Page 1

GROUP TAB LOCATOR Introduction

0 2 3 5 7 8A 8B 8E 8F 8G 8H 8I 8J 8L 8M 8N 8O 8P 8Q 8R 8W 9 11 13 14 19 21 22 23 24 25 30

Lubrication & Maintenance Suspension Differential & Driveline Brakes Cooling Audio Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame & Bumpers Fuel System Steering Transmission and Transfer Case Tires/Wheels Body Heating & Air Conditioning Emissions Control New Vehicle Preparation Component and System Index

Service Manual Comment Forms

(Rear of Manual)


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

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

page TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 VECI LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

BODY CODE PLATE

FASTENER IDENTIFICATION

DESCRIPTION

DESCRIPTION

A metal Body Code plate is located in the engine compartment and attached to the top of the right frame rail. The information listed on the plate (Fig. 1) is used for manufacturing and service purposes.

The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts.

Fig. 1 Body Code Plate


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FASTENER IDENTIFICATION (Continued)

FASTENER IDENTIFICATION


INTRODUCTION

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FASTENER STRENGTH

3


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FASTENER USAGE

DESCRIPTION - THREADED HOLE REPAIR

DESCRIPTION - FASTENER USAGE

Most stripped threaded holes can be repaired using a Helicoilt. Follow the manufactures recommendations for application and repair procedures.

WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

INTERNATIONAL SYMBOLS 1 2 3 4 5 6 7 8 9 10 11 12

High Beam Fog Lamps Headlamp, Parking Lamps, Panel Lamps Turn Warning Hazard Warning Windshield Washer Windshield Wiper Windshield Wiper and Washer Windscreen Demisting and Defrosting Ventilating Fan Rear Window Defogger Rear Window Wiper

13 14 15 16 17 18 19 20 21 22 23 24

Rear Window Washer Fuel Engine Coolant Temperature Battery Charging Condition Engine Oil Seat Belt Brake Failure Parking Brake Front Hood Rear hood (Decklid) Horn Lighter


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The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

METRIC SYSTEM DESCRIPTION - METRIC SYSTEM The metric system is based on quantities of one, ten, one hundred, one thousand and one million .

CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY

BY

5

TO GET

MULTIPLY

BY

TO GET

in-lbs

x 0.11298

= Newton Meters (N·m)

N·m

x 8.851

= in-lbs

ft-lbs

x 1.3558

= Newton Meters (N·m)

N·m

x 0.7376

= ft-lbs

Inches Hg (60° F)

x 3.377

= Kilopascals (kPa)

kPa

x 0.2961

= Inches Hg

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

mm

x 0.03937

= Inches

Feet

x 0.3048

= Meters (M)

M

x 3.281

= Feet

Yards

x 0.9144

= Meters

M

x 1.0936

= Yards

mph

x 1.6093

= Kilometers/Hr. (Km/h)

Km/h

x 0.6214

= mph

Feet/Sec

x 0.3048

= Meters/Sec (M/S)

M/S

x 3.281

= Feet/Sec

mph

x 0.4470

= Meters/Sec (M/S)

M/S

x 2.237

= mph

Kilometers/ Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilometers/Hr. (Km/h)

COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters

1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter

1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter

1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.)


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METRIC SYSTEM (Continued)

METRIC CONVERSION CHART


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TORQUE REFERENCES DESCRIPTION Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifications Chart for torque references not listed in the individual torque charts.

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TORQUE REFERENCES (Continued)

TORQUE SPECIFICATIONS


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VECI LABEL DESCRIPTION All vehicles are equipped with a combined VECI label(s). The label is located in the engine compartment on the vehicle hood (Fig. 2). Two labels are used for vehicles built for sale in the country of Canada.

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The VECI label(s) contain the following: • Engine family and displacement • Evaporative family • Emission control system schematic • Certification application • Spark plug and gap The label also contains an engine vacuum schematic. There are unique labels for vehicles built for sale in the state of California and the country of Canada. Canadian labels are written in both the English and French languages. These labels are permanently attached and cannot be removed without defacing information and destroying label.

VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) plate is attached to the top left side of the instrument panel. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the decoding chart to determine the identification of a vehicle.

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


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

INTERPRETATION

CODE = DESCRIPTION

1

Country of Origin

1 = United States

2

Make

J = Jeep

3

Vehicle Type

4 = MPV

4

Gross Vehicle Weight Rating

G = 5001-6000 lbs.

5

Vehicle Line

2= Grand Cherokee 4X2 (LHD) W = Grand Cherokee 4X4 (LHD)

6

Series

5 = Laredo 6 = Limited

7

Body Style

8 = 4dr Sport Utility

8

Engine

S = 4.0 Liter N = 4.7Liter

9

Check Digit

10

Model Year

1=2001

11

Assembly Plant

C = Jefferson Assembly

12 thru 17

Vehicle Build Sequence

VEHICLE SAFETY CERTIFICATION LABEL

• Country of origin. The label is located on the driver-side door shut-face.

DESCRIPTION A vehicle safety certification label (Fig. 3) is attached to every Chrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards. The label also lists: • Month and year of vehicle manufacture. • Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure. • Vehicle Identification Number (VIN). • Type of vehicle. • Type of rear wheels. • Bar code. • Month, Day and Hour (MDH) of final assembly. • Paint and Trim codes.

Fig. 3 Vehicle Safety Certification Label


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LUBRICATION & MAINTENANCE TABLE OF CONTENTS page INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . PARTS & LUBRICANT RECOMMENDATION STANDARD PROCEDURE . . . . . . . . . . . . . FLUID TYPES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . FLUID CAPACITIES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . FLUID FILL/CHECK LOCATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . .

......1 ......1 ......2 ......4 ......4 ......6 ......6 ......6

INTERNATIONAL SYMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).

page MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LIFT POINTS STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 12 HOISTING AND JACKING RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . 12 JUMP STARTING STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 13 EMERGENCY TOW HOOKS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 TOWING STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 14

PARTS & LUBRICANT RECOMMENDATION STANDARD PROCEDURES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 2) on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality.

Fig. 1 International Symbols Fig. 2 NLGI Symbol 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS

When service is required, DaimlerChrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing DaimlerChrysler Corporation vehicles.


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FLUID TYPES DESCRIPTION ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37 deg. C (-35 deg. F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F ).

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components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol.

ENGINE OIL WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to this service grade.

SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 3).

PROPYLENE-GLYCOL MIXTURES It’s overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol’s freeze point. The boiling point (protection against summer boilover) of propylene-glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system

Fig. 3 Temperature/Engine Oil Viscosity

ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.


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FLUID TYPES (Continued)

CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 4).

Fig. 5 Temperature/Engine Oil Viscosity - 3.2/3.5L Engine Fig. 4 Engine Oil Container Standard Notations

DESCRIPTION - ENGINE OIL WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 6).

Fig. 6 API Symbol

DESCRIPTION API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to this service grade.

SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These oils are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 5).

ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

A multi-purpose, hypoid gear lubricant which conforms to the following specifications should be used. Mopar Hypoid Gear Lubricant conforms to all of these specifications.

FRONT AXLE • The lubricant should have MIL-L-2105C and API GL 5 quality specifications. • Lubricant is SAE 75W-140 SYNTHETIC gear lubricant. REAR AXLE • The lubricant should have MIL-L-2105C and API GL 5 quality specifications. • Lubricant is a thermally stable SAE 80W-90 gear lubricant. • Lubricant for axles intended for heavy-duty or trailer tow use is SAE 75W-140 SYNTHETIC gear lubricant.


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FLUID TYPES (Continued) NOTE: Trac-lokY and Vari-lokY equipped axles require a friction modifier be added to the lubricant. CAUTION: If axle is submerged in water, lubricant must be replaced immediately to avoid possible premature axle failure.

DESCRIPTION - TRANSFER CASE - NV242 Recommended lubricant for the NV242 transfer case is Mopart ATF +4, type 9602 Automatic Transmission Fluid.

DESCRIPTION - TRANSFER CASE - NV247 Mopart Transfer Case Lubricant (P/N 05016796) is the only lubricant recommended for the NV247 transfer case.

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID NOTE: Refer to the maintenance schedules in this group for the recommended maintenance (fluid/filter change) intervals for this transmission. NOTE: Refer to Service Procedures in this group for fluid level checking procedures. Mopart ATF Plus 4, Type 9602, automatic transmission fluid is the recommended fluid for DaimlerChrysler automatic transmissions. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Mopart ATF Plus 4, Type 9602, automatic transmission fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. A dark brown/black fluid accompanied with a burnt odor and/or deterioration in shift quality may indicate fluid deterioration or transmission component failure.

FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter

clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

OPERATION - AUTOMATIC TRANSMISSION FLUID The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case.

SPECIFICATIONS FUEL REQUIREMENTS Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded “regular” gasoline having an octane rating of 87. The routine use of premium gasoline is not recommended. Under normal conditions the use of premium fuel will not provide a benefit over high quality regular gasolines and in some circumstances may result in poorer performance. Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available.


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SPECIFICATIONS (Continued)

REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as “reformulated” gasoline. Reformulated gasoline contain oxygenates, and are specifically blended to reduce vehicle emissions and improve air quality. We strongly support the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components.

GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle. CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage critical fuel system components.

MMT IN GASOLINE MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane number without MMT. Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. We recommend that gasolines free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gasoline retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasoline without MMT in Canada because MMT can be used at levels higher than allowed in the United States. MMT is prohibited in Federal and California reformulated gasoline.

SULFUR IN GASOLINE If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in states adopting California emission standards, your vehicles will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may

affect the performance of the vehicle’s catalytic converter. This may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. We recommend that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flashing, immediate service is required; see on-board diagnostics system section.

