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Содержание 1979 CJ-5

Страница 1: ...1979 SERVICE MANUAL...

Страница 2: ...ION 3N 3C 3J 3 A 3B 3D CHAPTERS 3A WATER LEAK WIND NOISE DIAGNOSIS AND REPAIR 3B METAL REPAIR AND PAINTING 3C INSTRUMENT PANELS AND COMPONENTS 3D HEATER 3E AIR CONDITIONING 3F BODY AND FRAME COMPONENT...

Страница 3: ......

Страница 4: ...included An alphabetical index of all subjects is located at the back of this manual Each chapter ends with specifications torque charts and special tools pertinent to that chapter Warnings anl Gamin...

Страница 5: ...Use Recheck The Set To value is used when assembling components The In Use Recheck value is used to check pre tightened items Refer to the Standard Torque Specifications and Cap screw Markings Chart i...

Страница 6: ...93 See figures A l and A 2 Beyond the 10 inch difference in wheelbase CJ 5 and CJ 7 differ pri marily in available options CJ 7 models are available with an automatic transmission Quadra Trac full tim...

Страница 7: ...ries model 25 and model 45 and the J 20 Series model 46 See figures A 7 and A 8 The 2 door model 16 is a dual purpose vehicle in the sports utility class featuring an all steel top front disc brakes a...

Страница 8: ...131 6200 J 20 46 131 6800 7600 8400 6 0 5 3 2 Four trim packages are available on Truck models Custom Honcho 10 4 and Golden Eagle The Custom package is available on all Trucks and features deluxe in...

Страница 9: ...ption No Vehicle Identification VIN Number Jeep Model No o 6 0 5 3 4 Disregard for factory use only Fig A 9 Vehicle identification Plate dealer in ordering correct replacement parts an SSR O number is...

Страница 10: ...on the door lock pillar on the driver s side DATE GVWR RAIN TIRE SIZE GAWR FRT MIN TIRE SIZE M GAWR RR MIN TIRE SIZE MAX COLD TIRE PRESS FRT RR RIM SIZE 1 VEHICLE NUMBER I TYPE Fig Safety Sticker 8 0...

Страница 11: ...nect rear propeller shaft WARNING Never tow a Jeep vehicle with Emergency Drive control activated or reduction unit in low range automatic transmission only Always use a safety chain system that is in...

Страница 12: ...absorbers Place tow bar under spring shackles Attach safety chains around spring shackles GENERAL INFORMATION Fig A 14 Front Towing Cherokee and Wagoneer Models Rear Refer to Figure A 15 Attach J hook...

Страница 13: ...nge cubic cen timeters to cubic inches multiply cubic centimeters by 0 061 cc x 0 061 equals cubic inch Cubic Inches to Centimeters To change cubic inches to cubic centimeters multiply cubic inches by...

Страница 14: ...utions Tire Data revolution per kilometer rev km elapsed time minute min hour h Pressure Tire kilopascal kPa day d Coolant Lubricating oil Velocity General use meter per second m s Fuel pump delivery...

Страница 15: ...6 6 Bolt 5 50 B C Cherokee Models 16 17 18 108 7 Inch Wheelbase 6200 GVWR 360 2V 0 1 S 1 11 0 1 O S O Dana Open End Dana 44 12 Inch Disc 11x2 Drum 1 5 x 6 6 Bolt 5 50 B C Cherokee Models 16 17 18 108...

Страница 16: ...40 6 12 4 44 5 13 6 44 5 13 6 Effective Leg Room Front Accelerator Rear Minimum 37 9 96 3 30 5 77 5 39 1 99 3 35 0 88 9 41 9 106 4 37 0 94 0 41 9 106 4 37 0 94 0 41 9 106 4 37 0 94 0 41 3 104 9 37 0 9...

Страница 17: ...6 2031 13 64 8 33 3281 21 64 17 46 6875 11 16 0330 6 6 2 6 1024 2040 6 8 4 3307 17 5 6890 85 0335 1040 37 5 2 2047 3320 Q 17 86 7031 4 5 6 4 0350 65 2 7 1063 2055 5 8 5 3346 18 0 7087 9 0354 1065 36 5...

Страница 18: ...r service manual What is your general reaction to this manual In your judgment is it complete accurate well organized well written Is it easy to use What features are most useful _ What faults do you...

Страница 19: ...Tear Fold Here and Staple BUSINESS REPLY MAIL No Postage Stamp Necessary if Mailed in the United States Postage will be paid by JEEP CORPORATION 14250 PLYMOUTH RD DETROIT MICHIGAN 48232 ATTENTION SER...

Страница 20: ...st under normal use and every 3 months or 3 000 miles 4 800 km whichever comes first under heavy duty operation Refer to Legend of Sym bols for definitions of the various symbols The num bers appearin...

Страница 21: ...followed by the time and or dis tance interval For example Engine Oil Number 10 should be drained and re placed every 5 months or 5 000 miles 8 000 km whichever comes first under normal use and every...

Страница 22: ...000 miles 24 000 km and every 15 000 miles 24 000 km thereafter c When most driving is on paved roads with trips of less than six miles 10 km change engine oil every 2 500 miles 4 000 km and oil filt...

Страница 23: ...LS FRONT AND REAR 30 000 mi 48 000 km 30 mo 30 000 mi 48 000 km 2 BEARINGS FRONT WHEEL 25 000 mi 40 000 km a 25 mo 25 000 mi 40 000 km 3 BRAKE AND CHASSIS INSPECTION BODY LUBRICATION Y 15 000 mi 24 00...

Страница 24: ...free play if necessary Lubricate Model 20 transfer case linkage Body Lubrication Lubricate the following items with the recommended lubricants Ashtray slides Courtesy light buttons Door hood liftgate...

Страница 25: ...iction material particles a complete transmission overhaul may be needed Examine the fluid closely If doubtful about its condition drain out a sample for a double check Refer to Chassis Components for...

Страница 26: ...lene glycol antifreeze and water Use this mixture year round for protection against corrosion boiling and engine damage 6 Drive Belts Check belts driving fan air pump alternator power steering pump an...

Страница 27: ...miles 8 000 km or every 5 months whichever comes first under normal conditions A full flow oil filter is mounted on the lower center right side of six cylinder engines and on the lower right side on e...

Страница 28: ...m torque 7 Remove fill plug and add new lubricant to fill hole level fig B 4 8 Install fill plug 2 Bearings Front Wheel Lubricate front wheel bearings as scheduled using a high quality wheel bearing l...

Страница 29: ...Fig 1 8 Door Latch and Lock Cherokee Wagoneer Truck Models Fig B 9DoorHingesCourtesy Light Button Cherokee Wagoneer Truck Models Front Brake Linings CJ Models Check both ends of the outboard lining b...

Страница 30: ...warn the driver that brakeshoes need replacement Rear Brake Linings All Models Replace linings worn to within 1 32 inch 78 mm of rivet head Rear Self Ad usting Mechanism Operate the adjuster cable CJ...

Страница 31: ...may in dicate underinflation or need for front end alignment tire rotation or wheel balancing Also check for bulging cracks or other road hazard damage Check and adjust inflation pressures according...

Страница 32: ...ines Apply grease gun pressure to sleeve yoke grease fit ting until lubricant appears at pressure relief hole in expansion plug at sleeve yoke end of spline At this point cover pressure relief hole wi...

Страница 33: ...ng or breakage of the aluminum unit After draining and refilling it may be necessary to drive the vehicle in circles in an open area both clock wise and counterclockwise for about 15 minutes to allow...

Страница 34: ...easure imperial Measure Metric Measure Engine Oil includes 1 quart for filter change 258 CID engines 304 CID 360 CID engines 6 0 quarts 5 0 quarts 5 0 quarts 4 2 quarts 5 7 liters 4 7 liters Cooling S...

Страница 35: ...e transmission and transfer case AMC Jeep All Purpose Lubricant or equivalent lithium base chassis lubricant Manual steering gear AMC Jeep All Purpose Lubricant or equivalent lithium base chassis lubr...

Страница 36: ...n Cooling Systems Batteries H Charging System f f 1 Starting System p Ignition System Cruise Command 1 fi u Mil j Fuel Systems la Exhaust Systems Power Plant Instrumentation Section 2 Chassis Section...

Страница 37: ......

Страница 38: ...nical Maintenance Schedule in Chapter B It is frequently helpful to know at a glance which emission related components are installed on a particu lar vehicle This information is contained in two emis...

Страница 39: ...M4 O Vac 220 7 in 0 A Vac 149 9 9 0 1 8 1 Blown Cylinder Head Gasket Diagnosis Compression Test Cylinder Leakage Test Diagnosis with Scope Analyser P i l l 1A 13 1A I1 1A 11 1A 11 General 1A 2 Intake...

Страница 40: ...has 8 Repair as necessary and tighten stripped threads 9 Rear oil gallery plug loose 9 Use appropriate sealant on gallery plug and tighten 10 Rear camshaft plug loose or 10 Seat camshaft plug or repla...

Страница 41: ...m 4 Remove and inspect oil inlet tube bly has restriction or air leak and screen assembly Fill pickup with lacquer thinner to find leaks 5 Excessive oil pump clearance 5 Check clearances refer to Oil...

Страница 42: ...ces sively loose or tight 6 Check ring side clearance repair as necessary 7 Carbon build up on piston is excessive 7 Clean carbon from piston VALVE TRAIN NOISE 1 Insufficient oil supply 1 Check for 1...

Страница 43: ...as necessary 11 Improper spark plug gap 11 Adjust gap 12 Incorrect initial timing 12 Adjust timing 13 Incorrect valve timing 13 Check valve timing repair as necessary ROUGH IDLE OR 1 Incorrect curb or...

Страница 44: ...or needle 4 Faulty elastomer valve Eight cylinder only 5 Worn or damaged pump diaphragm or piston 6 Leaking main body cover gasket 7 Engine cold and choke too lean 8 Improper metering rod adjustment Y...

Страница 45: ...wrong plug 6 Adjust gap install correct plug 7 Faulty choke operation 7 Adjust choke FAULTY HIGH SPEED OPERATION Continued 8 Partially restricted exhaust manifold exhaust pipe muffler or tailpipe 8 El...

Страница 46: ...11 Check manifold vacuum and repair as necessary 12 Improper carburetor settings 12 Adjust carburetor MISFIRE AT ALL SPEEDS Continued 13 14 Fuel pump volume or pressure low Blown cylinder head gasket...

Страница 47: ...choke operation 3 Repair as necessary 4 Exhaust leak 4 Locate and eliminate leak PING OR SPARK KNOCK 1 2 Incorrect ignition timing Distributor centrifugal or vacuum advance malfunction 1 2 Adjust tim...

Страница 48: ...therwise is similar to that of the point system in this area Other than the differences described scope ignition diagnosis procedures for point and SSI systems are es sentially the same COMPRESSION TE...

Страница 49: ...R O R P R I M A R Y C I R C U I T T E S T S P L U G S W I R E S C A P R O T O R O R E N G I N E C O N D I T I O N A F F E C T I N G P L U G F I R I N G P U L L O F F P L U G W I R E F I R I N G L I N...

Страница 50: ...s perform a compression test as out lined under Compression Test A cylinder head gasket blown between two cylinders will result in approx imately a 50 to 70 reduction in compression in the two affecte...

Страница 51: ...ove and examine spark plugs for burned electro des and dirty fouled cracked or broken porcelains Keep plugs arranged in the order removed from the engine An isolated plug displaying an abnormal condit...

Страница 52: ...Such plugs can be considered normal in condition and can be cleaned using standard procedures C Chipped Insulator Chipped insulators usually result from bending the center electrode while gapping of...

Страница 53: ...hes Ohms Oto 15 3 000 to 10 000 15 to 25 4 000 to 15 000 25 to 35 6 000 to 20 000 Over 35 8 000 to 25 000 60748 When installing spark plug wires and the coil high tension wire be certain a good tight...

Страница 54: ...urning through normal operation Check the inserts for evidence of mechanical inter ference with the rotor tip Initial Ignition Timing A graduated degree scale located on the timing case cover is used...

Страница 55: ...so may be tested with the dis tributor out of the vehicle Follow distributor test equip ment manufacturer s instructions Information given in the Distributor Curves is for on vehicle testing If the di...

Страница 56: ...ixture setting procedure takes more than 3 minutes run the engine at 2000 rpm in Neutral for 1 minute Be sure the curb idle setting is correct before ad justing mixture Be careful of fan belts and oth...

Страница 57: ...nual 49 State 20 304 2V Manual California CJ 100 304 2V Automatic 49 State 40 360 Manual 49 State 50 2V Automatic All 20 9 0 1 8 3 Choke Linkage Check all choke linkage including the fast idle cam for...

Страница 58: ...and emission levels Inspect the exhaust manifold heat valve for correct operation and lubricate with Jeep Heat Valve Lubricant or equivalent Refer to Chapter IK Exhaust Systems for service procedures...

Страница 59: ...1600 2400 3200 4000 400 1200 2000 2800 3600 4400 ENGINE RPM 36 32 yj 28 cc 2 24 Q tu 20 Z 0 16 Z yy u 1 8 Q 4 0 4 VACUUM IN HG MECHANICAL ADVANCE 3233174 360 CID EIGHT CYLINDEP 4 9 STATE M A N U A L A...

Страница 60: ...CHANICAL ADVANCE 3232434 258 CID SIX CYLINDER 4 9 STATE MANUAL CHEROKEE WAGONEER TRUCK CALIFORNIA M A N U A L AND AUTOMATIC 800 1600 2400 3200 4000 400 1200 2000 2800 3600 4400 ENGINE RPM 6 8 10 12 14...

Страница 61: ...CE AND DIAGNOSIS Distributor Wiring Sequence and Firing Order FRONT CLOCKWISE ROTATION 1 5 3 6 2 4 SIX CYLINDER ENGINES r LEFT BANK j CLOCKWISE ROTATION 1 8 4 3 6 5 7 2 RIGHT BANK EIGHT CYLINDER ENGIN...

Страница 62: ...r head valve engine fig 1B 1 and 1B 2 which operates only on no lead gasoline Cylinders are numbered from front to rear Firing order is 1 5 3 6 2 4 Crankshaft rotation is clockwise viewed from the fro...

Страница 63: ...NE ASSEMBLY SHORT BLOCK A service replacement short engine assembly short block may be installed whenever the original engine block is worn or damaged beyond repair It consists of engine block piston...

Страница 64: ...ig 1B 4 Oversize or Undersize Letter Code Location ENGINE MOUNTING Resilient rubber cushions support the engine and transmission at three points at each side on the center line of the engine and at th...

Страница 65: ...mpressor refrigerant to escape d Remove fittings from compressor 19 Attach engine lift device Pull engine forward to disengage from transmission Lift upward to remove ENGINE INSTALLATION 1 Remove righ...

Страница 66: ...ed Make certain bottom end of each rod is centered in plunger cap of hydraulic valve lifter 2 Install bridged pivots and pair of rocker arms to cylinders from which they were removed 3 Loosely install...

Страница 67: ...0 015 inch 0 381 mm and 0 030 inch 0 762 mm sizes Valve Guide Reamer Sizes Reamer Size Tool Number Size J 6042 1 0 003 inch J 6042 5 0 015 inch J 6042 4 0 030 inch 6 0 2 6 0 NOTE Ream valve guides in...

Страница 68: ...for removal procedure with the head removed The valve spring is held in place on the valve stem by a retainer and a set of conical type valve locks The locks can be removed only by compressing the val...

Страница 69: ...than at the rear to permit easy removal and installation of the camshaft Cam shaft bearing are lubricated under pressure NOTE It is not advisable to replace camshaft bearings unless equipped with spe...

Страница 70: ...aft Installation 1 Lubricate camshaft with Jeep Engine Oil Sup plement or equivalent 2 Install camshaft carefully to prevent damaging camshaft bearings 3 Install timing chain crankshaft sprocket and c...

Страница 71: ...unger and finally to the pushrod and rocker assembly The engine valve opens While the valve is open the trapped oil is subjected to considerable pressure and some of it escapes between the plunger and...

Страница 72: ...of ram to align pointer with SET mark on scale of tester and tighten hex nut 8 Slowly swing weighted arm onto ram Rotate cup by turning handle at base of tester clockwise one revolution every two seco...

Страница 73: ...tabs off replacement oil pan gasket cor responding to pieces cut off original gasket Install these pieces on oil pan and cement in place 3 Coat seal end tabs generously with Permatex No 2 or equivalen...

Страница 74: ...eplace the timing chain if it deflects more than 1 2 inch 13 mm The correct timing chain has 48 pins A chain with more than 48 pins will cause excessive slack Removal 1 Remove drive belt s 2 Remove en...

Страница 75: ...horn vent hose and solenoid wire if equipped 2 Disconnect accelerator cable from accelerator bellcrank 3 Disconnect PCV vacuum hose from intake manifold EXHAUST MANIFOLD 60116 Fig 1B 26 Intake and Exh...

Страница 76: ...tighten Manifolds must be held together loosely enough to slide when manifolds are attached to cylinder head 11 Install vacuum fittings 12 Install manifold assembly to head Refer to In take and Exhaus...

Страница 77: ...e 7 Connect PCV valve to grommet in cylinder head cover connect canister hose 8 Install air cleaner and connect PCV hose Installation Gasket Method 1 Position gasket on cylinder head cover flange Ceme...

Страница 78: ...blies to original locations Loosely install capscrews to each bridged pivot At each bridged pivot tighten cap screws alternately one turn at a time to avoid damaging bridge Tighten screws to 19 foot p...

Страница 79: ...Fig 1B 29 Lubrication Systtn 6 0 3 2 9...

Страница 80: ...ement filter gasket Install filter until gasket con VALVE SPRING BYPASS VALVE tacts the seat of the adapter Tighten by hand only following the instruction on the replacement filter If the instructions...

Страница 81: ...051 to 0 203 mm 0 051 mm preferred Alternate Method a Place straightedge across ends of gears and pump body b Select feeler gauge which fits snugly but freely between straightedge and pump body fig 1...

Страница 82: ...2 Remove starter motor 3 On CJ Models a Place jack under transmission bellhousing b Disconnect engine right support cushion bracket from block and raise engine to allow sufficient clearance for oil pa...

Страница 83: ...hose slipped over the screws will provide protection during installation 5 Install connecting rod bearing caps and inserts in same order as removed NOTE Oil squirt holes in connecting rods must face c...

Страница 84: ...ard 0 001 0 002 0 010 and 0 012 inch undersize The bearing size is stamped on the back of service replacement inserts NOTE The 0 002 and 0 012 inch undersize inserts are not used in production Removal...

Страница 85: ...ing and proceed to Installation 7 If oil clearance exceeds specification install 0 001 inch undersize bearing inserts and check clearance as described in steps 1 through 5 The clearance indicated with...

Страница 86: ...on to place it nearer the thrust side of the piston minimizing piston slap An arrow on the top surface of the piston ensures correct installation in the bore The arrow points toward the front of engin...

Страница 87: ...ect ring gap clearance Fig 1 1 4 4 Ring l i p Clearance Fig 1 I 4 S Stog Side Clearance Installation Refer to figure 1B 45 for position of ring gaps when installing rings 1 Install oil control rings a...

Страница 88: ...LEL TO PISTON PIN RING GAP POSITION MAY V A R Y 20 FROM POSITION ILLUSTRATED 8 0 1 2 4 RING EXPANDER RECOMMENDED Fig 1B 47Compression Ring Installation Fig 1B 45 Piston Ring Gap Position Fig 1 1 4 8 T...

Страница 89: ...main bearing An oil slinger is provided at the rear main journal inboard of the rear oil seal The component parts and crankshaft are individually balanced Then the complete assembly is balanced as a...

Страница 90: ...t used in production Removal 1 Drain engine oil 2 Remove oil pan 3 Remove main bearing cap and insert 4 Remove lower insert from bearing cap 5 Loosen other bearing caps and insert small cot ter pin in...

Страница 91: ...le If brittle obtain fresh stock SCALE Fig 1B 54 Checking Main Bearing Clearance with Plastigage 6 If correct clearance is indicated bearing fitting is not necessary Remove Plastigage from crankshaft...

Страница 92: ...r seal halves in pairs Removal 1 Drain engine oil 2 Remove oil pan 3 Remove rear main bearing cap and discard lower seal 4 Loosen all remaining bearing capscrews 5 Use brass drift and hammer to tap up...

Страница 93: ...with chisel 3 Apply heat to expand inside diameter of replace ment ring gear 4 Press flywheel onto replacement ring gear NOTE On manual transmission equipped cars the fly wheel is balanced as an indiv...

Страница 94: ...t 3 Install main bearing caps and inserts Apply oil to insert before installing Tighten screws to 80 foot pounds torque in steps of 40 60 and 80 foot pounds torque 54 81 108 N m Plastigage all bearing...

Страница 95: ...red Connecting Rod Journal Diameter Connecting Rod Journal Width Connecting Rod Bearing Clearance Maximum Out of Round All Journals Maximum Taper All Journals USA Inches Unless Otherwise Specified 2 0...

Страница 96: ...efinishing 0 010 0 25 Valve Springs Exhaust Valve Open 80 88 at 1 625 Valve Closed 210 226 at 1 188 I D 1 000 1 020 Valve Springs Intake Free Length 1 99 approx 50 55 approx Spring Tension Valve Close...

Страница 97: ...1 16 13 19 22 18 26 50 35 60 68 47 81 7 4 9 9 5 12 33 28 38 45 38 52 23 18 28 31 24 38 80 75 85 108 102 115 48 42 55 65 57 75 70 in lbs 60 80 in lbs 8 7 9 10 8 1 3 14 11 18 17 12 20 23 16 27 7 5 9 9 7...

Страница 98: ...al illustrations are used Identification The cubic inch displacement numbers are cast into both sides of the cylinder block These numbers are located between the engine mounting bracket bosses Build D...

Страница 99: ...acement tag to right cylinder head cover Installation includes transfer of component parts from the worn or damaged original engine Follow the appropriate procedures for cleaning inspection and torque...

Страница 100: ...harness from engine and move aside 11 Disconnect following lines if equipped Fuel supply and return lines at chassis tubing Vacuum line at power brake unit Vacuum line for heater damper doors at intak...

Страница 101: ...o the rocker arm assemblies Removal 1 Remove cylinder head cover 2 Remove two capscrews at each bridged pivot Alternately loosen capscrews one turn at a time to avoid damaging bridge 3 Remove bridged...

Страница 102: ...08 mm Valve Seat Refacing Install a pilot of the correct size in the valve guide and reface the valve seat to the specified angle with a good dressing stone Remove only enough metal to provide a smoot...

Страница 103: ...spring and retainer on cylinder head and compress valve spring with compressor tool Install valve locks and release tool 5 Tap valve spring from side to side with light hammer to seat spring properly...

Страница 104: ...tighten capscrews alternately one turn at a time to avoid damaging bridge Tighten capscrews to 19 foot pounds 25 N m torque 8 Reseal and install cylinder head cover 9 Install retaining screws and was...

Страница 105: ...aft Camshaft Removal 1 Drain radiator and cylinder block 2 Remove radiator assembly 3 If equipped with air conditioning remove con denser and receiver assembly as charged unit 4 Remove cylinder head c...

Страница 106: ...distributor cap 20 Install ignition wires 21 If removed install air conditioning condenser and receiver assembly CAUTION Both service valves must be open before the air conditioning system is operated...

Страница 107: ...et assembly in cleaning solvent to remove all varnish or gum deposits 4 Visually inspect each tappet assembly for signs of scuffing on barrel and face of tappet Inspect tappet face for wear using stra...

Страница 108: ...nder head cover Tighten retaining screws to 50 inch pounds 6 N m torque 6 Install intake manifold using replacement gas ket and end seals Tighten manifold retaining screws to 43 foot pounds 58 N m tor...

Страница 109: ...sponding hole in engine block g Install each cover retaining screw in same location as removed Tighten to 25 foot pounds 34 N m torque h Proceed to step 7 6 If RTV is used a Apply coating of RTV silic...

Страница 110: ...r 1C Cooling Fig 1B 77 Removing Timing Case Cover Oil Seal Timing Chain The timing chain consists of 62 links joined by 62 pins It is a single row design To ensure correct valve timing install the tim...

Страница 111: ...ves as an oil splash baffle The intake manifold contains coolant passages a crankcase ventilator passage and an exhaust crossover passage Passages are also incorporated within the in take manifold for...

Страница 112: ...eft exhaust manifold and numbers 2 4 6 and 8 of the right exhaust manifold California models only Refer to Chapter IK Exhaust Systems for description of the Air Guard system Removal 1 Disconnect ignit...

Страница 113: ...head and block to remove all dirt and gasket cement Remove carbon deposits from the combustion chambers and the top of each piston Use a straightedge and feeler gauge to check the flat ness of the cyl...

Страница 114: ...crankshaft rotates A small passage within the front camshaft bearing journal channels oil through the camshaft sprocket to the timing case cover area where the case and sprockets throw off oil to lubr...

Страница 115: ...1B 54 ENGINES 70001 Fig 1B 82 Lubrication System...

Страница 116: ...ch 0 229 mm to 0 279 mm thick Symptoms of excessive pump clearance are fair to good pressure when cold low or no pressure after starting a hot engine Preferred Method 1 Place strip of Plastigage acros...

Страница 117: ...en inspect for loose oil pump gear to shaft fit or worn front cover Oversize pump shafts are not available Installation 1 Install oil pressure relief valve in pump cover with spring and retaining cap...

Страница 118: ...onnecting rod bearing caps and in serts Keep in same order as removed NOTE Connecting rods and caps are stamped with the number of the cylinder to which they were assembled 11 Remove connecting rod an...

Страница 119: ...in production by a color coded paint mark on the adjacent cheek or counter weight toward the flanged rear end of the crankshaft Use color codes shown in the bearing fitting chart to identify journal...

Страница 120: ...in rod replace bearing and connecting rod and inspect crankshaft jour nal for scoring 3 Inspect for material imbedded in linings which may indicate piston timing gear distribution gear or oil pump gea...

Страница 121: ...d upper and 0 002 inch undersize lower 8 If oil clearance exceeds specification when 0 002 inch undersize inserts are installed measure connecting rod journal with micrometer If journal size is correc...

Страница 122: ...peat steps 2 and 3 with long 0 002 inch 0 051 mm feeler gauge Piston should bind If piston binds on the 0 0005 inch 0 013 mm gauge piston is too large or bore is too small If piston does not bind on t...

Страница 123: ...g gap spacing is shown in figure 1B 99 1 Install oil control rings as indicated by instruc tions in package Roll upper and lower rails into place without use of tool fig 1B 100 TOP COMPRESSION RING BO...

Страница 124: ...d Fig 1 B 103 Piston Pin Removal and Installation 2 With pin removed from piston clean and dry piston pin bore and piston pin 3 Position piston so that pin bore is in vertical position Insert pin in b...

Страница 125: ...before final torque tightening Crankshaft lain Baariip The main bearings are steel backed aluminum tin with overplated copper lead as an optional lining The main bearing caps are numbered 1 through 5...

Страница 126: ...erting cotter pin about 1 2 inch 14 mm long in crankshaft oil hole Bend cotter pin as shown in figure 1B 105 5 With pin in place rotate shaft so that upper bearing insert is rotated in direction of it...

Страница 127: ...clearance would be 0 002 inch 0 051 mm CAUTION Never use a pair of inserts which differ more than one bearing size as a pair For example do not use a standard upper and 0 002 inch undersize lower 10 I...

Страница 128: ...n both chamfered edges of rear main bear ing cap C A U T I O N Do not apply sealer to the cylinder block mating surface of the rear main cap as bearing clearance could be affected 8 Tighten all main b...

Страница 129: ...out lined in Engine Removal 3 Use engine stand to support engine assembly 4 Remove distributor 5 Remove cylinder head covers and gaskets 6 Remove rocker arms and bridged pivot assem blies Alternately...

Страница 130: ...caps and inserts If replace ment bearings are installed Plastigage each bearing 4 Install replacement oil pickup tube and screen assembly Do not attempt to install original pickup tube Be sure plastic...

Страница 131: ...0 001 0 0254 Cam Lobe Lift 304 360 0 266 6 7564 Intake Valve Timing Opens 304 360 14 75 BTDC Closes 304 360 68 75 BTDC Exhaust Valve Timing Opens 304 360 56 75 BBDC Closes 304 360 26 75 ATDC Valve Ove...

