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Jeep 2001 Wrangler TJ, Service Manual

The Jeep 2001 Wrangler TJ user manual and parts catalog is a vital resource for any owner or enthusiast. This comprehensive manual provides detailed instructions, diagrams, and specifications for easy maintenance and repair. Download it for free from manualshive.com and unleash the full potential of your Jeep experience.

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WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Disconnect and isolate the battery negative

cable. Disconnect the seat belt switch pigtail wire
connector from the body wire harness connector for
the seat belt switch on the floor near the driver side
seat belt buckle-half anchor. Check for continuity
between the seat belt switch sense circuit and the
ground circuit cavities of the seat belt switch pigtail
wire connector. There should be continuity with the
seat belt unbuckled, and no continuity with the seat
belt buckled. If OK, go to Step 2. If not OK, replace
the faulty seat belt buckle-half assembly.

(2) Check for continuity between the ground cir-

cuit cavity in the body wire harness connector for the
seat belt switch and a good ground. There should be
continuity. If OK, refer to for further diagnosis of the
instrument cluster chime service input from the seat
belt switch. If not OK, repair the open ground circuit
to ground (G302) as required.

SEAT BELT TURNING LOOP
ADJUSTER

REMOVAL

WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS

FOR

PROPER

INSTALLATION,

OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY

BELT

THAT

IS

TWISTED.

TIGHTEN

ANY

LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.

(1) Unsnap and lift the shoulder belt turning loop

cover to access the screw that secures the turning
loop to the adjuster (Fig. 29).

(2) Remove the screw that secures the shoulder

belt turning loop to the adjuster.

(3) Remove the shoulder belt turning loop and the

support/guide washer from the adjuster.

(4) Unsnap and remove the trim cover from the

height adjuster.

(5) Remove the two screws that secure the turning

loop adjuster to the sport bar.

(6) Remove the turning loop adjuster from the

sport bar.

INSTALLATION

WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS

FOR

PROPER

INSTALLATION,

OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY

BELT

THAT

IS

TWISTED.

TIGHTEN

ANY

LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.

Fig. 29 Front Turning Loop Height Adjuster

1 - HEIGHT ADJUSTER
2 - SPORT BAR
3 - TRIM COVER
4 - TURNING LOOP

TJ

RESTRAINTS

8Os - 27

SEAT BELT SWITCH (Continued)

Summary of Contents for 2001 Wrangler TJ

Page 1: ...B LOCATOR INs Introduction 0s Lubrication Maintenance 7s Cooling 8As Audio 8Js Instrument Cluster 8Os Restraints 8Wa Wiring 14s Fuel System 21s Transmission Transaxle Service Manual Comment Forms Rear of Manual ...

Page 2: ...mily Emission control system schematic Certification application Engine timing specifications if adjustable Idle speeds if adjustable Spark plug and gap The label also contains an engine vacuum sche matic There are unique labels for vehicles built for sale in the state of California and the country of Canada Canadian labels are written in both the English and French languages These labels are per ...

Page 3: ...3 4 in BODY CODE PLATE LINE 2 DIGITS 1 2 AND 3 Paint Procedure DIGIT 4 Open Space DIGITS 5 THROUGH 8 Primary Paint Refer to Group 23 Body for color codes DIGIT 9 Open Space DIGITS 10 THROUGH 13 Secondary Paint DIGIT 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20 21 AND 22 Engine Code EPE 2 5 L 4 cyl MPI Gasoline Fig 2 Body Code Plate Location 1 SNAP 2 REAR CARP...

Page 4: ... on the Vehicle Safety Certification Label Frame rail To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta tion The formula to use the check digit is no...

Page 5: ......

Page 6: ... to deliver enhanced emissions performance and durability for your vehicle We rec ommend the use of gasolines that meet the WWFC specifications if they are available REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as reformulat ed gasoline Reformulated gasoline contain oxygen ates and are specifically blended to reduce vehicle emissions and i...

Page 7: ...dealer for service assistance When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the tem perature is high use a premium unleaded fuel to help prevent spark knock If spark knock persists lighten the load or engine piston damage may result The use of fuel additives which are now being sold as octane enhancers is not recommended Most of these products contain hig...

Page 8: ...osion protection COOLANT PERFORMANCE The required ethylene glycol antifreeze and water mixture depends upon climate and vehicle operating conditions The coolant performance of various mix tures follows Pure Water Water can absorb more heat than a mixture of water and ethylene glycol This is for pur pose of heat transfer only Water also freezes at a higher temperature and allows corrosion 100 perce...

Page 9: ...NTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans Fig 2 MAINTENANCE SCHEDULES MAINTENANCE SCHEDULES There are two maintenance schedules that show proper service for the vehicle First is Schedule A It lists all the sche...

Page 10: ...e oil filter Lubricate steering linkage joints and outer tie rod ends 60 000 Miles 96 000 km or at 48 months Change engine oil Replace engine oil filter Replace engine air cleaner element Replace ignition cables 2 5L only Replace spark plugs Inspect drive belt adjust tension as necessary 2 5L only Inspect drive belt and replace as needed 4 0L only Lubricate steering linkage joints and outer tie ro...

Page 11: ... below 32 F 0 C Stop and go driving Extensive engine idling Driving in dusty conditions Short trips of less than 10 miles 16 2 km More than 50 of driving is at sustained high speeds during hot weather above 90 F 32 C Trailer towing Taxi Police or delivery service commercial ser vice Off road or desert driving If equipped for and operating with E 85 etha nol fuel 3 000 Miles 5 000 km Change engine ...

Page 12: ...g linkage tie rod ends Drain and refill front and rear axles Inspect brake linings Lubricate steering and suspension ball joints 51 000 Miles 82 000 km Change engine oil Replace engine oil filter Lubricate steering linkage tie rod ends 54 000 Miles 86 000 km Change engine oil Replace engine oil filter Lubricate steering linkage tie rod ends Lubricate steering and suspension ball joints 57 000 Mile...

Page 13: ...in and refill transfer case fluid Lubricate steering and suspension ball joints 93 000 Miles 149 000 km Change engine oil Replace engine oil filter Lubricate steering linkage tie rod ends 96 000 Miles 154 000 km Change engine oil Replace engine oil filter Lubricate steering linkage tie rod ends Drain and refill front and rear axles Inspect brake linings Lubricate steering and suspension ball joint...

Page 14: ...matic transmission fluid change filter and adjust bands Drain and refill transfer case fluid Drain and refill front and rear axles Inspect brake linings Lubricate steering and suspension ball joints Off highway operation trailer towing taxi limou sine bus snow plowing or other types of commercial service or prolonged operation with heavy loading especially in hot weather require front and rear axl...

Page 15: ......

Page 16: ... information you may be referred to another section of the Service Manual The Refer to is written differently than in prior years DESCRIPTION 4 0L ENGINE The cooling system Fig 1 is designed to maintain engine temperature at an efficient level during all engine operating conditions The components of the cooling system are A heavy duty radiator Cooling fan mechanical Thermal viscous fan drive Fan s...

Page 17: ...n the cooling system such as the following may be the cause PROLONGED IDLE VERY HIGH AMBIENT TEMPERATURE SLIGHT TAIL WIND AT IDLE SLOW TRAFFIC TRAFFIC JAMS HIGH SPEED OR STEEP GRADES Driving techniques that avoid overheating are Idle with A C off when temperature gauge is at end of normal range Increasing engine speed for more air flow is rec ommended TRAILER TOWING Consult Trailer Towing section ...

Page 18: ...ed with removing the radiator cap 5 Improper operation of internal heater doors or heater controls 5 Inspect heater and repair as necessary Refer to 24 HEATING AIR CONDITIONING DIAGNOSIS AND TESTING for procedures TEMPERATURE GAUGE READS HIGH OR THE COOLANT WARNING LAMP ILLUMINATES COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM THE COOLING SYSTEM 1 Trailer is being towed a steep hill is being clim...

Page 19: ...ls Refer to Radiator Cap in this Group Replace cap if necessary b Check condition of radiator filler neck If neck is bent or damaged replace radiator c Check condition of the hose from the radiator to the coolant tank It should fit tight at both ends without any kinks or tears Replace hose if necessary d Check coolant reserve overflow tank and tanks hoses for blockage Repair as necessary 8 Incorre...

Page 20: ...D TESTING Repair as necessary TEMPERATURE GAUGE READING IS INCONSISTENT FLUCTUATES CYCLES OR IS ERRATIC 1 During cold weather operation with the heater blower in the high position the gauge reading may drop slightly 1 A normal condition No correction is necessary 2 Temperature gauge or engine mounted gauge sensor defective or shorted Also corroded or loose wiring in this circuit 2 Check operation ...

Page 21: ... Pressure relief valve in radiator cap is defective 1 Check condition of radiator cap and cap seals Refer to 7 COOLING ENGINE RADIATOR PRESSURE CAP DIAGNOSIS AND TESTING Replace cap as necessary COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF GAUGE READING HIGH OR HOT 1 Coolant leaks in radiator cooling system hoses water pump or engine 1 Pressure test and repair as necessary Refer to 7 CO...

Page 22: ...SCOUS CLUTCH DESCRIPTION for an explanation of normal fan noise INADEQUATE HEATER PERFORMANCE THERMOSTAT FAILED IN OPEN POSITION 1 Has a Diagnostic trouble Code DTC been set 1 Refer to 25 EMISSIONS CONTROL DESCRIPTION for correct procedures and replace thermostat if necessary 2 Coolant level low 2 Refer to 7 COOLING DIAGNOSIS AND TESTING 3 Obstructions in heater hose fittings 3 Remove heater hoses...

Page 23: ... is the forc ing of water through the cooling system This is done using air pressure in the opposite direction of normal coolant flow It is usually only necessary with very dirty systems with evidence of partial plugging CHEMICAL CLEANING If visual inspection indicates the formation of sludge or scaly deposits use a radiator cleaner Mopar Radiator Kleen or equivalent before flushing This will soft...

Page 24: ...water flows through the lead away hose For more information refer to operating instructions supplied with flushing equipment Remove the lead away hose flushing gun water supply hose and air supply hose Remove the thermo stat housing Refer to 7 COOLING ENGINE EN GINE COOLANT THERMOSTAT REMOVAL Install the thermostat and housing with a replace ment gasket Refer to 7 COOLING ENGINE EN GINE COOLANT TH...

Page 25: ...VE BELTS INSTALLATION BELT TENSIONERS 4 0L DESCRIPTION The automatic belt tensioner Fig 2 is a spring loaded arm and pulley assembly The tensioner assembly is designed to apply constant pressure on the accessory drive belt to maintain proper belt ten sion There are three marks on the tensioner body these marks are there to indicate belt wear and belt tension NOTE On 4 0L engines the tensioner arm ...

Page 26: ...vel stops at this point 1 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 2 Remove tensioner assembly from mounting bracket Fig 3 WARNING BECAUSE OF HIGH SPRING TENSION DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER UNIT IS SERVICED AS AN ASSEMBLY INSTALLATION 1 Install tensioner assembly to mounting bracket align the two dowels on the tensioner with the mount...

Page 27: ...tage in the sensor increases OPERATION At key on the Powertrain Control Module PCM sends out a regulated 5 volt signal to the ECT sensor The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground sensor return When the engine is cold the PCM will operate in Open Loop cycle It will demand slightly richer air fuel mixtures and higher idle speeds This is done until norm...

Page 28: ...onnect coolant temperature sensor wire connector 3 Remove sensor from thermostat housing INSTALLATION 1 Apply sealant to sensor threads new replace ment sensors will have sealant already applied 2 Install coolant temperature sensor into thermo stat housing Tighten to 11 N m 8 ft lbs torque 3 Connect wire connector 4 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE Fig 2 Engine Coolant Tem...

Page 29: ...ids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 B 3 Verify pump power switch is turned OFF Con nect red alligator clip to positive battery post Connect black alligator clip to a good ground 4 Disconnect the cooler lines at the transmission NOTE When flushing transmission cooler and lines ALWAYS reverse flush NOTE The converter drainback valve must be removed ...

Page 30: ...ing information The wiring information includes wiring diagrams proper wire and connector repair procedures details of wire harness routing and retention connector pin out information and location views for the various wire harness connec tors splices and grounds WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRU...

Page 31: ...MENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove the glove box from the instrument panel Refer to 23 BODY INSTRUMENT PANEL GLOVE BOX REMOVAL 3 Reach through the instrument panel glove box opening to unplug the antenna coaxial cable connec tor Unplug the connector by pulling it apart while twisting the metal connector halves Do not pull on the cable 4 U...

Page 32: ...rom the instrument panel Refer to 23 BODY INSTRU MENT PANEL INSTRUMENT PANEL TOP COVER REMOVAL 3 Remove the ash receiver from the ash receiver housing in the lower instrument panel center bezel 4 Remove the one screw located in the back of the ash receiver housing that secures the center bezel to the lower instrument panel Fig 2 5 Remove the two screws that secure the center bezel to the top of th...

Page 33: ...all the one screw located at the back of the ash receiver housing that secures the center bezel to the lower instrument panel 8 Install the ash receiver 9 Connect the battery negative cable SPEAKER REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LA...

Page 34: ...battery negative cable 2 If the vehicle is equipped with the optional hard top remove the hard top from the vehicle Refer to 23 BODY REMOVEABLE TOP TOP REMOVAL 3 If the vehicle is equipped with the standard soft top lower the soft top Refer to Folding Down the Fabric Top in the Owner s Manual for the proce dures 4 Release the hook and loop closure on each out board end flap of the sound bar trim c...

Page 35: ...Position the sound bar onto the sport bar 2 Install the two screws retaining the sound bar to the sport bar 3 Connect the sound bar wire harness connector 4 Position the sound bar trim cover and attach the hook and loop 5 If the vehicle is equipped with the standard soft top raise the soft top 6 If the vehicle is equipped with the optional hard top install the hard top Refer to 23 BODY REMOVEABLE ...

Page 36: ...CATOR DESCRIPTION 25 OPERATION 25 MALFUNCTION INDICATOR LAMP MIL DESCRIPTION 26 OPERATION 26 ODOMETER DESCRIPTION 27 OPERATION 27 OIL PRESSURE GAUGE DESCRIPTION 28 OPERATION 28 SEATBELT WARNING INDICATOR DESCRIPTION 29 OPERATION 29 SHIFT INDICATOR TRANSFER CASE DESCRIPTION 29 OPERATION 30 DIAGNOSIS AND TESTING 31 PART TIME INDICATOR 31 FULL TIME INDICATOR 31 SPEEDOMETER DESCRIPTION 32 OPERATION 33...

Page 37: ...t connect the cluster to the vehicle electrical system through two take outs and connectors of the instru ment panel wire harness A single EMIC module is offered on this model however some variations of this module exist due to optional equipment and regulatory requirements This module utilizes integrated circuitry and infor mation carried on the Programmable Communica tions Interface PCI data bus...

Page 38: ...and to the EMIC through the use of a combination of soldered splices splice block connectors and many different types of wire harness terminal connectors and insulators Refer to the appropriate wiring infor mation The wiring information includes wiring dia grams proper wire and connector repair procedures further details on wire harness routing and reten tion as well as pin out and location views ...

Page 39: ...of the coils has a fixed current flowing through it to maintain a constant magnetic field strength Current flow through the second coil changes which causes changes in its magnetic field strength The current flowing through the second coil is changed by the EMIC circuitry in response to mes sages received over the PCI data bus The gauge nee dle moves as the movable permanent magnet aligns itself t...

Page 40: ...LECTRICAL INSTRUMENT CLUSTER DIAGNOSIS AND TESTING Proper testing of the PCI data bus and the data bus message inputs to the EMIC that control each indicator requires the use of a DRBIIIt scan tool Refer to the appropriate diag nostic information Specific operation details for each indicator may be found elsewhere in this service information CLUSTER ILLUMINATION The EMIC has several illumination l...

Page 41: ...e rear window defogger switch on the rear window defogger switch sense circuit and its control logic to determine the correct output to the rear window defogger relay The EMIC controls the ground path of the rear window defogger relay control coil through an output on the rear window defogger relay control circuit The EMIC is programmed to interpret each momentary ground signal it receives on the ...

Page 42: ... Turn the ignition switch to the On position Check for battery voltage at the fused ignition switch output run start fuse Fuse 10 10 ampere in the fuse block If OK go to Step 7 If not OK repair the open fused ignition switch output run start circuit between the fuse block and the ignition switch as required 7 Turn the ignition switch to the Off position Disconnect and isolate the battery negative ...

Page 43: ...ile still holding the odometer trip odometer switch button depressed turn the ignition switch to the On position but do not start the engine 4 Release the odometer trip odometer switch but ton 5 The instrument cluster will automatically begin the actuator test sequence as follows a The cluster will generate a single chime tone to confirm the functionality of the chime tone gen erator and the chime...

Page 44: ... harness routing and retention connec tor pin out information and location views for the various wire harness connectors splices and grounds WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR TH...

Page 45: ...ty between the door ajar switch output fuse Fuse 4 10 ampere in the fuse block and a good ground There should be continuity If OK go to Step 3 If not OK repair the open ground circuit between the fuse block and ground G300 as required 3 Disconnect and isolate the battery negative cable Disconnect the cross body wire harness connec tor for the driver and or passenger door ajar switch from the switc...

Page 46: ...er and the PDC as required CLUSTER ILLUMINATION DIAGNOSIS The diagnosis found here addresses an inoperative instrument cluster illumination lamp condition If the problem being diagnosed is a single inoperative illumination lamp be certain that the bulb and bulb holder unit are properly installed in the instrument cluster electronic circuit board If no installation problems are found replace the fa...

Page 47: ...l wire harness connectors for the instrument cluster from the connector receptacles on the back of the cluster housing 5 Remove the instrument cluster from the instru ment panel DISASSEMBLY Some of the components for the instrument cluster used in this vehicle are serviced individually The serviced components include the incandescent instrument cluster indicator and illumination lamp bulbs includi...

Page 48: ...REMOVAL 3 Remove the cluster lens from the cluster hous ing Refer to CLUSTER LENS for the proper cluster lens removal procedures 4 Work around the perimeter of the cluster hood and mask unit and disengage each of the latches that secure the cluster hood and mask unit to the cluster housing Fig 4 5 Gently pull the cluster hood and mask unit away from the cluster housing CLUSTER HOUSING REAR COVER 1...

Page 49: ...that secure the lens to the cluster housing is fully engaged 4 Reinstall the instrument cluster onto the instrument panel Refer to 8 ELECTRICAL IN STRUMENT CLUSTER INSTALLATION 5 Reconnect the battery negative cable TRIP ODOMETER RESET KNOB BOOT 1 Position the trip odometer reset knob boot to the mounting hole from the back of the cluster lens Fig 4 2 Gently pull the trip odometer reset knob boot ...

Page 50: ...icon to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by a Light Emitting Diode LED soldered onto the instru ment cluster electronic circuit board The ABS indi cator is serviced as a unit with the instrument cluster OPERATION The ABS indicator gives an indication to the vehi cle operator when the ABS system is faulty or inop erative This indi...

Page 51: ...as required AIRBAG INDICATOR DESCRIPTION An airbag indicator is standard equipment on all instrument clusters However on vehicles not equipped with airbags this indicator is electronically disabled The airbag indicator is located near the lower edge of the instrument cluster overlay to the right of the odometer trip odometer Vacuum Fluores cent Display VFD The airbag indicator consists of a stenci...

Page 52: ...applied or when there are certain brake hydraulic system mal functions This indicator is controlled by a transistor on the instrument cluster electronic circuit board based upon cluster programming electronic messages received by the cluster from the Powertrain Control Module PCM over the Programmable Communica tions Interface PCI data bus and hard wired inputs to the instrument cluster from the p...

Page 53: ... ILLUMINATES DURING BULB TEST BUT DOES NOT WHEN PARK BRAKE APPLIED 1 Disconnect and isolate the battery negative cable Disconnect the floor wire harness connector for the park brake switch from the switch terminal Apply the parking brake Check for continuity between the park brake switch terminal and a good ground There should be continuity If OK go to Step 2 If not OK replace the faulty park brak...

Page 54: ...luminated The indicator remains illuminated until the cluster receives a mes sage from the PCM indicating that the engine tem perature is about 124 C or lower about 255 F or lower or until the ignition switch is turned to the Off position whichever occurs first Engine Oil Pressure Low Message Each time the cluster receives a message from the PCM indicating the engine oil pressure is about 0 3 kg c...

Page 55: ...ndicator remains illuminated until the cluster receives a cruise lamp off message from the PCM or until the ignition switch is turned to the Off position whichever occurs first Actuator Test Each time the cluster is put through the actuator test the cruise indicator will be turned on then off again during the bulb check por tion of the test in order to confirm the functionality of the LED and the ...

