulic system, brake
2G-20
Hydraulic system inspection, brake
2G-21
Hydraulic system operation, automatic transmission.... 2C-3
Hydraulic valve tappets, eight-cylinder
1B-45
Hydraulic valve tappets, six-cylinder
1B-10
I
Identification, clutch plate and disc
Identification, eight-cylinder
Identification, six-cylinder
Identification, transmission
Identification, Truck Model
Identification, vehicle
Idle drop specifications
Idle setting procedure
Ignition coil
2F-44
1B-37
1 B-1
2C-1
A-5
A-6
1A-20
1 A-19
1G-2
ALPHABETC
I AL INDEX
Ignition coil.....
Ignition, lock cylinder
Ignition switch
Ignition switch
Ignition switch terminals
Ignition system
In-vehicle service and adjustment, automatic
transmission
In-vehicle service, Model 20 transfer case
In-vehiele service, power steering gear
In-vehicle service power steering pump
Inflation pressure chart, tire
Initial ignition timing
Inner oil seal installation-Model 44 front axle
Insert, first-reverse hub, installation
Inspection and adjustment, manual transmission
clutch....
Inspection, brake hydraulic system
Inspection, brakelining
Inspection, exhaust system
Inspection, Quadra-Trac drive chain tension
Inspection, Trac-Lok
Installation, clutch pack and side gear....
Installation, differential..
Installation, differential bearing
Installation, differential bearing
Installation, gear rotating tool
Installation, inner oil seal-AMC/Jeep axle
Installation, lock cylinder
Installation-Model 44 axle
Installation-Model 60 axle
Installation, pinion bearing
Installation, pinion gear
Installation, pinion gear thrust washer
Installation, pinion mate shaft
Installation, pinion seal..
Installation, rear axle-model 44 and 60 axle
Installation, ring gear
Installation, steering gear
Installation, steering gear, right-hand drive
Installation, step plate
Installation, third-fourth synchronizer shifting plate
and retaining ring
Installing pinion depth gauge tools
Installing pinion depth gauge tools
Instrument cluster, Cherokee, Wagoneer, Truck
Instrument clusier, CJ
Instrument cluster lamps
Instrument cluster replacement
Instrument illumination Cherokee, Wagoneer,
Truck
Instrument illumination, CJ
Instrument panel, Cherokee, Wagoneer, Truck
Instrument panel, CJ
1A-16
2J-38
3R-15
2J-37
3R-14
1G-1
2C-25
2D-3
2L-19
2L-37
2H-13
1A-17
2F-38
2B-8
B-12
2G-21
2G-17
.. B-12
2D-21
2F-43
2F-45
2F-30
2F-38
2F-29
2F-44
2F-17
3M-5
2F-17
2F-18
2F-35
2F-46
2F-46
2F-46
2F-19
2F-19
2F-28
2K-4
2K-12
2F-43
2B-24
2F-37
2F-28
3C-5
3C-1
3R-13
1L-4
3C-6
3C-3
3C-4
3C-1
Instrument panel, CJ
Instrument panel, CJ
Instrument panel switch
Instrument panel tailgate window switch
Instrument panels and components
Instrumentation diagnosis
Intake manifold, eight-cylinder
Intake manifold, six-cylinder exhaust manifold, sixcylinder
Interference entry-antenna
Interior lighting system
Interior wind noises
Intermittent failure diagnosis
Intermittent governor
3C-1
3C-1
3H-10
3H-8
3C-1
1L-3
1B-50
1B-14
3V-6
3R-12
3A-9
1G-5
3T-15
J
Joint double cardan
Joint, universal, axle shaft.
B-13
2F-8
K
Key coding template
Keylock
Key lock, Cherokee-Wagoneer Truck, doors
Keys and locks
A-7
3H-11
3J-7
A-7
L
Lamp, brake warning
Lamp, cargo
Lamp, cargo
Lamp, dome/reading
Lamp, engine compartment...
Lamp, glove box
Lamp, license plate
Lamps, aiming
Lamps, courtesy lamps/dome
Lamps, instrument cluster
Lamps, off road driving
Lamps, parking, side marker and directional
2G-14
3R-13
3R-7
3R-12
3R-11
3R-13
3R-6
3R-10
3R-12
3R-13
3R-10
3R-4
ALPHABETICAL INDEX
2C-12
2L-10
1C-11
1C-11
1C-12
1A-13
3E-8
3A-1
3R-6
3H-1
3R-13
3C-7
3C-4
3R-1
2A-6
B-12
2D-11
2M-1
B-13
B-12
3R-14
1J-6
2H-2
3M-5
2J-38
3M-5
3M-5
3G-3
2B-16
3H-7
3H-2
3J-11
3 J-6
3J-3
3H-11
2F-32
2F-23
2F-41
B-16
2D-11
2D-39
2B-1
B-13
B-9
2A-8
2E-9
2D-21
1 B-53
IB-17
3L-2
3L-2
3L-2
3L-2
3L-1
M
Magnetic clutch, Air Conditioning
3E-16
Magnetic timing probe
1 A-17
Main harness connector
3R-14
Main shaft gear train disassembly
2B-14
Main shaft gear train-disassembly
2B-6
Maintenance and condition, tire
2H-4
Maintenance and condition, wheel
2H-5
Maintenance, battery
ID-2
Maintenance, Jeep
B-1
Maintenance schedule
B-1
Maintenance schedule, engine
1A-14
Maintenance, unscheduled
B-15
Maintenence, power steering gear and pump
2L-15
Manifold, exhaust
1K-6
Manifolds, air injection
1K-12
Manual steering gear
2K-1
Manual steering gear
B-12
Manual steering gear fill hole location
B-12
Manual steering gear specifications
2K-3
Manual steering, service diagnosis
2K-2
Manual transmission
.
2B
Manual transmission case fluid change
B-14
Manual transmission clutch inspection and
adjustment
B-12
Manual transmission specifications T-150
2B-12
Master cylinder
2G-21
Master cylinder
B-11
Measurement and adjustment, pinion gear depth
2F-24
Measurement and adjustment, universal joint angle
2E-9
Measuring axle shaft end play-AMC/Jeep axle
2F-17
Measuring gauge block
2F-37
Measuring gauge block
2F-28
Measuring main shaft end play
2B-9
Measuring ring gear backlash
2F-38
Metal finishing, replacement parts
3B-2
Metal repair
3B-1
Metal repair and painting
3 B-1
Metallic color guide
3B-2
MetricSystem-SI
.... A - l l
Mirror, lighted vanity
3R-13
Mixture setting procedure-idle drop (tachometer)
1A-19
Model BBD-2 venturi carburetor
U-9
Model T-15a-exploded view
2B-13
Model T-15a 3-speed transmission
2B-12
Model T-150 3-speed transmission
2B-4
Model T-18a 4-speed transmission
2B-20
Model 20 transfer case
2D-1
Model 20 transfer case, service diagnosis
2D-3
Model 20 transfer case specifications
2D-11
Model 2100,2-venturi carburetor
1 J-20
ALPHABETICAL INDEX
1J-33
1 J-34
2F-14
2F-19
2F-18
2F-38
2F-32
2F-31
1J-36
2C-11
3H-11
3D-4
3H-10
3H-11
3T-2
3F-1
1K-8
N
Neutral safety switch
Neutral safety switch replacement
Noise, test, tire
Noises, wind, interior
Non-integral exhaust back-pressure sensor test
Non-linear vacuum regulator ( N L R V ) valve
Normal operating temperatures and pressures, Air
Conditioni ng
Notching bearing retainer ring
Number, paint option
Number, special sales request and order (SSR&O)
Number, trim option
Number, vehicle identification (vin)
2J-37
IF-14
2F-1
3A-9
1J-41
1G-20
3E-5
2F-18
A-7
A-6
A-7
A-6
O
Off-road driving lamps
Off-vehicle testing, starter
Oil cooler leakage...