Страница 132: ...il Control Steel Rail 304 0 010 0 025 0 25 0 64 360 0 015 0 045 0 38 1 14 0 010 0 020 0 25 0 51 preferred preferred Piston Ring Side Clearance 340 No 1 0 0015 0 0035 0 0015 preferred 0 038 0 089 0 038...

Страница 133: ...Bracket to Block Screw 35 25 40 47 34 54 Front Support Cushion to Bracket to Frame 37 3 0 5 50 41 61 Fuel Pump Screws 16 13 19 22 18 26 Idler Pulley Bearing Shaft to Bracket Nut 33 28 38 45 38 52 Idle...

Страница 134: ...N J 22700 OIL FILTER WRENCH J 8056 VALVE AND CLUTCH SPRING TESTER J 22248 TIMING CASE COVER ALIGNMENT TOOL AND SEAL INSTALLER SCREW TIMING CASE COVER CRANKSHAFT SEAL INSTALLER PART OF TOOL J 9163 J 56...

Страница 135: ...NOTES...

Страница 136: ...rature by allowing the engine to reach normal oper ating temperature as quickly as possible maintaining normal operating temperature and preventing over UPPER HEATER RADIATOR HOSE TO Fig 1C 1 Six Cyli...

Страница 137: ...ve 195 F 91 C coolant is allowed to flow to the radiator This provides quick warmup and overall temperature control The words TO RAD are stamped on the thermo stat to indicate the proper installed pos...

Страница 138: ...em has a gasket to prevent air leakage at the filler neck The cap is round to discourage unnecessary removal and has a mark on top which should be aligned with the overflow hose to indicate proper ins...

Страница 139: ...ets into both banks of the cylinder block It flows through the water jackets around all cylinders and up through holes in the block and head gaskets into the cylinder heads to cool the combustion cham...

Страница 140: ...ecovery bottle into the system to equalize the pressure Air is not admitted as long as the recovery bottle tube remains submerged CTO Operation Standard Cooling CTO Switch The standard cooling CTO swi...

Страница 141: ...y thermostat 12 Replace thermostat 13 Water pump shaft broken or im peller loose 13 Replace water pump 14 Radiator tubes clogged 14 Flush radiator 15 Cooling system clogged 15 Flush system 16 Casting...

Страница 142: ...orated because of age of contamination 6 Leaks due to loose hose clamps loose nuts bolts drain plugs faulty hoses or defective radiator 7 Faulty head gasket 8 Cracked head manifold or block 1 Faulty h...

Страница 143: ...ing worn 6 Remove belt to isolate Replace pump 7 Belt alignment 7 Check for improper pulley locations Shim power steering pump LOW TEMPERATURE INDICATION UNDERCOOLING 1 2 Thermostat stuck open Faulty...

Страница 144: ...Un even ness or Dirt Which Prevents Thermostat From Closing C NOT OK Torque Housing Bol Specifications ts to 70171 Engine Overheating Diagnosis Guide No Coolant Loss Check and Repair Gauge and or Send...

Страница 145: ...ing Check Exhaust Heat Valve Repair or Replace as Necessary NOT OK Replace or Rebuild Radiator Check for Collapsed Lower Radiator Hose I NOT OK OK Reposition Hose Stiffener or Replace Hose OK Check Co...

Страница 146: ...paired by a reputable radiator repair shop Checking for Internal Leakage 1 Remove oil pan drain plug and drain a small amount of oil Water being heaviest should drain first Run engine to churn oil the...

Страница 147: ...TESTING Coolant Freezing Point Test Coolant freezing point or freeze protection should be checked with an antifreeze hydrometer to determine protection level Refer to Coolant Radiator Pressure Cap Tes...

Страница 148: ...casting flash o r othei restrictions NOTE Remove pump from engine before revn iing n striction to prevent contamination pf coohmt with debris Refer to Water Pump Removal Tempatrol Fan Test 1 Start eng...

Страница 149: ...with air condi tioning use a matched pair of belts to drive the AC compressor and alternator Replace these belts in sets only Do not replace individual belts When checking belt tension check one belt...

Страница 150: ...Cylinder The six cylinder power steering pump is sandwiched between two bracket halves fig 1C 16 To adjust loosen the clamping screw and pivot screws Insert a suitable wrench in the bracket socket an...

Страница 151: ...Check hoses at regular intervals If a hose is cracked or feels brittle when squeezed it should be replaced If a hose swells excessively when under pressure it should be replaced In places where specif...

Страница 152: ...Crankcase Cleaner or equivalent to flush engine Engine Flushing 1 Remove thermostat housing and thermostat In stall thermostat housing 2 Attach flushing gun to upper radiator hose at radiator end 3 At...

Страница 153: ...d tighten 10 Install shroud attaching screws and tighten COOLANT RECOVERY BOTTLE Replacement 1 Remove hose from radiator filler neck 2 Remove bottle from radiator support panel 3 Pour coolant into cle...

Страница 154: ...g this pressure may dam age the radiator heater core or hoses 1 Disconnect radiator hoses 2 Attach piece of radiator hose to radiator bottom outlet and insert flushing gun 3 Connect water supply hose...

Страница 155: ...tery negative cable 2 Drain radiator and disconnect upper radiator hose at radiator 3 Loosen all drive belts 4 If vehicle is equipped with radiator shroud sep arate shroud from radiator 5 Install one...

Страница 156: ...er Operate engine with heater control valve open until thermostat opens Shut off engine and recheck coolant level 14 Reset clock if equipped SPECIFICATIONS Cooling System Components Cooling Package En...

Страница 157: ...ator Pivot Bolt or Nut Alternator Pivot Mounting Bolt to Head Crankshaft Pulley to Damper Screw Engine Block Heater Nut V 8 Compression Type Engine Block Heater Nut Six Cylinder T Bolt Type Fan Blades...

Страница 158: ...34 267 311 Fan 125 155 90 115 556 689 400 512 Power Steering Pump 125 155 90 115 556 689 400 512 6 0253 ALTERNATOR Engine Drive Belt Arrangement ALTERNATOR FAN A N D WATER PUMP FAN A N D WATER PUMP AI...

Страница 159: ...ING VIBRATION DAMPER AIR CONDITIONING A N D POWER STEERING SIX CYLINDER POWER STEERING AIR GUARD AND AIR CONDITIONING SIX CYLINDER FAN AND WATER PUMP ALTERNATOR AIR PUMP POWER FAN AND STEERING WATER P...

Страница 160: ...COOLING SYSTEMS TC 21 LEGEND FRONT BELT MIDDLE BELT REAR BELT 7 0 1 8 1 B Tools AJ42005...

Страница 161: ...NOTES...

Страница 162: ...icular battery model WARNING Explosive gases are present within the battery at all times Avoid open flames and sparks Wear eye protection when servicing any battery Reserve Capacity Ratings Reserve Ca...

Страница 163: ...irst Then connect and tighten negative cable NOTE The tapered positive terminal is 1 16 inch larger in diameter than the negative terminal and the opening in the positive cable clamp is correspondingl...

Страница 164: ...y when stored Batteries discharge faster when warm than when cold For example at 100 F 37 8 C a normal self discharge of 0 0024 specific gravity per day could be expected At 50 F 10 C a discharge of 0...

Страница 165: ...plates per cell 54 plates divided by 6 There is always one more negative plate per cell than positive so each cell has 5 negative and 4 positive plates The charging rate should be four amps A 66 plat...

Страница 166: ...er testing is required NOTE A sulfated battery may require an overnight slow charge to determine if the sulfation is light enough to be broken down by a charge In rare cases where a battery goes dead...

Страница 167: ...OFF position fig 1D 4 3 Turn selector knob to AMP position 4 Connect test leads as shown 5 Turn carbon pile knob clockwise until ammeter reading is equal to prescribed amperage 135 amperes for 75 min...

Страница 168: ...RD READINGS ELECTROLYTE LEVEL TOO LOW FOR SPECIFIC T E S T A D D WATER CHARGE BATTERY FOR 10 MIN AT 20 AMPS MEASURE SPECIFIC GRAVITY OK AVERAGE SPECIFIC GRAVITY 1 225 OR MORE CELL READINGS EQUAL WITHI...

Страница 169: ...AVERAGE SPECIFIC GRAVITY 1 225 OR MORE BUT CELL READINGS VARY 050 OR MORE o CLEAN BATTERY POST AND CABLE ENDS CONNECT HEAVY LOAD TESTER m DETERMINE HEAVY LOAD FROM CHART m ADJUST TESTER TO LOAD HOLD...

Страница 170: ...s Service In Use Recheck Torques should be used for checking a pre torqued item USA ft lbs Battery Box Screw Battery Holddown Screw Service Set To Torque 75 60 70 Service In Use Recheck Torque 50 90 M...

Страница 171: ...NOTES...

Страница 172: ...EW A Operation Specifications sting Off Vehicle Tools ling Page 1E 2 1E 14 1E 7 11 14 1E 3 Its major components are front and rear housings sta tionary windings stator rotating field windings rotor an...

Страница 173: ...of the voltage regulator and the amount of current being consumed by electrical loads such as heater blower mo tor lamps and rear window defogger Energizing the Systei When the ignition switch is turn...

Страница 174: ...enced by slow crank ing and low specific gravity readings An overcharged battery evidenced by excessive water usage Before making any electrical checks perform a visual inspection of all charging syst...

Страница 175: ...EGATIVE CABLE CONNECT JUMPER TERMINAL AND GROUND CONNECT VOLTMETER TERMINAL AND GROUND CRANK ENGINE LONG ENOUGH FOR STABILIZED READING NEEDLE BELOW 9 0V IF READING IS WITHIN 5 VOLT OF VOLTAGE AT ALTER...

Страница 176: ...T UNTIL UPPER RADIATOR INLET IS HOT AND VOLTMETER NEEDLE STOPS CHECK VOLTAGE READING IF METER READS UNDER 12 5V IF METER READS OVER 15 5V IF METER READS 12V TO 15 5V SEE NOTE 3 4 GROUND ALTERNATOR TOU...

Страница 177: ...OSS BATTERY START ENGINE DO NOT TOUCH ACCELERATOR PEDAL TURN OFF ALL ACCESSORIES WAIT UNTIL UPPER VOLTMETER RADIATOR INLET AND N E E D L E STOPS IS HOT I CHECK READING VOLTAGE IS READING 12 5V to 15 5...

Страница 178: ...test lamp should not light Test Results If ohmmeter indicates other than infinity or test lamp lights a short to ground exists Check soldered con nections at slip rings to be sure they are secure and...

Страница 179: ...sembly Refer to Disassembly for procedure An ohmmeter set to the 1 scale is used to perform the tests Touch ohmmeter leads to two stator leads and note reading fig 1E 8 Test all stator leads in this m...

Страница 180: ...E Do not use high voltage such as a 110 volt test lamp to check this unit 1 Connect ohmmeter to grounded heat sink and one of three terminal tabs fig 1E 11 Note reading 2 Reverse ohmmeter lead connect...

Страница 181: ...ure sensitive tape and not friction tape which would leave a gummy deposit on the shaft If brushes are to be reused clean with a soft dry cloth 4 Place rotor in vise and tighten vise only enough to pe...

Страница 182: ...slip rings for dirt and roughness Clean with solvent If necessary clean and finish slip rings with commutator paper or 400 grit polishing cloth Do not use metal oxide paper Spin rotor in lathe or othe...

Страница 183: ...all drive pulley nut 6 Place rotor in vise Tighten vise only enough to permit tightening of pulley nut 7 Alternate method of tightening pulley nut re quires use of Allen wrench to hold rotor from turn...

Страница 184: ...screw 19 Connect capacitor lead to rectifier bridge and tighten securely 20 Position diode trio to end housing 21 Install diode trio lead clip screw making sure insulating washer is over top of diode...

Страница 185: ...Solid State Adjustment None J 21008 CONTINUITY LIGHT 7 0 2 7 1 7 0 1 3 8 Torque Specifications Service Set To Torques should be used when assembling components Service In Use Recheck Torques should be...

Страница 186: ...nt to the Jeep part number The date is decoded as follows Year 8 1978 9 1979 Month A Jan B Feb Week A first week in month B second week Field Coils Four field coils are used Each is wrapped around an...

Страница 187: ...voltage to the starter solenoid S terminal when the ignition key is in the Start position This voltage energizes the solenoid pull in coil completing the circuit between the battery and the starter m...

Страница 188: ...LY STARTER CIRCUIT SHOWN NEUTRAL SAFETY SWITCH AUTOMATIC TRANSMISSION TO OTHER VEHICLE CIRCUITS AMMETER CHEROKEE WAGONEER AND TRUCK ONLY FUSIBLE LINK 14 GAUGE RED CJ YELLOW CKE WAG TRK SOLENOID PULL I...

Страница 189: ...nt 5 Check drive yoke pull down and point gap check for worn end bushings check ring gear clearance 6 Engine seized 6 Repair engine STARTER DRIVE WILL NOT ENGAGE SOLE NOID KNOWN TO BE GOOD 1 2 3 Defec...

Страница 190: ...w 2 Disconnect and ground ignition coil secondary wire 3 Connect remote control starter switch between battery positive terminal and S terminal of starter solenoid 4 Connect battery starter tester lea...

Страница 191: ...H R E E S E C O N D S 6 CYL 8 CYL TURN LOAD CONTROL UNTIL VOLTMETER SHOWS SAME VOLTAGE AS WHEN CRANKING 9 READ AMMETER NOTE READING FOR USE IN LATER STEPS OK 150 180 AMPS 160 210 AMPS ABOVE 180 AMPS...

Страница 192: ...ST MAXIMUM VOLTAGE DROP BY STARTER DRAW AMPERAGE AMPS 150 210 215 295 300 420 425 600 VOLTS 0 2V 0 3V 0 4V 0 5 V OK VOLTAGE AT OR BELOW MAX I MUM REPAIR SOLENOID VOLTAGE ABOVE MAXIMUM REPAIR BATTERY T...

Страница 193: ...end of the armature shaft 3 Disconnect starter from battery 4 Turn load control knob toward INCREASE clockwise until voltmeter reading matches reading ob tained with starter connected to battery If th...

Страница 194: ...nsulated Brush Connection Tsat TerminaMo Brush Continuity Test This test checks all field coil solder joints 1 Insert piece of paper between contact points to act as insulator fig 1F 9 2 Touch ohmmete...

Страница 195: ...lade parallel to and touching arma ture core Slowly rotate armature one or more revolu tions in growler jaws If steel blade vibrates at any area of core area is shorted and armature must be replaced A...

Страница 196: ...ssembly and armature Cleanini and Inspection 1 Use brush or air to clean starter frame field coils armature drive assembly and drive end housing 2 Wash all other parts in solvent and dry parts NOTE Do...

Страница 197: ...e of the ring gear 9 Inspect drive assembly clutch by grasping and rotating pinion gear Gear should rotate freely in one direction and lock in opposite direction 10 Inspect for broken brush springs Re...

Страница 198: ...rive End Bushing 1 Support drive end housing and remove original bushing and seal 2 Install replacement bushing using armature and pinion as bushing driver Do not install drive end hous ing seal at th...

Страница 199: ...ever in Park position and lock steering column 6 Move switch actuating lever of replacement switch to align with letter P stamped on back of switch 7 Insert 3 32 inch drill in hole located below lette...

Страница 200: ...ists of several major components ignition switch electronic ignition control unit ignition coil primary resistance wire and bypass distributor ignition wires and spark plugs CDitfDi O l i t The electr...

Страница 201: ...nector are of unique design Remove the connector from the coil by grasping both sides and pulling connector away from coil fig 1G 2 Fig IK Amoving Cill Connector When a tachometer is required for engi...

Страница 202: ...o as centrifugal spark advance When the engine is running under light load the car buretor throttle plates restrict airflow This causes a relatively lean mixture to enter the combustion cham bers Igni...

Страница 203: ...t Distributor Spark knock is not a failure mode The engine will start and will continue to run If not corrected spark knock can do extensive damage to internal engine components Ful Failure Diagnosis...

Страница 204: ...e organized to permit test ing each primary circuit separately and in the most logical order When the problem is located it is not necessary to perform further tests NOTE Perform the DARS charts in or...

Страница 205: ...6 Distributor leads installed in 6 Install leads correctly wrong sockets Install leads correctly EXCESSIVE FUEL 1 Incorrect ignition timing 1 Check timing Adjust as required CONSUMPTION Check timing...

Страница 206: ...ON SYSTEM 1G 7 SSI SYSTEM DIAGNOSIS AND REPAIR SIMPLIFICATION DARS CHART Note Refer to Chapter A General Information for details on how to use this D A R S chart C h a r t 1 STEP SEQUENCE RESULT 8 0 6...

Страница 207: ...TERMINAL IGNITION REMAINS ON OBSERVE VOLTAGE AT COIL POSITIVE TERMINAL VOLTAGE REMAINS AT BATTERY VOLTAGE REPLACE STARTER SOLENOID CONNECT JUMPER BETWEEN COIL NEGATIVE TERMINAL AND GROUND VOLTAGE DROP...

Страница 208: ...SISTANCE ACCEPTABLE 1 35 1 05 OHMS REPAIR RESISTANCE WIRE CONNECT OHMMETER BETWEEN DASH CONNECTOR A V A N D IGNITION SWITCH TERMINAL 11 I IGNITION REMAINS OFF o RESISTANCE ACCEPTABLE LESS T H A N 0 1...

Страница 209: ...1G 10 IGNITION SYSTEM Chart 2 STEP SEQUENCE RESULT LIMITS 80699D...

Страница 210: ...STEP SEQUENCE RESULT FROM CENTER TOWER OF DISTRIBUTOR AND HOLD 1 2 INCH FROM ENGINE WITH INSULATED PLIERS 8 0 6 9 9 E...

Страница 211: ...BOVE 0 002 OHM OHMMETER INDICATES ABOVE 0 002 OHM CONNECT OHMMETER BETWEEN D1 A N D BATTERY NEGATIVE TERMINAL LOCATE AND REPAIR SOURCE OF BAD GROUND GROUND CABLE RESISTANCE DISTRIBUTOR TO BLOCK RESIST...

Страница 212: ...ODULE AND CONNECT VOLTMETER BETWEEN F 2 AND GROUND mi VOLTMETER DOES NOT INDICATE BATTERY VOLTAGE WITHIN 0 2V OK LOCATE A N D REPAIR CAUSE OF VOLTAGE REDUCTION CORRODED DASH CONNECTOR IGNITION SWITCH...

Страница 213: ...move connector from coil 2 Depress plastic barb and withdraw positive wire from connector Barb is visible from coil side of connector Eigne Spark Knock Ping Piaposis Spark knock can be attributed to a...

Страница 214: ...gine Note posi tion of rotor and distributor housing in relation to sur rounding engine parts as reference points for installing distributor 5 Remove distributor holddown screw and clamp 6 Withdraw di...

Страница 215: ...magnetic probe and timing is indicated on a meter 8 Operate engine at 500 rpm and observe timing mark with timing light Rotate distributor housing as needed to align timing mark on vibration damper w...

Страница 216: ...ase plate screws for necessary clearance 3 Eight cylinder remove distributor cap Re move retainer from sensor pin Remove attaching screws and lift vacuum unit from distributor body Installation 1 If r...

Страница 217: ...s and foot pounds with dry fits unless otherwise specified 7 0 8 7 0 Distributor Wiring Sequence and Firing Order 0 0 CLOCKWISE ROTATION 1 5 3 6 2 4 SIX CYLINDER ENGINES FRONT 0 LEFT BANK CLOCKWISE RO...

Страница 218: ...ort 1 Carburetor ported vacuum is admitted through port 2 and is applied to port D The distributor spark advance diaphragm is now operated by ported vacuum This may be regarded as the normal operating...

Страница 219: ...rt 1 Carb closes and Port 2 Manifold is connected to Port D Dist Manifold vac uum should now be indicated Spark CTO Replacement Removal Six Cylinder 1 Drain coolant from radiator 2 Code vacuum lines a...

Страница 220: ...inear vacuum regulator valve With the en gine at idle speed a vacuum reading of 7 in Hg should be indicated As the throttle is opened and engine speed increases ported vacuum from the carburetor shoul...

Страница 221: ...NOTES...

Страница 222: ...slide switch to the RES position and releasing the switch When the RES function is used the rate of acceleration is regulated by engine intake manifold vac uum The rate of acceleration cannot be adju...

Страница 223: ...the actuator against the flyweights When the shaft is spun by the speedometer cable the flyweights are thrown outward by centrifugal force This forces the actuator to slide away from the flyweights a...

Страница 224: ...ON position current is supplied through the pushbutton to the cou pling coil which is energized The coupling coil grounds through the regulator case Note that the solenoid valve is in the relaxed pos...

Страница 225: ...move out ward uncovering the vacuum bleed port Decreased vac uum at the bellows causes the throttle to close Brake Release In the speed setting phase and the speed maintaining phase the vacuum soleno...

Страница 226: ...e the coupling coil circuit was not disturbed during brake release it continues to control vacuum bleed When the resume switch is returned to the ON posi tion the hold in circuit keeps the vacuum sole...

Страница 227: ...on Depressed Slide Switch On Red Brown Open Closed Closed Closed Red Green Open Closed Closed Open Red Yellow Open Open Closed Closed NOTE Pushtutton cannot be depressed with slide switch in resume po...

Страница 228: ...st lamp should light on brown and yellow wires and should not light on dark green or blue wire 6 Release SET SPEED button 7 Move slide switch to RES position and hold Ground one test lamp lead and tou...

Страница 229: ...test lamp lead to brown wire and then dark green wire Test lamp should light on these wires Touch lead to yellow wire Lamp should not light 13 Push SET SPEED in and hold Test lamp should light on brow...

Страница 230: ...heck from regulator to mounting bracket 6 Bad relay ground 6 Check ground wire for loose con nection use ohmmeter check from relay case to known good ground 7 Faulty connections 7 Check connections re...

Страница 231: ...hrottle chain linkage NOT RETURN TO adjustment NORMAL IDLE OR PULSATING 2 Speedometer cable or drive cable 2 Lubricate cable including tips ACCELERATOR PEDAL SPEEDOMETER 1 Speedometer cable not drivin...

Страница 232: ...o ground Correct any stoplamp problem before proceeding Check for burned out bulbs improper ground connections open or grounded circuits in the brake release switch or wire harness 1 Check all harness...

Страница 233: ...guide and pulley assembly Centering Spring Adjustment NOTE The centering spring adjustment is extremely sensitive and must never be turned more than one eighth turn in either direction Adjustment is m...

Страница 234: ...1 Remove the following Horn button insert Steering wheel Anti theft cover Locking plate and horn contact 2 Remove turn signal lever allow handle to hang loose outside steering column 3 Remove four wa...

Страница 235: ...NOTES...

Страница 236: ...e Maintenance Schedule More frequent replace ment is advisable when the vehicle is operated in dusty areas or on unpaved roads The air cleaner inlet neck contains the air valve for the Thermostaticall...

Страница 237: ...raps which run front to rear A fuel tank skid plate is optional on Cherokee Wagoneer and Truck models The various fuel tank and venting arrangements are illustrated in figures 1J 3 1J 4 and 1J 5 The f...

Страница 238: ...tlet and return lines 2 Position tank on jack 3 Connect outlet and return lines and sending unit wire 4 Raise tank and install straps 5 Connect four hoses at left front corner of tank 6 Install skid p...

Страница 239: ...1J 4 FUEL SYSTEMS Fig 1J 4 Fuel Tank and Vent Lines Cherokee and Wagoneer Models Fig 1J 5 Fuel Tank and Vent Lines Truck Models...

Страница 240: ...owl are collected in a charcoal filled canister and are metered into the intake manifold for combustion On all vehicles a rollover valve in the vent system prevents fuel from flowing out of the vent l...

Страница 241: ...ir cleaner for proper fuel flow This is accomplished by automatically closing the bowl vent by a mechanical link to the throttle Refer to Float Circuit in each carburetor subsection for specific opera...

Страница 242: ...Chapter 1L Power Plant Instrumentation for Operation Diagnosis and Replacement Service of the sending unit is covered under Fuel Tank in this chapter FUEL PUMP A single action stamped fuel pump is us...

Страница 243: ...raduated container 6 Operate engine at curb idle rpm and vent system into container by momentarily opening hose restrietor 7 Close hose restrietor allow pressure to stabilize and note gauge reading Ga...

Страница 244: ...taining screws 3 Remove pump and gasket Installation 1 Install pump and replacement gasket NOTE Be sure actuating lever is positioned properly on camshaft eccentric 2 Install retaining screws 3 Connec...

Страница 245: ...n 6 0 4 3 1 Fig 1J 17 Float Circuit When the fuel in the bowl fills to the proper level the float lever pushes the needle toward its seat and re stricts incoming fuel admitting only enough to replace...

Страница 246: ...pening Pump Circuit When the throttle is opened suddenly airflow re sponse through the carburetor is almost immediate FUEL SYSTEIS 1J 11 Fig 1J 19 Main Metering Circuit There is a brief time lag befor...

Страница 247: ...ever and disconnect vacuum hoses return spring choke clean air tube PCV hose fuel line choke heat tube and sole noid wire if equipped 4 Remove carburetor retaining nuts Remove car buretor Remove carbu...

Страница 248: ...VENTURI CLUSTER 25 GASKET 26 CHECK BALL SMALL 27 FLOAT 28 FULCRUM PIN 29 BAFFLE 4 30 CLIP 31 CHOKE LINK 32 SCREW 33 FAST IDLE CAM 34 GASKET 35 THERMOSTATIC CHOKE SHAFT 36 SPRING 37 SCREW 38 PUMP LINK...

Страница 249: ...Remove vacuum hose from carburetor main body and choke vacuum diaphragm Remove choke dia phragm linkage and bracket assembly Place dia phragm aside to be cleaned separately 8 Remove fast idle cam ret...

Страница 250: ...springs from throttle body 19 Remove screws attaching throttle body to main body and separate bodies Discard gasket Cleaning and inspection Dirt gum water or carbon contamination in the ca buretor or...

Страница 251: ...heck valve firmly against its seat Raise piston and press down No fuel should be emitted from either intake or discharge passages fig 1J 29 5 Clean passages and ball seat if leakage is evi dent If lea...

Страница 252: ...ing screw clockwise makes the fuel mixture richer Turning the adjusting screw counterclockwise makes the fuel mixture leaner Turn adjusting screw to set gap Refer to Specifications Vacuum Piston Adjus...

Страница 253: ...plate and air horn wall Refer to Specifications 5 Adjust clearance by bending diaphragm con nector link fig 1J 34 Fig 1J 34 Initial Choke Valve Clearance Fast Idle Cam Position Adjustment 1 Loosen cho...

Страница 254: ...Install choke control rod 6 Install choke lever to shaft 7 Install housing cover and set to specification SPECIFICATIONS Model BBD Carburetor Calibrations inches 8185 8186 8187 8188 8195 8229 Throttl...

Страница 255: ...0 1500M 1600A 1400 1600 1500 1700 T 8229 258 Manual Hilly Terrain 0 25 0 218 to 0 282 0 035 0 020 to 0 050 0 128 0 113 to 0 143 0 095 0 080 to 0 110 1NR 1 2 t o 1 1 2 0 520 0 500 to 0 540 0 280 1500 1...

Страница 256: ...engine The amount of fuel entering the bowl is regulated by the distance the fuel inlet needle is raised off its seat The float drops as the fuel level drops and raises the fuel inlet needle off its s...

Страница 257: ...n wells The fuel then moves up the main well tubes where it is mixed with air The air supplied through the main air bleeds mixes with the fuel through small holes in the sides of the main well tubes T...

Страница 258: ...ttle valves are closed The diaphragm return spring exerts force against the diaphragm and pushes it against the cover FUEL SYSTEMS 1J 23 Fuel is drawn through the inlet past the Elastomer valve and in...

Страница 259: ...cam rotates free of the fast idle speed adjusting screw allowing the throttle lever to return to curb idle If the engine is accelerated during the warmup period the resulting drop in manifold vacuum a...

Страница 260: ...ROD RETAINER PUMP LEVER BOWL VENT BELLCRANK FUEL INLET FITTING POWER VALVE GASKET POWER VALVE POWER VALVE COVER GASKET POWER VALVE COVER POWER VALVE COVER RETAINING SCREW 4 IDLE LIMITER CAP 2 IDLE MI...