MATERIALS ADDED TO FUEL All gasoline sold in the United States and Canada are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions.

FUEL SYSTEM CAUTIONS CAUTION: Follow these guidelines to maintain your vehicle’s performance: • The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance, damage the emission control system, and could result in loss of warranty coverage. • An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance. • When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the temperature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. • The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these products contain high concentrations of methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels or additives is not the responsibility of DaimlerChrysler Corporation and may not be covered under the new vehicle warranty. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you.


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FLUID CAPACITIES SPECIFICATIONS SPECIFICATIONS - FLUID CAPACITIES DESCRIPTION

SPECIFICATION

FUEL TANK

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

Engine Oil - with Filter 4.0L

5.7L (6.0 qts.)

Engine Oil - with Filter 4.7L

5.7L (6.0 qts.)

Cooling System - 4.0L

14.1L (15 qts.)***

Cooling System - 4.7L

13.7L (14.5 qts.)***

Power Steering AUTOMATIC TRANSMISSION Service Fill - 42RE

3.8L (4.0 qts)

O-haul Fill - 42RE

9.1-9.5L (19-20 pts)

O-haul Fill - 45RFE

13.33L (28.0 pts.)

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

INSPECTION The fluid fill/check locations and lubrication points are located in each applicable group.

TRANSFER CASE NV242

1.35L (2.85 pts.)

NV247

1.6L (3.4 pts.)

DESCRIPTION

FRONT AXLE Model 186 FBI

MAINTENANCE SCHEDULES

1.18L (2.5 pts.)

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

1.66L (3.5 pts.)*

Model 226 RBA

2.24L (4.75 pts.)**

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

FLUID FILL/CHECK LOCATIONS DESCRIPTION - TRANSFER CASE The fill and drain plugs are both in the rear case (Fig. 7). Correct fill level is to the bottom edge of the fill plug hole. Be sure the vehicle is level to ensure an accurate fluid level check.

There are two maintenance schedules that show proper service for the Grand Cherokee. First is Schedule “A”. It lists all the scheduled maintenance to be performed under “normal” operating conditions. Second is Schedule“B” . It is a schedule for vehicles that are operated under the following conditions: • Frequent short trip driving less than 5 miles (8 km) • Frequent driving in dusty conditions • Extensive idling • Trailer towing • Sustained high speed operation • Off road driving • Desert operation • Frequent starting and stopping • Cold climate operation • Commercial service Use the schedule that best describes the driving conditions. Where time and mileage are listed, follow the interval that occurs first.

EMISSION CONTROL SYSTEM MAINTENANCE The scheduled emission maintenance listed in bold typeon the Maintenance Schedules, must be done at the mileage specified to assure the continued proper


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MAINTENANCE SCHEDULES (Continued) functioning of the emission control system. These, and all other maintenance services included in this manual, should be done to provide the best vehicle performance and reliability. More frequent maintenance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving.

UNSCHEDULED INSPECTION AT EACH STOP FOR FUEL • Check engine oil level, add as required. • Check windshield washer solvent and add if required.

ONCE A MONTH • Check tire pressure (including spare) and look for unusual wear or damage. • Inspect battery and clean and tighten terminals as required. • Check fluid levels of coolant reservoir, power steering and transmission and add as needed.

AT EACH OIL CHANGE • Inspect exhaust system. • Inspect brake hoses. • Rotate the tires at each oil change interval shown on Schedule—A (7,500 miles) or every other interval shown on Schedule—B (6,000 miles). • Check coolant level, hoses and clamps. • Lubricate suspension ball joints. • After completion of off-road (4WD) operation, the underside of the vehicle should be thoroughly inspected. Examine threaded fasteners for looseness.

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

7,500 miles (12 000 km) or at 6 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 15,000 Miles (24 000 km) or at 12 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. • Lubricate upper knuckle ball stud.

22,500 Miles (36 000 km) or at 18 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect brake hoses. • Inspect exhaust system. 30,000 Miles (48 000 km) or at 24 months • Change engine oil. • Replace engine oil filter. • Replace engine air cleaner element. • Replace spark plugs. • Drain and refill transfer case fluid. • Lubricate upper knuckle ball stud. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 37,500 Miles (60 000 km) or at 30 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 45,000 Miles (72 000 km) or at 36 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Flush and replace engine coolant at 36 months or 52,500 Miles (84 000 km). • Lubricate upper knuckle ball stud. • Inspect exhaust system. 52,500 Miles (84 000 km) or at 42 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 60,000 Miles (96 000 km) or at 48 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Replace engine air cleaner element. • Replace spark plugs. • Inspect PCV valve and replace if necessary (4.7L only).* • Inspect brake hoses.


0-8

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MAINTENANCE SCHEDULES (Continued) • Inspect and replace drive belt if necessary (4.0L). • Drain and replace brake fluid. • Drain and refill transfer case fluid. • Lubricate upper knuckle ball stud. • Inspect exhaust system.

97,500 Miles (156 000 km) or at 78 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system.

67,500 Miles (108 000 km) or at 54 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake linings • Inspect brake hoses. • Clean and lubricate brake caliper pins. • Inspect exhaust system.

100,000 Miles (160 000 km) • Drain and refill automatic transmission fluid and change filter (except 45RFE & 545RFE applications). • Adjust bands (except 45RFE & 545RFE applications). • Drain and refill automatic transmission fluid and change main sump filter in 45RFE & 545RFE applications. • Change spin-on cooler return filter in 45RFE & 545RFE appications.

75,000 Miles (120 000 km) or at 60 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Flush and replace engine coolant if it has been 30,000 miles (48 000 km) or 24 months since last change. • Inspect and replace drive belt if necessary (4.0L).** • Inspect brake hoses. • Inspect exhaust system. • Lubricate upper knuckle ball stud. 82,500 Miles (132 000 km) or at 66 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Flush and replace engine coolant if it has been 30,000 miles (48 000 km) or 24 months since last change. • Inspect brake hoses. • Inspect exhaust system. 90,000 Miles (144 000 km) or at 72 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Replace engine air cleaner element. • Replace spark plugs. • Inspect PCV valve and replace if necessary (4.7L only).* • Inspect and replace drive (4.0L and 4.7L).** • Drain and refill transfer case fluid. • Inspect brake hoses. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Lubricate upper knuckle ball stud. • Inspect exhaust system.

105,000 Miles (168 000 km) or at 84 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Flush and replace engine coolant if it has been 30,000 miles (48 000 km) or 24 months since last change. • Inspect and replace drive belt (4.0L and 4.7L ).** • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 112,500 Miles (180 000 km) or at 90 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Flush and replace engine coolant if it has been 30,000 miles (48 000 km) or 24 months since last change. • Inspect brake hoses. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect exhaust system. 120,000 Miles (192 000 km) or at 96 months • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Replace engine air cleaner element. • Replace spark plugs. • Inspect PCV valve and replace if necessary (4.7L only).* • Inspect and replace drive belt (4.0L and 4.7L).** • Inspect brake hoses. • Drain and replace brake fluid. • Drain and refill transfer case fluid.


WJ

LUBRICATION & MAINTENANCE

0-9

MAINTENANCE SCHEDULES (Continued) • Lubricate upper knuckle ball stud. • Inspect exhaust system. NOTE: Inspection and service should also be performed anytime a malfunction is observed or suspected. *This maintenance is recommended, but is not required to maintain warranty on the PCV valve. **This maintenance is not required if the belt was previously replaced.

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

3,000 Miles (5 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 6,000 Miles (10 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 9,000 Miles (14 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 12,000 Miles (19 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Drain and refill front and rear axles. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 15,000 miles (24 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect engine air cleaner element, replace as necessary.

• Inspect brake hoses. • Inspect exhaust system.

18,000 Miles (29 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. • Lubricate upper knuckle ball stud. 21,000 Miles (34 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 24,000 Miles (38 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Drain and refill front and rear axles. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 27,000 Miles (43 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 30,000 Miles (48 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Replace engine air cleaner element. • Replace spark plugs. • Inspect PCV valve and replace if necessary (4.7L only).* • Inspect brake hoses. • Drain and refill automatic transmission fluid and change filter (except 45RFE & 545RFE applications). • Adjust bands (except 45RFE & 545RFE applications). • Drain and refill automatic transmission fluid and change main sump filter in 45RFE & 545RFE applications. • Drain and refill transfer case fluid. • Lubricate upper knuckle ball stud. • Inspect exhaust system.


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MAINTENANCE SCHEDULES (Continued) 33,000 Miles (53 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 36,000 Miles (58 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Drain and refill front and rear axles. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 39,000 Miles (62 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 42,000 Miles (67 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 45,000 Miles (72 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect and replace drive belt if necessary (4.0L only). • Inspect engine air cleaner element, replace as necessary. • Inspect brake hoses. • Inspect exhaust system. 48,000 Miles (77 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Drain and refill front and rear axles. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system.

51,000 Miles (82 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Flush and replace engine coolant. • Inspect brake hoses. • Inspect exhaust system. 54,000 Miles (86 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 57,000 Miles (91 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 60,000 Miles (96 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Replace engine air cleaner element. • Inspect PCV valve and replace if necessary (4.7L only).* • Replace spark plugs. • Inspect and replace drive belt (4.0L only).** • Drain and refill automatic transmission fluid and change filter (except 45RFE & 545RFE applications). • Adjust bands (except 45RFE & 545RFE applications). • Drain and refill automatic transmission fluid and change main sump filter in 45RFE & 545RFE applications. • Drain and refill transfer case fluid. • Drain and refill front and rear axles. • Inspect brake hoses. • Inspect brake linings. • Drain and replace brake fluid. • Clean and lubricate brake caliper pins. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 63,000 Miles (101 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system.