Oil filter
Oil filter, eight-cylinder
Oil filter, six-cylinder
3R-10
1F-8
1C-12
B-7
1*6-53
1B-19
3E-15
1B-56
1B-21
1L-2
1L-3
1B-53
IB-19
2F-21
On turns-differential operation
On-vehicle testing, starting system
Operation, charging system
Operation, cooling system
Operation, Cruise Command
Operation CTO
Operation, differential
Operation, heater and defroster
Operation, PCV system
Operation, power steering gear and pump
Operation, SSI system
Operation, starting system
Out-of-vehicle service and overhaul, automatic
transmission
Out-of-vehicle service, Model 20 transfer case
Overall steering/suspension action
Overhand, model BBD, 2-venturi carburetor
Overhaul, alternator
Overhaul, automatic transmission, out-of-vehicle
service and
Overhaul, automatic transmission subassembly
Overhaul, carburetor model 2100, 2-venturi
Overhaul, carburetor model 2150, 2-venturi
Overhaul, differential-AMC/Jeep axle
Overhaul, differential-model 30-44-60 axle
Overhaul, disc brake caliper, Cherokee, Wagoneer,
Truck
Overhaul, disc brake caliper, CJ
Overhaul, power steering gear subassembly
Overhaul standard column,-antomatic
Overhaul, standard steering column, manual
transmission
Overhaul, starter motor
Overhaul tilt column- Cherokee-Wagoneer-Truck
Overhaul, tilt column, C J models
Overhaul, Trak-Lok
Overlays, exterior woodgrain
Oversize components, eight-cylinder
Oversize or undersize components,six-eylinder
2F-21
1F-2
1E-2
1C-4
1H-2
1C-5
2F-21
3D-6
1J-42
2L-1
1G-3
1 F-2
2C-29
2D-6
B-12
1J-12
1E-10
2C-29
2C-40
1J-24
1 J-34
2F-21
2F-30
2G-43
2G-48
2L-24
2J-20
2J-13
1F-11
2J-24
2J-30
2F-42
3P-11
1B-38
1 B-2
P
Pad, crash, Cherokee, Wagoneer, Truck
Pad, crash, CJ
Paint option number
Paint repair
Paint repair with acrylic enamel
Painting, metal repair and
Painting tips
Panel, fuse
Panel, heater control
Panel, instrument, Cherokee, Wagoneer, Truck
3C-5
3C-2
A-7
3P-5
3B-1
3 B-1
3 B-2
3R-16
3D-7
3C-4
ALPHABETICAL INDEX
Panel, instrument, C J
3C-1
Panel, instrument, C J
3C-1
Panel, trim
3K-1
Panels
3F-7
Panels g a l v a n i z e d
3 F - 7
Panels, rear q u a r t e r
3F-8
P a r k test, wiper
3T-16
Parking brake
B-11
Parking brake adjustment
2G-15
P a r k i n g b r a k e cables
2G-16
P a r k i n g , side m a r k e r a n d directional l a m p s
3R-4
Parts i d e n t i f i c a t i o n - m o d e l BBD 2 - v e n t u r i c a r b u r e t o r . . 1 J - 1 3
Parts i d e n t i f i c a t i o n - m o d e l 2 1 0 0 , 2 - v e n t u r i
carburetor
1J-25
Parts identification, starter m o t o r
1F-l 1
P a w l assembly, tilt lock
3M-4
P C V air inlet filter
1A-20
P C V air inlet filter m a i n t e n a n c e . . . . .
1J-42
P C V filter
P C V system
P C V system o p e r a t i o n
P C V valve
P C V valve flow specifications
P C V valve test
Pedal, brake
P e r f o r m a n c e characteristics, radial tire
Periodic m a i n t e n a n c e p o w e r steering a n d g e a r . .
Pinion bearing c u p r e m o v a l
Pinion bearing c u p r e m o v a l - m o d e l 3 0 - 4 4 - 6 0 axle
Pinion bearing installation
P i n i o n bearing preload a d j u s t m e n t
P i n i o n depth g a u g e tools
P i n i o n depth m e a s u r e m e n t a n d a d j u s t m e n t
P i n i o n depth s h i m location a n d s t a n d a r d setting
B-8
U-41
1 J-42
B-8
1J-43
U-42
2G-14
2H-8
2L-15
2F-23
2F-33
2F-35
2F-36
2F-28
2F-34
dimension
P i n i o n gear b e a r i n g preload a d j u s t m e n t
P i n i o n gear d e p t h m e a s u r e m e n t a n d a d j u s t m e n t .
P i n i o n gear installation
P i n i o n gear installation a n d d e p t h a d j u s t m e n t
P i n i o n gear r e m o v a l
P i n i o n gear r e m o v a l - m o d e l 3 0 - 4 4 - 6 0 a x l e
P i n i o n gear thrust washer installation
P i n i o n installation a n d d e p t h a d j u s t m e n t
Pinion m a t e shaft
P i n i o n m a t e shaft a n d thrust block r e m o v a l
P i n i o n m a t e shaft installation
P i n i o n m a t e shaft lockpin r e m o v a l
P i n i o n m a t e shaft lockpin r e m o v a l . . . . .
P i n i o n m a t e shaft r e m o v a l
P i n i o n m a t e shaft snap r i n g r e m o v a l
P i n i o n rear bearing r e m o v a l
P i n i o n rear b e a r i n g r e m o v a l - m o d e l 3 0 / 4 4 a x l e
P i n i o n rear b e a r i n g r e m o v a l - m o d e l 3 0 - 4 4 axle
P i n i o n rear bearing r e m o v a l - m o d e l 60 axle
2F-25
2F-27
2F-24
2F-46
2F-25
2F-44
2F-31
2F-46
2F-35
2F-44
2F-23
2F-46
2F-32
2F-23
2F-23
2F-43
2F-23
2F-33
2F-31
2F-33
P i n i o n rear b e a r i n g r e m o v a l - m o d e l 60 axle
P i n i o n rear b e a r i n g r e m o v a l - m o d e l 60 axle
P i n i o n seal a n d y o k e
P i n i o n seal a n d y o k e - A M C / J e e p axle
P i n i o n seal a n d y o k e - m o d e l 4 4 a n d 60 axle
P i n i o n seal installation
P i n i o n t h r u s t washer r e m o v a l
Pinion variance chart
Pinion variance chart
P i n o n gear r e m o v a l
Piston fitting, eight-cylinder
P i s t o n f i t t i n g , six-cylinder
P i s t o n pins, e i g h t - c y l i n d e r
P i s t o n pins, six-cylinder
P i s t o n rings, e i g h t - c y l i n d e r
Pistons, e i g h t - c y l i n d e r
P i v o t shaft b o d y a n d linkage
P i v o t vent w i n d o w - C h e r o k e e
Plastic t r i m parts, finishing
P l a t e , lock, installation
P l a t e , vehicle identification
Positive crankcase v e n t i l a t i o n ( P C V ) system
Power brake units....
P o w e r p l a n t diagnosis
P o w e r p l a n t diagnosis, w i t h scope a n a l y s e r . . .
P o w e r p l a n t - m e c h a n i c a l diagnosis, service
P o w e r plant p e r f o r m a n c e diagnosis
2F-33
2F-31
2F-5
2F-18
2F-19
2F-19
2F-44
2F-34
2F-26
2F-23
1B-61
1B-25
1B-63
IB-26
1B-61
1B-60
3T-2
3K-1
3B-3
2B-16
A-6
1J-41
2G-29
1A-2
1A-l 1
1 A-3
1 A-6
P o w e r plant t u n e - u p
P o w e r steering gear
P o w e r steering gear a n d p u m p m a i n t e n a n c e
P o w e r steering gear assembly
P o w e r steering gear assembly a n d a d j u s t m e n t
P o w e r steering gear service, in-vehicle
P o w e r steering h y d r a u l i c pressure test
P o w e r steering p u m p
P o w e r steering p u m p
P o w e r steering p u m p .