Страница 261: ...ir horn and air horn gasket 4 Remove choke rod by loosening screw that se cures choke shaft lever to choke shaft Remove rod and plastic dust seal from air horn 5 Remove choke modulator assembly fig 1J...

Страница 262: ...g 1J 52 18 Remove Elastomer valve by grasping firmly and pulling out NOTE If the Elastomer valve tip breaks off during removal be sure to remove the tip from the fuel bowl Elastomer valve must be repl...

Страница 263: ...dle speed adjusting screw and spring on fast idle lever 2 Install solenoid if removed 3 Place fast idle lever assembly on throttle shaft and install retaining washer and nut 4 Lubricate tip of replace...

Страница 264: ...in body and gasket so that choke valve rod fits through opening in main body Be sure plastic shield is free to slide 38 Insert end of choke valve rod into choke valve lever 39 Install air horn attachi...

Страница 265: ...ermit to idle one minute to stabilize fuel level Turn engine off and check fuel level after each adjustment until specified level is obtained 5 Install replacement air horn gasket air horn assembly ca...

Страница 266: ...buretor casting or linkage After carburetor instal lation check for full throttle opening when throttle is operated from inside vehicle If full throttle opening is not obtainable it may be necessary t...

Страница 267: ...ompletely off fast idle cam 2 Manually depress stem of bowl vent valve and insert gauge between valve stem and flat on end of bellcrank Refer to Specifications for clearance 3 If clearance is not corr...

Страница 268: ...arburetor Overhaul 1J 34 Goners IJ 33 The Motorcraft Model 2150 carburetor with altitude compensation is installed on eight cylinder engines in vehicles sold for use at elevations of 4000 1 219 m feet...

Страница 269: ...is not adjustable ALTITUDE COMPENSAT80N CHOKE VALVE Fig 1J 64 ConpRSStloEi E t a Ctote Mm A thermostatic coil is used to operate the choke valve for cold engine start up The bimetal coil winds up whe...

Страница 270: ...rm the following Altitude Compensation ftsssiif Adjustment There are no adjustments to this assembly Do not attempt to turn the fitting on the aneroid It is set and sealed at the factory Initial Choke...

Страница 271: ...sts of a deceleration valve located at the right front side of the intake manifold and a throttle modulating diaphragm located at the carburetor base The deceleration valve is connected by one hose to...

Страница 272: ...with in tegral back pressure sensor EGR system with exter nal non integral back pressure sensor Fig U 68 Ell System Six Cylinder Typical The EGR CTO switch prevents EGR action until en gine temperatu...

Страница 273: ...es The unit combines the functions of the EGR valve and back pressure transducer into a single component A restrietor plate is not required FROM CARBURETOR PORTED VACUUM SOURCE A 4 2 0 1 3 Fig 1J 72 E...

Страница 274: ...cer if used EGR gasket and EGR valve 2 Install retaining screws and tighten 3 Connect vacuum lines and install air cleaner assembly if removed NOTE The non integral exhaust back pressure assem bly if...

Страница 275: ...from intake manifold Installation Eight Cylinder Engine 1 Install EGR CTO switch in intake manifold 2 Install coil and bracket with attaching screw 3 Connect vacuum hose to switch 4 Install air cleane...

Страница 276: ...pect for partially open throttle plate which could apply premature ported vacuum to back pressure sensor 5 Accelerate engine to 2000 rpm and observe vac uum gauge for the following If coolant temperat...

Страница 277: ...hrough the crankcase the vapor filled air is drawn HOSE TO MANIFOLD VACUUM SOURCE NON VENTED AT Fig U 77 PCV System Eight Cylinder Engine through the PCV valve into the intake manifold The vapors mix...

Страница 278: ...ix Cylinder Eight Cylinder A polyurethane foam PCV air inlet filter is located in the sealed oil filler cap 1 Remove oil filler cap from engine 2 Apply light air pressure in reverse direction of norma...

Страница 279: ...Remove air cleaner assembly from engine and allow to cool to room temperature 2 After cooling sight through air cleaner snorkel to observe position of air valve It should be fully open to outside air...

Страница 280: ...rrent to the fan through the sensor If the underhood temperature is above the sensor switching temperature the circuit is closed and the cool ing fan operates If during carburetor cooling operation th...

Страница 281: ...LACEMENT Removal 1 Open hood 2 Remove duct from fan 3 Unplug fan and remove screws 4 Remove vent and fan 1 Install vent and fan 2 Connect fan leads 3 Connect duct to fan 4 Close hood Carburetor Bowl C...

Страница 282: ...FUEL SYSTEMS 1J47 Tools J 23738 HAND OPERATED VACUUM PUMP...

Страница 283: ...NOTES...

Страница 284: ...parts that are badly corroded or damaged Do not attempt to repair RESTRICTED EXHAUST SYSTEM DIAGNOSIS A restricted or blocked exhaust system usually results in loss of power or popping through the ca...

Страница 285: ...t ports of exhaust manifold for casting flash by dropping length of chain into each port NOTE Do not use a wire or a light to check ports The restricted opening may be large enough for them to pass th...

Страница 286: ...EXHAUST SYTEMS 1K 3 8 0 2 3 0 Fig 1K 2 Exhaust System Eight Cylinder CJ Models...

Страница 287: ...TAILPIPE Fig 1K 3 Exhaust System Six Cylinder Cherokee TRANSMISSION AUTOMATIC TRANSMISSION Fig 1K 4 Exhaust System Eight Cylinder Cherokee and Wagoneer...

Страница 288: ...3 SPEED TRANSMISSION 8 0 1 3 7 Fig 1K 5 Exhaust System Six Cylinder Truck TAILPIPE HEAT VALVE GASKET WASHER 3 SPEED TRANSMISSION 4 SPEED TRANSMISSION AUTOMATIC TRANSMISSION 8 0 1 3 8 Fig 1K 6 Exhaust...

Страница 289: ...mp and set aside if equipped Do not remove hoses 13 Remove air conditioning drive belt idler assem bly from cylinder head if equipped 14 Disconnect exhaust pipe from manifold flange 15 Remove manifold...

Страница 290: ...anifold and retaining screws Tighten screws to 38 foot pounds 52 N m torque Tighten screws to 25 foot pounds 34 N m torque 4 Connect exhaust pipe using replacement seal if required Tighten nuts to 20...

Страница 291: ...haust heat through the intake manifold crossover passage fig 1K 11 The ex haust heat crosses through the intake manifold and dis charges into the left exhaust manifold until the engine reaches operati...

Страница 292: ...m USA ft lbs Metric N m Service Set To Torque Exhaust and Intake Manifold Screws and Nuts Six Cylinder 23 Exhaust Manifold Screws Eight Cylinder Center 2 25 Outer 4 15 Exhaust Pipe to Manifold Nuts 20...

Страница 293: ...ront bearing The housing also includes cast metering areas that reduce the noise of intake and compression Mounting bosses are located on the housing exterior NOTE The relief valve assembly is incorpo...

Страница 294: ...n aluminum housing to adjust belt tension Do not clamp pump in vise Do not permit liquids to enter pump when steam or pressure cleaning engine Sorwiio Prooolyres Removal Six Cylinder Engine 1 Disconne...

Страница 295: ...lso operates when pump output exceeds 5 psi 8 psi on some models 4 Slowly accelerate engine Between 2500 and 3500 rpm air should begin to flow from diverter vents Diverter Replacement The diverter val...

Страница 296: ...ylinder Eight Cylinder All torque values given in foot pounds and newton meters with dry fits unless otherwise specified Service Service Service In Use Service In Use Set To Recheck Set To Recheck Tor...

Страница 297: ...air pump or ignition problem should be corrected at the same time the converter is replaced and all other components of the exhaust sys t tern should also be checked for heat damage CATALYST REPLACEME...

Страница 298: ...ective and must be replaced 11 When coverter is full remove shop air hose from vibrator and remove vibrator from converter 12 Install plug on bottom of converter a Install screw into bridge and positi...

Страница 299: ...NOTES...

Страница 300: ...t voltage regulator CVR fuel gauge oil pressure gauge tachometer temperature gauge and voltmeter fig 1L 1 and 1L 2 These gauges are all electrically operated OPERATION Ammeter The ammeter is standard...

Страница 301: ...bimetal strip which responds to temperature changes A heating coil wrapped around the bimetal provides heat to operate the bimetal Current flows from the CVR through the heating coil and is grounded t...

Страница 302: ...onnect test lamp or ohmmeter lead to ground pin terminal and other lead to cluster metal case Test lamp should light or ohmmeter should read zero ohms 7 Replace printed circuit if lamp fails to light...

Страница 303: ...e moves but indicates a temperature that does not correspond with actual coolant temperature Needle moves to top of scale and remains there Needle pulsates Refer to DARS chart 6 for a systematic metho...

Страница 304: ...and face plate assembly Install attaching screws and washers 7 Check glass for fingerprints and debris 8 Install glass glass retaining bezel and outer be zel Crimp outer bezel lip four places 9 Insta...

Страница 305: ...and bracket behind in strument panel 3 Remove gauge from instrument panel 4 Position gauge in instrument panel opening 5 Install bracket and nuts 6 Connect wires in original locations and install lamp...

Страница 306: ...CATION D A R S C H A R T S P i i Fuel Gauge 1L 8 Fuel Gauge and Temperature Gauge Both Malfunction 11 19 Fuse Blown 1 U 7 Page Oil Pressure Gauge CJ Models 1L 21 Oil Pressure Gauge Cherokee Wagoneer T...

Страница 307: ...BEFORE STARTING TEST 1 0 ENGINE MUST BE WARM FUEL TANK MUST BE NEITHER COMPLETELY FULL NOR COMPLETELY EMPTY NEEDLE DOES NOT MOVE NEEDLE MOVES NEEDLE MOVES TO M A X I M U M AND STAYS NEEDLE PULSATES M...

Страница 308: ...POWER PUNT INSTRUMENTATION 1L 9 STEP SEQUENCE Chart 1 RESULT GROUND SENDER TERMINAL OF GAUGE STOP NEEDLE DOES NOT MOVE 6 LOCATE AND REPAIR OPEN CIRCUIT IN SENDER WIRE STOP 8 0 3 1 1 B...

Страница 309: ...FOR LOOSENESS AND CORROSION OK VOLTAGE PRESENT STOP o GROUND SENDER TERMINAL OF GAUGE NEEDLE DOES NOT MOVE NEEDLE MOVES REPAIR OPEN CIRCUIT IN SENDER WIRE GROUND FUEL GAUGE PIN TERMINAL ON CIRCUIT BOA...

Страница 310: ...IGNITION ON ADJUST TESTER TO SELECT OHM VALUES LISTED IN SENDING UNIT RESISTANCE REQUIREMENTS CHART OBSERVE FUEL GAUGE INDICATION AT EACH OHM SETTING GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING...

Страница 311: ...SOLDER OK NO LOOSE SOLDER REPLACE SENDING UNIT O 3 LOOSE SOLDER PRESENT REMOVE LOOSE SOLDER STOP STOP i t DISCONNECT BATTERY NEGATIVE CABLE REMOVE INSTRUMENT CLUSTER DO NOT DISCONNECT WIRE HARNESS CON...

Страница 312: ...ARD CHEROKEE WAGONEER TRUCK STOP i STOP STOP CONNECT ONE TESTER LEAD TO GROUND AND ONE LEAD TO SENDING UNIT WIRE GAUGE INDICATIONS NOT ACCURATE A T EACH OHM SETTING TURN IGNITION ON ADJUST TESTER TO S...

Страница 313: ...ON REPLACE IF NECESSARY AND TIGHTEN CONNECT BATTERY NEGATIVE CABLE CONNECT JUMPER WIRE FROM CLUSTER CASE TO GROUND CONNECT ONE TESTER LEAD TO FUEL GAUGE SENDING UNIT TERMINAL AND OTHER LEAD TO GROUND...

Страница 314: ...O GROUND CONNECT ONE TESTER LEAD TO FUEL GAUGE SENDING UNIT PIN TERMINAL A N D OTHER LEAD TO GROUND OK S T O P GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING REPLACE SENDING UNIT WIRE REPEAT TEST WITH...

Страница 315: ...CIRCUIT BOARD O r f i OHMMETER CONNECT OHMMETER LEADS TO GAUGE INPUT TERMINAL AND GAUGE SENDER TERMINAL COMPARE OHMMETER READING WITH VALUES LISTED IN GAUGE RESISTANCE VALUES CHART GAUGE RESISTANCE CO...

Страница 316: ...DOWN CIRCUIT REPAIR AS NECESSARY STOP DISCONNECT AUTOMATIC TRANSMISSION KICKDOWN SWITCH SHORT INDICATED SHORT NOT REPLACE INDICATED KICKDOWN SWITCH REMOVE INSTRUMENT CLUSTER DISCONNECT INSTRUMENT WIRE...

Страница 317: ...CHECK CIRCUIT BOARD FOR OBVIOUS DAMAGE OK CIRCUIT BOARD NOT DAMAGED CIRCUIT BOARD DAMAGED REPLACE CVR DETERMINE CAUSE OF DAMAGE CVR OR GAUGE FAULTY REPLACE CIRCUIT BOARD AND FAULTY COMPONENT CHECK INS...

Страница 318: ...T I O N S A M E A S S T E P 1 C H E R O K E E W A G O N E E R T R U C K CJ R E P A I R O R R E P L A C E I N S T R U M E N T P A N E L W I R E H A R N E S S STOP C H E C K G A U G E N U T S FOR A N D...

Страница 319: ...ER ATTACHMENT USING SAME TEST SET UP AS STEP 4 MOVE VOLTMETER CONNECTOR FROM CVR TERMINAL TO RADIO NOISE SUPPRESSOR OR CONNECTOR STRIP OUTPUT TERMINAL VOLTMETER INDICATION SAME AS STEP 1 VOLTMETER IND...

Страница 320: ...FILLED TO SPECIFICATION FUEL TANK MUST BE NEITHER COMPLETELY FULL NOR COMPLETELY EMPTY NEEDLE MOVES NEEDLE MOVES TO MAXIMUM AND STAYS NOTE Indicated Readings are Observed from Driver s Seat 6 OBSERVE...

Страница 321: ...TURN IGNITION ON CONNECT JUMPER WIRE FROM GAUGE GROUND STUD TO GOOD BODY GROUND VOLTAGE NOT PRESENT VOLTAGE PRESENT LOCATE AND REPAIR FAULT IN IGNITION FEED TO OIL GAUGE OK STOP NEEDLE MOVES LOCATE A...

Страница 322: ...AINS AT MAXIMUM m CONNECT ONE TESTER LEAD TO GROUND AND ONE LEAD TO SENDING UNIT WIRE TURN IGNITION ON m ADJUST TESTER TO SELECT OHM VALUES LISTED IN SENDING UNIT RESISTANCE REQUIREMENTS CHART OBSERVE...

Страница 323: ...ER PLANT INSTRUMENTATION hart 4 STEP SEQUENCE RESULT NEEDLE REMAINS AT MAXIMUM GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING GAUGE INDICATIONS REPLACE ACCURATE AT SENDING EACH OHM SETTING UNIT 8...

Страница 324: ...LE CONNECT JUMPER WIRE FROM GAUGE GROUND STUD TO BODY GROUND CONNECT ONE TESTER LEAD TO OIL GAUGE SENDING UNITS TERMINAL STUD AND OTHER LEAD TO GROUND GAUGE INDICATIONS NOT OBTAINED l O K J AT EACH OH...

Страница 325: ...BEFORE STARTING TEST OIL PAN MUST BE FILLED 3 TO SPECIFICATION FUEL TANK MUST BE NEITHER COMPLETELY FULL NOR COMPLETELY EMPTY NEEDLE DOES NOT MOVE NEEDLE MOVES NEEDLE MOVES TO M A X I M U M AND STAYS...

Страница 326: ...OSION VOLTAGE REPLACE NOT PRESENT CIRCUIT BOARD OK VOLTAGE PRESENT H STOP 6 GROUND SENDER TERMINAL OF GAUGE NEEDLE DOES NOT MOVE 0 I GROUND GAUGE PIN TERMINAL ON CIRCUIT BOARD REPAIR OPEN CIRCUIT IN S...

Страница 327: ...IGNITION ON ADJUST TESTER TO SELECT OHM VALUES LISTED IN SENDING UNIT RESISTANCE REQUIREMENTS CHART OBSERVE GAUGE INDICATION AT EACH OHM SETTING GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING OK...

Страница 328: ...ENDING i UNIT WIRE FROM CLUSTER NEEDLE DROPS FROM MAXIMUM REPAIR OR REPLACE SENDING UNIT WIRE NEEDLE REMAINS AT MAXIMUM REPLACE CIRCUIT BOARD DISCONNECT SENDING UNIT WIRE GAUGE INDICATIONS NOT ACCURAT...

Страница 329: ...ER CASE TO GROUND CONNECT ONE TESTER LEAD TO OIL GAUGE SENDING UNIT PIN TERMINAL AND OTHER LEAD TO GROUND OK GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING REPLACE SENDING UNIT WIRE GAUGE INDICATIONS...

Страница 330: ...RESULT OHMMETER CONNECT OHMMETER LEADS TO GAUGE INPUT TERMINAL AND GAUGE SENDER TERMINAL COMPARE OHMMETER READING WITH VALUES LISTED m GAUGE RESISTANCE VALUES CHART OK GAUGE RESISTANCE CORRECT REPLAC...

Страница 331: ...WARM r j x FUEL TANK MUST BE W NEITHER COMPLETELY FULL w NOR COMPLETELY EMPTY NEEDLE DOES NOT MOVE NEEDLE MOVES NEEDLE MOVES TO M A X I M U M AND STAYS NEEDLE PULSATES MORE T H A N WIDTH OF NEEDLE REP...

Страница 332: ...POWER PLANT INSTRUMENTATION STEP SEQUENCE Chart 6 RESULT 8 0 3 1 6 B...

Страница 333: ...1L 34 POWER PLANT INSTRUMENTATION Chart 6 STEP SEQUENCE RESULT WIRE FROM SENDING UNIT AT MAXIMUM...

Страница 334: ...ONE LEAD TO SENDING UNIT WIRE TURN IGNITION ON ADJUST TESTER TO SELECT OHM VALUES LISTED IN SENDING UNIT RESISTANCE REQUIREMENTS CHART OBSERVE GAUGE INDICATION A T EACH OHM SETTING GAUGE INDICATIONS N...

Страница 335: ...UM REPLACE CIRCUIT BOARD CHEROKEE WAGONEER TRUCK CONNECT ONE TESTER LEAD TO GROUND AND ONE LEAD TO SENDING UNIT WIRE TURN IGNITION ON m ADJUST TESTER TO SELECT OHM VALUES LISTED IN SENDING UNIT RESIST...

Страница 336: ...REPLACE F NECESSARY AND TIGHTEN CONNECT BATTERY NEGATIVE CABLE CONNECT JUMPER WIRE FROM CLUSTER CASE TO GROUND CONNECT ONE TESTER LEAD TO TEMPERATURE GAUGE SENDING UNIT TERMINAL AND OTHER LEAD TO GROU...

Страница 337: ...TO GROUND CONNECT ONE TESTER LEAD TO TEMPERATURE GAUGE SENDING UNIT PIN TERMINAL AND OTHER LEAD OK TO GROUND GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING REPLACE SENDING UNIT WIRE O K REPEAT TEST W...

Страница 338: ...REPLACE GAUGE 0 CONNECT OHMMETER LEADS TO GAUGE INPUT TERMINAL A N D GAUGE SENDER TERMINAL COMPARE OHMMETER READING WITH VALUES LISTED IN GAUGE RESISTANCE VALUES CHART OK GAUGE RESISTANCE CORRECT REP...

Страница 339: ...0 6 7 4 Fuel Gauge Resistance Internal CONTINUITY OHMS S to Ground 68 to 72 S to I 19 to 21 S to A 19 to 21 I to A ZERO I to Ground 49 to 51 A to Ground 49 to 51 8 0 6 7 1 Tachometer Calibrations RPM...

Страница 340: ...3 OIL GAUGE GROUND 4 VOLTMETER TERMINAL 5 VOLTMETER GROUND 6 FUEL GAUGE S TERMINAL 7 FUEL GAUGE A TERMINAL 8 FUEL GAUGE l TERMINAL 9 TEMPERATURE GAUGE S TERMINAL 10 TEMPERATURE GAUGE A TERMINAL Instr...

Страница 341: ...IGNITION SWITCH STARTER SOLENOID SPLICE RED OIL PRESSURE SENDING UNIT Oil Pressure Gauge Circuit CJ 8 0 2 8 8 TEMPERATURE GAUGE CVR INSIDE FUEL GAUGE TEMPERATURE GAUGE SENDING UNIT VOLTMETER YELLOW S...

Страница 342: ...uel Gauge Resistance Internal S to A 19 to 21 ohms 8 0 6 7 3 Oil Pressure Gauge Sending Unit Resistance Ohms PS 0 10 60 80 OHMS 69 77 35 38 13 15 9 5 10 5 8 0 6 7 8 Temperature Gauge Sending Unit Resi...

Страница 343: ...FEED SIDE OF RADIO SUPPRESSION 15 RADIO SUPPRESSION TO CVR LAMPS A ILLUMINATION B RIGHT TURN INDICATOR C LEFT TURN INDICATOR D BRAKE INDICATOR E EMERGENCY DRIVE INDICATOR F FASTEN BELT INDICATOR G NOT...

Страница 344: ...STARTER SOLENOID FUEL GAUGE SENDING UNIT Fuel Gauge Circuit Cherokee Wagoneer Truck Models 8 0 2 9 1 PRINTED CIRCUIT PRINTED CIRCUIT TEMPERATURE J J1 GAUGE CVR UJ A D CL AMMETER SPLICE C YELLOW IGNITI...

Страница 345: ...1L46 POWER PLANT INSTRUMENTATION Tools J 24538 FUEL AND TEMPERATURE GAUGE TESTER...

Страница 346: ...ER Propeller Shaft 2 E CHAPTER Axles 2 F CHAPTER Brakes 2 G CHAPTER Wheels and Tires 2 H Steering Columns E l E S Manual Steering Gear E l E S Power Steering Gear And Pump 2 L Steering Linkage 2 M Sus...

Страница 347: ......

Страница 348: ...with integral cushion springs and clutch friction material which is riveted to the hub fig 2A 1 The function of the cush ion springs is to absorb excessive torque loads and pro vide smoother clutch e...

Страница 349: ...m and slowly release clutch pedal When pressure plate makes initial contact with driven plate note clutch operation Press clutch pedal to floor and release accelerator pedal 3 Shift transmission into...

Страница 350: ...nt to shaft pilot hub 17 Install pilot bushing lubricating wick and install clutch components and transmission Refer to Clutch Installation NOTE Do not replace the throwout bearing unless it is defect...

Страница 351: ...al fully and shift transmission into first gear 2 Shift transmission into neutral but do not re lease clutch pedal 3 Wait 5 to 10 seconds and shift transmission into reverse If shift is smooth with no...

Страница 352: ...dition clean oil and dirt from clutch cover assembly using mineral spirits allow assembly to air dry and proceed to next step 7 Sand clutch cover pressure plate surface lightly using fine emery cloth...

Страница 353: ...ft Pilot Bushing Noise Pilot bushing noises can be described as squealing howling or elephant type trumpeting noises which are most noticeable when the engine is cold These noises occur during the fir...

Страница 354: ...ING OUTER SUPPORT BRACKET T H R O W O U T LEVER P R O T E C T I V E BOOT Fig 2A 3 Clutch Linkage CJ Models 60566 BUSHING PEDAL PEDAL SHAFT SHAFT INNER SUPPORT BRACKET W A V E WASHER O U T E R SUPPORT...

Страница 355: ...ng in clutch chatter when installed 7 Remove clutch cover bolts and remove cover and driven plate from flywheel NOTE Observe which side of the driven plate faces the flywheel before removing the plate...

Страница 356: ...ion or breakage Replace the bearing if it exhibits any of these conditions Transmission Front Bearing Cap Inspect the bearing cap for deep scoring or excessive wear Replace the bearing cap if worn or...

Страница 357: ...imately 1 8 inch from edge of bore fig 2A 5 41478 Fig 2A 5 M o u i A Dial tatotor 9 Rotate crankshaft and check face runout of housing Face runout must not exceed 0 010 inch 0 25 mm total indicator re...

Страница 358: ...rearward using a pry bar to elim inate end play 13 If adapter runout is above specified limits cor rect adapter misalignment as outlined in following steps 14 If adapter bore runout is within limits b...

Страница 359: ...g nut and re move switch from instrument panel 6 Disconnect wires at headlamp indicator and re move indicator from instrument panel 7 Remove steering column bezel 8 Disconnect clutch pedal push rod at...

Страница 360: ...ort bracket attaching bolts securely 14 Install steering column toe plates Tighten toe plate screws to 12 foot pounds 16 N m torque 15 Tighten bolts attaching steering column mount ing bracket to supp...

Страница 361: ...max 0 25 mm Clutch Housing Transmission Mounting Face to Crankshaft Centerline 0 010 max 0 25 mm Clutch Housing to Transmission Adapter Bore to Crankshaft Centerline 0 010 max 0 25 mm Clutch Housing...

Страница 362: ...CLUTCH 2A 15 Tools J 8001 DIAL INDICATOR SET J 1048 CLUTCH GAUGE PLATE J 22056 OR J 25353 ALIGNING TOOL J 23330 CLUTCH LEVER HEIGHT GAUGE 4 2 5 7 8...

Страница 363: ...NOTES...

Страница 364: ...KUP LAMP SWITCH A spring and plunger type backup lamp switch is used on all models The switch is located in the shift control housing and is actuated by the first reverse shift rail on Models T 150 an...

Страница 365: ...clutch housing or clutch housing to transmission adapter 5 Align and or tighten 6 Excessive transmission end play 6 Replace snap rings and thrust washer 7 Worn or loose engine mounts 7 Tighten or repl...

Страница 366: ...nsfer case and axle and remove shaft 9 Disconnect rear propeller shaft at transfer case 10 Disconnect speedometer cable backup lamp switch wires TCS switch wires if equipped and park ing brake cable i...

Страница 367: ...nd shift knob on shift lever 17 Check transmission for proper shifting 18 Check and correct lubricant level if necessary P i p Page Assembly 2B 7 Shift Control Housing 2B 11 Cleaning and Inspection 2B...

Страница 368: ...16 COUNTERSHAFT ACCESS PLUG 17 MAINSHAFT 18 MAINSHAFT SPACER 19 REAR BEARING ADAPTER LOCK RING 20 OIL SLINGER SPACER 21 REAR BEARING AND ADAPTER ASSEMBLY 22 WASHER 23 LOCKNUT 24 ROLL PIN 25 REVERSE ID...

Страница 369: ...0 5 5 2 Fig 21 7 Rear Bearing end Adapter Removal REVERSE IDLER GEAR SHAFT COUNTERBORE ALIGN ROLL PIN WITH COUNTERBORE WHEN INSTALLING 6 0 5 5 3 I Fig 2B 6 Clutch Shaft Removal Fig 21 8 Reverse Idler...

Страница 370: ...r at bolt holes Stripped threads in bolt holes Nicks burrs rough surfaces in shaft bores or on gasket surfaces Gear and Synchronizer Assemblies Broken chipped or worn gear teeth Damaged splines on syn...

Страница 371: ...embly 12 Install insert spring in first reverse hub Make sure spring is bottomed in hub and covers all three insert slots Position three T shaped inserts in hub with small ends in hub slots and large...

Страница 372: ...ce thrust washer and all snap rings on output shaft assembly 21 Install spacer and oil slinger on rear of main shaft Fig 2B 13 Second Third Synchronizer Assembly Fig 2B 14 Measuring Main Shaft End Pla...

Страница 373: ...cap oil return slot and case oil return hole are aligned 33 Make wire loop about 18 to 20 inches 45 7 to 50 8 cm long and pass wire under countershaft gear assem bly Wire loop will raise and support...

Страница 374: ...fork and roll pin NOTE The shift fork roll pin hole is offset Mark the position of the shift fork for assembly reference 8 Remove first reverse shift rail using brass drift or hammer Catch shift rail...