Page 56: ... indicator is illumi nated and a single chime tone is sounded The chime tone feature will occur only once per ignition cycle The gauge needle remains in the center of the red zone and the check gauges indicator remains illumi nated until the cluster receives a message from the PCM indicating that the engine temperature is about 124 C or lower about 255 F or lower or until the ignition switch is tu...

Page 57: ...ut to the instrument cluster can be diagnosed using conven tional diagnostic tools and methods Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR LEFT MULTI FUNCTION SWITCH OPERATION for more information on the fog lamp switch DIAGNOSIS AND TESTING FRONT REAR FOG LAMP INDICATOR The diagnosis found here addresses an inoperative front rear fog lamp indicator condition Before begin ning this test confirm ...

Page 58: ...en moves the gauge needle to the proper position on the gauge scale The algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank can have on accurate inputs from the fuel tank send ing unit to the PCM The gauge needle will continue to be positioned at the proper position on the gauge scale until the cluster receives a message from the PC...

Page 59: ...r for the following reasons Beam Select Switch Input Each time the cluster detects battery current on the beam select switch sense circuit beam select switch closed high beams selected or optical horn feature activated the high beam indicator will be illuminated solid This input can occur when the headlamp high beams are selected or when the optical horn feature is activated The indicator remains ...

Page 60: ...he left of the odometer trip odometer Vacuum Flu orescent Display VFD The low fuel indicator con sists of a stencil like cutout of the International Control and Display Symbol icon for Fuel in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated An amber lens behind the cutout in the opaq...

Page 61: ...it or component malfunction The MIL is controlled by a transistor on the instrument cluster electronic circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Pro grammable Communications Interface PCI data bus The MIL Light Emitting Diode LED receives battery current on the instrument cluster electronic circuit board through the fused ign...

Page 62: ...instrument cluster The rubber trip odometer reset knob boot on the outside of the cluster lens is available for separate service replacement OPERATION The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled This gauge is controlled by the instrument cluster electronic circuitry based upon cluster pro gramming and electronic messages receiv...

Page 63: ...n about 0 3 kg cm 4 psi and about 6 7 kg cm 95 psi the cluster moves the gauge needle to the appropriate linear position on the gauge scale to represent the actual engine oil pressure The gauge needle will continue to be positioned at the actual engine oil pressure position on the gauge scale until the cluster receives a message from the PCM that indicates the engine oil pressure is low or until t...

Page 64: ...on the seat belt switch sense circuit seatbelt switch closed seatbelt unbuckled with the ignition switch in the Start or On positions the seatbelt indicator will be illumi nated The seatbelt indicator remains illuminated until the seat belt switch sense input to the cluster is an open circuit seatbelt switch open seatbelt buck led or until the ignition switch is turned to the Off position whicheve...

Page 65: ... during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry The transfer case switch is connected in series between ground and the 4WD switch sense part time input to the instrument cluster The transfer case switch input to the instrument cluster circuitry can be diagnosed using conventional diagnostic tools and methods Refer to 21 TRANSMISS...

Page 66: ...d There should be continuity If OK go to Step 2 If not OK repair the open ground circuit to ground G105 as required 2 Reconnect the battery negative cable Turn the ignition switch to the On position Install a jumper wire between the 4WD switch sense part time cir cuit cavity of the engine wire harness connector for the transfer case switch and a good ground The part time indicator should light If ...

Page 67: ...ransfer case switch If not OK go to Step 3 3 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable Remove the instrument cluster from the instrument panel Disconnect the instrument panel wire harness connector Connector C2 for the instrument cluster from the connector receptacle on the back of the clus ter housing Check for continuity between the 4WD switch...

Page 68: ...tch is turned to the Off position whichever occurs first If a new speedometer message is not received after about six seconds the gauge needle will return to the far left low end of the scale Actuator Test Each time the cluster is put through the actuator test the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the func tiona...

Page 69: ...ometer and the tachometer Each turn signal indicator consists of a stencil like cutout of the Inter national Control and Display Symbol icon for Turn Warning in the opaque layer of the instrument clus ter overlay The dark outer layer of the overlay pre vents these icons from being clearly visible when they are not illuminated A green lens behind each cutout in the opaque layer of the cluster overl...

Page 70: ...d arrow icon that is a stencil like cutout in the opaque layer of the instrument cluster overlay The dark outer layer of the cluster overlay prevents the icon from being clearly visible when the lamp is not illuminated An amber lens behind the cutout in the opaque layer of the cluster overlay causes the icon to appear in amber through the translucent outer layer of the overlay when it is illuminat...

Page 71: ...eceived by the cluster from the Powertrain Control Module PCM over the Pro grammable Communications Interface PCI data bus The voltage gauge is an air core magnetic unit that receives battery current on the instrument clus ter electronic circuit board through the fused ignition switch output run start circuit whenever the igni tion switch is in the On or Start positions The clus ter is programmed ...

Page 72: ...er For further diagnosis of the voltage gauge or the instrument cluster circuitry that con trols the gauge Refer to 8 ELECTRICAL INSTRU MENT CLUSTER DIAGNOSIS AND TESTING If the instrument cluster turns on the check gauges indicator due to a charge fail or voltage high condi tion it may indicate that the charging system requires service For proper diagnosis of the charging system the PCI data bus ...

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Page 74: ... REMOVAL 19 INSTALLATION 19 PASSENGER AIRBAG DESCRIPTION 19 OPERATION 20 REMOVAL 20 INSTALLATION 21 PASSENGER AIRBAG ON OFF SWITCH DESCRIPTION 22 OPERATION 22 REMOVAL 23 INSTALLATION 23 REAR SEAT BELT RETRACTOR REMOVAL 24 INSTALLATION 25 REAR SEAT BELT BUCKLE REMOVAL 25 INSTALLATION 26 SEAT BELT SWITCH DESCRIPTION 26 OPERATION 26 DIAGNOSIS AND TESTING 26 SEAT BELT SWITCH 26 SEAT BELT TURNING LOOP ...

Page 75: ... The ACM and the EMIC each contain a central processing unit and programming that allow them to communicate with each other using the Programma ble Communications Interface PCI data bus net work This method of communication is used for control of the airbag indicator on all models Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES COMMUNICATION DESCRIPTION Hard wired circuitry connects the airbag s...

Page 76: ...oyment itself This is because the airbag deployment and deflation occur so rapidly In a typical 48 kilometer per hour 30 mile per hour barrier impact from the moment of impact until both airbags are fully inflated takes about 40 milliseconds Within one to two seconds from the moment of impact both airbags are almost entirely deflated The times cited for these events are approximations which apply ...

Page 77: ... of a non de ployed airbag When carrying a non deployed airbag the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment If the airbag unit is placed on a bench or any other sur face the trim cover or airbag cushion side of the unit should be face up to minimize movement in the event of an accidental deploymen...

Page 78: ...operation following the service or replacement of any airbag system component WARNING ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT ING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS CHARGE BEFORE PERFORMING FURTH...

Page 79: ...he ACM is connected to the vehicle elec trical system through a dedicated take out and con nector of the cross body wire harness The ACM cannot be repaired or adjusted and if damaged or faulty it must be replaced OPERATION The microprocessor in the ACM contains the airbag system logic circuits and it monitors and controls all of the airbag system components The ACM also uses On Board Diagnostics O...

Page 80: ...airbag system pro tection in case there is a loss of battery current sup ply to the ACM during an impact The capacitor is only serviced as a unit with the ACM Two sensors are contained within the ACM an electronic impact sensor and a safing sensor The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration which pro vides verification of the direction and severity...

Page 81: ...rance CPA locks on each side of the connector out about 3 millimeters 0 125 in b Squeeze the latch tabs on each side of the connector between the thumb and forefinger and pull the connector straight away from the ACM connector receptacle 7 Remove the ACM from beneath the instrument panel INSTALLATION WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUME...

Page 82: ... any airbag system component Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE VERI FICATION TEST CLOCKSPRING DESCRIPTION The clockspring assembly is secured with two inte gral plastic latches onto the steering column lock housing near the top of the steering column behind the steering wheel Fig 8 The clockspring consists of a flat round molded plastic case with a stubby tail that hangs below th...

Page 83: ... a plastic locking pin installed This locking pin should not be disen gaged until the clockspring has been installed on the steering column If the locking pin is removed or damaged before the clockspring is installed on a steering column the clockspring centering procedure must be performed Refer to 8 ELECTRICAL RE STRAINTS CLOCKSPRING STANDARD PROCE DURE CLOCKSPRING CENTERING STANDARD PROCEDURE C...

Page 84: ... be certain to turn the steering wheel until the front wheels are in the straight ahead position 1 Place the front wheels in the straight ahead position 2 Remove the driver airbag from the steering wheel Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 3 If the vehicle is so equipped disconnect the upper clockspring pigtail wire connector from the steering wheel wire harness for the speed co...

Page 85: ...roperly centered in rela tion to the steering wheel steering shaft and steer ing gear it may be damaged Refer to 8 ELECTRICAL RESTRAINTS CLOCKSPRING STANDARD PROCEDURE CLOCKSPRING CEN TERING Service replacement clocksprings are shipped pre centered and with a plastic locking pin installed This locking pin should not be removed until the clockspring has been installed on the steer ing column If the...

Page 86: ...0 Install and tighten the screw that secures the steering wheel to the steering column upper shaft Tighten the screw to 54 N m 40 ft lbs Be certain not to pinch the clockspring pigtail wires or the steering wheel wire harness between the steering wheel and the screw 11 If the vehicle is so equipped reconnect the upper clockspring pigtail wire connector to the steer ing wheel wire harness for the s...

Page 87: ...ontacts the skin eyes or breathing passages If skin or eye irritation is noticed rinse the affected area with plenty of cool clean water If breathing pas sages are irritated move to another area where there is plenty of clean fresh air to breath If the irritation is not alleviated by these actions contact a physician REMOVAL The following procedure is for replacement of a faulty or damaged driver ...

Page 88: ... FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI BLE PERSONAL INJURY WARNING THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLERCHRYSLER TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOL LOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL INCOMP...

Page 89: ...RBAG TRIM COVER FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT WARNING THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COL ORS PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG...

Page 90: ...RIES UPON AIRBAG DEPLOYMENT 1 Assemble the driver airbag trim cover onto the airbag housing Refer to 8 ELECTRICAL RE STRAINTS DRIVER AIRBAG ASSEMBLY 2 When installing the driver airbag reconnect the clockspring driver airbag pigtail wire connector to the airbag module connector receptacle by pressing straight in on the connector Fig 13 You can be cer tain that the connector is fully engaged by lis...

Page 91: ...r 5 Remove the screw that secures the retractor and lower seat belt anchor plate to the sport bar near its base Fig 19 6 Remove the front seat shoulder belt and retrac tor from the sport bar INSTALLATION WARNING DURING AND FOLLOWING ANY SEAT BELT SERVICE CAREFULLY INSPECT ALL SEAT BELTS BUCKLES MOUNTING HARDWARE AND RETRACTORS FOR PROPER INSTALLATION OPERATION OR DAMAGE REPLACE ANY BELT THAT IS CU...

Page 92: ...ERATION OR DAMAGE REPLACE ANY BELT THAT IS CUT FRAYED OR TORN STRAIGHTEN ANY BELT THAT IS TWISTED TIGHTEN ANY LOOSE FASTENERS REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE COR RECT NEW AND UNUSE...

Page 93: ... door will split at predetermined breakout lines then fold back over the top of the instrument panel and out of the way Following an airbag deployment the airbag cushion quickly deflates by venting the argon gas through the porous fabric material used on each end panel of the airbag cushion Some of the chemicals used to create the pressure to burst the argon gas containment disk are consid ered ha...

Page 94: ...PLOYMENT AND POSSI BLE PERSONAL INJURY WARNING WHEN REMOVING A DEPLOYED AIR BAG RUBBER GLOVES EYE PROTECTION AND A LONG SLEEVED SHIRT SHOULD BE WORN THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES IN LARGE DOSES THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES WARNING USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PAS SENGER AIRBAG OR BECOMING ENTRA...

Page 95: ...d or repaired and if faulty or damaged the switch must be replaced OPERATION The passenger airbag on off switch allows the cus tomer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired See the owner s manual in the vehicle glove box for specific recommendations on when to enable or disable the pa...

Page 96: ...onsole far enough to access and disconnect the cross body wire harness connector for the passenger airbag on off switch from the switch connector receptacle 4 Remove the passenger airbag on off switch and console switch bezel unit from the floor console 5 From the underside of the console switch bezel remove the three screws that secure the passenger airbag on off switch to the back of the bezel 6...

Page 97: ...and back unit forward against the backs of the two front bucket seats 3 Remove the screw that secures the lower anchor plate of the rear seat shoulder belt to the inner rear wheel house panel Fig 25 4 Remove the rear seat shoulder belt lower anchor plate from the inner rear wheel house panel 5 Unsnap and lift the rear shoulder belt turning loop cover to access the screw that secures the turn ing l...

Page 98: ...e panel Tighten the screw to 43 N m 32 ft lbs 8 Tumble the folded rear seat cushion and back unit rearward onto the rear floor panel 9 Slide both rear seat belt buckle units between the seat cushion and the seat back 10 Unfold the rear seat back from the seat cush ion until the seat back latch is fully engaged REAR SEAT BELT BUCKLE REMOVAL WARNING DURING AND FOLLOWING ANY SEAT BELT SERVICE CAREFUL...

Page 99: ...the floor panel transmission tunnel Fig 28 The seat belt switch is connected to the vehicle electrical system through a two wire pigtail wire and connector on the seat belt buckle half which is connected to a wire harness connector and take out of the body wire harness routed along the left side of the body sill in the pas senger compartment The seat belt switch cannot be adjusted or repaired and ...

Page 100: ...ARDWARE AND RETRACTORS FOR PROPER INSTALLATION OPERATION OR DAMAGE REPLACE ANY BELT THAT IS CUT FRAYED OR TORN STRAIGHTEN ANY BELT THAT IS TWISTED TIGHTEN ANY LOOSE FASTENERS REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT ALWAYS REPLACE DAMAGED OR FAULTY SEA...

Page 101: ... adjuster and using hand pressure press firmly and evenly on the cover until it snaps into place 4 Position the support guide washer and the shoulder belt turning loop onto the adjuster 5 Install and tighten the screw that secures the shoulder belt turning loop to the adjuster Tighten the screw to 43 N m 32 ft lbs 6 Fold and snap the shoulder belt turning loop cover back into place over the screw ...

Page 102: ...RANSMISSION CONTROL SYSTEM 8Wa 31 1 ANTILOCK BRAKES 8Wa 35 1 INSTRUMENT CLUSTER 8Wa 40 1 HORN CIGAR LIGHTER POWER OUTLET 8Wa 41 1 AIR CONDITIONING HEATER 8Wa 42 1 AIRBAG SYSTEM 8Wa 43 1 INTERIOR LIGHTING 8Wa 44 1 AUDIO SYSTEM 8Wa 47 1 REAR WINDOW DEFOGGER 8Wa 48 1 FRONT LIGHTING 8Wa 50 1 REAR LIGHTING 8Wa 51 1 TURN SIGNALS 8Wa 52 1 WIPERS 8Wa 53 1 SPLICE INFORMATION 8Wa 70 1 CONNECTOR PINOUTS 8Wa ...

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Page 104: ... all of their features and characteris tics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of the circuit is placed near the bottom of the page Fig 1 All switches components and modules are shown in the at rest position with the doors closed and the key removed from the ignition Fig 2 Components are shown two ways A solid li...

Page 105: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8Wa 01 2 8W 01 WIRING DIAGRAM INFORMATION TJ WIRING DIAGRAM INFORMATION Continued ...

Page 106: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 TJ 8W 01 WIRING DIAGRAM INFORMATION 8Wa 01 3 WIRING DIAGRAM INFORMATION Continued ...

Page 107: ...Fig 3 WIRING DIAGRAM SYMBOLS 8Wa 01 4 8W 01 WIRING DIAGRAM INFORMATION TJ WIRING DIAGRAM INFORMATION Continued ...

Page 108: ...YTIC CONVERTER AND MUFFLER WARNING DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY WARNING ALWAYS REMOVE RINGS WATCHES LOOSE HANGING JEWELRY AND LOOSE CLOTH ING DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are l...

Page 109: ...there are six steps which can aid in the procedure The steps are listed and explained below Always check for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify the problem 2 Verify any related symptoms Do this by per forming operational checks on compone...

Page 110: ...g harness STANDARD PROCEDURE TESTING FOR SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1 Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits 2 Replace the blown fuse 3 Supply power to the fuse by turning ON the ignition switch or re connecting the battery 4 Start connecting the items in the fuse circuit one at a time When the fuse blows the circuit wi...

Page 111: ...ls Fig 8 4 Using special tool 6932 push the terminal to remove it from the connector Fig 9 5 Repair or replace the terminal as necessary PROBING TOOL PACKAGE 6807 TERMINAL PICK 6680 TERMINAL REMOVING TOOL 6932 TERMINAL REMOVING TOOL 6934 Fig 8 AUGAT CONNECTOR REPAIR 1 LOCKING TAB 2 CONNECTOR Fig 9 USING 1 SPECIAL TOOL 6932 2 CONNECTOR 8Wa 01 8 8W 01 WIRING DIAGRAM INFORMATION TJ WIRING DIAGRAM INF...

Page 112: ...n the terminal Fig 11 5 Pull on the wire to remove it from the connector 6 Repair or replace the terminal as necessary INSTALLATION 1 Reset the terminal locking tang 2 Insert the removed wire in the same cavity on the repair connector 3 Repeat steps for each wire in the connector being sure that all wires are inserted into the proper cavities For additional connector pin out identifica tion refer ...

Page 113: ...he harness and remove the protective covering 3 Remove the diode from the harness pay atten tion to the current flow direction Fig 15 INSTALLATION 1 Remove the insulation from the wires in the harness Only remove enough insulation to solder in the new diode 2 Install the new diode in the harness making sure current flow is correct If necessary refer to the appropriate wiring diagram for current fl...

Page 114: ...red 2 Cut the repair wire to the proper length and remove one half 1 2 inch of insulation 3 Splice the repair wire to the wire harness 4 Insert the repaired wire into the connector 5 Install the connector locking wedge if required and reconnect the connector to its mating half compo nent 6 Re tape the wire harness starting at 1 1 2 inches behind the connector and 2 inches past the repair 7 Connect...

Page 115: ...ir area 3 Place the strands of wire overlapping each other inside of the splice clip Fig 19 4 Using crimping tool Miller p n 8272 crimp the splice clip and wires together Fig 20 5 Solder the connection together using rosin core type solder only Fig 21 CAUTION DO NOT USE ACID CORE SOLDER 6 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tigh...

Page 116: ...odule 8Wa 30 Fuel Pump Relay 8Wa 30 Fuses FB 8Wa 11 Fuses PDC 8Wa 10 Fuse Block 8Wa 11 Fusible Links 8Wa 10 20 Component Page Grounds 8Wa 15 Generator 8Wa 20 G Switch 8Wa 35 Headlamp Leveling Motor 8Wa 50 Headlamp Leveling Switch 8Wa 50 Headlamp 8Wa 50 High Note Horn 8Wa 41 Horn Relay 8Wa 41 Horn Switch 8Wa 30 41 Idle Air Control Motor 8Wa 30 Ignition Coil Pack 8Wa 30 Ignition Coil 8Wa 30 Ignition...

Page 117: ...rottle Position Sensor 8Wa 30 Torque Converter Clutch Solenoid 8Wa 31 Transfer Case Switch 8Wa 31 Component Page Transmission Range Indicator Illumination 8Wa 44 Turn Signal Lamp 8Wa 52 Underhood Lamp 8Wa 44 Vehicle Speed Sensor 8Wa 30 Wheel Speed Sensor 8Wa 35 8Wa 02 2 8W 02 COMPONENT INDEX TJ ...

Page 118: ...7 9 Fuse 3 PDC 8Wa 10 7 10 Fuse 6 PDC 8Wa 10 7 11 Fuse 7 PDC 8Wa 10 7 10 Component Page Fuse 8 PDC 8Wa 10 7 10 Fuse 9 PDC 8Wa 10 7 14 Fuse 10 PDC 8Wa 10 7 8 10 Fuse 12 PDC 8Wa 10 7 10 Fuse 13 PDC 8Wa 10 7 8 13 Fuse 14 PDC 8Wa 10 8 11 12 Fuse 15 PDC 8Wa 10 8 17 Fuse 16 PDC 8Wa 10 8 13 14 Fuse 18 PDC 8Wa 10 8 16 Fuse 19 PDC 8Wa 10 8 16 Fuse 21 PDC 8Wa 10 8 16 Fuse 23 PDC 8Wa 10 8 16 Fuse 24 PDC 8Wa ...