P o w e r steering p u m p disassembly
P o w e r steering p u m p specifications
P o w e r steering service diagnosis
P o w e r steering specifications
P o w e r steering tools
P o w e r tailgate w i n d o w c i r c u i t r y - C h e r o k e e W a g o n e e r models
P o w e r tailgate w i n d o w system
Power Train Combinations-1979 CherokeeWagoneer-Truck Models
Power Train Combinations-1979 C J Models
P o w e r u n i t diagnosis, b r a k e
P o w e r unit diagnosis, brakes
P o w e r units, b r a k e
P r e c a u t i o n s , safety
P r e l o a d a d j u s t m e n t , d i f f e r e n t i a l bearing
Pressure g a u g e a n d m a n i f o l d assembly
1 A-14
2L-19
2L-15
2L-21
2L-32
2L-19
2L-15
2L-37
2L-39
B-8
2L-40
2L-43
2L-6
2L-19
2L-44
3H-9
3H-8
A-12
A-12
2G-31
2G-4
2G-29
A-8
2F-29
3E-4
A L P H A B E T I C A L INDEX
3V-7
1L-6
1L-3
3R-2
1 A-19
1 A-18
2E-1
2E-1
2E-9
2E-10
2E-12
B-12
1C-18
2L-41
1J-8
U-7
2L-39
2L-37
B-8
1C-2
Q
Quadra-Trac, emergency drive
Quadra-trac fluid change
Quadra-Trac lubricants
Quadra-Trac lubrication
Quadra-Trac reduction unit.
Quadra-Trac service diagnosis
Quadra-Trac specifications, general
Quadra-Trac transfer case
Quadra-trac transfer case and low range reduction
unit fill plugs
Quadra-Trac transfer case service, in-vehicle
Quadra-Trac transfer case service, out-of-vehicle
Quadra-Trac with reduction unit
Quadra-Trac without reduction unit
Quarter,rear..
2D-13
B-13
2D-39
2D-21
2D-15
2D-17
2D-38
2D-12
B-14
2D-28
2D-32
B-13
B-13
3K-1
R
Racks, luggage
Radial tire performance characteristics
Radial, wide tread and snow tire applications
Radiator
Radiator......................
Radiator grilles
Radiator pressure cap
Radio, A M and F M reception
3L-1
2H-8
2H-5
1C-2
JC-18
3F-8
1C-2
3V-4
3V-4
3V-2
3V-11
3V-13
3V-10
3V-3
3V-9
3V-3
3V-5
3V-6
3V-7
3V-7
3V-4
3V-9
3V-4
3V-1
3V-13
3V-13
3 V-12
3V-3
A-15
2F-14
2F-19
2F-19
2F-20
2F-20
2B-7
2B-6
2B-17
2B-14
B-11
3F-12
3R-5
3M-7
1B-66
1 B-31
3K-1
3F-8
3K-3
3M-7
2N-6
2N-5
2N-4
A-8
3N-5
B-11
3N-1
2K-1
B-16
1C-3
2C-6
2D-15
2D-22
ALPHABETICAL INDEX
Regulator
Regulator, tailgate
Removal, axle shaft bearing-AMC/Jeep axle
Removal, axle shaft-model 44 & 60 axle
Removal, differential bearing
Removal, differential bearing-model 30-44 axle
Removal, differential bearing-model 60 axle
Removal, lock cylinder.
Removal-model 60 axle
Removal, pinion bearing cup
Removal, pinion bearing cup-model 30-44-60 axle
Removal, pinion gear
Removal, pinion gear
Removal, pinion gear-model 30-44-60 axle
Removal, pinion mate shaft
Removal, pinion mate shaft and thrust block
Removal, pinion mate shaft lockpin
Removal, pinion rear bearing
Removal, pinion rear bearing-model 30/44 axle
Removal, pinion rear bearing-model 60 axle
Removal, pinion thrust washer
Removal, rear axle
Removal, ring gear
Removal, steering gear
Removal, steering gear, right-hand drive
Removal, steering knuckle
Repair area, tire
Repair, diagnosis and, horn system
Repair, metal
Repair, tire
Repair, with acrylic enamel, paint
Replacement, alternator
Replacement, axle shaft bearing
Replacement, battery
Replacement, dimmer switch
Replacement,diverter
Replacement, exhaust pipe
Replacement, exterior decals
Replacement, headlamp switch
Replacement, neutral safety switch
Replacement, spring bushing
Replacement, starter motor
Replacement, tail pipe
Replacement, vinyl moulding
Replacement, vinyl mouldings
Resistance values, spark plug wires
Restricted exhaust system diagnosis
Restrictor plates, non-integral back pressure sensor
Reverse idler gear
Reverse idler gear romoval/installation
Reverse idler gear shaft removal-installation
Ring and pinion gear backlash adjustment
Ring, first gear synchronizer hub snap
Ring gear installation
3H-11
3H-11
2F-16
2F-18
2F-22
2F-32
2F-33
3M-5
2F-18
2F-23
2F-33
2F-44
2F-23
2F-31
2F-23
2F-23
2F-32
2F-23
2F-33
2F-33
2F-44
2F-19
2F-23
2K-3
2K-12
2F-9
2H-5
3S-1
3 B-1
2H-4
3B-1
1E-9
2F-17
1D-1
3R-3
IK-12
1K-9
3P-7
3R-2
1F-14
2N-7
IF-10
1K-9
3P-11
3P-7
1A-16
1K-1
1J-41
2B-23
2B-14
2B-6
2F-28
2B-15
2F-28
2F-28
2F-23
2F-18
2B-14
2C-8
1B-40
1 B-5
3F-14
2B-6
1 J-6
3P-2
3L-2
2F-46
2H-5
1 A-16
2G-50
2H-8
3H-4
3H-1
2F-29
2H-9
S
Safety certification sticker
Safety precautions
Safety switch
Schedule, engine maintenance
Schematic, horn circuit
Schematic, starting system
Schematic, Trac-Lok differential
Seal, axle shaft
Seal axle shaft
Seal, console cover
Seal, front bearing cap oil
Seal, front bearing cap oil
Seal installation, inner oil-AMC/Jeep axle
Sealer, bubber
Sealer, rubber
Sealing system
Sealing system Cherokee-Wagoneer rear doors
Sealing system Cherokee, Wagoneer Truck doors
Sealing system, CJ-7, door
Seat back, forward tilting, replacement-Cherokee
andTruck models
Seat belts...
Seat belts
Seat, rear folding-latched position
Seats, bucket-CJ
Seats, Cherokee-Wagoneer
Seats, C J .
Seats, CJ 2/3-1 / 3 style
A-7
A-8
3H-10
1 A-14
3S-1
IF-3
2F-42
2F-11
2F-11
3M-5
2B-18
2B-10
2F-17
3H-1
3H-4
3H-1
3J-9
3J-4
3J-1
3M-4
3M-8
3M-6
3M-7
3M-2
3M-7
..3M-7
3M-1
ALPHABETICAL INDEX
Seats, front..