Страница 375: ...Shift Control Housing to Case Bolt 22 20 25 30 27 34 Transfer Case Drive Gear Locknut 150 145 155 203 197 210 Transfer Case to Transmission Case Bolts 30 25 35 41 34 47 TCS Switch 18 15 20 24 20 27 Al...

Страница 376: ...T REVERSE IDLER GEAR THRUST WASHER 2 REVERSE IDLER GEAR REVERSE IDLER GEAR BUSHING ROLLERS REVERSE IDLER GEAR SHAFT MAINSHAFTLOCKNUT MAINSHAFT WASHER MAINSHAFT BEARING SPACER REAR BEARING ADAPTER REAR...

Страница 377: ...haft using tool J 25203 fig 2B 22 17 Remove reverse idler gear thrust washers and roller bearings as assembly GEAR 4 2 5 8 6 Fig 2B 22 Reverse Idler Gear Removal Installation Main Shaft Gear Train Dis...

Страница 378: ...Mark synchronizer sleeve and hub for assembly reference and remove sleeve and shifting plates from hub 4 2 5 9 0 Fig 2B Z6 First Gear Synchronizer Assembly PLATES 4 2 5 8 9 Fig 21 21 Second Third Sync...

Страница 379: ...lotted end of shaft is correctly aligned with lock plate 4 Install center spacer and Arbor Tool J 25199 in countershaft gear bore 5 Install bearing washer at each end of center spacer Slide washers ov...

Страница 380: ...ce CAUTION Do not use chassis grease or similar heavy grease in the clutch shaft bore This type of grease may plug the clutch shaft lubricant holes preventing proper lubrication of the roller bearings...

Страница 381: ...amp switch 2 Remove shift rail plugs from rear of housing fig 2B 34 Remove plugs by driving them sideways into bore then prying out 3 Move first reverse shift rail to first gear position 4 Remove roll...

Страница 382: ...les in rail and fork 16 Install roll pin 17 Install shift rail plugs backup lamp switch and TCS switch SPECIFICATIONS Transmission Specifications Model T15A Type Synchromesh Speeds 3 Forward 1 Reverse...

Страница 383: ...NING RING 8 THIRD FOURTH CLUTCH SLEEVE 9 THIRD FOURTH BLOCKING RING 10 THIRD FOURTH GEAR SYNCHRONIZER ASSEMBLY 11 THIRD GEAR 12 MAINSHAFT SNAP RING 13 SECOND GEAR THRUST WASHER 14 SECOND GEAR 15 MAINS...

Страница 384: ...MANUAL TRANSMISSION 2B 21 Fig 21 35 Model T 18A 4 Speed Transmission...

Страница 385: ...third fourth synchronizer snap ring and remove third fourth synchronizer assembly and third gear fig 2B 35 4 Remove first second synchronizer snap ring and remove first second synchronizer assembly f...

Страница 386: ...1 37 Supporting First Second Clutch Hub 3 Position first second clutch hub on top of third fourth hub so lock ball holes in first second hub are in uppermost position fig 2B 37 4 Align scribe marks on...

Страница 387: ...Install second gear rear snap ring blocking ring first second synchronizer assembly and snap ring from rear of mainshaft GROOVE TO REAR 4 2 6 0 9 Fig 2B41 First Second Synchronizer Installation NOTE...

Страница 388: ...and fourth gear blocking ring in case front bearing bore Insert shaft from case interior not from front or outside of case 10 Install mainshaft and gear train assembly 11 Install mainshaft pilot beari...

Страница 389: ...RTH SHIFT FORK SHIFT RAIL POPPET BORES THIRD FOURTH SHIFT RAI INTERLOCK PLUNGER ROLL PIN I I T ROLL PIN FIRST SECOND SHIFT FORK FIRST SECOND FIRST SECOND SHIFT RAIL SHIFT GATE POPPET BALLS POPPET SPRI...

Страница 390: ...s flat on reverse shift rail 35 Coat shift lever housing attaching bolts with nonhardening sealer and install bolts Tighten bolts to 12 foot pounds 16 N m torque 36 Shift gears through all positions t...

Страница 391: ...3 Coat interlock pin with petroleum jelly to hold it in place and install pin in third fourth shift rail pin bore 14 Install poppet spring and ball in third fourth shift rail poppet bore Compress ball...

Страница 392: ...27 Front Bearing Cap Bolt 15 12 18 20 16 24 Shift Control Housing to Case Bolt 12 10 15 16 14 20 Transfer Case Drive Gear Locknut 150 145 155 203 197 210 Transfer Case to Transmission Case Bolt 30 25...

Страница 393: ...2B 30 MANUAL TRANSMISSION Tools J 26092 BEARING INSTALLER TOOL J 25200 THRUST YOKE TOOL J 25203 REVERSE IDLER GEAR ARBOR TOOL J 22828 BEARING INSTALLER 80661...

Страница 394: ...NOTES...

Страница 395: ...NOTES...

Страница 396: ...d valve and detent switch provide detent downshift capabilities Power Flow The direct transmission to engine connection is through the torque converter which is connected to the engine crankshaft by a...

Страница 397: ...allowing the stator to revolve freely on the stator shaft When the stator free wheels there is no further multiplication of engine torque within the converter which has now achieved coupling speed At...

Страница 398: ...ctive in second gear D or 2 range only The low roller clutch is effective in first gear D or 1 range only In direct drive third gear the roller clutches allow free rotation of all members HYDRAULIC SY...

Страница 399: ...l attempting to move the piston upward Drive Range Third Gear An increase in direct clutch pressure plus accumula tor spring force overcomes servo pressure and moves the accumulator piston to the accu...

Страница 400: ...h a small orifice to one end of the detent valve In normal throttle operation the cavity at this end of the valve is sealed by a needle valve in the detent solenoid assembly This line pressure holds t...

Страница 401: ...the vehicle and tow with the front wheels raised Recreational Towing Jeep vehicles can be towed behind a recreational ve hicle such as a motor home however the following instructions must be followed...

Страница 402: ...ts and guides for further assistance in pinpointing cause of malfunction 10 Repair transmission as necessary Vehicle Not In Operating Condition 1 Check fluid level Refer to fluid level and condi tion...

Страница 403: ...ppage or engine speed flareup occurs during shifts Slippage or flareup may indicate clutch band or roller clutch problems In most cases a clutch band or roller clutch that is malfunctioning can be det...

Страница 404: ...165 psi 931 1 138 kPa 14 Shift transmission into reverse and increase en gine speed to 1000 rpm Record gauge pressure and close throttle Pressure should be 95 150 psi 655 1 034 kPa 15 Shift transmissi...

Страница 405: ...VACUUM TESTER TO PROVIDE A CONSISTENT VACUUM FOR LINE PRESSURE CHECKS AND OR WHEN CHECKING A MODULATOR AGAINST THE END OF THE HOSE AND APPLY 2 0 OF VACUUM VACUUM MUST NOT DROP ANY FOR AT LEAST 30 SECO...

Страница 406: ...ure Check On vehicles with an EGR valve the throttle is open enough in D range at 1000 rpm to cause the EGR valve to open When the valve opens exhaust gas enters the intake manifold and decreases mani...

Страница 407: ...C 5 and are described as follows Oil Pump Seal leaks past the seal lip tend to move along the converter hub and onto the rear of the converter housing However if total seal failure oc curs fluid will...

Страница 408: ...ause this symtom STEP SEQUENCE RESULT CHECK FLUID LEVEL ADD FLUID AS NECESSARY OK DISCONNECT DETENT WIRE AT TRANSMISSION 6 LIGHT O N CONNECT TEST LIGHT FROM DETENT WIRE TO GROUND LIGHT OFF ADJUST OR R...

Страница 409: ...LE LINKAGE MORE THAN 13 AND VACUUM RESPONDS QUICKLY TO THROTTLE CHANGE APPLY VACUUM AND WATCH FOR MOVEMENT OF PLUNGER PLUNGER MOVES AT LESS THAN 8 OR MORE THAN 2 0 VACUUM PLUNGER MOVES BETWEEN 8 AND 2...

Страница 410: ...AUTOMATIC TRANSMISSON 2C 15 STEP SEQUENCE RESULT 60 TO 90 PSI REPAIR V A L V E BODY 9 0 1 7 3 C...

Страница 411: ...N P RESULT REMOVE DIPSTICK A N D FEEL FLUID TEMPERATURE WIPE DIPSTICK CLEAN AND REINSERT REMOVE DIPSTICK AND NOTE READING Add 1 Pt A D D OR REMOVE FLUID TO MAKE LEVEL OK FOR TEMPERATURE TRANSMISSION O...

Страница 412: ...AUTOMATIC TRANSMISSQN 2C 17 STEP SEQUENCE RESULT REMOVE TRANSMISSION FOR REPAIRS 9 0 1 7 3 E...

Страница 413: ...IS RIVE REVERSE STEP SEQUENCE RESULT ENGINE IDLING SHIFT LEVER IN P REMOVE DIPSTICK AND FEEL FLUID TEMPERATURE WIPE DIPSTICK CLEAN AND REINSERT REMOVE DIPSTICK AND NOTE READING Add 1 Pt ADD OR REMOVE...

Страница 414: ...ODY NO POP OR NO RADIO S T O P FUSE REPLACE BLOWN FUSE FUSE BLOWS CHECK FOR SHORT INCLUDING OTHER ACCESSORIES ON FUSE REPAIR AS NECESSARY FUSE OK FUSE OK DEPRESS ACCELERATOR FUSE REPAIR SHORT IN BLOWS...

Страница 415: ...broken Squeal at Low Vehicle Speeds Speedometer driven gear shaft appears twisted check for presence of engine coolant in transmission Check transmission cooler for leaks Thoroughly clean dry and insp...

Страница 416: ...ghtened Rear seal assembly damaged or improperly installed or propeller shaft yoke damaged Extension housing gasket or seal damaged or im properly installed O ring on output shaft damaged oil leak at...

Страница 417: ...stuck or missing Defective modulator bellows Center support bolt loose Bolt may be tight in sup port but not holding support tight to case Center support oil rings or grooves damaged or missing Clutch...

Страница 418: ...er Vacuum at Modulator Modulator Hole in diaphragm Stuck valve Water in modulator Modulator inoperative Detent System D e t e n t switch plunger stuck shorted or misadjusted Detent wiring shorted Dete...

Страница 419: ...x 15 8 00 x 16 5 8 75 x 16 5 9 50 x 16 5 H78 x 15 HR78 x 15 Tire Rev Per Mile 750 750 728 728 728 707 677 728 Closed Throttle 1 2 2 3 3 1 1 10 18 2 10 8 16 3 1 1 11 19 2 10 9 17 6 14 20 28 5 13 17 25...

Страница 420: ...ist 3 Loosen gearshift rod trunnion locknut just enough to permit movement of rod in trunnion fig 2C 6 4 Place transmission outer range selector lever fully into neutral detent position and tighten ge...

Страница 421: ...NTIFICATION SQUARED t A OFF PRESSURE REG BOSS J 4 3 0 1 Fig 2C 7 Pressure Regulator Valve Applcation 1 Raise vehicle 2 Position drain pan under transmission 3 Remove oil pan and gasket and drain oil 4...

Страница 422: ...ent solenoid lead at electrical con nector in case 6 Remove detent roller spring assembly 7 Remove control valve attaching bolts but do not remove detent solenoid attaching bolts 8 Remove control valv...

Страница 423: ...er Installation 1 Insert modulator lever in modulator fig 2C 9 2 Install replacement washer and O ring seal on modulator 3 Install modulator in adapter 4 Install modulator retainer and attaching screw...

Страница 424: ...ee Wagoneer and Truck models re move parking brake cable jamnut and adjuster nut re move clip attaching parking brake cable to crossmember and pull cable out of crossmember 6 On Cherokee and Wagoneer...

Страница 425: ...cy Drive vacuum lines to transfer case vacuum control 22 Connect speedometer cable 23 On Wagoneer and Cherokee models with reduc tion unit install reduction unit and install shift lever on reduction u...

Страница 426: ...13 Oil Pan Removal Installation Fig 20 14 Oil Filter Removal Installation Detent Roller and Spring Control Valve Governor Screen Governor Pipes Removal 1 Remove detent roller spring fig 2C 15 Do not...

Страница 427: ...Rear Servo Cover Removal Installation Band Adjustment In the Jeep automatic transmission only the rear band is adjustable The front band does not have any provision for adjustment Rear band adjustment...

Страница 428: ...ich has three identifying rings b If gauge plate surface is between steps on gauge pin use medium length apply pin which has two identifying rings c If both steps of gauge pin are above gauge plate su...

Страница 429: ...c mallet 4 Remove snap ring from bearing fig 2C 25 Fig 2C 25 Extension Housing and Rear Bearing Front Unit End Play Measurement 1 Remove one oil pump attaching bolt and washer from 5 or 10 o clock pos...

Страница 430: ...64 2 74 mm 0 115 to 0 119 2 92 3 02 mm 0 126 to 0 130 3 20 3 30 mm Yellow 0 Blue 1 Red 2 Brown 3 Green 4 Black 5 Purple 6 8 0 6 8 2 NOTE An oil soaked washer will tend to discolor so it may be necessa...

Страница 431: ...etaining pin fig 2C 31 Fig 2C 31 Manual Shaft and Retaining Pin CAUTION Do not unthread the jamnut as it comes off the manual shaft 3 Remove jamnut manual shaft and seal 4 Remove manual shaft to case...

Страница 432: ...to remove plug fig 20 34 9 Remove parking pawl return spring parking pawl shaft and parking pawl fig 2C 35 Fig 2C 33 Parting Pawl Shaft Retainer Spring Removal Installation Fig 2C 35 Parking Pawl and...

Страница 433: ...red to adjust end play select it from following rear unit thrust washer chart Rear Unit Thrust Washer Chart Thickness Inch Notches and or Numeral 0 074 to 0 078 1 87 1 98 mm 0 082 to 0 086 2 08 2 18 m...

Страница 434: ...5118 fig 2C 42 3 Remove metal output shaft to case thrust washer from rear of output shaft or from case 4 Place gear unit assembly with output shaft fac ing downward in hole in work bench and Holding...

Страница 435: ...ated between reaction carrier and output carrier NOTE The plastic washer is factory installed only Service replacement washers are made of metal 8 Turn output carrier over 9 Remove snap ring retaining...

Страница 436: ...AUTOMATIC TRANSMISSON 2C 41 Fig 2C 48 Sun Gear Removal Fig 20 50 Main Shaft Snap Ring Removal...

Страница 437: ...low out all passages using compressed air Inspect the governor sleeve for nicks burrs scoring or galling Check the governor sleeve for free operation in the case bore Inspect the governor valve for ni...

Страница 438: ...rly seated fig 2C 55 J42476 Fig 2C 54 Governor Driven Gear Retaining Pin Removal 8 Remove any chips that may have shaved off gear hub and press gear inward until it bottoms on shoulder of sleeve 9 Mar...

Страница 439: ...m rear servo piston fig 2C 58 2 Remove E ring retaining rear servo piston to servo pin fig 2C 59 3 Remove rear servo piston and seal from servo pin fig 2C 59 4 Remove washer spring and retainer Inspec...

Страница 440: ...valve fig 2C 63 6 Remove retaining pin from next bore and re move 2 3 bushing 2 3 valve spring 2 3 modulator valve 2 3 spring and 2 3 valve fig 2C 64 7 Remove retaining pin from next bore and re move...

Страница 441: ...nd 3 2 spring into next bore 13 Insert 2 3 modulator control valve in bushing and install both parts in valve bore 14 Install 2 3 shift control valve spring compress spring and install retaining pin 1...

Страница 442: ...LUG SPRING RETAINER WASHER SNAP RING PRESSURE BOOST BUSHING PRESSURE BOOST VALVE OIL PUMP COVER J42484 Fig 2C 65 Oil Pump Cover Assembly Inspection CAUTION The solid type pressure regulator valve does...

Страница 443: ...assages Assambiy 1 Install drive and driven gears in pump body with alignment marks facing upward fig 2C 67 NOTE Position the drive gear with the drive tangs facing upward EXHAUST MODULATOR OR HOLE J4...

Страница 444: ...t in hole in bench and remove snap ring which retains forward clutch housing to direct clutch hub fig 2C 73 2 Remove clutch hub from housing 3 Remove forward clutch hub and thrust washers fig 2C 74 9...

Страница 445: ...h piston will be aluminum or stamped steel 10 Remove center piston seal from forward clutch housing fig 2C 77 4 2 4 9 5 Fig 2C 77 Forward Clutch Center Seal Installation Inspection Inspect composition...

Страница 446: ...ress springs using Clutch Spring Com pressor J 25148 and arbor press and install spring re tainer to piston snap ring 7 Press short spline end of turbine shaft into for ward clutch housing using arbor...

Страница 447: ...ATIC TRANSMISSION Fig 20 81 Forward Clutch Plate Installation IDENTIFICATION IDENTIFICATION IDENTIFICATION V NOTCH NONE U NOTCH USAGE OPTIONAL USAGE OPTIONAL USAGE OPTIONAL Fig 2C 82 Clutch Plate Iden...

Страница 448: ...OTE6 Some transmission models use five composi tion faced and five steel clutch plates Refer to the Clutch Plate Application Chart at the end of this section for details 5 Using Clutch Spring Compress...

Страница 449: ...lutch housing for scratches or wear Inspect the direct clutch housing for cracks wear restricted oil passages or wear of the clutch plate drive lugs Inspect the composition faced and steel plates for...

Страница 450: ...ings using a small screwdriver Fig 2C 93 Direct Clutch Piston Installation 9 Install waved steel and composition faced clutch plates Start with waved steel plate and alternately in stall remaining com...

Страница 451: ...95 Roller dutch Installation NOTE Apply air through the left oil feed hole only to actuate the clutch piston If air is applied through the reverse passage right oil feed hole it will escape from the...

Страница 452: ...inspect the piston for cracks Inspect the release springs for cracks fatigue and distortion Inspect the support to case spacer for burrs or raised edges Remove any burrs using an oilstone or fine san...

Страница 453: ...TERMEDIATE CLUTCH SPRING GUIDE 4 2 5 2 1 Fig 2C 103 Spring Guide Installation INTERMEDIATE CLUTCH R E L E A S E SPRING 3 Fig 2C 101 Intermediate Clutch Piston Outer Seal installation Fig 2C 104 Interm...

Страница 454: ...wear Inspect the roller clutch for damaged com ponents Inspect the roller clutch cage and retaining spring for damage Inspect the front internal gear ring for chipping or flaking and inspect the carri...

Страница 455: ...nd roller needle bearings fig 2C 112 5 Inspect thrust faces of pinion pockets in carrier for burrs Remove any burrs using crocus cloth 4 2 5 2 8 6 Install 18 needle bearings in each pinion gear Use pe...

Страница 456: ...the bushing journals for damage and the snap ring groove for damage Be sure the oil lubrication holes are open Front and Rear Rand Inspection Inspect the lining for cracks flaking burning or loos ene...

Страница 457: ...for damage Inspect the governor and modulator bores for scratches or scoring Inspect the intermediate clutch cup plug inside case for good staking and sealing fig 2C 118 Inspect the case bushing for...

Страница 458: ...the hub surfaces for scoring or wear and check the drive lugs for damage Check the torque converter housing for leaks as follows Fig 2C 119 Torque Converter Air Pressure Test 1 Install and tighten Le...

Страница 459: ...ownward 7 Assemble Installer J 21465 1 and Driver Handle J 8092 8 Position replacement bushing on Installer J 21465 1 NOTE If the bushing has a notch in it be sure to position the bushing so the notch...

Страница 460: ...or shavings generated by bushing installation Fig 2C 123 Sun Gear Shaft Bushing Installation Center Support Bushing 1 Position center support on wood blocks so seal ring hub faces downward 2 Assemble...

Страница 461: ...ENTER SUPPORT BORE 6 Insert Remover Installer J 21465 6 into bushing Drive bushing into bore until bushing is flush with or no more than 0 010 inch 0 25 mm below face of hub fig 2C 126 7 Remove bushin...

Страница 462: ...lush oil pump body with solvent to remove any chips or shavings generated by bushing installation Fig 20 127 Oil Pump Body Bushing Removal Fig 20 128 Oil Pump Body Bushing Installation Stator Shaft Fr...

Страница 463: ...lide Hammer J 2619 fig 2C431 4 Remove shaft and cover assembly from vise 5 Support pump cover on wood blocks with cover seal ring hub facing upward 6 Clean bushing bore 7 Assemble Installer J 21465 3...

Страница 464: ...bore until Adapter Ring J 21465 9 bottoms against case fig 2C 134 CAUTION Do not attempt to install the case bushing without using Adapter Ring J 21465 9 This tool posi tions the bushing 0 040 to 0 0...

Страница 465: ...2C 70 AUTOMATIC TRANSMISSION 80162 Fig 2C 135 Staking Transmission Case Bushing...

Страница 466: ...output carrier over main shaft and mesh carrier pinions with rear internal gear 4 Position assembled components so that main shaft extends downward through hole in bench and rear surface of rear inter...

Страница 467: ...rvice replacement front internal gear ring 15 Install center support to sun gear thrust bear ing and races as follows a Coat bearings and races with petroleum jelly b Install large race over main shaf...

Страница 468: ...ry the center support should turn counterclockwise only 21 Using Gear Assembly Clamp Set J 21795 clamp gear unit assembly together until it is installed 22 Install output shaft to case thrust washer a...

Страница 469: ...which is 0 01 0 inch 1 01 mm thick and both sides flat with either the center support to case snap ring one side beveled or the backing plate to case snap ring which is 0 093 inch 2 36 mm thick and b...

Страница 470: ...snap ring is flat on both sides Locate gap of snap ring opposite band anchor pin fig 2C 151 Measuring Rear Unit End Play 1 Install Slide Hammer J 25118 in extension hous ing attaching bolt hole fig 2C...

Страница 471: ...5 16 18 valve body bolts 2 Install guide pins in pump mounting bolt holes of transmission case 3 Position oil pump gasket on pump face of trans mission case Use petroleum jelly to retain gasket 4 Inst...

Страница 472: ...157 Servo Spring end Retainer Installation Fig 2C 158 Control Valve Spacer Gasket Installation 8 Install detent solenoid with solenoid wire facing outer edge of case Tighten solenoid bolts finger tigh...

Страница 473: ...on intake pipe Install filter on end of intake pipe marked filter 3 Install assembled filter and intake pipe and in stall filter to control valve retainer bolt fig 2C 162 CAUTION The oil filter must...

Страница 474: ...Face to Rotor End Play 0 0008 to 0 0035 inch 0 02 0 07 mm Front Unit End Play 0 003 to 0 024 inch 0 07 0 60 mm Bushing Clearance Max 0 008 inch 0 20 mm 7 0 5 2 0 A Torque Specifications Service Set T...

Страница 475: ...Plates Flat Steel Plates Waved Steel Plates Composition Plates Flat Steel Plates Waved Steel Plates Composition Plates CJ 7 258 304 400 JC 400 JS 3 3 1 1 4 4 3 3 4 4 2 2 1 1 3 3 Cherokee and Wagoneer...

Страница 476: ...ER INSTALLER J 25118 SLIDE J 21795 HAMMERS GEAR ASSEMBLY REMOVING AND INSTALLING TOOL J 21370 6 REAR BAND APPLY PIN SELECTOR FIXTURE J 21370 5 P I N R E A R BAND APPLY J 25148 FORWARD CLUTCH SPRING CO...

Страница 477: ...LER J 2619 4 ADAPTER J 21465 3 INSTALLER J 8092 DRIVER HANDLE J 21465 6 REMOVER INSTALLER J 21465 8 REMOVER INSTALLER J 21465 9 ADAPTER RING J 21465 13 DRIVER HANDLE EXTENSION J 21465 15 REMOVER J 214...

Страница 478: ...H Y D R A U L I C FLOW C H A R T S...

Страница 479: ......

Страница 480: ...AUTOMATIC TRANSMISSION 2C 85 Hydraulic Flow Chart NEUTRAL...

Страница 481: ...2C 86 AUTOMATIC TRANSMISSION Hydraulic Flow Chart DRIVE RANGE FIRST GEAR...

Страница 482: ......

Страница 483: ......

Страница 484: ......

Страница 485: ...VACUUM MODULATOR ASSEMBLY STRAINER ASSEMBLY MAINLINE PRESSURE INTAKE PRESSURE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE I 1 GOVERNOR ASSEMBLY...

Страница 486: ......

Страница 487: ...Hydraulic Flow Chart REVERSE...

Страница 488: ...on is used for stationary power takeoff appli cations such as winching In neutral power is not trans mitted to the wheels IlEITiFiClTill An identification tag that displays the vendor and Jeep part nu...

Страница 489: ...2D 5 Transfer Case Shift Knob tral and tow vehicle with front wheels raised Turn ignition key to Off position to unlock steering wheel Ignition Key Not Available and Vehicle is Locked Place dolly unde...

Страница 490: ...ems placed in or on the trailer or mounted camper will add to the load CAUTION Jeep Corporation will not be responsible for brake performance if the Jeep vehicle and trailer hydraulic brake systems ar...

Страница 491: ...t lever boot and knob CJ Models 1 If left side shift rod seal is to be replaced shift transfer case into 4L position 2 Raise vehicle 3 Remove clevis pins connecting control links to transfer case shif...

Страница 492: ...peedometer driven gear bushing using Bushing Installer Tool J 25169 2 Install front bearing cup in bore 3 Install front bearing on shaft 4 Install rear bearing cup in bore 5 Install speedometer drive...

Страница 493: ...ear engages trans fer case rear output shaft sliding gear Move transfer case forward until case seats against transmission CAUTION Be sure the transfer case is flush against the transmission Severe da...

Страница 494: ...ATE 29 LOCK PLATE BOLT 30 REAR OUTPUT SHAFT FRONT BEARING 3 1 REAR OUTPUT SHAFT FRONT BEARING CUP 32 SPEEDOMETER DRIVE GEAR 33 REAR OUTPUT SHAFT BEARING SHIM 34 REAR BEARING CAP GASKET 35 REAR BEARING...

Страница 495: ...ft through gear splines and drive shaft out of bearing using brass drift and hammer Cieaiiig aii Inspection Clean the case and components with solvent Remove all gasket material from gasket surfaces a...

Страница 496: ...earing cap gasket on case 26 Install rear bearing cap assembly and slide rear output shaft through gear Tighten bearing cap bolts to 30 foot pounds 41 N m torque 27 Install replacement front yoke seal...

Страница 497: ...remove rod 4 Remove clips from torsion spring retainer and remove rod and spring Assembly 1 Insert torsion spring retaining rod and clips 2 Install high low range shift rod and set torsion spring in...

Страница 498: ...ined by capscrews Locating holes are drilled in the support tube at the transfer case end to maintain link age alignment On CJ models with 3 speed transmission the transfer case must be removed in ord...

Страница 499: ...rive chain fig 2D 18 Engine torque is transmitted to the front and rear axles through the limited slip differential con tained within the differential sprocket An Emergency Drive system is built into...

Страница 500: ...extremely icy surfaces CAUTION Emergency Drive is provided for extreme situations only and must not be used for normal oper ation The Quadra Trac Transfer Case is designed to dissipate torque windup i...

Страница 501: ...Fig 21 19 Emergency Drive Vacuum Control System 8 0 2 5 4...

Страница 502: ...vement or at speeds above 20 mph 32 km h or spin the wheels excessively with Emergency Drive engaged This will result in harsh operation and accelerated wear or damage to the transfer case internal co...

Страница 503: ...ed towing speed must be limited to 30 mph 48 km h or less and for a distance no greater than 15 miles 24 km Automatic Transmission with Quadra Trac Less Reduction Unit Ignition Key Available Turn igni...

Страница 504: ...ing clunking rasping or grunt type noise This is a low frequency noise which is most no ticeable at slow speeds such as when slowly turning a corner or when maneuvering to park the vehicle Stick slip...

Страница 505: ...orn damaged or loose on shift rail spring pin broken 4 Reduction unit holding plate shift collar collar plate collar plate hub or pinion cage lock plate worn or damaged 5 Reduction unit incorrectly as...

Страница 506: ...er J 23738 Audible click should be heard as diaphragm piston moves shift fork Connect vacuum gauge to glove box switch and check vacuum through switch No vacuum through switch Vacuum through switch OK...

Страница 507: ...Connect vacuum gauge to glove box switch and check vacuum through switch No vacuum through switch Check switch to engine vacuum hose Hose loose or damaged Replace Repair hose Emergency drive disengag...