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MAINTENANCE SCHEDULES (Continued) 66,000 Miles (106 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 69,000 Miles (110 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 72,000 Miles (115 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Drain and refill front and rear axles. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 75,000 Miles (120 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect and replace drive belt(4.0L and 4.7L).** • Inspect engine air cleaner element, replace as necessary. • Inspect brake hoses. • Inspect exhaust system. 78,000 Miles (125 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 81,000 Miles (130 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Flush and replace engine coolant. • Inspect brake hoses. • Inspect exhaust system. 84,000 miles (134 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Drain and refill front and rear axles.

• • • • •

Inspect brake linings. Clean and lubricate brake caliper pins. Inspect brake hoses. Lubricate upper knuckle ball stud. Inspect exhaust system.

87,000 Miles (139 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 90,000 Miles (144 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Replace engine air cleaner element. • Replace spark plugs. • Inspect PCV valve and replace if necessary (4.7L only).* • Inspect and replace drive (4.0L and 4.7L).** • Drain and refill automatic transmission fluid and change filter (except 45RFE & 545RFE applications). • Adjust bands (except 45RFE & 545RFE applications). • Drain and refill automatic transmission fluid and change main sump filter in 45RFE & 545RFE applications. • Change spin-on cooler return filter in 45RFE & 545RFE appications. • Inspect brake hoses. • Drain and refill transfer case fluid. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 93,000 Miles (149 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 96,000 Miles (154 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Drain and refill front and rear axles. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system.


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MAINTENANCE SCHEDULES (Continued) 99,000 Miles (158 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Inspect exhaust system. 102,000 Miles (163 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 105,000 Miles (168 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect engine air cleaner element, replace as necessary. • Inspect and replace drive belt (4.0L and 4.7L).** • Inspect brake hoses. • Inspect exhaust system. 108,000 Miles (173 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Drain and refill front and rear axles. • Inspect brake linings. • Clean and lubricate brake caliper pins. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 111,000 Miles (178 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Flush and replace engine coolant. • Inspect brake hoses. • Inspect exhaust system. 114,000 Miles (182 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses. • Lubricate upper knuckle ball stud. • Inspect exhaust system. 117,000 Miles (187 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Inspect brake hoses.

• Inspect exhaust system.

120,000 Miles (192 000 km) • Change engine oil. • Replace engine oil filter. • Inspect engine coolant level, hoses, clamps. • Replace engine air cleaner element. • Inspect PCV valve and replace if necessary (4.7L only).* • Replace spark plugs. • Inspect and replace drive belt (4.0L and 4.7L).** • Drain and refill automatic transmission fluid and change filter (except 45RFE & 545RFE applications). • Adjust bands (except 45RFE & 545RFE applications). • Drain and refill automatic transmission fluid and change main sump filter in 45RFE & 545RFE applications. • Drain and refill transfer case fluid. • Drain and refill front and rear axles. • Inspect brake hoses. • Inspect brake linings. • Drain and replace brake fluid. • Clean and lubricate brake caliper pins. • Lubricate upper knuckle ball stud. • Inspect exhaust system. NOTE: Inspection and service should also be performed anytime a malfunction is observed or suspected. *This maintenance is recommended, but is not required to maintain warranty on the PCV valve. **This maintenance is not required if the belt was previously replaced.

LIFT POINTS STANDARD PROCEDURES - HOISTING AND JACKING RECOMMENDATIONS FLOOR JACK When properly positioned, a floor jack can be used to lift a WJ vehicle (Fig. 8). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: • • • • •

An axle tube. Aluminum differential. A body side sill. A steering linkage component. A drive shaft.


LUBRICATION & MAINTENANCE

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0 - 13

LIFT POINTS (Continued) • The engine or transmission oil pan. • The fuel tank. • A front suspension arm.

HOIST A • • •

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

NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 8). WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.

JUMP STARTING STANDARD PROCEDURE - JUMP STARTING PROCEDURE WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE: (1) Raise hood on disabled vehicle and visually inspect engine compartment for: • Battery cable clamp condition, clean if necessary. • Frozen battery. • Yellow or bright color test indicator, if equipped. • Low battery fluid level. • Generator drive belt condition and tension. • Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result.

Fig. 8 Correct Vehicle Lifting Locations

(2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF.


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LUBRICATION & MAINTENANCE

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JUMP STARTING (Continued) (3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 9). (6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery.

• When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. • Disconnect RED cable clamp from battery positive terminal on disabled vehicle.

EMERGENCY TOW HOOKS DESCRIPTION WARNING: REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS. THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY. Some Jeep vehicles are equipped with front emergency tow hooks (Fig. 10). The tow hooks should be used for EMERGENCYpurposes only. CAUTION: DO NOT use emergency tow hooks for tow truck hook-up or highway towing.

Fig. 9 Jumper Cable Clamp Connections 1 2 3 4 5 6 7

-

ENGINE GROUND NEGATIVE JUMPER CABLE BATTERY NEGATIVE CABLE POSITIVE JUMPER CABLE BATTERY POSITIVE CABLE BATTERY TEST INDICATOR

Fig. 10 Emergency Tow Hooks 1 - TOW HOOK

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. (7) Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine ground on disabled vehicle.

TOWING STANDARD PROCEDURES A vehicle equipped with SAE approved wheel lifttype towing equipment can be used to tow WJ vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with flatbed device can also be used to transport a disabled vehicle (Fig. 11).


WJ

LUBRICATION & MAINTENANCE

0 - 15

TOWING (Continued) WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING.

TWO WHEEL DRIVE TOWING-REAR END LIFTED CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

Fig. 11 Tow Vehicles With Approved Equipment

SAFETY PRECAUTIONS CAUTION: The following safety precautions must be observed when towing a vehicle: • Secure loose and protruding parts. • Always use a safety chain system that is independent of the lifting and towing equipment. • Do not allow towing equipment to contact the disabled vehicle’s fuel tank. • Do not allow anyone under the disabled vehicle while it is lifted by the towing device. • Do not allow passengers to ride in a vehicle being towed. • Always observe state and local laws regarding towing regulations. • Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. • Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. • Do not tow a heavily loaded vehicle. Use a flatbed device to transport a loaded vehicle.

TWO-WHEEL-DRIVE VEHICLE TOWING DaimlerChrysler Corporation recommends that a vehicle be towed with the rear end lifted, whenever possible. WARNING: WHEN TOWING A DISABLED VEHICLE AND THE DRIVE WHEELS ARE SECURED IN A WHEEL LIFT OR TOW DOLLIES, ENSURE THE TRANSMISSION IS IN THE PARK POSITION (AUTOMATIC TRANSMISSION) OR A FORWARD DRIVE GEAR (MANUAL TRANSMISSION).

2WD vehicles can be towed with the front wheels on the surface for extended distances at speeds not exceeding 48 km/h (30 mph). (1) Attach wheel lift device to rear wheels. (2) Place the transmission in neutral. (3) Raise vehicle to towing position. (4) Attach safety chains. Route chains so not to interfere with tail pipe when vehicle is lifted. (5) Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. (6) Secure steering wheel in straight ahead position with a clamp device designed for towing. (7) Place transmission in park.

TWO WHEEL DRIVE TOWING-FRONT END LIFTED CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. (1) Attach wheel lift device to rear wheels. (2) Place the transmission in neutral. (3) Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. (4) Attach wheel lift device to front wheels and raise vehicle to towing position. (5) Attach the safety chains. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. (6) Turn the ignition switch to the OFF position to unlock the steering wheel. (7) Secure steering wheel in straight ahead position with a clamp device designed for towing. (8) Place transmission in park.

FOUR-WHEEL-DRIVE VEHICLE TOWING DaimlerChrysler Corporation recommends that a 4WD vehicle be transported on a flat-bed device. A Wheel-lift device can be used provided the trailing wheels are off the ground and positioned in tow dollies.


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TOWING (Continued) WARNING: WHEN AND THE DRIVE WHEEL LIFT OR TRANSMISSION IS

TOWING A DISABLED VEHICLE WHEELS ARE SECURED IN A TOW DOLLIES, ENSURE THE IN THE PARK POSITION.

CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended.

FOUR WHEEL DRIVE TOWING—REAR END LIFTED WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING. (1) Attach wheel lift device to front wheels. (2) Place the transmission in neutral. (3) Raise the front of the vehicle off the ground and install tow dollies under front wheels. (4) Attach wheel lift device to rear wheels and raise vehicle to towing position. (5) Attach safety chains. Route chains so not to interfere with tail pipe when vehicle is lifted. (6) Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

(7) Secure steering wheel in straight ahead position with a clamp device designed for towing. (8) Place transmission in park.

FOUR WHEEL DRIVE TOWING—FRONT END LIFTED WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING. (1) Attach wheel lift device to rear wheels. (2) Place the transmission in neutral. (3) Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. (4) Attach wheel lift device to front wheels and raise vehicle to towing position. (5) Attach the safety chains. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. (6) Turn the ignition switch to the OFF position to unlock the steering wheel. (7) Secure steering wheel in straight ahead position with a clamp device designed for towing. (8) Place transmission in park.