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Page 136: ... FB 8Wa 11 6 Fuse 9 FB 8Wa 11 7 Fuse 10 FB 8Wa 11 7 Fuse 11 FB 8Wa 11 8 Component Page Fuse 12 FB 8Wa 11 7 Fuse 13 FB 8Wa 11 9 Fuse 14 FB 8Wa 11 9 Fuse 15 FB 8Wa 11 9 Fuse 16 FB 8Wa 11 10 Fuse 17 FB 8Wa 11 9 Fuse 18 FB 8Wa 11 10 Fuse 19 FB 8Wa 11 10 Fuse 20 FB 8Wa 11 9 Fuse Block 8Wa 11 2 4 5 6 7 8 9 10 G300 8Wa 11 4 Headlamp Leveling Switch 8Wa 11 10 Ignition Switch 8Wa 11 10 Instrument Cluster 8...

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Page 146: ... Turn Signal Lamp 8Wa 15 3 Left Front Position Lamp 8Wa 15 4 Left Front Turn Signal Lamp 8Wa 15 4 Left Headlamp 8Wa 15 3 4 Left Headlamp Leveling Motor 8Wa 15 4 Left License Lamp 8Wa 15 9 Left Rear Lamp Assembly 8Wa 15 9 Left Side Repeater Lamp 8Wa 15 4 Low Note Horn 8Wa 15 3 Manual Transmission Jumper 8Wa 15 11 12 13 Oxygen Sensor 1 2 Downstream 8Wa 15 12 Oxygen Sensor 2 2 Downstream 8Wa 15 12 Pa...

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Page 160: ...ler Antilock Brake 8Wa 18 2 Data Link Connector 8Wa 18 2 Fuse 24 PDC 8Wa 18 2 G105 8Wa 18 2 Component Page Instrument Cluster 8Wa 18 2 Power Distribution Center 8Wa 18 2 Powertrain Control Module 8Wa 18 2 Sentry Key Immobilizer Module 8Wa 18 2 TJ 8W 18 BUS COMMUNICATION 8Wa 18 1 ...

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Page 162: ...Motor 8Wa 20 2 Fuel Pump Relay 8Wa 20 2 Fuse 12 FB 8Wa 20 2 Fuse 9 PDC 8Wa 20 2 Fuse Block 8Wa 20 2 Component Page Fusible Link 8Wa 20 2 G104 8Wa 20 2 G106 8Wa 20 2 G107 8Wa 20 2 Generator 8Wa 20 2 Power Distribution Center 8Wa 20 2 Powertrain Control Module 8Wa 20 2 3 Sentry Key Immobilizer Module 8Wa 20 2 TJ 8W 20 CHARGING SYSTEM 8Wa 20 1 ...

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Page 166: ...8Wa 21 2 Engine Starter Motor 8Wa 21 2 3 Engine Starter Motor Relay 8Wa 21 2 3 Fuse 20 FB 8Wa 21 2 Fuse 6 PDC 8Wa 21 2 Component Page Fuse Block 8Wa 21 2 G105 8Wa 21 3 Ignition Switch 8Wa 21 2 Manual Transmission Jumper 8Wa 21 3 Park Neutral Position Switch 8Wa 21 3 Power Distribution Center 8Wa 21 2 TJ 8W 21 STARTING SYSTEM 8Wa 21 1 ...

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Page 170: ... Fuse 24 PDC 8Wa 30 17 Fuse 26 PDC 8Wa 30 4 5 7 Fuse Block 8Wa 30 2 3 15 18 Component Page G100 8Wa 30 20 G105 8Wa 30 2 3 14 16 17 18 G300 8Wa 30 16 20 G302 8Wa 30 18 Generator 8Wa 30 15 16 Horn Relay 8Wa 30 19 Horn Switch 8Wa 30 19 Idle Air Control Motor 8Wa 30 15 Ignition Coil 8Wa 30 4 Ignition Coil Pack 8Wa 30 5 Instrument Cluster 8Wa 30 17 18 Intake Air Temperature Sensor 8Wa 30 8 9 Leak Detec...

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Page 190: ...rlock Solenoid 8Wa 31 2 Fuse 10 FB 8Wa 31 2 Fuse 11 FB 8Wa 31 2 Fuse Block 8Wa 31 2 Component Page G105 8Wa 31 2 G300 8Wa 31 2 Instrument Cluster 8Wa 31 2 Powertrain Control Module 8Wa 31 2 Torque Converter Clutch Solenoid 8Wa 31 2 Transfer Case Switch 8Wa 31 2 TJ 8W 31 TRANSMISSION CONTROL SYSTEM 8Wa 31 1 ...

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Page 192: ...FB 8Wa 35 3 Fuse 7 FB 8Wa 35 2 Fuse 10 FB 8Wa 35 2 Fuse 8 PDC 8Wa 35 2 Fuse 12 PDC 8Wa 35 2 Component Page Fuse Block 8Wa 35 2 3 G Switch 8Wa 35 3 G100 8Wa 35 2 G101 8Wa 35 2 Instrument Cluster 8Wa 35 2 Left Front Wheel Speed Sensor 8Wa 35 4 Left Rear Wheel Speed Sensor 8Wa 35 4 Power Distribution Center 8Wa 35 2 Powertrain Control Module 8Wa 35 3 Right Front Wheel Speed Sensor 8Wa 35 4 Right Rear...

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Page 196: ...0 7 Fuse 10 FB 8Wa 40 2 Fuse 24 PDC 8Wa 40 2 Fuse Block 8Wa 40 2 7 G105 8Wa 40 5 G201 8Wa 40 2 Component Page G300 8Wa 40 7 G302 8Wa 40 4 Ignition Switch 8Wa 40 7 Instrument Cluster 8Wa 40 2 3 4 5 6 7 8 9 Multi Function Switch 8Wa 40 4 5 7 9 Park Brake Switch 8Wa 40 6 Passenger Door Ajar Switch 8Wa 40 7 Power Distribution Center 8Wa 40 2 Powertrain Control Module 8Wa 40 3 4 Radio 8Wa 40 5 Rear Win...

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Page 206: ...9 FB 8Wa 41 2 Fuse 13 PDC 8Wa 41 2 Fuse 18 PDC 8Wa 41 3 Fuse Block 8Wa 41 2 G102 8Wa 41 3 Component Page G200 8Wa 41 2 High Note Horn 8Wa 41 3 Horn Relay 8Wa 41 3 Horn Switch 8Wa 41 3 Ignition Switch 8Wa 41 2 Low Note Horn 8Wa 41 3 Power Distribution Center 8Wa 41 2 3 TJ 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8Wa 41 1 ...

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Page 210: ...Door Actuator 8Wa 42 2 3 Blower Motor 8Wa 42 2 3 Blower Motor Relay 8Wa 42 2 3 Blower Motor Resistor Block 8Wa 42 2 3 Fuse 8 FB 8Wa 42 2 3 Component Page Fuse 11 FB 8Wa 42 4 Fuse 1 PDC 8Wa 42 2 3 Fuse 21 PDC 8Wa 42 4 Fuse Block 8Wa 42 2 3 4 G105 8Wa 42 4 G200 8Wa 42 2 3 G202 8Wa 42 2 3 4 G203 8Wa 42 2 3 Power Distribution Center 8Wa 42 2 3 4 Powertrain Control Module 8Wa 42 4 TJ 8W 42 AIR CONDITIO...

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Page 214: ...43 3 Clockspring 8Wa 43 2 Data Link Connector 8Wa 43 3 Driver Airbag Squib 8Wa 43 2 Fuse 5 FB 8Wa 43 2 Component Page Fuse 9 FB 8Wa 43 2 Fuse 10 FB 8Wa 43 3 Fuse Block 8Wa 43 2 3 G301 8Wa 43 2 Instrument Cluster 8Wa 43 3 Passenger Airbag 8Wa 43 2 Passenger Airbag On Off Switch 8Wa 43 2 TJ 8W 43 AIRBAG SYSTEM 8Wa 43 1 ...

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Page 218: ... 8Wa 44 6 7 Ignition Switch 8Wa 44 6 Component Page Instrument Cluster 8Wa 44 5 6 7 Left Courtesy Lamp 8Wa 44 5 Multi Function Switch 8Wa 44 7 Passenger Door Ajar Switch 8Wa 44 6 Power Distribution Center 8Wa 44 2 3 5 Radio 8Wa 44 7 Rear Window Defogger Switch 8Wa 44 7 Rear Wiper Washer Switch 8Wa 44 7 Right Courtesy Lamp 8Wa 44 3 5 Transmission Range Indicator Illumination 8Wa 44 7 Underhood Lamp...

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Page 226: ...0 8Wa 47 2 G303 8Wa 47 4 Instrument Cluster 8Wa 47 2 Left Front Speaker 8Wa 47 3 Component Page Left Rear Speaker 8Wa 47 3 4 Power Distribution Center 8Wa 47 2 Radio 8Wa 47 2 3 4 Radio Antenna 8Wa 47 2 Radio Choke And Relay 8Wa 47 2 4 Right Front Speaker 8Wa 47 3 Right Rear Speaker 8Wa 47 3 4 Subwoofer 8Wa 47 2 4 TJ 8W 47 AUDIO SYSTEM 8Wa 47 1 ...

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Page 230: ...se 2 PDC 8Wa 48 2 Fuse Block 8Wa 48 2 G200 8Wa 48 2 G302 8Wa 48 2 Component Page Instrument Cluster 8Wa 48 2 Power Distribution Center 8Wa 48 2 Rear Window Defogger 8Wa 48 2 Rear Window Defogger Relay 8Wa 48 2 Rear Window Defogger Switch 8Wa 48 2 TJ 8W 48 REAR WINDOW DEFOGGER 8Wa 48 1 ...

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Page 232: ...ster 8Wa 50 3 4 5 7 8 9 Component Page Left Fog Lamp 8Wa 50 7 8 Left Front Park Turn Signal Lamp 8Wa 50 4 Left Front Position Lamp 8Wa 50 5 Left Headlamp 8Wa 50 3 9 Left Headlamp Leveling Motor 8Wa 50 6 Left Side Repeater Lamp 8Wa 50 4 Multi Function Switch 8Wa 50 2 4 6 7 8 9 Power Distribution Center 8Wa 50 2 7 8 Powertrain Control Module 8Wa 50 9 Right Fog Lamp 8Wa 50 7 8 Right Front Park Turn S...

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Page 242: ...300 8Wa 51 7 G302 8Wa 51 3 5 8 9 Instrument Cluster 8Wa 51 2 4 8 9 Component Page Left License Lamp 8Wa 51 8 9 Left Rear Lamp Assembly 8Wa 51 3 4 5 6 7 Multi Function Switch 8Wa 51 2 4 5 6 7 8 9 Park Neutral Position Switch 8Wa 51 2 4 Powertrain Control Module 8Wa 51 7 Radio Choke And Relay 8Wa 51 7 Rear Fog Lamp 8Wa 51 8 9 Right License Lamp 8Wa 51 8 9 Right Rear Lamp Assembly 8Wa 51 2 3 4 5 6 7 ...

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Page 252: ...ft Front Turn Signal Lamp 8Wa 52 5 Left Rear Lamp Assembly 8Wa 52 2 3 Component Page Left Side Marker Lamp 8Wa 52 4 Left Side Repeater Lamp 8Wa 52 5 Multi Function Switch 8Wa 52 2 3 4 5 Power Distribution Center 8Wa 52 2 3 Right Front Park Turn Signal Lamp 8Wa 52 4 Right Front Turn Signal Lamp 8Wa 52 5 Right Rear Lamp Assembly 8Wa 52 2 3 Right Side Marker Lamp 8Wa 52 4 Right Side Repeater Lamp 8Wa...

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Page 258: ... 8Wa 53 2 Fuse 6 FB 8Wa 53 3 Fuse Block 8Wa 53 2 3 G102 8Wa 53 2 G200 8Wa 53 3 Component Page G300 8Wa 53 2 G302 8Wa 53 3 Instrument Cluster 8Wa 53 3 Rear Washer Pump 8Wa 53 3 Rear Wiper Motor 8Wa 53 3 Rear Wiper Washer Switch 8Wa 53 3 Windshield Wiper Switch 8Wa 53 2 TJ 8W 53 WIPERS 8Wa 53 1 ...

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Page 262: ...0 11 S136 8Wa 10 7 S136 8Wa 20 2 S137 8Wa 15 12 S138 8Wa 50 6 S140 8Wa 10 13 S141 8Wa 50 4 S141 8Wa 52 4 5 Component Page S142 8Wa 50 4 S142 8Wa 52 4 5 S143 8Wa 70 2 S144 8Wa 70 2 S147 8Wa 70 4 6 7 8 S150 8Wa 15 5 S151 8Wa 11 10 S152 8Wa 50 3 9 S155 8Wa 40 9 S156 8Wa 50 7 8 S202 8Wa 44 5 S204 8Wa 10 17 S206 8Wa 44 7 S207 8Wa 15 6 7 S208 8Wa 42 2 3 S209 8Wa 18 2 S301 8Wa 50 2 S304 8Wa 15 8 S309 8Wa...

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Page 270: ...26 Hard Top 8Wa 80 19 C326 Hard Top 8Wa 80 20 C329 Built Up Export 8Wa 80 20 C329 Built Up Export 8Wa 80 20 C330 4 Spkr Sys 8Wa 80 21 C330 4 Spkr Sys 8Wa 80 21 C331 Hard Top 8Wa 80 21 C331 Hard Top 8Wa 80 21 Camshaft Position Sensor 8Wa 80 22 Cigar Lighter Power Outlet 8Wa 80 22 Circuit Breaker 8Wa 80 22 Clockspring 8Wa 80 22 Clockspring C2 8Wa 80 22 Clutch Pedal Position Switch M T 8Wa 80 23 Cont...

Page 271: ...le C1 8Wa 80 36 Powertrain Control Module C2 8Wa 80 37 Powertrain Control Module C3 8Wa 80 37 Radio C1 8Wa 80 38 Radio C2 8Wa 80 38 Component Page Radio Choke And Relay 8Wa 80 39 Rear Fog Lamp Built Up Export 8Wa 80 39 Rear Washer Pump Hard Top 8Wa 80 39 Rear Window Defogger Switch Hard Top 8Wa 80 39 Rear Wiper Motor Hard Top 8Wa 80 39 Rear Wiper Washer Switch Hard Top 8Wa 80 40 Right Courtesy Lam...

Page 272: ...RD DG RHD GROUND 1 Z11 20BK WT LHD GROUND 2 C36 20DB RD BLEND DOOR FEED BACK SIGNAL 3 F24 20RD DG LHD FUSED IGNITION SWITCH OUTPUT RUN 3 Z11 20BK WT RHD FUSED IGNITION SWITCH OUTPUT RUN 4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 5 Z1 20BK GROUND A C HEATER CONTROL C3 3 WAY CAV CIRCUIT FUNCTION A C90 20LG A C SELECT INPUT B C1 12DG BLOWER MOTOR FEED C Z1 12BK GROUND A C HIGH PRESSURE SWITCH 2...

Page 273: ... 8 R166 18LG BR LHD PASSENGER AIRBAG INDICATOR DRIVER 9 10 Z6 18BK PK GROUND 11 R65 18LG OR PASSENGER AIRBAG MUX SWITCH SENSE 12 13 14 15 16 17 F14 18LG YL FUSED IGNITION SWITCH OUTPUT RUN START 18 D25 18VT YL PCI BUS 19 20 F23 18DB YL FUSED IGNITION SWITCH OUTPUT RUN 21 22 R66 18LG DG LHD PASSENGER AIRBAG MUX SWITCH RETURN BACK UP LAMP SWITCH M T BLACK 2 WAY CAV CIRCUIT FUNCTION A L1 18VT BK BACK...

Page 274: ...TPUT 2 Z1 20BK GROUND 3 4 A111 12RD LG FUSED B 5 F24 20DB WT FUSED IGNITION SWITCH OUTPUT RUN BLOWER MOTOR RESISTOR BLOCK 4 WAY CAV CIRCUIT FUNCTION 1 C4 14TN BLOWER MOTOR LOW DRIVER 2 C5 14LG BLOWER MOTOR M1 DRIVER 3 C6 14LB BLOWER MOTOR M2 DRIVER 4 C7 12BK TN BLOWER MOTOR HIGH DRIVER BRAKE LAMP SWITCH GRAY 6 WAY CAV CIRCUIT FUNCTION 1 K29 20WT PK BRAKE LAMP SWITCH SENSE 2 Z1 20 BK SUBWOOFER GROU...

Page 275: ...AY CAV CIRCUIT FUNCTION 1 G9 20GY BK BRAKE WARNING INDICATOR DRIVER 2 G99 20GY WT BRAKE WARNING INDICATOR DRIVER C103 BLACK DASH SIDE CAV CIRCUIT 1 F142 18OR DG 2 K125 18WT DB 3 A14 14RD WT 4 K99 18BR OR 5 K299 18BR WT 6 K226 18DB LG 7 A141 18DG WT 8 K4 20BK LB 9 F12 20RD LG 10 Z12 20BK TN 11 Z12 20BK LB 12 G7 20WT OR DRL CANADA 13 G107 20BK RD 14 C3 20DB BK C103 BLACK ENGINE SIDE CAV CIRCUIT 1 F1...

Page 276: ...20BR LB 6 B3 18LG DB ABS 7 B4 18LG ABS 8 9 L1 20VT BK 10 F20 20VT WT 11 F42 18DG LG 12 T40 12BR 13 F15 20DB 14 A242 18VT OR 4 0L CALIFORNIA C104 LHD ENGINE SIDE CAV CIRCUIT 1 C90 20LG 2 C22 20DB WT 4CYL 2 C21 20DB OR 6 CYL 2 C21 20DB OR 6 CYL 3 B1 18YL DB ABS 4 B2 18YL ABS 5 T41 20BR LB 6 B3 18LG DB ABS 7 B4 18LG ABS 8 9 L1 20VT BK 10 F20 20VT WT 11 F42 18DG LG 12 T40 12BR 13 F15 18DB 14 A242 18VT...

Page 277: ...IT 1 C90 20LG 2 C21 20DB OR 6 CYL 2 C22 20DB WT 4 CYL 3 A42 18DG 4 F42 18DG LG 5 T41 20BR LB 6 T40 12BR 7 F15 18DB 8 A242 18VT OR 9 L1 20VT BK 10 F20 20VT WT C104 RHD ABS GRAY DASH SIDE CAV CIRCUIT 1 C90 20LG 2 C21 18DB OR 3 B1 18YL DB 4 B2 18YL 5 T41 20BR LB 6 B3 18LG DB 7 B4 18LG 8 9 L1 20VT BK 10 F20 20VT WT 11 F42 18DG LG 12 T40 12BR 13 F15 20DB 14 A242 18VT OR 8Wa 80 8 8W 80 CONNECTOR PINOUTS...

Page 278: ...CAV CIRCUIT 1 F30 12RD PK 2 L1 20VT BK 3 F20 20VT WT 4 F15 20DB 5 A1 14RD 6 A2 12PK BK 7 A6 12RD BK 8 C15 12BK WT 9 T141 14YL RD 10 F12 20RD LG 11 G9 20GY BK 12 A3 12RD WT C106 BLACK CROSSBODY SIDE CAV CIRCUIT 1 F30 12RD PK 2 L1 20VT BK 3 F20 20VT WT 4 F15 20DB 4 F15 20DB 5 A1 14RD 6 A2 12PK BK 7 A6 12RD BK 8 C15 12BK WT 9 T141 14YL RD 10 F12 20RD LG 11 G9 20GY BK 12 A3 12RD WT TJ 8W 80 CONNECTOR ...

Page 279: ...14 D21 18PK C107 YELLOW CROSSBODY SIDE CAV CIRCUIT 1 L7 18BK YL 1 L7 18BK YL 2 L60 18TN 3 L61 18GY 4 L3 14RD OR 5 L4 14VT WT 6 Z12 20BK LB 7 X3 20RD YL 8 V10 16BR 9 Z12 20BK TN 10 F61 16WT OR LHD 11 V30 20DB RD 12 B43 20PK OR LHD 13 D32 20LG 14 D21 20PK C108 BLUE DASH SIDE CAV CIRCUIT 1 V32 18YL RD 2 B41 18YL VT 3 K4 20BK LB 4 F39 16PK LG 5 B42 18TN WT 6 D25 18VT YL 7 L3 14RD OR EXCEPT DRL 8Wa 80 ...