Страница 508: ...7 N m torque and 5 16 18 bolts to 9 foot pounds 12 N m torque d Fill transfer case to fill hole level 2 quarts U S 1 89 liters or 1 7 quarts Imperial with Jeep Quadra Trac lubricant or equivalent only...

Страница 509: ...e removal involves removing the snap ring which secures the cage to the sprocket and sliding the cage rearward Reduction Unit Installation 1 If removed install pinion cage on transfer case drive sproc...

Страница 510: ...gear train in place on the socket to simplify assembly 7 Remove following components as assembly di rect drive sleeve and needle bearing shift collar hub and needle bearing reduction collar hub and ri...

Страница 511: ...oval 1 Move control lever to neutral center position and disengage shift collar from shift fork 2 Move control lever rearward to high range posi tion and align outer teeth on shift collar with inner t...

Страница 512: ...h 2 18 to 2 23 mm 2 Install front snap ring and bearing Install thickest rear snap ring that will seat completely Housing Disassembly 1 Remove shift fork locating pin with pliers Use pulling rotating...

Страница 513: ...ing fig 2D 36 2 Install reduction holding plate retaining snap ring Snap ring tabs must face forward Be sure snap ring seats completely in groove and clears shift fork 3 Install shift fork locating pi...

Страница 514: ...21 Install control lever on shift lever 22 Install shift collar as follows a Position shift fork in neutral center detent USE P M AS COMPRESSOR T O O L PIH FLUSH WITH FORK FLAT ON l i l t J 4 2 3 8 5...

Страница 515: ...ve assembled unit from support socket and install pinion cage 36 Remove socket from vise TRANSFER CASE SERVICE IN VEHIGLE Front Rear Output Shaft Seal Replacement 1 Raise vehicle 2 If front output sha...

Страница 516: ...taching rear cover assembly to front cover 13 Remove rear cover assembly Slide cover assem bly backward until disengaged with transmission output shaft and front output shaft Rear Cever Spreclets Driv...

Страница 517: ...g 21 45 Differentia mi Mm Sprockets Positioned for Chain Installation 3 Install drive chain on drive sprocket and differ ential sprocket fig 2D 46 NOTE Be sure the drive chain is fully engaged with th...

Страница 518: ...shaft and transmission out put shaft NOTE If necessary rotate the rear output shaft slightly to engage the two sets of splines 4 Move rear cover assembly forward until it seats on case 5 Remove two pi...

Страница 519: ...llation 1 Apply Permatex No 3 or equivalent sealer to both sides of transfer case to transmission gasket and position gasket on transmission 2 Install guide pins in upper and lower threaded holes in t...

Страница 520: ...ve snap ring and remove drive hub and drive sleeve NOTE The snap ring expanding tabs are accessible through a slot in the outside edge of the drive sleeve 8 If equipped with reduction unit remove pini...

Страница 521: ...polished and have some tarnished spots this is a normal condition Replace the assembly only if any com ponent is galled deeply scored cracked broken or ex cessively worn The thrust washers should be...

Страница 522: ...on brake cone 17 Place preload springs against thrust washer Be sure concave side of springs face brake cone 18 Lubricate remaining small thrust washer and install on remaining end cap 19 Place end c...

Страница 523: ...talled fig 2D 58 Fig 20 57 Drive Sprocket liar l i t i s Bearing lemoval Fig 2D 58 Drive Sprocket Rear Iseile Bearing Installation Annular Bearings NOTE The front and rear output shaft annular bear in...

Страница 524: ...ward Reach through differential needle bearing and support fork and hub with fingers to pre vent assembly from separating during installation 4 Insert control diaphragm rod into cover and through shif...

Страница 525: ...retaining nut Tighten nut to 120 foot pounds 163 N m torque Use tool J 8614 01 to hold yoke while nut is tightened SPECIFICATIONS Torque Specifications Service Set To Torques should be used when asse...

Страница 526: ...el Drive Make Warner Gear Model Quadra Trac Gear Ratio High 1 1 Low With Reduction Unit 2 57 1 Quadra Trac Transfer Case Quadra Trac Lubricant or equivalent 6 0 6 3 5 6 0 6 3 3 Tools J 25175 SHIFT ROD...

Страница 527: ...ALLER J 25161 BEARING REMOVER AND INSTALLER J25212 BEARING INSTALLER J 25213 SEAL INSTALLER J 25180 OUTPUT SHAFT SEAL REMOVER J 25213 1 SLEEVE I J 8614 02 AND 03 YOKE REMOVER TOOLS J 25162 CHAIN GAUGE...

Страница 528: ...ransmission is similar to the front shaft in appearance and construction Single cardan universal joints connect the shaft to both the axle and transfer case yokes and the slip yoke is located at the t...

Страница 529: ...e and transfer case yokes The double cardan joint also referred to as a constant velocity joint consists of two spiders a socket ball a link yoke a socket spring and dust seal a socket yoke and needle...

Страница 530: ...oints and are most noticeable in the 40 60 mph 64 97 km h speed range Vibration caused by a propeller shaft may be the result of Undercoating on the shaft tube Excessive shaft runout Cracked or broken...

Страница 531: ...ED ROAD TEST OK ROAD TEST DRIVE 5 1 0 MPH ABOVE VIBRATION R A N G E T H E N S H I F T TO NEUTRAL LET ENGINE IDLE AND COAST THROUGH VIBRATION RANGE ROAD TEST VIBRATION GONE VIBRATES DURING COAST THROUG...

Страница 532: ...A R P R O P E L L E R S H A F T A L I G N M A R K S H A F T A N D A X L E Y O K E F O R A S S E M B L Y R E F E R E N C E R O A D T E S T W I T H Q U A D R A T R A C I N E M E R G E N C Y D R I V E O...

Страница 533: ...0 15 mm REPLACEMENT YOKE RUNOUT SHOULD BE CHECKED ALSO IF RUNOUT IS 0 007 OR MORE REINDEX YOKE AND RECHECK RUNOUT REPLACE YOKE IF REINDEXING DOES NOT CORRECT RUNOUT ROAD TEST CHECK REAR PROPELLER SHA...

Страница 534: ...PELLER SHAFT OPERATION ROAD TEST 1 REMOVE FRONT PROPELLER SHAFT ALIGN MARK SHAFT A N D AXLE YOKES FOR ASSEMBLY REFERENCE 2 ROAD TEST WITH QUADRA TRAC IN EMERGENCY DRIVE OR MODEL 20 IN 4H WITH FRONT HU...

Страница 535: ...EINDEX SHAFT 180 A N D RECHECK RUNOUT MAXIMUM ALLOWABLE RUNOUT SPECIFICATIONS ARE FRONT REAR 0 015 0 38 mm CENTER 0 020 0 51 mm CHECK FRONT A X L E PINION AND FRONT PROPELLER SHAFT ANGLES FRONT AXLE P...

Страница 536: ...the pinion angle must by adjusted downward 3 degrees This changes the pinion downward angle to 4 degrees which is the required one degree less than the engine downward angle 6 Adjust pinion angle as o...

Страница 537: ...viced as assemblies Each of the three universal joint types can be disassembled for in spection and replacement purposes Disassembly Single C i f l i t Joint 1 If slip yoke universal joint is to be re...

Страница 538: ...s in solvent and wipe them dry with a shop cloth Inspect all bearings and bearing surfaces for excessive wear galling brinneling scoring flat spots or cracks Inspect the yokes for distortion cracks or...

Страница 539: ...r and trunnion cap on pin 8 Move housing forward and over ball and trun nion assembly Be sure assembly is correctly and com pletely seated in housing 9 Install replacement gasket and plate on housing...

Страница 540: ...n O P E L L E R SHAFT 2E 13 Tools LUBE FITTING ADAPTER TOOL J 25512 2 NOTES...

Страница 541: ...NOTES...

Страница 542: ...the road test stop vehicle shift the transmis sion into neutral and operate the engine at various speeds If the noise is heard during this test the noise is being produced by the engine exhaust system...

Страница 543: ...fications 2F 13 Axle Removal 2F 12 Spindle Bearing 2F 11 Axle Shaft 2F 6 Steering Knuckle Installation 2F 10 Axle Shaft Seal 2F 11 Steering Knuckle Removal 2F 9 Axle Shaft Universal Joint 2F 8 Steerin...

Страница 544: ...ERENTIAL BEARING CAP DIFFERENTIAL BEARING CUP 2 PINION MATE SHAFT THRUST WASHER DIFFERENTIAL SIDE GEAR DIFFERENTIAL PINION GEAR THRUST WASHER RING GEAR MOUNTING BOLTS DIFFERENTIAL BEARING 2 DIFFERENTI...

Страница 545: ...nu facture and cannot be adjusted An alignment rack should be used to check the align ment angles The use of a rack will ensure more accurate readings and avoid the possibility of incorrect adjustment...

Страница 546: ...sition steering knuckle on axle and install re placement lower ball stud jamnut finger tight only 9 Remove upper ball stud retaining nut 10 Remove upper ball stud split ring seat 11 Install replacemen...

Страница 547: ...shield 10 Remove spindle 11 Remove axle shaft and universal joint assembly Installstion CJ Meitls 1 Clean all parts thoroughly 2 Install axle shaft and universal joint assembly Insert splined end of...

Страница 548: ...alent and install hub cap in rotor 15 Install disc brake caliper Refer to Chapter 2G 16 Install wheel and tire 17 Lower vehicle AXLE SHAFT UNIVERSAL JOINT Replacement 1 Remove axle shaft 2 Remove snap...

Страница 549: ...2F 8 AXLES 90068B Fig 2F 6 Steering Knuckle Components 4 1 0 6 7...

Страница 550: ...ckle Position puller frame against knuckle and puller screw against Button J 25211 3 fig 2F 9 On CJ models be sure Adapter J 25211 4 is positioned between puller frame and steering knuckle 5 Tighten p...

Страница 551: ...all steering knuckle on axle yoke and install lower ball stud stud jamnut finger tight only Fig 2F 10 Lower Ball Stud Installation Fig 2F 11 UpperBallStudInstallation 3 Position and align Nut Wrench J...

Страница 552: ...aft Removal in this section for procedure 2 Remove seal from shaft fig 2F 14 3 Remove bronze thrust washer If washer is worn replace it 4 Clean dirt and foreign matter from seal area 5 Install bronze...

Страница 553: ...equipped with sway bar mount sway bar connecting links on tie plates 6 Tighten spring shackle bolts to 24 foot pounds 33 N m torque on CJ models and 100 foot pounds 136 N m torque on all other models...

Страница 554: ...se Service In Use Set To Recheck Set To Recheck Torque Torque Torque Torque Axle Housing Cover Bolts 20 15 25 27 20 34 Connecting Rod End Nut CJ 40 min _ 54 min Cherokee Wagoneer Truck 70 min _ 95 min...

Страница 555: ...ode Location AMC Jeep Axle Letter Codes Chart Letter Ratio Pinion Drive Letter Ratio Gear Teeth Standard X 3 07 14 43 Trac Lok N 3 54 1 11 39 Standard A 3 54 1 11 39 Trac Lok Y 3 07 14 43 60650 Model...

Страница 556: ...n hub with axle shaft key 2 Slide hub onto axle shaft as far as possible 3 Install axle shaft nut and washer 4 Install drum drum retaining screws and road wheel 5 Lower vehicle 6h 6 wheels 6 Tighten a...

Страница 557: ...Shaft Removal AMC Jeep Axle Installation NOTE Tapered shaft axle bearings do not have any provision for lubrication after assembly and must be packed with a high quality wheel bearing lubricant be for...

Страница 558: ...g Replacement CAUTION Under no circumstances should the axle shaft retaining rings or bearings be removed using a torch Heat will transfer into the axle shaft bearing journal and weaken it 1 Mount axl...

Страница 559: ...haft splines with the differen tial gear splines and the flange attaching holes with the hub studs 4 Install split washers lockwashers and flange bolts Tighten bolts PINION SEAL AND YOKE AMC JEEP AXLE...

Страница 560: ...tool J 25180 on Model 44 axle or tool J 25144 on Model 60 axle TOOL J 2 2 6 6 1 I 4 1 4 2 8 Fig 2F 28 Pinion Seal Installation Installation 1 Install replacement pinion seal using tool J 25104 2 Insta...

Страница 561: ...Jeep 8 875 inches 22 19 cm Rear Axle Lubricants Standard Differential Jeep Axle Lubricant or equivalent of SAE 90 A P I Grade GL 5 quality or axle lubricant grade MIL L 2105 B Trac Lok Differential J...

Страница 562: ...n the pinion mate shaft This occurs because input torque applied to the gears is divided and distributed equally between the two side gears As a result the pinion gears revolve with the pinion mate sh...

Страница 563: ...e but still in position differen tial can not fall out and sustain damage when pried out of axle housing 7 Pry differential loose in axle housing using two pry bars 8 Remove bearing caps and remove di...

Страница 564: ...Reinstall axle housing cover loosely using two bolts This is necessary to prevent pinion from falling out of housing when driven out of bearings Fig 2F 34 Pinion late Shaft and Thrust Block Removal 4...

Страница 565: ...are factory tested to detect ma chining variances Tests are started at a standard set ting which is then varied to obtain the most desirable tooth contact pattern and quiet operation When this settin...

Страница 566: ...iances intersect will provide approximate amount of change required to achieve desired starter shim thickness For example if the old pinion is marked 3 and the new pinion 2 chart procedure would be as...

Страница 567: ...of the bearing cup bore 7 Install rear bearing cup using Driver Handle J 8092 and Cup Installer J 8608 fig 2F 37 8 Install front bearing cup using Driver Handle J 8092 and Cup Installer J 8611 01 9 In...

Страница 568: ...ness Result is total measured pinion depth Measured Pinion Depth 2 550 6 47 cm Starter Shim Thickness 0 098 2 48 mm Total Measured Pinion Depth 2 648 6 72 cm Step 3 Determine correct shim thickness Su...

Страница 569: ...Use 0 080 inch 2 03 mm shims as starting point fig 2F 41 3 Install bearing caps and tighten bolts finger tight Mount dial indicator as shown in figure 2F 42 4 Using two screwdrivers pry between shims...

Страница 570: ...ms on each side totaling 0 180 inch 4 57 mm Backlash is checked and found to be 0 011 inch 0 27 mm To correct backlash add 0 004 inch 0 10 mm to shim on ring gear side and subtract 0 004 inch 0 10 mm...

Страница 571: ...at left side of axle shaft only 12 Install hubs drums and wheels 13 Lower vehicle Fig 2F 43 Checking Backlash Fig 2F 44 Differential Installation DIFFERENTIAL OVERHAUL MODEL 30 44 60 AXLE Differentia...

Страница 572: ...60 Axle 1 Remove pinion nut Use tool J 8614 01 to hold yoke while removing nut 2 Remove pinion yoke using tools J 8614 01 02 and 03 fig 2F 4 3 Remove dust cap from yoke end of pinion gear 4 Remove pi...

Страница 573: ...until chamfered edges of tool are well under bearing race 4 Position pinion gear and remover tool in arbor press and press pinion out of bearing J 4 2 3 0 7 Fig 2F48 Pinion Mate Shaft Lockpin Removal...

Страница 574: ...an all parts in solvent Allow bearings to air dry Dry all other parts with compressed air Inspect all bearings and cups for pitting galling flat spots or cracks Replace any bearing or cup that exhib i...

Страница 575: ...6 66 cm Model 60 3 125 7 93 cm If the pinion is marked 2 the gear set varied from standard by 0 002 inch 0 05 mm and will require 0 002 inch 0 05 mm less shims than a set marked zero 0 When a set is m...

Страница 576: ...on pinion gear Tighten nut only enough to remove end play and provide 10 to 15 inch pounds 1 to 2 N m of drag torque when pinion is rotated NOTE Do not install the pinion seal slinger dust cap or a ne...

Страница 577: ...m Correct Shim Thickness 0 079 2 00 mm r r a E M Z I W 1 Example II Pinion Depth Variance is Minus Model 60 Axle Step 1 Obtain desired pinion depth Subtract pinion depth variance marked on pinion gear...

Страница 578: ...staller J 22175 fig 2F 57 On Model 60 axles install bearings using driver handle and Installer J 24430 3 Install bearing cups on differential bearings 4 Install differential in axle housing 5 Install...

Страница 579: ...ds and install bolts On Model 30 axles tighten cap bolts to 40 foot pounds 54 N m torque On Model 44 and 60 axles tighten bolts to 80 foot pounds 108 N m torque 20 Mount Dial Indicator Set J 8001 on h...

Страница 580: ...eep Axle Semi Floating Tapered Shaft Axle Shaft End Play Shims Left Side Only 004 008 in 0 10 0 20 mm 006 in 0 15 mm desired desired Pinion Bearing Preload Collapsible Sleeve 17 25 in lbs 2 3 N m Diff...

Страница 581: ...C Jeep Axle Semi Floating Tapered Shaft Axle Housing Cover Bolts 170 in lbs 150 190 in lbs 19 17 21 Brake Tube to Rear Wheel Cylinder 97 in lbs 90 105 in lbs 11 10 12 Differential Bearing Cap Bolts 87...

Страница 582: ...le housing cover drain plug or cover and drain lubricant while warm only 4 Remove any residual lubricant from axle hous ing using shop cloths 5 Install drain plug If axle housing cover was removed cle...

Страница 583: ...case from axle shaft and remove ring gear 8 Remount differential case on axle shaft 9 Remove snap rings from pinion mate shaft fig 2F 63 Use two screwdrivers to disengage snap rings Place shop towel o...

Страница 584: ...the Belleville springs by the forcing screw be fore the gears can be rotated in the case 18 Retain upper side gear and clutch pack in case by holding hand on bottom of rotating tool while remov ing fo...

Страница 585: ...figure 2F 69 A B Fig 2F 69 Clutch Plate and Disc Identification DIFFERENTIAL ASSEMBLY 1 Lubricate differential gear teeth thrust faces and splines and lubricate clutch discs and plates with Trac Lok l...

Страница 586: ...hrust washers Use small screwdriver to guide washers into position fig 2F 74 CAUTION Be sure the shaft bores in the washers and gears are aligned with the case bores 17 Remove forcing screw rotating t...

Страница 587: ...3 9 Fig 2F 75 Pinion Mate Shaft Installation replace them Be sure shims and bearings are used on same sides of replacement case as on old case 5 Install shims and differential bearings Use step plate...

Страница 588: ...mm 6 0 6 5 7 B Torque Specifications Model 30 Front Axle Service Set To Torques should be used when assembling components Service In Use Recheck Torques should be used for checking a pre torqued item...

Страница 589: ...ke Tube to Rear Wheel Cylinder 97 in lbs 90 105 in lbs 11 10 12 Differential Bearing Cap Bolts 87 80 95 10 9 11 Ring Gear to Case Bolt 105 95 115 142 135 149 Rear Brake Support Plate Bolts 32 25 40 43...

Страница 590: ...OL J 22661 REAR PINION OIL SEAL INSTALLER J 21788 AXLE SHAFT OIL SEAL INSTALLER J 2498 AXLE SHAFT REMOVER J 8614 2 J 8614 3 YOKE REMOVER TOOLS J 9233 PINION OIL SEAL REMOVER J 23674 AXLE SHAFT BEARING...

Страница 591: ...NSTALLER SLEEVE J 8611 01 PINION FRONT BEARING CUP INSTALLER J 21784 DIFFERENTIAL BEARING INSTALLER J 5223 4 ARBOR J 5223 03 PINION DEPTH SETTING GAUGE SET J 22697 PINION REAR BEARING INSTALLER J 9233...

Страница 592: ...ued J 7079 2 DRIVER HANDLE NON THREADED J 24385 01 A X L E HOUSING SPREADER J 8092 DRIVER HANDLE THREADED J 24430 BEARING INSTALLER 80327B 4 J 8646 2 FORCING SCREW A N D J 23781 3GEAR ROTATING TOOL J...

Страница 593: ...NOTES...

Страница 594: ...for the front and rear brake units is used on all models A three function combination valve is used on all Jeep models The valve consists of a one piece housing con taining a front brake metering val...

Страница 595: ...pedal has a spongy feel when applying the brakes Bleed system If unable to bleed system properly see Service Diagnosis Test 3 Depress brake pedal and hold foot pressure on pedal If vehicle is equipped...

Страница 596: ...ctioning Inspect vacuum system components for loose broken collapsed vacuum hose faulty check valve restriction in vacuum hose fitting or manifold port See Service Diagnosis Test 5 With engine running...

Страница 597: ...Replace power unit GRABBING OR DRAGGING BRAKES 1 Bellcrank pivot pins binding CJonly 1 Remove clean lubricate and install pivot pins 2 Refer to PULLS and GRAB BING BRAKES in Brake Service Diagnosis Ch...

Страница 598: ...rsize specification 4 Replace drum s as required 5 Master cylinder filler vent clogged 5 Clean vent or replace cap bleed brakes 6 Hoses lines c o l l a p s e d kinked leaking 6 Replace as required m M...

Страница 599: ...n valve PULSATING BRAKE PEDAL 1 2 Drums out of round Loose brake drum on hub 1 2 Refinish or replace drums Tighten 3 Worn or loose wheel bearings 3 Replace or adjust 4 Bent shoes or linings 4 Replace...

Страница 600: ...master cylinder 5 Wheel cylinder pistons sticking 5 Overhaul wheel cylinder ONE WHEEL DRAGS 1 Weak or broken brake shoe retracting springs 1 Replace the defective brake shoe springs and lubricate the...

Страница 601: ...not held tightly against the shoe at the ends 3 Replace rivets Replace shoe lining assemblies if damaged 4 Drums distorted 4 Turn or replace drums 5 6 Shoes scraping on support plate ledges Weak or b...

Страница 602: ...gn and equal wear will be installed on the front wheels 7 Water mud or foreign matter in brakes 7 Remove foreign material from brake parts and inside of the drums Lubricate the shoe ledges and the rea...

Страница 603: ...e and snap back 1 Change drums side to side or turn drums in pairs 2 HolddoWn springs weak 2 Replace springs 3 Shoe bent 3 Replace shoes on both sides 4 Grooves in support plate ledges 4 Replace suppo...

Страница 604: ...otor thickness or drum dia meter below specification 1 Master cylinder pistons not re turning properly 5 Replace rotor and shoes 6 Replace shoes 1 Check operation Refer to Power Brake Units 2 Check bo...

Страница 605: ...es on same axle 3 Wheel bearings misadjusted or worn 2 Check for kinks or dents in steel lines Check rubber hoses for swelling or restrictions inside hose 3 Check and readjust to specifi cation Inspec...

Страница 606: ...or cracked 3 Calipers lopse 4 Loose master cylinder or brake booster attaching parts 4 Check for stuck piston 5 Replace shoe and lining on both sides Replace axle seals wheel cylinder cups or caliper...

Страница 607: ...d for brake adjustment Pedal free play should be 1 16 to 1 4 inch 1 58 to 6 35 mm Inadequate free play can result in brake drag or grab while excessive free play can produce a low pedal condition Free...

Страница 608: ...closing the switch internal contacts This completes the electrical circuit between switch and warning lamp causing the lamp to light Unless the ignition lock cylinder is turned to the OFF position the...

Страница 609: ...vehicles except those with Model 60 rear axle compress cable lock tabs at brake support plate using small hose clamp and remove cable On vehicles with Model 60 rear axle remove bolts attaching cable...

Страница 610: ...ditioning remove screws attaching evaporator housing to instrument panel and move housing away from panel 2 Press and hold brake pedal in applied position 3 Push brakelamp switch through mounting brac...

Страница 611: ...t NOTE The disc brakes hoes used on Cherokee Wagon eer and Truck models have a wear sensor attached to the inboard brakeshoe When the lining wears sufficiently the sensor contacts the rotor making a h...

Страница 612: ...lt Cke Wag Trk 160 in lbs 1 2 0 2 0 0 in lbs 18 14 23 Bleeder Screw 1 4 28 45 in lbs 40 50 in lbs 5 5 6 Bleeder Screw 3 8 24 90 in lbs 4 0 140 in lbs 10 5 16 Brake Support Plate Mounting Bolts Nuts J...

Страница 613: ...alcohol or any similar fluid containing mineral oil to clean or lubricate hydraulic system components These materials will cause swell ing deterioration and premature aging of rubber parts Use brake...

Страница 614: ...pair as necessary MASTER CYLINDER A dual reservoir master cylinder is used on all Jeep vehicles The hydraulic system for the front brakes is completely separate from the rear brakes In the event of hy...

Страница 615: ...soline kero sene alcohol or carbon tetrachloride Mineral oil is very harmful to the rubber piston cups and seals 8 Inspect tube seats in outlet ports Replace seats only if cracked scored cocked in bor...

Страница 616: ...seal on master cylinder cover Installation 1 Position master cylinder on dash panel or power unit and install attaching nuts and washers Tighten nuts to 30 foot pounds 41 N m torque 2 Connect brake li...

Страница 617: ...ke fluid Do not lubricate dust boots Install them dry only 10 Position replacement piston cups on com pression expanders and install assembled parts in cylin der bore Be sure expanders are seated in p...

Страница 618: ...lve activates the brake warning lamp if a pressure loss in the front or rear hydraulic system should ever occur This feature is provided as a method for alerting the driver if such a system malfunctio...

Страница 619: ...d end of tool J 23709 under bolt Push metering valve stem inward using tool to hold valve open and tighten mounting bolt to secure tool fig 2G 16 Fig 2G 16 Metering Valve Tool Installation Type D Comb...

Страница 620: ...l e master cylinder brake line connections NOTE When using pressure equipment the bleeding procedure is the same as outlined in the Manual Bleed ing Procedure except that a helper is not required to a...

Страница 621: ...Wag Trk 160 in lbs 120 200 in lbs 18 14 23 Bleeder Screw 1 4 28 45 in lbs 40 50 in lbs 5 5 6 Bleeder Screw 3 8 24 90 in lbs 40 140 in lbs 10 5 1 6 Brake Support Plate Mounting Bolts Nuts J 20 Trk 50 4...

Страница 622: ...the power piston and diaphragm Fig 2G 19 Power Brake Unit Cherokee Wagoneer Truck Models As the brake pedal is pressed the brake pedal push rod moves the air inlet valve away from the control valve fi...

Страница 623: ...20 30 BRAKES Fig 26 20 Single Diaphragm Power Unit Typical 8 0 3 8 3 Fig 26 21 TandemDiaphragmPowerUnit Typical...

Страница 624: ...ement unit P01ER UNIT INSTALLATION 1 On Cherokee Wagoneer and Truck models mount power unit on dash panel and install attaching washers and nuts Tighten nuts to 35 foot pounds 47 N m torque 2 On CJ mo...

Страница 625: ...All 50 min 68 min Wheel Bearing Inner Locknut Bearing Adjuster CJ Tighten to 50 ft lbs 68 N m and back off 1 3 turn while rotating wheel Cke Wag Trk Tighten to 50 ft lbs 68 N m loosen and retighten t...

Страница 626: ...ected to it by a pivot pin installed in the upper end of the lever The pin is re tained in the brakeshoe by a washer and U clip The parking brake cable is attached to the lower end of the lever A stru...

Страница 627: ...the adjuster mechanism This action will repeat on subsequent brake appli cations until the drum to lining clearance is reduced to a point where shoe movement is no longer sufficient to cause the adjus...

Страница 628: ...plates for distortion or cracks and check the support plate to axle flange bolt torques Clean the brake drums with a soap and water solution only Inspect the drums for excessive wear scoring runout cr...

Страница 629: ...hoe return spring fig 2G 28 J41135 Fig 20 25 Brake Drui Locating Screw Removal Model 60 Axle 6 Remove automatic adjuster actuating spring and secondary brakeshoe return spring using Spring Remover Too...

Страница 630: ...with hard spots Replace drums with this condition Assembly and Adjustment NOTE When it is necessary to replace the brake lining on one wheel the lining must also be replaced on the opposite wheel to m...

Страница 631: ...41 47 Caliper Anchor Bracket to Steering Knuckle CJ 85 75 95 115 102 129 Master Cylinder Mounting Bolts Nuts 30 25 35 41 34 47 Master Cylinder to Power Unit Mounting Nuts 25 20 30 34 27 41 Power Brake...

Страница 632: ...i tioned on mounting bolts located in the caliper support bracket fig 2G 28 Although the two caliper designs differ in construction caliper operation and service pro cedures are similar All models are...