SUSPENSION

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2-1

SUSPENSION TABLE OF CONTENTS page SUSPENSION DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2 SUSPENSION AND STEERING SYSTEM . . . . . . 2 WHEEL ALIGNMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 4 CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TOE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5 FRONT SUSPENSION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 6 SERVICE WARNINGS AND PRECAUTIONS . . . . 6 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BUSHINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 JOUNCE BUMPER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 KNUCKLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOWER BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SHOCK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SPRING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

page INSTALLATION. . . . . . . . . . STABILIZER BAR DESCRIPTION . . . . . . . . . . OPERATION. . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . TRACK BAR DESCRIPTION . . . . . . . . . . OPERATION. . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . UPPER BALL JOINT REMOVAL . . . . . . . . . . . . . UPPER CONTROL ARM DESCRIPTION . . . . . . . . . . OPERATION. . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . REAR SUSPENSION DESCRIPTION . . . . . . . . . . WARNING . . . . . . . . . . . . . DIAGNOSIS AND TESTING REAR SUSPENSION . . . SPECIFICATIONS . . . . . . . SPECIAL TOOLS . . . . . . . . JOUNCE BUMPER DESCRIPTION . . . . . . . . . . OPERATION. . . . . . . . . . . . LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . OPERATION. . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . SHOCK DESCRIPTION . . . . . . . . . . OPERATION. . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . SPRING DESCRIPTION . . . . . . . . . . OPERATION. . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . STABILIZER BAR DESCRIPTION . . . . . . . . . . OPERATION. . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION. . . . . . . . . .

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SUSPENSION

UPPER BALL JOINT DESCRIPTION . . . . OPERATION. . . . . . REMOVAL . . . . . . . INSTALLATION. . . .

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UPPER CONTROL ARM DESCRIPTION . . . . . . . OPERATION. . . . . . . . . REMOVAL . . . . . . . . . . INSTALLATION. . . . . . .

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SUSPENSION DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM CONDITION FRONT END NOISE

EXCESSIVE PLAY IN STEERING

FRONT WHEELS SHIMMY

VEHICLE INSTABILITY

EXCESSIVE STEERING EFFORT

VEHICLE PULLS TO ONE SIDE DURING BRAKING

POSSIBLE CAUSES

CORRECTION

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Loose or worn steering gear.

3. Adjust or replace steering gear.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Tires worn or out of balance.

3. Replace or balance tires.

4. Alignment.

4. Align vehicle to specifications.

5. Leaking steering dampener.

5. Replace steering dampener.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Tire pressure.

3. Adjust tire pressure.

4. Alignment.

4. Align vehicle to specifications.

1. Loose or worn steering gear.

1. Adjust or replace steering gear.

2. Power steering fluid low.

2. Add fluid and repair leak.

3. Column coupler binding.

3. Replace coupler.

4. Tire pressure.

4. Adjust tire pressure.

5. Alignment.

5. Align vehicle to specifications.

1. Uneven tire pressure.

1. Adjust tire pressure.

2. Worn brake components.

2. Repair brakes as necessary.

3. Air in brake line.

3. Repair as necessary.

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

KNOCKING, RATTLING OR SQUEAKING

IMPROPER TRACKING

POSSIBLE CAUSES

CORRECTION

1. Radial tire lead.

1. Cross front tires.

2. Brakes dragging.

2. Repair brake as necessary.

3. Weak or broken spring.

3. Replace spring.

4. Uneven tire pressure.

4. Adjust tire pressure.

5. Wheel Alignment.

5. Align vehicle.

6. Loose or worn steering or suspension components.

6. Repair as necessary.

7. Cross caster out of spec.

7. Align vehicle.

1. Worn shock bushings.

1. Replace shock.

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

2. Inspect, tighten or replace components as necessary.

3. Shock valve.

3. Replace shock.

1. Loose, worn or bent track bar.

1. Inspect, tighten or replace component as necessary.

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

2. Inspect, tighten or replace components as necessary.

WHEEL ALIGNMENT DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe position (Fig. 1). CAUTION: Never attempt to modify suspension or steering components by heating or bending. CAUTION: Components attached with a nut and cotter pin must be torqued to specification. Then if the slot in the nut does not line up with the cotter pin hole, tighten nut until it is aligned. Never loosen the nut to align the cotter pin hole. NOTE: Periodic lubrication of the front suspension/ steering system components may be required. Rubber bushings must never be lubricated. Refer to Lubrication And Maintenance for the recommended maintenance schedule.

OPERATION • CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle rearward provides positive caster. Tilting the top of the knuckle forward provides negative caster. Caster is a directional stability angle. This angle enables the front wheels to return to a straight ahead position after turns. • CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. The angle is not adjustable, damaged component(s) must be replaced to correct the camber angle. • WHEEL TOE POSITION is the difference between the leading inside edges and trailing inside edges of the front tires. Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear. The wheel toe position is the final front wheel alignment adjustment. • STEERING AXIS INCLINATION ANGLE is measured in degrees and is the angle that the steering knuckles are tilted. The inclination angle has a fixed relationship with the camber angle. It will not change except when a spindle or ball stud is damaged or bent. The angle is not adjustable, damaged component(s) must be replaced to correct the steering axis inclination angle.


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WHEEL ALIGNMENT (Continued)

Fig. 1 Wheel Alignment Measurements 1 2 3 4 5

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WHEEL CENTERLINE NEGATIVE CAMBER ANGLE PIVOT CENTERLINE SCRUB RADIUS TRUE VERTICAL

• THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle.

STANDARD PROCEDURE - CAMBER Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down three times. Always release the bumper in the down position. To obtain an accurate alignment, a 4 wheel alignment machine must be used and the equipment calibration verified. The wheel camber angle is preset. This angle is not adjustable and cannot be altered.

6 - KING PIN 7 - VERTICAL 8 - POSITIVE CASTER

STANDARD PROCEDURE - CASTER Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down three times. Always release the bumper in the down position. To obtain an accurate alignment, a 4 wheel alignment machine must be used and the equipment calibration verified. The wheel caster angle is preset. This angle is not adjustable and cannot be altered.

STANDARD PROCEDURE - TOE POSITION Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down three times. Always release the bumper in the down position.


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2-5

WHEEL ALIGNMENT (Continued) To obtain an accurate alignment, a 4 wheel alignment machine must be used and the equipment calibration verified.

SPECIFICATIONS

NOTE: For an accurate wheel toe position adjustment the engine must be engine running.

NOTE: Specifications are in degrees.

(1) Apply parking brakes. (2) Start the engine and turn wheels both ways before straightening the steering wheel. Center and secure the steering wheel. (3) Loosen the tie rod adjustment sleeve clamp bolts (Fig. 2) . (4) Turn the sleeve to obtain the preferred positive TOE-IN specification. Position the clamp bolts as shown (Fig. 2) for proper clearance. (5) Tighten the clamp bolts to 68 N·m (50 ft. lbs.).

FRONT WHEELS - STANDARD SUSPENSION

NOTE: Make sure the toe setting does not change during clamp tightening. (6) Verify alignment specifications, then turn the engine off.

ALIGNMENT

SPECIFICATIONS DESCRIPTION

SPECIFICATION

PREFERRED

CASTER + 6.75°

CAMBER − 0.37°

TOTAL TOE-IN + 0.20°

RANGE

+ 6.0° to + 7.5°

− 0.75° to + 0.5°

N/A

MAX RT/LT DIFFERENCE

0.5°

0.5°

0.5°

FRONT WHEELS - UP-COUNTRY SUSPENSION SPECIFICATIONS DESCRIPTION

SPECIFICATION

PREFERRED

CASTER + 6.5°

CAMBER − 0.37°

TOTAL TOE-IN + 0.20°

RANGE

+ 5.7° to + 7.2°

− 0.75° to + 0°

N/A

MAX RT/LT DIFFERENCE

0.5°

0.5°

0.05°

REAR AXLE SPECIFICATIONS

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

DESCRIPTION PREFERRED

CASTER

THRUST ANGLE

TOTAL TOE-IN

RANGE

0° to –0.5°

6 0.25°

0° to +0.5°

STEERING WHEEL CENTERING NOTE: The steering wheel can be centered without affecting the toe position. (1) Loosen the drag link adjustment sleeve clamp bolts. (2) Turn the adjustment sleeve to center the wheel. (3) Position the clamp bolts as shown (Fig. 2)for proper clearance. (4) Tighten the clamp bolts to 68 N·m (50 ft. lbs.). (5) Road test the vehicle to verify the wheel is centered.

SPECIFICATION

FRONT SUSPENSION DESCRIPTION The front suspension (Fig. 3) is a link/coil design comprised of : • Drive axle • Shock absorbers • Coil springs • Upper and lower suspension arms • Stabilizer bar • Track bar • Jounce bumpers


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FRONT SUSPENSION (Continued) slot in the nut does not line up with the cotter pin hole, tighten nut until it is aligned. Never loosen the nut to align the cotter pin hole. CAUTION: Suspension components with rubber bushings must be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort will be affected and cause premature bushing wear.

STANDARD PROCEDURES - SERVICE WARNINGS AND CAUTIONS Fig. 3 Front 1 2 3 4 5 6

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CAUTION: Suspension components with rubber bushings must be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort will be affected and cause premature bushing wear.

SHOCK COIL SPRING UPPER SUSPENSION ARM STABILIZER BAR LOWER SUSPENSION ARM TRACK BAR

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

SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

Shock Absorber Upper Nut

35

26

Shock Absorber Lower Nut

28

Suspension Arm Upper Axle Bracket Nut

61

45

Suspension Arm Upper Frame Bracket Bolt

61

45

Suspension Arm Lower Axle Bracket Nut

163

120

Suspension Arm Lower Frame Bracket Bolt

156

115

Stabilizer Bar Retainer Bolts

92

68

Stabilizer Bar Link Upper Nut

106

78

In. Lbs. 250

Stabilizer Bar Link Lower Nut

106

78

Track Bar Frame Bracket Nut

108

80

Track Bar Axle Bracket Bolt

100

74

Hub Bearing Knuckle Bolts

102

75


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SPECIAL TOOLS FRONT SUSPENSION

Remover C-4150A Remover/Installer Suspension Bushing 7932

Remover/Installer 6289

Spacer 8279

Reciever 6761

Nut, Long 7603

Installer 6752 Bolt, Special 7604

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BUSHINGS REMOVAL (1) Remove the upper suspension arm from axle. (2) Position Spacer 8279 over the axle bushing on a 4x2 vehicle and right side on a 4x4 vehicle. (3) Place Receiver 7932-1 over flanged end of the bushing. (Fig. 4). (4) Place small end of Remover/Install 7932-2 against other side of the bushing. (5) Install bolt 7604 through remover, bushing and receiver. (6) Install Long Nut 7603 and tighten nut too pull bushing out of the axle bracket.