Page 280: ...N WT LHD 6 D25 20VT YL 6 D25 20VT YL 7 G34 14RD GY 8 F3 14LB OR DRL 9 L50 18WT TN LHD 9 L50 18WT TN LHD 10 V37 20RD LG 11 L9 18BK WT 12 M1 20PK WT 12 M1 20PK WT 13 L22 20LG DG EXCEPT CANADA 14 K29 20WT PK 14 K29 20WT PK C110 BLACK HEADLAMP SIDE CAV CIRCUIT 1 L7 18BK YL 2 L60 18TN 3 L61 18GY 4 L3 14RD OR 5 L4 14VT WT 6 X2 18DG RD 7 8 V10 16BR 9 L22 20LG DG BUILT UP EXPORT 10 K52 20PK BK 11 F12 20DG...

Page 281: ... YL BUILT UP EXPORT C154 BLACK ENGINE SIDE CAV CIRCUIT 1 Z1 18BK RHD 1 Z1 20BK LHD 2 L1 20VT BK 3 T41 20BR LB EXCEPT 4 0L RHD 4 F20 20VT WT C154 BLACK TRANSMISSION SIDE CAV CIRCUIT 1 Z1 20BK 4 0L RHD 2 L1 18VT BK 3 T41 20BR LB EXCEPT 4 0L RHD 3 Z1 20BK 4 0L RHD 4 F20 18VT WT C170 LT GRAY DASH SIDE CAV CIRCUIT 1 L13 20BR YL BUILT UP EXPORT 2 C81 20LB WT 3 G99 20GY WT 4 5 G107 20BK RD 8Wa 80 12 8W 8...

Page 282: ...G99 20GY WT 4 5 G107 20BK RD 6 C90 20LG 7 8 G19 20LG OR 9 L39 16LB EXCEPT BUILT UP EXPORT 10 A111 12RD LB C202 GRAY I P SIDE CAV CIRCUIT A1 F24 20RD DG A1 F24 20RD DG A2 G75 20TN A3 G76 20TN YL A4 E2 20OR A5 A6 Z12 20BK LB A7 A8 G34 16RD GY A9 F38 16LB A10 G5 20DB WT A11 A12 C202 GRAY CROSSBODY SIDE CAV CIRCUIT A1 F24 20RD DG A2 G75 20TN A3 G76 20TN YL A4 E2 20OR A5 TJ 8W 80 CONNECTOR PINOUTS 8Wa ...

Page 283: ...HD B5 B6 L7 18BK YL B7 M1 20PK WT B8 D32 20LG B9 V20 18VT OR B10 D21 20PK B11 B12 F81 20DB RD B13 L38 18BR WT BUILT UP EXPORT B14 D25 20VT YL C203 GREEN CROSSBODY SIDE CAV CIRCUIT B1 L60 18TN B1 L60 18TN B2 L61 18GY B2 L61 18GY B3 G26 20LB B4 L50 18WT TN LHD B5 B6 L7 18BK YL B6 L7 18BK YL B7 M1 20PK WT B8 D32 20LG B9 V20 18VT OR B10 D21 20PK B11 B12 F81 20DB RD B13 L38 18BR WT B13 L38 18BR WT 8Wa ...

Page 284: ...ILT UP EXPORT C10 X12 16PK C11 X51 18BR YL C12 X57 18BR LB C13 X52 18DB WT C14 X58 18DB PK C204 RED CROSSBODY SIDE CAV CIRCUIT C1 X16 20LG C2 V13 18BR LG HARD TOP C3 G10 20LG RD C4 Z12 20BK TN C5 M2 20YL C6 V23 18BR PK C7 E19 20RD C8 L50 18WT TN LHD C9 L22 20LG DG C10 X12 16PK C11 X51 18BR YL C11 X51 18BR YL C12 X52 18BK LB C12 X57 18BR LB C13 X52 18DB WT C13 X52 18DB WT C14 X58 18DB PK C14 X58 18...

Page 285: ...1 20BK C205 HVAC SIDE CAV CIRCUIT 1 Z11 20DB WT 2 C4 14TN 3 C5 14LG 4 C6 14LB 5 F24 20OR 6 C36 20YL 7 C7 12BK TN 8 A111 12RD LG 9 F24 20DB WT 10 Z1 20BK C322 LHD BLACK REAR BODY SIDE CAV CIRCUIT G1 L7 18BK YL G2 L62 18BR RD G3 L1 20VT BK G4 L63 18DG RD G5 Z1 12BK G6 G10 20LG RD G7 L50 18WT TN G8 G9 G9 20GY BK G10 V23 18BR PK HARD TOP 8Wa 80 16 8W 80 CONNECTOR PINOUTS TJ ...

Page 286: ... BLACK REAR BODY SIDE CAV CIRCUIT 1 L7 18BK YL 2 L62 18BR RD 3 L1 20VT BK 4 L63 18DG RD 5 Z1 12BK 6 G10 20LG RD 7 L50 18WT TN 8 L38 18BR WT 9 G9 20GY BK 10 V23 18BR PK HARD TOP C322 RHD BLACK CROSSBODY SIDE CAV CIRCUIT 1 L7 18BK YL 2 L62 18BR RD 3 L1 20VT BK 4 L63 18DG RD 5 Z1 12BK 6 G10 20LG RD 7 L50 18WT TN 8 L38 18BR WT 9 G9 20GY BK 10 V23 18BR PK HARD TOP TJ 8W 80 CONNECTOR PINOUTS 8Wa 80 17 ...

Page 287: ...SYSTEM C323 LHD RED CROSSBODY SIDE CAV CIRCUIT H1 C15 12BK WT H2 M1 20PK WT H3 M2 20YL H4 V23 18BR PK H5 V13 18BR LG H6 V20 18VT OR H7 X51 18BR YL H8 C57 18BR LB H9 X52 18DB WT H10 X58 18DB PK C323 RHD GRAY REAR BODY SIDE CAV CIRCUIT 1 C15 12BK WT HARD TOP 2 M1 20PK WT 3 M2 20YL 4 V23 18BR PK HARD TOP 5 V13 18BR LG HARD TOP 6 V20 18VT OR HARD TOP 7 X51 18BR YL 4 SPEAKER SYSTEM 8 X57 18BR YL 4 SPEA...

Page 288: ...4SPEAKER SYSTEM 10 X58 18DB PK 4 SPEAKER SYSTEM C325 4 SPKR SYS WHITE REAR BODY CAV CIRCUIT 1 X57 18BR LB 2 X51 18BR YL 3 M1 20PK WT 4 M2 20YL 5 X58 18DB PK 6 X52 18DB WT C325 4 SPKR SYS WHITE SOUND BAR SIDE CAV CIRCUIT 1 X57 18BR LB 2 X51 18BR YL 3 M1 20PK WT 4 M2 20YL 5 X58 18DB PK 6 X52 18DB WT C326 HARD TOP REAR BODY SIDE CAV CIRCUIT 1 C15 12BK WT 2 3 V13 18BR LG 4 V23 18BR PK 5 V23 18BR PK 6 ...

Page 289: ...ESSORY RELAY BLACK 5 WAY CAV CIRCUIT FUNCTION 1 F30 12RD PK FUSED B 2 A31 14BK DG IGNITION SWITCH OUTPUT RUN ACC 3 4 F22 12WT PK CIGAR LIGHTER ACCESSORY RELAY OUTPUT 5 Z1 20BK GROUND 5 Z1 20BK GROUND C329 BUILT UP EXPORT BLACK REAR BODY SIDE CAV CIRCUIT 1 L38 18BR WT 2 L7 18BK YL 3 Z1 20BK C329 BUILT UP EXPORT BLACK BUMPER SIDE CAV CIRCUIT 1 L38 18BR WT 2 L7 18BK YL 3 Z1 20BK 8Wa 80 20 8W 80 CONNE...

Page 290: ... LB 2 X51 20BR YL 3 M1 20PK WT 4 M2 20YL 5 X58 20DB PK 6 X52 20DB WT C331 HARD TOP BLACK HARD TOP JUMPER SIDE CAV CIRCUIT 1 C15 12BK WT 2 3 V13 18BK LG 4 V23 18BR PK 5 V23 18BR PK 6 Z1 12BK 7 8 M1 18PK WT 9 M2 18YL 10 C331 HARD TOP BLACK HARD TOP SIDE CAV CIRCUIT 1 C15 12BK WT 2 3 V13 18BK LG 4 V23 18DB RD 5 V23 18BR PK 6 Z1 12BK 7 8 M1 20PK WT 9 M2 20YL 10 TJ 8W 80 CONNECTOR PINOUTS 8Wa 80 21 ...

Page 291: ... 2 3 Z1 16BK GROUND CIRCUIT BREAKER GRAY 2 WAY CAV CIRCUIT FUNCTION 1 A3 12RD WT HEADLAMP SWITCH RELAY FEED 2 F3 14LB OR DAYTIME RUNNING LAMP MODULE CLOCKSPRING C1 NATURAL 4 WAY CAV CIRCUIT FUNCTION 1 X3 20RD YL HORN RELAY CONTROL 2 V37 20RD LG SPEED CONTROL SWITCH SIGNAL 3 K4 20BK LB SENSOR GROUND 4 CLOCKSPRING C2 YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R45 18DG LB DRIVER AIRBAG LINE 2 2 R43 18BK LB ...

Page 292: ...DB FUSED B 10 B4 18LG LEFT REAR WHEEL SPEED SENSOR 11 B8 18RD DB LEFT FRONT WHEEL SPEED SENSOR 12 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 13 B43 18PK OR G SWITCH TEST SIGNAL 14 15 16 G83 18GY BK ABS RELAY CONTROL 17 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 18 B6 18WT DB RIGHT FRONT WHEEL SPEED SENSOR 19 20 D21 18PK SCI TRANSMIT 21 22 23 F20 18VT WT FUSED IGNITION SWITCH OUTPUT RUN 24 Z22 12BK PK GROUND ...

Page 293: ...UT 2 3 4 G34 14RD GY HIGH BEAM INDICATOR DRIVER 5 F12 20RD LG FUSED IGNITION SWITCH OUTPUT RUN START 6 F3 14LB OR FUSED B 7 G7 20WT OR VEHICLE SPEED SENSOR SIGNAL 8 Z1 18BK GROUND 9 10 L4 14VT WT DIMMER SWITCH LOW BEAM OUTPUT DRIVER AIRBAG YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R45 DG LB DRIVER AIRBAG LINE 2 2 R43 BK LB DRIVER AIRBAG LINE 1 DRIVER DOOR AJAR SWITCH NATURAL 3 WAY CAV CIRCUIT FUNCTION 1...

Page 294: ... SUPPLY 2 G60 18GY YL ENGINE OIL PRESSURE SENSOR SIGNAL 3 K4 20BK LB SENSOR GROUND EVAP PURGE SOLENOID BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K52 20PK BK EVAP PURGE SOLENOID CONTROL 2 F12 20RD LG FUSED IGNITION SWITCH OUTPUT RUN START FRONT WASHER PUMP BLACK 2 WAY CAV CIRCUIT FUNCTION A V10 18BR WASHER PUMP CONTROL SWITCH OUTPUT B Z1 18BK GROUND FRONT WIPER MOTOR BLACK 6 WAY CAV CIRCUIT FUNCTION 1 V6 ...

Page 295: ...8DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K12 18TN FUEL INJECTOR NO 2 DRIVER FUEL INJECTOR NO 2 4 0L 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K12 18TN FUEL INJECTOR NO 2 DRIVER FUEL INJECTOR NO 3 2 5L 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K13 18YL WT FUEL INJECTOR NO 3 DRIVER FUEL INJECTOR NO 3 4 0L 2 WAY CA...

Page 296: ...IC SHUT DOWN RELAY OUTPUT 2 K15 18PK BK FUEL INJECTOR NO 5 DRIVER FUEL INJECTOR NO 6 4 0L 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K16 18LG BK FUEL INJECTOR NO 6 DRIVER FUEL PUMP MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 A141 18DG WT FUEL PUMP RELAY OUTPUT 2 3 K226 20DB LG FUEL LEVEL SENSOR SIGNAL 4 K4 20BK LB SENSOR GROUND 5 6 Z1 18BK GROUND G SWITCH BLACK...

Page 297: ...N BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X2 18DG RD HORN RELAY OUTPUT 2 Z1 18BK GROUND IDLE AIR CONTROL MOTOR BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K59 18VT BK IDLE AIR CONTROL NO 4 DRIVER 2 K40 18BR WT IDLE AIR CONTROL NO 3 DRIVER 3 K60 18YL BK IDLE AIR CONTROL NO 2 DRIVER 4 K39 18GY RD IDLE AIR CONTROL NO 1 DRIVER IGNITION COIL 2 5L GRAY 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOW...

Page 298: ...10 Z1 20BK RHD GROUND 10 Z1 16BK LHD GROUND INSTRUMENT CLUSTER C1 8 WAY CAV CIRCUIT FUNCTION 1 L61 18GY LEFT TURN SIGNAL 2 L60 18TN RIGHT TURN SIGNAL 3 G34 16RD GY HIGH BEAM INDICATOR DRIVER 4 L7 18BK YL HEADLAMP SWITCH OUTPUT 5 Z2 18BK LG GROUND 6 L38 18BR WT BUILT UP EXPORT REAR FOG LAMP FEED 6 L39 16LB EXCEPT BUILT UP EXPORT REAR FOG LAMP FEED 7 G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START...

Page 299: ...ATOR INTAKE AIR TEMPERATURE SENSOR GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K21 18BK RD INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K4 20BK LB SENSOR GROUND LEAK DETECTION PUMP LHD 3 WAY CAV CIRCUIT FUNCTION 1 K107 18OR LEAK DETECTION PUMP SWITCH SENSE 2 K106 20WT DG LEAK DETECTION PUMP SOLENOID CONTROL 3 K125 18WT DB GENERATOR SOURCE LEFT COURTESY LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 M1 20PK WT FUSED B 2 ...

Page 300: ...KER 2 X55 18BR RD LEFT FRONT SPEAKER LEFT FRONT TURN SIGNAL LAMP BUILT UP EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L61 18GY LEFT TURN SIGNAL 2 3 Z1 18BK GROUND LEFT FRONT WHEEL SPEED SENSOR 2 WAY CAV CIRCUIT FUNCTION 1 B8 18RD DB LEFT FRONT WHEEL SPEED SENSOR 2 B9 18RD LEFT FRONT WHEEL SPEED SENSOR LEFT HEADLAMP BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L3 14RD OR DIMMER SWITCH HIGH BEAM OUTPUT 1 L3 14R...

Page 301: ...4 WAY CAV CIRCUIT FUNCTION 1 L63 18DG RD LEFT TURN STOP SIGNAL 2 L1 20VT BK BACK UP LAMP FEED 3 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 4 L7 18BK YL HEADLAMP SWITCH OUTPUT LEFT REAR LAMP ASSEMBLY EXCEPT BUILT UP EXPORT BLACK 6 WAY CAV CIRCUIT FUNCTION 1 L1 20VT BK BACK UP LAMP FEED 2 L63 18DG RD LEFT TURN STOP SIGNAL 3 L7 18BK YL HEADLAMP SWITCH OUTPUT 4 5 Z16 18BK GROUND 6 LEFT REAR SPEAKER SOUND BA...

Page 302: ...1 18BK GROUND LEFT SIDE REPEATER LAMP BUILT UP EXPORT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L61 18GY LEFT TURN SIGNAL 2 Z1 18BK GROUND LOW NOTE HORN EXCEPT BUILT UP EXPERT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X2 18WT RD HORN RELAY OUTPUT 2 Z1 18BK GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR 3 WAY CAV CIRCUIT FUNCTION 1 K4 20BK LB SENSOR GROUND 2 K1 18DG RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL 3 K7 20OR...

Page 303: ...EADLAMP LOW BEAM 17 L3 14RD OR HEADLAMP HI BEAM 18 F3 12LB OR FUSED B 19 F3 12LB OR FUSED B 20 F33 18PK RD FUSED B OXYGEN SENSOR 1 1 UPSTREAM 4 WAY CAV CIRCUIT FUNCTION 1 F142 18OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K99 18BR OR GROUND 2 K299 18BR WT EXCEPT 4 0L CALI FORNIA GROUND 3 K4 20BK LB SENSOR GROUND 4 K41 18BK DG OXYGEN SENSOR 1 1 SIGNAL OXYGEN SENSOR 1 2 DOWNSTREAM BLACK 4 WAY CAV...

Page 304: ...XYGEN SENSOR 2 2 SIGNAL PARK NEUTRAL POSITION SWITCH A T 3 WAY CAV CIRCUIT FUNCTION 1 F20 18VT WT FUSED IGNITION SWITCH OUTPUT RUN 2 T41 20BR LB PARK NEUTRAL POSITION SWITCH SENSE 3 L1 18VT BK BACK UP LAMP FEED PASSENGER AIRBAG YELLOW 2 WAY CAV CIRCUIT FUNCTION A R44 18DG YL PASSENGER AIRBAG LINE 2 B R42 18BK YL PASSENGER AIRBAG LINE 1 PASSENGER AIRBAG ON OFF SWITCH 6 WAY CAV CIRCUIT FUNCTION 1 F1...

Page 305: ...BK IDLE AIR CONTROL NO 2 DRIVER A11 K40 18BR WT IDLE AIR CONTROL NO 3 DRIVER A12 K10 18DB BR 2 5L POWER STEERING PRESSURE SWITCH SENSE A13 A14 A15 K21 18BK RD INTAKE AIR TEMPERATURE SENSOR SIGNAL A16 K2 18TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL A17 K7 18OR 5V SUPPLY A18 K44 18TN YL CAMSHAFT POSITION SENSOR SIGNAL A19 K39 18GY RD IDLE AIR CONTROL NO 1 DRIVER A20 K59 18VT BK IDLE AIR CONTROL ...

Page 306: ... SIGNAL B24 B25 B26 B27 G7 20WT OR 4 0L RHD EXCEPT DRL VEHICLE SPEED SENSOR SIGNAL B27 G7 18WT OR EXCEPT 4 0L RHD VEHICLE SPEED SENSOR SIGNAL B28 B29 B30 B31 K6 18VT OR 5V SUPPLY B32 POWERTRAIN CONTROL MODULE C3 GRAY 32 WAY CAV CIRCUIT FUNCTION C1 C13 18DB OR A C COMPRESSOR CLUTCH RELAY CONTROL C2 C3 K51 18DB YL AUTOMATIC SHUT DOWN RELAY CONTROL C4 V36 18TN RD SPEED CONTROL SPEED CONTROL VACUUM SO...

Page 307: ...OR SOURCE C26 K226 18DB LG FUEL LEVEL SENSOR SIGNAL C27 D21 18PK SCI TRANSMIT C28 C29 D32 18LG SCI RECEIVE C30 D25 18VT YL PCI BUS C31 C32 V37 18RD LG SPEED CONTROL SPEED CONTROL SWITCH SIGNAL RADIO C1 GRAY 7 WAY CAV CIRCUIT FUNCTION 1 2 K55 18BR RD LEFT FRONT SPEAKER 3 X56 18DB RIGHT FRONT SPEAKER 4 L107 20WT HEADLAMP SWITCH OUTPUT 5 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 6 X12 16PK FUSED...

Page 308: ...RCUIT FUNCTION A V20 18VT OR REAR WASHER MOTOR CONTROL B Z1 18BK GROUND REAR WINDOW DEFOGGER SWITCH HARD TOP 4 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 C80 20DB WT REAR WINDOW DEFOGGER SWITCH SENSE 3 F81 20DB RD FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL REAR WIPER MOTOR HARD TOP BLACK 3 WAY CAV CIRCUIT FUNCTION 1 V23 18BR PK FUSED IGNITION SWITCH O...

Page 309: ...IGHT FOG LAMP EXCEPT BUILT UP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L39 18LB FOG LAMP RELAY NO 1 OUTPUT RIGHT FRONT PARK TURN SIGNAL LAMP EXCEPT BUILT UP EXPORT BLACK 3 CAV CIRCUIT FUNCTION 1 L60 18TN RIGHT TURN SIGNAL 2 L7 18BK YL HEADLAMP SWITCH OUTPUT 3 Z1 18BK GROUND RIGHT FRONT POSITION LAMP BUILT UP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L7 18BK YL HEADLAMP SWITCH OUT...