Страница 633: ...ncreased piston extension fig 2G 29 A brakelining wear sensor which consists of a strip of flanged metal is attached to the inboard brakeshoe on Cherokee Wagoneer and Truck models a sensor is not used...

Страница 634: ...ablish normal seal deflection fig 2G 31 inboard shoe and lining pressing the lining against the rotor inboard surface At the same time pressure ap plied to the piston bore forces the caliper to slide...

Страница 635: ...per fltiiiSlii l i l t Removal ir Removal 9 Remove sleeves and rubber bushings from mounting bolt bores in caliper mounting ears fig 2G 27 10 Clean mounting bolts bolt bores and bushing grooves in cal...

Страница 636: ...rvoir rim 25 Apply brakes several times to seat brakeshoes 26 Check and correct master cylinder fluid level as necessary 27 Test brake operation before moving vehicle CALIPER OVERNAUL CHER0KEE 1AG0NEE...

Страница 637: ...ive plat ing will be removed Inspect the caliper piston Replace the piston if nicked scratched corroded or if the protective plating has worn off CAUTION Do not attempt to refinish the piston in any w...

Страница 638: ...J 4 1 1 3 1 Fig 28 39 Installing list lit on Piston J 4 1 1 3 3 Fig 2 1 4 1 Sosllng M Iml to Gounlerbore Installation 1 Install replacement copper gaskets on brake line and connect line to caliper Tig...

Страница 639: ...2G 43 4 2 8 7 2 Fig 2 8 4 2 Bottoming Caliper Piston 7 Remove caliper support key and spring using using punch and hammer fig 2G 44 8 Lift caliper upward and out of anchor plate and off of rotor fig...

Страница 640: ...ase Rust corrosion or foriegn material on these surfaces will impair the sliding action of the cali per in the anchor plate 16 Install inboard brakeshoe anti rattle spring on rear flange of inboard br...

Страница 641: ...and correct if necessary C A U T I O N Check for a firm brake pedal before mov ing the vehicle CALIPER OVERHAUL CJ MODELS Fig 2 1 4 1 tatafTi tote installation Removal 1 Remove two thirds of brake flu...

Страница 642: ...grease fig 2G 47 Clean the caliper and piston with brake cleaning sol vent and dry both parts using filtered compressed air Be sure to blow out all passages in the caliper Inspect the caliper piston f...

Страница 643: ...g air supply valve completely then opening it approximately 1 1 to 1 2 turn 7 As air pressure expends boot carefully work piston into boot until boot lip seats in piston groove When boot lip is seated...

Страница 644: ...cator reading c Lateral runout must not exceed 0 005 inch 0 12 mm Lateral runout will cause rotor wobble re sulting in chatter vibration pedal pulsation and exces sive pedal travel wobbling rotor will...

Страница 645: ...desired microfinish and Crosshatch pattern fig 2G 58 When rotor resurfacing or refinishing operations are completed recheck lateral runout thickness variation and overall thickness to be sure the rot...

Страница 646: ...t ening locknut to seat bearings uniformly 7 Loosen and retighten inner locknut to 35 foot pounds 47 N m torque Rotate wheel while tightening locknut to maintain bearing seating 8 Back off inner lockn...

Страница 647: ...Wag Trk 35 30 40 47 41 54 Front Wheel Bearing Adjusting Locknuts 50 50 55 68 68 75 Wheel Retaining Lugnuts CJ Models 75 65 80 102 88 108 Cherokee Wagoneer J 10 Truck 75 65 80 102 88 108 J 20 Truck 84...

Страница 648: ...re referred to as bias ply bias belted and radial ply construction The description for each construction type is derived from the method used to position the tire cord plies in relation to the tread c...

Страница 649: ...n this case letter H represents tire industry specifications for the load and inflation schedule for tires in this letter classification The number 78 in dicates tire section height as determined by t...

Страница 650: ...occurs and the tires are serv iceable rotate the tires and inflate them to recom mended levels when they are cool Rapid wear at the tread center is usually caused by overinflation or lack of rotation...

Страница 651: ...ire Weekly inspection intervals are recommended as a minimum More frequent inspections are recommended when extreme temperature changes occur or where road surfaces are rough or occasionally littered...

Страница 652: ...nce for the tire in the wheel well Refer to the Tire Inflation Pressure Chart for tire sizes allowable on each model Radial tires must never be intermixed with bias ply or bias belted tires on any veh...

Страница 653: ...rheat A loose adjustment allows the hub to shift position as bearing load varies during acceleration braking and cornering A loose bearing adjustment can produce shimmy vibration and low brake pedal h...

Страница 654: ...ct the flat side of the cup only 13 Install drive gear and drive gear snap ring 14 Coat hub cap rim with Permatex Form A Gas ket number 3 or equivalent and install hub cap 15 Lower vehicle Rear Wheel...

Страница 655: ...e highly flexible sidewall An objectionable waddle condition can be reduced only by rotating the tires Wheel balancing will not alleviate this condition Proper mounting of radial tires is very importa...

Страница 656: ...he centrifugal force generated by a tire spinning at high speed could cause damage and personal injury ments should be made on the vehicle with the tires inflated to recommended levels and with the wh...

Страница 657: ...lt through the seats floorpan or steering wheel and usually produce some visible motion in the rear view mirror fenders dash panel or steering wheel Audible vibrations are heard or sensed above normal...

Страница 658: ...o 88 km h Torque sensitive vibration UJ Universal Joints If needle bearings bearing cups or bearing ends of spiders are worn damaged over tightened or loose they will cause mechanical vibration at alm...

Страница 659: ...Sensitive w v n _l A R 1 Vehicle Speed Sensitive Torque Sensitive Torque Sensitive JA U J d J A Engine Speed Sensitive p O Engine Speed Sensitive E DEM A Vibration Sensitivity Correction Codes For Aud...

Страница 660: ...32 28 28 26 26 26 30 32 28 28 26 26 26 30 28 24 24 22 22 22 20 28 24 24 22 22 22 20 40 32 36 32 36 35 40 40 32 36 32 36 35 40 38 32 32 32 32 32 30 38 32 32 32 32 32 30 1 5 x 6 1 5 x 6 1 5 x 6 1 5 x 6...

Страница 661: ...149 203 Wheel Bearing Adjustment CJ Outer Locknut 50 50 min 68 68 min Inner Locknut Adjusting Nut Tighten to 50 foot pounds 68 N m torque and back locknut off 1 3 turn while rotating wheel Wheel Beari...

Страница 662: ...n key release lever A six position tilt column is available as an option on all models All steering columns used on Jeep vehicles have anti theft and energy absorbing features Each column is designed...

Страница 663: ...place 8 bent Straighten or replace 9 Distorted coupling slot in lock 9 Replace lock rack 9 rack tilt column 9 Replace lock rack WILL STICK IN 1 Remote rod deformed 1 Straighten or replace START 1 1 St...

Страница 664: ...lumn 7 Coupling pulled apart 7 Replace coupling 8 Broken coupling lower joint 8 Repair or replace joint and align column 9 Steering shaft snap ring not seated 9 Replace snap ring Check for proper seat...

Страница 665: ...mn only 8 Tighten screws HOUSING LOOSE TILT COLUMN ONLY 1 Excessive clearance between holes in support or housing and pivot pin diameters 1 Replace pivot pins and support 2 Housing support screws loos...

Страница 666: ...n not correctly aligned 1 Align column TILT COLUMN ONLY 2 Lower bearing not aligned 2 Assemble correctly correctly 3 Lack of grease on seal or lower 3 Lubricate with chassis 3 bearing areas grease IMP...

Страница 667: ...or not adjusted Adjust or replace switch IGNITION SWITCH 1 Defective ignition switch 1 Replace switch WILL NOT ACTUATE Replace lock sector MECHANICALLY 2 Defective lock sector 2 Replace lock sector 3...

Страница 668: ...parts WILL NOT STAY impeding movement of switch 1 Remove material and or parts IN TURN POSITION yoke 2 Defective switch 2 Replace switch HAZARD SWITCH 1 Foreign material between 1 Remove foreign mater...

Страница 669: ...switch into circuit and operate switch by hand If the vehicle s lights operate normally signal switch is inoperative STOP LIGHT NOT 1 Loose column to chassis 1 Connect securely ON WHEN TURN connectio...

Страница 670: ...gnal switch 5 connector Connect new switch Replace turn signal switch into system without removing old Operate switch by hand If flashing occurs at normal rate the signal switch is defective HAZARD SI...

Страница 671: ...ft for assembly reference 8 Remove steering wheel using Puller J 21232 fig 2J 1 Fig 2J 1 Steering Wheel Removal Clirikis liiiiiir Tfiil Models 1 Disconnect battery negative cable 2 Place front wheels...

Страница 672: ...eiver insulator on steering wheel and install insulator attach ing screws 10 Align reference marks on steering shaft and wheel and install wheel 11 Install contact plate and horn button receiver Insta...

Страница 673: ...SHAFT COUPLING 3 LOCK PLATE COVER 18 HOUSING RETAINING SCREW 4 34 TOE PLATE LOWER HALF 4 STEERING SHAFT SNAP RING 19 HOUSING 35 INTERMEDIATE SHAFT 5 LOCKPLATE 20 RACK PRELOAD SPRING 36 INTERMEDIATE S...

Страница 674: ...with air conditioning install left air duct extension 13 Connect transmission shift rod to steering col umn shift lever 14 On vehicles with automatic transmission check operation of gearshift manual...

Страница 675: ...to aid removal 12 Unhook turn signal switch wire harness con nector from bracket at lower end of steering column 13 Disconnect instrument panel harness connector from turn signal switch harness connec...

Страница 676: ...emove ignition switch from lower end of col umn fig 2J 10 20 Remove screws attaching housing and shroud to column jacket fig 2J 11 and remove housing and shroud 21 Disengage remote rod from lock rack...

Страница 677: ...ck bolt assembly fig 2J 14 Fig 2J 16 Lock Sector Removal 25 Remove rack preload spring fig 2J 15 26 Remove lock sector through lock cylinder hole in housing Push on block tooth of sector with blunt pu...

Страница 678: ...k away under impact 1 Coat all friction and bearing surfaces with chassis grease before assembly 2 Install lock sector on sector shaft Install sector through lock cylinder hole in housing fig 2J 17 Us...

Страница 679: ...er in housing Insert key in lock hold cylinder sleeve and rotate key clockwise until key stops this retracts actuator 13 Insert lock cylinder in housing bore with cylin der tab aligned with keyway in...

Страница 680: ...he compressor tool If the shaft has Ameri can threads use the compressor tool as is However if the shaft has metric threads fig 2J 2 replace the com pressor tool forcing screw with Metric Forcing Scre...

Страница 681: ...battery negative cable 2 Place front wheels in straight ahead position 3 Remove column to instrument panel bezel and left air conditioning duct if equipped 4 Cover painted areas of column 5 Remove st...

Страница 682: ...connect turn signal switch harness connector from instrument panel harness connector fig 2J 7 Lift connector lock tab to separate connectors 16 Using stiff wire or paper clip compress lock tab retaini...

Страница 683: ...med with the column mounted in the car the following steps can be performed only after the column has been removed BEARING LOCATOR CRIMP TYPICAL COLUMN JACKET TUBE UPPER END NOTCH TYPICAL Fig 2J 31 Sh...

Страница 684: ...tate shift bowl counterclockwise to stop and install upper housing Tighten housing attaching screws to 60 inch pounds 7 N m torque NOTE The shift bowl must be in the Park position and the rack pulled...

Страница 685: ...tallation 37 Install lower finish panel air conditioning duct if equipped and column to instrument panel bezel 38 Remove protective covering from painted areas of column 39 Connect battery negative ca...

Страница 686: ...nose pliers and remove quad rant fig 2J 30 24 Remove shift quadrant mounting bracket and light socket 25 Remove tilt lever 26 Remove cover retaining screws and remove cover from column 27 Remove lock...

Страница 687: ...washer 47 Remove shift tube from column jacket using Shift Tube Remover Tool J 23072 fig 2J 40 48 Remove retainer plate by rotating shift bowl clockwise sliding plate out of jacket notches tipping it...

Страница 688: ...STEERING COLUMNS 2J 27 LOCK LOCK PLATE CANCELING PLATE COVER STEERING S SHAFT SNAP t RING CAM LOCK RACK INTERMEDIATE SHAFT ASSEMBLY SHIFT TUBE 50286 Fig 2J 42 Tilt Steering...

Страница 689: ...gnition switch remote rod between shift bowl and column jacket and into guide channel in left side of support 21 Engage lock rack in remote rod fig 2J 45 REMOTE R C AJ70205 Fig 2J45 Look l i c k and l...

Страница 690: ...ue 46 Install upper bearing race bearing seat preload spring and canceling cam on steering shaft 47 Align lock plate splines with steering shaft splines and install lock plate Canceling cam shaft must...

Страница 691: ...unted in the vehicle the column must be removed if disassembly is to be more extensive If the column is removed use Sup port Fixture J 2307 to mount the column in a vise for service operations fig 2J...

Страница 692: ...ap ring Discard snap ring 11 Remove lock plate canceling cam and upper bearing preload spring fig 2J 47 12 Disconnect turn signal switch harness at lower right side of column jacket 13 Loosen all toe...

Страница 693: ...er tabs align with hous ing lugs Be sure screwdriver blade just fits into retainer slot WARNING The tilt spring guide is under strong spring pressure Fig 2J 53 Housing Removal HOUSING Fig 2J 54 Tilt L...

Страница 694: ...and remote rod from housing 34 Insert wedge between lock shoes and housing to relieve spring tension on tilt and lock shoe pins fig 2J 57 8 0 5 7 9 Fig 2J IS Steering Shift Removal Installation 35 Rem...

Страница 695: ...pward to remove 44 Disconnect ignition switch and neutral safety switch wire harness connectors and remove both switches from lower end of column 45 Remove snap ring retainer and bearing assem bly fro...

Страница 696: ...rd when first installing pins to prevent damaging pin holes in support When pins are started in both housing and support seat pins fully using hammer and punch 20 Insert tilt lever in housing and plac...

Страница 697: ...te and unseat snap ring c If shaft has metric threads replace com pressor tool standard forcing screw with Metric Forcing Screw J 23653 4 before installing tool on shaft 9 Remove compressor tool and s...

Страница 698: ...readjusted whenever it is removed during service operations or when diagnosis indicates adjustment is necessary Adjustment consists of reposi tioning the switch on the column jacket Refer to the foll...

Страница 699: ...ing cam and upper bearing preload spring 8 Remove turn signal lever attaching screw and remove lever 9 Press hazard warning knob inward and turn knob counterclockwise to remove it 10 Disconnect turn s...

Страница 700: ...d of clip about 1 4 inch 6 35 mm from end fig 2J 65 A41061 Fig 2J 66 Lock Cylinder and Sleeve Disassembled Fig U41 Ignition lock Cylinder Assembly RETAINER Fig 2J 65 Compressing Lock Cylinder Plunger...

Страница 701: ...rs to drop completely into place 5 Install a spring on each tumbler 6 Insert tumbler retainer so two end prongs slide into slots in cylinder 7 Press retainer downward until it is seated 8 Insert key i...

Страница 702: ...given in foot pounds with dry fits unless otherwise specified Service Set To Service In Use Service Set To Service In Use Torque Recheck Torque Torque Recheck Torque 30 25 35 41 34 47 45 40 55 61 54...

Страница 703: ...NOTES...

Страница 704: ...d is driven through steel ball bearings which circulate in spiral grooves machined in the wormshaft and ball nut The bearings act as a rolling thread between the wormshaft and ball nut The ball nut is...

Страница 705: ...if necessary 9 Front spring sag 9 Check front end jounce height It should be approximately the same at both wheels Replace front springs if sagged 10 Frame bent or broken 10 Repair frame as necessary...

Страница 706: ...r Shaft Shaft Bearing Clearance Maximum 0 010 in 0 25 mm 8 0 4 3 5 B 80435A STEERING G E A R LEFT H A N D DRIVE VEHICLES Page Page Assembly and Adjustment 2K 8 Removal 2K 3 Disassembly 2K 4 Specificat...

Страница 707: ...ering gear and install mount ing bracket to gear attaching bolts Tighten hex head bolts to 70 foot pounds 95 N m torque Tighten torx head bolt to 55 foot pounds 75 N m torque using Torx Head External...

Страница 708: ...ise to unthread side cover from screw and remove side cover and gasket 6 Slide adjuster screw and shim out of T slot in pitman shaft fig 2K 5 Retain shim and screw for end play measurement at assembly...

Страница 709: ...er installation fig 2K 7 3 Install one ball bearing in each ball guide hole 4 Move wormshaft up down and side to side until bearings roll into ball nut threads under wormshaft and support wormshaft 5...

Страница 710: ...o pry seals out fig 2K 12 2 Remove adjuster screw and shim from pitman shaft T slot if not removed previously Retain screw and shim for end play check Cleaning and Inspection Clean the housing and pit...

Страница 711: ...p is to be re placed remove old cup using hammer and brass punch fig 2K 14 2 Install replacement bearing cup using Installer J 5755 fig 2K 15 NOTE Do not install the wormshaft or pitman shaft seals at...

Страница 712: ...rmshaft seals as follows a Wrap 0 005 inch 0 1 mm thick shim stock or single layer of thinnest tape available around shaft splines and threads Shim stock or tape will serve as seal protecter when seal...

Страница 713: ...ing preload setting 5 Rotate shaft over center and continue tightening adjuster screw until drag torque is increased by addi tional 4 to 10 inch pounds 0 45 to 1 13 N m but do not exceed total of 16 i...

Страница 714: ...to frame 4 Remove gear by sliding gear slightly forward and to right and lifting gear out of engine compartment INSTALLAT101 1 Position gear on frame and install gear mount ing bolts 2 Attach steering...

Страница 715: ...ps as assemblies if worn or damaged NOTE The bearing balls must be replaced as afull set in each bearing ASSEMBLY AND ADJUSTMENT 1 Position replacement worm and roller shaft oil seals on seal bores in...

Страница 716: ...rns 4 Rotate worm gear shaft back and forth through center of travel and tighten adjustment screw until slight bind occurs at center of shaft travel 5 Loosen or tighten adjusting screw until rolling t...

Страница 717: ...2K 14 MANUAL STEERING GEAR Tools TORQUE WRENCH J 77S4 J 6632 PITMAN ARM PULLER SLIDE HAMMER J 2619 01...

Страница 718: ...rate man ually if a system malfunction should ever occur This feature provides the driver with continued steering con trol of the vehicle In this condition the gear operates like a manual steering gea...

Страница 719: ...fluid supply The reservoir cap is vented to maintain atmospheric pressure within the reservoir and allow air trapped in the system to escape A dipstick mounted in the reser voir cap is used to check...

Страница 720: ...ooves are aligned with high pressure fluid grooves in the valve body fig 2L 3 The spool valve left turn grooves are closed off from pump pressure and are aligned with the valve body fluid return groov...

Страница 721: ...2L 4 POWER STEERING GEAR AND PUMP RACK PISTON A J 4 2 0 7 8 Fig 21 3 Fluid Flow Right Turn Position...

Страница 722: ...ERING GEARANDPUMP2L 5 RETURN OIL TO UPPER SIDE OF RACK PISTON WORM SHAFT OIL PRESSURE OIL RETURN PORT V A L V E BODY HIGH PRESSURE LOW PRESSURE RACK PISTON A J 4 2 0 7 9 Fig 2L 4 Fluid Flow Left Turn...

Страница 723: ...g center tooth is in contact with the rack piston As a result initial movement of the rack piston in either direction produces a relatively small response of the sector and pitman arm This is due to t...

Страница 724: ...ace damper O ring CHIRP NOISE IN STEERING PUMP 1 Loose or damaged belt 1 Adjust belt tension or re place belt BELT SQUEAL PARTICULARLY NOTICEABLE AT FULL WHEEL TRAVEL AND STAND STILL PARKING 1 Loose o...

Страница 725: ...t valve in stalled incorrectly 1 Incorrect tire pressure 2 Front end misaligned 3 Unbalanced steering gear valve 1 Low oil level in pump 2 Pump belt slipping 3 High internal leakage 1 Replace housing...

Страница 726: ...ering linkage rod ends worn 3 Replace rod ends 4 Worn poppet valve Gear 4 Replace poppet valve 5 Insufficient wormshaft bearing preload 5 Adjust to specification with gear out of vehicle 6 Insufficien...

Страница 727: ...using 1 Remove burrs or dirt or replace Flush system 2 Correct 3 Replace parts Flush system 4 Replace parts Flush system 5 Install properly 6 Freeup by removing burrs varnish or dirt 7 Replace part 1...

Страница 728: ...plug O ring seal 9 If leak is from crack or porous spot in gear housing replace housing Leak Diagnosis ill Cgrraellon Pump NOTE Refer to figure 2L 8 for an illustration of the various pump leak source...

Страница 729: ...sult in ineffective repair Corrective Action Replace adjuster plug O ring seal Replace Dust and stub shaft seals If seepage is observed between the torsion bar and stub shaft do not attempt repair The...

Страница 730: ...ll bolts supplied in overhaul k i t If leak continues after tightening fitting nut to specified torque a Loosen nut and rotate tubing to reseat Tighten nut again and recheck If leak persists replace c...

Страница 731: ...hose b Remove hose and check sealing face for cracks If flare is cracked replace hose If not cracked replace connector seats c Replace brass connector seats and reface tube flare Check threads in pump...

Страница 732: ...e could occur 13 On CJ models maximum pump output pres sures should be in 1000 1100 psi 6 895 7 584 kPa range and not vary by more than 50 psi 345 kPa On all other models pressures should be in 1400 1...

Страница 733: ...ATION REPAIR OR REPLACE AS NECESSARY A L L THREE READINGS MUST BE ABOVE SPEC AND WITHIN 50 PSI 345 kPa OF EACH OTHER CLOSE V A L V E FULLY THREE TIMES RECORDING HIGHEST PRESSURE EACH TIME CAUTION DO N...

Страница 734: ...PRESSURES SEE STEP 4 PRESSURES OK PRESSURES REPLACE ROTATING LOW GROUP WITH VALVE OPEN TURN STEERING WHEEL A L L THE WAY LEFT AND RIGHT RECORD HIGHEST PRESSURE AT EACH STOP COPY HIGHEST PRESSURE FROM...

Страница 735: ...pounds 0 45 to 0 56 N m in addition to worm bearing preload but not to exceed total of 18 inch pounds 2 03 N m Steering Ratio CJ 17 5 1 constant ratio Cke Wag Trk 13 16 1 variable ratio Value Body Th...

Страница 736: ...Position drain pan under gear W VEHICLE SERVICE Steering Gear Adjustment Because of the complexity involved in adjusting worm bearing preload and pitman shaft overcenter drag torque plus the friction...

Страница 737: ...5 Install pitman arm on shaft and install replace ment pitman arm nut and lockwasher Tighten nut to 185 foot pounds 251 N m torque Stake nut in two places to retain it 16 Lower vehicle 17 Fill power s...

Страница 738: ...ve steering gear and mounting brackets as assembly d Remove mounting bracket to gear attaching bolts and remove upper and lower mounting brackets from steering gear STEERING GEAR INSTALLATION NOTE Pro...

Страница 739: ...gear will not be necessary Only those subassemblies that have malfunctioned should be dis assembled In addition steering gear repair operations must always be performed on a clean work bench Cleanlin...

Страница 740: ...urning screw clockwise 13 Rotate stub shaft until pitman shaft sector teeth are centered in housing 14 Remove pitman shaft from housing by tapping threaded end of shaft with plastic mallet NOTE Do not...

Страница 741: ...rosion can be removed using crocus cloth Inspect the pressure and return port hose connector seats and check the poppet check valve in the pressure port Replace the seats if cracked loose cocked worn...

Страница 742: ...nstall replacement check valve over spring so valve tangs face downward Be sure valve is centered on small end of spring 9 Coat replacement pressure port connector seat with petroleum jelly and positi...

Страница 743: ...isassembly 1 Remove thrust bearing retainer using screw driver fig 2L 23 Discard retainer Do not damage needle bearing bore when removing retainer 4 2 1 0 8 Fig 2L 23 Thrust Bearing Retainer Removal R...

Страница 744: ...26 Stub Shaft Seal Installation 3 Install bearing in adjuster plug until bearing is flush with bottom surface of stub shaft seal counterbore fig 2L 25 4 Install stub shaft seal in adjuster plug using...

Страница 745: ...ting downward Tap end of stub shaft lightly against wood block until shaft cap is free of valve body fig 2L 28 TEFLON RINGS 3 STUB SHAFT SPOOL VALVE O RINGS 3 INSTALLED UNDER TEFLON RINGS SHAFT CAP V...

Страница 746: ...valve is a loose fit binds or sticks or does not rotate freely within the valve body Assembly 1 Lubricate all valve body components with power steering fluid 2 Install replacement backup O rings in se...

Страница 747: ...se conditions Inspect the pitman shaft bearing and seal surfaces and sector teeth for cracks wear pitting or scoring fig 2L 33 Inspect the adjuster screw for looseness dam aged threads or distortion R...

Страница 748: ...Install silver ball bearing followed by black ball bearing until 18 bearings have been installed Rotate wormshaft slowly in counterclockwise direction when installing bearings and press each bearing...

Страница 749: ...rmshaft into valve body Rotate worm shaft until drive lugs engage in stub shaft cap and wormshaft locating pin engages in valve body notch fig 2L 38 L O W E R T H R U S T B E A R I N G TOPS OF CONES M...

Страница 750: ...or tooth of shaft with center tooth groove in rack piston 17 Align side cover on housing and install cover attaching bolts Tighten bolts to 45 foot pounds 61 N m torque Be sure cover gasket is properl...

Страница 751: ...uster plug locknut Place spanner wrench on adjuster plug to prevenf it from turning and tighten locknut to 85 foot pounds 115 N m torque us ing tool J 25194 Do not allow the adjuster plug to turn whil...

Страница 752: ...y turning pitman shaft ad juster screw clockwise until desired drag torque is ob tained Adjust drag torque to following limits On new gears add 4 to 8 inch pounds 0 45 to 0 90 N m torque to previously...

Страница 753: ...Trk 13 16 1 variable ratio Valve Body Three way open center rotary type 8 0 4 9 9 Torque Specifications Service Set To Torques should be used when assembling components Service In Use Recheck Torques...

Страница 754: ...l remover tool is not available remove seal as follows a Wrap length of 0 005 inch 0 12 mm thick shimstock approximately 2 1 2 inches 6 35 cm long around pump shaft Work shimstock under and past shaft...

Страница 755: ...nsion is obtained Refer to Specifications for belt ten sion figures for various models 5 Tighten all pump mounting and adjusting bracket bolts to 30 foot pounds 41 N m torque after adjusting belt tens...

Страница 756: ...s from side to side without contacting steering stops in either direction Maintain fluid level just above pump body Fluid with air in it will be full of bubbles and have light tan or tan orange colora...

Страница 757: ...l filler cap and clean pump with solvent to remove exterior dirt 3 Remove pump pulley using tool J 25034 fig 2L 47 4 Mount pump in vise so pump shaft is pointing downward Do not overtighten vise as pu...

Страница 758: ...Do not confuse this polish with wear or scoring Inspect the rotor surfaces for pitting wear cracks or scoring and check all the rotor vanes for free movement in the rotor slots The vanes must not sti...

Страница 759: ...spring on pressure plate Be sure spring is seated in plate spring groove fig 2L 58 15 Lubricate end plate outside diameter with pet roleum jelly and install plate in pump body bore ARROW 4 2 1 3 5 Fig...

Страница 760: ...psi 7584 8274 kPa Cke Wag Trk 1400 1500 psi 9653 10342 kPa Pressure Test Specifications Initial pressure engine at idle speed 80 125 psi 552 862 kPa Test pressures gauge valve closed Pressures must be...

Страница 761: ...hecking a pre torqued item USA ft lbs Metric N m Hose Fittings Pump Adjusting Bolts Nuts Pump Mounting Bracket Bolts Pump Mounting Studs Pump Union Fitting Service Service Service In Use Service In Us...

Страница 762: ...d an integral steering arm and steering knuckle Ball ends and adjusting tubes are used on the tie rod and connecting rod for toe in adjustment and steering wheel alignment fig 2M 1 and 2M 2 The connec...