Fig. 5 Bushing Installation 1 2 3 4 5

- REMOVER/INSTALLER - AXLE BRACKET - BOLT - RECEIVER - LONG NUT

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

HUB / BEARING DESCRIPTION Fig. 4 Bushing Removal 1 2 3 4 5

- RECEIVER - AXLE BRACKET - BOLT - REMOVER/INSTALLER - LONG NUT

(7) Remove nut, bolt, receiver, remover and bushing. NOTE: On 4x2 vehicle and right side of 4x4 vehicle, leave Spacer 8279 in position for bushing installation.

INSTALLATION (1) Place Receiver 7932-1on the other side of the axle bracket. (2) Position new bushing up to the axle bracket., and large end of Remover/Install 7932-2 against the bushing (Fig. 5). (3) Install bolt 7604 through receiver, bushing and installer. (4) Install Long Nut 7603 and tighten nut to draw the bushing into the axle bracket.

The bearing used on the front hub of this vehicle is the combined hub and bearing unit type assembly. This unit assembly combines the front wheel mounting hub (flange) and the front wheel bearing into a one piece unit. The wheel mounting studs are the only replaceable component of the hub/bearing assembly.

OPERATION The hub/bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts accessible from the back of the steering knuckle. The hub/bearing unit is not serviceable and must be replaced as an assembly if the bearing or the hub is determined to be defective.

REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper, caliper anchor, rotor and ABS wheel speed sensor,(Refer to 5 - BRAKES/ ELECTRICAL/FRONT WHEEL SPEED SENSOR REMOVAL). (4) Remove the cotter pin, nut retainer and axle hub nut.


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2-9

HUB / BEARING (Continued) (5) Remove the hub bearing mounting bolts from the back of the steering knuckle. Remove hub bearing (Fig. 6) from the steering knuckle and off the axle shaft.

KNUCKLE DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing.

OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered.

REMOVAL - STEERING KNUCKLE

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

INSTALLATION (1) Install the hub bearing to the knuckle. (2) Install the hub bearing to knuckle bolts and tighten to 102 N·m (75 ft. lbs.). (3) Install the hub washer and nut. Tighten the hub nut to 237 N·m (175 ft. lbs.). Install the nut retainer and a new cotter pin. (4) Install the brake rotor, caliper anchor, caliper and ABS wheel speed sensor,(Refer to 5 - BRAKES/ ELECTRICAL/FRONT WHEEL SPEED SENSOR INSTALLATION). (5) Install the wheel and tire assembly. (6) Remove the support and lower the vehicle.

Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Remove hub bearing and axle shaft. (2) Disconnect the tie-rod or drag link from the steering knuckle arm. Refer to Group 2, Suspension, for proper procedures. (3) Remove the cotter pins from the upper and lower ball studs. (4) Remove the upper and lower ball stud nuts. (5) Strike the steering knuckle with a brass hammer to loosen knuckle from the ball studs. Remove knuckle from ball studs (Fig. 7).

JOUNCE BUMPER DESCRIPTION They are mounted under the unibody rails to minimize transmission of noise to the passenger compartment.

OPERATION The jounce bumpers are used to limit suspension travel in compression.

Fig. 7 Steering Knuckle Removal/Installation 1 2 3 4

- AXLE YOKE - UPPER BALL STUD - LOWER BALL STUD - STEERING KNUCKLE


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KNUCKLE (Continued)

INSTALLATION

LOWER CONTROL ARM

(1) Position the steering knuckle on the ball studs. (2) Install and tighten the bottom retaining nut to 109 N·m (80 ft. lbs.) torque. Install new cotter pin. (3) Install and tighten the top retaining nut to 101 N·m (75 ft. lbs.) torque. Install new cotter pin. (4) Install the hub bearing and axle shaft. (5) Connect the tie-rod or drag link end to the steering knuckle arm. Refer to Group 2, Suspension, for proper procedures.

LOWER BALL JOINT

DESCRIPTION The lower suspension arms are hydroformed steel and use voided oval bushings at one end of the arm.

OPERATION The bushings provide isolation from the axle. The arms mount to the unibody frame rail bracket and the axle brackets. The arm and bushings provide location and react to loads from the axle.

REMOVAL

REMOVAL Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Position tools as shown to remove and install ball stud (Fig. 8).

(1) Raise the vehicle and support the front axle. (2) Remove the lower suspension arm nut and bolt from the axle bracket (Fig. 9). (3) Remove the nut and bolt from the frame rail bracket and remove the lower suspension arm (Fig. 9).

Fig. 8 Lower 1 2 3 4

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SPECIAL TOOL 6289–12 SPECIAL TOOL 6289–4 SPECIAL TOOL 4212F SPECIAL TOOL 4212F

5 - SPECIAL TOOL 6289–1 6 - SPECIAL TOOL 6289–3


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LOWER CONTROL ARM (Continued)

REMOVAL (1) Remove the nut, retainer and grommet from the shock stud in the engine compartment (Fig. 10).

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

INSTALLATION (1) Position the lower suspension arm in the axle bracket and frame rail bracket. NOTE: The end of the arm with the oval bushing attaches to the axle bracket.

Fig. 10 Upper Shock Mounting 1 2 3 4

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RETAINER STUD NUT GROMMET

(2) Raise and support the front axle. (3) Remove the lower mounting nuts from the axle bracket (Fig. 11). Remove the shock absorber.

(2) Install the axle bracket bolt and nut finger tight. (3) Install the frame rail bracket bolt and nut finger tight. (4) Remove support and lower the vehicle. (5) With the vehicle on the ground tighten the frame bracket bolt to 156 N·m (115 ft. lbs.). Tighten the axle bracket nut to 163 N·m (120 ft. lbs.). (6) Check the alignment if new parts were installed.

SHOCK DESCRIPTION The top of the shock absorbers are bolted to the body. The bottom of the shocks are bolted to the axle brackets. The standard shocks have conventional twin tube construction and are low pressure gas charged. Gas charging prevents cavitation during rough road operation. Up-Country shocks are mono tube design and are high pressure gas charged.

OPERATION The shock absorbers dampen jounce and rebound motion of the vehicle over various road conditions and limit suspension rebound travel.

Fig. 11 Lower Shock Mounting 1 - SHOCK ABSORBER 2 - MOUNTING NUTS

INSTALLATION (1) Position the lower retainer and grommet on the shock stud. Insert the shock absorber through the shock tower hole. (2) Install the lower shock studs into the axle bracket.


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SHOCK (Continued) (3) Install the mounting nuts and tighten to 28 N¡m (250 in. lbs.). (4) Remove support and lower the vehicle. (5) Install the upper grommet, retainer and nut on the stud in the engine compartment. Hold the shock stud with a 8 mm wrench and tighten the nut to 35 N¡m (26 ft. lbs.).

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

OPERATION The coil springs control ride quality and maintain proper ride height. The isolators provide road noise isolation.

Fig. 12 Front Coil Spring 1 2 3 4

-

UPPER ISOLATOR COIL SPRING LOWER ISOLATOR STABILIZER LINK

1 2 3 4

- LOCATING NUB - LOWER ISOLATOR - AXLE SPRING PAD - LOCATING HOLE

REMOVAL (1) Raise and support the vehicle. Position a hydraulic jack under the axle to support it. (2) Remove the wheel and tire assemblies. (3) Remove stabilizer bar links mounting nuts and bolts from the axle brackets. (4) Remove shock absorbers lower mounting nuts from the axle brackets. (5) Remove the track bar mounting bolt from the axle bracket. (6) Lower the axle until the spring is free from the upper mount and isolator (Fig. 12). (7) Remove the spring from the vehicle. (8) Remove and inspect the upper and lower spring isolators.

INSTALLATION (1) Install the upper isolator. (2) Install the lower isolator with the isolator locator nub in the axle pad hole (Fig. 13). (3) Position the coil spring on the axle spring pad. CAUTION: Ensure the spring is positioned on the lower isolator with the end of the spring coil against the isolator spring locator (Fig. 14). (4) Raise the axle and guide the springs onto the spring upper mounts and lower shock studs into the axle brackets. (5) Install the shock absorbers lower mounting nuts. (6) Install the stabilizer bar link to the axle bracket and install the mounting bolts and nuts.

Fig. 13 Lower Isolator

(7) Install the track bar to the axle bracket and install the mounting bolt. NOTE: It may be necessary to pry the axle assembly over to install the track bar bolt.


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2 - 13

SPRING (Continued)

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

(8) Tighten all suspension components to proper torque. (9) Install the wheel and tire assemblies. (10) Remove support and lower vehicle.

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

OPERATION

1 2 3 4

-

LINK STABILIZER BAR BUSHING RETAINER

(2) Install the links onto the stabilizer bar and axle brackets and install the bolts and nuts finger tight. (3) Remove the supports and lower the vehicle. (4) With the vehicle on the ground tighten the stabilizer bar link nuts to 106 N¡m (78 ft. lbs.).