Page 310: ...SOR RIGHT HEADLAMP BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L3 14RD OR DIMMER SWITCH HIGH BEAM OUTPUT 2 L4 14VT WT DIMMER SWITCH LOW BEAM OUTPUT 3 Z1 18BK GROUND RIGHT HEADLAMP LEVELING MOTOR BUILT UP EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L22 20LG DG FUSED HEADLAMP SWITCH OUTPUT 2 L13 20BR YL HEADLAMP ADJUST SIGNAL 3 Z1 20BK GROUND RIGHT LICENSE LAMP GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L7 18BK YL HEAD...

Page 311: ...TOP SIGNAL 3 L7 18BK YL HEADLAMP SWITCH OUTPUT 4 L63 18DG RD LEFT TURN STOP SIGNAL 5 Z1 18BK GROUND 6 RIGHT REAR SPEAKER SOUND BAR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X52 20DB WT RIGHT REAR SPEAKER 2 X58 20DB PK RIGHT REAR SPEAKER RIGHT REAR WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B1 18YL DB RIGHT REAR WHEEL SPEED SENSOR 2 B2 18YL RIGHT REAR WHEEL SPEED SENSOR RIGHT SIDE MARKER LAMP E...

Page 312: ...ON 1 2 D25 20VT YL PCI BUS 3 Z12 20BK LB GROUND 4 F15 20DB FUSED IGNITION SWITCH OUTPUT RUN START 5 Z1 20BK GROUND 6 F33 20PK RD FUSED B SOUND BAR DOME LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 M1 20PK WT FUSED B 2 M2 20YL COURTESY LAMPS DRIVER SPEED CONTROL SERVO BLACK 4 WAY CAV CIRCUIT FUNCTION 1 V36 18TN RD SPEED CONTROL VACUUM SOLENOID CONTROL 2 V35 18LG RD SPEED CONTROL VENT SOLENOID CONTROL 3 ...

Page 313: ... K22 18OR DB THROTTLE POSITION SENSOR SIGNAL 3 K7 20OR 5V SUPPLY TORQUE CONVERTER CLUTCH SOLENOID BLACK 2 WAY CAV CIRCUIT FUNCTION A F12 20RD LG FUSED IGNITION SWITCH OUTPUT RUN START B T23 18OR LG TRANSMISSION LOW OVERDRIVE SOLENOID TRANSFER CASE SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION A G107 20BK RD 4WD SENSE B Z1 20BK GROUND TRANSMISSION RANGE INDICATOR ILLUMINATION PRNDL BLACK 2 WAY CAV CIRCUI...

Page 314: ...OR GROUND 3 G7 20WT OR VEHICLE SPEED SENSOR SIGNAL WINDSHIELD WIPER SWITCH BLACK 7 WAY CAV CIRCUIT FUNCTION 1 V5 16DG YL WIPER PARK SWITCH SENSE 2 Z1 20BK GROUND 3 V10 16BR WASHER PUMP CONTROL SWITCH OUTPUT 4 V6 16PK BK FUSED IGNITION SWITCH OUTPUT RUN ACC 5 V4 16RD YL WIPER SWITCH HIGH SPEED OUTPUT 6 V3 16BR WT LOW SPEED WIPER SWITCH OUTPUT 7 TJ 8W 80 CONNECTOR PINOUTS 8Wa 80 45 ...

Page 315: ......

Page 316: ...7 A C Low Pressure Switch Near Powertrain Control Module 5 Airbag Control Module YL Front of Floor Pan Tunnel 8 9 Back up Lamp Switch M T BK Right Side of Transmission 20 21 Battery Temperature Sensor BK Under Battery Tray 3 4 Blend Door Actuator On HVAC Harness N S Blower Motor On HVAC Harness N S Blower Motor Relay BK On HVAC Harness N S Blower Motor Resistor Block On HVAC Harness N S Brake Lamp...

Page 317: ...gine 16 24 Cigar Lighter Power Outlet RD Rear of Cigar Lighter 10 12 Circuit Breaker GY Near Day Time Running Lamp Module N S Clockspring C1 NAT Rear of Clockspring 15 Clockspring C2 YL Rear of Clockspring 15 Clutch Pedal Position Switch M T BK Top of Clutch Pedal Bracket 8 9 13 Controller Anti Lock Brake Rear Left Side of Dash Panel N S Crankshaft Position Sensor At Rear of Intake Manifold 16 18 ...

Page 318: ... Panel 11 G203 RHD Left Rear of Instrument Panel 12 G300 LHD Left Kick Panel 8 G300 RHD Right Kick Panel 9 G301 LHD Between Front Seats 8 G301 RHD Left Kick Panel 9 G302 LHD Left Kick Panel 8 G302 RHD Right Kick Panel 9 G Switch BK Near T O for Controller Anti Lock Brake N S Generator BK Rear of Generator 16 Headlamp Leveling Switch Built Up Export WT At Switch 10 12 High Note Horn BK Left Front F...

Page 319: ...r N S Left Rear Wheel Speed Sensor Near Vehicle Speed Sensor T O 26 Left Side Repeater Lamp Built Up Export GY At Lamp N S Low Note Horn Except Built Up Export BK Left Front Fender Side Shield 1 Manifold Absolute Pressure Sensor BK Side of Throttle Body 17 18 Multi Function Switch GY Steering Column 15 Oxygen Sensor 1 1 Upstream On Front Exhaust Pipe 17 Oxygen Sensor 1 2 Downstream BK Rear of Cata...

Page 320: ...r Washer Fluid Reservoir 1 Rear Window Defogger Switch Hard Top GY Behind Rear Window Defogger Switch 10 12 Rear Wiper Motor Hard Top BK At Rear Wiper Motor N S Rear Wiper Washer Switch Hard Top WT Behind Rear Wiper Washer Switch 10 12 Right Courtesy Lamp BK Right Side of Instrument Panel 11 12 Right Fog Lamp Except Built Up Export BK At Lamp 2 Right Front Park Turn Signal Lamp Except Built Up Exp...

Page 321: ...peed Control Servo BK Left Side Engine Compartment 7 Subwoofer LTGY Floor Pan 8 9 Throttle Position Sensor WT Side of Throttle Body 17 18 24 Torque Converter Clutch Solenoid BK Left Side of Transmission N S Transfer Case Switch BK Left Side of Transfer Case 19 Transmission Range Indicator Illumination PRNDL BK Between Seats 8 9 Underhood Lamp BK Under Hood 3 Vehicle Speed Sensor BK Left Rear of Tr...

Page 322: ...Fig 1 LEFT HEADLAMP TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 7 CONNECTOR GROUND LOCATIONS Continued ...

Page 323: ...Fig 2 RIGHT HEADLAMP 8Wa 90 8 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 324: ...Fig 3 ENGINE COMPARTMENT REAR LHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 9 CONNECTOR GROUND LOCATIONS Continued ...

Page 325: ...Fig 4 ENGINE COMPARTMENT REAR RHD 8Wa 90 10 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 326: ...Fig 5 POWERTRAIN CONTROL MODULE Fig 6 FRONT WIPER MOTOR TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 11 CONNECTOR GROUND LOCATIONS Continued ...

Page 327: ...Fig 7 SPEED CONTROL SERVO 8Wa 90 12 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 328: ...Fig 8 DASH PANEL LHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 13 CONNECTOR GROUND LOCATIONS Continued ...

Page 329: ...Fig 9 DASH PANEL RHD 8Wa 90 14 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 330: ...Fig 10 LEFT SIDE INSTRUMENT PANEL BUX TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 15 CONNECTOR GROUND LOCATIONS Continued ...

Page 331: ...Fig 11 RIGHT SIDE INSTRUMENT PANEL LHD 8Wa 90 16 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 332: ...Fig 12 INSTRUMENT PANEL RHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 17 CONNECTOR GROUND LOCATIONS Continued ...

Page 333: ...Fig 13 LEFT COWL MANUAL TRANSMISSION LHD 8Wa 90 18 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 334: ...Fig 14 LEFT COWL PANEL LHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 19 CONNECTOR GROUND LOCATIONS Continued ...

Page 335: ...Fig 15 STEERING COLUMN 8Wa 90 20 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 336: ...Fig 16 4 0 LITER ENGINE RIGHT SIDE TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 21 CONNECTOR GROUND LOCATIONS Continued ...

Page 337: ...Fig 17 4 0 LITER ENGINE LEFT SIDE 8Wa 90 22 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 338: ...Fig 18 2 5 LITER ENGINE LEFT SIDE TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 23 CONNECTOR GROUND LOCATIONS Continued ...

Page 339: ...Fig 19 TRANSFER CASE Fig 20 MANUAL TRANSMISSION BUX 8Wa 90 24 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 340: ...Fig 21 MANUAL TRANSMISSION Fig 22 AUTOMATIC TRANSMISSION BUX TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 25 CONNECTOR GROUND LOCATIONS Continued ...

Page 341: ...Fig 23 4 0 LITER ENGINE AND TRANSMISSION RHD Fig 24 2 5 LITER ENGINE AND TRANSMISSION 8Wa 90 26 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 342: ...Fig 25 BODY CONNECTORS TJ 8W 90 CONNECTOR GROUND LOCATIONS 8Wa 90 27 CONNECTOR GROUND LOCATIONS Continued ...

Page 343: ...Fig 26 FUEL PUMP Fig 27 REAR LAMPS BUX 8Wa 90 28 8W 90 CONNECTOR GROUND LOCATIONS TJ CONNECTOR GROUND LOCATIONS Continued ...

Page 344: ...ar T O for Battery Temperature Sensor or Power Distribution Center 3 4 S113 Near T O for G100 3 4 S115 Except Built Up Export Near T O for Evap Purge Solenoid 1 S116 Except Built Up Export Near T O for High Note Horn 1 S117 Near T O for High Note Horn 1 S118 Near Left Headlamp T O 1 S121 Near T O for Powertrain Control Module C2 6 S122 Near Grommet for Left Front Turn Signal Lamp N S S123 Near T O...

Page 345: ...r Cigar Lighter T O 12 13 S208 Near Blower Motor N S S209 Near T O for C202 C203 and C204 12 13 S301 LHD Center Rear of Dash Panel 14 S301 RHD Near T O for Sentry Key Immobilizer 15 S304 LHD Center Rear of Dash Panel 14 S304 RHD Near T O for C202 C203 C204 C106 C107 and C108 15 S309 Front of Left Door Opening 16 S310 Left Rear Quarter Panel Near Body Grommet 16 S311 Near Left Rear Lamp Assembly Co...

Page 346: ...Near T O for Airbag Control Module 14 S336 RHD Near T O for 100 way Connector 15 S400 Near T O for Rear Window Defogger Feed N S S401 Near T O for Rear Window Defogger Feed N S TJ 8W 95 SPLICE LOCATIONS 8Wa 95 3 SPLICE LOCATIONS Continued ...

Page 347: ...Fig 1 HEADLAMP SPLICES 8Wa 95 4 8W 95 SPLICE LOCATIONS TJ SPLICE LOCATIONS Continued ...

Page 348: ...Fig 2 RIGHT HEADLAMP SPLICES TJ 8W 95 SPLICE LOCATIONS 8Wa 95 5 SPLICE LOCATIONS Continued ...

Page 349: ...Fig 3 REAR ENGINE COMPARTMENT LHD 8Wa 95 6 8W 95 SPLICE LOCATIONS TJ SPLICE LOCATIONS Continued ...

Page 350: ...Fig 4 REAR ENGINE COMPARTMENT RHD TJ 8W 95 SPLICE LOCATIONS 8Wa 95 7 SPLICE LOCATIONS Continued ...

Page 351: ...Fig 5 2 5 LITER ENGINE REAR Fig 6 4 0 LITER ENGINE REAR 8Wa 95 8 8W 95 SPLICE LOCATIONS TJ SPLICE LOCATIONS Continued ...

Page 352: ...Fig 7 4 0 LITER ENGINE Fig 8 4 0 LITER ENGINE RIGHT SIDE TJ 8W 95 SPLICE LOCATIONS 8Wa 95 9 SPLICE LOCATIONS Continued ...

Page 353: ...Fig 9 4 0 LITER ENGINE AND TRANSMISSION Fig 10 2 5 LITER ENGINE 8Wa 95 10 8W 95 SPLICE LOCATIONS TJ SPLICE LOCATIONS Continued ...

Page 354: ...Fig 11 2 5 LITER ENGINE AND TRANSMISSION Fig 12 INSTRUMENT PANEL LHD TJ 8W 95 SPLICE LOCATIONS 8Wa 95 11 SPLICE LOCATIONS Continued ...

Page 355: ...Fig 13 INSTRUMENT PANEL RHD 8Wa 95 12 8W 95 SPLICE LOCATIONS TJ SPLICE LOCATIONS Continued ...

Page 356: ...Fig 14 DASH PANEL LHD TJ 8W 95 SPLICE LOCATIONS 8Wa 95 13 SPLICE LOCATIONS Continued ...

Page 357: ...Fig 15 DASH PANEL RHD 8Wa 95 14 8W 95 SPLICE LOCATIONS TJ SPLICE LOCATIONS Continued ...

Page 358: ...Fig 16 BODY WIRING SPLICES TJ 8W 95 SPLICE LOCATIONS 8Wa 95 15 SPLICE LOCATIONS Continued ...

Page 359: ...Fig 17 REAR LAMPS 8Wa 95 16 8W 95 SPLICE LOCATIONS TJ SPLICE LOCATIONS Continued ...

Page 360: ...E DESCRIPTION 2 OPERATION 2 FUEL DELIVERY SPECIFICATIONS TORQUE FUEL DELIVERY DESCRIPTION N m Ft Lbs In Lbs Accelerator Pedal Bracket Mounting Nuts 8 5 75 Fuel Hose Clamps 3 25 Fuel Rail Mounting Bolts or Nuts 11 100 Fuel Tank Mounting Strap Bolts Refer to service manual text Fuel Pump Module Locknut 74 55 Fuel Tank Skidplate Bolts 16 141 TJ FUEL SYSTEM 14s 1 ...

Page 361: ...ent of an accidental vehicle rollover The EVAP canister draws fuel vapors from the fuel tank through these valves The valves are not serviceable If replacement is necessary the fuel tank must be replaced Fig 1 Rollover Valve Location 1 FUEL PUMP MODULE 2 FUEL SUPPLY TUBE 3 RETAINER CLAMP 4 FUEL FILTER FUEL PRESSURE REGULATOR 5 LOCKNUT 6 ROLLOVER VALVE 7 TOP OF FUEL TANK 8 ELECTRICAL CONNECTOR 9 RO...

Page 362: ...ICATIONS TORQUE FUEL INJECTION DESCRIPTION N m Ft Lbs In Lbs Accelerator Pedal Bracket Mounting Nuts 8 5 75 Engine Coolant Temperature Sensor 11 96 IAC Motor To Throttle Body Bolts 7 60 Intake Manifold Air Temp Sensor 28 20 MAP Sensor Mounting Screws 3 25 Oxygen Sensor 30 22 PCM Mounting Screws 4 35 Power Steering Pressure Switch 14 22 124 195 Throttle Body Mounting Bolts 11 100 Throttle Position ...

Page 363: ... 12 N m 9 ft lbs torque Sensor With One Bolt Mounting New replacement sensors will be equipped with a paper spacer glued to bottom of sensor If installing returning a used sensor to vehicle a new paper spacer must be installed to bottom of sensor This spacer will be ground off the first time engine is started If spacer is not used sensor will be broken the first time engine is started 4 New Sensor...

Page 364: ...lectrical solenoids The injector contains a pintle that closes off an orifice at the nozzle end When electric current is supplied to the injector the armature and needle move a short distance against a spring allowing fuel to flow out the orifice Because the fuel is under high pressure a fine spray is developed in the shape of a pencil stream The spraying action atomizes the fuel add ing it to the...

Page 365: ...xygen Sensor Heater Relay If the vehicle is equipped with 4 oxygen sensors a separate oxygen sensor relay is used to supply voltage to the sensor heating elements This particular relay is used only for the 1 2 and 2 2 downstream sensors Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay Refer to 8 Wiring Dia grams to determine which relay is used To avoid the l...

Page 366: ...ill make the downstream sensors output oxygen content correct The upstream oxygen sensors also provide an input to determine mini catalyst efficiency Main catalytic convertor efficiency is not calculated with this pack age Downstream Sensors Engine Equipped With 4 Sensors Two downstream sensors are used 1 2 and 2 2 The downstream sensors are used to deter mine the correct air fuel ratio As the oxy...

Page 367: ......

Page 368: ...Model Year All other Service Manual information is in the 2000 Model Year Service Manual When you are using this information you may be referred to another section of the Service Manual The refer to is written differently than in prior years MANUAL AX5 TABLE OF CONTENTS page page MANUAL AX5 DISASSEMBLY 2 ASSEMBLY 13 SPECIFICATIONS 24 SPECIAL TOOLS 25 BEARING RETAINER REMOVAL 26 INSTALLATION 26 INP...

Page 369: ...le speed sensor and speedometer adapter if necessary 5 Remove shift tower bolts and remove tower from transmission Fig 2 6 Remove shift tower gasket from shift tower or transmission Fig 3 Fig 1 Clutch Housing 1 HOUSING TO TRANSMISSION BOLTS 2 CLUTCH HOUSING 3 TRANSMISSION Fig 2 Shift Tower 1 SHIFT TOWER 2 ADAPTER EXTENSION HOUSING Fig 3 Shift Tower Gasket 1 SHIFT TOWER 2 GASKET 21s 2 MANUAL AX5 TJ...

Page 370: ...Remove shift arm retainer bolt Fig 7 Fig 4 Detent Ball Plug 1 TORX BIT 2 DETENT BALL PLUG Fig 5 Detent Spring 1 PENCIL MAGNET 2 DETENT BALL SPRING Fig 6 Detent Ball 1 PENCIL MAGNET 2 SHIFT DETENT BALL Fig 7 Shift Arm Retainer Bolt 1 RETAINER BOLT 2 SHIFT ARM TJ MANUAL AX5 21s 3 MANUAL AX5 Continued ...

Page 371: ...10 13 Remove shift arm from the adapter housing 14 Remove adapter extension housing bolts 15 Loosen adapter extension housing by tapping it loose with rawhide rubber hammer Fig 11 Fig 8 Shift Arm Restrictor Pins 1 RESTRICTOR PINS Fig 9 Shift Lever Shaft Plug 1 SHIFT LEVER SHAFT PLUG Fig 10 Shifter Shaft 1 SHIFT ARM SHAFT 2 LARGE MAGNET Fig 11 Adapter Extension Housing 1 INTERMEDIATE PLATE 2 ADAPTE...

Page 372: ...nsmission case 19 Remove bearing retainer from transmission case Fig 14 20 Remove input shaft bearing snap ring Fig 15 21 Remove countershaft front bearing snap ring Fig 12 Adapter Extension Housing Typical 1 ADAPTER HOUSING 2 INTERMEDIATE PLATE Fig 13 Speedometer Drive Gear Assembly 1 SNAP RING 2 LOCK BALL 3 SNAP RING 4 OUTPUT SHAFT GROOVES 5 SPEEDOMETER GEAR Fig 14 Front Bearing Retainer 1 FRONT...

Page 373: ...ear assem bly in vise on bolt heads Use enough washers to prevent bolts from touching 2 Remove countershaft fifth gear retaining snap ring Fig 19 Fig 16 Intermediate Plate and Transmission Case 1 INTERMEDIATE PLATE 2 RUBBER HAMMER 3 GEAR CASE Fig 17 Intermediate Plate from Transmission 1 GEAR CASE 2 INTERMEDIATE PLATE Fig 18 Positioning Intermediate Plate In Vise 1 INTERMEDIATE PLATE 2 BOLTS Fig 1...

Page 374: ...untershaft fifth gear assembly from countershaft Fig 23 Fig 20 Shift Fork Retainer Bolt 1 SHIFT FORK RETAINER BOLT 2 FIFTH GEAR SHIFT RAIL 3 FIFTH GEAR SHIFT FORK Fig 21 Fifth Gear Blocker Ring 1 FIFTH GEAR BLOCKER RING Fig 22 Fifth Gear Synchro Ring 1 FIFTH GEAR SYNCHRO RING Fig 23 Fifth Gear and Synchro 1 FIFTH GEAR SYNCHRO SLEEVE ASSEMBLY 2 COUNTER FIFTH GEAR TJ MANUAL AX5 21s 7 MANUAL AX5 Cont...

Page 375: ...e intermediate plate 10 Remove reverse idler gear shaft and reverse idler gear assembly Fig 26 NOTE Retrieve pin and compression spring from the reverse idler shaft 11 Remove output shaft rear bearing retainer bolts and remove retainer Fig 27 Fig 24 Fifth Gear Thrust Ring 1 LOCK BALL NOTCH 2 FIFTH GEAR THRUST RING Fig 25 Fifth Gear Thrust Ring Lock 1 PENCIL MAGNET 2 CLUSTER GEAR 3 LOCK BALL RECESS...