Страница 763: ...djusting tube The tie rod has a large boss located about eight inches from the unthreaded end A tapered hole machined in this boss accepts the connecting rod end The steering damper is connected to a...

Страница 764: ...ear pitman arm must be indexed with the alignment marks on the pitman arm and steering gear shaft and the steering gear must be centered When the steering arm is correctly positioned install the con n...

Страница 765: ...Wheel Toe In Top View Typical The distance between the rear of the tires should be greater than at the front by 3 64 to 3 32 inch 1 19 to 2 38 mm To adjust toe in loosen the adjuster tube clamp bolts...

Страница 766: ...ts or retaining nuts for being loose If loose tighten nuts or center bracket on tie rod and tighten attaching bolts 5 Check steering damper operation Disconnect damper at tie rod bracket and alternate...

Страница 767: ...3 8 24 CJ 22 16 28 30 22 38 Steering Damper Locknut 7 16 20 CJ 30 24 36 41 33 49 Upper Ball Stud Retaining Nut and Lower Bolt Stud Jam Nut 100 136 Upper Ball Stud Split Ring Seat 50 68 Tie Rod Clamp B...

Страница 768: ...n or shifted leaves loose or missing clips and broken center bolts Squeaking noises can be generated when movement between the spring bushings and metal parts occurs This noise can usually be eliminat...

Страница 769: ...eral oil base lubricants can cause deterioration of the bushing rubber The shock absorbers are not refillable or adjustable If a malfunction occurs the shock absorber must be re placed as an assembly...

Страница 770: ...remove hydraulic jack STA11L1ZE11A1 The stabilizer bar extends across the front undersides of the frame and is attached to the frame rails by clamps and rubber bushings fig 2N 7 The bar ends extend re...

Страница 771: ...tighten bolt at this time 2 Position spring front eye in shackle and loosely install attaching bolt and nut Do not tighten bolt at this time 3 Position axle on spring and install spring tie plate and...

Страница 772: ......

Страница 773: ...Remove bolt attaching spring rear eye to shackle 6 Remove bolt attaching spring front eye to mounting bracket on frame 7 Remove spring NOTE The spring can be disassembled by removing the spring reboun...

Страница 774: ...g Socket will serve as bushing driver NOTE The socket must be large enough in diameter to bear against the metal outer sleeve on the bushing but still be small enough to pass through the spring eye 3...

Страница 775: ...f pipe 7 Tighten nut at socket and press bushing out of spring eye 8 Remove tools and old bushing 9 Install replacement bushing on threaded rod and assemble bushing tools as outlined in previous steps...

Страница 776: ...s 3G Litigates Tailgates Doors Rear Quarter 3K Luggage Racks 3L Seat Assemblies 3M Windshield Rear Window Headlining Hardtop Enclosure Exterior Decals and Overlays Lighting Systems Horn Systems Windsh...

Страница 777: ......

Страница 778: ...all suspect areas and it would be difficult to deter mine the exact problem area Do not rush the water spray test The water may have to flow awhile before it shows up Try to simulate as close as poss...

Страница 779: ...the dash panel assembly and glass b Test vertical section of A pillar and across top of glass c Repeat steps a and b for other side of vehicle 3 If leaks are noted dry out suspect area as de scribed u...

Страница 780: ...hey are correctly installed If necessary apply sealant to ensure a water tight seal 11 Make sure that all suspect components and at taching hardware are properly installed If necessary apply above sea...

Страница 781: ...lines described under Spray Test above a Starting at front lower corner of door spray water between door lower edge to rocker panel b Move slowly up door to roof level c Move to door lower rear corner...

Страница 782: ...proximately 5 is obtained as an indication of a pos sible leak d Repeat test on other side of vehicle 4 Clean suspect area as described above under Bonding Surface Preparation 5 In instances of leakag...

Страница 783: ...n a Examine drip rail for small pin holes in drip rail sealer b Apply 3M All Around Autobody Sealant or equivalent to drip rail and touch up with matching body color when sealant is dry 6 Repeat ultra...

Страница 784: ...cedures for the rear doors Ultrasonic Diagnosis and Repair Repeat Front Doors and Glass Ultrasonic Diagnosis and Repair procedures for the rear doors Rear Quarter Windows The stationary and opening re...

Страница 785: ...er panel and extension panel seams c Also spray water across rear floorpan and extension panel plugs d Move spray slowly upwards until water is directed at each wheelhouse panel seam e Direct spray on...

Страница 786: ...lamp housing attaching hardware 13 Seal coach seams with sealant and touch up with matching body color after sealant is dry 14 Tighten fuel tank filler neck screws and seal any holes of breaks in gask...

Страница 787: ...road test It is usually helpful to have an assistant drive the vehicle or locate the noise Road test the vehicle with the front windows up and then down to be sure the noise is coming from outside the...

Страница 788: ...at are not properly aligned or tightly seated can allow air to flow under rather than over them generating a wind whistle Apply body tape to the suspected area and road test the vehicle If the wind wh...

Страница 789: ...S310N...

Страница 790: ...tic body filler and hardener accord ing to manufacturer s instructions 6 Apply plastic filler with a plastic spreader Use firm pressure to aid in removing air bubbles which will show up as pinholes 7...

Страница 791: ...1 Wash part with paint finish cleaning solvent such as DuPont Prep Sol Ditzler Acryli Clean or equivalent 2 Scuff sand part with 360 grade dry sandpaper Avoid cutting through and rewash part 3 Mix pri...

Страница 792: ...pray paint plastic and vinyl or equivalent CAUTION It is essential that the service part be primed first with a coating of Jeep 8993626 poly propylene primer or equivalent according to the in structio...

Страница 793: ...NOTES...

Страница 794: ...nstrument Panel INSTRUMENT CLUSTER Removal NOTE If equipped with air conditioning remove screws attaching evaporator assembly to instrument panel and lower evaporator assembly 1 Disconnect battery neg...

Страница 795: ...instrument panel and install attaching screws b Raise windshield to upright position c If equipped with a hardtop enclosure re move wood blocking supporting top and lower top onto body and windshield...

Страница 796: ...tom to release the small retaining tabs Push the lamp through the panel toward the steering wheel To install the molded lamps push into the panel until the retain ing tabs snap into place SPEEDOMETER...

Страница 797: ...inverted U and then cross the open ends Hold one end in the left hand the other in the right hand Twist one end applying light finger pressure to the other end If the core is satisfactory the turning...

Страница 798: ...all bolt in center of brace 3 Install steering column trim panel 4 Connect defroster hoses 5 Connect electrical connectors and courtesy lights 6 Install air vent cables 7 Install parking brake lever a...

Страница 799: ...ounter clockwise to expose the tumblers 2 Remove key and press retainer tumbler down 3 Insert key and remove lock cylinder 4 If replacement lock cylinder is being installed insert original key into re...

Страница 800: ...installing the odometer the separators must straddle a cross bar to maintain proper number alignment SIXTH FIFTH R R S T DIGIT SEPARATOR SEPARATOR 7 42236 Fig 3C 6 Advancing Odometer M i n g ftrr S o...

Страница 801: ...NOTES...

Страница 802: ...e Diagnosis for a list of the possible causes and recommended service procedures SYSTEM CONTROLS The heater and defroster controls consist of a fan control switch and three push pull knobs and cable a...

Страница 803: ...air and heated air The defrost control knob must be pushed in for the blended air to enter through the floor heat duct When the defrost control knob is pulled out completely all airflow will be direct...

Страница 804: ...y resistor 2 Replace resistor FAN RUNS BUT DOES 1 Intake blocked 1 Clean intake NOT CIRCULATE AIR 2 Fan not secured to 2 Tighten securely motor shaft Tighten securely HEATER WILL NOT 1 Coolant does no...

Страница 805: ...t panel press the plastic tabs together and pull out the cable 2 Remove cable from instrument panel 3 Remove cable to damper door 4 Route replacement cable through hole in in strument panel 5 Connect...

Страница 806: ...er housing to dash panel 8 Install glove box 9 Install speedometer cable 10 Install screw attaching heater housing to bracket 11 Connect wiring to A C switch 12 Install evaporator housing to instrumen...

Страница 807: ...ition control switch Off Low Medium and High which regulates the blower motor and airflow for heat defrost and fresh air ventilation There has been a vacuum storage tank added to pre vent the heater d...

Страница 808: ...m vacuum control switch NOTE Tag hoses according to their numbered location for ease of assembly 6 Remove cluster lamps 7 Disconnect cable from temperature control lever 8 Remove instrument cluster 9...

Страница 809: ...ped with a turnbuckle to simplify adjustment The turnbuckle is located under the instrument panel to the right of the steering column 1 Rotate turnbuckle counterclockwise to obtain complete closing of...

Страница 810: ...eparate housing 8 Remove heater core to housing attaching screws and remove core Installation 1 Position heater core in housing and install at taching screws 2 Seal and assemble two halves of heater c...

Страница 811: ...NOTES...

Страница 812: ...tered during operation The metering action of the expansion valve is controlled by the temperature sen sing bulb mounted on the outlet suction line of the evaporator Evaporator The evaporator is an ai...

Страница 813: ...D RECEIVER DRYER SCREEN 4 1 4 8 8 Fig 3E 1 Refrigeration Cycle GENERAL SERVICE PROCEDURES Charging System 3E 9 Checking for Leaks 3E 8 Checking System Pressures 3E 4 Compressor 3E 11 Discharging Syste...

Страница 814: ...hen charging the system so as to utilize the vapor instead of the liquid When metering R 12 into the refrigeration system keep the supply tank or cans in an upright position If the refrigerant contain...

Страница 815: ...ated on the gauges regardless of hand valve position Connecting the Pressure Gauge and Manifold Assembly 1 Remove protective caps from service valve gauge ports and valve stems 2 Close both hand valve...

Страница 816: ...255 30 70 80 90 100 1500 40 41 42 44 12 16 22 26 181 214 234 267 40 70 80 90 100 1500 40 42 43 44 13 18 23 26 185 220 243 278 50 70 80 90 100 1500 40 42 44 46 14 19 25 27 189 226 25 1 289 60 70 80 90...

Страница 817: ...sor 1 Connect pressure gauge and manifold assembly to proper service valves 2 Turn both manifold hand valves to maximum counterclockwise open position 3 Open both service valves a slight amount from b...

Страница 818: ...dle returns to zero rapidly install a partial charge in system and locate leak with leak detec tor Repair leak and repeat evacuation procedure 9 If gauge needle remains stationary and vacuum is mainta...

Страница 819: ...nt Halie Torch Leak Detection External leaks are detected and located with a halide torch tool J 6084 fig 3E 8 The torch burns propane fuel and is equipped with a search hose When air is drawn into th...

Страница 820: ...required 6 Evacuate system after all leaks are corrected 7 Charge system Filling Charging Cylinder 1 Be certain refrigerant drum is inverted and valve is open 2 Open right hand valve at base of chargi...

Страница 821: ...m will cycle properly refer to Checking System Pressures 12 Upon completion of operational check back seat suction and discharge service valves to their normal o p e r a t i n g p o s i t i o n by t u...

Страница 822: ...ompressor Mounting Sii Cflliiir Ceipressor Valve Leak Diagnosis The compressor should be at operating temperature to perform an accurate test 1 Install Pressure Gauge and Manifold Assembly J 23575 2 F...

Страница 823: ...ect clutch wire NOTE Remove alternator mounting bracket to obtain working clearance for removing compressor mounting bracket attaching bolts and nuts 5 Remove compressor and mounting bracket as an ass...

Страница 824: ...stall seal plate with polished face toward car bon ring 12 Install seal plate capscrews and tighten evenly Center seal plate on shaft by lightly tapping plate Tighten capscrews in a diagonal pattern t...

Страница 825: ...that discharge valve is at top Figure 3E 13 illustrates correct assembly sequence 10 Install new head gasket locating it on dowel pins 11 Install head Tighten compressor head cap screws to 15 foot po...

Страница 826: ...pressor in operating position and only after the car interior air has been cooled to the desired temperature Operating the system stabilizes the oil entrained in the system and provides an accurate oi...

Страница 827: ...lley and plate assembly is mounted on the compressor shaft When the air condi tioner is off the pulley is free to turn on the clutch hub bearing When the clutch is energized the plate is mag netically...

Страница 828: ...heck discharge air temperature with thermometer Discharge air temperature must cor respond to ambient air temperature as shown in Normal Operating T e m p eratures and Pressures Chart System cools and...

Страница 829: ...t light blue wire to thermostat and disconnect red wire Turn thermostat on and contact jumper wire to red terminal Disconnect light blue wire at fuse block and connect jumper to terminal Clutch operat...

Страница 830: ...rect belt tension 1 Set belt tension Refer to Compressor Belt Tension 2 Clutch loose 2 Tighten clutch 3 Overcharged 3 Discharge evacuate and install correct charge 4 Pulley misaligned 4 Align pulley C...

Страница 831: ...lace expansion valve 4 Drive belt slipping 4 Set belt tension LOW SIDE H I G H HIGH SIDE HIGH 1 2 Clogged condenser fins Air in system 1 2 Clean out condenser fins Evacuate leak test and charge system...

Страница 832: ...AIR CONDITIONING 3E 21...

Страница 833: ...2 conditions and make sure that the condenser is free of bugs or other foreign matter The air conditioner also can be used for fast efficient defogging of windows during cool damp weather The condense...

Страница 834: ...o condenser 2 Place condenser in position and connect receiv er dryer to evaporator hose at receiver dryer 3 Install condenser attaching screws 4 Connect pressure line at condenser 5 Install radiator...

Страница 835: ...3E 24 AIR CONDITIONING Fig 3E 19 Evaporator Housing Assembly CJ Models...

Страница 836: ...nsion valve and line with insulation 9 Install evaporator housing assembly 10 Evacuate leak test and charge system CHEROKEE WAGONEER T R U C K A I R CONDITIONING Page Evaporator Housing Assembly 3E 27...

Страница 837: ...cks with at least one window open During this time place the TEMP control in the MAXposition and the FAN control in the HI or PC position This permits the evapo rator to precool in hot weather CAUTION...

Страница 838: ...Install evaporator and condenser lines to receiver dryer 3 Remove block and install inner panel bolt 4 Install grille 5 Install headlamp assembly 6 Install headlamp trim ring 7 Evacuate charge system...

Страница 839: ...defective valve requires replacement 1 Discharge system 2 Remove evaporator housing assembly 3 Remove insulation wrapped around suction line and expansion valve Mark capillary tube location on suction...

Страница 840: ...n loose Page Body Mouldings 3F 1 or fatigued spacers permit the body to settle causing body lean or possible interference between the floorpan and various chassis components BODY MOULDINGS Trim Moulii...

Страница 841: ...In the event of collision damage it is important that the frame alignment be checked and realigned to frame dimensions shown on the individual dimension charts fig 3F 1 through 3F 5 Wheel geometry and...

Страница 842: ...BODY AND FRAME COMPONENTS 3F 3 Fig 3F 2 CJ 7 Model Frame Dimensions Inches...

Страница 843: ...A 12 05 B 5 46 C 10 60 D 9 94 E 16 17 F 10 82 G 14 03 H 45 26 J 57 25 K 24 68 L 69 00 N P Q R S T U V w X 59 63 46 76 23 38 47 02 17 88 43 54 45 88 42 50 11 52 32 40 35 22 60583 Fig 3F 3 Cherokee and...

Страница 844: ...NTS 3F S A 11 97 L 48 79 B 5 39 M 23 38 c 11 35 N 45 72 D 9 94 p 45 92 E 16 80 Q 42 52 F 12 55 R 32 40 G 16 78 S 17 69 H 45 23 T 46 75 J 57 22 u 17 06 K 96 80 11 52 Fig 3F 4 Truck Frame Dimensions 119...

Страница 845: ...LINE u c r I A 11 97 L 60 79 B 5 39 M 23 38 c 11 35 N 45 72 D 9 94 P 45 92 E 15 92 Q 42 52 F 12 57 32 40 G 16 78 S 17 69 H 4 5 2 3 T 46 75 J 56 47 U 17 06 K 96 80 V 11 52 Fig 3F 5 Truck Frame Dimensi...

Страница 846: ...ld be the same To locate the points at which the frame is sprung measure the diagonals between selected points on the frame fig 3F 1 through 3P 6 If the diagonals in each pair are within 1 8 inch that...

Страница 847: ...anel CJ Models 4 2 6 4 6 Fig 3F 7 Rear Quarter Panel 2 Doer Cherokee T Fig 3F 8 Rear Quarter F anei Wagoneer 4 Door Cherokee Similar RADIATOR GRILLES CJ Models The CJ grille and the support and baffle...

Страница 848: ...ssmember holddown assembly 5 Position guard panel to fenders and install at taching bolts and washers 6 Install radiator and radiator shroud to radiator guard panel attaching screws and washers 7 If e...

Страница 849: ...el bracket NOTE Note the number and position of shims between fender and rocker panels so they can be assembled in the same position 9 Open doors and remove fender from vehicle 10 Remove or disconnect...

Страница 850: ...d with a rear bumper have a one piece step bumper Front bumper guards are available as an option on standard bumpers on all models except CJ FRONT BUMPERS CJ Models Removal 1 Remove nuts and bolts att...

Страница 851: ...and tighten all attach ing hardware 4 Install horizontal bumper guard if equipped 5 Install vertical bumper guard if equipped REAR BUMPERS CJ Models Removal 1 Remove nuts and bolts attaching rear bum...

Страница 852: ...on 1 Position arms on vehicle frame and install at taching bolts washers and nuts NOTE Do not tighten attaching hardware until com plete bumper is installed on vehicle frame and properly aligned 2 Pos...

Страница 853: ...oll bar on body and align bolt holes with body 2 Position spacers between body side panels and roll bar bottom angle 3 Install bolts washers and nuts attaching side of roll bar angle to body using Tor...

Страница 854: ...ntil roll bar is completely installed and properly aligned 3 Install bolts washers nuts and nut plates at taching roll bar to side of pick up box 4 Align roll bar assembly and tighten all attach ing h...

Страница 855: ...3F 1 l O i f AND FRAME COMPONENTS Fig 3F 28 Brush Guard Cherokee Truck Models Tools J 25359 02 TORX BIT A N D SOCKET SET 70119...

Страница 856: ...2 Position hood panel assembly and align hinges with scribe marks on the respective mounting panels Torque all attaching screws 3 Check hood alignment Adjust if necessary Alignment The hood hinge moun...

Страница 857: ...emoved clean off all loose cement and pad particles from panel to ensure good adhesion when recemented 3 Position hood panel assembly and align hinges with scribe marks on the respective mounting pane...

Страница 858: ...t of center and by pulling to the left on the catch To secure the hood in the raised position remove the sup port bar from its retaining clip and insert the free end into the support bar bracket Chero...

Страница 859: ...NOTES...

Страница 860: ...use graphite brake fluid or wax on rubber sealer Replicement Replacement rubber sealers are coated with powder to prevent stickiness in storage Remove all powder with a dampened cloth before installat...

Страница 861: ...OTE Soap solution should be removed from the weatherstrip and glass before installing sealer 11 Using a pressure type applicator apply 3M Windshield Sealer or equivalent between weatherstrip and glass...

Страница 862: ...le or repair the supports 3 Using Torx Bit Tool J 25359 02 remove screws attaching hinge to liftgate 4 Using Torx Bit Tool J 25359 02 remove screws attaching hinge to enclosure Remove hinge from enclo...

Страница 863: ...the side as needed 2 Tighten bolts AILGATE G E N E R A L The tailgate is hinged at the bottom and held in the closed up position with dual latches The tailgate is supported in the open position by tw...

Страница 864: ...on the body pillars near the striker plates and are adjustable The dovetail caps are located on the tailgate and are nonadjustable Replacement Replacement rubber sealers are coated with powder to prev...

Страница 865: ...Handle 16 Oval Head Screw 17 Outer Panel 18 Tailgate 19 Machine Screw 20 Speed Nut 21 Plastic Rivet 22 Tailgate Sealer 23 Machine Screw 24 Bracket Bumper 25 Stop Bracket 26 Machine Screw 27 Torque Rod...

Страница 866: ...uipped 6 Connect wiring and replace tailgate access cover plate and carpeting if equipped 7 Adjust tailgate LOCK SYSTEM Remote Control Replacement 1 Lower tailgate and move tailgate glass to the extre...

Страница 867: ...en two cap screws on either side panel of the tailgate fig 3H 3 2 Raise and lower glass several times with tailgate in the closed position This will align the glass with the channel 3 Open tailgate sl...

Страница 868: ...CIRCUIT LP SWITCH FEED 53 RED 12 GROUND A BLACK 18 INSTRUMENT PANEL TAILGATE WINDOW SWITCH 9G BLACK 18 47 BROWN 14 47 BROWN 14 48 TAN 14 9G BLACK GROUND 48 TAN UP 47 BROWN DOWN 46 R E D W T R H O T 48...

Страница 869: ...p lights and motor does not operate replace motor If lamp does not light check feed circuit to motor and repair as necessary 2 Place test lamp probe to brown No 47C wire at electric motor Close safety...

Страница 870: ...er ten sion bracket using large screwdriver 2 Position motor on regulator and install attach ing screws 3 Position regulator in tailgate and install attach ing screws 4 Connect wiring harness to motor...

Страница 871: ...3H 12 LIFTGATES TAILGATES 90186 Fig 3H 5 Power Tailgate Regulator and Motor...

Страница 872: ...el Trim panels consist of fiber board composition cov ered with a vinyl material They are fastened to the door with spring clips inserted into holes in the door inner panel Page Sealing System 3J 1 Wi...

Страница 873: ...sting screw 4 Install water shield and door trim panel Door Gloss Adjustment One adjustment point is available which regulates the amount of effort required to raise and lower the door glass The door...

Страница 874: ...replacement outside handle is furnished without the lock cylinder The lock cylinder is furnished uncoded without the keys 1 Remove screws attaching outside door handle to door using Torx Bit Tool J 2...

Страница 875: ...and install clips in holes in inner door panel pencil marks and install screws using Torx Bit Tool J 25359 02 7 Position hinge on body align carefully with pen cil marks and install screws using Torx...

Страница 876: ...move dust and dirt from rubber sealer door and body opening 3 Install upper front corner of sealer to body first 4 Work rubber sealer onto flange completely around door opening WINDOW SYSTEM Door Glas...

Страница 877: ...on leading edge of door frame and under base of vent weatherseal fig 3J 2 5 Move vent assembly toward rear of door tipping it to clear upper door frame 6 Pull ventilator assembly straight out until u...

Страница 878: ...ert cylinder into opposite end of fixture with notched side of key down fig 3J 3 NOTE This side of the fixture can be identified as the end without the double slot cut out 180 apart 7 File tumblers fl...

Страница 879: ...ew on each hinge Tighten screws to 25 to 35 foot pounds 34 to 47 N m torque 13 Remove door holding fixture 14 Check door alignment Adjust if necessary refer to Door Adjustment 15 Connect door speaker...

Страница 880: ...l window regulator handle and door latch remote control handle 4 Install armrest and metal strip SEALING SYSTEM Water Shield The water shield is attached to the door inner panel with adhesive To remov...

Страница 881: ...annel 8 Remove stationary vent assembly attaching screws fig 3J 4 9 Tilt top of vent assembly forward approx imately one inch 10 Push lower end of rear glass channel toward rear of door to release gla...

Страница 882: ...Installation 1 Position regulator on inner door panel and se cure with attaching screws 2 Install regulator pin in glass channel and install retaining clip 3 Install water shield and door trim panel...

Страница 883: ...nt up down in or out To adjust forward or back add or remove shims between the hinge and hinge pillar Prior to any door adjustment or alignment the ad justable striker must be removed to allow the doo...

Страница 884: ...all armrest and armrest metal overlay strip if equipped 4 Install ash receiver holder and ash receiver if equipped PIVOT IENT WINDOW CHEROKEE NOTE The glass only can be removed without remov ing weath...

Страница 885: ...10 If water leakage is evident between weath erstrip and flange apply 3M Auto Bedding and Glazing Compound or equivalent to affected areas and realign weatherstrip STATIONARY WINDOW CJ 7 WITH HARDTOP...

Страница 886: ...lass and weatherstrip into position in window opening with ends of cord hanging outside ve hicle fig 3K 3 4 Pull on ends of cord to pull lip of weatherstrip over body panel With cord removed weatherst...

Страница 887: ...NOTES...

Страница 888: ...nch located in the vehicle glove box facilitates securing the adjustable end rails The ends and center supports are attached to the roof top with rubber coated well nuts and machine screws The roof sl...

Страница 889: ...l 1 Remove screws attaching side rail to supports 2 Remove screws attaching end support to roof NOTE Do not apply extreme pressure to support at taching screws during removal or installation as this m...

Страница 890: ...LUGGAGE RACKS 3L 3 J 25359 02 TORX BIT AND SOCKET SET 7 0 1 1 9 7 0 3 0 1...

Страница 891: ...NOTES...

Страница 892: ...iances during production assembly of seats and seat support components The turnbuckle permits the seat sliding and latching components to be adjusted for trouble free operation Adjustment of the turnb...

Страница 893: ...3M 2 SEAT ASSEMBLIES SEAT Fig 3M 1 Bucket Seats CJ Models 70506...

Страница 894: ...SEAT ASSEMBLIES 3M 3 1 3 SEAT Fig 3M 2 2 3 1 3 Style Front Seat CJ Models...

Страница 895: ...ng Torx Bit Tool J 25359 02 3 Remove screws attaching hockey sticks to bot tom frame using Torx Bit Tool J 25359 02 4 Remove seat back 5 Position seat back on bottom frame and install screws attaching...

Страница 896: ...The floor console cover is provided with a lock and two depressions de signed to hold beverage containers The bottom of the floor console is equipped with a hole in the rear allow ing ice water to dr...

Страница 897: ...at belt retractor trim cover R E A R S E A T S Cherokee Wagoneer Seats 3M 6 Seat Belts 3M 7 CJ Seats 3M 6 CJ SEATS The rear seat assembly fig 3M 6 is mounted by bolts to supports which in turn are sec...

Страница 898: ...raising the latch lever fig 3M 8 and simultaneously pulling the seat back forward Adjusttnont 1 Tilt seat back forward and loosen striker bolt to allow forced movement of striker 2 Raise seat back to...

Страница 899: ...ol J 25359 02 7 Remove seat belt retractor 8 Inspect seat belt material for evidence of wear cuts or fraying Replace as required Installation 1 Install seat belt and seat belt retractor anchor bolts T...

Страница 900: ...ndshield glass In this case the mirror is simply transferred from the damaged windshield to the bracket on the replacement windshield If the replacement windshield does not have a bonded mirror bracke...

Страница 901: ...s a Instruction sheets b One six ounce cartridge of urethane adhesive c One pointed dispensing nozzle d Five daubers for applying glass and rubber cleaners and primers e Glass blackout primer f Rubber...

Страница 902: ...windshield immediately using cold water spray Allow water to spill over edge of glass and rubber weatherstrip Do not direct hard stream of water on fresh urethane adhesive 7 Install all previously re...

Страница 903: ...pply tape to top sides and bottom as shown in figure 3N 5 1 2 INCH MASKING TAPE 8 0 4 2 1 Fig 3N 5 Installation of Windshield Glass Masking Tape 2 Using dauber supplied in kit wipe surface of glass to...

Страница 904: ...ip leaving enough cord hanging out at each end to permit a good grip on cord 22 Working first with either left or right bottom moulding place moulding in groove 23 Starting at the outside corner of th...

Страница 905: ...nter of the mirror bracket bonding surface Use bottom of adhesive tube to distribute the adhesive evenly over the entire surface 9 Position bottom straightedge of the bracket on the horizontal line fi...

Страница 906: ...WINDSHIELD REAR WINDOW 3N 7 Tools J 25359 02 TORX BIT A N D SOCKET SET...

Страница 907: ...NOTES...

Страница 908: ...hile pushing up on either outside edge 8 Push cargo lamp through die cut opening in headlining 9 Remove rear headlining through tailgate opening 10 Free front headlining from J moulding by pull ing do...

Страница 909: ...indow panel and install dome lamp lens 6 Install windshield moulding and end cap 7 Install sun visors and center support H A R D T O P ENCLOSURE P l General 3P 2 Installation 3P 2 Removal 3P 2 Repair...