TRACK BAR DESCRIPTION The bar is attached to a frame rail bracket and axle bracket. The bar is forged and has non replaceable isolator bushings at both ends.

OPERATION

The stabilizer bar is used to control vehicle body roll during turns. The spring steel bar helps to control the vehicle body in relationship to the suspension.

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

REMOVAL

REMOVAL

(1) Raise and support the vehicle. (2) Remove link nuts and bolts (Fig. 15) and remove the links. (3) Remove the stabilizer bar retainer bolts (Fig. 15)from the frame rails and remove the stabilizer bar.

(1) Raise and support the vehicle. (2) Remove the nut and bolt from the frame rail bracket (Fig. 16). (3) Remove the bolt from the axle shaft tube bracket (Fig. 17). Remove the track bar.

INSTALLATION

(1) Install the track bar to the axle tube bracket. Install the retaining bolt finger tight. (2) Install track bar to the frame rail bracket. Install the bolt and nut finger tight.

(1) Position the stabilizer bar on the frame rail and install the retainers and bolts. Ensure the bar is centered with equal spacing on both sides. Tighten the bolts to 92 N¡m (68 ft. lbs.).

INSTALLATION


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TRACK BAR (Continued)

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

NOTE: It may be necessary to pry the axle assembly over to install the track bar to the frame rail bracket. (3) Remove the supports and lower the vehicle. (4) With the vehicle on the ground tighten the nut at the frame rail bracket and to the bolt at the axle bracket to 100 N·m (74 ft. lbs.). (5) Check alignment specifications if a new track bar was installed.

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

UPPER BALL JOINT REMOVAL Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Position tools as shown to remove and install ball stud (Fig. 18).


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2 - 15

UPPER BALL JOINT (Continued)

Fig. 18 Upper

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

OPERATION The arms mount to the unibody frame rail bracket and the axle brackets. The arm and bushings provide location and react to loads from the axle. The bushings provide isolation from the axle.

REMOVAL (1) Raise vehicle and support the axle. (2) Remove the upper suspension arm mounting nut and bolt (Fig. 19) from the axle bracket. (3) Remove the nut and bolt (Fig. 19) at the frame rail and remove the upper suspension arm.

INSTALLATION (1) Position the upper suspension arm at the axle and frame rail. (2) Install the bolts and finger tighten the nuts. (3) Remove the supports and lower the vehicle.

Fig. 19 Upper Suspension Arm 1 - UPPER SUSPENSION ARM 2 - FRAME BOLT 3 - AXLE BOLT

(4) With the vehicle on the ground tighten the axle bracket nut and the frame bracket bolt to 61 N¡m (45 ft. lbs.). (5) Check the alignment if new parts were installed.


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REAR SUSPENSION DESCRIPTION The rear suspension (Fig. 20) is comprised of : • Drive axle • Shock absorbers • Coil springs • Lower suspension arms • Upper suspension arm • Stabilizer bar CAUTION: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. This will maintain vehicle ride comfort and prevent premature bushing wear.

WARNING WARNING: Suspension components with rubber bushings must be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort will be affected and cause premature bushing wear.

Fig. 20 Rear Suspension 1 2 3 4 5

-

SHOCK UPPER SUSPENSION ARM COIL SPRING STABILIZER BAR LOWER SUSPENSION ARM

DIAGNOSIS AND TESTING - REAR SUSPENSION CONDITION VEHICLE INSTABILITY

VEHICLE PULLS TO ONE SIDE

KNOCKING, RATTLING OR SQUEAKING

POSSIBLE CAUSES

CORRECTION

1. Loose or worn wheel bearings.

1. Replace wheel bearings.

2. Loose, worn or bent suspension components.

2. Inspect, tighten or replace components as necessary.

3. Tire pressure.

3. Adjust tire pressure.

1. Weak or broken spring.

1. Replace spring.

2. Alignment.

2. Align vehicle to specifications.

3.Tires.

3. Replace tires.

4. Brakes.

4. Repair as necassary.

1. Worn shock bushings.

1. Replace shock.

2. Loose shock mounting.

2. Tighten to specifications.

3. Shock valve.

3. Replace shock.

4. Loose upper ball joint.

4. Replace ball joint.

5. Loose, worn or bent suspension components.

5. Inspect, tighten or replace components as necessary.


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2 - 17

REAR SUSPENSION (Continued) CONDITION IMPROPER TRACKING

POSSIBLE CAUSES

CORRECTION

1. Loose, worn or bent suspension components.

1. Inspect, tighten or replace components as necessary.

2. Bent axle.

2.Replace axle.

SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Shock Absorber Upper Nut

108

80

Shock Absorber Lower Nut

115

85

Suspension Arm Upper Ball Joint Nut

142

105

Suspension Arm Upper Frame Bolts

100

74

Ball Joint Plate Bolts

136

100

Suspension Arms Lower Axle Bracket Nut

163

120

Suspension Arms Lower Frame Bracket Nut

156

115

Stabilizer Bar Retainer Bolts

54

40

Stabilizer Bar Bar Link Nut

54

40

Stabilizer Bar Bracket Link Nut

92

68

SPECIAL TOOLS

JOUNCE BUMPER

REAR SUSPENSION

DESCRIPTION The jounce bumpers are mounted inside the coil spring, between the axle and the frame rail, to minimize transmission of noise to the passenger compartment.

OPERATION The jounce bumpers are used to limit suspension travel in compression.

LOWER CONTROL ARM Remover 8278

DESCRIPTION The lower suspension arms are hydroformed steel and use voided oval bushings at each end of the arm.


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LOWER CONTROL ARM (Continued)

OPERATION The bushings provide isolation from the axle. The arms mount to the unibody frame rail bracket and the axle brackets. The arm and bushings provide location and react to loads.

brackets. The standard shocks have conventional twin tube construction and are low pressure gas charged. Gas charging prevents cavitation during rough road operation. Up-Country shocks are mono tube design and are high pressure gas charged.

REMOVAL

OPERATION

(1) Raise the vehicle and support the rear axle. (2) Remove the lower suspension arm nut and bolt from the axle bracket (Fig. 21). (3) Remove the nut and bolt (Fig. 21) from the frame rail and remove the lower suspension arm.

The shock absorbers dampen jounce and rebound motion of the vehicle over various road conditions and limit suspension rebound travel.

REMOVAL (1) Raise and support the vehicle. Position a hydraulic jack under the axle to support the axle. CAUTION: Do not allow the axle to hang from the upper suspension arm ball joint. (2) Remove the upper nut and bolt from the frame bracket (Fig. 22). (3) Remove the lower nut and bolt from the axle bracket. Remove the shock absorber.

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

INSTALLATION (1) Position the lower suspension arm in the axle bracket and frame rail bracket. NOTE: The end of the arm with the oval bushing attaches to the axle bracket. (2) Install the axle bracket bolt and nut finger tight. (3) Install the frame rail bracket bolt and nut finger tight. (4) Remove the supports and lower the vehicle. (5) With the vehicle on the ground tighten the nut at the frame to 156 N路m (115 ft. lbs.). Tighten the nut at the axle bracket to 163 N路m (120 ft. lbs.).

SHOCK DESCRIPTION The top of the shock absorbers are bolted to the body. The bottom of the shocks are bolted to the axle

Fig. 22 Shock Absorber 1 - SHOCK

INSTALLATION (1) Install the shock absorber in the frame bracket and install the bolt and nut. (2) Install the shock absorber in the axle bracket and install the bolt and nut. (3) Tighten the upper mounting nuts to 108 N路m (80 ft. lbs.). Tighten the lower mounting nuts to 115 N路m (85 ft. lbs.). (4) Remove the supports and lower the vehicle.


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2 - 19

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

OPERATION The coil springs control ride quality and maintain proper ride height.

REMOVAL (1) Raise and support the vehicle. Position a hydraulic jack under the axle to support the axle. (2) Remove the wheel and tire assemblies. (3) Remove the stabilizer bar link from the stabilizer bar (Fig. 23). (4) Remove the shock absorber lower bolt from the axle bracket. (5) Lower the hydraulic jack and tilt the axle and remove the coil spring (Fig. 23).

CAUTION: Ensure the spring is positioned on the lower isolator with the end of the spring coil against the isolator spring locator (Fig. 25).

Fig. 23 Coil Spring

Fig. 25 Isolator Spring Locator - Typical

1 2 3 4

-

COIL SPRING ISOLATOR STABILIZER LINK ISOLATOR

(6) Remove and inspect the upper and lower spring isolators (Fig. 23).

INSTALLATION (1) Install the upper isolator. (2) Install the lower isolator with the isolator locator nub in the axle pad hole (Fig. 24). (3) Pull down on the axle and position the coil spring in the lower isolator.

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

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

(4) Raise the axle with the hydraulic jack. (5) Install the shock absorber to the axle bracket and tighten to specification. (6) Install the stabilizer bar link to the stabilizer bar. (7) Install the wheel and tire assemblies. (8) Remove the supports and lower the vehicle. (9) Tighten the stabilizer bar links to specification.


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STABILIZER BAR

UPPER BALL JOINT

DESCRIPTION

DESCRIPTION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT

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

OPERATION The stabilizer bar is used to control vehicle body roll, during turns. The bar helps control the vehicle body in relationship to the suspension.

REMOVAL (1) Raise and support the vehicle. (2) Remove the stabilizer bar links from stabilizer bar and frame mount. (Fig. 26). (3) Remove the stabilizer bar retainer bolts. (4) Remove the stabilizer bar.

The suspension arm uses vertical spool bushings to isolate road noise. The suspension arm is bolted through bushings to cage nuts in the body and a ball joint plate to the top of the differential housing.