3M-1
Seats, rear
3M-7
Seats,CJ bucket
3M-1
Second gear and thrust washer installation
2B-24
Second gear installation
2B-9
Second-third clutch hub snap ring removal/
installation
2B-14
Second-third synchronizer assembly
2B-15
Second-third synchronizer assembly
2B-9
Secondary resistance test
1G-14
Sending unit, fuel tank
1J-3
Sensor and trigger wheel
1G-2
Sensor, non-integral, exhaust back-pressure
1 J-40
Sensor, thermal, TAC system
1J-44
Service adjustment procedures, carburetor model
2100, 2-venturi
U-29
Service adjustment procedures, carburetor model
2150, 2-venturi
1J-35
Service adjustment procedures, model BBD, 2venturi carburetor
1J-17
Service and adjustment, automatic transmission, invehicle
2C-25
Service and overhaul, automatic transmission
2C-29
Service brake adjustment
2G-17
Service, choke mechanism, carburetor model BBD 2venturi
1J-19
Service, choke mechanism, carburetor model 2100,
2-venturi
1J-32
Service, clutch
2A-8
Service diagnois, starting system
1F-4
Service diagnosis
2B-2
Service diagnosis charts
A-2
Service diagnosis, clutch
2A-1
Service diagnosis, Cruise Command
1H-9
Service diagnosis-disc brakes
2G-10
Service diagnosis-drum brakes
2G-4
Service diagnosis-emergency drive system
2D-19
Service diagnosis-mechanical, power plant
1 A-3
Service diagnosis-Model 20 transfer case
2D-3
Service diagnosis-performance, power plant
1 A-6
Service diagnosis, power steering
2L-6
Service diagnosis-power unit, brakes
2G-4
Service diagnosis, Quadra-Trac
2D-17
Service, disc brake rotor
2G-50
Service, general, diagnosis and
1 A-l
Service Manual Improvements
A-3
Service, Model 20 transfer case, in-vehicle
2D-3
Service, out-of-vehicle, Model 20 transfer case
2D-6
Service, power steering pump, in-vehicle
2L-37
Service procedures, general, Air Conditioning
3E-2
Service, propeller shaft
2E-10
Service, Quadra-Trac reduction unit
2D-22
Service, Quadra-Trac transfer case, in-vehicle
2D-28
Service, Quadra-Trac transfer case, out-of-vehicle.... 2D-32
:
A L P H A B E T I C A L INDEX
3V-12
Special sales request and order (SSR&O) number
A-6
Specific gravity, battery
1D-6
Specifications AMC/Jeep axle (semi-floating
tapered shaft)
2F-39
Specifications, automatic transmission
2C-79
Specifications, automatic transmission test.
2C-23
Specifications, axle torque
2F-39
Specifications, brake
2G-19
Specifications, carb idle drop
1A-20
Specifications, carburetor model BBD 2-venturi
1 J-20
Specifications, carburetor model BBD 2-venturi..
1 J-19
Specifications, carburetor model 2100, 2-venturi
1J-33
Specifications, carburetor model 2100,2-venturi......... 1 J-32
Specifications, carburetor model 2150, 2-venturi
1J-36
Specifications, charging system
1E-14
Specifications, clutch
2A-14
Specifications, clutch housing alignment
2A-14
Specifications, cooling system
1C-22
Specifications, cooling system...
1C-21
Specifications, differential
2F-39
Specifications, disc brake, general
2G-53
Specifications, distributor and coil
1G-18
Specifications, drive belt tension
2L-44
Specifications, drum brakes, general
2G-38
Specifications, eight-cylinder
1B-70
Specifications front axle
2F-13
Specifications, front wheel alignment
2M-6
Specifications, fuel pump
1 J-9
Specifications, general, brake fulid
2G-27
Specifications, horn system......
3S-2
Specifications, manual specifications T-150
2B-12
Specifications, Model 20 transfer case
2D-11
Specifications, model 30 front axle
2F-39
Specifications, model 44 axle (full-floating and semifloating types)
2F-39
Specifications, model 60 axle....
2F-39
Specifications, PCV valve flow
1J-43
Specifications, power steering
2L-19
Specifications, power steering pump
2L-43
Specifications, propeller shaft
2E-12
Specifications, Quadra-Trac, general
2D-39
Specifications, rear axle
2F-20
Specifications, rear window
3N-6
Specifications, six-cylinder
1B-34
Specifications, starter motor
1F-14
Specifications, steering column
2J-41
Specifications, steering gear
2K-10
Specifications, steering linkage
2M-6
Specifications, suspension
2N-8
Specifications, suspension
Specifications, T-15A transmission torque
Specifications, T-l 50 manual transmission torque
Specifications tune-up
Specifications^- 15A transmission
Speedometer calibration Cherokee, Wagoneer,
Truck.....
Speedometer calibration, CJ
Speedometer, Cherokee, Wagoneer, Truck
Speedometer, CJ
Sport steering wheel skirt, replacement
Spreading axle housing
Spring bushing replacement
Spring, front
Spring, rear
SSI system diagnosis and repair simplification
(DARS) chart
SSI system schematic
Stabilizer bar
Stabilizer bar mounting
Stabilizer bar position
Standard column
Standard column overhaul-automatic transmission
Standard column overhaul-manual transmission
Standard cooling CTO switch...
Standard differential
Standard setting dimension and pinion depth shim
location
Standard torque specifications and capscrew
markings chart
Starter motor overhaul.................
Starter motor parts identification
Starter motor replacement..
Starter motor specifications
Starter ring gear assembly, eight-cylinder..
Starter ring gear assembly, six-cylinder
Starter testing, off-vehicle
Starter volt, drop test diagnosis & repair
simplification (DARS) char
Starting system
Starting system components
Starting system operation
Starting system schematic
Starting system service diagnosis
Starting system testing, on-vehicle
Starting system tools
Starting system troubleshooting
Stationary vent window,
Stationary window-CJ-7 with hardtop enclosure
Stationary window-2-door Cherokee
Stationary window-4-door Cherokee-Wagoneer
Steering column-automatic transmission
Steering column diagnosis
Steering column-manual transmission
2N-8
2B-19
2B-12
1A-21
2B-19
3C-7
3C-3
3C-7
3C-3
2J-11
2F-32
2N-7
2N-3
2N-6
1G-7
1G-4
2N-3
2N-6
2N-6
3R-16
2J-20
2J-13
1C-5
2F-21
2F-25
A-2
1F-11
1F-11
IF-10
IF-14
1B-68
1B-32
1F-8
T 1F-6
1F-1
1 F-l
1 F-2
IF-3
1F-4
1 F-2
1F-14
1 F-2
3J-3
3K-2
3K-2
3K-2
2J-20
2J-1
2J-12
ALPHABETICAL INDEX
?
r-
* I
Support system..
Supporting first-second clutch hub...
Suspension
Suspension
Suspension action/overall, steering
Suspension specifications.
Swingout spare tire carriers
Switch, backup lamp
Switch, brakelamp
Switch, directional signal..
Switch, directional signal..
Switch, dual range C T O
Switch, EGR-CTO
Switch, fan control
Switch, headlamp
Switch, ignition
Switch, ignition
Switch, instrument panel tailgate window
Switch neutral safety
Switch, neutral safety, replacement
Switch, single function CTO
Switch, spark coolant temperature overide (CTO)
Switch, standard cooling CTO
Switch, stoplamp
Switch, tailgate instrument panel
Switch, tailgate safety
Switch, tailgate window
Switch, tailgate window
Switch, tailgate window
Switch, tailgate window safety
Switch, TCS
Switch test
Switch test,TailgateWindowDefogger
Switches and backup lamps
Synchronizer, assembling first-second
Synchronizer, first gear
Synchronizer, first-second
Synchronizer installation, third-fourth
Synchronizer installations, first-second
Synchronizer, second-third
Synchronizer, second-third, assembly
System, brake hydraulic
System, charging..