Page 376: ...g from the intermediate plate The countershaft will release from the counter shaft bearing first and can be removed by moving the countershaft rearward and downward Fig 31 17 Remove the mainshaft forward until the mainshaft rear bearing is clear of the intermediate plate and then rotating the mainshaft downward out of the shift forks Fig 32 Fig 28 Shift Fork Bolts 1 1 2 SHIFT FORK 2 3 4 SHIFT FORK...

Page 377: ...emove lock ball and spring from with pencil magnet Fig 35 NOTE The bottom spring is shorter in length than the other two springs Fig 32 Mainshaft 1 SHIFT FORKS 2 MAINSHAFT Fig 33 Shift Rails and Forks 1 3 4 SHIFT FORK 2 3 4 SHIFT RAIL 3 1 2 SHIFT RAIL 4 1 2 SHIFT FORK Fig 34 1 2 Shift Fork 1 1 2 SHIFT FORK 2 3 4 SHIFT RAIL 3 1 2 SHIFT RAIL Fig 35 Lock Ball And Spring 1 THREADED PLUGS 2 LOCK BALL 3...

Page 378: ...gear check ball Fig 37 and interlock pin 25 Remove reverse shift head and rail assembly Fig 38 26 Remove snap ring holding reverse shift rail into intermediate plate 27 Remove reverse shift rail and reverse shift fork and arm assembly from intermediate plate Fig 39 Fig 36 Fifth Gear Shift Rail 1 INTERMEDIATE PLATE 2 FIFTH GEAR SHIFT RAIL Fig 37 Check Ball 1 FIFTH GEAR CHECK BALL Fig 38 Shift Head ...

Page 379: ...n from 1 2 shift rail Fig 42 33 Remove 1 2 shift rail elongated check ball from intermediate plate Fig 43 34 Remove 3 4 shift rail from intermediate plate Fig 40 Reverse Interlock Pin 1 REVERSE SHIFT RAIL 2 INTERLOCK PIN Fig 41 Check Ball 1 REVERSE CHECK BALL Fig 42 1 2 SHIFT RAIL 1 INTERLOCK PIN 2 1 2 SHIFT RAIL Fig 43 1 2 Check Ball 1 1 2 CHECK BALL 2 3 4 SHIFT RAIL 21s 12 MANUAL AX5 TJ MANUAL A...

Page 380: ...installing check balls and interlock pins Check balls and interlock pins must be installed in original location 1 Install 3 4 shift rail into the intermediate plate Fig 44 Shift Rail Components 1 3 4 FORK 2 3 4 SHIFT RAIL 3 1 2 FORK 4 INTERMEDIATE PLATE 5 FIFTH GEAR FORK 6 FIFTH GEAR SHIFT RAIL 7 1 2 SHIFT RAIL 8 REVERSE SHIFT RAIL TJ MANUAL AX5 21s 13 MANUAL AX5 Continued ...

Page 381: ...hift rail 6 Install reverse check ball into the intermediate plate Fig 47 7 Install interlock pin into the reverse shift rail Fig 48 Fig 45 1 2 Check Ball 1 1 2 CHECK BALL 2 3 4 SHIFT RAIL Fig 46 1 2 Shift Rail Interlock Pin 1 INTERLOCK PIN 2 1 2 SHIFT RAIL Fig 47 Reverse Check Ball 1 REVERSE CHECK BALL Fig 48 Reverse Interlock Pin 1 REVERSE SHIFT RAIL 2 INTERLOCK PIN 21s 14 MANUAL AX5 TJ MANUAL A...

Page 382: ... Fig 51 11 Install reverse shift head and rail assembly into the intermediate plate 12 Install fifth gear interlock ball and check ball Fig 52 Fig 49 Reverse Arm Bracket And Fork 1 REVERSE SHIFT FORK 2 REVERSE ARM BRACKET Fig 50 Reverse Shift Rail 1 REVERSE SHIFT RAIL AND FORK Fig 51 Reverse Snap ring 1 SNAP RING 2 REVERSE SHIFT RAIL Fig 52 Check Ball 1 FIFTH GEAR CHECK BALL TJ MANUAL AX5 21s 15 M...

Page 383: ...but not fully driven in at this point 22 While an assistant supports the mainshaft align rear of countershaft with inner race of counter shaft rear bearing 23 Raise countershaft upward until gears mesh with the mating gears on the mainshaft 24 With a rubber mallet tap on the input shaft and the front of the countershaft equally to install mainshaft rear bearing into intermediate plate and the rear...

Page 384: ...ft and reverse shift arm 32 Install compression spring and pin into the reverse idler gear shaft Fig 58 33 Install reverse idler shaft through the inter mediate plate and reverse idler gear assembly Fig 59 until idler shaft pin contacts the gear assembly NOTE The notched cut out in the idler shaft goes toward the rear of the transmission Fig 56 Shift Fork Bolts 1 1 2 SHIFT FORK 2 3 4 SHIFT FORK Fi...

Page 385: ...he way through the reverse idler gear assembly 37 Position reverse idler gear shaft lock plate onto the intermediate plate 38 Install a new bolt to hold the idler gear shaft lock plate to the intermediate plate 39 Install fifth gear thrust ring lock ball to the countershaft Fig 62 40 Install fifth gear thrust ring onto the counter shaft and over the lock ball Fig 63 Fig 60 Align Idler Shaft Pin 1 ...

Page 386: ...ing to hold fifth gear blocker ring onto countershaft 51 Remove intermediate plate from vise and remove bolts and washers from intermediate EXTENSION AND ADAPTER HOUSING 1 Remove any residual sealer from transmission case intermediate plate and adapter extension hous ing 2 Apply a 1 8 to 3 16 inch wide bead of Threeb ondt Liquid Gasket TB1281 Make sure to keep sealer bead to inside of bolt holes F...

Page 387: ...asket TB1281 or equivalent to sealing surface of adapter extension housing Keep sealer bead to inside of bolt holes 9 Install adapter or extension housing on inter mediate plate Fig 70 Tighten housing bolts to 34 N m 25 ft lbs 10 Position shift arm in shifter tower opening of adapter or extension housing Fig 71 Verify shifter arm is engaged into the shift rails Fig 67 Front Bearing 1 FRONT BEARING...

Page 388: ...il the hole in the shift arm is aligned with the hole in the shaft 13 Install shift arm retainer bolt and tighten to 38 N m 28 ft lbs Fig 73 14 Install and tighten shifter arm shaft plug to 18 N m 13 ft lbs Fig 74 Fig 71 Position Shift Arm 1 SHIFT ARM Fig 72 Shifter Arm Shaft 1 SHIFT ARM 2 ADAPTER OR EXTENSION HOUSING Fig 73 Shift Arm Retainer Bolt 1 RETAINER BOLT 2 SHIFT ARM Fig 74 Shifter Arm Sh...

Page 389: ...Install shift detent ball in detent opening of case Fig 76 17 Install detent spring in case Fig 77 18 Install detent plug and tighten to 19 N m 14 ft lbs Fig 78 Fig 75 Shifter Restrictor 1 RESTRICTOR PINS Fig 76 Detent Ball 1 PENCIL MAGNET 2 SHIFT DETENT BALL Fig 77 Detent Spring 1 PENCIL MAGNET 2 DETENT BALL SPRING Fig 78 Detent Ball Plug 1 TORX BIT 2 DETENT BALL PLUG 21s 22 MANUAL AX5 TJ MANUAL ...

Page 390: ...nstall new metal o ring onto the backup lamp switch 24 Install backup lamp switch Fig 80 and tighten to 44 N m 32 5 ft lbs 25 Install new seal in adapter extension housing 26 Install vehicle speed sensor if necessary 27 Install clutch housing release bearing release fork and retainer clip Fig 79 Shift Tower 1 SHIFT TOWER 2 ADAPTER EXTENSION HOUSING Fig 80 Backup Lamp Switch 1 SHIFT TOWER 2 BACKUP ...

Page 391: ...nt 19 14 Screws Propeller Shaft Clamp 16 23 140 200 Bolts Rear Mount to Transmission 33 60 24 44 Nut Rear Mount Clevis 54 75 40 55 Nuts Rear Mount to Crossmember 41 68 30 50 Pins Restrictor 24 7 20 Bolts Reverse Shift Arm Bracket 18 13 Screw Shift Arm Set 38 28 Screws Shift Fork Set 20 15 Nut Shift Knob 20 34 15 25 Screws Shifter Floor Cover 2 3 17 30 Bolts Shift Tower 18 13 Nuts Transfer Case Mou...

Page 392: ...TOOLS TRANSMISSION Dial Indicator C 3339 Installer C 3995 A Handle C 4171 Installer 8211 Installer 8212 Installer 8208 Splitter P 334 Installer 8109 Tube Driver L 4507 TJ MANUAL AX5 21s 25 MANUAL AX5 Continued ...

Page 393: ...nt bearing retainer gasket to the front bearing retainer 4 Install the front bearing retainer onto the transmission case 5 Install the bolts to hold the bearing retainer onto the transmission case 6 Tighten the bolts to 17 N m 12 ft lbs 7 Install release bearing and lever onto the transmission INPUT SHAFT DISASSEMBLY 1 Verify that the 3 4 synchronizer is in the neu tral position 2 Separate input s...

Page 394: ...earing onto input shaft with Driver L 4507 3 Select the thickest snap ring that will fit into the snap ring groove of the input shaft Fig 84 4 Lubricate output shaft pilot bearing bore of input shaft with petroleum jelly Fig 83 Input Shaft Components 1 BEARING 2 SYNCHRO RING 3 INPUT SHAFT 4 BEARING SNAP RING Fig 84 Select Input Shaft Bearing Snap ring I D Mark Snap Ring Thickness mm in 0 2 05 2 10...

Page 395: ...litter P 334 or press plates positioned under first gear press fifth gear rear bearing first gear and first gear bearing inner race off output shaft Fig 88 5 Remove first gear needle roller bearing from output shaft 6 Remove first gear bearing inner race lock ball with pencil magnet Fig 89 7 Remove first gear synchronizer ring 8 With Bearing Splitter P 334 or press plates positioned under second g...

Page 396: ...RING ASSEMBLY Fig 89 First Gear Bearing Inner Race Lock Ball 1 LOCK BALL 2 PENCIL MAGNET Fig 90 Second Gear Reverse Gear And 1 2 Synchronizer 1 PRESS RAM 2 SECOND GEAR 3 1 2 SYNCHRONIZER HUB Fig 91 3 4 Synchronizer Snap Ring 1 3 4 SYNCHRONIZER SNAP RING TJ MANUAL AX5 21s 29 OUTPUT SHAFT Continued ...

Page 397: ...haft 8 Select the thickest snap ring that will fit into the snap ring groove of the output shaft Fig 95 9 Install snap ring to hold 3 4 synchronizer onto output shaft 10 Verify third gear thrust clearance with feeler gauge Fig 96 Clearance should be 0 10 0 25 mm 0 004 0 010 in If clearance is out of specification refer to Cleaning and Inspection 11 Install second gear needle bearing onto output sh...

Page 398: ... 80 0 0689 0 0709 D 1 80 1 85 0 0709 0 0728 D 1 1 85 1 90 0 0728 0 0748 E 1 90 1 95 0 0748 0 0768 E 1 1 95 2 00 0 0768 0 0787 F 2 00 2 05 0 0788 0 0807 F 1 2 05 2 10 0 0807 0 0827 Fig 96 Third Gear 1 FEELER GAUGE 2 THIRD GEAR Fig 97 First Gear Bearing Inner Race Lock Ball 1 FIRST GEAR LOCK BALL TJ MANUAL AX5 21s 31 OUTPUT SHAFT Continued ...

Page 399: ...econd gear thrust clearance Fig 99 Standard clearance is 0 10 0 25 mm 0 004 0 010 in If clearance is out of specification refer to Cleaning and Inspection 25 Position fifth gear onto output shaft with the gear s short shoulder toward the rear of shaft Ensure that the gear and output shaft splines are aligned 26 With Adapter 6747 1A Driver L 4507 and a shop press press fifth gear onto output shaft ...

Page 400: ...1 B 2 73 2 78 0 1075 0 1094 C 2 79 2 84 0 1098 0 1118 D 2 85 2 90 0 1122 0 1142 E 2 91 2 96 0 1146 0 1165 F 2 97 3 02 0 1169 0 1189 G 3 03 3 08 0 1193 0 1213 H 3 09 3 14 0 1217 0 1236 J 3 15 3 20 0 1240 0 1260 K 3 21 3 26 0 1264 0 1283 L 3 27 3 32 0 1287 0 1307 TJ MANUAL AX5 21s 33 OUTPUT SHAFT Continued ...

Page 401: ...smember 10 Disconnect necessary exhaust system compo nents 11 Remove slave cylinder Fig 1 from clutch housing 12 Mark rear propeller shaft and rear axle yokes for installation alignment Fig 2 13 Mark front propeller shaft axle and transfer case yokes for installation alignment if equipped 14 Remove propeller shaft s 15 Unclip wire harnesses from transmission and transfer case if equipped 16 Discon...

Page 402: ... 30 Pull transmission jack rearward until input shaft clears clutch Then slide transmission out from under vehicle 31 Remove clutch release bearing release fork and retainer clip 32 Remove clutch housing from transmission Fig 4 Fig 2 Propeller Shaft And Axle Yokes 1 REFERENCE MARKS Fig 3 Crankshaft 1 ENGINE SPEED SENSOR 2 GROMMET 3 MOUNTING BOLT S 4 LEFT REAR OF ENGINE 5 TRANSMISSION Fig 4 Clutch ...

Page 403: ...the housing just forward of shift tower 7 Remove shift shaft detent plug with Remover 8117A Attach the fingers of the remover to the detent plug Fig 8 Then push the cup down till it contacts the trans Tighten the nut Fig 9 till it pulls the plug from the trans case Fig 5 BACKUP LIGHT SWITCH 1 BACKUP LIGHT SWITCH Fig 6 SHIFT TOWER 1 SHIFT TOWER AND LEVER ASSEMBLY 2 SHIFT SOCKET 3 SEAL Fig 7 SHIFT S...

Page 404: ...e bearing retainer from input shaft Fig 12 11 Remove snap ring that secures input shaft in front bearing Fig 13 Fig 9 PULL DETENT PLUG 1 NUT 2 REMOVER Fig 10 DETENT PLUNGER 1 FRONT HOUSING 2 PLUG 3 SPRING 4 PLUNGER Fig 11 BEARING RETAINER 1 PRY TOOL 2 INPUT SHAFT BEARING RETAINER Fig 12 INPUT SHAFT BEARING RETAINER 1 SHAFT BEARING 2 BEARING RETAINER 3 INPUT SHAFT Fig 13 INPUT SHAFT SNAP RING 1 INP...

Page 405: ...ar housing Fig 15 With a plastic mallet tap the front housing off the alignment dowels 14 Remove and inspect input shaft bearing and countershaft front bearing race Fig 16 Fig 14 HOUSING AND BEARING RETAINER BOLTS 1 RETAINER BOLTS 2 HOUSING BOLTS 3 RETAINER BOLT 4 HOUSING BOLT LOCATIONS Fig 15 FRONT HOUSING 1 FRONT HOUSING 2 REAR HOUSING 3 DOWELS 2 4 PLASTIC MALLET Fig 16 INPUT SHAFT AND COUNTERSH...

Page 406: ...toward the side of the case This positions the roll pin at a slight angle to avoid trapping the pin between the gear teeth c Tighten the tool to press the roll pin down ward and out of the shift socket Fig 19 NOTE Press the roll pin just enough to clear the shift shaft Be careful not to push the pin into the geartrain Fig 17 REVERSE BLOCKER 1 REVERSE BLOCKER 2 SHIFTER SHAFT BUSHING 3 VENT Fig 18 G...

Page 407: ...eve until fork clears shift arms on 1 2 and fifth reverse forks then remove 3 4 fork Fig 24 Fig 20 SHIFT SHAFT LEVER AND BUSHING ROLL PIN 1 PIN PUNCH 2 BUSHING AND LEVER 3 SHIFT SHAFT Fig 21 SHIFT SHAFT 1 SHIFTER SHAFT 2 SHIFTER SHAFT DETENT 3 3 4 SHIFT FORK Fig 22 SHIFT SOCKET AND ROLL PIN 1 SHAFT BORE 2 ROLL PIN 3 SHIFT SOCKET Fig 23 SHIFT SHAFT LEVER AND BUSHING 1 SHAFT LEVER AND BUSHING 2 3 4 ...

Page 408: ...ol onto input shaft counter shaft and idler gear Fig 27 d Stand geartrain and rear housing upright on fixture Fig 28 Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position 11 Remove rear bolt holding reverse idler shaft in housing Fig 25 REVERSE IDLER SHAFT SUPPORT BOLT 1 SUPPORT BOLT 2 SHAFT BOLT Fig 26 IDLER SHAFT SUPPORT 1 IDLER SHAFT 2 IDLER S...

Page 409: ...Fig 30 3 Lift rear housing up and off geartrain Fig 31 4 Remove countershaft rear bearing from coun tershaft Fig 32 5 Examine condition of bearing bore and idler shaft notch in rear housing Replace housing if any of these components are damaged Fig 30 REAR HOUSING 2WD 1 REAR HOUSING 2 PLASTIC RAWHIDE MALLET 3 FIXTURE Fig 31 REAR HOUSING 1 REAR HOUSING 2 SHIFT FORKS AND GEARTRAIN Fig 29 OUTPUT SHAF...

Page 410: ...tput shaft with snap ring pliers Fig 35 Fig 32 COUNTERSHAFT REAR BEARING 1 COUNTERSHAFT REAR BEARING 2 OUTPUT SHAFT 3 COUNTER SHAFT Fig 33 SEAL DIMPLES 4WD 1 LOCATION OF DIMPLES 2 SEAL FACE Fig 34 REAR SEAL 4WD 1 SLIDE HAMMER 2 REMOVER TOOL 3 REAR SEAL Fig 35 REAR BEARING SNAP RING 4WD 1 HEAVY DUTY SNAP RING PLIERS 2 REAR BEARING SNAP RING 3 OUTPUT SHAFT TJ MANUAL NV3550 21s 43 MANUAL NV3550 Conti...

Page 411: ...nput shaft 6 Lift and remove input shaft pilot bearing and fourth gear synchro ring from assembly fixture tool OUTPUT SHAFT NOTE The synchronizer hubs and sleeves are dif ferent and must not be intermixed Remove each synchronizer unit as an assembly to avoid intermix ing parts Reference mark or tag each synchro hub and sleeve for correct assembly 1 Remove snap ring that secures 3 4 synchro hub on ...

Page 412: ...g synchro fric tion cone and synchro cone Fig 42 8 Remove interm ring 9 Remove 1 2 synchro hub snap ring Fig 39 THRUST WASHER 1 PRY TOOL 2 THRUST WASHER RETAINING RING Fig 40 TWO PIECE THRUST WASHER 1 SECOND GEAR 2 THRUST WASHER 2 PIECE 3 WASHER LOCATING LUG Fig 41 SECOND GEAR AND NEEDLE BEARING 1 SECOND GEAR 2 SECOND GEAR NEEDLE BEARING Fig 42 SECOND GEAR SYNCHRO RING AND CONES 1 1 2 SYNCHRO HUB ...

Page 413: ...put shaft bearing 14 Remove fifth gear Fig 46 15 Remove fifth gear needle bearing Spread bearing apart just enough to clear shoulder on output shaft Fig 47 Fig 43 HUB SLEEVE AND 1 2 SYNCHRO 1 1 2 SYNCHRO HUB AND SLEEVE 2 SPECIAL TOOL 1130 Fig 44 FIRST GEAR NEEDLE BEARING 1 FIRST GEAR NEEDLE BEARING Fig 45 OUTPUT SHAFT BEARING SNAP RING 1 OUTPUT SHAFT BEARING 2 BEARING SNAP RING 3 SNAP RING PLIERS ...

Page 414: ...DLE BEARING SPREAD BEARING TO CLEAR SHOULDER ON SHAFT Fig 48 FIFTH REVERSE SYNCHRO HUB SNAP RING 1 FIFTH REVERSE SYNCHRO HUB AND SLEEVE 2 SYNCHRO HUB SNAP RING 3 SNAP RING PLIERS Fig 49 FIFTH REVERSE SYNCHRO HUB AND SLEEVE 1 PRESS 2 FIFTH REVERSE SYNCHRO HUB AND SLEEVE 3 REVERSE GEAR 4 OUTPUT SHAFT Fig 50 REVERSE GEAR AND NEEDLE BEARING 1 REVERSE GEAR AND NEEDLE BEARING TJ MANUAL NV3550 21s 47 MAN...