OPERATION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT The upper suspension arm provides fore/aft and lateral location of the rear axle. The suspension arm travel is limited through the use of jounce bumpers in compression and shock absorbers in rebound.

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

Fig. 26 Rear Stabilizer Bar 1 2 3 4

-

LINK RETAINER BUSHING STABILIZER BAR

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

INSTALLATION (1) Position the stabilizer bar on the axle and install the retainers and bolts. Ensure the bar is centered with equal spacing on both sides. Tighten the bolts to 54 N·m (40 ft. lbs.). (2) Install the links to the stabilizer bar and frame brackets. (3) Tighten the nuts at the stabilizer bar to 54 N·m (40 ft. lbs.). (4) Tighten the nuts at the frame brackets to 92 N·m (68 ft. lbs.). (5) Remove support and lower the vehicle.

(4) Separate ball joint from the arm with Remover 8278 (Fig. 28). NOTE: It may be necessary to strike the upper control arm with a hammer to separate the ball joint from the arm. (5) Remove the ball joint mounting bolts (Fig. 29)from the differential housing. (6) Remove the ball joint from the differential housing.


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2 - 21

UPPER BALL JOINT (Continued) (2) Install the ball joint mounting bolts and tighten to 136 N·m (100 ft. lbs.). (3) Raise the rear axle with a hydraulic jack to align the upper arm with the ball joint. (4) Pull the arm down on the ball joint stud and install a new nut. Tighten the nut to 142 N·m (105 ft. lbs.). (5) Remove the supports and lower the vehicle.

UPPER CONTROL ARM DESCRIPTION The suspension arm uses vertical spool bushings to isolate road noise. The suspension arm is bolted through bushings to cage nuts in the body and a ball joint plate to the top of the differential housing.

OPERATION

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

The upper suspension arm provides fore/aft and lateral location of the rear axle. The suspension arm travel is limited through the use of jounce bumpers in compression and shock absorbers in rebound.

REMOVAL (1) (2) (3) from

Raise and support the vehicle. Support the rear axle with a hydraulic jack. Remove the park brake cables and brake hose the arm (Fig. 30).

Fig. 30 Park Brake Cables And Brake Hose Fig. 29 Ball Joint Mounting Bolts 1 - BALL JOINT 2 - MOUNTING BOLTS

INSTALLATION (1) Install the ball joint on the differential housing.

1 - UPPER SUSPENSION ARM 2 - REAR BRAKE HOSE 3 - PARK BRAKE CABLES

(4) Remove the ball joint nut from the top of the upper suspension arm (Fig. 31). (5) Separate ball joint from the arm with Remover 8278 (Fig. 32).


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UPPER CONTROL ARM (Continued)

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

NOTE: It may be necessary to strike the upper control arm with a hammer to separate the ball joint from the arm. (6) Remove the upper suspension arm mounting bolts and remove the arm (Fig. 33).

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

INSTALLATION (1) Position the upper suspension arm in the frame rail brackets. (2) Install the mounting bolts and tighten to 100 N·m (74 ft. lbs.). (3) Pull the arm down on the ball joint stud and install a new nut. Tighten the nut to 142 N·m (105 ft. lbs.). (4) Install the park brake cables and brake hose to the arm. (5) Remove the supports and lower the vehicle.

Fig. 33 Upper Suspension Arm Mounting Bolt 1 - UPPER SUSPENSION ARM 2 - MOUNTING BOLT


DIFFERENTIAL & DRIVELINE

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DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page

page

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1 FRONT TUBE AXLE . . . . . . . . . . . . . . . . . . . . . . 15 FRONT AXLE - 186FBI . . . . . . . . . . . . . . . . . . . . 16

REAR AXLE - 198RBI . . . . . . . . . . . . . . . . . . . . . 49 REAR AXLE - 226RBA . . . . . . . . . . . . . . . . . . . . . 87

PROPELLER SHAFT TABLE OF CONTENTS page PROPELLER SHAFT DESCRIPTION . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . DIAGNOSIS AND TESTING . . PROPELLER SHAFT . . . . . STANDARD PROCEDURE . . . PROPELLER SHAFT . . . . . SPECIFICATIONS . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . PROPELLER SHAFT - FRONT REMOVAL . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . .

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.1 .1 .2 .2 .4 .4 .6 .7

................7 ................7

PROPELLER SHAFT DESCRIPTION A propeller shaft (Fig. 1) is the shaft which connects the transmission/transfer case to the axle differential. This is the link through which the engine power is transmitted to the axle. The propeller shaft is designed and built with the yoke lugs in line with each other which is called zero phasing. This design produces the smoothest running condition, an out-of-phase shaft can cause a vibration. Tubular propeller shafts are balanced by the manufacturer with weights spot welded to the tube. Two styles of front propeller shafts are used on this vehicle. The 4.7L engine propeller shaft uses a single cardan U-joint at the axle end and a double cardan U-joint at the transfer case end. The rest uses a Constant Velocity (C/V) joint at both the axle and transfer case end of the propeller shaft. The C/V joint at the axle end contracts and extends (plunges) as nec-

page PROPELLER SHAFT - FRONT 4.7L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PROPELLER SHAFT - REAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DOUBLE CARDAN UNIVERSAL JOINTS DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 essary to accommodate the variations in length necessary due to suspension travel. The C/V joint at the transfer case end of the propeller shaft is fixed. The two C/V joints are connected by a hollow tube shaft. The shaft length is not adjustable and does vary according to application.

OPERATION The propeller shaft must operate through constantly changing relative angles between the transmission and axle when going over various road surfaces. It must also be capable of changing length while transmitting torque. The axle rides suspended by springs in a floating motion. This is accomplished through universal joints, which permit the propeller shaft to operate at different angles. The slip joints (or yokes) permit contraction or expansion. Before undercoating a vehicle, the propeller shaft and the U-joints should be covered to prevent an out-of-balance condition and driveline vibration.


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PROPELLER SHAFT (Continued)

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

-

REAR AXLE STRAP BOLT SLIP YOKE REAR PROPELLER SHAFT

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

CAUTION: Use original equipment replacement parts for attaching the propeller shafts. The specified torque must always be applied when tightening the fasteners.

DIAGNOSIS AND TESTING - PROPELLER SHAFT VIBRATION Tires that are out-of-round, or wheels that are unbalanced, will cause a low frequency vibration. (Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND TESTING)

Brake rotors that are unbalanced will cause a harsh, low frequency vibration. (Refer to 5 - BRAKES - DIAGNOSIS AND TESTING) Driveline vibration can also result from loose or damaged engine mounts. Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a specific speed range is not usually caused by a propeller shaft being unbalanced. Defective universal joints, or an incorrect propeller shaft angle, are usually the cause of such a vibration.


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PROPELLER SHAFT (Continued) DRIVELINE VIBRATION Drive Condition Propeller Shaft Noise

Universal Joint Noise

Possible Cause

Correction

1) Undercoating or other foreign material on shaft.

1) Clean exterior of shaft and wash with solvent.

2) Loose U-joint clamp screws.

2) Install new clamps and screws and tighten to proper torque.

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

3) Install new yoke.

4) Incorrect driveline angularity.

4) Measure and correct driveline angles.

5) Rear spring center bolt not in seat.

5) Loosen spring u-bolts and seat center bolt.

6) Worn U-joint bearings.

6) Install new U-joint.

7) Propeller shaft damaged or out of balance.

7) Installl new propeller shaft.

8) Broken rear spring.

8) Install new rear spring.

9) Excessive runout or unbalanced condition.

9) Re-index propeller shaft, test, and evaluate.

10) Excessive drive pinion gear shaft runout.

10) Re-index propeller shaft and evaluate.

11) Excessive axle yoke deflection.

11) Inspect and replace yoke if necessary.

12) Excessive transfer case runout.

12) Inspect and repair as necessary.

1) Loose U-joint clamp screws.

1) Install new clamps and screws and tighten to proper torque.

2) Lack of lubrication.

2) Replace U-joints as necessary.

BALANCE

(9) Install a screw clamp at position 1 (Fig. 2).

NOTE: Removing and re-indexing the propeller shaft 180° relative to the yoke may eliminate some vibrations. If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure: (1) Raise the vehicle. (2) Clean all the foreign material from the propeller shaft and the universal joints. (3) Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the propeller shaft is bent, it must be replaced. (4) Inspect the universal joints to ensure that they are not worn, are properly installed, and are correctly aligned with the shaft. (5) Check the universal joint clamp screws torque. (6) Remove the wheels and tires. Install the wheel lug nuts to retain the brake drums or rotors. (7) Mark and number the shaft six inches from the yoke end at four positions 90° apart. (8) Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine.

Fig. 2 Clamp Screw At Position 1 1 - CLAMP 2 - SCREWDRIVER

(10) Start the engine and re-check for vibration. If there is little or no change in vibration, move the


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PROPELLER SHAFT (Continued) clamp to one of the other three positions. Repeat the vibration test. (11) If there is no difference in vibration at the other positions, the source of the vibration may not be propeller shaft. (12) If the vibration decreased, install a second clamp (Fig. 3) and repeat the test.

Fig. 3 Two Clamp Screws At The Same Position (13) If the additional clamp causes an additional vibration, separate the clamps (1/4 inch above and below the mark). Repeat the vibration test (Fig. 4).