System components, Air Conditioning
System controls, heater
System, cooling, carburetor bowl
System, door sealing, CJ-7
System, emission control fuel tank vapor
System, exhaust
System, fuel return
System, interior lighting
System, liftgate hinge
System, liftgate lock
System, liftgate sealing
3H-3
2B-23
2N-1
B-12
B-12
2N-8
3F-13
2B-1
2G-17
3R-8
3R-7
1C-5
U-39
3D-4
3R-2
3R-15
2J-37
3H-8
2J-37
1F-14
1C-5
1C-4
1C-5
3R-9
3H-10
3H-10
3H-8
3H-10
3H-11
3H-10
2B-1
3T-14
3U-2
3R-6
2B-23
2B-15
2B-23
2B-24
2B-24
2B-15
2B-9
2G-20
1E-1
3E-1
3D-1
1J-45
3J-1
1A-20
1A-21
U-6
3R-12
3H-3
3H-2
3H-1
A L P H A B E T I C A L INDEX
S y s t e m , liftgate w i n d o w
3H-1
System operation, A i r Conditioning
3E-1
System operation, P C V
1 J-42
System, P C V
U-41
System troubleshooting, A i r Conditioning
3E-17
S y s t e m , C h e r o k e e - W a g o n e e r , lock
3H-7
S y s t e m , C h e r o k e e - W a g o n e e r p o w e r tailgate w i n d o w ... 3 H - 8
System,Cherokee-Wagoneer window
3H-7
Systems,
Systems,
Systems,
Systems,
Systems,
Systems,
Systems,
Systems,
Systems,
cooling...
exhaust
fuel
fuel
horn
ignition
lighting
radio sound
spark control
1C-1
1K-1
1 J-l
1A-18
3S-1
1G-1
3R-1
3V-1
1G-18
T
T - 1 5 A - e x p l o d e d view
T - 1 5 A transmission specifications
T - 1 5 A transmission t o r q u e specifications
T - 1 5 0 m a n u a l transmission t o r q u e specifications
2B-13
2B-19
2B-19
2B-12
T - 1 8 , specifications....
2B-28
T A C system
T A C system testing
T A C system t h e r m a l sensor
Tachometer
T a c h o m e t e r diagnosis
T a i l a m p s , rear d i r e c t i o n a l , side m a r k e r , a n d stop
T a i l g a t e hinge lubrication h o l e - C h e r o k e e a n d
W a g o n e e r models
T a i l g a t e lubrication p o i n t s - C h e r o k e e a n d W a g o n e e r
models
T a i l g a t e w i n d o w defogger
Tailgate window motor
T a i l g a t e w i n d o w safety switch
T a i l g a t e w i n d o w switch
T a i l g a t e w i n d o w switch
Tailgates, Cherokee Wagoneer
Tailgates, C J - 5
Tailgates, C J - 7
Tailgates,truck..
T a i l l a m p housing
T a i l p i p e replacement
T a n k , fuel
T a n k , f u e l , vent lines a n d , C h e r o k e e - W a g o n e e r
T a n k , fuel, vent lines a n d , C J - 5 a n d C J - 7
T a n k , f u e l , vent lines a n d , T r u c k
T a p e head a n d capstan cleaning
T a p e head a n d capstan cleaning p r o c e d u r e
U-43
1J-44
1J-44
1L-2
1L-4
3R-5
B-10
B-10
3U-1
3H-10
3H-10
3H-8
3H-10
3H-5
3H-4
3H-4
3H-11
3R-6
1K-9
U-2
1J-4
1J-3
1 J-4
3V-3
3V-3
3V-3
T a p e player o p e r a t i o n
3V-3
T C S switch...
Temperature gauge
Temperature gauge
T e m p e r a t u r e g a u g e diagnosis
T e m p e r a t u r e s a n d pressures, A i r C o n d i t i o n i n g
normal operating
T e m p l a t e , key coding
T e r m i n a l s , ignition switch
T e s t analysis, a u t o m a t i c transmission h y d r a u l i c
2B-1
1L-2
1C-3
1 L-4
pressure
T e s t , a u t o m a t i c transmission h y d r a u l i c pressure
T e s t , a u t o m a t i c transmission r o a d
T e s t , check v a l v e
T e s t , coil o u t p u t
T e s t , compression
T e s t , coolant f r e e z i n g p o i n t . . . . . . .
T e s t , cylinder leakage
T e s t , cylinder l e a k a g e , diagnosis
Test,diverter
Test, E G R - C T O
Test, E G R valve
T e s t , fuel p u m p c a p a c i t y .
T e s t g a u g e installation, a u t o m a t i c transmission
T e s t h y d r a u l i c p o w e r steering
Test, modulator
T e s t , n o n integral e x h a u s t b a c k pressure sensor
Test-non-linear v a c u u m regulator valve
3E-5
A-7
3R-14
2C-11
2C-9
2C-8
IK-12
1G-15
1A-l 1
1C-12
1 A-11
1A-13
IK-12
1 J-40
1J-38
1J-8
2C-10
2L-15
2C-11
1J-41
1G-21
Test, P C V valve
T e s t , pressure, fuel p u m p
T e s t procedures, a u t o m a t i c transmission diagnosis
and,
T e s t specifications, a u t o m a t i c transmission
T e s t , starter v o l t a g e d r o p , D A R S charts
T e s t , t o r q u e bias, Q u a d r a - T r a c .
Test, T r a c - L o k operational
T e s t i n g a l t e r n a t o r , off-vehicle
2C-6
2C-23
1F-6
2D-21
2F-41
1E-7
Testing, battery
T e s t i n g , cooling system c o m p o n e n t s
T e s t i n g , diagnosis, axles
T e s t i n g - o f f vehicle, a l t e r n a t o r
T e s t i n g , starter, off-vehicle
T e s t i n g , starting s y s t e m , on-vehicle
T e s t i n g , T A C system
T e s t s , fuel e c o n o m y
T e s t s , fuel p u m p v a c u u m
1D-5
1C-12
2F-1
1E-7
1F-8
1F-2
1 J-44
1J-9
1 J-8
T e s t s , tire noise
T e s t s , wheel b e a r i n g
T h e r m a l sensor, T A C system
2F-1
2F-1
1 J-44
Thermostat
T h e r m o s t a t i c a l l y controlled air cleaner ( T A C )
system
T h e r m o s t a t i c a l l y controlled air cleaner ( T A C )
system
U-42
1 J-8
1C-2
U-43
1A-21
ALPHABETICAL INDEX
Tools, brake
Tools, charging systems
Tools, clutch
Tools, fuel system,...
Tools, pinion depth gauge
Tools, power steering
Tools, rear quarter
Tools, starting system
Tools, steering column
Tools, transfer case
Tools, water leak/wind noise diagnosis
Tools, windshield and rear window
2B-24
2B-24
1J-36
2A-2
2B-24
2M-3
3R-16
2J-24
2J-30
3M-4
2J-27
1B-47
IB-12
1B-49
1B-14
1 B-13
1 A-l7
1A-17
1A-18
3B-2
2H-5
B-12
2H-1
2H-2
2H-13
2H-4
2F-1
2H-4
2H-5
2H-5
2H-8
2H-2
2H-3
2H-1
3V-4
3 V-4
2M-4
3E-21
2C-81
2F-48
2G-54
IE-14
2A-15
1J-47
2F-37
2L-44
3K-3
1F-14
2J-41
2D-39
3A-l 1
3N-7
ALPHABETICAL INDEX
T r a n s m i s s i o n installation, m a n u a l
Transmission, manual
T r a n s m i s s i o n m o d e l T-15A-shift control housing
T r a n s m i s s i o n , m o d e l T-18A4-speed
Transmission removal
Transmission removal, manual
T r a n s m i s s i o n , service diagnosis m a n u a l
T r a n s m i s s i o n , 3-speed model T - 1 5 0
T r a n s m i s s i o n , 3-speed model T - 1 5 0
T r i m option n u m b e r
T r i m panel
T r i m parts, plastic, finishing
T r i m m e r adjustment
T r i m m e r , radio a n t e n n a
T r o u b l e s h o o t i n g , A i r C o n d i t i o n i n g system
T r o u b l e s h o o t i n g , c h a r g i n g system
Troubleshooting, Cruise C o m m a n d . . . .