Page 415: ...ove 2 Install the first spring in the hub Then install a strut over the spring Be sure the spring is seated in the spring bore in the strut 3 Slide the sleeve onto the hub just far enough to hold the first strut and spring in place 4 Place the detent ball in the top of the strut Then carefully work the sleeve over the ball to hold it in place Use a small flat blade screwdriver to press the ball in...

Page 416: ...stall brass synchro ring on reverse gear Fig 55 4 Assemble fifth reverse synchro hub sleeve struts springs and detent balls if not previously done CAUTION One side of the hub has shoulders around the hub bore this side of the hub faces the front of the shaft One side of the sleeve is tapered The tapered side faces the front of the shaft 5 Start fifth reverse synchro assembly on output shaft spline...

Page 417: ...ring spreading bearing only enough to clear shoulder on output shaft Fig 59 Verify bearing is properly seated 9 Install fifth gear on shaft and onto bearing Fig 60 Fig 57 FIFTH REVERSE SYNCHRO HUB SNAP RING 1 FIFTH REVERSE SYNCHRO ASSEMBLY 2 SNAP RING 3 PRESS BED 4 PRESS BLOCKS Fig 58 FIFTH GEAR SYNCHRO RING 1 FIFTH SPEED SYNCHRO RING 2 FIFTH REVERSE SYNCHRO ASSEMBLY Fig 59 FIFTH GEAR BEARING 1 SH...

Page 418: ... the synchro sleeve is marked First Gear Side Verify this side of the sleeve is facing first gear 15 Start 1 2 synchro assembly on shaft by hand Fig 64 Verify synchro sleeve is properly positioned 16 Press 1 2 synchro onto output shaft using suitable size pipe tool and shop press Fig 65 CAUTION Align the synchro ring and sleeve as hub the is being pressed onto the shaft The synchro ring can crack ...

Page 419: ... synchro ring is properly seated 20 Install synchro friction cone and synchro cone in synchro ring Fig 64 STARTING 1 2 SYNCHRO 1 1 2 SYNCHRO ASSEMBLY 2 CUP 3 FIRST GEAR SIDE OF SYNCHRO SLEEVE Fig 65 PRESS 1 2 SYNCHRO 1 SUITABLE SIZE PIPE TOOL 2 SYNCHRO RING 3 SPECIAL TOOL 6310 1 4 1 2 SYNCHRO ASSEMBLY 5 PRESS RAM Fig 66 1 2 SYNCHRO HUB SNAP RING 1 1 2 SYNCHRO 2 SPECIAL TOOL 3 SYNCHRO SNAP RING Fig...

Page 420: ...groove and that washer lugs are seated in shaft lug bores Verify i d grooves and markings noted during removal are facing the correct direction Fig 68 SECOND GEAR BEARING 1 SECOND GEAR BEARING 2 SPECIAL TOOL 6310 1 Fig 69 SECOND GEAR 1 CUP 2 1 2 SYNCHRO ASSEMBLY 3 BEARING 4 SECOND GEAR Fig 70 TWO PIECE THRUST WASH 1 WASHER GROOVE IN SHAFT 2 LUG BORE 3 THRUST WASHER LUGS 4 LUG BORE 5 LUG 6 WASHER H...

Page 421: ...d gear needle bearing on shaft Fig 73 27 Install third gear on shaft and bearing Fig 74 Fig 71 RETAINING RING 1 THRUST WASHER RETAINING RING 2 THRUST WASHER HALVES 3 SECOND GEAR 4 LOCATING DIMPLE Fig 72 THRUST RETAINER 1 PLASTIC MALLET 2 THRUST WASHER RETAINING RING Fig 73 THIRD GEAR BEARING 1 THIRD GEAR BEARING Fig 74 THIRD GEAR 1 THIRD GEAR 2 BEARING 21s 54 MANUAL NV3550 TJ MANUAL NV3550 Continu...

Page 422: ...o output shaft as possible without contacting the shaft splines 32 Install 3 4 synchro hub snap ring Fig 78 and verify snap ring is seated NOTE Snap rings are available in thicknesses from 2 00 mm to 2 30 mm 0 078 to 0 090 in Install thickest snap ring that will fit in shaft groove Fig 75 THIRD SPEED SYNCHRO RING 1 THIRD SPEED SYNCHRO RING 2 THIRD GEAR Fig 76 3 4 SYNCHRO HUB ON OUTPUT SHAFT 1 GROO...

Page 423: ...ve should be facing forward First gear side of 1 2 sleeve should be facing first gear Tapered side of fifth reverse sleeve should be facing forward Fig 80 SYNCHRO SLEEVE LOCATIONS 1 DOUBLE GROOVE FORWARD 2 GROOVE FORWARD 3 FIRST GEAR SIDE MARKING TOWARD FIRST GEAR 4 TAPER FORWARD 5 GROOVE FORWARD 6 5TH REV SYNCHRO SLEEVE 7 1 2 SYNCHRO SLEEVE 8 3 4 SYNCHRO SLEEVE Fig 79 OUTPUT SHAFT BEARING 1 BEARI...

Page 424: ...pect shift shaft bushing and bearing for damage and replace if necessary 1 Locate a bolt that will thread into the bushing without great effort 2 Thread the bolt into the bushing allowing the bolt to make its own threads in the bushing 3 Attach a slide hammer or suitable puller to the bolt and remove bushing 4 Use the short end of Installer 8119 to install the new bushing 5 The bushing is correctl...

Page 425: ...t plunger bushing on the long end of Installer 8118 4 Start the bushing in the detent plunger bore in the case 5 Drive the bushing into the bore until the tool contacts the transmission case 6 Install a new detent plunger bushing on the short end of Installer 8118 7 Start the bushing in the detent plunger bore in the case 8 Drive the bushing into the bore until the tool contacts the transmission c...

Page 426: ... one side that goes towards the countershaft 8 Slide countershaft and adapter into fixture slot Verify countershaft and output shaft gears are fully meshed with the mainshaft gears Fig 89 9 Check alignment of countershaft and output shaft gear teeth Note that gears may not align per fectly A difference in height of 1 57 to 3 18 mm 1 16 to 1 8 in will probably exist This difference will not interfe...

Page 427: ...er Then position retainer on fifth gear as shown Fig 91 12 Assemble 1 2 and fifth reverse shift forks Fig 92 Arm of fifth reverse fork goes through slot in 1 2 fork 13 Install assembled shift forks in synchro sleeves Fig 93 Verify forks are properly seated in sleeves Fig 89 COUNTERSHAFT ON FIXTURE 1 OUTPUT SHAFT AND GEARTRAIN 2 COUNTERSHAFT SLIDE INTO PLACE ON FIXTURE TOOL Fig 90 REVERSE IDLER ASS...

Page 428: ...ring in bearing race Fig 95 Fig 92 1 2 AND FIFTH REVERSE 1 INSERT ARM THROUGH 1 2 FORK 2 1 2 FORK 3 FIFTH REVERSE FORK Fig 93 SHIFT FORKS IN SYNCHRO 1 SYNCHRO SLEEVES 2 FORK ARMS 3 SHIFT FORKS Fig 94 REAR HOUSING DOWELS 1 HOUSING ALIGNMENT DOWELS 2 REAR HOUSING 3 DOWEL FLUSH WITH SURFACE Fig 95 COUNTERSHAFT REAR BEARING 1 COUNTERSHAFT REAR BEARING 2 REAR BEARING RACE 3 REAR HOUSING 4 PETROLEUM JEL...

Page 429: ...Also be sure countershaft and output shaft bearings are aligned in housing and on counter shaft It may be necessary to lift upward on counter shaft slightly to ensure that the countershaft rear bearing engages to the countershaft before the rear output shaft bearing engages the housing 8 Seat rear housing on output shaft rear bearing and countershaft Use plastic or rawhide mallet to tap housing in...

Page 430: ...d bearing race 5 Install countershaft rear bearing in bearing race Fig 96 CAUTION Be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing Fig 96 6 Apply extra petroleum jelly to hold counter shaft rear bearing in place when housing is installed 7 Apply light coat of petroleum jelly to shift shaft bushing bearing in adapte...

Page 431: ...own 3 Slide the end of shift shaft with shaft detent notches through 3 4 shift fork 4 Assemble shift shaft shift lever and bushing Fig 104 Be sure slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft 5 Install assembled lever and bushing on shift shaft Fig 105 6 Slide shift shaft through 1 2 and fifth reverse fork and into shift lever opening in rear housing Fig 1...

Page 432: ... Shift socket roll pin is approxi mately 33 mm 1 1 4 in long 10 Align roll pin holes in shift shaft lever and bushing Then start roll pin into shaft lever by hand Fig 109 Fig 105 LEVER AND BUSHING ASSENBLY 1 SHIFT SHAFT 2 SHAFT LEVER AND BUSHING 3 3 4 FORK Fig 106 SHAFT IN LEVER OPENING 1 SHIFT SHAFT Fig 107 SHIFT SOCKET 1 SHIFT SOCKET 2 SHIFT SHAFT Fig 108 ROLL PIN IDENTIFICATION 1 SHAFT LEVER RO...

Page 433: ...ng and use plastic mallet to seat bearing Bearing goes in from front side of housing only 3 Apply liberal quantity of petroleum jelly to countershaft front bearing Then insert bearing in front housing race Fig 113 Large diameter side of bearing cage goes toward countershaft Fig 114 Small diameter side goes toward bearing race in housing 4 Reach into countershaft front bearing with fin ger and push...

Page 434: ... in horizontal position 11 Apply Mopar Gasket Maker or equivalent to housing attaching bolts Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads Fig 116 12 Install and start housing attaching bolts by hand Fig 116 Then tighten bolts to 34 N m 25 ft lbs 13 Install shift shaft bushing lock bolt Fig 117 Apply Mopar Gasket Maker or equivalent to bolt threads shank an...

Page 435: ...detent plug into transmission case until plug seats 17 Install backup light switch Fig 119 18 Install input shaft snap ring Fig 120 Fig 116 HOUSING BOLTS 1 HOUSING ATTACHING BOLTS APPLY SEALER BEFOREHAND Fig 117 SHIFT SHAFT BUSHING LOCK BOLT 1 SHIFT SHAFT LOCK BOLT 2 SHAFT SOCKET Fig 118 SHIFT SHAFT DETENT PLUNGER 1 FRONT HOUSING 2 PLUG 3 SPRING 4 PLUNGER Fig 119 BACKUP LIGHT SWITCH 1 BACKUP LIGHT...

Page 436: ...e aligned before seating retainer NOTE Ensure no sealer gets into the oil feed hole in the transmission case or bearing retainer 22 Install and tighten bearing retainer bolts to 7 10 N m 5 7 ft lbs Fig 124 Fig 121 OIL SEAL IN FRONT BEARING RETAINER 1 INSTALLER 2 FRONT BEARING RETAINER Fig 122 SEAL BEARING RETAINER AND HOUSING 1 APPLY SEALER BEAD 2 INPUT SHAFT BEARING RETAINER Fig 123 INPUT SHAFT B...

Page 437: ...Tighten 7 16 diameter bolts to 58 N m 43 ft lbs Tighten M12 bolts to 75 N m 55 ft lbs 8 Be sure transmission is in first or third gear 9 Install rear crossmember and tighten cross member to frame bolts to 41 N m 31 ft lbs 10 Install fasteners to hold rear cushion and bracket to transmission Then tighten transmission to rear support bolts nuts to 54 N m 40 ft lbs 11 Remove support stands from engin...

Page 438: ...wo M6X1 0 bolts and thread the bolts into the threaded holes at the base of the shift lever 32 Tighten the nuts equally until the shift lever will slide over the shift tower stub shaft 33 Install the floor console and shift boot SPECIFICATIONS TRANSMISSION NV3550 TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Clutch Housing Bolts 54 61 40 45 Crossmember To Frame Bolts 61 75 44 55 Crossmember ...

Page 439: ...V3550 MANUAL TRANSMISSION Remover C 3985 B Installer C 3972 A Remover Bushing 6957 Installer Bushing 6951 Handle C 4171 Remover 8117 Remover Installer 6858 Fixture 6747 21s 72 MANUAL NV3550 TJ MANUAL NV3550 Continued ...

Page 440: ...ter 6747 2B Cup 8115 Splitter Bearing 1130 Tube 6310 1 Installer 8118 Remover Installer 8119 Pin Alignment 8120 Installer C 3860 A Installer 8123 Installer Bearing Cone 6448 TJ MANUAL NV3550 21s 73 MANUAL NV3550 Continued ...

Page 441: ...conditions the PCM adjusts the Idle Air Control IAC motor to maintain a desired MAP value Under idle conditions the PCM adjusts the IAC motor to maintain a desired engine speed REMOVAL The Vehicle Speed Sensor VSS is located on the speedometer pinion gear adapter If equipped with 4WD this adapter is located on the transfer case extension left side Fig 128 If equipped with 2WD this adapter is locat...

Page 442: ...sing REMOVAL 1 Raise and support vehicle 2 Mark reference lines on the propeller shaft and remove the shaft 3 Remove housing yoke seal 4 Insert Remover 6957 into rear housing and tighten tool to bushing and remove bushing Fig 131 INSTALLATION 1 Place seal in position on transmission housing 2 Drive new seal into transmission housing with Installer C 3972 A and Handle C 4171 Fig 132 3 Carefully gui...

Page 443: ...951 and Handle C 4171 3 Install new oil seal in housing using Installer C 3972 A Fig 133 4 Install propeller shaft with reference marks aligned 5 Remove support and lower vehicle 6 Check transmission fluid level Fig 133 Rear Housing Seal 1 HANDLE 2 INSTALLER 21s 76 MANUAL NV3550 TJ EXTENSION HOUSING Continued ...

Page 444: ... B or similar type stand Fig 1 7 Remove extension housing 8 Remove fluid pan 9 Remove park neutral position switch and seal Fig 2 10 Remove valve body 11 Remove accumulator spring and piston Fig 3 12 Measure input shaft end play Fig 4 a Attach Adapter 8266 7 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission and ti...

Page 445: ... bolts of Slide Hammer Tools C 3752 into threaded holes in pump body flange Fig 6 16 Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case Fig 6 17 Loosen front band adjusting screw until band is completely loose Fig 5 18 Squeeze front band together and remove band strut Fig 7 Fig 4 Checking Input Shaft End Play 1 TOOL 8266 8 2 TOOL 8266 7 3 TOOL C 3339 Fig...

Page 446: ...clutch hub Fig 10 22 Remove output shaft thrust plate and washer from output shaft hub Fig 10 Fig 8 Front Rear Clutch Assemblies 1 FRONT BAND 2 FRONT CLUTCH AND DRUM 3 TRANSMISSION HOUSING 4 REAR CLUTCH Fig 9 Separating Front Clutch From Rear Clutch 1 FRONT CLUTCH 2 REAR CLUTCH Fig 10 Output Shaft Thrust Plate and Washer 1 OUTPUT SHAFT 2 THRUST PLATE 3 THRUST WASHER Fig 7 Front Band Strut 1 BAND L...

Page 447: ...ub however do not remove drum Fig 14 29 Remove bolts attaching rear support to trans mission case and pull support from low reverse drum Fig 15 30 Remove bolts attaching overrunning clutch cam and low reverse drum to transmission case Fig 16 Fig 11 Front Band 1 FRONT BAND 2 TRANSMISSION HOUSING Fig 12 Planetary Geartrain 1 SLOTS 2 LOW REVERSE DRUM 3 PLANETARY GEARTRAIN 4 TRANSMISSION HOUSING 5 LUG...

Page 448: ...pull rear band lever pivot from transmission case Fig 22 e Separate rear band servo lever from trans mission 35 Compress front servo rod guide about 1 8 in with large C clamp and Tool C 4470 or Spring Com pressor Tool C 3422 B Fig 23 36 Remove front servo rod guide snap ring Fig 23 Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised Fig 15 Rear S...

Page 449: ...en remove compressor tools and remove rear servo spring and piston Fig 20 Front Band Reaction Pin 1 PENCIL MAGNET 2 FRONT BAND REACTION PIN Fig 21 Front Band Lever 1 FRONT BAND LEVER Fig 22 Rear Band Servo Lever Pin 1 PARALLEL JAW SNAP RING PLIERS 2 REAR BAND LEVER PIVOT PIN Fig 23 Compressing Front Servo 1 SPRING COMPRESSOR TOOL C 3422 B 2 ROD GUIDE SNAP RING Fig 24 Compressing Rear Servo Spring ...

Page 450: ...n prior years OPERATION The application of each driving or holding compo nent is controlled by the valve body based upon the manual lever position throttle pressure and governor pressure The governor pressure is a variable pres sure input to the valve body and is one of the signals that a shift is necessary First through third gear are obtained by selectively applying and releasing the different c...

Page 451: ...ont clutch hub and rear clutch retainer stops at the rear clutch retainer Therefore no power flow to the output shaft occurs because no clutches are applied The only mechanism in use at this time is the park ing sprag Fig 1 which locks the parking gear on the output shaft to the transmission case NEUTRAL POWERFLOW With the gear selector in the neutral position Fig 2 the power flow of the transmiss...

Page 452: ... pin ions is transferred to the rear annulus gear which is splined to the output shaft The output shaft in turn rotates with the annulus gear in a counterclockwise direction giving a reverse gear output The entire transmission of torque is applied to the rear plane tary gearset only Although there is torque input to the front gearset through the sun gear no other member of the gearset is being hel...

Page 453: ...rotate back in a clockwise direction With the rear annulus gear stationary the rear planet rotation on the annulus gear causes the rear planet carrier to revolve in a counterclockwise direc tion The rear planet carrier is splined into the low reverse drum and the low reverse drum is splined to the inner race of the over running clutch With the over running clutch locked the planet carrier is held ...

Page 454: ...gear sta tionary the annulus rotation causes the front planets to rotate in a clockwise direction The front carrier is then also made to rotate in a clockwise direction but at a reduced speed This will transmit the torque to the output shaft which is directly connected to the front planet carrier The rear planetary annulus gear will also be turning because it is directly splined to the output shaf...

Page 455: ...iven direct drive results Therefore when two members are rotating at the same speed and in the same direction it is the same as being locked up The rear planetary set is also locked up given the sun gear is still the input and the rear annulus gear must turn with the output shaft Both gears are turning in the same direction and at the same speed The front and rear planet pinions do not turn at all...

Page 456: ...haft turns but wheels do not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and check for debris If pan is clear remove transmis sion and check for damaged drive plate converter oil pump or input shaft c If propeller shaft does not turn and transmis sion is not noisy perform hydraulic pressure test to determine i...

Page 457: ...tighten band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out with pump and possibly damaging clutch or pump components 14 Remove oil pump bolts 15 Thread bolts of Slide Hammer Tools C 3752 into threaded holes in pump body flange Fig 13 16 Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case...

Page 458: ...20 Remove front band lever Fig 16 Fig 13 Oil Pump Reaction Shaft Support 1 OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 2 SLIDE HAMMER TOOLS C 3752 Fig 14 Front Band Strut 1 BAND LEVER 2 BAND STRUT 3 FRONT BAND Fig 15 Front Band Reaction Pin 1 PENCIL MAGNET 2 FRONT BAND REACTION PIN Fig 16 Front Band Lever 1 FRONT BAND LEVER TJ AUTOMATIC 32RH 21s 91 AUTOMATIC 32RH Continued ...

Page 459: ...t hub Fig 19 26 Slide front band off driving shell Fig 20 and remove band from case 27 Remove governor body and park gear from output shaft 28 Remove output shaft and planetary geartrain as assembly Fig 21 Support geartrain with both hands during removal Do not allow machined sur faces on output shaft to become nicked or scratched Fig 17 Front Rear Clutch Assemblies 1 FRONT BAND 2 FRONT CLUTCH AND...

Page 460: ...enter punch to mark case and support 34 Remove rear support bolts and remove sup port from low reverse drum and case Fig 26 Keep rear support bolts together for assembly reference 35 Remove bolts attaching overrunning clutch cam to case Fig 27 Fig 20 Front Band 1 FRONT BAND 2 TRANSMISSION HOUSING Fig 21 Planetary Geartrain 1 SLOTS 2 LOW REVERSE DRUM 3 PLANETARY GEARTRAIN 4 TRANSMISSION HOUSING 5 L...