Страница 910: ...move paint and to outline damaged area a Use a grade 24 disc for initial grinding b Follow up with a grade 50 disc to prevent coarse scratches from showing up in final finish 2 Apply plastic body fill...

Страница 911: ...esive according to manufac turer s instructions apply liberally to break as shown in figure 3P 4 Fig 3P 4 Applying Structural Adhesive to Broken Piece and Enclosure 5 Use an air file or hand file boar...

Страница 912: ...int Re pair Procedure 6 0 8 2 0 Fig 3P 8 Applying Structural Adhesive to Fractured Area Paint Repair 1 Clean repair area using wax and silicone re mover or such as DuPont Prep Sol or Ditzler Acryli Cl...

Страница 913: ...ass frame Remove glass and frame assem bly from the metal roof frame by rotating glass and frame assembly forward until hinges disengage from the metal frame Bliss Frame Assembly Removal 1 Remove glas...

Страница 914: ...or face of stripes and decals may be covered with an easy release paper for protection during shipment or storage The paper should be removed after installation Operator The operator regulator is reta...

Страница 915: ...ng the spray up and down the decal 6 Allow remover to stay on decal for 20 minutes 7 After 20 minutes peel decal away from flange areas Then start in one corner and peel decal away from panel fig 3P 1...

Страница 916: ...General Purpose Adhesive Cleaner or equivalent Wipe surface with clean cloth and allow to dry NOTE Freshly painted surfaces must be thoroughly dry Residual solvents in fresh paint may cause decal to...

Страница 917: ...paper backing side up Bend a corner of the decal toward the decorative face side and with a flick of the finger separate the paper backing from the decal Hold decal firmly to surface of table and rem...

Страница 918: ...lation Woodgrain and Stripe Remover 3M or equivalent Adhesive Remover 3M or equivalent Liquid detergent Joy Vel or equivalent Wax and silicone remover 3M General Purpose Adhesive Cleaner or equivalent...

Страница 919: ...ings printed on label 5 Spray entire panel again this time moving the spray up and down the overlay 6 Allow remover to stay on overlay for 20 minutes 7 After 20 minutes peel overlay away from flange a...

Страница 920: ...ment of the over lay while positioning it on a panel surface 6 Immediately apply wetted overlay to the repair panel surface Position overlay in the center of the area to be covered with at least 1 2 i...

Страница 921: ...y into depressions to ob tain formed bond 14 With sharp knife carefully cut out excess over lay at door handles side marker lamps and other open ings in panel 15 Inspect overlay installation using ref...

Страница 922: ...a single headlamp system The round headlamp used with the CJ system is iden tified by the number 2 embossed on the sealed beam face The new large rectangular headlamp system is used on all Cherokee Wa...

Страница 923: ...right and left of middle tape at half this distance 9 Measure distance from center of each lamp to surface on which vehicle rests 10 Position marker tape horizontally on screen to cross vertical tape...

Страница 924: ...9 INPUT TERMINAL OUTPUT TERMINALS J 4 2 7 3 0 Headlamp Dimmer Switch Fig 3R 4 2 Remove screws attaching dimmer switch to floorboard 3 Remove switch 4 Check operation of dimmer switch with test light C...

Страница 925: ...okee Wagoneer Truck Models The parking lamps are mounted in the panel just above the bumper fig 3R 6 The front side marker lamps flash in unison with the front directional indicator bulb when the head...

Страница 926: ...mp Housing Replacement Disconnect wiring remove taillamp lens and remove three screws attaching taillamp assembly body and re move from rear of body Side Marker Bulb Replacement Turn the bulb socket 1...

Страница 927: ...e rear frame crossmember Bulb replacement is accomplished by re moving the bulb lens The ground circuit for the license plate bulb is completed through metal to metal contact between the bulb bracket...

Страница 928: ...the normal rate usually indicates a shorted out bulb in the circuit If a three lamp flasher is installed in a vehicle having only two lamp bulbs per side the lamps will light but will not flash If a t...

Страница 929: ...teering wheel with Steering Wheel Puller J 21232 01 6 Lift lock plate cover 7 Use Lock Plate Compressor Tool J 23653 to depress lock plate fig 3R 12 8 Pry round wire snap ring from steering shaft groo...

Страница 930: ...l receiver and bushing Receiver must be free to move after bushing screws are tightened 11 Line up notch on receiver with nib on horn but ton Push button until in snaps into place 4 WAY EMERGENCY FLAS...

Страница 931: ...oad Driving Lamps and lill Bar Truck Models Aiming Lamps 1 Position vehicle on a flat surface facing and approximately 25 feet from a wall 2 Remove lamp stone shields 3 Install fuse in fuse holder if...

Страница 932: ...above ENGINE COMPARTMENT L A i P This optional lamp obtains current at the battery ter minal of the starter solenoid A single wire in corporating a fusible link for protection passes current to the la...

Страница 933: ...me lamp base to retain it The lens is removed by pulling it downward or by prying it down with a small screwdriver fig 3R 21 Fig 3R 21 Removing Dome Lamp Lens Cherokee Wagoneer Models To install align...

Страница 934: ...rcuit is SWITCH I B Fi 31 24 Ufjiisi Vanity Mirror Qrarokee Wagoneer M e l s grounded at the front roof bow and obtains current from the dome reading lamp circuit Refer to Wiring Dia grams at the end...

Страница 935: ...terproof sealer Do not use string type body caulk as a sealer Fusible Links Fusible links are harness wires covered with a special non flammable insulation The links protect circuits which are not nor...

Страница 936: ...isconnect switch from remote rod 3 Disconnect harness connector and remove switch from steering column Testing The ignition switch terminals are shown in figure 3R 25 To test the ignition switch circu...

Страница 937: ...urely 6 Connect white connector and then black con nector to switch 7 Install steering tube cover Tilt Column 1 With actuator rod disconnected position switch as shown in figure 3R 26 2 Move slider to...

Страница 938: ...e fuse panel One circuit breaker is used in the instrument panel switch circuit and the other is used in the tailgate key operated switch circuit Torque Specifications Service Set To Torques should be...

Страница 939: ...3R 18 LIGHTING SYSTEMS Tools J 21232 01 FRONT PUMP OIL SEAL REMOVER J 23653 LOCK STEERING WHEEL PULLER PLATE COMPRESSOR J 21008 CONTINUITY LIGHT 4 2 2 7 1 B...

Страница 940: ...ck for battery voltage in the red lead to relay before individual com ponents are tested or replaced 2 A lack of voltage indicates fusible link or har ness is open and cause of failure must be determi...

Страница 941: ...rrent to 4 5 amps NOTE Do not stuff rags or other materials in the horn protector to muffle the sound while adjusting as this changes the vibration frequency and would give a raise in current setting...

Страница 942: ...Wiper Arm Replacement 3T 2 Wiper Blade Replacement 3T 1 GENERAL WIPER BLADE REPLACEMENT All CJ models are equipped with a two speed electric wiper motor The motor is mounted on the lower left corner o...

Страница 943: ...nk to left wiper pivot 3 Install right and left access hole covers 4 Raise windshield to upright position and install right and left windshield holddown knobs 5 Install nuts attaching pivots to windsh...

Страница 944: ...nal motor connection or a stuck low speed brush To obtain high speed connect a jumper wire between terminals 3 and B If wiper motor fails to operate there is an open in the red wire a defective intern...

Страница 945: ...are actuated by a link and pivot assembly attached to the wiper motor The wiper motor is mounted to an adapter plate mounted to dash panel The wiper arms move in a tandem like action and park to the r...

Страница 946: ...ck Park position by operating wiper motor several times ON and OFF WIPER PIVOT SHAFT BODY AND LINKA8E Rnowal 1 Remove wiper arms pivot shaft nuts washers escutcheons and gaskets fig 3T 8 BLADE 2 Disco...

Страница 947: ...FOR FOREIGN OBJECT INTERFERING WITH LINKAGE SYSTEM IS FREE HIGH OR LOW SPEED WITH IGNITION SWITCH ON AND WIPER SWITCH AT LOW SPEED A N D THEN HIGH SPEED SETTING CON NECT A TEST LIGHT BETWEEN THE TERMI...

Страница 948: ...S OK NO PARK WITH IGNITION SWITCH ON AND WIPER SWITCH AT OFF PARK SETTING DO THE FOLLOWING AT THE WIRING HARNESS PLUG THAT CONNECTS TO MOTOR CONNECT A TEST LIGHT BETWEEN GROUND A N D PINK W TR LEAD CH...

Страница 949: ...O P S T A L L E D M O T O R i C L E A N G L A S S A N D O R R E P L A C E W I P E R B L A D E S R E P E A T 5 C Y C L E T E S T S T I L L S T O P S D U R I N G T E S T R E P L A C E B L A D E S S T I...

Страница 950: ...STOP A N D START IN MIDDLE OF CYCLE ERATICALLY YES NO TEST CIRCUIT BREAKER CHECK CONTINUITY OF WIPER SWITCH NOT OK REPLACE SWITCH OK CHECK CONTINUITY OF WIRING BETWEEN SWITCH GOVERNOR AND GROUND NOT O...

Страница 951: ...ECK CONTINUI1fY OF WIPER SWITCH NOT OK REPLACE WIPER SWITCH OK VERIFY THE CONDITION WIPER SWITCH OPERATES ERRATICALLY IN INTER MITTENT OR LOW SPEED HIGH SPEED O K CHECK FOR LOOSE CONNECTORS ON GOVERNO...

Страница 952: ...SE CHECK FOR DIRT OR ICE IN JET OPENINGS NOT OK OK OK REPLACE FUSE DISCONNECT HARNESS PLUG AT RESERVOIR AND CHECK FOR POWER BY INSERTING A TEST LIGHT ACROSS CONNECTOR TERMINALS ENERGIZE WASHER CIRCUIT...

Страница 953: ...ITCH OPERATES TWO SETS OF CONTACTS SIMULTANEOUSLY SWITCH POSITIONS P OFF L LOW H HIGH WASHER PUMP WIPER MOTOR NOTE IN RUN MODE MOTOR SWITCH CONTACTS MOVE TO INTERMITTENT PARK POSITION ONCE EVERY MOTOR...

Страница 954: ...I INTERM L LOW H H I G H C C I Q UJ cc H Q UJ C C FUSE BLOCK 1 a GROUND THROUGH INSTRUMENT PANEL INTERMITTENT GOVERNOR NOTE IN RUN MODE MOTOR SWITCH CONTACTS MOVE TO INTERMITTENT PARK POSITION ONCE EV...

Страница 955: ...intermittent wipe cycle is not operating but system does operate at both low and high speed resistance between number 4 and 5 terminals should be checked With switch control knob rotated to full coun...

Страница 956: ...attaching motor adapter plate to dash panel 2 Separate wiper wiring harness connector at motor 3 Pull motor and linkage out of opening to expose drive link to crank stud retaining clip Raise up lock t...

Страница 957: ...ushes harness and springs from end head 8 Remove end head assembly 9 Remove parking lever pin from gear housing 10 Remove all old lubricant from gear housing and components 11 Inspect gear housing and...

Страница 958: ...28 29 30 31 32 SEAL Fig 3T 17 Wiper Motor and Transmission Components 41532 12 Install motor housing on armature holding ar mature worm gear to prevent magnetic field from pull ing armature out of pos...

Страница 959: ...ounded to the car body by a ground wire It is ener gized by a feed wire from the No 6 and 7 terminals on the control switch Fig 3T 18 Tag Wire Brush Retainers SPECIFICATIONS Torque Specifications Serv...

Страница 960: ...witch pilot lamp timer relay and wire harness complete the circuit Braided wire soldered to each bus bar at 2 1 2 inch intervals serves as the electrical feed and ground for the grid The grid feed wir...

Страница 961: ...pening ignition switch must remain On If the time period is too short or excessively long relay is defective 4 If relay did not energize connect jumper wire to known good 12 volt source in tailgate an...

Страница 962: ...ticles mixed throughout fluid Apply coat ing to break in grid with small brush furnished in kit Apply heavy coat of mixture extending approximately 1 4 inch on either side of break 5 Start engine and...

Страница 963: ...NOTES...

Страница 964: ...door and rear quarter trim panel A front to rear speaker fader control is used with the 4 speaker system It is located behind the manual station tuning knob Truck models use a 2 speaker system with th...

Страница 965: ...the greatest vol ume can be obtained without touching the volume control 7 Install inner and outer tuning control knobs if removed CONTROLS The radio has external fader and balance controls fig 3V 2 A...

Страница 966: ...will automatically change and play in succession without pushing control To turn the tape player off pull the tape cartridge out approximately one inch Stereo Test Tape A Stereo Test Tape Cartridge J...

Страница 967: ...eferred to as picket fencing Hertz Cycles per second Ignition Noise Undesirable radio signals or noise that interfere with the reception of desired radio signal Monaural A system utilizing a single si...

Страница 968: ...by a direct signal and a reflected one arriving at the vehicle s antenna causing distortion partial or complete loss of the station or poor FM Stereo reception This type of interference is usually of...

Страница 969: ...interference point of entry and elimination There are two major ways interference enters the radio the antenna and the A line or power feed wire to the radio 12 INCHES CLIPS A J 4 2 2 4 3 Fig 3V 11 Im...

Страница 970: ...so affect AM Normally one of two conditions will be found in the radio Ignition noise all across FM band and possible on AM Ignition noise loud in between stations but not on a strong station When the...

Страница 971: ...d Truck models equipped with a radio This sup pressor choke is plugged into the back of the cluster on a printed circuit board Be sure the choke has not been installed over the copper strip installed...

Страница 972: ...tch or the flasher It is less likely but possible that the low frequency components of the interruptions are reaching audio stages of the radio The test is to check if the noise is present with the vo...

Страница 973: ...0763 u 2 7 0 7 3 7 27 0863 1 2 7 0 8 3 7 1 9 27 1063 l z 2 7 1 0 3 7 27 1163 J 27 1137 27 1263 2 7 1 2 3 7 27 1363 2 7 1 3 3 7 1 f i 27 1563 27 1537 1 7 27 1663 1 2 7 1 6 3 7 1 R r 27 1763 27 1737 27...

Страница 974: ...Ground to Baltery Ground Test This test verifies that the antenna base has a good ground Touch one ohmmeter lead to the fender and the remaining prod to the battery negative post 0 3 The resistance s...

Страница 975: ...3 1 2 inches long a With antenna mast installed insert wrench into antenna base slug and turn slug clockwise or counterclockwise in one quarter turn increments to obtain lowest possible SWR reading on...

Страница 976: ...rcing wire harness Radio Speaker Replacement CJ Models To remove the speaker remove the four attaching nuts from the mounting studs Cherokee Wigoneer Tnick Models The AM speaker is located above the r...

Страница 977: ...NOTES...

Страница 978: ...ALPHABETICAL INDEX...

Страница 979: ......

Страница 980: ...E 2 2 A i r Conditioning C J 3 E 2 2 A i r Conditioning compressor 3 E 1 1 A i r Conditioning compressor oil level checking 3 E 1 5 A i r Conditioning compressor purging of air 3 E 1 5 A i r Condition...

Страница 981: ...nsmission specifications 2C 79 Automatic transmission subassembly overhaul 2C 40 Automatic transmission test guage installation 2C 10 Automatic transmission test specifications 2C 23 Automatic transmi...

Страница 982: ...diagnosis 2G 1 Brake fluid 2G 20 Brake fluid level 2G 21 Brake hydraulic system 2G 20 Brake lines fittings and hoses B 11 Brake linings front CJ models B 10 Brake master cylinder 2G 21 Brake parking...

Страница 983: ...tem specifications 1E 14 Charging system tools 1E 14 Charging system tools IE 14 Charging system troubleshooting 1E 3 Charging the Air Conditioning system 3E 9 Charging the system Air conditioning 3E...

Страница 984: ...Clutch pedal pulsation 2A 5 Clutch plate and disc identification 2F 44 Clutch plate application automatic transmission 2C 80 Clutch plates and disc Trac Lok 2F 43 Clutch related vibrations 2A 5 Clutch...

Страница 985: ...ooting 1H 5 CTO operation 1C 5 CTO switch EGR U 39 CTO test EGR U 40 Cylinder block eight cylinder 1B 68 Cylinder block six cylinder 1B 32 Cylinder bore reconditioning eight cylinder 1B 68 Cylinder bo...

Страница 986: ...44 Differential side gear adjustment 2F 36 Differential Specifications 2F 39 Differential standard 2F 21 Differential Trac Lok 2F 40 Differential warning valve B 11 Dimmer switch replacement 3R 3 Dire...

Страница 987: ...spark knock ping diagnosis 1G 14 Evacuating Air Conditioning system 3E 6 Evacuating system Air Conditioning 3E 6 Exhaust back pressure sensor non integral 1J 40 Exhaust back pressure sensor non integ...

Страница 988: ...Fuel gauge diagnosis 1L 3 Fuel pump U 8 Fuel pump 1 J 7 Fuel pump capacity test U 8 Fuel pump pressure test U 8 Fuel pump pressure test 1J 8 Fuel pump specifications 1 J 9 Fuel pump vacuum tests U 8...

Страница 989: ...ing effort 2F 4 Hinge system 3H 3 Hinge system Cherokee Wagoneer replacement rear door 3J 12 Hinge system Cherokee Wagoneer Truck 3J 8 Hinge system CJ 7 with hardtop top enclosure 3J 3 Hinges 3H 5 Hoo...

Страница 990: ...e 2F 19 Installation ring gear 2F 28 Installation steering gear 2K 4 Installation steering gear right hand drive 2K 12 Installation step plate 2F 43 Installation third fourth synchronizer shifting pla...

Страница 991: ...ge rack side rail 3L 2 Luggage rack support 3L 2 Luggage racks 3L 1 M Magnetic clutch Air Conditioning 3E 16 Magnetic timing probe 1 A 17 Main harness connector 3R 14 Main shaft gear train disassembly...

Страница 992: ...ting starting system 1F 2 Operation charging system 1E 2 Operation cooling system 1C 4 Operation Cruise Command 1H 2 Operation CTO 1C 5 Operation differential 2F 21 Operation heater and defroster 3D 6...

Страница 993: ...ear bearing removal model 30 44 axle 2 F 3 1 Pinion rear bearing removal model 60 axle 2 F 3 3 Pinion rear bearing removal model 60 axle 2 F 3 3 Pinion rear bearing removal model 60 axle 2F 31 Pinion...

Страница 994: ...Radio antenna 3V 11 Radio bulb chart 3V 13 Radio bulb replacement 3V 10 Radio CB controls 3V 3 Radio CB diagnosis 3V 9 Radio CB operation 3V 3 Radio FM fading 3V 5 Radio interference diagnosis 3V 6 Ra...

Страница 995: ...stricted exhaust system diagnosis 1K 1 Restrictor plates non integral back pressure sensor 1J 41 Reverse idler gear 2B 23 Reverse idler gear romoval installation 2B 14 Reverse idler gear shaft removal...

Страница 996: ...ce Quadra Trac reduction unit 2D 22 Service Quadra Trac transfer case in vehicle 2D 28 Service Quadra Trac transfer case out of vehicle 2D 32 Service Quadra Trac transfer case out of vehicle 2D 32 Ser...

Страница 997: ...ecifications six cylinder 1B 34 Specifications starter motor 1F 14 Specifications steering column 2J 41 Specifications steering gear 2K 10 Specifications steering linkage 2M 6 Specifications suspensio...

Страница 998: ...iker adjustment 3H 3 Studs steering knuckle ball 2F 9 Subassembly overhaul automatic transmission 2C 40 Subassembly overhaul steering gear 2K 6 Sun roof 3P 6 Support luggage rack 3L 2 Support system 3...

Страница 999: ...e head and capstan cleaning procedure 3 V 3 T a p e player operation 3 V 3 T C S switch 2B 1 Temperature gauge 1 L 2 Temperature gauge 1 C 3 Temperature gauge diagnosis 1 L 4 Temperatures and pressur...

Страница 1000: ...dshield and rear window 3N 7 Tools windshield and rear window 3N 7 Torque bias test Quadra Trac 2D 21 Torque converter 2C 2 Torque information A 2 Torque specifications 1G 18 Torque specifications AMC...

Страница 1001: ...Vacuum tests fuel p u m p 1 J 8 Vacuum throttle modulating V T M system 1 J 3 6 Value brake combination 2 G 2 4 Valve diverter bypass 1 K 1 1 Valve diverter bypass 1 K 1 1 Valve E G R 1J 38 Valve E G...

Страница 1002: ...y 3T 12 Windshield wiper components 3T 1 Windshield wiper components 3T 5 Windshield wiper diagnosis and circuitry 3T 6 Windshield wiper with intermittent governor circuitry 3T 13 Windshield wipers 3T...

Страница 1003: ......

Страница 1004: ...VACUUM line ROUTING D I A G R A M S...

Страница 1005: ...SWITCH PURGE VALVE SIGNAL CANISTER AIR PUMP PURGED VAPORS F R O M FUEL EVAP SYSTEM DISTRIBUTOR PORTED V A C U U M j r j 2 0 9 FRONT J 90191A 49 STATE 258 CID ENGINE WITH MAN TRANS CJ CHEHOKEE J l0 TRU...

Страница 1006: ...90191B 49 STATE 258 CID ENGINE WITH MAN TRANS AND H D COOLING CJ CHEROKEE J 10 TRUCK MODELS...

Страница 1007: ...E VALVE SIGNAL CANISTER CHECK VALVE AIR P U M P PURGED VAPORS F R O M FUEL EVAP SYSTEM FRONT DISTRIBUTOR MANIFOLD VACUUM PORTED VACUUM 90191C 49 STATE 258 CID ENGINE WITH AUTO TRANS CJ 7 CHEROKEE WAGO...

Страница 1008: ...EGR CTO SWITCH A I R CLEANER EGR VALVE PURGE VALVE SIGNAL CANISTER SPARK CTO SWITCH DUAL AIR PUMP 90191D C 3 49 STATE 258 CID ENGINE WITH AUTO TRANS AND H D COOLING CJ 7 CHER0KEE WAG0NEER J 10 TRUCK...

Страница 1009: ...ALVE PURGE VALVE SIGNAL CANISTER DIVERTER VALVE PCV AIR IN THERMAL VACUUM SWITCH AIR PUMP PURGED VAPORS FROM FUEL EVAP SYSTEM FRONT DISTRIBUTOR MANIFOLD VACUUM PORTED VACUUM CALIFORNIA 258 CID ENGINE...

Страница 1010: ...TAC SIGNAL CALIFORNIA 258 CID ENGINE WITH MAN TRANS AND H D COOLING CJ MODELS 90191J...

Страница 1011: ...GNAL AIR CLEANER V EGR VALVE sssf PURGE VALVE SIGNAL CANISTER MANIFOLD VACUUM PORTED VACUUM AIR PUMP PURGED VAPORS FROM FUEL EVAP SYSTEM FRONT DISTRIBUTOR CALIFORNIA 258 CID ENGINE WITH AUTO TRANS CJ...

Страница 1012: ...ALVE PURGE VALVE SIGNAL CANISTER AIR PUMP PURGED VAPORS F R O M FUEL EVAP SYSTEM DISTRIBUTOR FRONT M A N I F O L D V A C U U M j PORTED V A C U U M j i CALIFORNIA 258 CID ENGINE WITH AUTO TRANS AND H...

Страница 1013: ...90191N 49 STATE 304 CID ENGINE WITH MAN TRANS CJ MODELS...

Страница 1014: ...90191P 49 STATE 304 CID ENGINE WITH MAN TRANS AND H D COOLING CJ MODELS...

Страница 1015: ...9 0 1 9 1 L 49 STATE 304 CID ENGINE WITH AUTO TRANS CJ 7...

Страница 1016: ...90191M 49 STATE 304 CID ENGINE WITH AUTO TRANS AND H D COOLING CJ 7...

Страница 1017: ...90191R CALIFORNIA 304 CID ENGINE WITH MAN TRANS CJ MODELS...

Страница 1018: ...RGE VALVE SIGNAL CANISTER AIR PUMP SPARK CTO SWITCH DISTRIBUTOR OIL FILLER CAP MANIFOLD VACUUM PORTED VACUUM 90191S 49 STATE 360 CID ENGINE WITH AUTO TRANS CHEROKEE WAGONEER TRUCK MODELS DIVERTER VALV...

Страница 1019: ...CANISTER EGR CTO SWITCH DISTRIBUTOR AIR PUMP CO OIL FILLER CAP SPARK CTO SWITCH DUAL PORTED VACUUM f z r 90191Y CALIFORNIA 360 CID ENGINE WITH AUTO TRANS AND H D COOLING CHEROKEE WAGONEER TRUCK MODELS...

Страница 1020: ...CALIFORNIA 360 CID ENGINE WITH MAN TRANS CHEROKEE MODELS...

Страница 1021: ...PURGE VALVE SIGNAL CANISTER EGR CTO SWITCH DISTRIBUTOR AIR PUMP OIL FILLER CAP PORTED VACUUM 90192A CALIFORNIA 360 CID ENGINE WITH MAN TRANS AND H D COOLING CHEROKEE MODELS DIVERTER VALVE...

Страница 1022: ...CALIFORNIA 360 CID ENGINE WITH MAN TRANS TRUCK MODELS 90191W...

Страница 1023: ...90192C CALIFORNIA 360 CID ENGINE WITH MAN TRANS AND H D COOLING TRUCK MODELS...

Страница 1024: ...90191T CALIFORNIA 360 CID ENGINE WITH AUTO TRANS CHEROKEE WAGONEER MODELS...

Страница 1025: ...90191V CALIFORNIA 360 CID ENGINE WITH AUTO TRANS TRUCK MODELS...

Страница 1026: ...R GCTOV A L V E P C V V A L V E E G R C T O S W I T C H D I S T R I B U T O R A I R P U M P O I L F I L L E R C A P M A N I F O L D V A C U U M P O R T E D V A C U U M 90192B CALIFORNIA 360 CID ENGIN...

Страница 1027: ...NOTES...

Страница 1028: ...NOTES WIRING DIAGRAMS SECTION INDEX Accessories W 7 Cherokee Wagoneer Truck W 5...

Страница 1029: ...D 7 Ignition Switch C 8 Kickdown Quadra Trac 6 Cylinder E 3 Left Turn Indicator Hazard Lamp D 8 NOMENCLATURE LOCATION Marker Reflector Right Side A 2 Marker Reflector Left Side E 2 Marker Reflector Ri...

Страница 1030: ...nder E 9 Glove Box Lamp Feed A 9 Headlamp Left Side D 1 Headlamp Right Side B 1 Heater Blower Motor 8 Cylinder C 3 Heater Control Switch C 9 Heater Ground C 9 Heater Lamps C 7 NOMENCLATURE L Ignition...

Страница 1031: ...10 11 B TAIL STOP LAMP TAIL STOP LICENSE LAMP...

Страница 1032: ...I 14 VIODULE ASS Y IGNITION 8 ENGINE WIRING 6CYL AIRCOMP 50BROWN 16 13B RED TR 2D RESISTANCE 1 35 RED WHITE _ 13A RED TR 10 13F RED 4 TR 10 _ SPLICE L VLOLET 18 ORANGE 1 8 GREEN 18 79 DARK GREEN 16 82...

Страница 1033: ......

Страница 1034: ......

Страница 1035: ...R O S S H A R N E S S C U P ELEC BRAKE FEED 1 8 A W H I T E 1 6 2 3 A L T G R E E N T R 1 6 2 4 A L T G R E E N 1 6 3 4 A Y E L L O W 1 6 r Q F J 1 8 B G R E E N 1 6 t n TAIL MARKER RELAY 7 2 B L A C...

Страница 1036: ...BLACK 18 SIC BROWN 18 fc 51E BROWN 18 51B 8ROWN 18 jsTi Sic DOME READING LAMP DOME LP CARGO LP STD CARGO LAMP CARGO LAMP SWITCH TIMER SWITCH i s CARGO LAMP SWITCH SW T GATE1 51D BROWN 1 8 j l Q VANITY...

Страница 1037: ...es W 8 WIRING DIAGRAMS TACHOMETER T C S SWITCH O O C O Z LU O k z D C O SPEED SW CO D 1 _ CALIF ONLY EMISSION STD AUTO TRANS i h B L A C K f I t i i JL J 0 j LU o z _ _ J i N of ENGINE HARNESS I P HAR...

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Jeep 1979 CJ-5, Техническое и сервисное руководство

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