RUNOUT (1) Remove dirt, rust, paint, and undercoating from the propeller shaft surface where the dial indicator will contact the shaft. (2) The dial indicator must be installed perpendicular to the shaft surface. (3) Measure runout at the center and ends of the shaft sufficiently far away from weld areas to ensure that the effects of the weld process will not enter into the measurements. (4) Refer to Runout Specifications chart. (5) If the propeller shaft runout is out of specification, remove the propeller shaft, index the shaft 180°, and re-install the propeller shaft. Measure shaft runout again. (6) If the propeller shaft runout is now within specifications, mark the shaft and yokes for proper orientation. (7) If the propeller shaft runout is not within specifications, verify that the runout of the transmission/ transfer case and axle are within specifications. Correct as necessary and re-measure propeller shaft runout. (8) Replace the propeller shaft if the runout still exceeds the limits. RUNOUT SPECIFICATIONS Front of Shaft

0.020 in. (0.50 mm)

Center of Shaft

0.025 in. (0.63 mm)

Rear of Shaft

0.020 in. (0.50 mm)

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

STANDARD PROCEDURES - PROPELLER SHAFT ANGLE Fig. 4 Clamp Screws Separated 1 - 1â „2 INCH

(14) Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen. (15) If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. (16) Install the wheel and tires. Lower the vehicle.

The procedure applies to both the front propeller shafts and the rear propeller shaft. To obtain the front (output) angle on the C/V front propeller shaft, the inclinometer is placed on the machined ring of the pinion flange. To obtain the propeller shaft angle measurement on the C/V front propeller shaft, the inclinometer is placed on the propeller shaft tube. (1) Raise and support the vehicle at the axles as level as possible. Allow the wheels and propeller shaft to turn. (2) Remove any external bearing snap rings from universal joint if equipped, so the inclinometer base will sits flat.


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PROPELLER SHAFT

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PROPELLER SHAFT (Continued) (3) Rotate the shaft until transmission/transfer case output yoke bearing cap is facing downward, if necessary. Always make measurements from front to rear. (4) Place Inclinometer on yoke bearing cap, or the pinion flange ring, (A) parallel to the shaft (Fig. 5). Center bubble in sight glass and record measurement. This measurement will give you the transmission or Output Yoke Angle (A).

Fig. 6 Propeller Shaft Angle Measurement (C) 1 - SHAFT YOKE BEARING CAP 2 - INCLINOMETER

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

(5) Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing cap, or propeller shaft tube on C/V propeller shaft, parallel to the shaft (Fig. 6). Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the propeller shaft angle (C). (6) Subtract smaller figure from larger (C minus A) to obtain transmission output operating angle. (7) Rotate propeller shaft 90 degrees and place Inclinometer on pinion yoke bearing cap parallel to the shaft (Fig. 7). Center bubble in sight glass and record measurement. This measurement will give you the pinion shaft or input yoke angle (B). (8) Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules given below and the example in (Fig. 8) for additional information.

Fig. 7 Rear (Input) Angle Measurement (B) 1 - PINION YOKE BEARING CAP 2 - INCLINOMETER

• Good cancellation of U-joint operating angles (within 1°). • Operating angles less than 3°. • Operating angles less than 10° for double cardan U-joint. • At least 1/2 of one degree continuous operating (propeller shaft) angle.


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PROPELLER SHAFT

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SPECIFICATIONS (Continued)

Fig. 8 Universal Joint Angle Example 4 - 3.0° Angle (A) 5 - Output Yoke

1 - 4.9° Angle (C) 2 - 3.2° Angle (B) 3 - Input Yoke

SPECIFICATIONS PROPELLER SHAFT TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

Front Shaft - Companion Flange Bolts

32

24

Rear Shaft - Yoke Nuts

19

14

In. Lbs. — —


PROPELLER SHAFT

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SPECIAL TOOLS SPECIAL TOOLS

Inclinometer 7663

PROPELLER SHAFT - FRONT REMOVAL NOTE: Different length propeller shafts are used for different drivetrain applications. Ensure that the correct propeller shaft is used. (1) Place vehicle on floor or drive-on hoist with full weight of vehicle on suspension. (2) Shift the transmission and transfer case, if necessary, into the Neutral position. (3) Measure the distance from the face of the C/V joint cup to the end of the C/V joint boot (Fig. 9).

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(5) Mark a line across the companion flange at the transfer case and C/V joint at the rear of the front propeller shaft for installation reference. (6) Mark a line across the C/V joints and the pinion companion flanges for installation reference. (7) Remove bolts from the front C/V joint to the pinion companion flange. (8) Remove bolts from the rear C/V joint to the transfer case companion flange. (9) Push the propeller shaft forward to clear transfer case companion flange and remove the shaft.

INSTALLATION NOTE: Different length propeller shafts are used for different drivetrain applications. Ensure that the correct propeller shaft is used. (1) Install the shaft between companion flanges. (2) The shaft should rotate freely in the pinion flange. (3) Align marks on the companion flanges with the marks on the C/V joints. (4) Install bolts to the front C/V joint and tighten bolts to 32 N¡m (24 ft. lbs.). (5) Install the bolts to the rear C/V joint and tighten bolts to 32 N¡m (24 ft. lbs.). (6) Verify propeller shaft length. (7) Lower vehicle.

PROPELLER SHAFT - FRONT 4.7L REMOVAL

Fig. 9 Measurement 1 - C/V JOINT CUP 2 - C/V BOOT END 3 - MEASUREMENT

(4) The correct length is 142.7 mm (5.61 in.). NOTE: If the measurement is not correct, the wrong shaft may have been installed or a mating component (front axle or transfer case) may be installed incorrectly. Investigate and correct as necessary.

(1) Raise and support vehicle. (2) Remove crossmember/skid plate as necessary to gain access to the propeller shaft. (3) Shift transmission and transfer case, if necessary into Neutral. (4) Mark a line across the yoke at the transfer case, link yoke and propeller shaft yoke at the rear of the front propeller shaft for installation reference (Fig. 10). (5) Mark a line across the propeller shaft yoke and pinion shaft yoke for installation reference. (6) Remove the U-joint strap bolts at the pinion shaft yoke (Fig. 11). (7) Remove bolts holding rear universal joint to the transfer case yoke. (8) Separate the rear universal joint from the transfer case yoke.


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PROPELLER SHAFT

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PROPELLER SHAFT - FRONT 4.7L (Continued) (3) Align mark on the rear link yoke and universal joint to the mark on the transfer case yoke. (4) Loosely install bolts to hold universal joint to transfer case yoke. (5) Align mark on front universal joint to the mark on the axle pinion yoke. (6) Tighten the U-joint strap/clamp bolts at the axle yoke to 19 N·m (14 ft. lbs.). (7) Tighten the universal joint to transfer case bolts to 27 N·m (20 ft. lbs.). (8) Lower the vehicle.

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

(9) Push rear of propeller shaft upward to clear transfer case yoke. (10) Separate front universal joint from front axle. (11) Separate propeller shaft from vehicle.

(1) Raise and support vehicle on safety stands. (2) Shift the transmission and transfer case if necessary, to their neutral positions. (3) Mark a line across the axle pinion yoke and the propeller shaft yoke for installation reference. (4) Remove the bolts holding the universal joint clamps to the pinion yoke. (5) Slide the slip yoke off of the transmission, or transfer case, output shaft and remove the propeller shaft (Fig. 12).

Fig. 11 Front Propeller Shaft - 4.7L 1 2 3 4 5 6 7 8 9

-

FRONT AXLE BOOT PROPELLER SHAFT DOUBLE CARDAN U-JOINT TRANSFER CASE BOOT SLINGER CLAMP YOKE

Fig. 12 Rear Propeller Shaft

INSTALLATION (1) Position front propeller shaft under vehicle with rear universal joint over the transfer case yoke. (2) Place front universal joint into the axle pinion yoke.

1 2 3 4 5 6

-

SLIDING YOKE PROPELLER SHAFT PINION YOKE CLAMP/STRAP BOLT OUTPUT SHAFT


PROPELLER SHAFT

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PROPELLER SHAFT - REAR (Continued)

INSTALLATION (1) Slide the slip yoke on the transmission, or transfer case, output shaft. (2) Align the installation reference marks made on the propeller shaft and pinion yoke. (3) Position universal joint into pinion yoke. (4) Install the universal joint clamp and clamp bolts to the pinion yoke. Tighten bolts to 19 N¡m (14 ft. lbs.). (5) Lower the vehicle.

SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. (1) Remove the propeller shaft. (2) Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring. (3) Remove snap rings from both sides of yoke (Fig. 13).

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

(7) If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. (8) To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed (Fig. 15). CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur.

ASSEMBLY Fig. 13 Remove Snap Ring 1 - SNAP RING

(4) Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. (5) Position the yoke with the grease fitting, if equipped, pointing up. (6) Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap (Fig. 14).

(1) Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation. (2) Position the cross in the yoke with its lube fitting, if equipped, pointing up (Fig. 16). (3) Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 17). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly. (4) Press the bearing cap into the yoke bore enough to install a snap ring. (5) Install a snap ring.


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PROPELLER SHAFT

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SINGLE CARDAN UNIVERSAL JOINTS (Continued)

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

1 - BEARING CAP 2 - TRUNNION

(6) Repeat Step 3 and Step 4to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. (7) Add grease to lube fitting, if equipped. (8) Install the propeller shaft.

DOUBLE CARDAN UNIVERSAL JOINTS DISASSEMBLY

Fig. 16 Cross In Yoke 1 - CROSS 2 - YOKE

Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. (1) Remove the propeller shaft. (2) Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring. (3) Remove all the bearing cap snap rings (Fig. 18). (4) Set the joint in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the link yoke. (5) Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and partially press one bearing cap from the outboard side of the link yoke enough to grasp the bearing cap with vise jaws (Fig. 19). Be sure to remove grease fittings that interfere with removal.


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2001 jeep grand cherokee service repair manual  
2001 jeep grand cherokee service repair manual  
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