Page 461: ...EACTION PINS Fig 25 Marking Rear Support To Aid Assembly 1 REAR SUPPORT 2 ASSEMBLY REFERENCE MARKS Fig 26 Rear Support 1 OIL PAN FACE 2 TRANSMISSION HOUSING 3 REAR SUPPORT Fig 27 Overrunning Clutch Cam Bolt Locations 1 OVERRUNNING CLUTCH CAM BOLTS 21s 94 AUTOMATIC 32RH TJ AUTOMATIC 32RH Continued ...

Page 462: ...LUTCH 1 Examine bolt holes in overrunning clutch cam Note that one hole is not threaded Fig 29 This hole must align with blank area in clutch cam bolt circle Fig 30 2 Mark location of non threaded hole in clutch cam and blank area of case with paint stripe Fig 31 3 Align and install overrunning clutch cam in case Fig 31 Be sure cam is correctly installed Bolt holes in cam are slightly countersunk ...

Page 463: ... clutch rollers 5 Rotate drum in clockwise direction and push drum inward until race is seated in overrunning clutch 6 Install rear band lever Fig 35 Be sure lever pivot pin is fully seated in case afterward Fig 30 Location Of Blank Area In Clutch Cam Seat Of Case 1 CLUTCH CAM SEAT IN CASE 2 NON THREADED HOLE IN CLUTCH CAM ALIGNS HERE BLANK AREA OF SEAT Fig 31 Overrunning Clutch Cam Alignment 1 TR...

Page 464: ... drum to hub of rear support Fig 37 Fig 34 Rear Band And Low Reverse Drum 1 REAR BAND 2 LOW REVERSE DRUM Fig 35 Rear Band Lever And Pivot Pin 1 REAR BAND LEVER 2 O RINGS 3 BAND LEVER PIVOT PIN 4 SPRING 5 SPRING RETAINER 6 SERVO SNAP RING Fig 36 Rear Support 1 OIL PAN FACE 2 TRANSMISSION HOUSING 3 REAR SUPPORT Fig 37 Low Reverse Drum Snap Ring 1 REAR BAND 2 REAR SUPPORT HUB 3 LOW REVERSE DRUM SNAP ...

Page 465: ... into place in rear support Fig 41 f Verify that governor valve shaft holes in out put shaft and governor body are still in alignment Reposition governor body and park gear if align ment is not correct g Tighten bolts attaching governor body to park gear to 11 N m 95 in lbs torque 5 Install first E clip on governor valve shaft Then install governor valve and shaft in governor body Fig 42 Be sure v...

Page 466: ...ear 1 GOVERNOR PARK ASSEMBLY 2 GOVERNOR VALVE SHAFT BORE 3 REAR SUPPORT 4 OUTPUT SHAFT SPLINES 5 SEAL RINGS Fig 42 Governor Valve And Shaft 1 E CLIP 2 REQ D 2 GOVERNOR VALVE SHAFT 3 GOVERNOR VALVE 4 GOVERNOR BODY Fig 43 Securing Governor Valve Shaft With New E Clip 1 SECOND E CLIP 2 GOVERNOR VALVE SHAFT TJ AUTOMATIC 32RH 21s 99 AUTOMATIC 32RH Continued ...

Page 467: ...ar clutch 5 Coat output shaft thrust washer with petro leum jelly Then install washer in rear clutch hub Fig 47 Use enough petroleum jelly to hold washer in place Be sure grooved side of washer faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub 6 Align drive teeth on rear clutch discs with small screwdriver Fig 48 This will make installa tion on front...

Page 468: ... 50 3 Install front band lever strut lever pin and adjusting screw Fig 51 4 Tighten front band adjusting screw until band just grips clutch retainer Verify that front rear clutches are still seated before continuing 5 Coat band lever pin access plug with sealer and install plug in converter housing Fig 52 6 Verify that reaction shaft support hub seal rings are hooked together Fig 53 7 Coat front c...

Page 469: ...T BAND Fig 52 Installing Front Band Pivot Pin Access Plug 1 1 4 DRIVE EXTENSION 2 FRONT BAND REACTION PIN ACCESS PLUG Fig 53 Reaction Shaft Support Seal Rings 1 REACTION SHAFT SUPPORT HUB 2 THRUST WASHER 3 SEAL RINGS Fig 54 Reaction Shaft Thrust Washer Installation 1 THRUST WASHER 2 CHAMFERED SIDE OF WASHER BORE GOES TOWARD PUMP 21s 102 AUTOMATIC 32RH TJ AUTOMATIC 32RH Continued ...

Page 470: ... play is incorrect transmission is incorrectly assembled or output shaft thrust washer and or thrust plate are worn and need to be changed a Attach Adapter 8266 7 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266 7 to secure it to the input shaft d Position the dial ...

Page 471: ...park neutral position switch in case Tighten switch to 34 N m 25 ft lbs torque 8 Align valve body on case Fig 59 9 Install and tighten valve body to case bolts alternately and evenly to 12 N m 105 in lbs torque Start at center and work outward when tight ening bolts Do not overtighten valve body bolts This could result in distortion and cross leak age after installation 10 Connect converter clutch...

Page 472: ...g transmission on jack and before moving transmission back under vehicle Use metal strapping C clamp or locking pliers to hold converter in place Attach hold ing tool to converter housing SPECIFICATIONS 32RH AUTOMATIC TRANSMISSION SPECIFICATIONS COMPONENT METRIC INCH Oil pump gear tip clearance 0 089 0 190 mm 0 0035 0 0075 in Planetary end play 0 127 1 22 mm 0 005 0 048 in Input shaft end play 0 5...

Page 473: ...ront of output shaft 1 0 1 1 mm 0 040 0 044 in 1 6 1 7 mm 0 062 0 066 in 2 1 2 2 mm 0 082 0 086 in PRESSURE TEST ITEM RANGE PRESSURE Line pressure at accumulator Closed throttle 372 414 kPa 54 60 psi Front servo Third gear only No more than 21 kPa 3 psi lower than line pressure Rear servo 1 range No more than 21 kPa 3 psi lower than line pressure R range 1103 kPa 160 psi at idle builds to 1862 kPa...

Page 474: ...ed or collapsed BANDS ADJUSTMENT FRONT BAND The front kickdown band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers 1 Raise vehicle 2 Loosen band adjusting screw locknut Fig 62 Then back locknut off 3 5 turns Be sure adjusting screw turns freely in case Apply lubricant to screw threads if necessary 3 Tighten band adjusting screw...

Page 475: ...uids can result in transmission failure The usual results are erratic shifts slippage abnormal wear and eventual failure due to fluid breakdown and sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped clean before checking fluid level Dirt grease and other foreign material on the cap and tube could fall into the tube if not removed b...

Page 476: ...emperature up to normal hot operating temperature of 82 C 180 F 2 Position vehicle on level surface 3 Start and run engine at curb idle speed 4 Apply parking brakes 5 Shift transmission momentarily into all gear ranges Then shift transmission back to NEUTRAL 6 Clean top of filler tube and dipstick to keep dirt from entering tube 7 Remove dipstick Fig 64 and check fluid level as follows a Correct a...

Page 477: ... Fig 66 11 Separate filter from valve body and pour fluid in filter into drain pan 12 Dispose used trans fluid and filter properly 13 Inspect bottom of pan and magnet for exces sive amounts of metal or fiber contamination A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompa nied by slipping condition or shift lag If fluid and pan are contam...

Page 478: ...rce acting on the residual fluid trapped in the clutch piston retainer DISASSEMBLY 1 Remove waved snap ring and remove pressure plate clutch plates and clutch discs Fig 67 2 Compress clutch piston spring with Compressor Tool C 3575 A Fig 68 Be sure legs of tool are seated squarely on spring retainer before compress ing spring 3 Remove retainer snap ring and remove com pressor tool 4 Remove spring ...

Page 479: ...utch Components Typical 1 SNAP RING WAVE 7 SEAL 2 REACTION PLATE 8 PISTON 3 CLUTCH DISC 9 SPRING 4 CLUTCH PLATE 10 SNAP RING 5 SEAL 11 SPRING RETAINER 6 CLUTCH RETAINER 21s 112 AUTOMATIC 32RH TJ FRONT CLUTCH Continued ...

Page 480: ...ve old cable from vehicle INSTALLATION 1 Route cable through hole in dash panel Fully seat cable grommet into dash panel 2 Place the auto transmission manual shift con trol lever in PARK detent rearmost position and rotate prop shaft to ensure transmission is in PARK 3 Connect shift cable to shifter mechanism by snapping cable retaining ears into shifter bracket and press cable end fitting onto le...

Page 481: ...ropeller shaft Shaft will not rotate when park lock is engaged 8 Slide cable eyelt onto transmission shift lever 9 Snap shift cable adjuster into mounting bracket on transmission 10 Lock shift cable by pressing cable adjuster clamp down until it snaps into place 11 Lower vehicle and check engine starting Engine should start only in PARK and NEUTRAL GOVERNOR AND PARK GEAR DISASSEMBLY 1 Remove gover...

Page 482: ...or weights and bores for scoring or wear Replace the governor body and weights if damaged 3 Insert spring into intermediate weight 4 Insert inner weight into intermediate weight and install snap ring Fig 75 Verify snap ring is fully seated in groove in intermediate weight Fig 74 5 Assemble governor weights into governor body Fig 73 6 Install washer and snap ring to hold weights in governor body 7 ...

Page 483: ...e park neutral position switch and connects the outer two terminals of the switch to provide continuity for the back up lamp cir cuit REAR SERVO DISASSEMBLY 1 Remove small snap ring and remove plug and spring from servo piston Fig 77 2 Remove and discard servo piston seal ring ASSEMBLY 1 Lubricate piston and guide seals Fig 78 with petroleum jelly Lubricate other servo parts with Mopart ATF 4 type...

Page 484: ...ully forward position 4 Slide cable off attachment stud on throttle body lever 5 Compare position of cable end to attachment stud on throttle body lever Cable end and attachment stud should be aligned or centered on one another to within 1 mm 0 039 in in either direction Fig 81 If cable end and attachment stud are misaligned off center cable will have to be adjusted as described in Throttle Valve ...

Page 485: ...orth until the centerlines of the T V cable end B and the throttle bell crank lever C are aligned within one millimeter 1mm Fig 81 7 While holding the T V cable in the set position push the T V cable lock A into the down position Fig 81 This will lock the present T V cable adjust ment NOTE Be sure that as the cable is pulled forward and centered on the throttle lever stud the cable housing moves s...

Page 486: ...tput shaft boot from slinger or out put shaft damper and output shaft 4 If the vehicle is not equipped with an output shaft damper remove the output shaft rear slinger using Puller MD 998056 A Fig 1 5 If the vehicle is equipped with an output shaft damper use Screws 8421 and the puller yoke and forcing screw from a bolt grip puller set such as those used to remove steering wheels and harmonic bala...

Page 487: ...he oil pump from under the edge of the rear case half and sliding the pump Fig 5 13 Remove pick up tube o ring from oil pump Fig 6 if necessary Do not disassemble the oil pump it is not serviceable Fig 3 Output Shaft Rear Bearing Retaining Ring 1 SNAP RING PLIERS 2 REAR BEARING I D RETAINING RING Fig 4 Rear Retainer Removal 1 MAINSHAFT 2 REAR RETAINER Fig 5 Oil Pump Removal 1 OIL PUMP Fig 6 Pick u...

Page 488: ...move sector to neutral position and remove range lever from shaft Fig 9 FRONT OUTPUT SHAFT AND DRIVE CHAIN 1 Support transfer case so rear case is facing upward 2 Remove bolts holding front case to rear case The case alignment bolts require flat washers Fig 10 3 Loosen rear case with flat blade screwdriver to break sealer bead Insert pry tool blade only into notches provided at each end of case Fi...

Page 489: ...ut shaft and chain Fig 11 Loosening Rear Case 1 REAR CASE 2 PRY TOOL IN CASE SLOT 3 FRONT CASE Fig 12 Oil Pickup Tube Removal 1 CONNECTING HOSE 2 PICKUP SCREEN 3 PICKUP TUBE Fig 13 Mode Fork Spring Removal 1 MODE SPRING Fig 14 Remove Front Output Shaft And Chain 1 DRIVE CHAIN 2 FRONT OUTPUT SHAFT 3 SHAFT FRONT BEARING 21s 122 TRANSFER CASE NV231 TJ TRANSFER CASE NV231 Continued ...

Page 490: ...e range fork and hub as an assembly Fig 17 Note fork position for installation reference 5 Remove shift sector from front case Fig 18 6 Remove shift sector bushing and O ring Fig 19 Fig 15 Detent Plug Spring And Plunger Removal 1 POPPET 2 SPRING 3 SCREW 4 POPPET BORE IN CASE Fig 16 Mode Fork And Sleeve Removal 1 MODE SLEEVE 2 MODE FORK AND RAIL Fig 17 Range Fork And Hub Removal 1 RANGE HUB 2 RANGE...

Page 491: ...2 Fig 19 Sector Bushing And O Ring Removal 1 SEAL RETAINER 2 SECTOR SHAFT BORE 3 O RING SEAL Fig 20 Mode Hub Retaining Ring Removal 1 MODE HUB 2 SNAP RING PLIERS HEAVY DUTY 3 MODE HUB RETAINING RING Fig 21 Mode Hub Removal 1 MAINSHAFT 2 MODE HUB Fig 22 Drive Sprocket Removal 1 DRIVE SPROCKET 2 MAINSHAFT 21s 124 TRANSFER CASE NV231 TJ TRANSFER CASE NV231 Continued ...

Page 492: ...horizontal position Then remove input gear and low range gear as an assem bly Fig 26 Tap gear out of bearing with plastic mallet if necessary Fig 23 Front Bearing Retainer Bolts 1 FRONT CASE 2 FRONT BEARING RETAINER 3 RETAINER BOLTS Fig 24 Front Bearing Retainer Removal 1 FRONT BEARING RETAINER 2 RETAINER SLOT Fig 25 Removing Input Gear Retaining Ring 1 INPUT GEAR BEARING RETAINING RING 2 INPUT GE...

Page 493: ...ust washer from low range gear Fig 31 Fig 27 Input Gear Snap Ring Removal 1 CARRIER LOCK RETAINING RING 2 INPUT GEAR 3 PLANETARY CARRIER 4 SCREWDRIVER Fig 28 Input Gear Retainer Removal 1 INPUT GEAR 2 LOW RANGE GEAR 3 RETAINER Fig 29 Front Tabbed Thrust Washer Removal 1 FRONT TABBED THRUST WASHER Fig 30 Input Gear Removal 1 INPUT GEAR 2 LOW RANGE GEAR 21s 126 TRANSFER CASE NV231 TJ TRANSFER CASE N...

Page 494: ...ing ring with screwdriver Fig 33 3 Remove bearing with Tool Handle C 4171 and Tool 5065 Fig 34 4 Install front output shaft front bearing in case with Tool Handle C 4171 and Installer 5064 Fig 35 Fig 31 Rear Tabbed Thrust Washer Removal 1 LOW RANGE GEAR 2 REAR TABBED THRUST WASHER Fig 32 Front Output Seal Removal 1 OUTPUT SHAFT SEAL 2 PRYBAR Fig 33 Front Output Shaft Bearing Retaining Ring Removal...

Page 495: ...shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 38 8 Install new bearing with Tool Handle C 4171 and Installer 5066 Fig 39 The bearing bore is chamfered at the top Install the bearing so it is flush with the lower edge of this chamfer Fig 40 Fig 35 Front Output Shaft Bearing Installation 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 5064 Fig 36 Installing Output Shaft Front ...

Page 496: ...e bearing locating ring must be fully seated against case sur face Fig 42 Fig 39 Output Shaft Rear Bearing Installation 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 Fig 40 Output Shaft Rear Bearing Installation Depth 1 BEARING SEATED AT LOWER EDGE OF CHAMFER 2 CHAMFER Fig 41 Input Shaft Bearing Removal 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL C 4210 Fig 42 Seating Input Shaft Bearing ...

Page 497: ...7 Remove seal from oil pump housing with a suitable pry tool 18 Install new seal in oil pump housing with Installer 7888 Fig 46 19 Remove rear retainer bearing with Installer 8128 and Handle C 4171 20 Install rear bearing in retainer with Handle C 4171 and Installer 5064 Fig 47 Fig 43 Remove Input Gear Pilot Bearing 1 DRIFT 2 INPUT GEAR Fig 44 Install Input Gear Pilot Bearing 1 SPECIAL TOOL C 4171...

Page 498: ...assem bly in front case Fig 49 Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing 2 Install snap ring to hold input low range gear into front bearing Fig 50 Fig 46 Oil Pump Seal Installation 1 HOUSING SEAL 2 SPECIAL TOOL 7888 3 OIL PUMP FEED HOUSING Fig 47 Installing Rear Bearing In Retainer 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 506...

Page 499: ...ve SHIFT FORKS AND MAINSHAFT 1 Install new sector shaft O ring and bushing Fig 52 2 Install shift sector in case Fig 53 Lubricate sector shaft with transmission fluid before installa tion 3 Install range lever washer and nut on sector shaft Fig 54 Tighten range lever nut to 27 34 N m 20 25 ft lbs torque 4 Assemble and install range fork and hub Fig 55 Be sure hub is properly seated in low range ge...

Page 500: ...oat of petroleum jelly 13 Install detent plunger spring and plug Fig 59 14 Verify that plunger is properly engaged in sec tor Fig 53 Shift Sector Installation 1 SHIFT SECTOR Fig 54 Range Lever Installation 1 RANGE LEVER 2 LEVER NUT Fig 55 Install Range Fork And Hub Assembly 1 RANGE HUB 2 RANGE FORK Fig 56 Mainshaft Assembly Installation 1 DRIVE SPROCKET 2 MODE HUB 3 MAINSHAFT Fig 57 Assembling Mod...

Page 501: ...cket onto mainshaft drive gear Fig 60 5 Install mode spring on upper end of mode fork shift rail Fig 61 Fig 58 Mode Fork And Sleeve Installation 1 MODE SLEEVE 2 MODE FORK AND RAIL Fig 59 Shift Detent Components 1 POPPET 2 SPRING 3 SCREW 4 POPPET BORE IN CASE Fig 60 Installing Drive Chain And Front Output Shaft 1 FRONT OUTPUT SHAFT 2 DRIVE CHAIN 3 MAINSHAFT 4 DRIVE SPROCKET Fig 61 Install Mode Fork...

Page 502: ... case dowels are aligned and that mode fork rail extends through rear case before seating rear case on front case 8 Install case attaching bolts Alignment bolts at each end of case are only ones requiring washers Fig 65 9 Tighten case bolts to 27 34 N m 20 25 ft lbs torque YOKE AND RANGE LEVER 1 Install indicator switch in front case Tighten switch to 20 34 N m 15 25 ft lbs torque 2 Install range ...

Page 503: ... bearing I D retaining ring and spacer on output shaft 4 Apply liberal quantity of petroleum jelly to new rear seal and to output shaft Petroleum jelly is needed to protect seal lips during installation 5 Slide seal onto Seal Protector 6992 Fig 69 Slide seal protector and seal onto output shaft 6 Slide Installer C 4076 B onto seal protector with the recessed side of the tool toward the seal Drive ...

Page 504: ...gh the slots of the damper c Thread the puller screw of Installer 8422 into the output shaft by hand only Make sure the screw is fully threaded into the output shaft d Using a wrench to hold the pulling screw sta tionary Fig 73 turn the pulling screw nut until the driver legs contact the rear face of the transfer case rear retainer When the legs contact the retainer the damper is properly position...

Page 505: ...ioned push in on secondary release lock Fig 75 on side of connector and pull connector from sen sor 3 Remove sensor mounting bolt Fig 76 4 Remove sensor pull straight out from speed ometer pinion gear adapter Fig 76 Do not remove gear adapter from transmission Fig 73 Install Damper 1 DAMPER 2 INSTALLER DRIVER 3 PULLING SCREW NUT 4 PULLING SCREW Fig 74 Slinger Boot Installation Typical 1 SPECIAL TO...

Page 506: ... sensor is fully seated mounted flush to speedometer pinion gear adapter 3 Tighten sensor mounting bolt to 2 2 N m 20 in lbs torque 4 Connect electrical connector to sensor Fig 76 VSS Removal Installation 1 ELECTRICAL CONNECTOR 2 SENSOR MOUNTING BOLT 3 O RING 4 SPEEDOMETER PINION GEAR 5 SPEEDOMETER PINION GEAR ADAPTER 6 O RING 7 VEHICLE SPEED SENSOR TJ TRANSFER CASE NV231 21s 139 SPEED SENSOR Cont...

Page 507: ..._____________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ What comments or suggestions do you have ________________________________________ __________________________________________________________________________...

Page 508: ...DaimlerChrysler International Operations Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 ...

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