T r o u b l e s h o o t i n g procedures, w i p e r m o t o r
T r o u b l e s h o o t i n g , S S I system
T r o u b l e s h o o t i n g , starting system
T r u c k M o d e l Identification
Truck Models
T r u c k tailgates
Tune-up
T u n e - u p , p o w e r plant
T u n e - u p specificationsT u n i n g the C B a n t e n n a / s p l i t t e r b o x
T u r n signal a n d C r u i s e C o m m a n d switch
T u r n i n g angle a d j u s t m e n t
2B-4
2 B-1
2B-18
2B-20
2B-3
2B-3
2B-2
2B-12
2B-4
A-7
3K-1
3B-3
3V-2
3V-2
3E-17
1E-3
1H-5
3T-3
1G-3
1F-2
A-5
A-4
3H-11
B-8
1A-14
1A-21
3V-11
2J-36
2F-12
U
U - j o i n t , steering shaft
U n d e r s i z e c o m p o n e n t s , eight-cylinder
U n d e r s i z e c o m p o n e n t s , six-cylinder
B-13
1B-38
1 B-2
U n i t , control
Unit, vacuum
U n i v e r s a l j o i n t angle chart
U n i v e r s a l j o i n t angle m e a s u r e m e n t a n d a d j u s t m e n t
U n i v e r s a l j o i n t application
U n i v e r s a l j o i n t , a x l e shaft
U n i v e r s a l j o i n t service
Unscheduled maintenance
1G-1
1G-17
2E-12
2E-9
2E-2
2F-12
2E-10
B-15
V
V a c u u m tests, fuel p u m p
V a c u u m throttle m o d u l a t i n g ( V T M ) system
Value, brake combination
V a l v e , diverter bypass
1 J-8
1J-36
2G-24
1K-11
V a l v e , diverter bypass
Valve, E G R
V a l v e , E G R , w i t h b a c k pressure sensor
V a l v e , E G R , w i t h o u t b a c k pressure sensor
V a l v e , heat
V a l v e , liquid check
V a l v e maintenence, E G R , Cherokee-WagoneerTruck
V a l v e , rollover check
V a l v e springs, eight-cylinder
V a l v e springs, six-cylinder
V a l v e t r a i n , eight-cylinder
V a l v e t r a i n , six-cylinder
V a l v e s , eight c y l i n d e r . . . .
V a l v e s , six-cylinder
Vehicle identification..
V e h i c l e identification n u m b e r ( V I N )
V e h i c l e identification plate
V e n t , bowl vapor
V e n t window, pivot, Cherokee
V e n t i l a t i o n , fresh air
V e n t i l a t i o n , fresh air
Vibration
V i b r a t i o n d a m p e r , eight-cylinder
V i b r a t i o n d a m p e r , six-cylinder
V i b r a t i o n diagnosis
V i b r a t i o n diagnosis chart
V i b r a t i o n diagnosis, driveline
V i b r a t i o n , driveline
V I N decoding c h a r t
V i n y l m o u l d i n g replacement
V i n y l m o u l d i n g s replacement
Voltmeter
V o l t m e t e r diagnosis
V S W R r e a d i n g b y C B channels
1K-11
1J-38
1 J-38
1 J-38
1K-7
1 J-6
U-39
1 J-6
1B-42
1 B-7
1B-40
1B-4
1 B-40
1 B-5
A-6
A-6
A-6
1 J-6
3K-1
3D-2
3D-7
2H-10
1B-67
1 B-31
2H-10
2H-12
2E-3
2E-3
A-6
3P-11
3P-7
1L-2
1 L-4
3V-11
W
W a g o n e e r m o d e l 15
Wagoneer Models
W a r n i n g s a n d cautions
W a s h e r , first gear t h r u s t , installation
Washer pump
W a t e r l e a k / w i n d noise diagnosis a n d repair
W a t e r leaks
W a t e r leaks, windshield
Water pump
W a t e r p u m p pulley
W e a r , tire, a b n o r m a l
W e a t h e r s e a l glass f r a m e
W h e e l alignment, front
W h e e l a n d tire r u n o u t
A-5
A-4
A-l
2B-9
3T-3
3 A-1
3A-l
3N-2
1C-2
1C-18
2H-3
3P-6
2M-4
2H-9
ALPHABETICAL INDEX
Wheel balancing
Wheel bearing adjustment....
Wheel bearing tests
Wheel cylinder
Wheel maintenance and condition
Wheels
Wheels and tires
Wind noise/water leak diagnosis and repair
Wind noises, interior
Wind whistles, exterior
Window, pivot vent, Cherokee
Window, stationary, CJ-7 with hardtop enclosure
Window, stationary, 2-door Cherokee
Window, stationary, 4-door Cherokee, Wagoneer
Window switch
Window system
Window system
Window system, CJ-7 with hardtop enclosure
Window system, CJ-7, with hardtop enclosure
Window system, rear door Cherokee, Wagoneer..
Windshield- rear window
Windshield, folding, CJ
Windshield hinge lubrication hole - CJ models
Windshield mounted rear view mirror bracket
location -CJ models
Windshield-rear window
Windshield, tools and material
Windshield washers
Windshield water leaks
Windshield water leaks
Windshield weatherstrip cross section
Windshield wiper circuitry
Windshield wiper components
Windshield wiper components
Windshield wiper, diagnosis and circuitry,
Windshield wiper with intermittent governor
circuitry
Windshield wipers
Windup bumper, front axle
Wiper and washer control
Wiper arm replacement
Wiper arm replacement
Wiper blade element replacement
Wiper blade replacement
Wiper blade replacement
Wiper, circuit breaker test
Wiper, control switch
Wiper motor...
Wiper motor and transmission components
Wiper motor current draw test connections
Wiper motor troubleshooting procedures
Wiper motor, two speed
Wiper, park test
Wiper pivot shaft body and linkage
2H-6
2H-6
2F-1
2G-23
2H-5
2H-5
2H-1
3A-1
3A-9
3 A-10
3K-1
3K-2
3K-1
3K-2
3H-11
3H-1
3H-7
3J-5
3J-2
3J-10
3N-1
3N-1
B-10
3N-5
3N-6
3N-2
3T-18
3N-2
3N-2
3N-3
3T-12
3T-1
3T-5
3T-6
3T-13
3T-1
2N-1
3T-2
3T-2
3T-4
3T-4
3T-4
3T-1
3T-14
3T-14
3T-15
3T-17
3T-15
3T-3
3T-2
3T-16
3T-5
3T-5
3T-2
3T-14
3T-1
. 3H-10
3R-14
3P-11
2K-1
Y
Yoke and pinion seal-AMC/Jeep axle
Yoke and pinion seal-model 44 and 60 axle
Yokes, sleeves, (splines)
1979 Jeep maintenance schedule
1979 Model Jeep Vehicles
2-venturi carburetor, model BBD
4-way emergency flasher (hazard warning)
2F-18
2F-19
B-13
B-2
A-3
1J-9
3R-9
V A C U U M line
ROUTING D I A G R A M S
2
09
AIR P U M P
PURGED VAPORS
/ F R O M FUEL
/
E V A P . SYSTEM
FRONT
>
DISTRIBUTOR
PORTED V A C U U M
j ^ r - = ^ j
90191A
J!
90191B
49-STATE 258 CID ENGINE WITH MAN. TRANS. AND H.D. COOLINGCJ-CHEROKEE-J-10 TRUCK MODELS
SPARK C T O S W I T C H
P U R G E VALVE S I G N A L
(CANISTER)
AIR P U M P
CHECK
VALVE
PURGED VAPORS
F R O M FUEL
EVAP. SYSTEM
FRONT
DISTRIBUTOR
MANIFOLD VACUUM
PORTED VACUUM
90191C
49-STATE 258 CID ENGINE WITH AUTO. TRANS.CJ-7 CHEROKEE-WAGONEER-J-10 TRUCK MODELS
TAC SIGNAL
CLEANER),
( A I R
EGR VALVE
SPARK CTO
SWITCH (DUAL)
AIR PUMP
90191D
49-STATE 258 CID ENGINE WITH AUTO. TRANS. AND H.D. COOLINGCJ-7-CHER0KEE-WAG0NEER-J-10 TRUCK MODELS
C/3
Ol
TAC SIGNAL
(AIR CLEANER)
EGR VALVE
DIVERTER VALVE
AIR PUMP
PURGED VAPORS
FROM FUEL
EVAP. SYSTEM
PCV AIR IN
THERMAL V A C U U M SWITCH
FRONT
MANIFOLD V A C U U M
DISTRIBUTOR
PORTED VACUUM
90
TAC SIGNAL
90191J
CALIFORNIA 258 CID ENGINE WITH MAN. TRANS. AND H.D. COOLINGCJ MODELS
TAC SIGNAL
(AIR CLEANER)
EGR VALVE
sssf-
EGR CTO
SWITCH
AIR PUMP
PURGED VAPORS
FROM FUEL
EVAP. SYSTEM
FRONT
MANIFOLD VACUUM
PORTED VACUUM
DISTRIBUTOR
90191K
EGR C T O S W I T C H
EGR VALVE
TAC SIGNAL
CLEANER)
A
P U R G E VALVE S I G N A L
(CANISTER)
SPARK C T O
S W I T C H (DUAL)
AIR P U M P
PURGED VAPORS
F R O M FUEL
EVAP. SYSTEM
FRONT
MANIFOLD VACUUM
DISTRIBUTOR
PORTED V A C U U M
i
^ " " - j
90191H
CALIFORNIA 258 CID ENGINE WITH AUTO. TRANS. AND H.D. COOLINGCJ-7
90191N
90191P
49-STATE 304 CID ENGINE WITH MAN. TRANS. AND H.D. COOLINGCJ MODELS
90191L
90191M
49-STATE 304 CID ENGINE WITH AUTO. TRANS. AND H.D. COOLINGCJ-7
90191R
MANIFOLD VACUUM
PORTED VACUUM
90191S
AIR PUMP
CO
PORTED VACUUM
f=z^r^--^
90191Y
CALIFORNIA 360 CID ENGINE WITH AUTO. TRANS. AND H.D. COOLINGCHEROKEE-WAGONEER-TRUCK MODELS
AIR PUMP
EGR CTO SWITCH
DISTRIBUTOR
PORTED VACUUM
90192A
CALIFORNIA 360 CID ENGINE WITH MAN. TRANS. AND H.D. COOLING-CHEROKEE MODELS
90191W
90192C
CALIFORNIA 360 CID ENGINE WITH MAN. TRANS. AND H.D. COOLING-TRUCK MODELS
90191T
90191V
PURGE VALVE
(CANISTER)
DIVERTER
SIGNAL
VALVE
AIR P U M P
ORIFICE PLATE
EGR CTO
E R GCTOV A L V E
SWITCH
DISTRIBUTOR
PCV
VALVE
OIL FILLER
MANIFOLD VACUUM
PORTED VACUUM
90192B
CALIFORNIA 360 CID ENGINE WITH AUTO. TRANS. AND H.D. COOLINGTRUCK MODELS
CAP
NOTES
NOTES
WIRING
DIAGRAMS
SECTION INDEX
Accessories
Cherokee-Wagoneer-Truck
W-7
W-5
W-2
WIRING DIAGRAMS
NOMENCLATURE
Accessory Feed
Air Conditioner Compressor, 8-Cylinder
Alternator, 8-Cylinder
Alternator, 6-Cylinder
Anti-Diesel Solenoid, 8-Cylinder
Anti-Diesel Solenoid, 6-Cylinder
Back-up Lamp, Right Side
Back-up Lamp, Left Side
Back-up Light Switch
Manual Transmission
Back-up Light Switch
Manual Transmission
Battery, 8-Cylinder
Battery, 6-Cylinder
Body, 8-Cylinder
Body, 6-Cylinder
Brake Failure Switch
Brake Warning Lamp
Capacitor Jumper, 8-Cylinder
Capacitor Jumper, 6-Cylinder
Chassis, 8-Cylinder
Chassis, 6-Cylinder
Cigar Lighter Feed
Coil, 8-Cylinder
Coil, 6-Cylinder
Dimmer Switch
Distributor, 8-Cylinder
Distributor, 6-Cylinder
Electric Choke
Fuel Gauge
Fuel Sender
Ground Air Lamp Feed
Ground Defogger Lamp Feed
Ground Fan Lamp Feed
Ground Temperature Lamp Feed
Headlamp, Right Side
Headlamp, Left Side
Heater Motor, 8-Cylinder
Heater Motor, 6-Cylinder
Heater Switch
High Beam Indicator
Horn
Horn Relay
Ignition Switch
Kickdown & Quadra-Trac,
6-Cylinder
Left Turn Indicator &
Hazard Lamp
LOCATION
C-8
B-3
B-2
D-3
A-4
D-4
C-11
D-11
C-4
E-2
A-4
C-4
A-4
C-4
E-3
C-7
A-3
C-2
A-4
C-4
D-9
A-2
C-2
D-6
A-2
C-3
A-6
B-8
D-9
A-7
A-7
A-8
A-7
B-1
D-1
B-3
D-3
B-5
D-5
E-4
D-7
C-8
E-3
D-8
NOMENCLATURE
Marker & Reflector, Right Side
Marker & Reflector, Left Side
Marker & Reflector, Right Side
Marker & Reflector, Left Side
Module Assembly Ignition,
8-Cylinder
Module Assembly Ignition,
6-Cylinder
Neutral Safety Switch
Oil Lamp Gauge
Oil Pressure Sender, 8-Cylinder
Oil Pressure Sender, 6-Cylinder
Oil Pressure Switch
Panel Lamp
Panel Lamp
Park & Signal Lamp, Right Side
Park & Signal Lamp, Left Side
Parking Brake
Quadra-Trac Lamp
Resistor Heater Blower Motor
Splice, 8-Cylinder
Splice, 6-Cylinder
Splice, 6-Cylinder
Splice, 6-Cylinder
Splice, 6-Cylinder
Splice, 6-Cylinder
Splice
Splice
Splice
Splice
Splice
Starting Motor, 8-Cylinder
Starting Motor, 6-Cylinder
Starter Solenoid, 8-Cylinder
Starter Solenoid, 6-Cylinder
Stop Lamp Switch
Tail & Stop Lamp, Right Side
Tail & Stop Lamp, Left Side
T.C.S. Manual Transmission
Temperature Gauge
Temperature Sender, 8-Cylinder
Temperature Sender, 6-Cylinder
Transmission Kickdown Switch
Turn Signal Switch
Voltmeter Gauge
Windshield Wiper & Washer Lamp
Windshield Wiper Motor
Windshield Wiper & Washer Switch
LOCATION
A-2
E-2
B-10
E-10
B-2
D-3
C-8
B-7
B-3
C-4
A-6
A-7
B-7
A-1
D-1
C-7
B-7
B-6
B-4
A-1
C-4
A-1
C-2
C-3
B-6
C-6
C-6
C-7
C-7
A-4
C-4
A-3
C-3
D-6
C-11
D-11
B-4
C-8
A-4
C-4
E-6
D-7
B-7
D-8
C-9
D-8
WIRING DIAGRAMS
W-3
w-4
winiNii uiAunnma
Wiring Diagram
CI Models
NOMENCLATURE
Air Conditioner Compressor, 6-Cylinder
Air Conditioner Compressor, 8-Cylinder
Alternator, 6-Cylinder
Alternator, 8-Cylinder
Anti-Diesel Solenoid, 8-Cylinder
Ash Tray Lamp Feed
Back-up Switch
Back-up Lamp, Left Side
Back-up Lamp, Right Side
Back-up Lamp
Back-up Light Switch
Back-up Switch
Battery, 6-Cylinder
Battery, 8-Cylinder
Body, 6-Cylinder
Body, 8-Cylinder
Brake Warning
Capacitor Jumper, 6-Cylinder
Capacitor Jumper, 8-Cylinder
Chassis, 6-Cylinder
Chassis, 8-Cylinder
Cigar Lighter
Clock
Clock Lamp
Cluster Connection
Cluster Connection
Coil, 6-Cylinder
Coil, 8-Cylinder
Courtesy Lamp
Distributor, 6-Cylinder
Distributor, 8-Cylinder
Dome & Courtesy Light Ground
Dome & Courtesy Light Ground
Dome Lamp
Door Fan
Door Fan
Door Fan
Door Switch
Electric Choke, 8-Cylinder
Frame Harness
Fuel Sender
Glove Box Lamp Feed
Headlamp, Left Side
Headlamp, Right Side
Heater Blower Motor, 8-Cylinder
Heater Control Switch
Heater Ground
Heater Lamps
LOCATION
D-4
A-4
D-3
A-2
B-3
C-7
B-7
C-11
C-11
G-12
D-11
B-7
C-4
A-4
C-4
A-4
E-9
C-2
A-3
C-4
A-4
A-7
C-9
C-7
B-7
C-3
C-2
A-3
A-9
C-3
B-2
D-9
E-9
D-9
A-10
A-11
B-10
E-10
B-3
E-5
E-9
A-9
D-1
B-1
C-3
C-9
C-9
C-7
NOMENCLATURE
Ignition Switch, Left Side
Ignition Switch, Right Side
Kickdown & Quadra-Trac
Light Switch
License Lamp
License Lamp
License Lamp
Marker & Reflector
Marker & Reflector
Marker & Reflector
Marker & Reflector Lamp,
Left Side
Marker & Reflector Lamp,
Right Side
Module Assembly Ignition,
6-Cylinder
Module Assembly Ignition,
8-Cylinder
Neutral Safety Switch
Oil Pressure, 6-Cylinder
Oil Pressure, 8-Cylinder
Park & Signal Lamp, Left Side
Park & Signal Lamp, Right Side
Parking Brake Warning Swich
Seat Belt Buzzer
Seat Belt Lamp
Seat Belt Timer
Starter Solenoid, 6-Cylinder
Starter Solenoid, 8-Cylinder
Starting Motor, 6-Cylinder
Starting Motor, 8-Cylinder
Stop Light Switch
Stop Light Switch & Cruise
Control
Tail & Stop Lamp
Tail & Stop Lamp
Tailgate Switch
Tail, Stop & Back-up Lamp
Tail, Stop & Back-up Lamp
Tail, Stop & Marker Lamp
Tail, Stop & Marker Lamp
Temperature Sender, 6-Cylinder
Temperature Sender, 8-Cylinder
Transmission Kickdown Switch
Turn Signal Switch
Washer Bottle, 6-Cylinder
Windshield Wiper Motor, 6-Cylinder
Windshield Wiper Motor, 8-Cylinder
L
B
A
E
D
C
C
C
B
D
D
B
B
D
B
E
A
C
E
E
E
C
A
A
C
A
A
B
D
E
C
D
A
E
D
B
B
A
E
D
C
10
11
ELECTRIC
CHOKE
H
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SENDER
MOTOR@~
70BLACK-16 -
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IJSMI
ALTERNATOR
H|
2 0 T A N
H 0 T C A B L E )
-35A-GRN./TR.-1SOIL PRESSURE
SWITCH
1 4
1-PURPLE /TR.-18
50-BROWN t
ig-
4B-LIGHT BLUE-1
22 BROWN / TR.-16.
34 WHT./TR. 1 6 - ^
20A-TAN /TR.-16.
RESISTOR
HEATER BLOWER MTR.
35B GRN./TR. 16
X
0RANGE-18-1
I C.S.
^GREEN-18MANUAL TRANS.
82-VIOLET-16
|D 35A-GRN.-7TR.-1680-ORANGE 16
81 BLACK-16
SPLICE K
546043-C-79-DARK GREEN-16
^
12D-RED-14
12C-RED-10 ^ " ( F U S I B L E LINK!" J,
<R
-13E-RED / TR 18
BLACK
BODY ,|
-80-ORANGE-16-
SPLICE N
75A-RED / TR-ID-
] CHASSIS 4
5359388*
(S.O-5350447-CL
14A-LIGHTBLUE-14
- 8 2 VIOLET-16
CAPACITOR
JUMPER
illi-
-75B RED/TR.-10-
TEMP.
SENDER
13D-RED/TR.-18
[F5
-74-RED/TR.-16.
-12C-RED-1017B RED /TR.-14
BACK UP
LITE SW.
MANUAL TRANS.
39-PINK 16
SPLICE D
79 DARK GREEN-16
r-ii
STARTER
MOTOR
OIL PRESSURE
SENDER
78-BROWN-24 J RESISTANCE! 5) _
ALTERNATOR
VIODULE ASS'Y. IGNITION
7PURPLE-18-
JDf[IOBPD-Di _
67DYELLOW-10
,66-RED /
TR-18
HEATER MOTOR [H
AIRCOMP
50BROWN-16 13B-RED / TR.-2D (RESISTANCE 1.35 ) RED13F RED
WHITE13A-RED/TR.-10.)-4
/TR -10.
_-SPLICE L
"_=<*:
HIGH BEAM
ND.
a Z
CP-
LOW BEAM LP
2-GRAY /'
TR.-18
_11A-0RN.-18
-4ARED-18
-17A-RED /TR.-14-
VLOLET-18
I|
h-201
>-78ANTI DIESEL
SOLENOID
>-?
-cl
DIMR. SW.
>-l-
81-BLACK-16
KICKDOWN &
QUADRA-TRAC
II
54-YELLOW-1656-ORANGE-16-
54-YELLOW-1656-ORANGE-16-
3F-(
TR 14
_19A-WHITE 16
-25AGRAY-16
-BA-GRN./TR.16-
0$
BACK UP
LITE SW.
- 57C BLK.-1657B-BLK.-16
WIPER SW. TO
WASHER MtR.
35A-GRN / TR-16 (MAN.L-
"12C-< M
50
- 3A-GRAY/TR.14- 5A GRN.-16
4 5
-< [
5A-<:;
54-<
7C<;
3A-C:;
57B<;
30-Ci:
>_5A_
)-57B-.
-8A-<
25A<
_ _ _ _ _
19A<
>-3
>-57A_
>-3C
>-8A
_45-RED/TR.-16_
_ 5 A GRN. 18
54 YELLOW 16
57BBLK 18
- 3 - G R A Y / T R -14 _57A-BLACK-18
- 3 0 YELLOW 16
BAGRN / TR 1 8 _25-GRAY)6
_ 1 8 WHITE-16
W-6
WIRING DIAGRAMS
TRAILER CONNECTOR
FRAME
HARNESS
46F RED/TR.
12"
te>
34 A Y E L L O W
~ F J
B O D Y CROSS
HARNESS
tn
ELEC. BRAKE
FEED
16-
18B G R E E N
16-
' -
72 BLACK
1 2 -
i TRAILER CONN.
GRN
276 B L U E
24B
12
BROWN
CUP
TRAILER
CONNECTOR
23B RED
18A WHITE
16-
23ALT. GREEN/TR.
2 4 A L T . GREEN
161 6
LT. TU RN &
16-
5464458 8 (FOR
15)
Hi
3 GREEN 18-
6 SLACK 18
FUSE 8LOCK
DOME LT, CARGO LT. & SW. (OPT. FOR 25, 45 & 46)
TIMER SWITCH
Sic
48 RED/TR. 14-
is*
MOTOR T GATE
a
IVM0 806 -|
SPLICE
ngoai
9 BLACK
o
DOME LP. & CARGO LP. (STD.)
DOME & READING LAMP
CARGO LAMP
47 BROWN 121
2
" a
z
fc_
HEATED WINDOW
o<
^
3 O
oo
a. <f
2?
DISCONNECT SW.
z- o5
< EG
CARGO LAMP
SWITCH
W-8
WIRING DIAGRAMS
TACHOMETER
T.C.S. SWITCH
f \
OO
CO
LU
<
k z
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CO DC
D-1
SPEED SW.
Accessories
JL-J-
CALIF. ONLY
EMISSION S T D .
AUTO T R A N S .
ihBLACK -
j
LU
o
z
<
ENGINE
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of
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HARNESS
/
I.P. HARNESS
T O I.P. H A R N E S S
L I G H T SW.